| Thu 11/18/99 |
5
|
Began laying out fuselage jigs for chapter 5 on
1x8 pine boards. When I got home I discovered that the 1x8 are
actually about 1x7. This makes fitting the jigs harder. Using CAD I
created the four FJA pattens to get a smooth curve. |
2 |
| Fri 11/19/99 |
5
|
I cut out the FJA templates I made and rubber
cemented them to the 1x8 pine. Cut all four out on the band saw.
Clamped them all together and sanded them all to the same exact
shape. |
2 |
| Sat 11/20/99 |
5
|
Cutout jigs FJB, FJC, FJD, and FJE. Made all the
longeron doublers and stiffeners. Cutout LWX and LWY. Using CAD I
made a template for the fuselage sides.
I actually went flying today. First time in about 6 weeks. I
don't want to get too rusty.
|
4 |
| Sun 11/21/99 |
5
|
Made the masonite fuselage jigs. I cut a 6.5" inch
wide piece from a 2' x 4' sheet and 5-minute epoxied it to the 4' x
8' sheet using two scraps on the underside. The scraps were sized
and positioned so they won't interfere with the pine fuselage jigs.
Than using some interesting contortions I cut the two jigs to shape
on the bandsaw. In the process I managed to knock the jar of rubber
cement onto the concrete floor. That made quite a mess. |
4 |
| Mon 1/31/00 |
5
|
Layed out and nailed down jigs FJA, FJB, and FJC
for making the longerons. Prepared and epoxied the 6 105" strips to
make the longerons. Secured them in place against the jigs. |
3 |
| Tue 2/1/00 |
5
|
Glued all the doublers in place using flox. The
long doubler was nailed in place and cut at the bends. |
2 |
| Wed 2/2/00 |
5
|
Removed the longerons from the jigs. Sanded all
the shiny epoxy.
Finished the fuselage side jigs by making sure both pieces of
masonite are the same size. Glued 3/8" foam to size to make the
sides. Each side was made from four pieces. Cut the foam to shape
using the masonite as a jig. Setup the FJA, FJB, FJC, FJD, and FJE
jigs on the table and bondoed them in place.
|
4 |
| Thu 2/3/00 |
5
|
Layed the masonite sides onto the jigs and nailed
them into place leaving a 7/8" gap between the top edges. I had to
drill the nail holes to keep the jigs from splitting.
Using small daps of 5 minute epoxy I attached the 3/8" foam to
the masonite. I don't think I used enough bads. I dabbed mostly
around the edges. I should've used more in the center. In the end I
should be all right though.
That's it until after next week - going skiing at Jackson
Hole!
|
2 |
| Sun 2/13/00 |
5
|
Rough cut the foam that goes around the perimeter
of the fuselage. |
2 |
| Tue 2/15/00 |
5
|
Beveled all the foam to shape for one side of the
fuselage. Used a hacksaw blade and sandpaper to make all the
bevels. |
2 |
| Wed 2/16/00 |
5
|
Beveled all the foam to shape for the other side
of the fuselage. Microed the two larger pieces at the aft ends of
the fuselage. Used lots of nails to hold them in place. Made sure
the surface was flat in the direction perpendicular to the upper
edge. |
3 |
| Thu 2/17/00 |
5
|
Test fit LWX and LWY against the foam spacer.
Cut the electrical channel in the aft portion of the foam spacer
on both fuselage sides. Microed the spacers in place along the
bottom edge of the right fuselage side.
|
2 |
| Sat 2/19/00 |
5
|
Removed all the nails from the previously attached
spacers. Microed into place all the remaining spacers around the
edge of the fuselage sides.
Made the circular depression in the fuselage sides for the
control stick.
|
4 |
| Sun 2/20/00 |
5
|
Made depressions for the fuel gauges. I will be
using Vance Atkinson's fuel gauges. Test fit the longerons in
place. Sanded the space between the two sides to ensure an even gap
for longeron placement. Sanded all the foam smooth. Rounded all
edges in preparation for glassing. Cleaned up a bit in preparation
for the glassing of the sides. Placed box tape in place in fuel
gauge depressions.
