Log Entries - Chapter 5

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