Constructed canopy slide rail

November 11th, 2006

I had tweak the bend in the C-763 slide spacer a bit to make it match the profile shown in the plans, but match it does:

I clamped a couple scrap pieces of angle to the table on my drill press, which created a little channel to help me keep all holes in the slide spacer exactly on center. It's a good idea here to check the prospective hole locations against the fuselage skin before drilling, to make sure there's nothing in the way of where you want to put your attach screws. The locations given in the plans worked well except for the most forward screw, which I moved forward by about 3/16" from the specified location in order to miss a rivet underneath.

After that I bent the C-762 slide rail to match the contour of the slide spacer:

Then I centered the rail on the spacer and match drilled them together, using the old clecoes into the workbench trick:

The two pieces of the rail assembly are double flush riveted together, since it has to sit on top of the fuselage skin. The plans call for AN426AD3-6 rivets here, but I found that I didn't get much of a shop head by using that length. I went up to -7 rivets, which worked just fine. I wish the double flush rivets on the rudder were this easy.

After that, I was able to put the canopy frame on the fuselage for the first time:

I found some baby c-clamps at the hardware store, which are now being used to hold the rollers to the canopy frame:

The slide rail is currently duct taped in place while the canopy frame gets tweaked. You can see how the bend in the rail makes the canopy get pulled down when it closes, which is a clever design. I bent the tab in the skin downwards to clear the rail.

I can tell that the canopy frame is going to need some bending to make it fit the fuselage properly. The plans call for the sides of the frame to be inset 1/16" from the sides of the fuselage, so I made this little tool out of some 1/4" and 1/16" ply I had laying around. Tomorrow when the glue dries I'll use it to check the dimensions of the side rails.

Started canopy frame

November 9th, 2006

I haven't had much of a chance to work on the plane lately, but tonight I did have time to assemble the canopy rollers:

…and temporarily put them into the canopy frame tubes. The plans suggest a small c-clamp to hold them in place but I don't have any that are small enough. Time for a hardware store run I suppose.

I cut the slide tracks to length, laid out and drilled the pilot holes for the screws that hold them to the fuselage sides, and temporarily clamped them in place.

Then I drilled a hole through the canopy slide block and the aft end of the canopy. This would have been a great place for a pilot hole, as it was hard to hold everything together while drilling. The edge distance looks pretty small in this photo but it's adequate in real life (you don't need as much E.D. with steel as with aluminum). Also, the specified AN3-21A bolt was too short and I don't have any extra -22A's, so I'm using a thin AN364 nut on here for now.

Finished riveting aft top skin

November 5th, 2006

Mary came down and helped me finish riveting on the aft top skin. She held the back rivet bar on the manufactured heads of the rivets and I leaned way into the fuselage to hit the rivet tails with the back rivet set in my rivet gun. Do you think I could possibly have used the word "rivet" enough in the preceding sentence?

The skin rivets all turned out very nice. I had to use a pop rivet in this one hole at the center of the aft edge where the underlying F-707B angle clip leaves no room under the skin for a rivet set or bucking bar. I suppose if I'd noticed this I'd have waited to install the F-787 stiffener until after the skin was on, but oh well.

After the skin was riveted on and the F-6111 reinforcement ribs were riveted to the skin, I sprayed paint over the exposed rivet heads and the places where I'd knocked paint off while riveting. I'm happy that I picked an interior paint that comes in a can – it makes it trivial to come back and touch up spots when necessary.

Seaplane training

November 3rd, 2006

I spent two days at Jack Brown's Seaplane Base in Florida, earning my single-engine seaplane rating in a Piper J-3 Cub on floats:

What a blast. Another day, another rating:

Partially riveted aft top skin

October 29th, 2006

I primed and painted the interior face of the aft top skin (sorry, no photo) and made it ready to be riveted to the fuselage:

I was able to drive all the rivets along the top side by myself, but I need Mary's help to get the aft edge and longerons since I can't reach both sides at the same time. She has a bunch of tests to study for this week, though, so I must be patient.

You can also just barely see in the above photo the area where I doubled the number of rivets along the forward portion of both side stringers, to hide a stupid mistake I made when fitting the skin. Now that the rivets are in for good, it looks almost like it was designed that way – barring one or two rivets that are just barely not in line with the others, although you have to look really close to notice it.