Apr 01, 2024     Frustrations Category: home

As this site keeps sending me nags that I have not updated the progress on this build, I doubt I will be going further. I have Long Covid and live in a state that essentially prohibits curing this man made disease. My mind and my body are shutting down, slowly and very uncomfortably. In early May my wife and I host our Chapters "Spring Fling" fly-in breakfast. WX permitting I will bring this over for display and with for sale signs. I am crying as I write this but that is life, well the slow and miserable end to it.

  Aug 21, 2023     Unknows Category: home

I am at a frustration point in life. I might abandon this project.

  May 03, 2023     Oil cap in place       Category: Engine

Here is the cap in place, O-ring is installed. I still need to drill the perimeter lip for safety wire.

  Apr 30, 2023     Oil cap       Category: Engine

This is the roughed out plug for the original oil filler tube, I still need to machine the top allowing it to be gripped and safetied.

  Apr 15, 2023     A few morning photos       Category: home

This gets me sun from the other side.
These shots show the lower cabin door swing and the main/lower baggage door which swings forward/dowm.full open it is an inch or so from the ground with this mockup landing gear and Stearman wheels. Being that Grove will not be able to supply the aluminum leaf spring I will be going with an Olio style which will be closer to a J4 main gear but with 80+ years better technology utilized.

  Apr 15, 2023     Rolled out for a few photos.       Category: Engine

Not much to say, I will let the photos speak
The last shot, I am sitting in the plane with the camera at my eye, this shows my view out the front quarter. Probably hard to tell the temporary bracket for the instrument panel. This is the outer edge allowing me a rather good front quartering view.
In a side view of the engine, my tall dipstick/oil fill will be right at the cowl door. This will allow a very easy oil level check and top up.

  Apr 15, 2023     Trial fitting the engine       Category: Engine

Having had the steering box on my Kubota fail a week ago stopping progress on my trial fitting of the engine, The marvels of 50+ YO tractor. Order a complete new steering system on Thursday, it was delivered Friday morning, Tractor running in the afternoon and the engine was hung on the airframe an hour later.
I was a good feeling to bring this out in the sun for a photo session.

  Apr 09, 2023     Almost but no.       Category: Engine

Today was above freezing, clear and sunny, my full intention was to roll the engine stand to the door, lift the engine with a chain from the bucket on my Kubota, bring it down below and mount it on the airframe.
Everything is ready, spirits were high, and as I was driving my tractor up to the door, something inside the steering box broke. The steering wheel spins 3 turns, move up and down but will not steer the wheels. Oh well, luckily most every part is available for Kubotas so I will order the parts tomorrow.
Here is a pic of the engine with the nose bowl "paper doll" template in place sitting just inside the shop door.

  Apr 08, 2023     Engine not mounted Category: home

I was going to be posting pictures of the engine mounted on the airframe. I got everything ready, rolled the engine stand to the basement door.
I have the mount rubbers in place, hardware set in place for easy grabs.
I go up back, fire up my old Kubota and drive it down, as I am turning to line up with the door, something odd, the steering wheel releases and spins free, WTF.
The shaft is turning with the wheel, the issue is inside the steering box.
So in reverse I go and using the brakes I drive it back and park it in the snow, I will get to it later.
And yes I poured myself a shot of Makers Mark to sip on.

  Apr 08, 2023     Humm, thinking Category: home

Sometimes thinking is good, sometimes not. As I review where I am at on this intake and needing to understand how the 4 into 1 exhaust blends in. It might be time to hang the engine on the airframe.
Our next few days are forecast to warm up a bunch, as in reaching 50 deg, F during a few days.
Might be time to fire up my tractor and carry the engine down to the garage where the fuselage has been stored since it was displayed at our fly in last fall.
Heck my intention is to have this back at KRUT for a display at our May 7th fly-in breakfast lunch.

  Apr 08, 2023     Intake flanges       Category: Engine

I have shaped the outside of the intake flanges on my 18 inch disc, at this point with a course grit which will be blended smooth later. This allows my to get a better look with the carb located and the first intake tubes set in place I can now get working on the plenum design as well as determine if the carb is located where I actually want it. Allot of learning going on right now.

  Apr 07, 2023     Hanging the carb       Category: Fuselage

Part of the design/build of the intake is positioning the carburetor allowing me to finalize the intake plenum.
As I was laying out the "paper doll" for the aft face of the nose bowl I realized it can support the carb allowing me to determine just where I want it. Here are a few images of what I am working with.

