Not sure, anybody interested?

[B45]

Ta very much. Never heard of it but looks good!

[Pogo]

'Bout spit my coffee out when I saw that sheriff's mug.

MAN, that's cool stuff! The EDM parts, I mean.

[DH82EH]

Okay, wait, wait, wait!
What is this witchcraft?

That is like magic! Sooo cool

Please explain to us simple minded types how this was done.

Thanks Scott

Andy

[sdennison]

Assuming you are referring to the EDM part cause anybody can squash tubes. The part was laid out in the billet blank in CAD for the one profile end to end of the billet. Then a small hole is drilled in the billet at each 1/4" hole in the spud end. A wire is fed through the pilot hole and the CNC program moves the table to cut each hole. The wire runs through the material like an electrical band saw blade. The whole operation is done in a water bath. It has to be repeated for each hole and the wire is disposable.

The small hole next to each shape is again the starting point where the wire is fed through. Again, the CNC program moves the table to cut the shape. Voila! You have extremely close tolerance parts and to me, the most logical way to produce these parts.

They could be milled. I had thought about gun drilling a plate and then combine male and female radius cutters but that would have been much more complicated and time consuming. Always multiple methods of manufacturing.

[sdennison]

How involved can it be to make a little bracket? This is the oil cooler door position sensor mount tab. Either a link to an electronic sensor or an actual hard cable to a mechanical gauge indicates to the pilot, the cooler door position.



There are multiple versions as I have a Dash 1 door and a Dash 4 door. I have used the Dash 1 version. The drawing does not show the lack of parallel but the two real world samples I have are the same. So, female form die.



PVC form block using annealed .125" 2024



Couple holes and some massaging, ready for heat treat and assembly. Simple

[sdennison]

Here is the beginnings of the drop tank and bomb mount reinforcement fitting. A piece that ties to the forward side of the main spar along with a larger forging that ties to the rear of the main spar providing a secure mount for the drops and bombs. In the race mod, these were removed. I need it because it also is the lower mount for the center section main rib and the aft elliptical tube. It's a pretty convoluted part and will take some planning to decode the drawing and figure out the missing data.

Center drill



Pilot drill



Size drill



Will get final size ream later

[sdennison]

Chips, chips everywhere. Still roughing these pieces and dreaming at night how the heck to finish and fixture all the operations needed. Gonna take them to the plane as soon as I finish this operation on number two. Want to confirm the bolt fit. This better be one where the plane matches the print.

[Triplane102]

Scott, Great work as always ! Thanks for posting ! We don 't get to see this kind of talent in the internet ! Again, Great Work Scott !

Last edited by Triplane102 on Sun Mar 29, 2015 11:00 pm, edited 1 time in total.

[sdennison]

So, before I got too much time in these pieces, I figured I'd better take them to the plane to see if the drawing dimensions of the holes actually fit our plane. Haven't developed much confidence in that so far. Quick trip to East Troy and I win. Fit perfectly so now on to trying to figure out the rest of the operations to finish these. Really need to think in 3D.

Last edited by sdennison on Sat Mar 21, 2015 9:36 am, edited 1 time in total.

[Cvairwerks]

Quick trip to Eat Troy and I win.

Obviously no indigestion there.....

Looking good Scott!

[sdennison]

DOH! uh that would be East Troy...

[sdennison]

Wooden ailerons are being replicated by Max Aero in Hartford WI. Mark is the producer of Howard wings, Pitts Model 12 wing kits, Waco wing kits, Wittman wing kits and many of the spars for WAG Aero. The Wood God, a good friend and the right guy for this project. So, guess what, there are metal bits in these as well and I have been tasked with reconditioning the existing hinges and manufacturing the new third hinges. The racers cut the wings down and obviously, the ailerons. They were cut just outboard the trim tab on the LH side and matched, of course, on the RH. Also, the balance tabs on each wing were modified so the linkages and pivot arms all have to be remade. The goal is to have all these completed by the time the wings return to East Troy mid-year.

Inboard LH hinge


Center LH hinge


Center RH hinge


Inboard RH hinge


Both side balance tabs pivots were drilled and pinned for a solid mount. Pins removed, pivots and linkages will be restored.


Number 16 in your parts manual, number 1 in your heart...

[sdennison]

A little stripping today...

Before


After...ohhh I hate that stuff but it sure works.

[Have Blue]

Scott, thanks so much for taking time to chat extensively with Frankie and me when we tagged along with Marc the other week. We're in awe of the skill you guys have and are really excited to be able to help with the project!

[pilot06]

What stripper has given you the best results with chromate?

Keep up the great thread.
Patrick