small bits, big bits.... every bit counts

Although I've read it many times, watched and listened to other successful builders state it many times, one of the truisms I have really realized the value over the past couple of weeks is consistent shop time.  Not leaving so much time between shop sessions leaves previous work accomplishments and next steps fresh in mind, saving tons of re-thinking everything each weekly visit.

To that end, I'm planning on adding 2 nights a week to the full Saturdays I'm currently spending in the shop.  Some nights, I might be only a couple of hours, some more.  The point is I need to keep at it if I ever expect to get this project done.  Blogs will be more frequent too.  Tonight was my first evening session.

I decided to get the strut support section done.

Like the jury strut brackets, I found the scaling of my original templates lacking some accuracy, so I did up a new template on cardstock.  I left the lower end a little wider than the plans call for - that give me room to trim it after I bend the flange over to match the strut pick-up.

Found a nice piece of 063 perfectly sized for this - nice to find in scrap bin! 

Bending this bracket took a fair amount of figuring out.  The point of the curve needs to mate up to the curve of the strut pickup.  I measured three times and used a cut-off piece of 063 as a proof piece first to establish correct angle and bend line:

Trimmed the lower flange to match the upright flange of the strut support angle - perfect fit, glad I took the time to measure thrice!

Seven measured A3 (small bit) pilot holes in the lower flange:

 
​Some small C-clamps hold everything in place nice and tight and even:

Match drill the bracket to the angle.  This is challenging, but easily do-able with a very long A4 drill bit and 90 degree air drill.  

Match drill the 3/8 strut bolt hole in the support bracket by back-drilling (BIG bit) through the strut pick-up:

A5 (big bit) rivet hole as per the plans, drilled through both:

Everything comes apart, bracket to angle rivets are upsized to A5 and deburred.  Scrub down with Scotchbrite and prime (I did the front jury strut brackets at the same time.

As the title says, every bit counts.  More to come.