  Apr 04, 2023     Nose bowl template       Category: Fuselage

Here I paste another full size print of the aft cross section of the nose bowl onto a leftover wall paneling/ Masonite.
This has two holes that will allow this to be fastened to the front of the cylinders.
Down low will be a few fasteners to stabilize the HA-6 carburetor where I expect it will be.
My next step, well other than cutting around the perimeter will be to cut out space for the engine case, starter and alternator so this will attach to the front of the engine.
Allot of learning will then happen, depending on my pace building the intake manifold the engine will be hung back on the fuselage.
I then can verify the lines/curvature of the fuselage. This will be an important step to visually verify the lines/curves of the fuselage.
.

  Apr 02, 2023     Nose bowl       Category: Fuselage

Oh one more tidbit, When I had cut out a Masonite template awhile back for the nose bowl I determined the outer cheeks needed to be raised up to properly clear the heads. Here is the template set over the drawing of the new shape om paper with the outer portion raised 1 1/2 inch. Quite a difference. The pen marks on the bottom are depicting where the carb inlet will be.

  Apr 02, 2023     More flange work,       Category: Engine

Our morning started beautiful out and I hid in the shop for the most of it. Only went down to the lower garage to pull a few flap parts off the airframe.
I the shop I did a few finish details on the inside of the flanges followed with installing a fresh blade on the saw and cut the flanges apart.
Decision to make is if I shave the outsides down on the disc sander or mount some tooling on the mill and machine these.

Until the outside is finish shaped these will not fit on the engine, so no show & tell yet.

  Apr 02, 2023     Intake flanges yet again Category: Engine

I ground a radius cutter to finish the seating area that the intake tubes lock in against,
Next will be to cut the aluminum bar into individual parts then shape the outside.
No photos taken

And well, I was just was back down in my shop and realized I drilled these flanges for 5/16 fasteners.
I will cut some sleeves from tubing, more of an irritant than an issue.

Today I am also preparing to cut the revised front cowl template in Masonite as well as fabricating new templates for the flap actuators that broke last fall towing the plane to KRUT for display which if weather permits it will be at my Spring Fling fly-in breakfast a month from now.

  Apr 01, 2023     Intake flange clamps       Category: Engine

Here are a few images as I machine the flange clamps.
I neglected to grab the camera when using the boring bar to accurately size the hole and machine the step inside the flange.
My design callas for a radius on the step but I need to grind a cutter to machine this., Later for this.
My drawing for this was printed on four sheets showing the four main steps to this point, I will take pics of them for display in my next post.

  Mar 23, 2023     Intake flange       Category: Engine

I just machined the first, prototype intake to cylinder tube end flange.
I feel I want to "tweak" the dimensions a bit for the for actual parts, but I like what I have in concept.
I have rough cut two intake tubes, I think I have the dimensions and angle of bend in the ballpark but I need to form the center intake plenum before anything is locked down.
With these rings in process I can clamp a bar of aluminum onto the mill and start machining them.

  Mar 11, 2023     Cowl template, Carb positioning       Category: Engine

The lower cowl template is now properly anchored to the cylinder heads, this allows me repeatability as I move forwards.
I have now made a temporary support for the carburetor. I will keep the shop upright and engine upside down for now.
This is a simple strap mount allowing me to mockup a few possible positions leading up to building the intake manifold.

  Mar 05, 2023     Paper doll 2       Category: Engine

These images flipped, granted different camera position will make a difference but I feel the side cheek are too low to fit over the heads.

  Mar 05, 2023     A paper doll of the nose cowl       Category: Engine

I am not sure I have this right. Hard to tell from the few shots I took but the curve of the cowl at the top of the cylinders is to close. This is why I depend on these templates. And yes camera angle and focal distance has allot to do here. I was concentrating on locating the HA6 carb. That looks fine but the cylinders need more room.
Oh yes the engine is upside down on the stand, maybe should flip the images.

  Feb 25, 2023     Nose bowl Category: Engine

The past few days I have been back on the drawing board, well not really, although this project did start on my 8' drafting table utilizing my Vemco V track drafting machine I generally work with a near antique ACAD 14 program.
At this time I am laying out the templates for the nose bowl so I can verify some details. Part of my goal at this time is how snug I can be around the alternator, starter and forward facing carb. I feel I have plenty of room but best to prove it before I get going on the intake manifold.
Once I have cut some Masonite I will have something to take pictures of.

  Feb 20, 2023     Sump 2       Category: Engine

I am getting the side walls tacked to the top plate. I am liking it.
Soon I need to finalize where I want the temp sender, low oil indicator and the oil drain. I fully expect I want the engine hung on the airframe to do so. All this will be determined before I weld the bottom on.
So I might transition to building the intake manifold and can then understand the exhaust which also needs the engine on the airframe.

As such

  Feb 19, 2023     Sump       Category: Engine

I chose to cut more of the top plate out, clamp the sump in place after a few tweaks to it and then trial fit the filler tube.
And well, the shop is not actually upside down in that second image.

