Latest photo of progress on the hinge blocks.
Attachment 5763
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Latest photo of progress on the hinge blocks.
Attachment 5763
I received the hinges from my dad.
Attachment 5783
Attachment 5784
Attachment 5785
In case you are wondering, they weigh about 8.5 ounces each.
The hole in the cutout will be threaded for a bolt that will be run through the rear spar.
Dale
First wing pretty much done with exception of root rib and leading edge sheet:
(now it won't fit in my rigging jig:rollseyes:)
Attachment 5787
Second lower wing coming along:
Attachment 5788
Dale
Forming spar end for tip bow
Attachment 5795
Attachment 5796
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Attachment 5798
Getting help from Rosie the Riveter
Attachment 5799
Both lower wings framed up pending leading edge sheeting
Attachment 5800
Modifications were required to the rigging frames after trailing edges were added:
Attachment 5801
Attachment 5802
After several hours fiddling, the first of 6 leading edge sheets is attached.
Attachment 5803
Dale
I see you went with the kit sheets of 6161-T6....and I am humbled by your work.
I made a complete mess of them and just bit the bullet and bought some T6 leading edge material....and thankfully my covering job concealed most of my buggering it up.
I have to admit that when I actually worked for a living, I installed air conditioning so I have a fair bit of experience with sheet metal. However, that was steel and did not usually require the finesse the thin aluminum does.
Due to problems forming the sheet around the leading edge, and not being pleased with the sheet anyway, I scrapped that plan and started with false ribs.
Attachment 5838
My son Rob was in for a few days and helped out forming, drilling and riveting.
Attachment 5839
We got most of the false ribs on one lower wing.
Attachment 5840
Unfortunately, due to drilling 20 holes in the leading edge of the other lower wing, I have to change out that leading edge tube. A major rebuild of the wing structure.:rollseyes:
Dale
Ooooh, she's starting to really come together!
I made the trip to Aircraft Spruce to pick up the 11' tube for the replacement leading edge, then removed the one I drilled full of holes.
Attachment 5894
I needed to match the angle of the root cut for dihedral and sweep, so I made a pattern of the old tube.
Attachment 5895
After marking the new tube, I cut it with an angle grinder with cut off wheel.
Attachment 5896
With the root end at the correct angle, I carefully measured the location for the compression strut bolt holes and rivet locations for the rib attach plates.
All fit together with clecos.
Attachment 5897
Attachment 5898
I took it apart, primed the areas where parts connect then reassembled and riveted it together. This evening I reattached the internal cables.
Attachment 5899
Now I am officially where I was with this wing a month ago.:rollseyes:
Time to start forming false ribs.
Dale
What are the advantages/disadvantages of the sheet leading edge vs. false ribs?
The kit was designed for sheeting. Mostly for simplicity I assume to keep from cutting, bending and finishing an additional 60+ short ribs. Both are for the purpose of helping ramp up the air over the leading edge of the wing. Without one or the other, the fabric sags between the main ribs.
I started with the sheeting that was provided, but was unable to get the fit I wanted. Partly due to the grain running perpendicular to the roll. Leading edge sheeting sold by Aircraft Spruce has the grain running lengthwise, but by the time I figured that out, I had decided to go with the original type false ribs.
The sheeting probably adds a little torsional strength, but it is not necessary in this build as there are other compensating factors.
By the way, the planes Robert built for the movie FlyBoys used the false ribs rather than the sheeting.
Dale
Yes, the false ribs look more correct for that period. History books show most planes of that era had "sagging" fabric between ribs. Which one do you think is lighter or heavier?Quote:
Originally Posted by bookmaker
The false ribs are probably a little heavier, but not by much. My original plan was to go the "easy" route with the aluminum sheet, then run a couple layers of tape up the sheet to fake the false ribs. But, messing with the aluminum sheet was becoming more work than making the ribs.
The sheet would have ended about 1/4" below the centerline if the front of the LE. I just could not get it to lay perfectly flat between the rivets at 4" apart. Some other builders I have talked to just live with it, but it bothered me. SOOOOO!
