Heat

There has been some lack of progress following the failure of my shop heater.  I followed all the instructions in the owner's manual, and went through the troubleshooting guide, all to no avail.  I attempted to contact the manufacturer with the symptoms, with, to date, no response.

So yesterday I bit the bullet and bought a new heater.

It is slightly different than the old one and is working quite satisfactory.  In fact, about two hours into my projects today I had to shut it off. It was getting just a bit too toasty in the shop!

The old one is sitting forlornly behind the new one.  The old is quite a satisfactory little heater.  But if I can't fix it (and the owner's manual is quite emphatic about that) it is useless.  I bought an extended warranty for the new one.

Here is the project for today:

This is the fabrication jig for the the aileron hinges.  It needs one more small part, a support close to the 1/4" rod sticking up near the right end.  That part will be added after I have the component parts made so I know exactly where it needs to go.  The metal plate will protect the wood from the tack welding heat and provide a grounding plate.  I plan to do the tack welding with the TIG.

This jig will make sense once I have a completed hinge to show you.  Patience!

I worked on some practice pieces today as well.  The major lesson I learned is that I need to spend some time learning to control the TIG with the foot pedal.  Using a set amperage does not work when welding on small parts.

Pressing Matters

Some small progress got made in the last couple of days. 

First, a friend of mine welded up the SWAG Off Road press brake kit.  This is a high quality, very hefty product.  I am very impressed. 

Getting it home I couldn't wait to bend some metal and check out the results.  Which turned out somewhat disappointing.  On heavy gauge metal, like 1/8" and thicker, this thing is killer.  But the bend radius on lighter gauge metals (like .050") is far too generous.  Also, I couldn't bend a flange less than 3/4".  To do the fittings on the airplane I need to get down to 3/8".

After some soul searching, fussing, and inventing, I acquired various sizes of angle iron from 1" down to 3/8".  By stacking these in the female die of the press I was able to bend flanges down to 1/4" and achieve a reasonable bend radius with .050" 4130.

Here is the SWAG unit mounted in a Harbor Freight press:

And this shows, if you look closely, my modifications for lighter gauge metals.

I played with welding up my modification, but it works well loose.  I am not sure how well it work welded up.

I also considered grinding the taper on the male die to a sharper point.  But I am getting a good bend radius without taking that drastic step.

And here is the product of the day:

The wooden piece is the cutting template.  This part is the brace for the aileron hinge.  This is a great day for me.  I have not produced an airplane part since the end of August, the time (and money) being taken up figuring out how to bend up these parts without having to purchase a $2,500 press that would take up too much of my limited shop space.  The SWAG press works well, was a reasonable price, and takes up very little shop space.

Rough Roads

The EAA literature will tell you that many projects get stopped in their tracks by difficulties encountered by the builders.  This is especially true of plans-built projects as there are many more opportunities for problems and typically less support from the plans provider. 

I entered this project well aware of the problem and determined to slog through the difficult times. 

Well, I have been slogging through one of those times.  I have not completed an airplane part since August.  But work, and the expenditure of money, has continued.  The transition from the woodworking exercise of rib fabrication to the metal fabrication of the construction of the numerous fittings necessary to complete the wings has proved to be difficult, frustrating, and time consuming. 

The first difficulty was re-acquiring what welding skills I once had.  Only to learn that the skills I once possessed did not translate well to airplane construction.  My previous skills centered around fabricating tractor parts.  Welding heavy duty parts is actually a lot easier than welding the much lighter metals involved in airplane construction.  I am now reasonably confident in these skills.  But it took purchasing a lot of equipment (including both oxy/acetylene and TIG welding equipment) and a lot of practice.

Then I was stymied by difficulties encountered in bending metal fittings.  Perversely, while much of the welding is on thin gauge metal, an appreciable amount of the bending must be done on some heavier gauge metals.  I have solved the problem of bending small fittings from .060" to .090" 4130 steel.  But parts with dimensions greater than a couple of inches stopped me cold. 

My first attempts using the 18" bench top leaf brake that I own were total failures, despite the fact that the specs for the brake indicated it was up to the job.  Not even close.  I spent about a week fussing about the next step.  I contemplated purchasing the Harbor Freight floor model leaf bender.  Its specs were about the same as the little bench top model.  I was loath to spend the money for that brake only to find it was not up to the job, either.

But then I ran across a company called SWAG Off Road.  They manufacture a kit that converts the Harbor Freight hydraulic arbor press into a press brake.  This is a very impressive piece of equipment, so I sprang for the HF press and the SWAG kit.  While the hydraulic press is typical HF, but adequate for the job, the SWAG kit is very high quality.

Problem solved!  Not exactly.  The SWAG kit assembly requires welding.  I was not intimidated, what with my newly acquired welding skills.  But alas.  My welding equipment is sized for aviation welding.  Not the heavy gauge welding required to assemble this kit. I have been unable to get a puddle (welders will understand) going on any of the components.  The lightest components are fabricated from 1/4" 4130. 

At this moment I am awaiting the assistance of a friend with much heavier duty welding equipment than mine to complete the kit.  Until then, I am at a standstill.

I thank all of you who have been checking in from time to time only to see no progress.  Progress will continue in the very near future.

Just because some photos are better than none, here are some shots of my little shop as it looks today.