  Feb 19, 2023     Dip stick tube Finis       Category: Engine

This part is done, welded, blended and finish texture.

  Feb 18, 2023     Dip stick tube, yet again       Category: Engine

This time I think I got it.
The first go at machining the top of the DS tube I had the wrong tap, a 1.125X14 thread, but nope Lycoming uses a 1.125X12 on this part. the first tap was not crazy money but this on in country was stupid money. So off to China I go and ho ho I have a tap, made my part and in a box the tap will go, probably never be used again.
But this time I have a sweet, usable part. Not finished yet as nothing on this project is. At this point the head of the tube gets welded on. I need to get a 3/16 aluminum rod for a longer dipstick and that will be as far as I can logically go with this part.
As can be seen I built in a scupper to reduce the dribbles during use.

  Feb 03, 2023     Exhaust system prep       Category: Engine

Nothing really to show, guess I could post a few renderings, these are not up to date, I have just ordered most all the material to build a 4 into 1 header with top quality merge collector as I build fro performance and road race cars.
I will be machining my own flanges, these will be rather stout compared to what is commonly used for aircraft. I intend to utilize seal rings rather than gaskets such that there will be considerably less chance of leaks or failure.
Building the intake will be part of this step but I expect I can not get real far till I can get time on a friends forming equipment which will not be till summer.
I should ad here, being older than average for designer/builders these drawings and renderings are drawn on AutoCad 14, not 2014, this is the 1997 program.

  Jan 31, 2023     Sump Floor       Category: Engine

First task of today, well after plowing snow, was to layout, cut and form the floor for the oil sump.
This is just roughed and will not be welded in place until I trial fit the engine and understand where it is best to install the oil drain so there is the least interference with the 4-1 exhaust.
One detail with this sump is the oil strainer plug is the absolute lowest part of the sump such that it is not real important if the quick drain lets all the oil out.

  Jan 30, 2023     Just a prop       Category: Engine

OK so it was lonely and cold outside.

  Jan 30, 2023     Modifying the oil sump       Category: Engine

It has been on my mind since the beginning of this oil sump that there are chances with low oil levels that the pickup could get unported. I would like the pickup pretty far back to make sure oil pressure is maintained during steep climbs. Today I chose to ramp the front edge up allot.
Being the O-360 sump is 5" deep and mine is 7" this works for me.
I will next look into sloping each side wing up to reduce the chance of issues during a steep slip.
At this time this sump is 5 1/2 Lbs, the original is 11, granted it has the center intake included but I will still beat that weight allot.

  Jan 29, 2023     Carb, again       Category: Engine

A few shots from the rear of the carb as it sits in place.

  Jan 29, 2023     Carb       Category: Engine

I have machined the intake flange for the carburetor and am trial fitting, or call it mocking up where it will fit,
Guess I should have a picture of the flange, I will get one or two as this develops.

  Jan 29, 2023     More dipstick tube       Category: Engine

The filler/dipstick tube is roughed out. I need to rework one section of weld, I expect it is porous.
Plenty more to do with oil feed and baffles.

  Jan 27, 2023     Dip stick tube Category: Engine

Camera did not join me in the shop today, kind of distracted with EAA webinars through the afternoon.
I welded the vertical seam on the front of the oil sump followed with forming and fitting the lower dipstick tube and cutting the sump for it to fit.
I expect photos in a day or two.

  Jan 26, 2023     Oil sump progress       Category: Engine

This is shaping up nice, I will be making some tooling/spacers to locate it as I prepare to weld it to the plate.
I also need to make the decision if I want to TIG weld this step or use MIG.
I have the spool gun for my MIG machine which is essentially new in box for the past 30+ years. Kind of a decision if I TIG this or take it over to another shop since he has many hours with the MIG machine. That decision is a few weeks away. For now the can is close, my original intention was to roll the lower edge at the seam to the bottom. I am starting to find the limits with my bad arm so it will be interesting to see where I am at in the near future.

  Jan 25, 2023     Oil sump sides       Category: Engine

This session is forming the sides of the oil sump. The material is 6061 .090 thick.
I got this far but my bad arm ha called for a break. I am also at the point I can not form the front corners and further on the brake.
As such I have a very nice small roller set, it just is not mounted on a bench, which It is clear this needs to be done now.
An off topic note, I see the viewers over the past weeks are many times the numbers seen in the past. I hope my true hands on build intrigues a few minds. I am one of the few true aircraft builders who designs and builds most everything I own.

  Jan 23, 2023     Oil strainer       Category: Engine

I have welded the oil strainer tube to the base plate. Here is an image of the machined in O-ring groove that was machined with the inner and outer face on different parts, These images are a slightly different angle not knowing if one presents this better.

