Album by John Cronin. Photos by John Cronin. 1 - 113 of 113 Total. 4449 Visits.
Shopping list.
Just picked up the fuselage wood at Con-Way freight. I'm often glad I kept the old family van.
Fuselage jig base level and ready to go.
I've inventoried and labeled the shipment.
First pieces in the jig. I steamed the area where the lower longeron bends before placing it in the jig.
Supports and gussets cut and ready to glue.
Glueing and nailing the gussets.
Inside of right fuselage done.
Measurements on the plans include the 1/8" outside plywood, which gets attached later. For now, 1/8" shims will do (because I forgot about that).
That stick on the jig is where the fuselage begins to bend.
I marked the 1/2" line along the back. I previously tried sanding, but noticed it wasn't going to work well, so that's why there's a bit of a slope.
I'm making a jig so I can use my router. I've made a template of the area I'll be cutting.
My router is on the second step with the stop slightly extended.
The blade is Bosch 85227MC 1/2" X 1" two flute straight/mortising. I used 1,800 RPM.
I check the blade location against my marks on the tail post. I adjusted the height with nylon lock nuts under the board.
Ready to cut.
The board is held with lock nuts. The ones directly under the board will not be moved when the other side tail post is placed in the jig. The board in front is one of several to hold the tail in position.
There's a board to hold the tail section down flat against the work bench.
After the cut.
Dismantling the jig to remove the tail. The small piece near the wrench is to keep the top jig board in precise position as there's a bit of play since those bolt holes were diagonally drilled. The larger board act's as a "stop" against which the tail post is positioned.
After both sections were trimmed, I found I was off slightly. The back edge had a slight gap as the sides met at the area where the angle transitions to the uncut region. I needed a more shallow angle.
I used this sanding board to knock off enough wood to get the sides to make more contact when joined together. This idea comes from Mr. Chase.
I've placed a board to lock the upper longeron at the 24" point in position (square) and prevent bowing out when the tail is joined. Technically, as the fuselage is upside down, it's the lower longeron.
Can't move inward or outward.
I've placed a board at the firewall to keep the sides square.
I cut some white ash for the landing gear area, then ran them through the planer; one to 1" and the other to 3/4". Fun.
I made this swinging holder. It moves out of the way so I can glue the tail post, then I can screw it into position to hold it in place.
I installed two braces at the 22" wide area.
Discovered I was using measurement location from the profile view, which are from the back of the vertical struts. Width measurements are from the front, so I'm 3/4" off. I re-measured and reinstalled the brace at the correct location.
I've installed braces at the 11" wide area and the tail post were pressed together. I took the opportunity to sand the tail and it worked great. The sanding board makes the tail off-center when just laying loose.
Forward seat back.
I'm driving 5/8" brad nails through the plywood into the spruce sticks behind.
All done!
Well, plans have an error. The spruce V sticks should join and end an inch before the bottom of the plywood. I trimmed them. There's a small space where the cross piece meets the left piece. I sanded (on one end) then inserted a 1/16" piece of wood to fill the gap. I'll also insert wood to make sure the V has solid contact with the white ash cross strut.
I've cut the forward 1" white ash board and trimmed the ends to 3/4".
I've glued both seat backs, tail, a rear gusset and the ash cross piece at the firewall.
I've glued the rear cross strut, diagonal cross strut and another gusset.
Started work on the floor. After I calculated a pivot point. I used a punch to make sure the nail would be in the precise spot.
Starting to sand the edges to the line. The sides have been trimmed to near the line. Once it's glued in place, I'll sand the edges to match the longerons.
Floor glued. I still have to trim the edges.
Seat bottoms ready for glue. I'll install them like this for now. The plywood bottoms will go on after the flight controls are installed. There's going to be a 1/8" plywood sheet at the front of each. I forgot to cut the seat bottoms to that, so I have to make those again.
Large bottom gussets and tail gusset glued.
Last two lower rear cross struts in place. I have yet to trim all gussets flush to longerons.
She's free of the jig and right side up. Glueing the two ash strut's and a spruce. On a side note, the plans state the V sticks on passenger seat back go on the front. I'm not sure how this will work with a cushion.
Gluing front seat frame to support.
About to cut pilot seat support.
Front seat installed and glued in. Weights to help hold legs tight to cross strut and that to the floor.
I'll install/glue pieces under the 'V' sticks soon. Not on the plans, but I've installed legs under the seat to support a person standing on it (to get in). I orientated the legs in a way to support the left and right frame as well as the forward and back frame. Legs are beveled to the cross strut.
Pilot seat frame glued to support.
The back three top gussets in place. The two gussets in front of the tail post are located to match the tail section attachment points. I'm building the long fuselage, but the tail still sits on the rear 18", so the gussets are not in position as seen on the short fuselage.
Problem. Can't get pilot seat in as back rest is bowed. The reason is the vertical struts to which it's glued are not parallel due to fuselage starting to bend inward. With back rest glued to the forward face of the vertical struts, it naturally bowed. Ugh!
After considering several options, I decided to trim the bottom so it meets the seat frame. The seat bottom will conceal the edge.
Just a trial fit. Looks like it'll work. The seat bottom will be cut to match the bowed back rest. By the way, the bowing at the center was 3/8".
Gluing pilot seat support and cross strut.
I added a wedge to the passenger back legs.
Gluing some gussets and one cross strut.
I've been gluing the small quarter inch strips between guests.
Installed blocks for seat belt brackets.
Checking the fit. Not bad.
36" chain from Hobby Lobby. About to make template for instrument panel and cowl support.
I leveled it with chain hanging just a bit in front of the board. Tugged on loose end until chain hit my mark and then taped the end on back.
Looks good.
Had to make a second one for firewall and forward panel/cowl as the fuselage is a bit wider up there.
These aren't on the plans, but they are needed for the struts, so just glued them in.
Using poster-board templates as I start work for seat belts, shoulder harnesses and the turtle deck. Once I see how it all looks I'll cut the wood.
These blocks will go in the longerons. They will be the attach points for shoulder harnesses.
Using poster-board to see where the shoulder harnesses will go and help figure out the helmet box.
Made templates so I know where to drill after the sides are mounted. Photo also shows the bushings and 1/4" reinforcement pieces. Two smaller pieces are fillers (next photo).
Fillers glued in.
Making slots for seat belt brackets.
Drilling holes in the seat belt brackets.
Now a bolt is in to hold the position. This pair will be kept together until assembly,
I finish up with the router (holes drilled with a "D" bit.
I'm making a template of the part that holds the turtle deck boards.
Now using foam board to make the turtle deck and the pilot back board.
Took this paper and used it to mark foam board.
Ended up with this.
Initial try. Didn't work. The grooves were too high. To lower them would go out the bottom, so I made a new foam board support.
There's the new mid-support. I had to slowly whittle away each one to reach the correct depth.
All the sticks end at the 18" mark (give or take a bit until I'm ready to finish it off).
Glued pieces for shoulder harness brackets.
Sanding the gussets for shoulder harness mounts.
Making brackets for pilot shoulder harness.
Gluing the top board at shoulder harness attach area.
Drilled holes for the shoulder harness bolts.
With double sided tape, I should be close enough to start making trial templates.
After working with paper, then poster board; finally able to use foam board.
I made a wooden mid-support for the forward position.
Cut the final piece from 6mm Okome.
Using the scroll saw.
It works!
Making the stringer support for back of pilot headrest.
Pilot headrest in place (temporarily).
Gluing the stringer support board in place.
I'll glue this stick on the belly to keep fabric away from wood and provide water drainage.
