Slow going??

[John Harmon]

I do not know why but I am having a slow time fitting in the tubes from top longeron to bottom. I was having a terrible time trying to fit the pieces individually so I construct the vee flat, tack weld it and then fit it in place. I'm really happy that I only have one more of these fiddly things to fit.

[Jlwright]

I am right there with you. I wish I had more experience but a friend that built a Pitts is coming over to give me some pointers. that should help a lot.
I feel your pain!

[John Harmon]

I am glad to hear that I am not the only one.

[rockiedog2]

are you guys using a 1/2" grinding wheel with the edges radiused to make your fishmouths? it goes pretty quick and easy with that

[Sam Buchanan]

I used aviation snips to get the rough fit (use eye protection!) then finished it with the bench grinder.

[Jlwright]

I am going to get a 1/2 inch wide wheel today and dress it into a radius. I saw that on a video and should help.

[John Harmon]

I have a flap disc that it's for cleaning up fillet welds. Just happens to have a 5/8"radius on it.

http://m.homedepot.com/p/Diablo-4-1-2-in-40-Grit-Ultra-Coarse-Steel-Demon-Corner-Edge-Flap-Disc-DCC045040N01F/202830906/

Here's a picture of my coping station.

[Tom H]

John, your angle grinder with flap disk mounted to table reminded of another method I used.  Put a slightly worn (rounded, worn circumference edges) grinding disk on it.  You can do real fine fit-up grinds on tube ends with it.

I do most tube ends with radius-ed bench grinding wheel, then fine tune, if necessary, with the mounted angle grinder w/ grinding disk.

I've seen guys doing the shaping with aviation snips and rat-tail files, but those methods don't work for me.

Tom H

[weasel]

I have a flap disc that it's for cleaning up fillet welds. Just happens to have a 5/8"radius on it.

http://m.homedepot.com/p/Diablo-4-1-2-in-40-Grit-Ultra-Coarse-Steel-Demon-Corner-Edge-Flap-Disc-DCC045040N01F/202830906/

Here's a picture of my coping station.

Consider moving the angle grinder to the other side and flipping it over so that it doesnt through sand in your face.  

Nice set up!