  Jan 23, 2023     De tap is here       Category: Engine

After 12 days for this 1"-20 tap to make it half way cross the country, and 12 min of working with it I have the oil strainer tube ready for welding to the top plate.
Tomorrow the .090 aluminum should arrive so I can start forming the outside of the sump, that should be fun.
In another month I will have the 1 1/8-14 tap to thread the top of the dipstick tube which I expect most of the rest of the sump will be completed by then and I will possibly be making the intake manifold, which the material for the carb flange is on the mill already.

  Jan 22, 2023     Oil sump parts       Category: Engine

A bit more on the oil sump.
I have been machining the new dipstick tube for this sump. I am waiting on the tap needed to thread where the factory dipstick threads in. I will be a month for it to arrive from oversea.
The vertical tube is the pump inlet oil strainer, this will move along quicker if the Postal service ever lets my package through a sort facility this tap has been stuck in for a week. As it is I will have better part of $150 in two single use taps for this sump.

  Jan 22, 2023     Another paper doll in this case it is aluminum.       Category: Firewall

I worked on the aluminum template for the firewall. My original part proved to be too wide, I had marked it at the time but just today took the time to trim and reform the perimeter. I like it but need to hang the engine and prove out other aspects before laying out and cutting the stainless.
First photo is with the FW hung on the fuselage which is stored for the time being over a car I built and of all things my wife's car drives nose in under the plane.
Other photos show how parts are laid out around the firewall. This is the first time I have had it hung in place with it pretty close to being proper dimensions. .

  Jan 14, 2023     Now these holes are radiused on top.       Category: Engine

With the holes in the sump plate rounded over I have set the plate back on the engine. One issue I now need to resolve is the angle of the oil fill tube which results in the oil level gauge being way up front in the sump.
Two issues here, this is a tailwheel aircraft and the oil level will not be gauged accurately.
Second and a real issue, the forward portion of this part is the air plenum for the intake, that I need to figure out.

  Jan 14, 2023     Four more holes       Category: Engine

Roughing in the holes for engine oil to drain into the sump.
These will get rounded over on the upper face with a sharp edge left on the bottom.

  Jan 13, 2023     Top of sump       Category: Engine

Here is the top of the sump set on the case, long way to go still.

  Jan 13, 2023     Oil strainer and top plate of sump       Category: Engine

I have machined a tube that will contain the oil pickup strainer which will stand vertically in the aft center of the oil sump. I am waiting on a 1"-20 tap to thread where an original O-360 strainer will be installed. It will be a week or so for the tap to arrive so nothing will get done quick here.
Some detail where the tube will press in place is there are radius reliefs cut in both the male and female half of the hole to retain an O'ring where the sump mates to the rear case. I will not be utilizing a gasket between the sum and case, Sealant tech has changed over the 80-90 years since these engines were drawn up and first produced.

  Jan 06, 2023     Oil sump       Category: Engine

I am starting the prep work on some engine parts, I am going to utilize a forward facing HA-6 carburetor at least in the early stages, possibly an electronic fuel injection in the future. Room gets tight with allowing for a generous air filter such that dusty ground operations do not rear their head in the future.
I have a compact Denso alternator mounted with a small Sky-tec 12LS starter. and the carb has to be in just the right place.
The intake will be cold and separate from the oil sump. Yes some people do not like this and my final decision is months away. I might find things easier to build the intake integral to the sump.
For the time being here is the first step in building the sump, The top plate that bolts to the case. Not happy with the two bolt holes that did not transfer well. The filter screen will be vertical and I am waiting for the tap needed to machine this part from round bar such that this will be slow going.
I kind of want to hang the engine back on the frame to confirm some dimensions so that may get done while I wait.

  Jan 04, 2023     A new year with nothing new to show. Category: home

After the delight of displaying my fuselage at our Leaf Peeper fly-in I ended up putting the fuselage in storage as I had to catch up on other non aviation tasks. It was my intention that I would have placed the material order for building the wings, That has not happened yet. Gee am I waiting for prices to climb more. It feels that way.
What is going on,
I have some new tools available to me for machine forming ribs. So far allot of thought for developing the process, no calculations or drawings yet. Just allot of planning.
When I do get going and summer rolls near I might be bringing on one of my YE youths as a helper. He is young and able, it will be nice to mentor a youth again. My previous ones have made a mark for themselves.

  Oct 14, 2022     First night out       Category: home

I loaded it on my trailer and over to the airport we went. It is tucked away on the side of the hangar that will house a C-402 overnight and in the morning we setup our flyin breakfast, looks like a great year for it.

  Oct 13, 2022     Prepping for it's first display Category: home

I spent the morning getting my flatbed trailer ready for this project's first outing. I will have this on display at KRUT for our Leaf Peeper flyin breakfast on Sat the 15th.

