Project: Patrol   -  
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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

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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


 
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.


 
Sep 08, 2021     Joggle - (8 hours)       Category: Tools


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


 
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.


 
Sep 16, 2020     Level for straight holes       Category: Tools


 
Sep 16, 2020     Level for straight holes       Category: Tools
To be safe match both bubble levels


 
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.


 
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


 
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.


 
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.


 
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


 
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.


 
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.

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Sep 23, 2019     Rear Capstrip drilling and riveting       Category: Tools
The rear capstrip uses AD4 rivets. To hold capstrip I used 3mm screws.


 
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.


 
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.


 
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.


 
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.


 
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


 
Sep 23, 2019     Table for spars       Category: Tools
Capstrips are matched drill to spars. Shelf has lots of slotted holes for clamping capstrips


 
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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