Not sure, anybody interested?

[sdennison]

Tried out test with my newly built "Chalkie" press. Works really nice. This is a test skin for the TH55A horizontal stab to get the initial bend correct. The press will work well for other duties as well and I have plenty in the queue.





This is bent with a 1/2'' nose bar but the press can do up to about a 3" radius as I have it configured.

[sdennison]

Here's the finished "Chalkie" Press.



Today I used it for non wing skin application on a part for the Corsair. This is the #3 former cap strip that I had previously tooled for and made a test piece. I now have the proper .071" 2024-0 material.

I hand formed the basic shape from a strip and then clamped it in the form blocks and the press.



Then used a tapered poly hammer to rough form the turn down edges followed by the flow form gun.





Next, some tweaking in the shrinker and stretcher, edge trim, and finish fit. Only thing left is to trim the ends to fit the RH and make the other side.

[DH82EH]

That is really nice Scott. Applying multiple steps that you have gone through with your students.
I love the name on your "Chalkie" press.
Nice dedication

Andy Scott

[sdennison]

That is really nice Scott. Applying multiple steps that you have gone through with your students.
I love the name on your "Chalkie" press.
Nice dedication

Andy Scott

Thanks for the kind words Andy. I have no students, I'm no teacher, just a one man band trying to share with those interested, my lucky opportunity and my approach to making some of these bits.

[Mark Allen M]

Ha! I was going to let it ride for a while, but it could backfire as well and I certainly don't want to insult anyone. Thought I would try to pull a fast one on ya Scott. The fellas name is David Glen. Talk about some talent. Amazing work isn't it? Reminds me of you, but on a smaller scale.

http://imodeler.com/2014/11/amazing-15- ... ent-196152

[sdennison]

Yeah, thought so but I'm no one to critque anyone... My cousin runs the craftsmanship museum so I have seen a lot of that amazing talent displayed.

http://www.craftsmanshipmuseum.com/

[sdennison]

Did the other cap strip today using hammers only. Worked nicely. Clamped the blank in the Chalkie after hand forming as before. Then, set the edges, both sides, using the small tapered poly hammer.





Then I used a larger tapered poly to hit the small one more precisely forming the edge



Finished setting the edge with old rawhide. Then some final adjusting with the shrinker and stretcher.

[Buck Rivitz]

Scott,

A few posts ago, you mentioned spot welding some doublers. I'd love it if you could elaborate on that.

I've noticed lots of spot welds on warbirds. It seems like a quick method for mass production, but I've always wondered how the process is tackled in a shop setting.

I love your posts, by the way. Like everybody on WIX, I think restored warbirds are awesome, but the journey is at least as interesting as the destination.

Thanks,

m

[sdennison]

m, It is a very specific process that requires the proper welding power source and techniques. For our purposes, I will be utilizing the services of Odegaard Wings in Kindred, ND. They have the proper equipment and skills. I have a vintage manual from the Navy at the shop. I will bring it home and scan some of the details for you.

Thanks for the comments.

[sdennison]

Buck Rivitz, here's some info from the day out of a 75 page Navy manual. Just printed a few pages. This is why I defer to a shop that has the proper experience and equipment.

[Buck Rivitz]

Thanks for taking the time to post that. It definitely seems like some expertise would be required to confidently spot weld structural components.

For critical applications, I'll stick with my hardware store bolts and krazy glue.

[ChrisAldridge]

Thank you for providing us your helpful knowledge on metal fabrication.
Is all of your material 2024-O, as stated earlier in the thread?

[sdennison]

Chris,

I follow the original drawing specs. For parts that require a considerable amount of forming, the material is 2024-0 then heat treated. For parts that have simple bends and the drawing calls for "ST" material, that is 2024-T3 and no heat treatment is required.

Hope that answers your question.

[sdennison]

So, we finished fitting the two former #3 cap strips RH and LH. Final fit will come in the fixture and the rivet holes, 26 will be drilled.

[sdennison]

So, how ironic? The last two pieces necessary to complete the structures for RH and LH lower sections are these. Ha! Major milestone. Happy, happy!