Warbird Information Exchange

I am really amazed and speechless every time i see your updates!!
the workshop looks like a candy store, I would not find it a punishment to be locked up here.
Please, continue with the good work, and the nice update`s that will follow.

Well, well, well. Seems once you pull your head out and use your brain, what seems like the most difficult can be overcome. This shroud has been kicking my ass since July. Converting two piece aluminum to one piece stainless steel. It only took my Pullmax to make compound form tool, modified and new bead roller dies, wire form buck, FSP and linear stretching in the Pullmax. Then guess what, the basics of metal shaping took over. Yup, happy camper here. Dumb but happy...





FSP (flexible surface pattern) on the two piece shroud fit to the wire form buck




New bead roller die and lower stop ring to set the tipping point on the shroud flange


FSP on stainless sheet for layout prior to cutting


Compound curve form made on the Pullmax to start the flange bending by hand

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"There are old pilots and bold pilots but few old, bold pilots."

The Corsair ailerons are amazing. I knew they were fabric covered, but not that they were of wood construction. Works of art I agree! Thanks for sharing all your projects with us!

Your FSP is made primarily from duct tape?

The first few layers are low stick masking tape. Then layers of staring tape. Lay the tape so the edges touch but don't overlap. Then do multilayers with strands in varying direction to the previous layer. 3 or 4 layers will be sufficient.
Carefully peel off the FPS. Use baby powder on the inside to dust off any sticky and you have a pattern that will hold 3D shape.

_________________
"There are old pilots and bold pilots but few old, bold pilots."

NFL, that is strapping tape...Im going to kill the auto correct people if I ever find them...

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"There are old pilots and bold pilots but few old, bold pilots."

Cool! I guess that shows you where you need to do shrinking as well. Probably not stretching so much due to the fibers in the tape.

Cooler doors and skins in the works. First the fancy 3D flash forms taken off loaner doors.

Lower skins formed.


More fancy tooling...


Inner skin starting the flow forming


More




Fitting skins

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"There are old pilots and bold pilots but few old, bold pilots."

Just an update...old computer issues and extortion by photobucket have led me to do my postings on my Dennison Enterprises LLC Face Book page. That is quite current and you can follow progress on the Corsair and other projects there.

Sorry for all the trouble and thanks for the great interest.

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"There are old pilots and bold pilots but few old, bold pilots."

WooooHoooo! I'm back....new lap top, Win10, Photobucket behaving so I'll pick up with the cooler doors.

Final tweeks using my Gen Two tooling...




Tips n Tricks...diving weights work really well for ballast and work holding. These coated ones rock.


A little more on the curve


Drilled then off to heat treat

_________________
"There are old pilots and bold pilots but few old, bold pilots."

He's back!

So, remember the L39 shroud project from earlier posts? Here is the finished piece installed. Ironically, the aircraft is two hangars away from me. I did the shroud for the owner's maintenance shop not knowing the owner would be located near me.

_________________
"There are old pilots and bold pilots but few old, bold pilots."

Dent Doctor...

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"There are old pilots and bold pilots but few old, bold pilots."

New upper leading edges being fit...

_________________
"There are old pilots and bold pilots but few old, bold pilots."

Well, here we go again...now Photobucket removed the "image" button for posting pictures...now what?

_________________
"There are old pilots and bold pilots but few old, bold pilots."