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Old 11-16-2017, 05:34 AM   #26
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Beautiful workmanship. Why not use wood for you trailing edges. Can laminate 1/4" strips to your desired contour.


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Old 11-16-2017, 12:41 PM   #27
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Looking good!


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Old 11-16-2017, 01:16 PM   #28
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Originally Posted by mc06854 View Post
If I buy the aluminum trailing edge from ACSS or Wicks, what's the best way to bend them to the shape of the wing trailing edge?
The original parts were stretch formed on special tooling. Dave Baxter posted some sketches of the process a few years ago. This is not really something the homebuilder is expected to do. As far as I know the aluminum TE parts are no longer available.

I will be trying to make similar parts for my Pitts aileron TE but I have no idea if it will work or not. I think the fall back for these parts is to use wood. The Starduster guys will give you better info than I can.
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Old 11-16-2017, 09:39 PM   #29
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Default Curved Aluminum Trailing Edges

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Originally Posted by mc06854 View Post
If I buy the aluminum trailing edge from ACSS or Wicks, what's the best way to bend them to the shape of the wing trailing edge?
Mike I am not sure if they are still available from A/C Spruce? The fixtures that Starduster had to stretch form them still exist, but I do not know if they can supply them? Try calling A/C Spruce and ask, I am not sure the guy that has them is still in business?

They are made by stretch forming them over full size curved aluminum plate fixtures. This is done after bending up straight trailing edges, and has to be done with either 6061 or 5052 .040 aluminum.

The original drawings used 1/4" 5 ply mahogany. This worked, however many of these airplanes over the yrs suffered from warped trailing edges!

If you can not get them from spruce, then as Dennis or others have suggested one might make them by laminating long pieces of 1/4 X 1/4" spruce cap strip like I did on my SA-100 single place ailerons. Dave
SAM_1320 small.jpg   SAM_1401 small.jpg  
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Old 11-16-2017, 10:08 PM   #30
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Dave very nice. Have you covered them? Just wondering how it looked with Those gussets on top.
My armchair quarterbacking I would leave a 1/4" notch where the rib would fit in and put
thicker gussets on the inside. Let the T.E. Rib be a little narrower than the T.E. so when rib stiching the tape you put down just before rib stiching will fill that gap and no bumb.
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Old 11-17-2017, 01:41 AM   #31
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Dennis the fabric is flush on the upper ailerons I built, and tried my best to replicate the lower aileron as best I could. Dave
SAM_2299 small.jpg   SAM_2331small.jpg  
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Old 11-17-2017, 05:51 AM   #32
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Good stuff gents. I will have a go at it.
Thank you
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Old 11-17-2017, 11:06 PM   #33
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Thank you Dave. You should be very pround of your accomplishments.
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Old 11-17-2017, 11:14 PM   #34
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Default Starduster ribs

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How did you route your ribs? Did you make one template or multiples? I have all my ribs rough cut (within about 1/16-1/8Ē from edge) but have been debating on what would be the easiest way to route them and what kind of jig I need to build to do it. I havenít routed any plywood like this before so itís been a learning experience for me.
I just purchased a very nice Starduster from builder Andrew Kolak. He is giving me some jigs and custom tooling he used in making the ribs.
I can send them your way to use as long as you like. I'm picking up the airplane next week.
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Old 11-22-2017, 05:52 PM   #35
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What a beautiful job you are doing. Keep up the good work. I am in about the same place with mine but it has been stretched out over 20 years. ( That seem easy to say. Life does get in the way.)
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Old 11-23-2017, 06:33 PM   #36
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Old 11-23-2017, 07:13 PM   #37
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Looking good Mike, it appears your not only good at flying Helios your also good at building biplane wings! Dave
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Old 11-23-2017, 10:05 PM   #38
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Thank you Dave. Couldn’t have done it without mostly your and others advice. It’s been a challenge. Happy Thanksgiving to you and yours.
Mike
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Old 11-23-2017, 11:51 PM   #39
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Old 11-24-2017, 04:21 AM   #40
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Looking Great!
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Old 12-13-2017, 01:12 AM   #41
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