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IMG_1183
Putting the large large piece of bid into the landing gear bay. They said that the wheel chock was the most difficult part to make. Bullshit. This is bloody impossible, period. If I ever had any chance of getting into heaven, my language use today has ruined that.
I also have deep respect for people who wait to do this after the top is on as the manual seems to suggest, or (aargh!) do this as a modification to a finished plane.
Date: 10/11/2009
Views: 7140
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IMG_1184
Starting a the front and working backwards seems to make the best of a bad job, because then the fabric hangs over the back edge and has less tendency to fall back in. Some people claim to have put it in in one piece, but I find that cutting it in is unavoidable. Well, if its good enough for the gynaecologist, it's good enough for me
Date: 10/11/2009
Views: 1640
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IMG_1186
One hot and stressed out plane builder. Bending over all that time does not do wonders for your back either
Date: 10/11/2009
Views: 1621
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IMG_1175
Its all in, sort of. The pieces of uni and bid that go on top of the first layup suddenly seem ridiculously easy
Date: 09/29/2009
Views: 1562
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IMG_1187
Putting on a single ply of bid on the outside
Date: 10/11/2009
Views: 1695
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IMG_1176
Peel plied. Especially in the corners bubbles easily form and this helps considerably. Even so, a few Botox injections proved necessary anyway
Date: 09/29/2009
Views: 2073
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IMG_1177
Peel ply on the outside. Not just necessary for the next layup, it also stops the bid from falling off
Date: 10/02/2009
Views: 1765
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IMG_1189
Setting up the main landing gear legs is a complicated and fiddly job. It needs to be just right otherwise the plane will only run in circles. Here I am using a plumb bob to align the fuselage on the centre line drawn on the floor, and on top of Fuselage Station 40 which is the starting point of all measurements.
Date: 10/25/2009
Views: 1826
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IMG_1192
Another bob, as far as possible to the rear, to make sure the fuselage is fully in line
Date: 10/25/2009
Views: 1440
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IMG_1199
The fuselage has to be 413mm off the floor according to the manual, which as luck would have, it happens not to be. I can either lower the jig or raise the floor. The last is actually easier, as can be seen here. The ends of the legs have to be a precise distance form the centre line, but I find that in order to make the socket plates touch the fuselage, the ends have to be moved in by 4-6mm. Marcel has apparently had the same problem which assures me I have not done anything stupid. I make it so.
Date: 10/27/2009
Views: 1437
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IMG_1201
Bonding in the socket tube and plate. Some parcel tape to prevent the leg being glued in prematurely
Date: 10/27/2009
Views: 1487
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IMG_1202
Socket tube in place and ready to cure. The bolt is a very difficult fit. You can ream the hole in the leg but I choose brute force. That f...s up the bolt but replacements are cheap and you avoid any slop later.
Date: 10/27/2009
Views: 1519
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IMG_1203
Four ribs need to be cut, trimmed, bonded and laminated in place. I start with rib #1. It is already obvious that it doesn't fit properly into the corner, but I put that down to "build tolerances".
Date: 11/01/2009
Views: 1699
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IMG_1205
Sticking it in with araldite
Date: 11/01/2009
Views: 1434
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IMG_1207
Bid needs to be laid up all the way around the socket, and from both sides. I make a paper template so I can trim the plies to their net size on the plastic sheeting before putting them in.
Date: 11/07/2009
Views: 1406
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IMG_1208
The first rib in with six layers, and peel plied. Just seven more of these to go.
Date: 11/08/2009
Views: 1479
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IMG_1211
Bonding in the second rib. I have already laminated in rib 2 on both sides when I find that the templates for ribs 3 and 4 suggest the socket tube is too far back. I check with Marcel and Europa and they both have it 1,5 cm forward compared to mine. I am beginning to get a sinking feeling....
Date: 11/22/2009
Views: 3412
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06122009385
Just to ease my mind I rejig the leg. SHIT! Out of line and out of place. How this came about only St Jude (Patron Saint of Lost Causes) can know. I send this picture to the factory who tell me it is, as Hirohito would phrase it: "a development not necessarily to my advantage".
Jack advises me to cut my losses and dig it all out. I go through the phases- denial, anger and when I come to resignation I decide he is probably right.
Date: 12/06/2009
Views: 1634
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IMG_1253
I spend most of Christmas taking the stuff out again. First with a chainsaw (no pictures, I don't want a PG rating) then with a powerfile. Lots of dust, so I do it outside. Even then, and with a mask, I get a splitting headache. All in all not to be recommended.
Date: 12/24/2009
Views: 8675
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IMG_1339
So back to the start again. This time the ribs fit much better.
Date: 01/16/2010
Views: 1460
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IMG_1383
Laying up Rib #4. What seems to work best is using a minimum of Redux to bond in the ribs, then after cure filling and radiusing the corners with fresh Redux (using a 50cc syringe) and laying up over it immediately. This avoids bubbles in the many tight corners.
Date: 01/30/2010
Views: 1511
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IMG_1385
Finishing touch is a uni layup on the tops of the ribs. All in all 56 pieces laminated in, not counting the abortive first attempt.
Date: 01/31/2010
Views: 1506
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IMG_1386
The outside of the socket tube also gets a reinforcement.
Date: 02/01/2010
Views: 1460
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IMG_1348
Not a very common view here, but beautiful anyway
Date: 01/24/2010
Views: 2350
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IMG_1389
Nose gear leg fixed to the mounting frame.
Date: 02/04/2010
Views: 3437
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IMG_1390
The nose wheel hub fitted with tyre
Date: 02/04/2010
Views: 1560
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06022010409
The axle and bearings laid out ready for assembly.
Date: 02/06/2010
Views: 1583
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IMG_1391
Nose wheel fork fitted to leg.
Date: 02/04/2010
Views: 6566
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IMG_1456
After reopening the hole in the reinforcement ply the leg is inserted and bolted in. Next is the brake assembly.
Date: 02/07/2010
Views: 1552
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IMG_1457
The stbd main wheel attached to the leg.
Date: 02/07/2010
Views: 1532
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IMG_1458
All wheels now on. At least I can now come into the garage and kick the tires (old aviation tradition)!
Date: 02/09/2010
Views: 1867
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IMG_1463
The Nose LG leg requires springs as a back up to the suspension by the leg itself. These need to be tensioned. As this requires a lot of force I go to the neighbourhood Volvo dealer for industrial strength equipment.
Date: 02/12/2010
Views: 2695
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IMG_1461
Inserting 6mm bolts in the spring to keep it open
Date: 02/12/2010
Views: 2961
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IMG_1465
With this the springs can be put on the frame. The 6mm bolts as in the manual prove too small so first I have to redo them with 8mm ones (7mm doesn't exist, of course).
Date: 02/13/2010
Views: 1536
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IMG_1470
The only way to get the bolts out again is to stretch the springs beyond that point. With a sandbag, a bag of fertiliser and some rocks in the cockpit I still need these two sitting on the footwells to pull it down far enough. The bolts rattle out. IT STANDS!
Date: 02/13/2010
Views: 2766
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IMG_1466
The cradle has served its purpose. Here we lift up the plane to take it out.
Date: 02/13/2010
Views: 2691
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IMG_1469
Taking it outside.
Date: 02/13/2010
Views: 2228
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