Not sure, anybody interested?

[sdennison]

I'm thinking this is getting a bit tedious for all you guys but this is day to day stuff for me. Sorry and it is what I face with my portion of this project. I love it but could be boring to most.

I'm generally pissed that you don't post more.

Exxxxcuuuuuuuse me! Doin the best I can. Remember, I am an old Fart.

[C VEICH]

I still check in every time there is an update to the thread. No boredom here I can assure you!

[Matthew Murray]

Scott, I've been lurking anonymously for some time on this forum but had to sign-up to say i've really been enjoying this thread in particular.

Keep up with the - regular - updates.

[cooper9411]

Scott you definitely will not hear any complaints from me and if you do, it would be that there are not enough posts/updates from you! Haha

Last edited by cooper9411 on Thu Apr 16, 2015 8:17 pm, edited 1 time in total.

[sdennison]

First of all, thanks for the kind words Gents.

So we finished (to this point) both RH and LH cutout plates for the outboard aileron hinges. The hinge is positioned within the cutout and the wooden aileron skin is sandwiched between these plates and an outside cover plate. You can see all the individual components for the hinge assembly in the picture showing the pieces as removed from the aileron. The cover plate bolts to these cutout plates.


Set for nut plates


LH outboard versus LH inboard


Inboard hinge parts. Outboard is all the same pieces just different configuration.

[sdennison]

Outboard aileron hinge bits fabricated. Need some heat treated, all alodined, painted, nut plates attached. Still need to make the lower tear drop cover plates.

[sdennison]

A little chemistry today. Alodine action on the new stuff. Next paint.

[Left Seat]

Alodine is a conversion coating used on aluminum alloys (MIL-C-81706 and MIL-DTL-81706).

It provides improved corrosion protection and paint adhesion.

[sdennison]

Alodine is a conversion coating used on aluminum alloys (MIL-C-81706 and MIL-DTL-81706).

It provides improved corrosion protection and paint adhesion.

[Jim MacDonald]

Hi Scott,

Hopefully you'll post your work getting the lower tear drop cover plates fabricated. I'm interested on how you'll do those.

Thanks,

Mac

[sdennison]

Hi Scott,

Hopefully you'll post your work getting the lower tear drop cover plates fabricated. I'm interested on how you'll do those.

Thanks,

Mac

Mac, for sure, especially if my plan works.

[sdennison]

I hate when I get a better idea or find I screwed up and have to spend non-rev time to correct it but I have to make it right. Thought I'd go through the stack up of parts for these outboard hinges and make sure all was good when put together. Then it struck me. Our aileron "Master" has a CNC wood mill for his work. I had laid out the crush plates by hand and was pleased with their outcome. However, his holes in the spar will be generated by a CNC, mine by a "blacksmith" so I thought I'd better revisit the total accuracy of these parts. Drilling to fit in assembly on these critical hinges is not a good idea. So I made a PVC holding fixture and did the layout in the mill. Happy now that my new pieces will fit his work and should not require any adjustments. Now I can sleep.

Milled a .040" deep blank profile in the PVC tooling plate to locate the .032" thick blanks.



Blanks accurately located then all the holes were located on the mill +/-.002".

[sdennison]

Getting hinge bits ready for paint. Bead blasted and alodined. These are the lower hinge covers for the ailerons. Still have to make the two outer hinge covers. Film at 11.

[shrike]

Do I sense a greasegun in the near future?

[pilot06]

New found appreciation for the construction of the Corsair. My god, that is one hell of a main spar.

http://www.sandersaircraft.com/restoration_fg1d-sanders.asp

Keep up the great work.

Patrick