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Old 06-19-2017, 05:36 PM   #26
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Ah yes, I remember those straps. I wasn't involved with the wing building and only have one photo of a wing under construction, it shows the ribs clamped to the widgets but no straps. The photo of Steve sitting in the naked airframe shows the straps if you look closely.

Yes, 2216 was what we used for everything back then.


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Old 06-29-2017, 02:34 AM   #27
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Parts pile getting bigger.


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Old 07-16-2017, 03:42 AM   #28
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This weeks work. Started with a few aluminum parts. Drag tube brackets and I strut fittings.
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Old 07-16-2017, 04:01 AM   #29
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Awesome. Where did you source the aluminum channel? I couldn't find what Ed spec'd out so I bought rectangle tube and ripped it in a table saw.
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Old 07-16-2017, 05:01 AM   #30
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I got some 6063 C channel from Online metals and milled the legs down to size. I tried everywhere to find the proper extrusion but it just wasn't out there.

I do have a little concern with the inside corner radius's on the extrusion. They are small to non existent (looks pretty sharp to me). Checked with radius gauges not quite as big as I would like or called for. I will take some closeups tomorrow and post them. I hope they will pass scrutiny by those who know on here .
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Old 07-16-2017, 05:06 AM   #31
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Another picture of the whole parts pile. Growing little by little. I forgot that I made more 4130 parts as well since my last picture post.
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Old 07-16-2017, 05:13 AM   #32
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I also thought about the sharp radius but its relatively soft aluminum and thick. Then I decided I was overthinking it. I'm pretty sure if I finish a Bitts it will withstand anything I can do to it. I was told that the 6063 is used a lot by awning makers.
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Old 07-16-2017, 06:17 AM   #33
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Everyone has an opinion and I am not building one so much for my armchair quarterbacking. But I would like to see the turtle deck different maybe lower at the tail
end and shape the tail feathers to look like the real little stinker
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Old 07-16-2017, 10:37 AM   #34
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I know Carlson Aircraft used to keep the aluminum channel in stock. Knight Twister's solution sounds good....Tail Shape: The fin on the Bitts looks a bit different than a stock S-1 Pitts. I agree it could look better, but I needed more volume area for yaw stability with the low stall speed, and decided early on to push out the leading edge radius a bit...did not want to raise the height too much. This is why I call it a standoff scale reproduction. Good progress in the photos. It takes high discipline to make all the little parts first. Most of us want to weld up a fuselage first, so we have something to sit in and roll around the shop......
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Old 07-16-2017, 01:47 PM   #35
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The little stuff doesn't take up much space. A card table in my bedroom. I'll finish up all the steel tabs and stuff that I can and then have parts "in stock" when I need them. I am going to work on wing parts next as I have that material. Need to make a bending brake and building table of some sort and probably start on the ailerons.
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Old 09-04-2017, 03:38 PM   #36
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Been busy. Here are a couple of pics of lovingly bent tubing. Packed with sand, was much easier than expected.

More fittings pictures to follow later.
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Old 09-04-2017, 05:16 PM   #37
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Packing sand in that diameter tubing must have been fun.
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Old 09-04-2017, 11:58 PM   #38
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Ribletts and a few piles of tabs and bent up parts.
Wing tip bow attachment parts and made two wing tip bows. Still trying to figure out how I didn't order enough material for all four bows
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Old 09-30-2017, 03:26 AM   #39
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Been busy cutting aluminum sheet into rough stock in preparation for bending and forming. Making an 8 foot metal brake.
I bent up four L.E. skins with some plastic, a vacuum cleaner and a piece of long pipe as a mandrel. This was fun and turned out great. Shamelessly stolen idea from Sonex and Sonerai builders. Thank you Youtube!
003a.jpg   011a.jpg  
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Old 09-30-2017, 03:39 AM   #40
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You were a little concerned about the corner radius on the extrusions. While a small radius is better than a sharp corner, on an extrusion it's not as important as it is on a "bent" piece. The bending can induce stress that can crack the material along the outside of the bend line due to excessive stretching. An extruded piece has not been "bent", so those stresses don't exist.
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Old 09-30-2017, 11:49 AM   #41
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Quote:
Originally Posted by planebuilder View Post
You were a little concerned about the corner radius on the extrusions. While a small radius is better than a sharp corner, on an extrusion it's not as important as it is on a "bent" piece. The bending can induce stress that can crack the material along the outside of the bend line due to excessive stretching. An extruded piece has not been "bent", so those stresses don't exist.
That makes sense. I was a little concerned that "any" stress might concentrate there and propagate a crack.
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Old 09-30-2017, 11:57 AM   #42
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On the subject of bending. I have to bend some longer stock with the grain
( .025 and .020 6061 T6). I was initially going to use a .0625 corner radius, (which is over the 2X thickness) but had read that I should double it because I am bending with the grain. Some pieces are 5-8 feet long.

Do I need to use a bigger corner radius than normal because I am bending with the grain?
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Old 09-30-2017, 04:04 PM   #43
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Bigger is usually better, within reason. This is an academic conversation, but helps with overall understanding, and therefore comfort. I like to imagine extremes to help understand things. Imagine if you bent that .025 part with a 3" radius, It would be "floppy", "a big spring", useless at supporting a load, but it illustrates how increasing the radius adds flexibility. Flexibility leads to fatigue. That is an extreme, enlarging the radius a bit won't hurt, and is a lesser evil than a cracked bend line. You also have to look at the specific part, will a bigger radius consume the flat area you need to install another part or rivet on? I encourage builders to do it wrong on purpose, to see the results. Bend some scraps with progressively less and less radius, until you get failure, and inspect the bend lines with a magnifying glass. That will give you real life understanding and show you what to watch out for. Always inspect your bends, even if you did ten good ones, look at # 11, when you know what to look for it only takes seconds.
We bent lots of parts from .125 6061T6. On a new batch, I found cracks starting, the worker wasn't inspecting. We had done it the same way, with the same die and alloy for years, with no problems? We scrapped a whole 4x12 sheet of 6061! ???
Turned out the aluminum company supplied the last order off a roll and leveled it (straightened it through rollers) . It was still 6061T6, but was work hardened! They said, oh, if you want the good stuff, order "flat never rolled sheet"!
1. Know what to look for.
2. Look.
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Old Yesterday, 04:20 AM   #44
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I've been busy making my version of Dave's cheap sheetmetal brake and a nice build table ( pictures soon). Getting ready to form some aluminum parts. I have all the stock cut for the wings. Rivets are here and hope to have a wing rib soon.

Here is a pic of my efforts for the past two nights. This is the fuselage firewall and front cabane almost ready to tack weld.
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Old Yesterday, 05:40 AM   #45
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lakeracer69
you will like Dave's brake. I just finished mine. and used it to bend up some .024 stainless worked fine. I had to make up some threaded dowels so that I could mount it to my work bench as I have 2x4s up to the edge. helps make it a little bit stiffer.


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