  Oct 09, 2022     Weight       Category: Fuselage

It has been a few years since I weighed the bare bones of the fuselage at #109.
Now with allot more done but more to go it comes in at #265.
This is with a seat, control system, horizontal and one elevator structure along with some stuff in it.
If weather allows this weekend, Oct 15th I will have this on display at KRUT for our Leaf Peeper fly-in breakfast, we have rain coming before the event and this has unfinished welds and bare steel. I have no desire to oil it to withstand moisture.
The numbers are 159-160 at the front spar and 80# at the tail wheel.

  Oct 06, 2022     Lower door 2       Category: Fuselage

The past few days I have made good progress on this door, Dang lot of hours in this one but the frame is roughed out and on hinges. And there is more to do, no doubt. One thing I discovered early in this task was the lower stringer where it attaches to the door frame was too high up. I am glad I went for building this door otherwise I might have ended up with so rework to do with a section of stringer out of place which would have ended up with sloppy visual lines when done.

  Oct 04, 2022     Lower baggage door       Category: Fuselage

For the lower baggage door I am building it,"design as I go"
I had decided the door will swing forward rather than down, Granted this may change once I release the bungees holding to door in the fuselage either later tonight or tomorrow. It took a fair bit of time to form the upper tube of the door to suit the curve in the longeron.
This is just tack welded at this time. But for now I think I like it.

  Sep 23, 2022     Cabin top center       Category: Cabin

With the fuselage back inside and in the bay where everything started a few yours back, I am working of the skylight center support. This a 304 Stl strip that is roll formed to the CL profile blending the airfoil back into the aft deck. This strip has many weldnuts inside it, the forward inside section will have the pitch trim indicator that will slid in a slot with either a 1:1 or a 2:1 ratio, only just now thinking about a longer travel allowing for more resolution being I have no clue how sensitive the trim will be. I will be utilizing some electronics to allow the electric only trim to have a soft start and variable speed. The images here, I utilized a rectangular fiberglass strip allowing me to visualize the arc. I have made a number of changes since I first formed the center channel and after upper fuselage. The last two shots here is the ratchet that provides each flap position and a shot of the partially made flap handle pivot. This pivot like most all of them in this plane utilize ball bearings. I am nearing the point I can move forward with the flap release trigger design. The trigger will utilize a spring allowing the trigger to be fully drawn even with full load on the ratchet.

  Sep 17, 2022     Out in the sun       Category: home

I have been working on detail bits around the cabin and flap system. Decided it was time to get the fuselage outside and look things over since it has been awhile. This is the first time I get a look at the partially built flap actuator as well. I am also tending to think I want the seating up a bit higher as well, but that really needs to be adjustable so it can be dealt with once flying.
This is also the first time the fuse has set on the mockup main gear. I think I like it but with Grove essentially out of the business of building custom gears I am going back to using an Olio style gear. It will be draggier in flight but might well be better in operation.

  Aug 04, 2022     Picking away at small things/ with a rather big inturuption.       Category: Landing Gear

Mostly detail work but I have lost the warm and fuzzy feeling that Grove would build my custom aluminum main gear. This started eating at me a month ago and with Airventure looming I realized I need to stand down and be patient. When cleaning up around my large plotter I pulled out an early rendering with the plane sitting on an Oleo style gear, a real lookalike to the original J4. I set that drawing on top of a pile under the printer
As things happen I ended up failing to travel out to OSH due to a Laryngeal Virus setting in my body, this has been a month long not so enjoyable ride, still have a low grade of it.
But this let me sit on my butt for hours redrawing the early landing gear to how I would build it today.
Being most all vendors are getting settled back in from OSH I made a call to Grove, The young lady on the phone was pleasantly an honest strait shooter, just the opposite from who I spoke with a few months ago, I think she was an owner or management, she was a flat out liar.
This recent conversation after I mentioned I have been seeing help wanted ads for every skilled position in the company she did state that they have not built one landing gear this year.
I am glad that when I built the hardpoints into my fuselage they were designed for either a leaf spring or the more complex olio gear.
As such this part of the build will be more time consuming but cost me about $3500 less. Weight wise the leaf spring was in the 55-58 lb range, the two rather stout Olio units are less than 20 without oil.
The image to the left was a render from early in design before building started. Image to the right is a current rendering. These are not photo real since I draw on a mid 90's version of Autocad.

