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Wendell Hostetler Bonanza Build

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Old 03-27-2017, 06:53 AM
  #51
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The lawn mower in the background gives a sense of scale to the fuselage. Your work is very neat and very good!
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Old 03-27-2017, 11:18 PM
  #52
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Did not get much done last night as I had to get some supplies first after work...hobby supplies naturally
I did manage to do the left side outer's and then clipped them to the plane to get idea of size and a "vision" of shape
Left outer spar boxes drying (1).jpg (82.34 KiB) Viewed 11 times

Left outer spar boxes drying (2).jpg (84.21 KiB) Viewed 11 times

Outer spar boxes clipped in place for idea of size (1).jpg (90.75 KiB) Viewed 11 times

Outer spar boxes clipped in place for idea of size (2).jpg (97.18 KiB) Viewed 11 times

Outer spar boxes clipped in place for idea of size (3).jpg (78.23 KiB) Viewed 11 times


Think I may need a bigger workshop with everything going on in there at the moment
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Old 03-27-2017, 11:28 PM
  #53
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Quote:
Originally Posted by FlyerInOKC View Post
The lawn mower in the background gives a sense of scale to the fuselage. Your work is very neat and very good!
Thanks Fly, I try my best...yeah, this bird is huge, worked out the sheeting within +- 10 -15% either way...69sheets of 3mm balsa
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Old 03-28-2017, 07:22 AM
  #54
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If I ever get my DR1 and 182 finished my next project has A 84.5" to 88" single piece wing depending which project I start.
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Old 04-02-2017, 09:39 AM
  #55
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Good work so far! Just received the plans. I don't see any notations for removable/2 piece wings? Curious what your provisions for breaking this bird down for transport would be. Keep up the good work and the progress reports!
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Old 04-03-2017, 01:08 AM
  #56
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I'm signed on to watch
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Old 04-03-2017, 05:39 AM
  #57
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Any work done on over the weekend or did you go flying?
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Old 04-11-2017, 01:26 AM
  #58
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Quite a fiddle getting a good fit on the joiner plugs...started with the center rear...it's a case of cut, sand fit, then sand some more, fit some more, sand some more, fit some more and.....till it's right


Well I finally got the rear joiner plugs fitting in the center spar boxes...the different tapers actually make for a nice fit, not too tight but 100% zero slop.
First rear center joiner plug fitting.jpg (85.77 KiB) Viewed 47 times

First rear joiner plug fitting.jpg (74.35 KiB) Viewed 47 times

Second rear joiner plug fitting.jpg (82.33 KiB) Viewed 47 times

Both rear joiner plugs fit (1).jpg (92.39 KiB) Viewed 47 times

Both rear joiner plugs fit (2).jpg (85.77 KiB) Viewed 47 times


Will close up the box today and then start on the outer boxes
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Old 04-11-2017, 01:26 AM
  #59
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Right, weekend was spent on Mud Bath prep so last night was set for Bonnie work...until the dam power went out AGAIN
All I got done on ANYTHING was closing up the rear spar box ...think there's enough weight on it
Rear spar box setting.jpg (106.75 KiB) Viewed 6 times


