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-   -   RV-8 Chris S. Johnson (https://vansairforce.net/community/showthread.php?t=113651)

CSJohnson 01-08-2015 06:01 AM

Retractable Gear for Workbenches
 
I used Mike Becker and Mike Hertz's plans to add retractable gear to two of my EAA Workbenches. Again, I'm going to be doing this project alone a lot of the time so this should be a convenient solution rather than waiting for help or dragging the benches across the floor.

It works remarkably well and I'm very pleased with the result. Thanks guys!


CSJohnson 01-08-2015 06:20 AM

Bench Grinder and Band/Disc Sander
 
For a "bench" grinder I purchased the Jet G577101 JBG-6A 6 inch along with the Jet 577172 Pedestal. (Prices has gone up as I got it for $89.)

I left the regular grinding wheel on the left side and installed the 3M 7A Medium 6" that came with the tool kit on the right side.



I also purchased the Jet 577003 J-4002 1 . 42 in. Belt and 8-inch Disc Sander. (Geez, that price went up a lot too!)

I replaced the stock band with a 3M Scotchbrite Medium Maroon.



I know that I'm not skimping on tools, and am putting out a lot of coin, but my experience from rebuilding a couple of car engines is that quality tools make a difference, particularly in avoiding downtime, and that they can be easily resold on Craigslist or eBay and without losing much value.

CSJohnson 01-08-2015 06:35 AM

Van's Practice Projects - Toolbox
 
So after all this time, effort, and money getting the workshop setup, it's finally time to build something! I decided to do both of Van's practice kits, the Toolbox and Airfoil.

First, my father and I went to work on the toolbox. There is so much to learn! We had a lot of fun working together, learned a lot, made mistakes, but ultimately experienced success.

At one point one of the sides of the box was dimpled in the wrong direction. Okay, a few raps with a hammer to flatten it out, then dimple it the right way. WRONG!!! It doesn't work like that. We installed it anyway and you could definitely tell a difference with how the rivets set. Great lesson to learn.



Next we're planning to attack the airfoil which will require a number of new techniques:


In addition to learning about the building process, I also learned a lot about the choices I made with tools and setting up the workshop. I know this is but a small project compared to the RV-8 kit, but I'm very pleased with the setup.

Tools were readily accessible. Having multiple drops from the compressor, the lightweight hoses, and two drills with different bits made it easy for us to both work at the same time.

We did some deburring manually, even using a file, and then with the grinder and band sander. The difference in time and results was very significant. Thus far I'm very happy with the setup and hope that continues. I owe a lot to this website as there's a ton of information and guidance from those who've already been there, and I hope I can also contribute to the knowledge.

Time to order the empennage!!! :D

dhc2jeep1 01-13-2015 10:28 AM

Quote:

Originally Posted by CSJohnson (Post 948319)
I've gone back-and-forth on this one, and finally decided on a portable unit rather than messing with the air handler in the garage.

Insulating the attic seems to have paid off as this morning it is 37 degrees outside but 62 degrees in the garage/workshop.

After a lot of research (of course!) I purchased the Whynter ARC-14SH portable air conditioner/heater. It's rated to handle 500sf of space and that's right about where I'm at.

I removed a window from a side door and replaced with a mount I fabricated for the intake and exhaust hoses. It really hasn't been fully tested yet and think that will come during the summer when it's 98 degrees with 98% humidity.

I use an LG 12,000 BTU portable AC unit vented the same way and it works perfectly. When it is 100 F/ 90% humidity outside, it is a comfortable 72 F /low humidity inside. My garage is attached, 19x18, with insulated walls and doors. You should have no problems with your set-up, even with more humid conditions in Tampa.

-Chris

bird 01-14-2015 06:41 AM

Good decision getting the belt sander, you will find that you will use it more than any othe grinder types. I never used a scotchbrite belt but sounds good, I always kept about 220 grit belt on my one inch sander. Very useful, however I usually done my part deburring and edge prep by hand :)

Bird

CSJohnson 01-20-2015 09:08 PM

Empennage Arrived!!!
 