  Jul 14, 2022     Stresses Category: Wings

As I have a number of other tasks going on not related to this project, I am caught up with preparation for my YE event in two days I am finding it time to start to finalize the math for my wings on this plane. I went through the numbers a bit over 3 years ago but have made numerous design changes, not to mention I find the math to be not as easy as it was forty some years back. The wings are built up two spar aluminum construction with a single lift strut that attaches about 1/3 cord. I will utilize a steel weldment between the spars as the outer pickup. The aileron cable passes within the strut with the balance cable crossing forward on the front spar. I am looking at options for attaching ribs that will reduce errors. This project also utilizes wet wings. Looks like the new sealants are rather pricey. Probably will not finish this task of calculating before flying out to Osh.

  Jun 16, 2022     A short wing Piper anyone?       Category: Wings

How about real short? In a few months I want to bring this over to the airport to display at one of my Young Eagles events. As such I am going to rough out one or two 2' span wings both for the display but also to help with design of things such as the grey tint Lexan cabin top which extends out 15" on each wing.

  Jun 10, 2022     Flap inner mount, a little more.       Category: Controls

I have the front anchor points for the inner mounts formed and partially welded in place. At a later date when the frame is back on the rotisserie I will final weld these as well as add a doubler should I feel it necessary.

  Jun 09, 2022     inner flap mounts 4       Category: Controls

I am getting close with these and I am liking the change. Most recent steps had been to verify that the pivot weldment is accurate to my design. It is, so I installed the side windows and using the same mockup
I drilled pilot holes through the window, the on the mill opened these to the needed size.
Reassembled the mockup system and ran it through it's range. It is sweet.

  Jun 07, 2022     Inner flap mounts 3       Category: Controls

Now I have fully welded these mounts and hung them in place. My "paper doll" flaps and linkage had the main pivots opened up to fit the bearing sizes that will be used in the future. Now with them hung on the real mounts I can move the flaps through their motion for real.

  Jun 06, 2022     Inner flap mounts 2       Category: Controls

Feeling close on my desired design change I have moved forward to make the parts.
At this point the design was locked, tubes were formed with end mountings fabricated. Got these tack welded in place and decided to walk away.

  Jun 03, 2022     Inner flap mounts       Category: Controls

The huge double flaps on this plane, I decided I will fabricate the inner mounts inside the aircraft now, Well the structure will be inside but two stubs will protrude through the D windows. I am utilizing all the CNC machined template/jigs to locate these mounts as I fabricate the structure. There will be a few entries made during this process.
Here is one side located as I machine the structure that will all become one bolt in place weldment.

  May 27, 2022     Might need to completly change my landing gear design Category: Landing Gear

Well Grove landing gear is functionally no longer in business. It appears all their skilled employees have left the company. The people I had been working with over the phone and email are no longer employed there as well, I only got one real snippy attitude person who I hope I do not ever need to talk to again.
I am not in a time crunch but I expect I will probably need to go a different direction which will need a rework of my existing structure. Oh well.
I could always go back to an olio style landing gear should I choose.
I have also been looking at Cessna springs from either a 172 or 150, many options.

  May 17, 2022     Updated the main gear mounts       Category: Landing Gear

These strap mounts are not flight worthy but are something I can move the plane around on. Once I built the actual straps they will utilize all six fasteners and will be quite beefy.

  May 17, 2022     Proof of concept Landing gear main spring       Category: Landing Gear

Having a rather expensive aluminum leaf spring on order I am taking a bit of time and material to do a proof of concept part so I can better visualize what will be coming to me. So I ran some mild steel tube through the bender, welded it up and hung it under the airframe. This will be mounted better and spacers made so I can mount the wheels allowing me to roll this around.
And FWIW I am making changes to the actual spring I have on order so this was well worth doing.
Again, this is just a mockup not a real part.

  May 13, 2022     Flap actuation yet again       Category: Controls

I got the materials to finalize the flap handle pushrod, nice to have this in usable form.
I have now run the flaps though their full range with the proof of concept ratchet/latch system. I might be changing the catch and release system, not deciding this right now.
What I have done I operated the flaps one notch at a time and marked the motion as to where each notch lands, I will soon do this again with a digital protractor and log the positions but I will say I like it.

  May 13, 2022     Flap ratchet again       Category: Controls

I have edge dressed this ratchet arm, I do feel I made mistakes in it's design such that this is scrap, but for now it will be used as a proof of concept and learn just what each notch offers for flap deployment and other tasks.
It appears the flash did not fire on my camera this morning.

  May 12, 2022     Flap ratchet       Category: Controls

Material arrived for me to make the ratchet for the flap system. Not truly sure I like what I made but it is usable as a proof of concept.

  May 08, 2022     Flap actuator       Category: Controls

I am moving forward on the flap actuator now and happy with the redesign.
I have made the connecting arm that will be for both the pushrod from the handle as well as the ratchet mechanism to hold the flaps in desired position.

