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Builder Name:	Stan Timmerman -

Project:	Bearhawk - Patrol
Total Hours:	1029.5
Total Expense:	$10696.05
Start/Last Date:	Jul 01, 2014 - No Finish Date

Friendly URL:	https://eaabuilderslog.org?s=Patrol

Home or Last Project Picture

Sep 23, 2019 metal brake MOD

Category: Tools

https://eaabuilderslog.org/?blprojphoto&proj=7XFn3SHmH&p=7XO1oVbeg&listcat=tools&cat=&e=7XGUzxbsX
latest update

A standard sheet metal brake does not have the adjustment range I need for radiused corners.  Angle brackets need a substantial radius.  The foot has to be set way back.

The adjustment is done with this slotted brace.  The original brace is cut out.

My new brace is used in place of original.  The adjustable screw can lock a radiused nose  piece in the correct location

Article on modification

This what a real metal brake looks like

Failed attempt to make foot out of mdf

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Nov 27, 2019 Aileron and flap - (16 hours)

Category: Hinge

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Jan 11, 2024 Pictures

Category: Wing Attach

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Mar 23, 2023 Attach skin

Category: Skin flap

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Jul 19, 2023 PATROL TUBING

Category: BOM

08-28-2021, 05:41 PM
Here's mine for fuselage frame tubing, no landing gear or controls;
T-5 25'
T-7 40'
T-8 20'
T-10 50'
T-11 60'
T-13 3'
T-14 40'
T-15. 3'
T-16. 5'
T-18. 4'

Empennage tubing;
T-1 12'
T-2. 2'
T-3. 14'
T-4. 1'
T-5. 20'
T-6 4'
T-8 2'
T-9. 2'
T-12. 2'
T-13 10'
T-14 20'
T-17 2'
Did not compute sheet stock. No guarentee of accuracy. Added some in many cases for welding practice and test samples.
Gerry
Patrol #30

Last edited by geraldmorrissey; 08-28-2021, 05:48 PM.

Patrol 4130 tubing.ods

Patrol 4130 tubing.pdf

Nov 15, 2019 SHEETS TO PURCHASE FOR WING - (4 hours)

Category: Wing Skin

minimum number of sheets for patrol skin

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Jun 05, 2023 Skin

Category: FLAP

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Mar 16, 2023 2024 skin for flap - (8 hours)

Category: flapskin

rolled skin for flaps

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70067612153__50F0E939-861C-46CA-9F32-AFA3129477BD.mov

70067628704__17789F2E-03E9-4B02-8796-2B9E485CB4E9.mov

70067646411__35D936E0-C9D3-4C88-98BF-CCF433B14AAE.mov

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70094367010__34537A44-FB55-40DD-A320-08D6E764DC86.mov

70094405355__641BD3BC-5086-4A58-AF24-7596D3A86D99.mov

70094443836__C1630BB5-2B4C-4E51-919C-0AFC1BF7F7A6.mov

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Feb 26, 2023 Sheet roller - (28 hours)

Category: Tools

2- 10foot 1 1/4 inch black iron pipe
1- 10 foot 1 inch black iron pipe
2 3/4" Shaft Coupler with Keyway Carnell Sales, Inc. SHFTR-1200
2- 10 Tooth Sprocket for #40 Roller Chain Carnell Sales, Inc. 40B10
2- #40 Roller Chain Carnell Sales, Inc. 40-1R

5- 1 1/4 pvc couplers cut long ways
5- 1 inch pvc coupler cut long ways

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my first attempt at  holding 1 inch pipe down with a 10 foot 2x4 did not work

I tried to make bearings out of pvc fittings and polyurethane blue

the first methond with 2x4 only worked for small widths

3/4" Shaft Coup with Keyway ,10 Tooth Sprocket for #40 chain

roller only worked for small widhths

I wanted to create a small radius on bottom

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hand bent bottom to make small radius

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initial bend started by pinching metal down with pipes and using a length of wood to start bend

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without the use of a center clamp

difference with and without center clamping

center clamp used to pinch 1 inch pipe against the two 1 1/4 pipes

center clamp released and applied as metal is rolled

center clamp released rolled and the center clamp applied

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70043789519__8836AB08-538B-4489-9F3E-0440A6B045F0.mov

tiny index between application of center clamp

roll, center clamp, center release, roll - repeat

the 2x4 end clamps will move during the rotation

center clamp is needed since the 1 inch deflects in the center

both ends are clamped.  The 2x4 clamp will move as pipes are rotated

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pvc pipe used to keep pipes from spreading when forced together

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over view walk around

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Jan 30, 2020 Leading edge bend Test with sheet metal brake - (40 hours)

Category: Tools Useful

Modify sheet metal brake to bend leading edge

scrap steel for bracket

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bracket material split in two

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test of brackets attached to moving clamp bar

1 1/4 black iron pipe (there is internal weld seam)

bracket attached to moving brake clamp.  The black blocks ""fingers""  will not be used.

Axle 1 3/8 with groove that will slide into pipe

1 1/2 pvc pipe is split and overlays 1 1/4 iron pipe.  The slot is used to expose the set screws.

adjustable bearing offset

axle has 1/4 tapped thread to ease assembly

screw used to pull axle out of pipe.  Lock ring fixes axle in place

adjustable bearing (25 mm axle)

set screws lock axle in place

set screws lock axle

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stainless 1/4 20 screws hold sheet metal against ""mandrel foot""

mandrel does not move and is lowered in the normal fashion  like any sheet metal brake

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mandrel is moved up and out with the normal adjustments any sheet metal brake has.

top wrench pulls together bottom wrench locks in place

Mandrel does not move it is the sheet metal brake foot.  Lower 1 1/2 pipe rotates around mandrel

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70156325636__4F7A51BE-498B-49F7-9314-0289FDFEF627.mov

Mar 14, 2023 COVER BEHIND REAR SPAR - (4 hours)

Category: AILERONCOVER

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70051475948__B96AD86A-2F3F-4AD4-8678-4097370BAE25.mov

70051489848__FAADDFCC-F247-4689-8517-EEA995F68471.mov

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70051501491__C3D3A6CB-FFF7-436C-A90B-6C868F272958.mov

70051510943__3F1BC9C7-BD39-4EA5-8A11-5692E255360E.mov

70051529550__9F7C2706-4936-4417-8575-9DEF83C778CD.mov

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70051541916__8045EB6C-4005-4D0E-9D80-2BC1275CA0B8.mov

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Nov 19, 2021 Bending Aileron - (12 hours)

Category: Aileron bend

This method did not work!
This method did not work!
This method did not work!

A sheet roller was later made using iron pipes to roll aileron.

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Oct 20, 2019 make guide for rivet gun with adjustable set - (4 hours)

Category: Tools

Squeezers can have adjustable sets. There are commercial adjustable sets for c-yokes. The commercially available c-yokes would not reach main spar AD5 rivets. I made my own c-yoke and adjustable set; I was annoyed that it kept changing settings between rivets. I made this copolymer plastic guide that keeps it from rotating.

The problem is that an ad4 rivet is just on the edge of what can be done with a tatco squeezer. The squeezer can reach the rivets on a rear spar. It simply requires to much effort to squeeze the rivet. I could use a rivet gun to tune up the rivet latter, but chose to touch up the rivets with the squeezer. I have seen others modify their tatco squeezer an make the handles longer. That is a reasonable approach. This would only work on the capstrips of the rear spar not the main spar.

This only applies to the rear spar. The main spar is beyond the ability of a pneumatic or hand squeezer because it has AD5 rivets. Also no commercial yoke could clear the main spar web. Only a c-frame or a rivet gun can set the AD5 rivets.

I do not own a cleavland main squeeze or a longeron yoke. That would be the best tool for the job. But, that setup could only be used on the rear spar, since the web of the main spar is to big for the longeron yoke. Also, it can only reach the rivet from one direction. Hence, you would have to rivet the spar laying in the direction that it is when mounted in the airplane. It is not practical to rivet in the level flat condition with a longeron yoke. It could be done it just would not be comfortable.

In all cases both the main spar and the rear spar could be done with a rivet gun. The only limit is that that is a two man job. Some one has to hold the gun, and someone has to hold the bucking bar. I was not successful using a rivet gun doing it as a one man job.

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Oct 21, 2019 Anvil

Category: Tools

I had old air hammer tools that I annealed and cut to make parts that could mount in rivet gun or height adjustable anvil.

I used copolymer plastic as the back support for the anvil.

mobile pedestal to move under spar, made from brake drums and pipe.

grade 8 hitch pin from tractor Supply  $7

hitch pin was bored out to receive avery retrofit kit

various home made anvils and receiver

Avery C-Frame Retrofit Kit  $36

mobil pedestal variable height back rivet

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grade 8 hitch pin from tractor Supply  $7

Apr 07, 2021 Align

Category: Wing hanger

The iron shelf brackets are match drilled.  A plastic spacer accounts for vertical distance matching

The bottom attach point has to be offset.

A plumb bob is threaded thru a bolt with a concentric hole

The wing tip iron angle has multiple match drilled holes.

The wing tip is spaced up to be level with root spar and locked in place

A water level is used to level the main spar from root to wing tip

water level used for vertical spacing at wing tip

Water level used for vertical spacing at root

match holes can be seen the string is tied at matching holes

matchng hole for wing tip

Clamp for both vertical and rotation to match string

water level

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Need plunger to be used when moving water level vial around.

Plunger is used to keep water from spilling while moving

water level used along lengh of spar with 2x4 adjustable legs

Level checked along length adjusted with 2x4 with adjustable feet

Root rib locked into place so that rear spar is correct relative to main spar

Main spar plumb bob

Black washer spaces 1/2 inch away from bolt attach hole

Rear spar has to be 1/2 inch high but otherwise centered.

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3/16 lathe bit to check that spar is parallel to string along span

3/16 lahe bit used to check middle of spar for rotation

3/16 bit used to chech wing tip is rotated correctly before locked down

Jan 10, 2022 Channels

Category: Wingassemble

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Apr 15, 2021 MASTER 032 TEMPLATE - (6 hours)

Category: TOOLS_MDF

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Jun 20, 2022 LSA

Category: WING STRUT

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Sep 29, 2019 Attach Plate Web Splice

Category: Wings 2024

Lexan slide used to mark C Web

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reference lines made with magic marker mounted in sliding tray

string held with lead weight

string aligns the web and reference lines

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Attach Plate

Route Attach Plate

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Jan 27, 2022 vendors Category: Reference

http://www.wentworthaircraft.com/
aircraft engines

Jan 26, 2022 TIG

Category: Reference

TIG Weld Procedure.pdf

4130_FINALDRAFT rev 2.pdf

Sep 29, 2019 Alodine

Category: Painting

aileron and flap parts anodized

anodized nose ribs

small part anodize

shower pan sheet used to make trough for anodize 8 foot webs

rain drip edge with plastic sheeting for trough for anodize ribs

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anodized nose and center rib

4 inch pvc pipe split in half to make trough for 12 foot capstrips

3 troughs - water,acid,alodine

buff markings in capstrip to keep them organized

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8 foot trough - acid,alodine,water

8 foot trough for web spar anodize

priming

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Aug 31, 2021 Reducer - (5 hours)

Category: MDF

commercially available bearing for shaving off 10 thousandths

custom tool made to for removing 60 thousandths from mdf.  Uses 7/16 drill rod

Need a 3/8 threaded nut that will not interfere with bearing

The 7/16 composite bearing using drill rod and two 3/8 bearings.

