Pre-war Chief spar making

Pre-War Aeroncas
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shorty
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Re: Pre-war Chief spar making

Post by shorty » Tue Sep 08, 2009 19:51

I like your rib jig, much higher tech than mine. And you get no staple holes, 8)
I'm using epoxy glue on my ribs, as it's a little more forgiving of joint tolerances.

My 2nd cousin bought new wings for the family pre-war, from a company in Wi.
I'm sure that he still has all the fittings from the old wings.
Thanx
Shorty

Rafael
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Re: Pre-war Chief spar making

Post by Rafael » Wed Feb 24, 2010 15:09

Here is the process to make the jig for making the drag wire holes in the spar. The diameter of the wire is smaller than the diameter of the hole needed in the spar. II put a bolt with the diameter of the drag wire in the fitting and then sleve it out till I have the diameter of the spar hole. I sleved the brass with a steel tube with the right diameter, got it welded, and then run a bit thru it to make the hole on the fitting the right side. Trial test in scrap wood came out perfect.
Rafael
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Re: Pre-war Chief spar making

Post by joea » Wed Feb 24, 2010 15:48

Good to see you making progress on the Spars!

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shorty
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Re: Pre-war Chief spar making

Post by shorty » Thu Jun 10, 2010 22:23

What are you using to build the ribs out of?
I believe they were origionally Mahogony.
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Rafael
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Re: Pre-war Chief spar making

Post by Rafael » Fri Aug 13, 2010 09:48

Ribs are made out of spruce as original and gussets are mahogony as fish paper is not an option anymore
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Re: Pre-war Chief spar making

Post by Rafael » Fri Aug 13, 2010 09:52

Well back at working on the spars. Gluing such a big area with resorcinols has provent to be a bit of a challenge and specially it will be at the strut area reinforcements but so far so good. Next is drilling and then beathing again
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Glass blasted, magnaflux and epoxy primed, they look like new!
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Re: Pre-war Chief spar making

Post by Rafael » Fri Aug 13, 2010 09:55

Nice clean edge that will be the datum for the rest of the meassurements
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Re: Pre-war Chief spar making

Post by Rafael » Sun Aug 15, 2010 19:16

Got to love resorcianol!!
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Re: Pre-war Chief spar making

Post by Rafael » Tue Aug 24, 2010 10:50

Now finishing the strut reinforcement
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Dad "hard" at work
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Re: Pre-war Chief spar making

Post by Rafael » Tue Aug 24, 2010 11:04

On the original rear spars, the wing root fitting holes show elongations on the two middle holes. Other two holes are not elongated. Seems like they were redrilled to match the fitting.
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Re: Pre-war Chief spar making

Post by Rafael » Tue Aug 24, 2010 14:54

Per 5-20 rear spars drawing. Per pic the fitting center holes are a bit off from the origal dimensions, that is why they re-drilled the center holes so it will fit. Precision in making these spars in 1938 was not too good :)
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Re: Pre-war Chief spar making

Post by Rafael » Mon Aug 30, 2010 11:36

Per drawing, I did draw the locations of all teh holes on the spars. Now using the old spars as template I made jig of all the different sets of holes. To do this I used fostener drill bits as the eat only on the bottom and not the sides assuring a centered hole.
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Re: Pre-war Chief spar making

Post by Rafael » Tue Sep 21, 2010 11:30

This is what one of the drilling jigs look like. Ended up with quite a few of them. After I made them I position them on top of the blnal spars and compared the location of teh drawn lines with the locations of the holes on the jig. A perfect match
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Re: Pre-war Chief spar making

Post by Rafael » Tue Sep 21, 2010 11:34

As I had the original spars, some changes were made on the drawings after my plane came out of the roduction line. Those changes included making couple of the holes bigger and intalling bushings on them. I procedded to make the jig as per the origina spar, located it over the blank and drilling it as such. To make the larger holes I purchase a counter-bore drill bit from "Forest City Tools" and the used some 4130 to make the center shaft. This way the smooth shaft assured the bit to be centered and the holes came out perfec.
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Re: Pre-war Chief spar making

Post by Rafael » Tue Sep 21, 2010 12:17

Next step was light sanding on all sides and killing the edges. Then I draw the location off all the ribs and erased all other left over pencil lines. I used the Polyfiver varnish, first coat brushed, then 3 coats sprayed with sanding after first and second coats. Nice, shinny and smooth
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