  May 07, 2022     Flaps, reworking the motion ratio of the acuation system.       Category: Controls

Many hours of thought in the flap system I finally decided to look into a change. Originally the main element of the flap could come down over 75 deg. I felt I may never need or want this travel but wanted to have it available to try.
This morning I decided to rework the linkage bringing the main flap travel to 55 deg, a more logical range of travel. With some fiddling of linkage I am able to achieve a very nice motion ratio of the mid flap with nice even gaps that should provide a high energy flow throughout the range of travel. At this point I will get back into the books and see if my gaps are what is wanted or to tight now.
The later images are as the flap travel was and the first shots are after I reduced the range.

  May 05, 2022     Flap torque tube again       Category: Controls

With more machined parts I have hung the TT in the airframe. Roughed out the center support but can not really reach it to would yet. I then machined the pins that drive the outer flap torque arms. For the time being though the pins can drive the paper dolls that represent the actual flap profile.

  May 04, 2022     Flap torque tube       Category: Controls

I got more done on the flap torque tube that installs in the aft cabin. Allot of machined parts and small accurate weldments here. Still more to do.

  Apr 27, 2022     The other brake pedals       Category: Controls

Today's task was to make the outer pedals brakes. Started with pulling the pedals to bore the outer face allowing for the full 5/8 D of the pedal shaft through as I built the inner pedals. I had the bushings roughed out from when I made the batch of the so that part went quick, press them in and ream them to size.
Next was a quick layout, bend the uprights and tackweld these pedals.

  Apr 23, 2022     Rework of right brake torque tube       Category: Controls

Pulled the tube, cut off the arm that I had clocked wrong, figured out my error and spent time to jig it right. Now all four attach points for the pushrods from the pedals are inline.

  Apr 23, 2022     Brake pedal torque arms       Category: Controls

Spent the day making the arms to connect the pedals to the torque tubes, the tube for the left master came out fine but the right pedal arm for the right side is not clocked right. And being between seasons the heat is off in the shop and it is just 49F down there, I will fix this another day.

  Apr 20, 2022     Brake pedals       Category: Controls

I then roughed out the inner brake pedals for each side, These weldments are made with 5/8 .028 in 304 STL such that they like the pedals themselves will not need any painting over the decades, not that I have decades left in me. These are far from complete.

  Apr 18, 2022     Pedals are welded       Category: Controls

Kind of a pile on the bench but I pulled the pedals for finish welding.

  Mar 17, 2022     Corner supports       Category: Instrument Panel

The cutting tool I needed arrived and I now have the tooling I needed, guess I should have taken a few shots.
I sheared then formed a few U channels in .020 mild steel on my press, then setup the tool, a mandrel into my tube bender and formed these half round corner supports. These are to help support the outer ends of the main instrument panel.
These will have a composite overlay when done and might even be considered redundant parts in the end. But for now they are a useful tool.

  Mar 15, 2022     Instrument Panel Category: Instrument Panel

I am waiting on a 3/8 roundover router bit which I need to build some tooling I need to form some half diameter tubing that will support the outer ends of the instrument panel. This will present itself better once I am progressing on this task. I should get started on the brake pedals at this point but am putting time on the road vehicle project which was the big delay to this build.

  Mar 05, 2022     Pedal adjusters yet again.       Category: Controls

Today I welded up a forward brace that will take the foot loads on the pedals and brakes, well it is supposed to but they need to go right up to where the adjuster shaft anchors so this tube will be changed out in time.
I also finish up the shots with a closeup of the quick release for the right pedals, this works slick.

  Mar 04, 2022     Pedal adjusters       Category: Controls

As the bracket for the pedal adjusters progresses I have the right side quick stow mechanism built, clearly I decided how I wanted to build it during my sleeping hours. And today I did so. Next task here will be the forward support for this structure.
What the pics show, pedals full aft, pull back slightly and lift the adjust shaft, let it slide free and the pedals lay down in the full forward position. In time once the brake pedals have been built there will be a travel limiter added in.

  Mar 03, 2022     More on the pedal bracket       Category: Controls

I am roughing out the right side of the stand, tending to think I will not include the quick release feature, but time will tell. This structure will end up with a stay going forwards primarily to take the brake pedal loads since all pedal loads are fed back through these pedal height adjusters.

  Mar 03, 2022     Padal adjuster again       Category: Controls

This is the first part of the bracket that will hold the adjuster knobs for the pedal height. I rill next work on the right side which I intend to make a quick release allowing the pedals to drop out from position. Not guaranteed I will build that though.

  Mar 02, 2022     Pedal adjuster       Category: Controls

Since I am utilizing a fixed bench seat I am making the pedals adjustable, each side separately and the right side will easily be stowable in the forward position. This afternoons task was to get started on the threaded shafts and the support structure for the adjuster knobs. As of my end of day break I have the left side roughed out. I am happy with where I am at but it is time to sleep on it and review what I have done.

