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gjdale

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Posts posted by gjdale

  1. Chris,

     

    You can’t go better than the Byrnes saw and many of us Aussies have the privilege of owning one. You just have to be prepared to pay the exorbitant postage fees, which are beyond Jim’s control. At the time I bought mine, the postage added about 50% to the cost of the saw. Nowadays, you’ll also have to be prepared to pay GST as well....

     

    It hurts, but it’s worth every penny! As the saying goes, “quality is remembered long after price is forgotten”.

  2. Thanks Carl, and to all of the "likes".

     

    Construction of the wings begins by placing the shaped ribs individually over the wing plan and cutting a variety of lengths and shapes. The photo below shows some of these ready for use:

    1026636602_29WingFrameComponents.jpg.bd38f0d68803878a6ed0a4b468254a96.jpg

    Once all ribs are cut to size/shape, the wings are built up over the wing plan, in alphabetical order. Here is what this phase looks like:

    2053083573_30WingConstruction.jpg.c06510e5e1258d9f61ba78bd0b6e0974.jpg

    Here is a photo of the wings at this stage, removed from the wing plan:

     

     

     

    Two wing struts were then made, fitted with hardware and seized with thread – the plans call for them to be slightly different lengths:

    472609242_32WingStruts.jpg.bb5622fc2e3ffab13bfb7188d907b707.jpg

    Construction of the tail section begins with creating a curved “shaper” made up by laminating three pieces of 1/8” x 1/32” Cherry around a plywood former created from the supplied template. The “shaper” is then placed over the wing plan and trimmed to final size/shape:

    233603818_33TailFormer.jpg.8363c0328771ee73d283ba05dd23de87.jpg

    Two of the remaining wing ribs are then glued and seized together such that they curve in three dimensions. Here are all of the tail pieces prior to final assembly:

    704812055_34TailPieces.jpg.d7f18f4e0240c30a75bb4cf546d44cbc.jpg

    Tail construction then proceeds with the shaper and two outer ribs glued together over the wing plan:

    512989379_35TailConstruction1.jpg.bcab128eaa93ae53e2abd880063f48cf.jpg

    The two inner ribs are then notched on the underside and placed over the shaper. The blob of “yellow tack” is to provide some weight/balance so that the inner ribs set in the correct position:

    544020710_36TailConstruction2.jpg.dd137621772163f10e1744209eb39e0a.jpg

    The Tail Mounting Bracket is then made by first bending a piece of (very) stiff wire to shape and then adding a leather strap, which was first cut to shape and fitted with a “buckle” as well as two slits for the wire:

    1121525456_37TailMountingBracket.jpg.3c48c5a6451f1126f13fd7a76f20c257.jpg

    The Tail Mounting Bracket is then attached to the Tail Assembly:

    1310820089_38TailConstruction3.jpg.bc4cfc27180c93b3c6a3100c235d57ee.jpg

    Finally, some cable (thick thread) was added in accordance with the Wing Plan. Here is the final Tail Assembly:

    786861483_39TailConstructed.jpg.f1ceff386c275338e9865b5ad20ff30a.jpg

    The next step will be to cover both wings and tail assembly with mesh, followed by final assembly of all parts to the fuselage. The finish line approaches…

  3. 5 hours ago, vossiewulf said:

    BTW do you know if brass blackener works on copper?

    For blackening copper, you need to use Liver of Sulfur. Readily available online. I use the gel form. A little goes a long way. The best thing about it is that you can use it ‘in situ’ and just rinse off the surrounding wood with water if there is any overspill. Much easier to use than brass blackening solutions too! Ed Tosti uses it extensively on his builds (Naiad, and Young America) - he actually uses copper where he can instead of brass.

  4. It's been a long time between drinks for this log! The usual "life got in the way" excuse applies - mainly work-related - but I have managed to re-commence work on this project in the last couple of weeks - spurred on by receipt of my Medway Longboat kit from Chuck!😉

     

    The somewhat tedious process of shaping all of the spars was the next step. 

     

    The two spars of shape ‘B’ were sanded square and set aside. Of the 30 spars of shape ‘A’, eight were sanded square and set aside. The remaining 22 were tapered square from two thirds of the way back to the end of each rib. After tapering square, these 22 along with two that were not tapered, were all shaped octagonal. I found the easiest way to do this was using a very small hand plane. All the spars were then given a finish coating of Shellac followed by furniture wax. Here are the resulting spars, although the photo does not really show the shaping terribly well.

     

    409822236_26WingSparsCompleted.jpg.e40fdcc7fa84701e38c5d10a8b4623cc.jpg

     

    It was then on to the main wing spar shafts. Although the kit provided some 3/16” dowel for these, I used some 1/4" square boxwood stock to make these. After cutting to length, I started by drilling the holes as indicated in the plans while the stock was still square. I then used an approximation of the 7/10/7 rule to draw some layout lines for shaping to octagonal, for which I again used a small hand plane. The spars were then chucked in a hand drill and sanded round to the final thickness of 3/16”. It sounds like a lot of work, but this progressed quite quickly in the end. One end of each main spar was then shaped with a ‘step’ to receive two parts similar to a gaff neck (the part is unnamed in the instructions). These parts, together with the shaped end of the spar shaft, form a housing for the next part called a ‘spring clamp’, into which a wing-tip spar (cut from the spar shape 'B') was inserted. Once all the shaping was complete, the spar shafts received the usual treatment of shellac/furniture wax. I forgot to take any progress photos of this stage. 

     

    The spring clamps were shaped from 1/4” x 3/32” Cherry stock and fitted to the spar shaft housings using a dab of glue and three ‘seizings’. Here is a photo of the completed main spar shafts, with wing-tip spars inserted.

     

    1175700181_27MainSparShafts.jpg.5d64ee159477a76025ba7bbfdccb755a.jpg

     

    and a close-up of the spring-clamp arrangement... 

     

    1215241175_28MainSparSpringClamps.jpg.5eac439ee0feaad3e615b8ba1583d78f.jpg

     

    All of the shaped spars, together with the main spar shafts, will now be used to construct the wings.

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