A little progress XL H-58

[Chuck in Indiana]

We must have a different plywood manufacturer. I had one crack bending it around a nose rib. Fortunately, it was on an outer edge and I hadn't trimmed it to width yet.

[Chuck in Indiana]

If you are using the Iron Design drawings..K block installation on rib 7 and 12.

Did the math, made a "for instance" part  measured, and this is the first sort of "for real" aileron cove.


Decided I could make it in two pieces with the join at rib 9.
First piece glued down.

This gutter flashing is *kind of*  delicate. Just look at it crosswise and it will dent.
So far, so good. Even a blind hawg will find the occasional acorn..

[jrbirdman47]

Very nice installation! Is it one piece?

[Chuck in Indiana]

Two pieces joined at rib 9.I only have a 4 foot break.

[Chuck in Indiana]

Hmmm, thought I'd posted this.. at any rate, I'm calling them done. Except for varnish..

[Chuck in Indiana]

That piece of ply at the far end of the bench is the one I've been looking for.. the *last* one. 

I'll get it fit up and varnished today, and glue it tomorrow.
FWIW, my plywood was very stiff. To form it, I glued and stapled the first side, then laid hot wet towels on it and let it soak a bit. YMMV of course. Finishing these up just in the nick of time.  I'm going in for hand surgery (so I can use the clutch on my motorcycles) next week, so this project will stall for a while.

[Chuck in Indiana]

Temporarily installed the ailerons in the wings, and started looking for something I could possibly do with one hand    after the operation. Sitting in front of the tube is not an option.
Hmmm, maybe I can start on the control stick.. here's the "sketch" with a fair amount left to the imagination. 


I much prefer real engineering drawings with real dimensions.
Rummaged around in my good airplane junk pile, and picked my best 3" pulley. Drilled the lightening holes in it..


And chucked up a piece of steel to make a 3/8" to 3/"16 bushing. The drive belt on the lathe broke. Crap.. I'll put the old one on that I replaced. It broke, too.    Ordered three new belts. I normally get several years out of a belt, so looking at the actuarial tables, that should be a lifetime supply. Oh, well.. another small bite out of the elephant. I did *something.* That is the only way a guy gets an airplane built, even something a simple as a Legal Eagle.

[Chuck in Indiana]

A guy can't read all of the time.. Started doing miesen plas (if I were cooking) for when I can weld again. Made most of the front pulley bracket on the stick assembly sketch.
Found some 1 1/8 dia. 1/8" wall 4130 tubing, and drilled out to 1"

Normally, a drill will drill a little oversize, so it should slide over the 1" aluminum tube. My persistence on setting up the toy lathe included indicating and grinding the tailstock ways dead nuts paid off, though,,and it drilled right on size.   
Bored them out to a slip fit on the tube.

Here's how it will assemble. Eventually.

It took way longer than it should, naturally, but it got me out of the house.

[Steve]

_{You have a great sequence going here C-i-I ! ! ! Steve}

[Chuck in Indiana]

 Thanks, Steve. I realize some (or much) of what I'm posting was probably on the old Yahoo list, but as a new LE builder, I couldn't find a lot of info by searching. I'm hoping to kind of "fill in some blanks" for builders like me. I was planning on flying "bullet"  within a year of starting, but this hand operation has slowed progress.

[Chuck in Indiana]

Looking for something to do with one hand.. I decided I could lay out the tail feathers. Did ok until I came to the rudder. I would recommend some changes to your drawing if you are at this point.

The flange width (circled) should be 1/2". FAA 4313 calls for the edge distance from the rivet center to the edge to be "a minimum of 2X the rivet diameter."
The 22" dimension circled can't be right. That would put it in the center of the cluster.
The 10" dimension apparently goes to nothing.(?)
Here is what I'm going to do:

This puts the hinge locations 3" from each end and the main cluster. The 3.99" dimension is where I happened to click the mouse after deciding Leonard wanted the rib to end up close to it in his sketch. I would think anything from 4-5" would be fine.

[Chuck in Indiana]

Continuing to find things to do with one hand    I started varnishing.

As you can see, my bicycle wheels arrived yesterday. The hold up was the special high pressure tire.

Total weight of the wheel, tire, biggest rotor I could find, and caliper is 4 lbs. 4 oz.
I know many are using the Black Max wheels and brakes, but I decided to go this way for ground clearance of the big prop on the Verner. The landing gear is (sort of) marginal as is, and making it longer would exacerbate that. My bicycle guy swears this double wall aluminum wheel and high pressure tire will do the job. I guess I'll be the guy that finds out. 
The bearings are 15 mm, so I'll turn 5/8" 1/8" wall tubing down to fit.

[Kevin N.]

Love those wheels. I've got the standard plastic spoke ones from LEAF. In post #157 on your torque tube have you determined the stick pivot point in relation to the front pulley?  I have all the sub assemblies made up but haven't drilled the stick pivot point yet. Might be one of those field fit mysteries. (fellow Hoosier here, Floyd County, near Louisville)

[Chuck in Indiana]

^^^^^ HTFIFPTM.

Hammer to fit in field, paint to match. Most likely I'll cleco the stick assembly, mount it, sit in the seat, put my hand out and say, "the stick needs to be right *here*". Then.. make that happen.

[Chuck in Indiana]

I haven't gotten much done, but did as much one handed work as I could.  I *did* manage to varnish the wings and ailerons. I'm out of the cast, finally, and starting to do something again.
Back in the Pleistocene, I bought a bucket of AN hardware for pennies on the pound mil surplus. That's why I'm drilling these hinge pins instead of (cough cough) buying some drilled head bolts.

More mil surplus hardware holding on the aileron actuating arm..

Those pins and Delrin bushings are as smooth as glass, btw.
Everything installed and temporarily forgotten about.

I like to get the wings done first on an airplane project. That way, when the fuselage is on the gear, the engine mounted up, etc.and I'm all excited.. I still don't have the chore of building wings ahead of me.