Arnie Zimmerman on his Breezy, N3AZ.
11-13-2009 The decision is made and an entry in my note book, "Breezy begins today." Other than some tooling work, almost the entire next year was spent researching aircraft construction techniques, and the Breezy. After reading everything I could get my eyes on and seeking advice from builders, engineers, and Breezy owners, I chose to go with the J-3 replica wing and tail feathers from the Wag-Aero Sport Trainer.
3-7-2010 I purchased a set of Sport Trainer plans
3-11-2010 Received plans and began studying them.
5-13-2010 Built the form block and templates needed to build aileron bulkheads and riblets.
8-14-2010 Ordered aluminum from Wag Aero for ailerons.
8-15-2010 Wag Aero called and said .020 1100 H14 was on backorder, and would be another three weeks.
9-16-2010 No metal. Called Wag Aero and was told it would be another three weeks.
10-18-2010 Still no metal. Called and was told it could be up to a year before they were going to get any more 1100 H14. Cancelled order. Placed order with Aircraft Spruce.
10-21-2010 Received metal.
10-26-2010 Adjusted and refined aileron metal tooling. Made first prototype of bulkhead.
10-31-2010 Cut all aileron aluminum blanks except leading, and trailing edges. Picked up spars and trailing edges. Made three more bulkheads.
11-1-2010 Made ten more bulkheads.
11-3-2010 Fourteen more bulkheads. Made aileron riblet setup on brake.
11-7-2010 Made ten more bulkheads with lots of help.
Hope this doesn't count against the 51% rule.
11-9-2010 Finished forming bulkheads, QCed all. Remade two.
11-10-2010 Made first aileron riblet.
11-11-2010 Bent bottom and side flanges on all riblets, right and left.
11-12-2010 Bent remaining flanges.
11-13-2010 ONE YEAR MARK.
11-14-2010 Fine tuned riblet flanges and QCed.
11-15-2010 Made setup to notch trailing edges for riblets.
11-26-2010 Refined trailing edge notch setup, and test fit. Marked trailing edges for notching.
The reason I used a dovetail is because the angle matches the angle of the TE when laid flat on the table. I then set up a rip fence that allowed the bit to cut through the flange, yet leaving a nice radiused edge on the upper (and lower) plane.
12-3-2010 Cut notches in both aileron trailing edges. Made spar drill template.
12-4-2010 Drilled right aileron spar.
12-5-2010 Drilled left aileron spar.
12-6-2010 Drilled 17 bulkheads, all riblets and test assembled to right aileron spar and trailing edge. Ordered more Clecos.
12-8-2010 Experimented with aileron tip tube radius.
12-12-2010 More tip tube trials.
12-13-2010 Cut right aileron trailing edge, and tip tube to length. Made angles for aileron end rib.
12-14-2020 Layout for drilling -2 and -3 gussets.
12-15-2010 Drilled gussets for top of right aileron spar, and Clecoed them to spar. Drilled holes in/for tip tube and Clecoed. Overall length of right aileron is +.0625.