And all done. Checked on it this morning and just have to lightly sand the joiner plugs as even after using Sean's method there is still enough residue to make for a "sticky" fit.
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Old 04-11-2017, 05:44 AM
  #60
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You keep going like that you are going to have a straight and true wing on the first try and you won't know how to act! ;-)
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Old 04-11-2017, 09:42 PM
  #61
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Quote:
Originally Posted by Av8tr001 View Post
Good work so far! Just received the plans. I don't see any notations for removable/2 piece wings? Curious what your provisions for breaking this bird down for transport would be. Keep up the good work and the progress reports!
This bird does not have a removable two piece wing. The centre is permanent part of the fuselage and the two outer panels outside of the retract bays are removable. One could I suppose make the wing in two pieces and removable but this would take a bit of re-engineering of the structure of both wing and fuselage, also one would have to leave out the operational door on the right side of fuselage.
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Old 04-11-2017, 09:43 PM
  #62
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Quote:
Originally Posted by FlyerInOKC View Post
You keep going like that you are going to have a straight and true wing on the first try and you won't know how to act! ;-)
That is the general idea Fly...I don't like to do things twice
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Old 04-12-2017, 05:32 AM
  #63
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How far past the fuselage side does the center of the wing extend?
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Old 04-12-2017, 08:47 PM
  #64
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Quote:
Originally Posted by FlyerInOKC View Post
How far past the fuselage side does the center of the wing extend?
See where the glass in the centre ends, that's +- where the side of the fuselage is, so from there to the end of the spar box on each side, roughly 350mm each side.
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Old 04-12-2017, 09:27 PM
  #65
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Well I got the glass n stuff for this bird yesterday, whole 10m of 25g cloth, mixing cups, latex gloves etc....sounds like I'm going to do surgery
10m of 25g cloth (1).jpg (65.1 KiB) Viewed 40 times

10m of 25g cloth (2).jpg (71.66 KiB) Viewed 40 times


I decided to check the fit of the joiner plugs after closing the center spar box and found them to be a bit tight. I started by trying to relieve the fit on the right plug first only to discover that my brain cell had gone on holiday somewhere without my knowledge...I had been trying to put the plug in upside down ... now the right side plug is a touch loose, which isn't a problem as I will put a layer of glass on one side ans a 1/32 ply strip on the top or bottom and then sand everything back to the correct fit
The left side fit was only a touch tight right at the inner end and that just took a very light sanding and was sorted...helps when one puts things in the right way round
Joiner plugs fit in centre box (1).jpg (82.13 KiB) Viewed 40 times

Joiner plugs fit in centre box (2).jpg (81.59 KiB) Viewed 40 times


Started fitting the left plug to it's outer box, little bit more sanding and it will be a good fit.
Fitting plug in left outer box.jpg (82.5 KiB) Viewed 40 times
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Old 04-12-2017, 09:29 PM
  #66
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Well in spite of having to get my wife off to hospital and running around yesterday, I still managed to do some work on two planes, not much, but some at least.

I decided to use .6mm ply strips to laminate to the joiner plugs where the fit is a tad loose, I just felt it is easier and much quicker than glass and sands easier too.
.6mm ply strips used on plugs (1).jpg (71.37 KiB) Viewed 3 times

.6mm ply strips used on plugs (2).jpg (66.57 KiB) Viewed 3 times


I laminated the strips with half hour epoxy and wrapped them tight with masking tape to cure.
Laminating the .6mm ply to the plug.jpg (77.89 KiB) Viewed 3 times


Then it was again sand, fit, sand, fit till the fit was correct.
After sanding to fit.jpg (84.78 KiB) Viewed 3 times


If you look closely you can just make out the lamination on the joiner plug.
Can just see the ply lamination.jpg (83.85 KiB) Viewed 3 times


Once the fit was correct I closed up the outer left spar box, also with half hour epoxy.
Left outer spar box setting.jpg (100.52 KiB) Viewed 3 times


I wasn't taking chances this time with glue setting and having to sand the joiner plug again to fit so I constantly put it in and took it out to get the glue out the joiner cavity...fit looks good.
Plug fit between centre spar box and outer spar box (1).jpg (87.25 KiB) Viewed 3 times

Plug fit between centre spar box and outer spar box (2).jpg (86.71 KiB) Viewed 3 times

Plug fit between centre spar box and outer spar box (3).jpg (85.03 KiB) Viewed 3 times


Tonight I start on the right side, and being LOONG weekend I should have more time to get more done...during hospital visits of course
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Old 04-13-2017, 03:59 AM
  #67
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Thanks for the nice construction pictures, I find it interesting to look at. And also that they are not taken with an excessive resolution, my low end laptop is a bit too lazy to show me the high resolution pictures that some are using I have found.

