Author Topic: full speed ahead!  (Read 1022 times)

Offline Theodore

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full speed ahead!
« on: February 14, 2021, 08:51:04 AM »
building again, too cold to weld(an excuse) i have wired the HF Vulcan protig, burned holes in the thin wall tubing, first part weld is rudder pedals. im embarrassed to post pics.
using piano hinges on Empennage(i can rivet post build).
Biggest News and reason why i building again, I have new friend Steve i call him Aeromentor. he like father already(listen and obey)!
hope he reads this and laugh! he on here, but remain incognito maybe, talk about experience he has got it, accomplished is the word, three experimental builds and a CFI with strip at home.

pictures worth a thousand words... i post some soon...
""Take care of your wish""

Offline GTS225

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Re: full speed ahead!
« Reply #1 on: February 15, 2021, 12:29:40 PM »
Theodore,  If I may be so bold as to suggest; Try small spot welds to weld thin wall tubing together.  I've welded 1/2" EMT with a MIG welder, on a very low setting, but had to grind/sand off the galvanizing and do small spots completely around the circumference to get it done successfully.  If done nicely, one can get that "stack of dimes" look that denotes a quality TIG weld.  (I have no experience with TIG welding.)
It's way easy to blow holes in thin stuff, and will test one's patience.

Good Luck.....Roger

Offline Theodore

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Re: full speed ahead!
« Reply #2 on: February 15, 2021, 04:37:03 PM »
Yes be Bold! Thank you, I'm welding Aluminum too, it drinks in the heat, practice pieces not so thin(6061&4130)
I want good ventilation for dust and fumes, sanding dust, gases from welding, epoxy etc. I wait until 55 deg out and open Gdoor. TIG less to exhaust, mounted whole house vac on Exterior wall w/2" hose on large funnel, Works great but still draws in very cold air from outside(i closer to NPole than Equator)
Thankyou
""Take care of your wish""

Offline GTS225

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Re: full speed ahead!
« Reply #3 on: February 15, 2021, 07:29:23 PM »
Yes be Bold! Thank you, I'm welding Aluminum too, it drinks in the heat, practice pieces not so thin(6061&4130)

I did get a spool gun with my MIG, but haven't had any opportunity to use it yet, so almost zero experience with aluminum alloys.


I want good ventilation for dust and fumes, sanding dust, gases from welding, epoxy etc. I wait until 55 deg out and open Gdoor. TIG less to exhaust, mounted whole house vac on Exterior wall w/2" hose on large funnel, Works great but still draws in very cold air from outside(i closer to NPole than Equator)[/quote]

I can certainly understand the good ventilation part.  Some of the off-gasses can be nasty toxic.
Iowa is just this week coming out of a single digit and sub-zero cold snap, so I haven't been out to my shop for a spell.  I'm a wuss though, and don't care for cold weather anyway.  Maybe in late March.

Roger

Offline CHARLES DEBOER

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Re: full speed ahead!
« Reply #4 on: February 15, 2021, 10:21:13 PM »
Yes be Bold! Thank you, I'm welding Aluminum too, it drinks in the heat, practice pieces not so thin(6061&4130)
I want good ventilation for dust and fumes, sanding dust, gases from welding, epoxy etc. I wait until 55 deg out and open Gdoor. TIG less to exhaust, mounted whole house vac on Exterior wall w/2" hose on large funnel, Works great but still draws in very cold air from outside(i closer to NPole than Equator)
Thankyou
Too much air flow can draw off the shielding gas.  It should be relatively calm air where you are welding.  In cold temps. (below 65 room ) try pre-heating your weld joint with propane torch.

Offline Theodore

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Re: full speed ahead!
« Reply #5 on: February 25, 2021, 09:28:42 AM »
I guess keep everything in one thread....
Empenage 95 percent, not perfect, next one will be made from chromoly 4130
need to give everything a close look, ease some edges and sand sharps, i know theres covering tape, also thinking of painting
This took nearly four weeks, for six parts, ohmy see why this build could take four years.
I cut notch for rudder horn with angle grinder, slightly large, but still 3/4" of gusset there.
""Take care of your wish""

Offline Theodore

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Re: full speed ahead!
« Reply #6 on: October 20, 2021, 08:43:43 AM »
welding again, couple hours per day. Coping/fitting tubing no big deal, i just use simple hand tools. the 1/2 file from harbor freight is already showing signs of wear, the 5/8" file is Nicholson bought at Grainger best quality yep.
I tried the flap disc method and hole saw didnt like
Score lines on the tubing with back edge of handsaw(harder metal) must have axis marks on tube yes
""Take care of your wish""

Offline Theodore

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Re: full speed ahead!
« Reply #7 on: October 28, 2021, 06:00:40 AM »
station #1 with engine mounts
check and recheck, measure one, two three times, still off ohmy.
drilled 1/4" holes then laid mount frame over engine(marked the bolts with tape), then took a chain saw file(7/32) work the holes until centered over threads. lower two was spot on, upper ones needed some moving. then watched hole saw pilot bit carefully(likes to walk on me)

Wish i had lathe for those 45 deg chamber inside 1 1/8 thick wall, i used unibit first then carbide tip router bit in drill press
welding these are going to be tricky 1/8" to .063 use gas there i guess
""Take care of your wish""

Offline Chuck in Indiana

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Re: full speed ahead!
« Reply #8 on: October 30, 2021, 04:15:07 AM »
Quote
welding these are going to be tricky 1/8" to .063 use gas there i guess

Attaboy.  :) If you can weld the thin stuff with TIG, the thick stuff is easier.

Offline Theodore

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Re: full speed ahead!
« Reply #9 on: November 15, 2021, 06:39:03 AM »
Leonard says dont waste time building jigs... :emoji_u1f61c:
thats impossible, virtuly every tube held by clamp/wood.
my fuselage width is 21", table is fir doors 24"
""Take care of your wish""

Offline Chuck in Indiana

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Re: full speed ahead!
« Reply #10 on: November 15, 2021, 04:05:43 PM »
Agreed. It would be next to impossible to build this airplane without jigs to hold parts in location. It may be "just an ultralight,"  :) but it is very difficult to build. It is about as far from a "kit built" as there is.. much like in the old days of making every part. This is number 7 for me, and one of the more difficult.

Offline Theodore

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Re: full speed ahead!
« Reply #11 on: November 16, 2021, 10:22:32 AM »
yes sigh,
and i choose this LEXL for my first build 'cause the support forum here.

spent alot o time on the engine mounts cutting the 45 on 1/8 steel and Alum inserts,
""Take care of your wish""

Offline DA Miller

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Re: full speed ahead!
« Reply #12 on: November 16, 2021, 04:26:41 PM »
I'd like to complement you on your coping skills.  Your first picture shows a fairly complicated junction of 4130 tubing with nicely coped joints with small gaps.  This kind of work will lead to easier welding and strong joints.   :) Keep plugging away.

Offline Theodore

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Re: full speed ahead!
« Reply #13 on: November 24, 2021, 12:34:47 PM »
did i take a short cut here? the frt one i notched before bending.
Thx
Theo
i thought to make a Youtube vid re: steps i take to cope by hand
""Take care of your wish""

Offline Theodore

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Re: full speed ahead!
« Reply #14 on: November 25, 2021, 05:52:50 AM »
repaired PCV on global engine, hope the mesh stops the oil. On vw cars this connects to induction air
both valve/rocker covers have same hose barb
hole for the grommet is undersized for very tight fit
""Take care of your wish""

 

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