As if I hadn't convinced myself and others already that I was going to do this, I ordered the empennage and it was delivered by FedEx today.

I decided to put the retractable wheels on my other two workbenches, and still need to get the C-Frame setup with the Numatx equipment installed. I also want to finish the second practice project before I start, but expect to officially start the build in the next week or two.






CSJohnson 03-26-2015 01:19 PM

C-Frame and Table Installation
 
It's been awhile, but progress continues. Getting the C-Frame installed was a particular challenge. I'm using Mark Swinford's Numatx setup. I had the C-Frame fabricated from his drawings, and it's a 106lb hunk of steel.

Mark has an elegant table design that includes the ability to retract and raise the C-Frame as needed. I attempted to execute this design, and despite getting pretty good with the mitre saw, I just don't have the woodworking skills to pull it off with the precision necessary for the pieces to fit together properly. The EAA Chapter 1000 tables are much easier to build.

I thought I would take two EAA tables, slap a sturdy 2X10 on each side, drill mounting holes and off I'd go. But, once again, I couldn't achieve the precision necessary as even with a drill press I couldn't get the holes just in the right place, and when I mounted the C-Frame it wasn't level or flush enough with the tables. (I am a bit of a perfectionist.)

So, I decided I needed both a way to adjust the C-Frame to get it where I want it, and also the ability to mount either the Numatx or the Experimental Aero C-Frames. Yes, I have both, to learn, use when I do have help, and as backups.

I decided to mount both C-Frames to wood, two 2x4's for the Numatx, and a one 2x10 for the Experimental Aero. Then I installed four T-nuts on each and inserted elevator bolts. I moved the 2x10's I attached to the sides of the EAA tables down and they will form a shelf onto which the C-Frames sit and then the elevator bolts can be used to adjust height and level. Here's the result:

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Both C-Frames mounted with elevator bolts on the bottom.

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Resting on the "shelves."

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Not flush or level, but I can use the elevator bolts to adjust.

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Works beautifully.

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I can dimple so fast that I need to slow down as it's easy to hit the pedal before the hole is aligned with the dimple die. The result is not good. Just need a steady pace and care.

CSJohnson 03-26-2015 01:25 PM

Webcam
 
Something else I did since my last post was to upgrade a very old Pentium 4 computer to allow me to install Windows 7, a webcam, and yawcam.com webcam software.

The software allows the webcam to be motion sensitive. Once motion is detected it will activate and take pictures (or video). I'm going to set it up to take a picture every 30 or 60 minutes.

While I don't plan on streaming or otherwise having the pictures automatically post to the Net, it will give me a record of the build and maybe even the ability to create a cool time-lapse video of the build.

CSJohnson 03-30-2015 11:38 AM

The Jig is Up!
 
I know it's not required, especially with the empennage, but I decided to build a jig that I can use for the emp and wings for convenience. I'd need to build another workbench anyway, so why not just build a jig.

I used a hybrid design of two I saw by searching Google and Bing. I'm pretty happy with the result. I put it on lockable wheels that are threaded and go into T-nuts so I can level. The height is such that it won't hit the garage door or opener. It's 114" wide from between the posts. A few things I learned:

1. 2x4's are easier to come by and handle than 4x4's, at least in my area. All the 4x4's are treated for outdoor use and not very straight, at least from the Big Box stores.

2. Lowe's has both Select and Premium 2x4x8's, and the Premiums are much truer - nice and straight. Unfortunately they don't have Premium 2x4x10's.

3. Lumber cut from the center of the tree is generally straighter than those cut from the outside, so look at the ends for that small dot surrounded by tight circles and you're near the center.

4. If you take your time, you can find pretty straight and flat 2x4x10's. Whether it makes a huge difference in the end result of the airfoils I don't know, but it is easier to measure, glue, and build from straight and flat lumber.

5. Elmer's Wood Glue is strong!

Here's the result. I'll modify as needed when I get to the wings.






rightrudder 03-30-2015 04:22 PM

Impressive, Chris. It's been (accurately) said that a lot of wood is needed to build an aluminum airplane!


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