Jason builds a plane

701 wing repair / extension getting closer to being done

24/1/2018

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Good day in the shop yesterday.  Worked exclusively on the 701 wing repair and tip extension.

Lots of practice driving solid rivets in the spar extension caps.  Ron showed me a great trick on how to secure the work piece to the bench that's I'll have to remember for my wing spars.  By the time mine are done on the 750 I'll have driven over 400 of them!

Here is the completed spar tip extension:
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Rear side
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Forward side

More pictures showing the installation of the new wing and nose ribs.  For now we've got them clecoed in place temporarily until the flap and slat extensions are complete.  Once these are done we'll line them up properly prior to drilling the mounting brackets.
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The outboard wing rib looks out of line with the rear wing rib because it wasn't attached to the rear spar in this picture. Hidden from view is the new inside splice plate, now attached by solid rivets at the spar extension joint.
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Front view
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Close up of front splice plate.

Amazing how solid riveting the front and back splice plates on either side of the spa web and caps make this a solid extension with no flex in the joint.  Exactly what we want!

Finally starting to see the light at the end of the tunnel with this wing.  Next up begin the skinning process..... and more learning :)
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Tail group parts bent

16/1/2018

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Spent 4 hours in the shop yesterday bending a large group of tail parts for my 750.  Nice to get back there.  Here's what I got done:
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Horizontal stabilizer tip rib, in the forming blocks, waiting to be bent
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Crimping the edges of the flange ahead of time makes forming the curve easier. I think I'll groove the forms for the wing ribs to make it even easier.
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Two HS tip ribs, ready for tail assembly.
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Two elevator nose ribs
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4 horizontal stabilizer rear ribs
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Three horizontal stabilizer nose ribs
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Two elevator tip ribs. These need some fine tuning to get them perfectly straight.
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Thirteen parts made - a good morning in the shop

Here's a diagram of what I've got done so far (completed parts shaded in blue):
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Happy with how these parts turned out, but need some more practice to make them perfect.  Back to the shop in a couple of days.  Spars and various fittings to be cut out then I'm ready to start building the tail group.
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continue plugging away....

9/1/2018

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I had every intention of spending the entire day in the shop today.  I'd taken the time last week to mark specific "shop days" on the calendar - days that are set aside for the shop and my build.  A discussion with Brenda and our girls regarding my build led us to an agreement that these days are next to untouchable on the schedule so that I can make real progress this year.  Obviously if something special comes up that can't be scheduled somewhere else my shop day can be compromised by moving it to another day, but the goal is to maintain a regular shop presence.

​So, I discovered that "something special" can also includes those days when I physically can't go.  Today was one of those days.

​Last night at Natalie's Scout meeting, I tried to prove that I could still play volleyball like a 20 year old.  A "I-used-a-could-do-that" type of thing.  Needless to say I slept poorly last night and felt like I'd been run over by a Russian cargo plane today, so I missed the shop.

​After some rest and feeling sorry for myself, I decided I didn't need to go over to Ron's and could at least get something done here in my own shop.

​I pulled out something simple to work on - the flaperon rear ribs.  These are simple flanged parts, really just smaller versions of the elevator rear ribs I made before (see my previous blog post here).

​It starts with lining the forms up on the metal template.  Unlike other templates, due to their size they don't have bolt holes for the forms.  Just line them up and place the entire sandwich in the vice:
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​The soft faced dead blow hammer is used to gently form the flange over the edge of the form:
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​Turns out the flanges are a bit wider than the thickness of the form.  With the short top-to-bottom height of these ribs, I had to devise a way to protect them when I inverted the form to bend the opposite flange.  To do this, I added two blocks on each side.  One of them had a small groove cut in it to make room for the opposite flange but still enough area to hold the forms:
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​As per the plans I need 8 left hand and 8 right hand rear ribs and I made a conscious decision to do only six right hand ones first in case I mistakenly made a right hand one when making the left hand ones.  Hate to end up with extras - that would mean making replacement templates for each one I screw up. It's easy to see how this could happen, glad I thought of it ahead of time.  Good trick to remember for later when I start working on all the wing ribs!

It's amazing!  With a bit of attention to detail, I managed to bang out 16 flaperon ribs, all of equal dimensions and quality.  Really cool.​
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Yes that is my autographed photo of astronaut Chris Hadfield on the wall behind me. That's from Oshkosh 2013 where he was a guest speaker at Theatre in the Woods. A favourite memory and amazing Canadian! Also behind me out of sight is my original Top Gun theatre poster.... I'm such a geek.
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​16 complete ribs....  not bad for a day I didn't feel up to doing anything :)
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​I also got a new 14 tooth-per-inch blade for my band saw.  Installing the new blade was challenging, but I learned on YouTube how to properly set the tension and blade guides for my model.  Once I make some of the rougher cuts on the plate aluminum using the big industrial saw at Ron's shop, I can use my fine tooth band saw to make the final cuts.

​I've said it before....  a little shop therapy goes a long way :)

​p.s.  Photo credits to my daughter Natalie.... thanks for making me look good!
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    Husband, father and 911 dispatcher.  Long time pilot with a licence that burns a hole in my pocket where my student loan money used to be.  First time aircraft builder. Looking to fly my own airplane.

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