Jim's XL build D-25

[Jlwright]

Finished cutting all the seat parts today. Sure is nice to have access to a hydraulic shear. Now to figure out how to make the spacing nice and even for drilling.

[Poorman2]

Jim, It looks like you added an extra one on the length and width (9 x 15 instead of 8 x 14 rows).Yes a shear is nice to have. It makes quik work of cutting out your seat parts. I got lucky on my rib gussets. The kit I bought allready had the ribs made. I did make a rib jig and made a trial rib in it before I found the partially built kit. It already had the spars built as well. I now have both wings built. The fuselage and landing gear is made, but It was not built to plans dimentions. That is why I was interested in how much 1/2 and 5/8 tubing you used. I am going to build another fuselage to exact plans dimentions. I am also going to rebuild the tail feathers as he did not wrap the gussets all the way around  to tie the ribs to the leading and trailing edge. I thought I was getting a quik build kit, but I didn't get what I thought I was getting. Live and learn I guess. Since it is my life rideing on it, I wan it right. Do it right the first time!

[Jlwright]

I would certainly order 140 ft. Of tubing. Is the fuselage a different shape or length? Seems a shame to have to start over. That is a lot of extra work. Are you sure you can't save what you already have. Do you have any pictures?

I had an extra strip made so I just squeezed the spacing a little. The overall width is still to plans. I also added one extra of the cross strips.  If I had it do do again I would make some kind of form to bend the end tabs over with so they would all be exactly the same width.

[Poorman2]

Jim, it is a different length and width. The tubes don't come together at a center point. It has some rust pitting. He substituted 1/2 in place of 5/8 in several places. I just feel better building it myself.

[Jlwright]

I don't blame you. I have seen several on the web that didn't bring all the tubes to a central point and I'm sure that probably doesn't make much difference in an ultralight. It would be easier to weld up and easier to fit the individual tubes. I tried to make all mine join up together and it does require quite a bit more effort. This is just my opinion but I would not make the top longeron in one long single piece. I would do it like the plans show, 
There is a lot of tubing you could salvage from the old fuselage too.

[Poorman2]

There probably is some tubing I could cut out and use from it. I do have pictures, but I have to get my son-in-law to help download them when he is able to come over. I might could use it as is, just cut out some tubes and replace them. I'm not sure my carlson struts will be long enough though. I had them cut at 80 inches for shipping. the fuselage is only about 21 inches wide in between station 2 and 3. When you make changes to the plans, it affects a lot of other thing.

[Jlwright]

Have you looked at a set of plans for the regular Legal Eagle. That is about what the width is on it. Maybe you just have an LE fuselage. I have a set of plans for an LE if you need to compare any numbers. The only reason I am building an XL is because the plans are updated. I didn't need the extra room or weight allowance.

[Poorman2]

Jim, I think it is a mixture of the two. Try this link and see the kit I bought on July 29,2012.  http://picasaweb. google.com/VansAirForce/LEXL . It looks good in the pictures. The plans that came with it are #LEXL-A-05.

[Jlwright]

Would you send me an email. I may know something about this plane.

[Jlwright]

You might also ask Sam Buchanan about this kit as he may know something about the history.

[Poorman2]

Thanks Jim. Keep up the good work on your plane.

[Jlwright]

I deleted the post with your email so it wouldn't be out there for the world to see. You are Randy, right?

[Bob S.]

Seems you didn't delete his email.... You will have to contact one of the moderators if you really want it deleted...

[Jlwright]

It is gone from my thread. Hit refresh and see if it is still there.  Thanks for the heads up.

[Sam Buchanan]

Jim, It looks like you added an extra one on the length and width (9 x 15 instead of 8 x 14 rows).Yes a shear is nice to have. It makes quik work of cutting out your seat parts. I got lucky on my rib gussets. The kit I bought allready had the ribs made. I did make a rib jig and made a trial rib in it before I found the partially built kit. It already had the spars built as well. I now have both wings built. The fuselage and landing gear is made, but It was not built to plans dimentions. That is why I was interested in how much 1/2 and 5/8 tubing you used. I am going to build another fuselage to exact plans dimentions. I am also going to rebuild the tail feathers as he did not wrap the gussets all the way around  to tie the ribs to the leading and trailing edge. I thought I was getting a quik build kit, but I didn't get what I thought I was getting. Live and learn I guess. Since it is my life rideing on it, I wan it right. Do it right the first time!

I remember when your "kit" was purchased by the individual from whom you got it and how everyone seemed to be impressed with the build quality. I was surprised by your comments so went back and looked at the photos.

That looks like a very nicely built Eagle. I would not hesitate to fly the tail group as is, wrapping the gussets won't add any more strength to what is already there. I would add gussets and/or straps to the cabin cabanes where they are bent but the rest of the fuse looks great in the photos. You are aware that some of the diagonals in the rear of the fuse are supposed to be 1/2"? Surface rust is normal for 4130 that has sat around for awhile, but if it cleans off with light sanding you are good to go.

Maybe the plane looks worse in person than in the photos, but to me it looks very nice....probably a lot better than many flying Eagles! I would have no second thoughts flying that plane with the mod mentioned above. You might want to get an opinion from an experienced local light aircraft builder before scrapping that fuse and tail group.

Post a sign in your shop that reads thus: We are building an airplane here, not heart valves.