  Feb 26, 2022     Front floor revisited       Category: Cabin

I mirrored the right side cabin floor, still a bit of trimming and details but I like it.

  Feb 25, 2022     Firewall revisited.       Category: Firewall

The result of pondering, staring, measuring, calculating and finally just going with a gut feeling of what I want. I sat down to my antique Autocad and redrew the outline of what I want the firewall to be. This allows the smoothest arc from the front of the engine all the way back on the airframe. I have also lowered the top of the cowling providing a bit better view over the nose.
This image is a full size print of the drawing overlaid on the existing aluminum mockup.

  Feb 25, 2022     Front floor started.       Category: Cabin

I got my start on building the front floor. This is just roughed in, plenty more to do.

  Feb 21, 2022     Firewall shape       Category: Firewall

Many years back when I started this build I made an aluminum "paper doll", a mockup of what the outer shape of the firewall is expected to be. As time creeps by and with hanging the engine on the mount I am finding I might be best off narrowing the fuselage a few inches here. I can not get the engine in place now but with working flexible strips & tube I am confirming what shape the FW should be. And yes,it will be narrower than the cad drawings depicted it. Just how much, this is the value of mocking things up. I am also finding the curvature of the lower door should be greater than I have it, good time to address this as well.
I am getting closer to making this panel in Stainless.

This allows me to make brackets to support the outer edges of the FW and cowl section.

  Feb 17, 2022     Seat brackets       Category: Cabin

Having built the initial seat mounting we got to sit in this again. I think the last time in this I had not had the lower doors roughed out. This cabin is 46 wide, compared to planes i am used to this is huge.
Your shoulders are not against the door and no need to shrug shoulders. The sticks are in a comfortable position, pedals have a long adjustment, we are 5'6, pedals can come back some more but can still go forward a huge amount.

  Feb 09, 2022     Door hinges       Category: Fuselage

I used some 6061 bar stock and made the hinges for the upper baggage door, I think I like them. Hardware is temporary for now just for jigging and weld purposes. I will machine some Delrin bushings and change the hardware when the time comes.

  Feb 09, 2022     Upper door stringer       Category: Fuselage

I have formed the mid stringer and tack welded it in place on the upper door. The front vertical is straight, the four other tubes are all curved, I feel I got them right. I intend to finish weld the door, then make the tabs for the hinges. I am not 100% sure what the latch will be a the rear of it. Might be a pull latch from the inside, or use that as the security catch and still have a second catch at the door. Either way this is where this task is at and I like it.

  Feb 09, 2022     Upper baggage door       Category: Fuselage

The past few days I have been picking away at this door frame. This morning I tack welded the outer frame and like what I have started.

  Feb 07, 2022     Upper baggage door hinge       Category: Fuselage

Decision made, whether I like it or not I am building to utilize front hinges for the upper door. I expect I will leave these tabs tack welded for awhile, at least till the door itself is made and see how I like it.
I do expect some interference with the flaps when they are partially or fully deployed.
Time will tell.

  Feb 04, 2022     Flap handle       Category: Controls

Now for something a bit different, I get to start building the flap handle. The pivot end is formed from a piece of 3/4 X 1-1/2 STL tube. This gets a few cuts into it, formed, welded and a bit of machining. Basically bored in the end too receive the handle and from the sides for the ball bearings it will pivot on. I then pressed in and welded the 3/4 X .035 tube. Once dressed I hung it on it's bearings to see what I got.

  Jan 30, 2022     Right Dee frame getting close.       Category: Fuselage

The right side is fully tack welded. This gets me where I can design the upper baggage door that is just aft of this. I am not even sure where I will hinge the door. Top so less weather gets in when open, lower hing so it could be a shelf, but might hinder reaching all the way in. Or front hinge simply since that is safe if it does not get latched. This since I do not know if I will use cam locks, Hartwell or just what.

  Jan 29, 2022     Dee he he       Category: Fuselage

I decided I was far enough along to weld on the aft outer frame of the window. Why not I say, so grab a couple of strips of 1/8 copper bar to set the pacing, Copper is used sine the weld will not adhere nor distort the copper providing a relatively clean channel for the window. With the strips in place and the first clamps on I first welded the lower portion to the stainless strip in front of it, then moved to the top and aft from there. Note, for welding the 304 STL to mild steel you use 309 fill rod.

I like it, I have just rough ground the seams and called it a day. The third image is looking up at the aft portion showing the inner frame that retains the window in that area.

  Jan 29, 2022     More Dee window frames       Category: Fuselage

Back on the port side the aft inner and forward upper are in.

  Jan 27, 2022     Flap handle       Category: Fuselage

My flap handle just arrived, well some assembly required. And that takes some machining, forming and welding to achieve.