3/8 reamer finishes the inside of the 7/16 drill rod

7/16 bearing made out of drill rod and two 3/8 bearings

Bearing assembly with capture nut on top

The purpose of the tool is to make duplicate mdf form blocks each slightly smaller.

Use whatever mdf form block needed and hammer a joggle that fits the spar.

Alternate joggle tool made out of 5/8 keystock from grainger

Use of alternate joggle tool with vice and hammer

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Oct 30, 2021 How to

Category: Brake

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Oct 29, 2021 sheets

Category: Wing Skin

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Sep 29, 2019 Bending C channel spar

Category: Wings

The flap spars require a 10 foot brake. A lot of effort was placed in making the foot for the brake.

Bends made with the use of a angle inclinometer

The green nose (radius) shoes are covered with a sheet of roofing sheet metal.  Taped to brake.

premade radius bends made on brake in various sizes.  made out of steel strapping.

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After hammering on 10 degree over for spring back

pneumatic hammer or mallet

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Sep 16, 2021 sheet metal edge - (6 hours)

Category: Tools

The aileron and flap have 020 sheet metal wrap around nose material. The 020 edge is rolled over the top of the 032 spars. To aid the bend, the 032 spar can have a slight rolled edge also. The commercial tool does not allow for its use in this manner. This modification allows the dies to be used in a similar matter but also roll the edge of the 032 spar material

commercially available edge roller and parts for modified edge roller

commercially available edge roller can not roll edge because of bolt and nut

the dies are 5/16, so a coupling nut is drilled out enough for 5/16-18 bolt

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ream out a few threads

bolt can now be threaded into coupling nut for precise fit

measured distance of commercial edge roller and made a jig to hold bolts that far apart.

Cut off end of new vice grips and tig welded coupling nuts using jig for spacing

This is the new edge roller - with needed clearance

new and original edge roller

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Sep 08, 2021 Joggle - (8 hours)

Category: Tools

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Aug 31, 2021 Trim

Category: MDF

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scotch brite 7 med wheel

Aug 25, 2021 Lightning holes - (10 hours)

Category: Spar holes

tool bit grind

support plate bolted down

1/4 pilot holes

as many clamps as possible

tool bit grind for cutting holes

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Jun 22, 2021 layout dwg for flap spar - (6 hours)

Category: Wing Flap

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Jun 15, 2021 nutplates

Category: Reference

nutplates.pdf

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Jun 13, 2021 Military rivet spec

Category: Reference

Military spec

MIL-R-47196A_MI.pdf

Jun 11, 2021 RIB FORMING - (20 hours)

Category: FLAP

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Jun 07, 2021 Drill Jig for Aileron and Flaps - (4 hours)

Category: Tools Useful

Drill Jig for Aileron and Flaps

I stole the spring and 12-24 screw from these side clamps

New clamp jaws that have a replacable drill bushing

The new jaw can fit into tight spcace of aileron and flap ribs

Bottom Jaw shaped to reach under flange

2 Dowel pins keep the assembly from rotatating

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Jun 05, 2021 General Methond of Final rib forming - (40 hours)

Category: RibForming

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Jun 05, 2021 rib joggle - (20 hours)

Category: Wing Flap

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Jun 05, 2021 General methond of making ribs - (40 hours) Category: RibForming

May 15, 2021 How to setup - (6 hours)

Category: Brake

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May 05, 2021 AileronFlap - (6 hours)

Category: Wing False

Layout leading edge material for Aileron and Flap

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Apr 29, 2021 False spar - (6 hours)

Category: Wing False

Top flange 83 degees; bottom flange 87 degrees.

4 foot brake with bending radius nose attached.

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Mar 01, 2021 Aileron support

Category: Wings 4130

I found it easier to plug the end of the support tubes.

I added some weld material for use latter in welding tube to bracket.

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Tube oil

Tube with end welded shut to contain tube oil

solid 3/4 chrome molly used to make end caps

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welded end

Apr 21, 2021 False Rib - (8 hours)

Category: Wing False

Make the false ribs

4 False rib blanks routed with template.

1/2 inch spiral flush bit used to remvove aluminum

Each blank is deburred

Master bending mdf with rounded corner.  Top hold down has beveled edge for hammer blows.

The 032 flase rib blanks do not get the internal bevel

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Plastic hammer used to set the edge over master template

gouges are made in template to help make flanges square.

Aluminum requires an over bend to get the final rib to have square flanges

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Tool used to bend square flanges

Check for square flanges

Over kill method of creating square flanges

Jig was made to support the blank for

Jig holds material for setting flanges.

Wood dowel used to punch in material at correct locations

Notch must be made for capstrip thickness

Check for square edges.

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Check for capstrip clearance

Apr 15, 2021 Other parts

Category: TOOLS_MDF

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Apr 15, 2021 Mdf for round champfer

Category: TOOLS_MDF

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Apr 15, 2021 Mdf for blanks

Category: TOOLS_MDF

1618518065489-727085650.jpg

1618517700144-335793098.jpg

Mar 29, 2021 Level step1

Category: Wing hanger

image.jpg

image.jpg

image.jpg

image.jpg

image.jpg

Oct 11, 2019 Aileron Hinge - (8 hours)

Category: Aileron 4130

bandsaw and file final shape

20 ton press with cold roll steel form block

Hammer crisp edge

shape after 20 ton press

Cut off one wing

beginning shape before bandsaw

image.jpg

Mar 28, 2021 Final rivets - (2 hours)

Category: Wingassemble

Final rivets in wing tip to spar connection

image.jpg

Feb 02, 2021 Assembly Category: Receipt

Example wing installs

Jan 29, 2021 Support bracket - (8 hours)

Category: Welding 4130

1611957037624-1296307859.jpg

Dec 05, 2020 Proprietary 3

Category: Wing Skin

https://bearhawkforums.com/filedata/fetch?photoid=59943

image_8179.jpg

https://bearhawkforums.com/filedata/fetch?id=30128&d=1495894248

https://bearhawkforums.com/filedata/fetch?id=30127&d=1495894353

Dec 03, 2020 B-SPOT BUCKING BAR - (12 hours) Category: Tools

Dec 01, 2020 Aileron Drive Linkage - (8 hours)

Category: Aileron 4130

16068565100321601993188.jpg

1606863547950562721909.jpg

1606857275905-1465588414.jpg

1606857505522-1878733372.jpg

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1606863526711-1867454993.jpg

1606864018867373761936.jpg

16068639198221819272070.jpg

Dec 01, 2020 Rear spar bracket

Category: Aileron 4130

1606856802608-673590042.jpg

Dec 01, 2020 Rear spar bracket

Category: Aileron 4130

1606856802608-673590042.jpg

Dec 01, 2020 Rear spar bracket

Category: Aileron 4130

1606856802608-673590042.jpg

Nov 16, 2020 Bracket for wing tip - (12 hours)

Category: Wing hanger

wing tip brackent

Wing tip bracket

The surface with blue pen will be 1/4  lower then the surface with red pen.

The angle with the yellow pen does not touch spar.  It is only used as an attach point for strings.

16058073299041947497039.jpg

The level is displaced by 1/4 lathe bits to the height of the 032 spar web.

brackets are level in two directions

bracket is level in two directions

bracket height is set with water level

16058075461351409130435.jpg

water level used to set height of brackets that are 172 inches apart

1605820760115107058774.jpg

The bracket is symetric for supporting right and left wing

160590832330498852845.jpg

2x4 will support rear spar weight

Nov 16, 2020 https://bearhawk.tips/ Category: Reference

https://bearhawk.tips/

Nov 16, 2020 Elevator Push PUll

Category: Safety Notic

oct2010a.jpg

Nov 16, 2020 Push Pull tube

Category: Safety Notic

oct2010b.jpg

Nov 16, 2020 Fuel line location

Category: Fuel System

https://eaabuilderslog.org/?blprojentry&proj=7XFn3SHmH&e=7i3WAE4Py&listcat=&sid=

Engineering Notice January 2011.html

engntc0411.jpg

fuelmount.jpg

Nov 16, 2020 Fuel Line Mounting Bracket

Category: Safety Notic

engntc0411.jpg

fuelmount.jpg

Engineering Notice January 2011.html

Nov 16, 2020 correct on 284

Category: Safety Notic

changeaug11.jpg

Nov 16, 2020 Fire Wall

Category: Safety Notic

firewall.jpg

Nov 16, 2020 upper wing strut end

Category: Safety Notic

strutfit.jpg

Nov 16, 2020 tube layout

Category: Safety Notic

notice0312.jpg

Nov 16, 2020 Hinge

Category: Safety Notic

patrolnotice12-12.jpg

Nov 16, 2020 Door sill

Category: Safety Notic

change0113.jpg

Nov 16, 2020 MAXIMUM ALLOWABLE DIVE SPEED

Category: Safety Notic

vne.pdf

Nov 16, 2020 Deflection Stop

Category: Safety Notic

notice0913.jpg

Nov 16, 2020 Control stick hardware on Bearhawk LSA Drawing #26 and Patrol Drawing #29.

Category: Safety Notic

Engineering Notice Feb12.html

noticedec13.jpg

Nov 16, 2020 Change pre 284

Category: Safety Notic

changelrg.jpg

EngineeringChange Notice Mar 2014.html

Nov 16, 2020 Engineering Change Notice

Category: Safety Notic

September 2015.html

Nov 16, 2020 Forward Wing Skin Stiffener

Category: Safety Notic

2020a.jpg

February 2020.html

Nov 16, 2020 Landing Gear Change Shock

Category: Safety Notic

June 2016.html

june2016.jpg

Nov 16, 2020 Elevator Trim Cable Tension

Category: Safety Notic

Elevator Trim Cable Tension

March 2019.html

Nov 16, 2020 Tail Post

Category: Safety Notic

mar2018tailpost.png

March 2018.html

June 2016.html

Nov 16, 2020 All current safety notices Category: Safety Notic

http://bearhawksafety.com/Patrol/patrolengineer.html

Nov 16, 2020 Safety update stabilizer

Category: Safety Notic

http://bearhawksafety.com/factory/2020_0624.html

Bearhawk Safety Updates Stabilizer.html

Nov 16, 2020 Fuel Tank

Category: Safety Notic

Fuel tank

Bearhawk Operation Notice - Fuel System - bearhawkpatrol@gmail.com - Gmail.html

Nov 15, 2020 Reference strings - (3 hours)

Category: Wing hanger

Holes are matched drilled  so that they line up across from one another

Holes used for reference lines as needed built into support bracket

match drilled supports with  holes to tie strings used for reference lines.

