In which we continue the saga of building this beautiful bird
Another view of the clamping process.
And again. A detail of the nose area
Now that the sides are done, it's time to work on the various cross panels for the nose( firewall), seat backs, etc.
A view from the tail, all clamped up, straight and true.
View from the side, nose to the left, bottoms up. Note the splice in the1/8" ply side( dark line ). All ready for trimming the edges. Corvair engine parts in the forground.
Near the top and bottom appear bent sticks. These are another type of clamp, holding the crosspiece down to the fuselage bottom while the epoxy dries. This is the front seat support. See a diagram of the stick clamps in the Tools and Tips page.
View to the bottom through the pilots cockpit. Foreward is left. The mess on the bottom is the seat support structure gluing up.
Fuselage right side up with pilots upper seat back clamped on. Larger curved panel to right is front seat back.
Another view towards the tail. Before actualy mounting any of this upper work, the landing gear and control fittings have to be made and fitted. Otherwise it would be very difficult to get at those things.
Front seat bottom and back. The side holes are for the pilots legs and the front hole is for the control mechanism. The rudder bar crosses from side to side pivotting under the seat.
Rear seat bracing ready for seat panel. Notice the floor panel ends just past the foreward seat support.
Baby grinder with stone removed and shaft extension in place. The three wheels you see are flap sanders, one each of 60, 80 and 120 grit. These make the finishing of the edges and surfaces of the steel
fittings a lot faster and easier.
A dremel or other make with an extension shaft and a fibre cutoff wheel makes short work of small jobs such as cutting off the corners of these braces before grinding the edges round.
Here's the 60 grit wheel being used to smooth the grinding marks out of a fitting. There can be no scratches or nicks in the finished piece as these will be a place for cracks to begin.
The yellow rod is brass, known as a "drift". It is used to bend the end ofthe part clamped in the vise by hammering on the end. The brass won't damage the steel part as hammering directly would. Also, the part is protected from the sharp vise jaws with soft aluminum angle.
Here's another view. The alum. vise jaws have been rounded where the fitting is being bent so that the bend is rounded. A sharp angle here would eventualy cause the part to break. The hammer is just out of the picture to the left.
The fire brick is heavy and stays where it's put while drawing lines and marking a set of tail brackets for drilling
Two bricks this time. The brass tool at left is a spring loaded center punch. Place it were you want to drill a hole, push down and snap! A punched mark to center the drill bit. I paint the tip black with a felt marker to make it easier for me to see where the point is.
All four outer strut/landing gear brackets drilled at once. One set of punch marks does the whole thing.
Inner and outer bracket plates with strut mounting bars ready for bending.
A few of the brackets needed, some bent some not, yet.