The false ribs definitely look better. I now need to make 15 for this wing panel. There will be about 36 for the upper wings. :rollseyes:
While the turkey was in the smoker on Thanksgiving, Rose and I formed and trimmed the nose ends of the false ribs for the other lower wing.
Attachment 5913
Last evening, we got some time to work on the project and formed the bend in the aft end of the false ribs, cut them to length and mounted them in the wing.
Attachment 5914
Both lower wings basically complete, stored for next project
Attachment 5915
Attachment 5916
Dale
The lower wings were hauled out to the hangar and mounted for test fitting of the wing with the new leading edge and to see how they look with the false ribs. :):thumbsup:
Attachment 5917
While at the hangar, we removed the upper wing cores and brought them home to start attaching ribs, ailerons, etc.
Moving slow, but moving.
Dale
This evening work started on attaching ribs to the upper wing cores.
Attachment 5920
Attachment 5921
Dale
The other night I mounted the aileron hinges and torque tube.
Attachment 5924
Attachment 5925
Last night, I fit the nose pieces to both aileron wishbones and got one mounted to the torque tube. Only about 4 hours work measuring, lining up, remeasuring, drilling, etc.
Attachment 5922
Attachment 5923
Dale
Adding the main trailing edge.
Attachment 5930
Dale
Started on the aileron
Attachment 5946
Attachment 5947
Also started sorting out ribs in the root area, the box around the aileron wishbone and cockpit cut out bow.
Attachment 5948
Attachment 5949
Dale
Last weekend I started forming the aileron ribs. I started with the middle rib since the metal on hand was not long enough for the longer 2 ribs. I start with the longer ones so I have a chance of salvaging the piece for a shorter one if I screw up the measurement.:rollseyes:
Attachment 6014
Attachment 6015
Attachment 6016
I cut the ribs for both wings while cutting, but the other side is still pending. Hopefully the metal for the longer ribs will arrive by the weekend.
Dale
Continued working on the right aileron. All ribs are formed and slid on the torque tube. The inner rib was lined up with the control wishbone and riveted in place. The remaining ribs need to be lined up with the inner rib, then riveted in place.
Attachment 6050
Attachment 6051
I used extra aileron attachment "top hats" as stops to set the position of the torque tube. Here is the one inside the outer hinge. I set the end play movement to about 1/32" You can't see it in the photo, but the delren bushing in the hinge has a flange the stop rides against. No metal to metal.
Attachment 6052
Once the ribs are lined up and riveted to the torque tube, then it is on to forming the wing tip bow, then forming the ends of the spars to meet and hold the wing and aileron tip bows.
Dale
Aileron ribs have been permanently attached and work on the tip begun.
First bend of tip bows. 3/4" aluminum tubing.
Attachment 6120
Forming mid-airfoil curve using the TLAR method of alignment.
Attachment 6121
Not too bad!
Attachment 6122
Drilling for the attachment to the leading edge.
Attachment 6123
Inletting the spar for the bow.
Attachment 6124
After annealing, the tip was squeezed to taper to the tip bow.
Attachment 6125
The aileron spar was subjected to the same treatment and here is the test fit.
Attachment 6126
Attachment 6127
Moving slow, but moving.
Dale
I was unable to post photos for a while, but that seems to have cleared up.
I have completed attaching the wing tip, aileron and main trailing edge.
Attachment 6141
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Attachment 6143
I have started the work on the root end, pilot cut out and box around the aileron control wishbone.
Attachment 6144
Attachment 6145
But this week has been pretty busy with work and treating my wife to Valentines dinner.
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Dale
Progress on the root area.
Attachment 6150
Attachment 6151
Before fixing these parts, I needed to duplicate the pilot cut out bows.
Attachment 6152
I used these hi-tec forms (including the time) to make the bends.
The day after the last photos were posted, I got a call from my father that he was in the emergency room in Miami. He had just turned 86 a few days before. I caught the next plane down. Unfortunately, he contracted pneumonia and that complicated heart and lung problems he already had and he passed away March 7. I was out of town for little over 3 weeks. He was a great help to me and a great friend. I miss him terribly.
