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  #1  
Old 06-04-2016, 03:01 PM
Allan Stern Allan Stern is online now
 
Join Date: Jan 2006
Location: Cape Coral, Florida
Posts: 259
Default Forming the longerons

I am at the stage of forming the longerons for fuselage. Is ther an easier way to form them than putting them in a vise and hitting them with a rubber mallet? Are there any forms, jigs or patterns one can use? Any companies that sell them already formed or will form them for you? How was your experiences in bending them?

Thanks

2016 paid
RV 6A sold
RV 8A flying
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  #2  
Old 06-04-2016, 03:15 PM
wirejock's Avatar
wirejock wirejock is offline
 
Join Date: Oct 2005
Location: Estes Park, CO
Posts: 3,947
Default Buller dies

Quote:
Originally Posted by Allan Stern View Post
I am at the stage of forming the longerons for fuselage. Is ther an easier way to form them than putting them in a vise and hitting them with a rubber mallet? Are there any forms, jigs or patterns one can use? Any companies that sell them already formed or will form them for you? How was your experiences in bending them?

Thanks

2016 paid
RV 6A sold
RV 8A flying
Ask around for a set of Buller Longeron dies. Easy Peasy.
http://www.bullerent.com/longerondies.htm
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Larry Larson
Estes Park, CO
http://wirejockrv7a.blogspot.com
wirejock at yahoo dot com
Donated 12/03/2019, plus a little extra.
RV-7A #73391, N511RV reserved (2,000+ hours)
HS SB, empennage, tanks, wings, fuse, working finishing kit
Disclaimer
I cannot be, nor will I be, held responsible if you try to do the same things I do and it does not work and/or causes you loss, injury, or even death in the process.
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  #3  
Old 06-04-2016, 04:23 PM
daveyator daveyator is offline
 
Join Date: Jan 2011
Location: adelaide, south australia
Posts: 171
Default

Like most builders, I approached the longerons with a sense of dread. My advice is to follow the instructions exactly, and you will be pleasantly surprised. I spent quite some time "creatively visualising" what had to be done before starting. A small workshop press was ideal for opening up the end angle. The 'preload and bend method is really quite simple and effective. Take your time and work in small increments, your technique will improve rapidly.
You are not bashing them into shape, you are easing them. A two pound dead blow hammer works a treat.
Many words have been written on the longeron subject, and after completing them, I really don't know what the fuss is all about. It is actually one of the more satisfying tasks you will tackle up to that point in the project.
Again, follow the instructions. There are some clever people at Vans.
Cheers, and have fun.
DaveH
120485
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  #4  
Old 06-04-2016, 05:35 PM
LittleJoeA LittleJoeA is offline
 
Join Date: Nov 2010
Location: Livermore, CA
Posts: 124
Default Longerons

The Buller dies in a vise worked for me. I was able to bend a little at a time until everything was right on.
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Livermore, CA
RV-12, S/N 120419
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  #5  
Old 06-04-2016, 05:36 PM
redbaron redbaron is offline
 
Join Date: Aug 2013
Location: Lucerne,Ca
Posts: 272
Default Don't do it with out Buller dies.

These dies take a[look the work out of the project. Under squeeze the vice at first. You will happy you bought them
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  #6  
Old 06-04-2016, 07:59 PM
nilberg nilberg is offline
 
Join Date: Dec 2012
Location: Katy, TX
Posts: 233
Default

I've tried both the dies and the method shown in the Orndorf videos.
I found the Orndorf worked best for me.
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  #7  
Old 06-04-2016, 09:04 PM
PilotBrent PilotBrent is offline
 
Join Date: Dec 2011
Location: Hackettstown, NJ
Posts: 459
Default

Followed the Van's instructions as closely as I could (first time builder) parts came out exactly as expected. I've heard that the dies would have made it easier but they are not essential.
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  #8  
Old 06-04-2016, 09:13 PM
wirejock's Avatar
wirejock wirejock is offline
 
Join Date: Oct 2005
Location: Estes Park, CO
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Default Dies

Here's another consideration.
Totally my fault but when the fuse was going together, the longeron bend didn't perfectly match the canopy rails and aft deck. Bend was a tad too shallow.
I removed the side skins and tweaked the longerons in place with the Buller Dies using a vice clamped to a jack. Only took a few minutes to get the bends perfect.
Just another point. Nothing wrong with hammer and vice.
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Larry Larson
Estes Park, CO
http://wirejockrv7a.blogspot.com
wirejock at yahoo dot com
Donated 12/03/2019, plus a little extra.
RV-7A #73391, N511RV reserved (2,000+ hours)
HS SB, empennage, tanks, wings, fuse, working finishing kit
Disclaimer
I cannot be, nor will I be, held responsible if you try to do the same things I do and it does not work and/or causes you loss, injury, or even death in the process.
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  #9  
Old 06-04-2016, 10:05 PM
RFSchaller RFSchaller is offline
 
Join Date: Oct 2010
Location: Phoenix, AZ
Posts: 2,820
Default

The hammer worked for me --- and I found it quite therapeutic!
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  #10  
Old 06-05-2016, 06:24 AM
BigJohn BigJohn is offline
 
Join Date: Nov 2008
Location: Gloversville, NY
Posts: 1,587
Default

Everyone has had a different experience and therefore a different perspective on this task. There are several posts here from folks who found this job not too hard with the brute force method. However my experience was different. Six years ago when I did the lomgerons there were no dies available (at least that I knew of), and as a first time builder I struggled mightily for a couple of VERY frustrating days to get them somewhere near correct. I am pretty mechanically inclined but at the time did not have any experience with forming metal components. And, just the idea of beating the **** out of a piece of my future airplane was intimidating to me.

My advice to you is to get the dies, and if at all possible engage the help of someone who has bent longerons before. Previous experience with the task is invaluable.
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