Nov 15, 2020 Water level - (1 hour)

Category: Wing hanger

Mark support for level

16054559405971947497039.jpg

1605454394434-356202069.jpg

1605455582153-1661510361.jpg

Nov 03, 2020 Nose ribs - (12 hours)

Category: Wing build

nose ribs lined up with string and indexed to follow spar profile

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keep ribs square with sting

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nose rib 8 was cut in such away to leave as much of the flange top and bottom un touched

nose rib 8 is the only rib that takes more time to measure and cut notches

Oct 22, 2020 Weld 0.1 doubler - (2 hours)

Category: Wing pulley

16033077305351700154057.jpg

Oct 21, 2020 Weld 0.1 doubler - (2 hours)

Category: Wing pulley

1603307710579-394734311.jpg

16033077305351700154057.jpg

Oct 20, 2020 Bend - (40 hours)

Category: Wing pulley

I would like to say this took 6 hours. But It took 40 hours. I had to try many methods. I even tried to form the part with heat. That was a mistake. There is a picture of a cracked pulley bracket made using heat.

I abandoned all heat and ended up forming the part with single cold form bends. Using form blocks and a 20 ton press the exact shape could be made without using a torch. Most of the 40 hours was experimenting and making different form blocks

Once the form blocks were made and the method settled on then it only took 6 hours.

part made with an 8 inch length of 1/8 x 1 inch strip. The 1 inch strip was reduced to 3/4 inches

a form block with the 6 degree angle

all bends are made cold  no bending back and forth

6 degree form block used to set bends

The 6 degree form block used to set two bends

two additional blocks made to form the feet

preliminary partial bend

Two additional blocks one is 3/16 shorter then the other

feet form blocks set angle and distance

shape match to drawing after forming feet.

this is an example of why forming hot is a bad idea.

20 ton press used to set the angle of the feet.

first bend with 6 degree block and 20 ton press

C clamps keep vise from breaking

6 degree form block

2 form blocks used ro form feet at correct distance and angle

Oct 13, 2020 Wing Skin 1 Category: How to Video

https://www.youtube.com/watch?v=tX0NrNY1Q7o&list=PLWY4f_BKuRl7UzNJb7MycGhkuhxiVyrIC&index=6

Oct 13, 2020 Wing Skin 2 Category: How to Video

https://www.youtube.com/watch?v=vy0JVh5TljE&list=PLWY4f_BKuRl7UzNJb7MycGhkuhxiVyrIC&index=2

Oct 13, 2020 Fuel tank stiffener Category: How to Video

https://www.youtube.com/watch?v=e8zDiLFADJs&list=PLWY4f_BKuRl7UzNJb7MycGhkuhxiVyrIC

Oct 13, 2020 straighten ribs Category: How to Video

https://www.youtube.com/watch?v=_F7jObc0ajA

Oct 12, 2020 Layout table reference lines

Category: Wing build

IMAG0510.jpg

Oct 12, 2020 Layout table reference lines

Category: Wing build

IMAG0510.jpg

Oct 11, 2020 Layout table reference lines - (15 hours)

Category: Wing build

Two rectangles 172 3/4 x 32 and 174 x 36 are laid out on large table. The rectangles have right angles and the correct web center distances.

Two blue angle plates are locked into position. The blue angle plates have one edge along the 32 inch web line. The other face of the blue angle plates are set back to account for attach plates.

In the case of the rear spar it is set back the 3/16 inch distance which accounts for the rear attach plate thickness . An additional distance which represents the thickness of the grey square which will eventually be clamped to the face of the attach plate.

The rear spar attach hole is to be centered on the grey square. The face of the rear attach plate sets one distance. The center of the rear attach plate sets the other distance.

The main distance is similar. One face of the blue angle plate is along the 32 inch line. The other face is set back the 1/4 inch distance to account for the thickness of the main spar attach plates.

two large rectangles laid out 172 3/4x32 and 174x36

layout two rectangles 172 3/4x32 and 174x36

Rear attach plate hole is centered on 172 3/4x32 grid

Main spar is locked in place offset by attach plate distance.  Lathe bit sets main spar attach hole.

Main web is supported with wood set back cap strip distance using lathe bit

Main spar is locked in place in two directions

Main spar locked in place with angle set back attach plate distance

the blue angle is locked in place  off of spar web line.  The square should bisect attach holes.

Thickness of square + 3/16 for attach plate.

The blue angle is locked in place  3/16+square thickness off rear spar web line.

The square is locked to the angle.  The sqaure is set back the thickness of the square plus 3/16 .

Rear spar long distance set by centering on attach holes

Main spar attach hole center is used to set main spar long distance

Rear spar has to be spaced up 1.34 inches.

Rear spar is set in long distance by centering on attach hole

The drill rod demonstrates that the attach holes are not concentric.  Off by 1/2 inches

Sharpened drill rod demonstrates 1/2 offset.  Drill rod is parallel to table.

Oct 07, 2020 Press bend - (6 hours)

Category: Tools Useful

I need to bend .125 chrome moly with a 20 ton press

I need a way of making sure nothing flys out of press

This is thar part that I have to bend up.

16021727604621775506352.jpg

1602172828304-717679234.jpg

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1602173406432-1007805736.jpg

1602173535442-1662320457.jpg

1602173782093720688778.jpg

1602175088671-1110566569.jpg

1602175628954877256385.jpg

IMAG0545.jpg

IMAG0546.jpg

IMAG0547.jpg

IMAG0548.jpg

IMAG0549.jpg

IMAG0550.jpg

IMAG0551.jpg

IMAG0552.jpg

1602176460220-1574016930.jpg

1602188684062619366323.jpg

part still needs trim

Oct 11, 2020 Calculations wood block - (1 hour)

Category: Reference

Center line to mylar edge at main spar is 2.7

Center line to mylar edge at rear spar is 1.363

2.7-1.363=  1.34 inch wood blocks to support  rear spar

Oct 11, 2020 Calculations - (12 hours)

Category: Reference

.sldasm

.sldprt

A.sldasm

_angleddown.SLDAS.sldasm

_done.SLDAS.sldasm

_drillwingf.sldasm

_fin.sldasm

_fuselageattachfittin.sldasm

_mai.sldasm

_mainattachplate.SLDPR.sldprt

_mainf.sldasm

_mainf.sldprt

_mainweb.SLDPR.sldprt

_proble.sldasm

_rearattachplate.SLDPR.sldprt

_rearf.sldasm

_rearf.sldprt

_rearweb.SLDPR.sldprt

_wing.SLDAS.sldasm

blockofwood.jpg

blockofwood.xcf

perpattach.jpg

perpattach.xcf

perpfuse.jpg

perpfuse.xcf

pointie.jpg

pointie.xcf

problemstatement.jpg

problemstatement.xcf

rearblock.SLDAS.sldasm

rearfitting1.jpg

rearfitting1.xcf

resultsinnotconcetric.jpg

resultsinnotconcetric.xcf

sortof.jpg

sortof.xcf

wing2.SLDAS.sldasm

wingfit1.jpg

wingfit1.xcf

Sep 09, 2020 Saw jig with tenryu blade - (6 hours)

Category: Tools

The table saw jig is used for trimming the the spars to the correct length. I recommend leaving the rib blanks all the same length and only trimming for cap strips just before assembly. The ribs are cut from different sections and orientations of a sheet of 2024. The grain pattern for the ribs will be different. No matter how hard you try there will be variation in the construction of the ribs. The spar also has some variation during the bending process.

If the ribs are left full size, then they can be placed at different rib locations. It is possible to optimize the ribs that go on the spar for best fit.
Only after best fit arrangement is established should the material be removed for the capstrips arrangement at that rib location.

Also, I use various standard size lathe bits as tools for setting up cuts to the correct length. The aluminum fence is a calibrated distance from the back of the blade. Various arrangements of lathe bits allow for a rib to be put in the jig and maintain a parallel cut.

Table saw jig with hold down clamps

The center of the spars are 32 inches all rib blanks were cut to 32 - 1/2 (.032) - 1/2(032).)

accurately move fence to the correct distance from the cutting edge teeth.

rib distance set from fence to cut off the correct amount of material

rear spar requires the removal of material accross the edge - not just notch for capstrips

Oct 06, 2020 TOTAL EXPENSE TO DATE Category: BOM

TOTAL FOR PROJECT TO DATE IS $6,600

DOES NOT INCLUDE ALL TOOLS
DOES NOT INCLUDE SHIPPING CHARGES
DOES NOT INCLUDE BUILDING TABLES

DOES INCLUDE SOME TUBING FOR FUSELAGE
DOES INCLUDE SOME BOLTS NUTS PULLEYS
DOES INCLUDE PRIMER,ALODINE
DOES INCLUDE SOME TOOLS

THE WEBSITE DOES NOT REPORT CORRECT EXPENSE

Oct 07, 2020 PDF

Category: BOM

Patrol_BOM.pdf

Oct 03, 2020 Rear spar

Category: Last check

rear spar centered over table marking

rear spar is 172 3/4

16017515344161805974566.jpg

rib offset compare main to rear spar

measure main spar ribs

Oct 03, 2020 Main spar

Category: Last check

attach holes are meant to be centered on table markings

rib distance compare main and rear spar

main spar locked into position centered on table marking

main spar 032 is over line, blue angle plate is offset 1/4 back to be flush with attach plate

both main and rear spar rib distances are measured

Oct 04, 2020 Lock spars so attach holes are in correct location

Category: Wingassemble

main spar is offset to center of attach hole referenced to table

16018334625802124394578.jpg

rear attach hole referenced to table

1601833523624-422371374.jpg

rear spar spaced up 1.34 inches

rear spar is slid over to cover half of attach hole referenced to table markings

Sep 26, 2020 Measure

Category: Time

1601162986899-331762637.jpg

rear attach hole with horizontal drill rod

16011630441332124394578.jpg

main spar

cord line is at right angles to both spars

1601219523062180854321.jpg

horizontal needs blocks 1.337 inch to make cord parallel with table

rear spar

1601219558216522464905.jpg

theoretical offset if a plumb bob was used is 1/2 inch

should be offset by 1/2 when done horizontaly or in a vertical wing stand

solidworks 32 model of wing

Oct 04, 2020 Attach holes

Category: Details

ribs were made 32-.032 in length for proper spacing

attach holes are not concentric by 1/2 (by design)

rear attach lined up with table with square

drill rod is 1/2 inch high at rear spar (by design)

drill rod is concentric with main spar

drill rod is in the correct position

1601837647639-1501048199.jpg

Oct 04, 2020 Drill

Category: Wingassemble

easiest way to drill thru pilot holes in attach angles

ribs are notched for capstrips

1601835490013-226704629.jpg

rib 6

rib square with spar

rib square with spar

Sep 30, 2020 Rivet - (8 hours)

Category: Wing ribs

1601508827276-331762637.jpg

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Oct 03, 2020 Rear spar Category: Last check

Oct 03, 2020 Spar layout Category: Table grid

Oct 03, 2020 Spar layout

Category: Table grid

1601566010891-331762637.jpg

1601568625471-1209961120.jpg

16015686660842124394578.jpg

1601577729416637672927.jpg

1601578106278-422371374.jpg

16017494838301591375059.jpg

1601749499485180854321.jpg

Sep 29, 2020 Notch - (5 hours)

Category: Wing trim

1601403364313-331762637.jpg

1601403421263-1209961120.jpg

16014053895642124394578.jpg

1601405601842637672927.jpg

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1601478157368-1209961120.jpg

16014781774942124394578.jpg

Sep 23, 2020 Measure - (3 hours)

Category: Time

Measured rear spar displacement at 1.34 inches.

