Wings are back home

January 31, 2011

When I got the wings home I decided to do some cleaning of the basement to so I had a clean place to work. I got the lower wings up on the tables and I measured and cut the last trailing edge pieces for the lower wings. I didn’t have whole lot of time after the clean up so that is all that I got done tonight.

Time spent 0.5 hours
Total time spent 471 hours

Fitting the Slave struts

January 29, 2011

Today I wanted to get the slave struts fitted so that I could get the wings off the fuse and brought back home for finishing. There are several options for the end of the slave strut one can use a fork but it has to be custom machined like the S1-11 drawings call for or you can use a rod end. I decided to use a rod end. Anyway I when to fit the slave strut with the fork up like on the S-1S and S1-11 drawings however this doesn’t fit with the Raven control arm. The control arm hits the back of the slave strut. So what I did was decided to remove a little material to allow more room to get the appropriate control throw. I don’t have a picture of this but I don’t recommend it. Anyway I decided that wasn’t going to work very well and I had seen on the S-1T that the slave struts are actually inverted so that the rod end bearing was on the upper aileron. It wouldn’t make any difference which side it was on anyhow and it fit much better. However, I had to remove a lot material from the leading edge the same width of the slave strut almost all the way back to the spar, but I figured it would be ok since there is a larger flange on the spar there to distribute the load over the area. I will take a picture later and post it. Any way I think I have it all figured out. The current cut out is rough and will need to radius widened, this was just to get it to temp fit. The only other problem is there isn’t a whole lot of room for the bolt to fit in-between the hinge mount and the slave drive arm. I might need to shim it out some from the bracket it is attached to.

****UPDATED with Pictures****

I got everything I need to get done at the airport so I took the wings off and took them home. Time to finish these things off and get them covered.

Time spent 3 hours
Total time spent 470.5 hours

Slave struts #2

January 28, 2011

Tonight I wanted to finish the slave struts so that I could take the wings back home for finishing. I started by measuring to get the right length. I then cut a piece of 7/16 X 0.120 to 1.75″. I used a #1 drill to ream it out so that I could tap to 1/4-28 for the rod end. I then drilled the other side out to 19/64″ (its what I had 5/16″ would have worked) I only ran that drill down 1 1/8″ so that I maintain about 5/8″ of threads. After that I cut a 3/16 slit in the streamline tube up 1.5″ along the length of the tube toward the front. After that I cut the taper on the back side. Using some clamps I squeezed it all together leaving the insert tube off the end by 1/4″. I welded everything up running two passes down the slit. I then ran beads down the back taper and finished by welding around the end to close everything up. After that I finish welded the top bracket where I left it yesterday and finished by taping the insert tube to 1/4″-28. Rinse and repeat on the other tube.

Time spent today 5.5 hours
Total time spent 467.5 hours

Slave struts

January 27, 2011

Tonight I got the airport and imediatly folded a new set of slave strut channels to the correct dimension this time. I then brought them down to my hangar to drill the holes and fit them them. I used the paper template hole location and drilled a 3/32 hole I then measured where the hole should be in the channel and drilled a 3/32 holes there. Using a cleco I checked the fit all was good. I then proceded to tack the channel in place. I welded the channel to the strut and then re-attached the outside piece using a cleco and a clamp tacked those in place. I welded as much as I could then formed the rest of the outside to match the shape of the stream line tube. It was pretty late so I called it a night. Tomorrow I will wil finish weld the tops and then start on the bottoms.

Time spent today: 3.5 hours
Total time spent: 462 hours

Slave struts and controls

January 26, 2011

Tonight I got my shipment from Aircraft Spruce that had the 0.040 4130 steel plate I needed to make the slave struts, the 4130 tube I need to finish off my lower wing controls and the weld in rod ends I needed to finish off the control tubes. I started with the control tube rod ends by lightly chucking them up in my drill press and using some sand paper to remove the CAD plating. I then took them to the airport to install them in the control tubes. I had a 36″ tube that needed to by cut to 33 3/8″ and the rod ends inserted to check the control system before fishmouthing and welding them. I got everything temp installed and checked the control travel, all is perfect.

I then moved on to the slave struts. I used my CAD program (Solidworks) to draft up the top of the slaves struts so that I can print them out and glue them to the steel sheet for cut out templates. I have done this before and it works well. I then cut out the inside pieces and used a brake to fold them. Unfortunalty I decided to fold them the same outside dimension as the slave strut tube which is a little less than 9/16″ which results in a .450 inside dimension. I checked the drawings and found realized I did this wrong and it need to be an inside dimension of 0.375. So I will fold a new set tomorrow to the correct dimensions.

