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"Scratch" build of #398

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  • "Scratch" build of #398

    I've FINALLY gotten started building. It took longer to get my shop cleared out and ready to work in again than I thought it would (or should have)

    I'm starting with the ailerons both from advice on here as well as a little logical thinking of what's the best way to learn the processes. I'll get both ailerons built and then move on to building both flaps before starting on the wings. Hopefully this will also give Mark time to get the new one-piece spar caps produced for the Patrol and selling to homebuilders.

    I started a YouTube channel I'm using to document everything, some on here are already watching I know...

    https://www.youtube.com/channel/UCS_..._as=subscriber

    For people who don't watch YouTube, I'll be posting up some pics and descriptions on here that I capture from video. I'm looking forward to the ride, but I know it's gonna be a long one! "small bites"
    https://www.youtube.com/user/fastfox23
    Patrol plans #398

  • #2
    I bought the spar and rib package from Mark, seemed like a cost effective move to me, and so far I'm happy with the parts I've got.
    So far, I've got the spars marked with rib and hinge locations, I built a couple tools to help prep the ribs, and I've wasted time waiting on my aluminum to show up...


    Rib straightener.jpg I stole this design from B-Spot, who stole it from the RV guys. It's just a simple, fast way to complete the 90 degree flanges


    fluting anvil.jpg Also stolen from B-Spot, this is the start to my fluting tool. It will operate in the same way as the flange strightener, but with the dowel set in there it SHOULD give me nice flutes... we'll see if it actually works later.
    https://www.youtube.com/user/fastfox23
    Patrol plans #398

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    • #3
      So, looking at the plans, it's a little confusing for me to determine how many rivets I should be using, or rivet spacing along the ribs, etc... any tips? I'm currently working on my aileron rib attach angles, I "think" it calls for 5 rivets into the spar??? And looks like 4 into the rib? Is that right?
      https://www.youtube.com/user/fastfox23
      Patrol plans #398

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      • #4
        Screen Shot 2020-08-28 at 8.00.43 AM.png
        Looks to me like the plans call out four rivets (AN470AD-3) in my plans to attach the Ribs to the Aileron Spar.

        Plans p.3 call out 1.5 inch spacing using AN426AD-3 to attach the skin to the ribs.
        Brooks Cone
        Southeast Michigan
        Patrol #303, Kit build

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        • Russellmn
          Russellmn commented
          Editing a comment
          Thanks, after I had posted this, I realized it was just 4 from the attach angle to the rib as well. Part of the fun is figuring out the drawings I guess!

      • #5
        I'm hoping if I'm wrong, someone will tell me...
        My plan on the ailerons is: I've got the attach angles built and drilled, 4 rivet holes to the spar, and 4 to the rib. I believe this is correct? Moving forward, I plan to clamp the two spars together back to back, so I can drill both spars identical/symmetrical. Then I'll position the attach angle as needed to place the rib where it goes and drill through both spars using the predrilled angles as a guide. To my mind, this will result in both spars being drilled the same and ready to rivet the angles on.

        Does anything sound wrong about this? Am I totally off base? Or will that work?

        Appreciate any and all comments/criticisms/etc...

        Russell
        https://www.youtube.com/user/fastfox23
        Patrol plans #398

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        • #6
          Originally posted by Russellmn View Post
          I'm hoping if I'm wrong, someone will tell me...
          Moving forward, I plan to clamp the two spars together back to back, so I can drill both spars identical/symmetrical. Then I'll position the attach angle as needed to place the rib where it goes and drill through both spars using the predrilled angles as a guide. To my mind, this will result in both spars being drilled the same and ready to rivet the angles on.

          Does anything sound wrong about this? Am I totally off base? Or will that work?

          Appreciate any and all comments/criticisms/etc...

          Russell
          You will be assembling and dis-assembling things a number of times. Like drilling, then removing then priming each part, etc. Keeping all the parts in order becomes a considerable task if all the parts are not identical.

          So therefore, Consider making a drilling jig for your attach angles. Make it out of steel (to limit hole elongation with use) and place the holes in the jig symmetrically so the jig does not have to be oriented upside down or right side up. Symetrical & identical attach angles is a blessing.
          Last edited by Bcone1381; 09-03-2020, 08:01 AM. Reason: clarification
          Brooks Cone
          Southeast Michigan
          Patrol #303, Kit build

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          • Russellmn
            Russellmn commented
            Editing a comment
            I built a jig based off of Dave Bottita's (Desert Bearhawk) design. All the angles are drilled and ready to go.

        • #7
          If you screw up your layout, you'll scrap/repair two parts instead of one. Drill to a #40 first and then to net. A second set of eyes you trust might not hurt. Your plan seems OK, let us know how it works. It's on the horizon for me.
          Gerry
          Patrol #30

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          • #8
            Got the spars drilled today. Went pretty well, drilled to a #41.
            https://www.youtube.com/user/fastfox23
            Patrol plans #398

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            • #9
              Latest video is up...

              https://www.youtube.com/watch?v=37JUBLXprqo
              https://www.youtube.com/user/fastfox23
              Patrol plans #398

              Comment


              • Bcone1381
                Bcone1381 commented
                Editing a comment
                You do a very nice job with your Videos, Russel!!

              • Russellmn
                Russellmn commented
                Editing a comment
                Thanks, I'm learning. I wasn't terribly happy with Ep. 4, but I think 5 came out much better.

            • #10
              Got my ailerons all drilled up and cleco'd together!


              I'll get going on building the hinges and finishing out the aluminum work on these this week, we'll see if I can get it all done this week or if it'll be next week before tearing it apart and deburring and prepping for primer.
              https://www.youtube.com/user/fastfox23
              Patrol plans #398

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