Rear spar displacement measured using wing cord line as referenece

Rear spar displacement using cord reference

The measurement of the offset from the cord to the edge of rear spar is 1.35 inches.

Rear Spar has to be spaced up 1.34 inches

1.34 inch spacers for rear spar

(Center of web to attach main spar is 1.5)(Center of rear spar web to attach is 1.125 inches)

1600894079914-1209961120.jpg

$gallery thumbnail$

1601071540328-331762637.jpg

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IMAG0451.jpg

finalrearpic.jpg

Sep 27, 2020 Solidworks - (10 hours)

Category: Tools

I thought it would be useful to have a way of presenting the bucking bar to the shop end without having to keep such a close eye on it being square to the rivet.
To that end I designed a prototype holder for my bucking bar.

I can then concentrate on the factory side with the rivet gun.

The holder could be clamped onto the surface without the rubber bands. The bar can then be inserted into the holder.

It is also possible to just free hand the foot to be square with the sheet metal. The rubber bands will hold the tungsten against shop head during riveting.

This foot design is meant to go over L angle brackets

The rivet gun will push angle bracket and sheet metal together.  It pushes against rubber band.

Tungsten bar with typcal holder.

Different foot designs  allow acess to confined area.

feet and holder printed separately and glued together as needed.

Sep 25, 2020 solidworks

Category: Tools

A.sldasm

Part2.SLDPR.sldprt

Part2.ST.stl

Part2_B.SLDPR.sldprt

Part2_B.ST.stl

Part3.SLDPR.sldprt

foot_b.sldprt

foot_base_fi.sldprt

foot_base_fi.stl

foot_twi.SLDPR.sldprt

foot_twi.ST.stl

part2_A.SLDPR.sldprt

part2_A.ST.stl

Sep 25, 2020 Rearspar offset - (5 hours)

Category: Time

Master rib pattern used to double check cord line and spars

Cord line is parallel with table and spar is at right angles

Rear spar at right angles to table

Wood shims 1.35 inches used along the lenght of rhe rear spar

Rear spar has to be spaced up 1.35 inches before assembly

Ribs were left full size (31.66 inches) and notched.

Ribs are 31.66 inches and spar ends are parallel.  Ribs are square at both spars .

Top surface is considered the reference for vertical placement.

Cord line is parallel with table

Cord line is parallel with table

mai.sldasm

mainweb.SLDPR.sldprt

rea.sldasm

rearattach.SLDPR.sldprt

rearweb.SLDPR.sldprt

wing.SLDAS.sldasm

mai.sldprt

rea.sldprt

rearattach.SLDPR.sldprt

rearweb.SLDPR.sldprt

mai.sldasm

rea.sldasm

wing.SLDAS.sldasm

Sep 16, 2020 Level for straight holes

Category: Tools

1601071233575674372462.jpg

Sep 17, 2020 Work table

Category: Wingassemble

Flat table.
2x4 cut to 31.66 to space center of spars at 32".
Rear spar raised off of table with shims.

Rib pre cut to 31.66. and Notches for capstrips are done.

The Rear spar is raised and a drill rod is used to check alignment of attach holes.

Sep 16, 2020 Level for straight holes

Category: Tools

To be safe match both bubble levels

there are two bubble levels for reference

Sep 16, 2020 Rivet

Category: Rib angles

1600280006004-331762637.jpg

1600280032706-1209961120.jpg

Sep 16, 2020 youtube Category: Rib Straight

https://www.youtube.com/watch?v=jqNoVAQLo0M

Sep 16, 2020 Notch jig

Category: Tools

1600265058424-1722961894.jpg

1600265201688637672927.jpg

1600265307372-422371374.jpg

1600265550631180854321.jpg

16002661642731935117965.jpg

1600266195729522464905.jpg

1600266724717-226704629.jpg

Aug 24, 2020 Water level - (2 hours)

Category: Tools

WATER LEVEL FOR TABLE

WATER LEVELLING TABLE

Each leg of table has an adjustment screw

Aug 20, 2020 Table - (2 hours)

Category: Workshop

shelves for sheet and chrome molly

1597931938553420697673.jpg

1597931961149-621598820.jpg

15979319786681365562429.jpg

level table

vacuum 2 inch pipe

adjustable legs for non level garage floor

adjustable legs

2 inch pipe with vacuum port locations

Nov 09, 2019 Alodine tray for center ribs

Category: Painting

97.png

98.png

99.png

1598565722060-1951846686.jpg

1598988137026-1984844550.jpg

Aug 27, 2020 Table - (8 hours)

Category: Spar

1598565655625628754098.jpg

1598565688731-178726640.jpg

15985657033541498677341.jpg

1598565722060-1951846686.jpg

Jun 22, 2020 Trim - (1 hour)

Category: Wing Attach

1592843036269815451194.jpg

image_6392.jpg

159284348283821857228.jpg

15928438625111495132394.jpg

Dec 14, 2019 iteration - (1 hour)

Category: Aileron

Spars are cut into strips that should be about right. Then throw away coupons of material are trial bent until the angle and length under the
brake foot produce the desired fit on the airfoil shape.

keep bending trial strips until match is found.

Dec 14, 2019 3/32

Category: Stiffener

stiffener that goes under skin near flap

angle.pdf

angle.png

Dec 14, 2019 trailing edge - (6 hours)

Category: Stiffener

The only way to get the trailing edge down to the 18 degrees is by using a 10 foot brake.

Tape and some straps are used to hold nose against the brake.

Protective foot with 3/32 radius for flap stiffener.

Protective foot for bending spars.

brake has to have set back after adding foot.

This is the protective foot used for bending spars.

Close the trailing edge down to 18 degree by crushing it down.

Tape is used to keep trailing edge from being scratched.

Crushing the trailing edge down to for an 18 degree angle, while protecting the bend with 3/32 rod

Nov 27, 2019 Aileron and flap

Category: Hinge

1574886318455395422049.jpg

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Nov 21, 2019 Make

Category: Attach Angle

the extra angle material is slid under foot to be cut off later.

It is faster to run angle thru table saw.

cheap belt sander works great.

Nov 20, 2019 Cut

Category: Attach Angle

1574266014193494877577.jpg

1574268285686592392183.jpg

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Nov 08, 2019 Rivet pattern

Category: Wing Skin

15732280296467286470.jpg

1573228636648-317563405.jpg

AD4 RIVETS @ 032 SKIN TO REAR SPAR

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Nov 12, 2019 Bolts

Category: Reference

bolts1.pdf

Nov 12, 2019 Standard Practices

Category: Reference

StandardPractices1.pdf

StandardPractices2.pdf

StandardPractices3.pdf

Nov 12, 2019 Sheet Metal Bending

Category: Reference

https://www.youtube.com/watch?v=h9fxo95D4Ik

bendallowance1.jpg

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Nov 11, 2019 Aileron

Category: Access Panel

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Nov 11, 2019 Aileron Servo

Category: Controls

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Nov 11, 2019 Torque tube

Category: Wing Flap

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Nov 11, 2019 Wing Tip Skin overlap

Category: Wing Skin

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Nov 11, 2019 Hidden holes @ overlap

Category: Wing Skin

I do not know who to credit for this technique

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Nov 10, 2019 First sheet 032

Category: Wing Skin

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Nov 10, 2019 Main Spar Capstrips

Category: Capstrip

2024T3 SQ & RECT 1/8X1 12FT 03-42700-12 14 $22.20 $310.80 08/13/15 'www.aircraftspruce.com 2024T3 SQ & RECT

I made and extra Master Capstrip

I made this 1 inch centering punch for master capstrip

Master capstrip held down

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slot in 2x4 used as clamp to clean up and debur

Bubble level and centering punch

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debur tool

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I wanted capstrips accurate to reference edge -use clamps to force to one side

Nov 09, 2019 Rear Capstrip

Category: Wings 2024

2024-T3 .063 AL,CLAD,PVC/1 4'x12' 1 $303.60 $303.60 07/27/18 wicks aircraft

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Sep 25, 2019 Wing parts made with 2024

Category: Wings 2024

ALCLAD/PVC 2024T3 ALUM SHEET .032 4'X12' 03-28010 1 $169.99 $169.99 07/05/14 'www.aircraftspruce.com 2024T3 SHEET
2024T3 ALUM SHEET .032 4 X12 03-28010 1 $169.90 $162.91 08/13/15 'www.aircraftspruce.com 2024T3 SHEET
2024T3 ALUM SHEET .032 4'X8' 03-28020 2 $113.89 $210.70 07/05/14 'www.aircraftspruce.com 2024T3 SHEET

Construction of ribs

Nov 09, 2019 Pocket

Category: Aileron

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Nov 09, 2019 Attach Screws

Category: Wing Tip

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Sep 23, 2019 C-frame used for riveting

Category: Tools

Home made C-frame is very useful. Although picture shows rivet gun, many AD5 rivets are set with mallet.

Home made C-frame

The only part that is required is a rivet set holder from cleavelandtool

1/2 inch O1 drill rod.  I did use a lathe to shape the 0.401 rivet gun.  I also use a torch and hardened the ends.