Time spent today 3.5 hours
Total time spent 458.5

More controls

January 24, 2011

In my last post I got the lower wings rigged. The last thing I did that night was remove the wings to make sure with the tension on them now they didn’t move. I only checked to make sure they would go back in the lower spar brackets not to check to see if they moved at all. Turns out the lower right wing moved a little bit or enough to cause me to want to loosen the wires and re-rig that wing. This took awhile but I finally got it back in again, but this time I lifted the wing off the pieces of wood that hold them up to make sure they didn’t move some. I then got back into the controls again. The last post I was having issues getting to 25 deg of aileron travel without running my hand into my knee really hard. I double checked all the controls and found that the aileron control arm (the arm that attaches to the spar of the aileron) was 5/8 longer than the S1-11 drawings and 7/16″ longer than the S-1S drawings (the distance from the control rod attach to the hinge attach). According to the drawings the hinge attach should be 2 3/8″ and mine is at 3″. This extra length was causing the gearing issue with the controls not allowing enough travel. I emailed Raven and asked why this is and he said it was initially to allow more room for the control rod to clear the spar. It was a change he made awhile ago and to correct the other end he made the tower on top of the torque tube higher to keep the gearing ratio. Well if you have a stock torque tube you won’t get enough throw. I don’t have any issues clearing the spar so I will simply shorten the aileron control arm to the correct dimension and go with that. For now I simply clamped the control rod the correct location and tried it and viola 29-30 deg of travel when I hit my knee so I can back that off using torque tube stops to 25 and have enough room not to hit my knee with my hand.

On a side note: Rob mentioned that he originally made the change to the control arm length a long time ago as they did that on a homebuilt Pitts and forgot about, after they started selling kits, that length wouldn’t work for a stock torque tube, turns out I am the only one to ask or to even mention it. It’s an easy fix anyway.

Time spent today 3.0
Total time spent 455.0

Lower wing control tubes and rigging the lower wings

January 23, 2011

Today I brought my small dremel drum sander bit to clean out in the inside of the control tube so that the rod ends inserts fit. I was able get the inserts to slide in so that I can check the control tube fit. Once I got the tubes temp installed I hooked up the last linkage to make the aileron attach to the stick. I took the opportunity to check and see if I could get full travel of the aileron with the stick rigged for the standard pitts wings. As I found out my legs the length they are kinda get in the way to get all the way up to 30 deg of travel. I can achieve 25 but that is running my hand into my knee pretty goo to get that.

Anyway I moved on to the rigging of the lower wing drag, anti-drag wires. The lower wing root ribs have been curing for 2 days now so I figured they would be good. The lower wing was pretty much in the place I needed it but needed to be trammeled a bit to get the center section to come forward about 1/8 of inch. I tighten and loosened the appropriate wires to get the leading edge straight and the went ahead and tensioned all the wires. Rinse and repeat for the right side then followed everything up by using my Holloway Engineering wire tensiometer to set the wires to 350 lb. After that I decided to call it a night.

Time spent today 5.5 hours
Total time spent 452 hours

Lower wing control tubes

January 22, 2011

Today I went out to the airport to check on the lower root ribs to make sure they were curing ok in the low temps. T-88 manual says they take approx a week to cure at 32 deg F or so. As i turns out they were curing faster then I expected, but they still need a little more time. I also wanted to get the lower wing control tubes cut a trial fit. I measured and then cut the tube to fit and trial fit it. It came out good. Now I need to get one more tube and cut and fit that one too.

Time spent 1.5 hours
Total time spent 446.5 hours

Lower wing root rib gluing

January 21, 2011

Today I had to work a half day (this i normally my day off) I the made it out to the airport to glue my lower wing root ribs so that I can tension the lower wing drag wires to finally rig the wings so that I can take them back home for finishing. I had to remove the landing wires and I-struts to glue the ribs which took a little while. I got the ribs glued but they will take a while to cure because of the colder weather. Fortunately the hangar gets up to 50-55 deg during the day solar heat. I also messed around with making the slave struts but I quickly realized that I didn’t have the sheet metal to make the upper bracket, so I will have to order that along with some other items. I then decided to document how much my old wings weigh the results are lower right wing 30 lb lower right 32 lb and upper wing 63 lb. So 125 lb total. When I glued my lower wing I had the opportunity to weight the lower wings. I came out to 26 lb but it had two clamps and some 1×2 clamped to it, so I should have some room to work to make the wing as light as my old wings. I also removed the fabric from the right side of the fuselage.

Time spent today 3 hours
Total time spent 441 hours.

Aileron Bearing and Landing wires

January 19, 2011

Well today was sort of christmas in January. I received my landing wires from the wires I chose were good quality Brunton wires and they fit perfect. I also got new aileron bearings. I broke down and ordered ball bearing bearings for the hinges because the accuracy that is required to set the hinges and brackets so that spherical bearings can be used is just to tight. The ball bearings provide less friction and will last long anyhow. was able to ship me the RE3M6-2N bearings for $42 each which is $10 less per bearing then Aircraft Spruce. Anyway I got the bearings installed and the ailerons are smooth as silk with little to no friction. Installing the bearings and getting the ailerons back on the wings took a really long time, much longer than I thought.

Time spent 2.5 hours
Total time spent 438 hours