This'n That ( Sept 29th, 2001)

My progress is very slow. Maybe lack of motivation? -don't know. This is what happened this month:

• Polished aft turtledeck skins and stored them away. I will not rivet the aft fuse now (I dont'dare to do this now)
• Drilled the rudder cable guide holes. Actually I wanted to wait with this until tail is installed so I could adjust the holes precisely. But it's easier to do it now when the bulkhead lies flat on the table. I accidentally drilled the 3/4" holes too big for the snap-in bushings. Actually I didn't like these bushings anyway. I'll make nice guides out of 5mm thick Delrene (Delrin).
• Acquired an (almost) complete Type 4 engine. This one looks good, never overhauled (so first oversize bearings can be used), no visual signs of abuse . Removed blower, exhaust, oilcoolder and some more. Next steps will be:
  • build engine stand, remove flywheel, mount engine
  • close all openings
  • bring engine for steam-cleaning (~USD 20)
  • bring engine for glass-bead blasting (case only) (~USD 30)
  • remove heads and cylinders
  • bring heads for glass-bead blasting

that's enough for short-term engine planning.

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Never Ending Beding Story, ( Sept 8th, 2001)

I've digged a bit deeper into my bending misery (see 'Fuse Joint' below). My bending block seems guilty for the misplaced bend tangents.

The depression from bending is clearly visible. This 3/16" 6061 is tough stuff. So even I used hardwood I need something still harder. My latest try is a bending block made from aluminum from the junkjard.

Filing the 1/2" radius was less painful as expected (< 30 min work). I first made two 45 deg. cuts at the bandsaw then filed the radius to size, finally pulled a strip of 280 grid sandpaper over for final finish. We'll see how this works out...

Lower Fuse Joint, ( Sept 5th, 2001)

Before you start fabricating the F26-06/07 fuse spliceplates, I may probably save you an hour of extra work if you read this:

These is one of the four corner joints (left bottom) which connect the rear fuselage with the cockpit section. As you can see there's a gap (1) between F26-06 (the 'T') and F26-07 which is not what we want to see here.

Reason for this is that the 13.6 degree bend (2) of F26-07 is not exactly where it should be. Making such bends very precise is not easy using the vise and sledgehammer method.

Here's a foolproof method to make this part perfect:

DO NOT cut F26-07 to exact size before you bend it. Instead cut roughly (add about 1/4" to the overall length and width). Then do the bend. Using the bend tangents as reference lines, cut the part to final shape and drill the holes.

Now I'll start making F26-07 version number two (after finishing the ~fourth~ incarnation of turtledeck former #2).

Don't worry - be happy