$36     http://www.cleavelandtool.com/Avery-C-Frame-Retrofit-Kit/productinfo/Z-CF-AVERY/#.XYoqgHVKhUQ

The problem with the cleavelandtool rivet set is that eventually the 3/16 pin breaks off in the hole.  There is no way to remove it.  I made my own by annealing old rivet sets, cutting to length and drilling a hole straight thru.  After the hole is drilled I hardened and tempered.hru.  After the hole is drilled I hardened and tempered.hru.  After the hole is drilled I hardened and tempered.hru.  After the hole is drilled I hardened and tempered.hru.  After the hole is drilled I hardened and tempered.hru.  After the hole is drilled I hardened and tempered.hru.  After the hole is drilled I hardened and tempered.hru.  After the hole is drilled I hardened and tempered.

If you are making a fuselage, you have a acetylene torch.  If you have a torch you can make what ever you want out of junk.

Step 1 heat hardened steel until glowing then bury in vermiculite.

Step 2 Machine anything you want from annealed steel.

Step3 heat what ever needs to be hardened, and quench in transmission oil.

Step 4 The hardened steel is polished, and a small flame is used to draw out the color indicated the temper of the part.

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Jun 07, 2017 Main Spar 4130 @ splice

Category: Wings 4130

03-25700
4130 STEEL SHEET 9 X 18 X .190
$38.75/Sheet
Aircraft Spruce

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Nov 06, 2019 Attach angles Right Rear Spar - (6 hours)

Category: Rear spar

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Nov 05, 2019 Finished LEFT Rear spar capstrip AD4 AD5 rivets - (6 hours) Category: Rear spar

Nov 05, 2019 Aileron Pocket Rib Locations

Category: Rear spar

Reference is center of attach bolt

Do not rivet at angle attach locatoins

Do not rivet at hinge

hinge

attach angles for Aileron pocket ribs (other side)

Do not rivet at attach angle locations for pocket ribs (other side)

pocket rib used as reference (actual mount is 180 degrees around))

Aileron hinge and pocket ribs attach(other side)

Aileron pocket rib @wing tip

Oct 30, 2019 Right Rear Spar rivet cap strip - (8 hours) Category: Rear spar

Oct 29, 2019 Mark do not rivet locations with blue tape - (.5 hour)

Category: Rear spar

The pocket rib goes at these locations

Aileron pocket rib goes at these locations

Aileron pocket rib goes at these locatons

Aileron pocket rib here

Nov 05, 2019 rear spar ad4 capstrip riveting - (1 hour)

Category: Rear spar

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Nov 04, 2019 rear spar ad4 capstrip riveting - (1 hour) Category: Rear spar

Oct 31, 2019 AILERON POCKETS - (4 hours)

Category: Rear spar

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End of Flap spar distance check

Flap hinge distance check

Do not rivet capstrip this location

Aileron hinge distance double check; Do not rivet in these locations in capstrip

Location 12 Do not rivet attach angle yet

Location 13 do not rivet attach angle yet

Rib 14 2 pocket ribs spacing not symmetric.  Do not Rivet yet

Marked the location where aileron ends and where pocket rib will be attached on back side of spar

Oct 29, 2019 Rivet right rear Spar CAPSTRIPS AD4 - 6 - (8 hours)

Category: Rear spar

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Oct 29, 2019 Mark do not rivet locations with blue tape - (.5 hour) Category: Rear spar

Oct 29, 2019 Cleco and bolt cap strips on right spar - (6 hours)

Category: Rear spar

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Oct 28, 2019 Should not have done at this point

Category: Rear spar

I need to remove these rivets so I can attach pockets from behind

Oct 24, 2019 Attach Angles - (8 hours) Category: Rear spar

Oct 24, 2019 Attach Angles - (1 hour)

Category: Rear spar

step 1 small rivets to hold spacers in place held with tape

2 Attach angles are made in matching sets if they go on Main Spar

3 rivets do not protrude all the way thru

4 special clamps were made that have the necessary clearance

5 Square used to set angle and clamp in place

6 As a precaution I use a clamp to keep end from moving while drilling

7 I copied the bubble level from another bearhawk builder

copolymer rod has been cut to have clearance with attach angles

drilled out from backside

always moving clamp to give support before drill

debur the holes

back rivet with C-Frame

Oct 23, 2019 Aluminum rivet squeezer handles - (3 hours)

Category: Tools

The wood handles would bend under AD4 rivets. I drilled out and bored new aluminum handles

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Oct 22, 2019 Attach angle clamps - (20 hours)

Category: Tools

Various clamps made for the attach angles. Holding the 032 attach angles in place for drilling requires clamps with special clearance for the attach angle flanges.

The clamps are habor freight. They are probably cast iron. I use a dremel to cut out areas required to make screw threads.

The white material is copolymer rod from amazon. Usually, about $8 for 1 foot lengths of different diameters.

The acme screw has a piece of copolymer rod that has been bored out enough for the foot of the clamp to fit inside. I then use epoxy to hold the copolymer material to the foot.

Harbor freight clamps cut so that I can put a threaded set screw on top

acme screw has a copolymer rod epoxied to foot of clamp

The whole point is to have clearance for the 032 attach angle flanges.  Width reduced to fit on 032

Oct 22, 2019 Left rear Spar attach angle - (3 hours)

Category: Rear spar

Attach angles requre AD4-6.5 rivets. I use a lathe to trim AD4-7 rivets. Do not waist money on rivet cutter.

1/16 6061 spacer for 2024 t3-032 attach angle

short ad4 rivets used to hold spacers in place while drilling from other side

032 attach angle can pivot about cleco

special clamps made to hold 032 attach angle at right angles

lock 032 attach angle in place and drill from other side

c-frame used to rivet with 3x rivet gun

Oct 22, 2019 Spar attach ad5 rivets all capstrip rivets done - (7 hours)

Category: Rear spar

rivet cutter are useless, since I do not have the right size rivet I use a lathe to trim off a longer rivet to make the correct size. Do not use rivet cutters. They make cuts that are not square.

C-frame for AD5 rivets.  There is a block off steel to protect drill rod.  AD5 rivets require hammer

c-frame back rivet hard to reach rivets, and all AD5 rivets.

rivet in home made aluminum collet to trim excess off.

rivet lengths are checked

cutters are useless waist of money and time

back rivet with mallet

Oct 21, 2019 TP116 rivet squeezing ad4-6 RIVETS

Category: Rear spar

TP116 - Hand Rivet Squeezer
AD4-6 RIVETS CAN BE DONE IF HANDLES HAVE MORE LEVERAGE
1 1/2 inch clearance required for rear spar web flange.

Can not be used on Main Spar.
Small white copolymer washer used if rivet needs to be seated before squeezing.

TP116 - Hand Rivet Squeezer, Also the plastic washer used sometimes to seat rivets before squeezing

Oct 21, 2019 left rear spar more riveting - (8 hours) Category: Rear spar

Oct 21, 2019 TP116 - Hand Rivet Squeezer - (2 hours)

Category: Tools

TP116 - Hand Rivet Squeezer (Has built in adjustable rivet set.)
The best tool for rear spar AD4 capstrips

The gap is 1 1/2 which will clear web flange.

Wood handle extension

TP116 - Hand Rivet Squeezer

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TP116 - Hand Rivet Squeezer

Oct 20, 2019 more riveting on left rear spar - (6 hours) Category: Rear spar

Oct 19, 2019 Rivet - (8 hours)

Category: Rear spar

I use cleco and 3mm screws to hold capstrip while riveting.

3mm screws bought on amazon with nuts and washers

Oct 18, 2019 Table Rear Spar support

Category: Workshop

pedestals level long way as a group

rear spar on pedestal support

pedestals aligned so that they do not interfere with capstrips

pedestals leveled individually

Oct 18, 2019 Begin riveting

Category: Rear spar

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Oct 13, 2019 Finished priming all rear spar parts and wingtips and 13 center ribs - (8 hours) Category: Rear spar

Oct 12, 2019 Coverage - (3 hours)

Category: Painting

coverage one side of capstrips and one side for rear spar and one side of spacers, and one side of attach plates.

2 oz cataylst 72g
4 oz primer green base 181g
3 oz thinner 84g

Using the above gram weight I can mix a very small patch
Air pressure set at 30 lbs.

Primer applied as thin as possible.

one side of rear spars

one side of capstrips

one side of spacers

Safety gear for epoxy primers

$97 STITS EPOXY PRIMER KITS GREEN EP-420 / EP-430 / E-500

STITS EPOXY PRIMER KITS GREEN EP-420 / EP-430 / E-500

STITS EPOXY PRIMER KITS GREEN EP-420 / EP-430 / E-500

cheap $10 harbor freight gun

mixing cups $10

Sep 29, 2019 Building 18 foot mdf table - (100 hours)

Category: Workshop

https://eaabuilderslog.org/?blprojphoto&proj=7XFn3SHmH&p=7XPm6U2NG&listcat=articles&cat=&e=7XPC0ujcj

The legs of the table are splayed more then the 48 inch wide mdf sheets. I have built several shelf under table to hold 12 foot sheets of alcad aluminum

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strips of 1/2 mdf used

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torsion box construction

level waxed sheet used to make flat surface.  Glue holds flat reference surface.

1/2-13 nut plates everywhere

table.odt

Oct 11, 2019 Anodize 032 center ribs and nose ribs - (20 hours)

Category: Wing anodize

Nose rib drying

tubs that can be drained back into jug containers

Flowing water makes cleaning easier

Trays for anodize made from a roof drip edge strip and plastic sheet

Center rib drying

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epoxy primer

Oct 10, 2019 Arrange for primer - (2 hours)

Category: Wings 2024

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Oct 10, 2019 scotch brite and anodize center ribs - (6 hours)

Category: Wings 2024

clean water

dry after soap water and scotch brite

center ribs anodized after scotch brite

Oct 10, 2019 Scotch-Brite 20:24 Center ribs 18 total - (5 hours)

Category: Wings 2024

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Oct 09, 2019 Remove plastic cover on alcad remove ink - (4 hours) Category: Rear spar

Oct 09, 2019 anodize - (4 hours)

Category: Rear spar

Source of Constant Flowing Water

Before and After Scotch Brite

Alodine

Wing Tips

Water,acid,alodine

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Rear spar parts and Wing Tips

Oct 08, 2019 Debur and scotch brite - (9 hours) Category: Rear spar

Oct 07, 2019 Alodine capstrips for rear spar - (6 hours)

Category: Painting

Three troughs alodine,water,acid

flowing water in center trough depth regulated with valve.

Valves allow regulating flow and empting troughs.

6061 1/16 spacers are also to be anodized in trough

Chemicals can be emptied back into jugs by opening valves.

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Alodine 6061 spacers.

Level troughs can be emptied with squeegee.