Last edited by ibuild; 04-13-2017 at 04:02 AM.
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Old 04-13-2017, 06:02 AM
  #68
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The pictures really do tell a great story!
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Old 04-13-2017, 08:39 AM
  #69
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Quote:
Originally Posted by FlyerInOKC View Post
The pictures really do tell a great story!

Absolutely mr.FlyerInOKC, and based on my experience that story is going to follow me around and ring in my ears for years to come.
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Old 04-13-2017, 08:49 PM
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Quote:
Originally Posted by ibuild View Post
Absolutely mr.FlyerInOKC, and based on my experience that story is going to follow me around and ring in my ears for years to come.
Pleasure Ibuild, glad you are enjoying the build...hope it's not TOO extensive, but I do like to give detail in case someone else can learn something from it. I take all my build pictures with my simple Samsung J1 smart phone, much easier than keeping a camera around the workshop...
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Old 04-17-2017, 10:43 PM
  #71
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Managed to get a little bit done yesterday even though I was feeling pretty rotten...must be something I ate

Anyway due to finally having my belt sander working things went a lot quicker. I did the finish sanding on the rear spar boxes and glued the center rear into the fuselage.
Rear center spar box glued into fuselage.jpg (101.71 KiB) Viewed 27 times


I also sanded the main joiner plugs to fit the main spar box, I will close up the main spar box tomorrow after final fitting but so far it looks good.
Main joiner plugs fitting to main spar box (1).jpg (80.31 KiB) Viewed 27 times

Main joiner plugs fitting to main spar box (2).jpg (90.88 KiB) Viewed 27 times

Main joiner plugs fitting to main spar box (3).jpg (86.81 KiB) Viewed 27 times
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Old 04-18-2017, 05:18 AM
  #72
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Beautiful work!

Mike
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Old 04-21-2017, 12:45 AM
  #73
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Was messing around a bit last night checking the size of the Bonnie...@$#%&@&*@ this bird is huge...NO I'm not short, I'm under tall [ATTACH]2210605[/IMG]
The total span will be to the top of the rule, 340mm each side of current rear spar.
size of this beast (1).jpg (85.9 KiB) Viewed 5 times
size of this beast (2).jpg (92.33 KiB) Viewed 5 times
size of this beast (3).jpg (89.19 KiB) Viewed 5 times

And that's why it all takes a while, a VERY busy workshop [ATTACH]2210606[/IMG] [ATTACH]2210607[/IMG] [ATTACH]2210608[/IMG] [ATTACH]2210609[/IMG] There are 6 current planes in progress in the photo and the little Cessna was started about five or six years ago...yeah yeah, I know...one day [ATTACH]2210605[/IMG] [ATTACH]2210611[/IMG]
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Old 04-21-2017, 12:45 AM
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Was messing around a bit last night checking the size of the Bonnie...@$#%&@&*@ this bird is huge...NO I'm not short, I'm under tall [ATTACH]2210610[/IMG]
The total span will be to the top of the rule, 340mm each side of current rear spar.
size of this beast (1).jpg (85.9 KiB) Viewed 5 timessize of this beast (2).jpg (92.33 KiB) Viewed 5 timessize of this beast (3).jpg (89.19 KiB) Viewed 5 times

And that's why it all takes a while, a VERY busy workshop [ATTACH]2210612[/IMG] [ATTACH]2210613[/IMG] [ATTACH]2210614[/IMG] [ATTACH]2210615[/IMG] There are 6 current planes in progress in the photo and the little Cessna was started about five or six years ago...yeah yeah, I know...one day [ATTACH]2210610[/IMG] [ATTACH]2210616[/IMG]
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Old 04-21-2017, 05:07 AM
  #75
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To paraphrase my old 7th grade 5 ft tall Algebra teacher, "You are as tall as everyone else, your feet reach the floor!"

It is one BIG bird!
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