Did a lot of studying and calculating. This including verifying
the placement of the fuel guages. Also questioned how the longerons
fit on the foam since the aft portion of the fuselage has a twist
in it and the longerons don't. Nat replied to fill the space with
flox which was my first solution.
|
5 |
| Mon 2/21/00 |
5
|
I did the exhausting marathon step of glassing the
fuselage sides and attaching the upper longerons. Microed the
surfaces, filled dings and holes with dry micro. Layed out the
first layer of glass. Wet that out. It took some work to get the
glass to sit right in the depressions. Added the second layer and
wet it out. Added peel ply to the bottom edges and the landing gear
bulkhead area. Added Saran wrap to the depressions to get them to
sit better. Floxed the longerons into place. Used lots of weights
and clamps. Peel plied the upper edge below the longeron. Knife
trimmed the electrical cutout. |
11 |
| Wed 2/23/00 |
5
|
Removed all the weights and clamps from the
longerons. Removed all the peel ply. Sanded a radius on the
longeron in preparation for the 4 layer UNI layup. |
1 |
| Fri 2/25/00 |
5
|
Played with a scrap of UNI to determine the best
way to do the 4 layer layup over the upper longerons.
Marked the proper location of the lower longeron based on the
dimensions given in Figure 5-5.
Cut a bunch of slits on the lower longerons so they would bend
to the shape of the fuselage sides. Experimented with various ways
to clamp them in place. Made some small wood blocks with 45°
cuts in them. Test clamped the lower longeron with these blocks and
it worked great. Floxed one lower longeron in place.
|
3 |
| Sat 2/26/00 |
5
|
Cut all the glass for the 4 layer upper longeron
layup. I made eight, 4.5" wide strips, 100" long. Each side will
get four. I layed up four layers on the left longeron. I had
problems with masking tape I used to keep the edges from fraying.
When trying to remove the tape it would make a mess of the fibers.
Probably worse than not using the tape. I peel plied where the
layup met the fuselage side. |
5 |
| Sun 2/27/00 |
5
|
Applied the 4 layers of UNI on the other upper
longeron. Floxed the other lower longeron into place.
Glassed the inside of the electrical channel. Knife trimmed
later.
Made the electrical channel cover forms, covered with box tape,
and glassed them with a ply of BID.
|
6 |
| Mon 2/28/00 |
5
|
Floxed the lower longeron doubler, LWX, and LWY
onto the right fuselage side. Added the BID tape to LWX and LWY.
Removed the electrical channel covers from the molds and trimmed
them.
|
2 |
| Tue 2/29/00 |
5
|
Floxed the lower logneron doubler, LWX, and LWY
onto the other fuselage side. Added the BID tape to LWX and LWY.
Sanded down the previous nights layup. 5 minute epoxied the
electrical channel cover in place on the right fuselage side. Cut
foam to fill the space. Microed it into place. Weigthed it down to
dry.
Cleaned the workshop. It was getting a bit cluttered from all
the chapter 5 work.
|
3 |
| Wed 3/1/00 |
5
|
In preparation for starting chapter 6 very soon I
decided it would be a good idea to have an EAA Technical Advisor
check out my work to date. Terry Sickler from Chapter 301 came to
my shop and looked over my fuselage sides and bulkheads. He was
very pleased with my glass work. Needless to say I was please that
he was pleased. All my worrying in the past about possibly dry
layups from peel ply were for not. He said there was nothing wrong
with what I have done.
Sanded the previous layup. Glued the other electrical channel
into place and filled the surrounding space with foam.
|
2 |
| Mon 3/6/00 |
5
|
Sanded all the foam smooth and even with the
surrounding wood. Did the six ply BID layup on the right fuselage
side. Peel plied. |
2 |
| Tue 3/7/00 |
5
|
I popped (literally) the right fuselage side off
of the jig. I carefully scraped off foam I wished to glue back into
place and then scraped the rest of the glue and foam off the
masonite. Sanded the UNI strands along the top of the upper
longeron smooth. Made measurements to cut the side to length. |
1 |
| Wed 3/8/00 |
5
|
Did the six layer BID layup on the other fuselage
side. Glued a foam divot back into place on the removed fuselage
side.
Cut the right fuselage to length - 101.75". Cut out the 5.5" x
8.7" area for the spar.
|
5 |
| Fri 3/10/00 |
5
|
Cut the other fuselage side to length and made the
spar cutout. Sanded along the top longeron.
Cleaned up in prepartion for the next chapter.
|
3 |
| Chapter Total |
85 |