Oct 06, 2019 Alodine reference

Category: Painting

The Desert Bearhawk Project: The Alodine Process.html

Sep 25, 2019 Tools I find useful

Category: Tools Useful

V shape debur

Scotch brite wheels

rubber bands,extra long dummy rivets,squares

Debur for edges

Soft backed fine grain sanding attachment

miles of blue tape

Bubble level epoxied on air drills (n3uw)

scotch brite

Table saw with slide for making square cuts

Random heavy weights

rock tumbler for mixing primer

various levels and ITOYA 18x24 art profolio (recommended by Alaska Bearhawk))

paper cutter can shear up to 032 if hold down clamp installed

waxed slide with runners for table saw square cuts

I used a OLFA knife to cut many strokes across cross grain aluminum 2024t3. For 032 I typically used

lathe cutitng tools can be used for dimensional spacing.  They can take the heat.

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mdf jig fixed to drill press.  The wings to the side allow for clamping spars with F clamps.

rock tumbler used to mix paint

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Oct 04, 2019 prep for anodize capstrips - (8 hours)

Category: Rear spar

Capstrips have to have holes debured, and scotch brite. After several cleanings they are ready for the acid bath. The felt markings will not survive the acid. I have some alodine markings that should survive. Just in case I place a placed a couple of rivets to align the match drill sets (front and back). I then sand a unique pattern in the end while taking a picture allowing the set to be identified as a backup plan.

The trough for the etch alodine process was made for the Main Spar capstrips. I already had the parts but it still takes time to level the split 4 inch pipe.
One trough is water,one trough is acid,and the final trough is alodine.

There are other ways of alodining capstrips, this is just my preference.

Place 4 inch pvc on semi circle holders

Prepare table level for semi circle holders

Place a unique pattern of end treatment for each pair of capstrips

Place a unique pattern of end treatment for each pair of capstrips

Place a unique pattern of end treatment for each pair of capstrips

Place a unique pattern of end treatment for each pair of capstrips

Trim a tiny bit off matched set of capstrips

Oct 04, 2019 1/16 spacer - (2 hours)

Category: Rear spar

I could not find 1/2 inch strips of 1/16 6061. I purchased several lengths of 3/4 6061 angle.
Both legs of the angle can be salvaged.
6061T6 ANGLE 3/4X3/4X.062 8FT 03-00185-8 1 $19.68 $19.68 08/13/15 'www.aircraftspruce.com 6061T6 SQ & RECT

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Oct 03, 2019 rear Spar parts anodized - (1 hour)

Category: Rear spar

Ran a quick test to see if my new marking system would survive the acid- alodine. With the main spar I used a magic marker and a lot of effort to redraw ink after each process.

This is my plan for parts for the rear spar. I buff a small area - and clean with acetone - on parts that I want to mark. I paint the lettering that at this point only exist as a felt marker.

The part is then placed in the acid bath - alodine cycle. I found that the alodine markings survive the acid bath. They also are visible thru after the real alodine dip.

I try to put such a thin coat of primer on that the markings should still be visible thru the primer after drying.

ALODINE �� ALUM COND 1201-GAL 1 $44.83 $44.83 07/27/18 http://www.wicksaircraft.com
ALUMIPREP **HAZARDOUS** 33-GAL 1 $36.89 $36.89 07/27/18 http://www.wicksaircraft.com CHEMICAL

Test of chemicals shows that 2 minutes is enough for fresh alodine

With a small paint brush parts are marked.

Keep track of which part is match drilled for which side is time consuming

Oct 02, 2019 rib spring back adjust

Category: Tools Useful

The rib flange is made 90 degrees with this flange adjust tool. It is bolted to the table and the flange is sequenced under the hammer handle. The next one I make will have a longer handle.

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Oct 03, 2019 prep for anodize of rear spar - (8 hours) Category: Rear spar

Oct 02, 2019 Rear Spar ready for anodize - (8 hours)

Category: Rear spar

All holes completely match drilled. At least one of the Hinge mounting locations expanded to 3/16 per drawing. Extra material trimmed off of end of outer web.
All critical dimensions measured and verified. Made some more tooling.

Heavy weight holds C channel stable.

Careful check of cut line

Table saw blade height raised to cut flange

Table saw blade just proud of slt for first cut.

Support C-channel for cut

Table Saw cross cut slide

Oct 01, 2019 thin kerf blade for 2x4

Category: Tools Useful

Cutting 1/16 capstrips from 12 foot sheet of 2024 with a different saw blade. This thin kerf wood blade is use to cut a thin slot in a 2x4 that will hold the 1/16 strips so that the edges can be deburred. This blade was not meant for a table saw but it will fit in a table saw for cutting the thin kerf slot.

Thin kerf 7 1/4 blade mounted in table saw to make slot in 2x4

The capstrips are 12 foot long.  A 2x4 with slot holds for debur

Oct 01, 2019 used to cut 1/16 x 12 foot capstrip from 2024

Category: Tools Useful

The portable saw was modified my rewiring it to run of a 12 volt car battery. The saw is light enough to handle while cutting long strips from the 4 foot by 12 foot sheet of 1/16 2024

hand held saw for cutting strips of 2024

Oct 01, 2019 aluminum cutting blade for table saw

Category: Tools Useful

There may be the need to square up the C channel at the web splice to make a tighter fit. Also there is a very small amount to cut off from the full 8 foot C Channel Web.

10 inch non ferrous metal blade

trim edge of C-channel

Jig for square cross cuts.

Oct 01, 2019 aluminum blade for chop saw

Category: Tools Useful

Very useful.

12 inch non ferrous aluminum cutting blade.

Hard stops and hold down clamps for repetitive accurate cuts

Oct 02, 2019 locations offset by 1 1/4

Category: Rear spar

9.677= 6 3/8 + 1 1/4 +(2*1.021)

7 5/8= 6 3/8 + 1 1/4

reference is the attach hole not capstirp

center of reference hole

75=73 3/4+ 1 1/4   LOCATION RIB 7

62 3/4=61 2/4 + 1 1/4 RIB LOCATION 6

50 2/4= 49 1/4 + 1 1/4 RIB LOCATON 5

FALSE SPAR RIB 4   ~36.25= 38.25 - (2*1.021))

FALSE SPAR RIB 3 ~22 = 26-(4*1.021))

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FLAP ~97 1/2 = 99 1/2 - (2*1.021)  )

87 1/4= 86 + 1 1/4 RIB LOCATION 8

 85.69 = 84.44+ 1.25  SPLICE

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124 = 122 3/4 + 1 1/4

117 7/8 = 124 - (6*1.021)  Aileron hinge)

111 3/4 = 110 2/4 + 1 1/4  RIB LOCATION 10

99 2/4 = 98 1/4 + 1  1/4  RIB LOCATION 9

172 3/4 = DIRECT FROM PLANS

162.79=159 2/4 + 1 1/4 + (2*1.021))  AILERON HINGE OUTER

161 3/4= 159 2/4 + 1 1/4  RIB LOCATION 14

148 2/4 = 147 1/4 + 1 1/4 RIB LOCATION 13

136 1/4 = 135 + 1 1/4 RIB LOCATION 12

Oct 01, 2019 Spiral trim router bits

Category: Tools Useful

The 1/2 inch up cut is the most important for making MDF tooling, and cutting several rib blanks all in a single pass. This bit did the rough cut of all blanks and lightening holes in ribs before the flange was bent.

The 1/4 inch was only used while making some of the pocket ribs.

Routers are dangerous. Metal -hot metal- goes everywhere. The upcut pulls chips into the router and away from you. That is good for you and bad for the router. I modified my router so that the holes were blocked. I also used a vacuum to pull out as much as I could. Chips still go everywhere.

One last important observation is that even if you use a router table it will grab the work and pull it out of your hands. The key to this is that you must never try to trim more then a radius of material. In the case of the 1/2 bit, if you try to trim 1/4 or more it will certainly pull away from you. If you use less then the radius of the bit you can slowly and controllably remove metal safely.

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Oct 01, 2019 flap outer hinge

Category: Rear spar

flap outer capstrip location ok

Oct 01, 2019 flap inner hinge

Category: Rear spar

flap inner hinge capstrip location ok

Oct 01, 2019 aileron inner hinge

Category: Rear spar

Aileron inner capstrip location ok

Oct 01, 2019 outer aileron hinge

Category: Rear spar

Aileron Outer hinge capstrip location ok

Crush thick paper to imprint location of capstrip hole

Oct 01, 2019 check center flap hinge - (5 hours)

Category: Wings 4130

The hole pattern in the capstrip measures within 20 thousandth across long distance (4 - 5/8).
I have not enlarged the holes to accommodate the 3/16 holes required for bolts that attach hinge to spar

This is the center location for flap

While studying this location, I have come to the conclusion that my original plan fro drill sequence will not work.
Because the hinge overhangs the lower hole, it is the lower hole (not the top one or two) that must be drilled first.

I always meant to pre drill one side only. I was going to use the hinge to establish the hole center for the other side.

I then examine the imprint of the capstrips  and measure for accuracy.

I took a piece of stiff paper and crushed it at hinge mount location

Oct 01, 2019 aileron hinge mount

Category: Rear spar

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Sep 30, 2019 hinge

Category: Rear spar

hinge mounts 4130 steel

Sep 30, 2019 hinge - (8 hours)

Category: Rear spar

Completed match drilling. Spar Ready for debur anodize, and prime.

Match drill hinges to Rear Spar

Layout hinges.

Sep 30, 2019 Edge Debur

Category: Wings 2024

Edge debur

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Sep 30, 2019 Bubble Level Drills

Category: Tools Useful

Epoxy bubble level to drills while being held perpendicular

If table is level bubble is a good reference

Sep 29, 2019 Main Spar Capstrip - Attach Plate

Category: Wings 2024

I worked hard at making the Attach Plate (Force Fit) the capstrip.
It required several assemble, sand operations

The goal is to have attach plate butt up against capstrip

Capstrip was made long is carefully adjusted

line contact

Sep 29, 2019 Main Spar Construction

Category: Wings 2024

capstrip has to have spacing adjusted here

String is used to check main spar straight

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The 1 9/16  is the key measurement for laying out capstrip

1 9/16 from splice to capstrip

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Device used to find center of web

Center of web

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Table saw used to square web at splice

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Splice to capstrip rivet

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String is used check center of web

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Rubber bands hold capstrips tight to spacer

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Special effort to hold capstrip against attach plate

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Modify hole saw for aluminum

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Edge debur

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Hole debur

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Sep 29, 2019 Main Spar Construction

Category: Wings 4130

Belt sander used to clean up edges

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Front and back 4130 match drilled.

4130 is match drilled to splice plate  and c web

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Sep 29, 2019 N289R

Category: Patrols

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Sep 29, 2019 N240BP

Category: Patrols

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Sep 29, 2019 Master Tooling

Category: Rib Tooling

The Patrol plans come with a mylar sheet. The mylar sheet contains the airfoil shape. The sheet would not last long, so, it is glued to a piece of 032. The 032 sheet is carefully filed to the profile of the airfoil.

After the 032 airfoil master is made it is used as a template to make a MDF Form that contains all of the details of ribs.

