Joe's LEXL E-95

[joecnc2006]

Here are my Bell Crank bearing housing.
Cheaper than buying them since I have all the bearings and aluminum already.
http://www.aircraftspruce.com/catalog/appages/bc4w10.php

Two side machine operation, using probe to find center.

[Poorman2]

It is looking good Joe. It is nice to have the capability to make your own bellcrank bearings.  I got my dorsal fin, rudder and horizontal stabilizers covered. I still need to cover my elevators though. I am using green 3M Fastbond glue also. I also made a laminated tail spring out of 10 Maple strips 1/16th thick glued with t-88 epoxy then placed in a jig. I made the jig out off two 3/4x12x24 inch pieces off mdf glued and nailed together. I drew the shape I wanted on the front and used a band saw to cut it out. Then I cleaned up the edges with my sanding block. It worked real good. It feels very light compaired to the leaf spring I bought from Northern Tool. I hope it will hold up to the abuse..

[joecnc2006]

It is looking good Joe. It is nice to have the capability to make your own bellcrank bearings.  I got my dorsal fin, rudder and horizontal stabilizers covered. I still need to cover my elevators though. I am using green 3M Fastbond glue also. I also made a laminated tail spring out of 10 Maple strips 1/16th thick glued with t-88 epoxy then placed in a jig. I made the jig out off two 3/4x12x24 inch pieces off mdf glued and nailed together. I drew the shape I wanted on the front and used a band saw to cut it out. Then I cleaned up the edges with my sanding block. It worked real good. It feels very light compaired to the leaf spring I bought from Northern Tool. I hope it will hold up to the abuse..

That's exactly what I want to do is the laminated tail spring, do you have some pictures in your build on the jig and the glue up and also of course the finished.

[Poorman2]

Joe I do have pictures, but I am not smart enough to post them. My son-in-law is an expert on computers and he usually does my pictures for me. He lives in another county though. I might could take a picture with my cell phone and send it to your phone.

[dz1sfb]

Love to see the laminated tailspring also. It would be a great thread on its own.

Nice work Joe!

[joecnc2006]

Ok, here is the rest of the story on the aileron Bellcranks.

I used skate bearings and made the spacers for the 1/4" bolts to mount them on the struts. the spaces serve as three things, as the spacer mentioned, washers and standoffs. The 1/8" aluminum arm is riveted in 6 places, don't think I need all twelve. when riveted it captured the bearing and the bearing housing has lip on the other side so the bearing is very secure on the outer race, the spacers fit inside this and have very smooth action, I believe they will work well. it is from the DE as posted in the discussion here and with the spacers I will wait and see how much if any i need to bend the connecting arm outward to have clearance and proper alignment.

[joecnc2006]

Almost time to start on the main wings. Here is the Jig i made the spruce is a nice snug fit. should have very good uniformity.
I will use a clamp and a small aluminum plate per gusset to create even clamping pressure.

[dz1sfb]

Nice jig!

Is that nylon, delrin, etc...?

[joecnc2006]

Nice jig!

Is that nylon, delrin, etc...?

It is cut from HDPE. glue will not stick to it and ribs pop out easily when pulled out.

[PropMan]

Looking great Joe, you'll be flying before long.

[dz1sfb]

Nice jig! Is that nylon, delrin, etc...?

It is cut from HDPE. glue will not stick to it and ribs pop out easily when pulled out.

Kudos!

[Terry Lundby]

Joe, you should sell these jigs.  Perhaps Leonard would include your information in his plans.  I would be interested if I had not completed my ribs.

[dz1sfb]

Joe,
What do you think about adding a clearance pocket for the gussets on the jig side to be able to make a one step assembly?

[joecnc2006]

Joe,
What do you think about adding a clearance pocket for the gussets on the jig side to be able to make a one step assembly?

I had thought about that, I have seen a couple just like you have which have the cutouts (rib-o-matic), but I did not want to worry or be troubled by having to ensure the gussets did not slip on both sides when clamping and add more work sanding them down over the edges more than the standard smoothing them out. This may not be an issue but i elected to make it the way i did. Tine is not of the essence, since I am saving the time of the staples anyway. and I also use the cutout lines of the jig to make a closer fit of each rib. as shown in the picture below.

[joecnc2006]

The Jig seems to be working pretty well, the spruce is regular from the 0.25" so you have to rotate it to get best fit in jig. but it fits good.
5 down 21 to go I believe