Attachment 6281
Add that to the fact I am a CPA and up to my ears in tax returns, not much got accomplished on my project. That was until last weekend.
After listing the remaining projects to complete the upper right wing (a longer list than I hoped), it was decided to start on the false ribs. There are 19 per wing and end up about 9” long. Bending that short of a tube is difficult, so we started out with 16” blanks. That was still tough, but a lever bar helped. Last Sunday we attached all but one false rib to the upper right wing.
Attachment 6280
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Attachment 6286
Moving slow, but moving
Dale
Fantastic work, as always, and a great demonstration on how the basic Baslee kit can be turned into something really special.
Thanks Frank. I am trying to make it a nice one.
Tonight I added wing tip braces to prevent bowing by the covering.
Attachment 6288
Last weekend, we flipped the wing and started on the lower pilot cutout bow, wishbone opening framing and surround and root rib area.
As usual, what Robert Baslee can do in 10 minutes took me several hours. Getting the angle cuts on the mating tubes took me forever with a file and sandpaper.
Attachment 6312
We did manage to get the framing and surround for the wishbone complete and moved ahead on the root.
Attachment 6313
However, since there is a plate that attaches the spar to the rear cabane tower, the lower cutout bow has to be cut off about 6" from the root (red line on spar in photo). This generates a lot of head scratching, but I have decided to sheet the rear 6" or so from the root rib to the second rib with thin aluminum leaving a permanent opening for the plate and access to the center spar nuts. For access to the front spar nuts, I will embed an aluminum surround in the covering, then attach a small aluminum access door.
By the way, the aluminum angle at the root in the photo is just for alignment and not part of the wing.
Dale
Hey, neat - you made two bows for that spot, a top and a bottom.
I just went with the one.
Correct Frank. The original had a flat face on the cut out. I am doing my best to replicate it.
I have finally completed engineering and assembly of the root end of the right upper wing.
Attachment 6326
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Dale
I'm continuously impressed on how you're elevating the basic plans and "kit" to something really special.
Refresh my memory - are you going to have the center section cut out and mounted permanently with the cabanes and slide these wings into it, or the standard two big pieces to slide together?
Frank, if I understand your question, the wing is split in the center. The rear spar slips between the two plates on top of the rear cabane A frame.
That's why the face plate on the pilot cutout does not go all the way to the end of the spar.
Here is a photo of the sheet I added to the bottom, for access to the nuts and for the cabane mount plate to fit.
Attachment 6331
The whole section not covered by aluminum in this area will remain open.
The "design" I came up with will not require a large panel to be removable to access the centerline bolts. Just this opening in the back, and small access doors in the covering for access to the front nuts.
Did this answer your question?
Dale
Here is a photo of the spar assemblies on the cabanes.
Attachment 6332
Actually, you answered the question without quite understanding it!
Jeff's Nieuport 17 actually has a permanent section where the center section always stays on, and he has a sort of splinting system to slide the wings onto them.
Yours is like mine in that's it's two wings that meet in the middle all by themselves.
We were supposed to be out of town this weekend, but plans got changed. Today Rose and I started on the aileron leading edge.
Attachment 6340
Attachment 6341
I made a test piece for the wing aileron cutout. Looks pretty good.
Attachment 6342
Dale
Finished the aileron tip leading edge and riveted it in place. This little piece is a real pain.
Attachment 6553
Attachment 6554
It's official. I hate you.
My leading edges never, ever came out that clean.
:)
Finished the right aileron leading edge today. Lots of fiddling with just a few parts trying to get it to look decent.
Attachment 6585
There is about 5/16" gap between the spar and the aileron leading edge. The compression strut bolt just cleared, but covering would interfere, so I cut a slot for the bolt head.
Attachment 6586
I also stole an idea from the Culpeper N28 guys and added flanges around the aileron hinge slots to attach covering. I will likely add a brace at the rear of the outer flanges for support. The inner flanges are supported by the rib and I think OK as is.
Attachment 6587
Attachment 6588
Now on to the wing trailing edge seal.:rollseyes:
Dale