Elevator bolts hold MDF together

Before Master rib is used as a template it is bolted together

Bottom MDF with elevator bolts, spacers , and MASTER 032, and Top Cover used to bolt together

Spray glue mylar to 032

A jig saiw is the only way to make MDF blanks.

Sep 29, 2019 Make Rib Blanks

Category: Rib Tooling

Metal Master Rib is used to make MDF forms

Metal Mater is used to make all MDF forms

Example of MDF tooling used to bend flange

Example of MDF tool for making rib blanks

Router is used to make blanks

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Upside down router mounted in table

Stack of blanks coming out of MDF forms

MDF forms for cutting out blanks

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Sep 29, 2019 Flange Tool

Category: Rib Tooling

Step 1 router a bunch of rib blanks all at once.
Step 2 debur edges.
Step 3 Press rib blank and make round flanges.
Step 4 Put blank with round flanges in a mdf assembly
Step 5 Rubber mallet $7
Step 6 Add scallops while slowly being formed

There are many ways of straightening potato chip rib once flanges are hammered.

This is my way of doing it:
Step 7 Place rib in my flange finish tool
Step 8 Press down- Clamp Flange edges with set screws.
Step 9 Use wooden dowel to force flutes into scalloped out mdf form
Step 10 Still have to over bend flange because of aluminum spring back.

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Step 1

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Step 4

Step 4-5-6

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Step 7-8-9

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Step 10 All methods require dealing with spring back

Step 7-8-9

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This is what potato chip looks like

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Step 10

Finished no potato chip

Step 3

Step 2

Sep 29, 2019 Round Flange with Hydraulic Press

Category: Tools

The 20 ton press is quite useful for many tasks. I probably spent more on the 1 inch material then on the whole 20 ton press. I tried rubber pieces if tire like in the EAA video on hydro forming but did not find it adequate.

I copied https://www.youtube.com/watch?v=SYnX5-2m4HQ

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Sep 29, 2019 Rivet gun Hammer

Category: Tools

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Sep 29, 2019 How I bent my flanges

Category: Wings 2024

Fluting pliers used during the bending of flange

I built scalloped out area in mdf for setting flutes in JIG later

My way of removing Potato chip twist

My way of removing potato chip twist

My jig holds flange firmly and wooden dowel sets flute.

tool I use to bend past 90 accounting for spring back

Flanges have to be adjusted with spring back

Square check

Fluting pliers and round that I use as a square

Home made fluting pliers

Sep 29, 2019 Experimental way of bending flange

Category: Wings 2024

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Sep 29, 2019 Bob Barrows Surface

Category: N289R

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Sep 29, 2019 Bob Barrows Panel

Category: N289R

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Sep 29, 2019 Bob Barrows Interior

Category: N289R

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Sep 29, 2019 Bob Barrows GEAR

Category: N289R

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Sep 29, 2019 Bob Barrow's Firewall

Category: N289R

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Sep 29, 2019 Bob Barrow's Engine

Category: N289R

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Sep 29, 2019 Bending spars for patrol on 10 foot brake.

Category: Articles

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Sep 29, 2019 broom

Category: Workshop

One on off switch, and two 3 way switches for Hi med Lo

Old HVAC blower used to blow out aluminum chips

Sep 29, 2019 vacuum

Category: Workshop

Vacuum plumbed to under table manifold, and exhaust is vented outside.

Under table vacuum manifold

Sep 29, 2019 air compressor

Category: Workshop

I thought about use PEX but went with standard 1/2 iron pipe. Long lengths of pipe cool air and help get water out of line. PEX is insulated and would not help cool air. The long lines of iron pipe are my number one defense against water in line. Slanted iron pipe, inverted U bends and water drains run across ceiling.

I did install a cross over system so that I could get full pressure and volume for sand blasting.

I highly recommend the HI flow connectors. The will still connect the older style but have a quick connect push in with out pulling collar back.

$8 walmart hi flow connector.  Compatible with both kinds of connecors

3HP compressor.  I did not need the volume or the flow but the noise of the other style was murder.

7$ Harbor freight automatic water drain.

$8 per ball valve drain.  Drains on slanted 1/2 iron pipe every slant

As many means as possible to Drain water.  Capture water,  filter air.  Long lengths of iron pipe.

Cross over arrangement so that I can get full volume and pressure when sandblasting

Sep 28, 2019 Drill jig

Category: Tools Useful

1/2-13 bolts have holes drilled in them to be used as bushings. Drill rod inserts are used to line up #40 holes before being clamped with vice grips. Drill rod is removed and #40 hole is drilled out to what ever size (bushing,drill rod) pair is used.

Aluminum insert machined to be with of capstrip and also clear spar flange. Threaded for 1/2-13 bolts. Also several holes drilled to help with aluminum shavings while drilling.

drill rod  with tapered end to engage #40 holes

1) aluminum insert, lower width same as capstrip, length clear spar

vice grip with bail bolted in place of original foot

2) Steel sleeve bored out to press fit aluminum insert that has 1/2-13 thread

3) assembled insert and sleeve

4) cheap vice grip clamp with sling to hold sleeve on threaded pins

top and bottom can rotate to any angle to be square when clamped.  Drill rod and 1/2-13 busihings

Apr 10, 2015 MDF rib forms

Category: Wing Tooling

I preferred the kind of MDF you get from a cabinet shop. I used a lot of 3/4 MDF from LOWES, but the best stuff can only be gotten at a cabinet shop. The cabinet shop has MDF that is 1 inch thick and is actually a little larger then 48 inches wide.

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Apr 10, 2015 MDF forms for bending ribs

Category: Wings 2024

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Feb 03, 2015 Flanging tool

Category: Tools

Ground some drill round shapes and welded to vice grip.

Drill rod shaped and polished

Drill rod would harden if I did not put it in vermiculte

Flange tool is use like this

Flange Tool Construction

Sep 28, 2019 Match drill web and spacers. Upsize to #30 for AD4-5.5 - (8 hours) Category: Rear spar

Sep 28, 2019 Sheet metal

Category: Tools Useful

The proper tool for cutting 025 and 032 sheets.

Sep 28, 2019 Silver solder jig

Category: Tools Useful

buy band saw blades.  Cut them to length scarf and silver solder

Sep 28, 2019 Not useful

Category: Not Useful

premade bolts ok, but plastic cup to big for any use.

rivet cutter, do not use, destroy on site

nibbler, One of my worst ideas.

Sep 28, 2019 attach plate - (1 hour)

Category: Rear spar

The four pieces that made up the attach plate are already match drill (undersize #40) . The goal of this operation is to match drill the whole assembly to the web and the front and back capstrips. In general the capstrips are match drilled already. In the area under the attach plate however, there are no holes until this operation is completed.

The drilling jig is a cheap vice grip that has been cut up and attached to a floating drill bushing. The drill busing is a 1/2-13 bolt that has been center drilled with the drill size to be used. The attach plates had a #40 match drill already. The pin's tip is sized for a #40. The pin's shank is 1/8. By placing the pin in the #40 attach plate hole, and then locking pliers down, a larger concentric hole can be made thru entire assembly. I use a 1/2-13 bolt as the bushing. It can be swapped out with whatever size drill bushing I need.

The advantage of this clamping fixture in addition to assuring concentricity is that there will be no metal shavings between plates after drilling.

match drill 2024 attach plate to capstrips.

special drilling jig with centering pin shown

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Sep 27, 2019 match drill spacers - (4 hours)

Category: Rear spar

The spacers are undersize.  The spacer rivet line is lined up with the capstrip with a straight edge

The webs splice rivet line is aligned with capstrip at attach angles.

Sep 27, 2019 Checking web splice Center

Category: Rear spar

Check web splice

Web splice is centered under reference string

Web splice must be aligned with capstrip rivets at attach angle location

Sep 27, 2019 Rear web splice

Category: Rear spar

Match drill rear and front web splice

Front and Rear web splice match drill undersize #40

After checking that the row of rivets near the web spice is safe, the last 6 near the splare drilled

Sep 23, 2019 Metal bandsaw made from a wood bandsaw

Category: Tools

I documented how I made band saw blades in a chapter newsletter.
http://www.958.eaachapter.org/Newsletters/2015/1015.pdf

A vacuum is installed to limit metal filings.

The motor and pulley arrangement for a wood saw has to be changed.  Here I have used a DC motor that runs the blade much slower then a wood saw blade

I modified my 12 inch wood bandsaw with a 6 inch pulley and a 90 VDC motor.

bandsaw.odt

Sep 27, 2019 match drill spacers webs and capstrips - (4 hours) Category: Rear spar

Sep 27, 2019 match drill spacers - (4 hours)

Category: Rear spar

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Sep 27, 2019 match drill spacers - (4 hours) Category: Rear spar

Sep 27, 2019 Final string check - (3 hours)

Category: Rear spar

The front and rear capstrips are matched drilled.
The rear and web are matched drilled
The rear,web and front are now mated together with undersize holes #40

Next step is upsize the holes to #30 for AD4-5.5 RIVETS

string check

Sep 27, 2019 String used to align web

Category: Rear spar

USING LATHE BITS TO HOLD STRING ABOVE MARKS

The other end of the line is supported at attach plates

Check of the center of the web using the splice plate.

lock into place

lock into place

Sep 27, 2019 Attach plate

Category: Articles

Match drilled Attach plate  fixed into plate

Sep 27, 2019 Attach plate

Category: Articles

Attach plate set for right spar

Sep 27, 2019 Attach plate

Category: Rear spar

Right attach plate set is match drilled to itself

Sep 27, 2019 align rear web and front capstrips Category: Rear spar

Sep 27, 2019 right rear Spar assembly Category: Rear spar

Cap strips for top of Spar matched to cap strips for bottom of Spar. Rear cap strips are matched drill to web. Then Rear,Web, and Front capstrips assembled.

Sep 26, 2019 Match drill rear spar - (8 hours)

Category: Rear spar

Left rear spar match drill finished to final rivet size.

left spar done

Sep 25, 2019 Construction of Attach Angles

Category: Attach Angle

The attach angles are made out of 025 and 032. I mark the material with a knife (scar several strokes) then snap scarred 2024 in metal brake.

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Sep 25, 2019 Wing parts made with 4130

Category: Wings 4130

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SportsAir workshop on welding

Sep 25, 2019 Welding Info

Category: Welding

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Sep 25, 2019 Chapter articles

Category: Articles

Bending ribs

20 ton press

modify sheet metal brake

My Table

Article only accurate on how to make bandsaw blades.  Bandsaw now uses DC gear motor for low rpm.

Construction of ribs

SportAir welding

Sep 24, 2019 Spar center finder - (4 hours)

Category: Tools

1/4 thick lexan plate. Holes drilled marking capstrips and center of C channel spar. The plate sides are cut the same angle as the C channel bend. Felt tip markers are placed in holes and plate is slid first along the length of the C channel on one side. Then the plate and felt tip marker is slid along the other side.
The center of the spar is the average of the lines traced.

