1-2-2011 Built 1 inboard aileron brace. Yuck! I miss Ron's shear.
1-3-2011 Built 1 outboard aileron brace. Again, yuck.
1-4-2011 Built 3 more tip tubes. 1 right, 2 left.
1-24-2011 Had pieces cut for aileron braces X4. Thanks, Leon!
3-2-2011 Built 4 aileron braces - discarded 2. Built set by Piper drawings
( http://www.supercubproject.com/drawings/main.aspx ). Outboard braces too short - using inboard for all 4 - good fit and I like them better than the Wag Aero ones.
3-11-2011 Trying to find the best way to deburr.
5-7-2011 To make the nose radius for the aileron covers, I built this simple brake. E-mail me if you would like more details about how to build this brake, materials used, or, for that matter, anything you see here.
5-9-2011 Built trailing edge drill jig for O.A. width of 13.5" per Piper drawings.
5-29-2011 Spent the weekend at T67 at Ron's hangar. Cut aileron leading edge cover blanks. Rolled and formed 14.5" and 17.5". Met Bob Avery of Avery Tools ( www.averytools.com ) who carries the perfect deburring tools (1046 and 22022).
5-30-2011 Cut blanks for hinge and horn backs. Deburr, deburr, deburr...
7-12-2011 Laid out hinge blanks.
7-13-2011 Had Leon cut long cuts on .050 4130 for hinge blanks. Too thick for my shear.
7-14-2011 Set up and cut half of hinge blanks.
7-15-2011 Cut rest of hinge blanks. Drilled and slit all.
7-17-2011 Cut radii and laid out bend on hinge blanks, backs, and control horn backs.
7-18-2011 Cut 1 control horn and half the notches in hinge and horn backs. Formed horn.
7-19-2011 Cut rest of notches in hinge and horn backs.
7-25-2011 Made set up to bend hinges. Epic failure! Ruined all extras. Bent rest by eye. Whew!! All within .010". P.I.T.A.
7-27-2011 Bent hinge and horn backs.
7-29-2011 Cut second control horn, and -1, and -2 inserts.
SORRY, THE NEXT GROUP OF PHOTOS WERE TAKEN WITH MY PHONE.
THE QUALITY IS POOR SO I WON'T BE DOING THAT AGAIN.
8-2-2011 Formed all long aileron leading edge covers. My slip roll is large and will leave too wide of an "initial flat," so I used my 1/4" radius brake give the blank a flat that would better match the 7/8" top flange of the aileron spar, bending it about 8ยบ.
Then, I inserted the blank in the slip roll, bend first, and rolled all but the last 4" to a radius matching the aileron nose blocks.
Then, I loaded the flat edge into the radius brake.
Broke the blank.
And, viola! One perfect aileron leading edge cover.
8-4-2011 Formed other control horn. Too freaking hot in the shop. That's all I'm going to do for a month or so.