All C- channel have custom made lexan slides made for tracing reference lines.

lexan plate center finder

high test fishing line for straight measurements

rubber bands to hold things before clamping

long rivets and rubber bands for temporary holders before drilling

The actual parts used as spacers

string, rubber bands, thousands of clamps

bubble level drill for match drilling C-channel

Sep 23, 2019 Duplicate parts

Category: Tools

I mounted a router upside down. The router had a 1/2 inch spiral flute bit with a bearing.
Whiteside Router Bits RFT5125 1/2-Inch Diameter Spiral Flush Trim Up Cut with 1-1/4-Inch Cutting Length

This is my starting point for duplicate parts.  It is a cheap piece of aluminum probably meant for the kick stop of a door.  I can very accurately scratch and make a template.

It takes a while to make the spacers and hold down covers that are used to sandwich the template and the aluminum blank.

The parts are sandwiched together in such a way that the bearing rides on the template.

It is important to keep the aluminum blank as close to the correct size.  Routers will grab the part if you are routing to much in one pass.

Bearing rests on template.  Aluminum chips will go every where.

Every piece of safety gear you can think of is called for.  A vacuum is also used to try to deal with all the chips

I modified my 2HP router with a lexan cover over vent holes.  The chips would destroy routero help remove chips.  Lastly a upcut spiral bit is used

Sep 23, 2019 Cut off saw used to accurately make capstrip parts

Category: Tools

Since I made the capstrip spacers accurate, I go to the extra effort to make sure that the matching (front and rear) capstrips are using the same reference edge. In summary a master capstrip is used to drill one rear capstrip at a time. Then the rear capstrip is placed against a square reference edge so that the front capstrip will have the same distance to the reference edge.)

The spacers can only be identical in length if extra care is made while drilling capstrips. Everyone has their own way of doing things. This picture is before capstrip is match drilled to spar. I put a couple of rivets in the holes thru capstrip. At this point there is no hole thru spar. I use rubber bands to hold capstips tightly against capstrip spacers. I then clamp and drill capstrips thru spar. When everything is assembled after anodize and painting everything will be in the exact location to be tight. the holes thru capstrip.

All capstrip spacers are made with a 100 tooth saw.  The blade is made for metal.

Since everything is matched drilled with respect to reference edge I keep track of which strip and which reference edge is to be used

Master capstrip was used to drill rear capstrip one at a time.  Then a reference edge was used to match drill rear to front capstrip

Rear reference edge is square to its mate capstrip on front side.  That way the capstrip spacers can all be same length.

The spacers can only be identical in length if extra care is made while drilling capstrips. Everyone has their own way of doing things. This picture is before capstrip is match drilled to spar. I put a couple of rivets in the holes thru capstrip. At this point there is no hole thru spar. I use rubber bands to hold capstips tightly against capstrip spacers. I then clamp and drill capstrips thru spar. When everything is assembled after anodize and painting everything will be in the exact location to be tight. holes thru capstrip. holes thru capstrip. holes thru capstrip. At this point there is no hole thru spar. I use rubber bands to hold capstips tightly against capstrip spacers. I then clamp and drill capstrips thru spar. When everything is assembled after anodize and painting everything will be in the exact location to be tight. holes thru capstrip. holes thru capstrip. holes thru capstrip. At this point there is no hole thru spar. I use rubber bands to hold capstips tightly against capstrip spacers. I then clamp and drill capstrips thru spar. When everything is assembled after anodize and painting everything will be in the exact location to be tight. holes thru capstrip. holes thru capstrip. holes thru capstrip. At this point there is no hole thru spar. I use rubber bands to hold capstips tightly against capstrip spacers. I then clamp and drill capstrips thru spar. When everything is assembled after anodize and painting everything will be in the exact location to be tight. holes thru capstrip. holes thru capstrip. holes thru capstrip. At this point there is no hole thru spar. I use rubber bands to hold capstips tightly against capstrip spacers. I then clamp and drill capstrips thru spar. When everything is assembled after anodize and painting everything will be in the exact location to be tight. holes thru capstrip. holes thru capstrip. holes thru capstrip. At this point there is no hole thru spar. I use rubber bands to hold capstips tightly against capstrip spacers. I then clamp and drill capstrips thru spar. When everything is assembled after anodize and painting everything will be in the exact location to be tight. holes thru capstrip. holes thru capstrip. holes thru capstrip. At this point there is no hole thru spar. I use rubber bands to hold capstips tightly against capstrip spacers. I then clamp and drill capstrips thru spar. When everything is assembled after anodize and painting everything will be in the exact location to be tight. holes thru capstrip. holes thru capstrip. holes thru capstrip. At this point there is no hole thru spar. I use rubber bands to hold capstips tightly against capstrip spacers. I then clamp and drill capstrips thru spar. When everything is assembled after anodize and painting everything will be in the exact location to be tight. holes thru capstrip. holes thru capstrip.

Sep 23, 2019 Rear Capstrip drilling and riveting

Category: Tools

The rear capstrip uses AD4 rivets. To hold capstrip I used 3mm screws.

Use 3mm screws for holding capstrips

Sep 24, 2019 Match drill front and rear caps trips to c channel - (8 hours)

Category: Rear spar

Capstrip was first match drill with a #40.  Capstrips then placed on C-channel and match drill to final size #30 AD4 rivet size

Sep 24, 2019 Rib attach angles

Category: Tools

https://www.youtube.com/watch?v=gIk3M7DMZpY

Many angles,many lengths,many thickness

I used lathe bits in different sizes just as a quick way to set up sheet in lathe.

Cut to correct length

Edge cleaned up step 4

Bent past 90 degrees because of spring back.

Edges cleaned step 1

Edges cleaned up step 2

All strips are cut with this knife as descriped in  https://www.youtube.com/watch?v=gIk3M7DMZpY

Chamfer corners. Step 3

Sep 24, 2019 Favorite builder websites Category: Research

Favorite web resources:
https://www.youtube.com/user/dbottita/videos
https://www.youtube.com/watch?v=EMlbOkrVxZM
https://www.youtube.com/user/HomebuiltHELP

Sep 22, 2019 Cut holes in spar to reduce weight. - (4 hours)

Category: Rear spar

This is a dangerous operation with a fly cutter. Jig is securely attached to drill press. C-channel is securely clamped to jig. Drill press slow speed.

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Sep 23, 2019 Making steel hinges

Category: Tools

4130 chrome moly has to bent into hinges

More hinges

Start with a metal bandsaw cutting sheets.

In some cases it is easier to cut off unused wing from a symmetric part,

Place sheets in a cold rolled steel die that has radiused corners

20 ton press.  Note the C-clamp keeps the variable open die from being destroyed

Various features can be made.

Final squared up form

Sep 23, 2019 Tool for notching center ribs around capstrips.

Category: Tools

I do not cut my center ribs early. I like to hand select which rib best fits each position along spar. There is a variable number of capstrips along the length. Having chosen which rib would be best for a location, I notch out whatever is required to clear capstrips.

Small tool used to quickly make notches in ribs

Sep 23, 2019 Table setup for drilling and attaching capstrips to spars

Category: Tools

Floating spacer blocks lined up to support spar

Floating blocks leveled using 1/2-13 set screws .

Floating blocks are then leveled long ways.

Spar is now supported and work can be done on either side of spar.  C hand rivet tool can be slid under for riveting.

Sep 23, 2019 Transfer punch and drill bushing

Category: Tools

example of comercial drill bushing

Home made drill bushing clamp used to transfer holes from master capstrip to matching capstrip while pressed against straight edge

Transfer punch used to line up holes and then clamp in place.  Transfer pin removed and hole drilled in matching capstrip

Comercial bushing holders would not work.  If you have a lathe you can make a holder that is the length to clear spar bend

I used grade 8 bolts drilled to various sizes.  I could use the commercial drill bushings in my custom holder.  All drill bushings have 1/2-13 thread.

Sep 23, 2019 Large holes

Category: Tools

Cut large holes is dangerous work. Drill press is set low speed and a hole cutter is slowly applied.
The jig that holds spar is firmly clamped to drill press.
The spar is firmly clamped to jig.

Hole cutters are dangerous.

Sep 23, 2019 Clean up edges of capstrips

Category: Tools

The saw marks are removed from cut strips using a slotted 2x4 to hold strips so they can be cleaned up with files or rotary tools.

slot is cut in long 2x4

Thin kerf blade intended for hand power saw mounted in table saw to make slot

Edges are cleaned up with the 2x4 holder

Sep 23, 2019 Cut 1/16 capstrips

Category: Tools

1/16 capstrips are required for rear spar. I used a lite portable saw to cut stips from a 12 foot sheet.
I also used the home made 12 foot straight edge.

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Sep 23, 2019 Make Straight Edge

Category: Tools

Big box stores sell straight edges. The problem is that I needed a 12 foot straight edge. I bought several straight edges and made a long MDF board that spanned several straight edges. Gorilla glue then is used to permanently connect them and hold them fixed

A 12 foot sheet is used as my reference edge

A MDF board is glued to the commercial straight edges

Tape is added to the back to prevent marring sheets of aluminum

Sep 23, 2019 Handy home made tools

Category: Tools

Sometimes it is necessary to have drill press engaged in the hole and activating switch requires another hand.
This is a simple remote control interface that can turn on a drill press or a remote vacuum.

30 Amp Contactor  Approx $7.  The coil is 120 volts and is wired to the output of remote switch (white)

remote control outlet $12.  The remote control switch is made for very light loads.  The white switch could not normally be used for devices with motors.

The drill bit is engaged with dimple.  Right hand holds drill press down.  Remote control is also in right hand for activating drill press.

Sep 23, 2019 spar is made straight

Category: Tools

A string is used to make sure multiple sections of spar are straight

Heavy duty fishing 70lb test line is used as a reference line.

Sep 23, 2019 Table for spars

Category: Tools

Capstrips are matched drill to spars. Shelf has lots of slotted holes for clamping capstrips

MDF boards used as a work surface

2x4 bolted to table have MDF boards with slots that were used to make level surface

Sep 23, 2019 Drilling and riveting Main Spar capstrips

Category: Tools

The main spar uses AD5 rivets. When drilling and riveting the capstrip needs to be held securely. 8-32 screws are a few thousand to big but can be touched up with a file.

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Sep 23, 2019 Joggle tool for adjusting ribs to fit ribs.

Category: Tools

Tool made out of 5/8 keystock. Cost about $7. Got the idea from Desert Bearhawk videos

Each rib is adjusted for its location on spar.  It is best to leave each rib full size so that they can be chosen for the best location

rib is clamped in vice and a soft mallet is used to adjust joggle.