Wendell Hostetler Bonanza Build
03-14-2017, 10:26 PM
#26
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I worked on the rudder last night. First I cut a sheet template for the rudder skins and then the skins. then I had to replace two of the rudder ribs as they were wrong size and also had to chamfer the rudder post to the right angle on both sides before assembling the first side of the rudder.
Rudder skin template.jpg (63.42 KiB) Viewed 6 times
First rudder skin.jpg (59.64 KiB) Viewed 6 times
First side with rudder post and ribs.jpg (68.13 KiB) Viewed 6 times
First side of rudder with fin.jpg (66.87 KiB) Viewed 6 times
Then I laminated the bottom rudder hinge and horn block.
Stabilizer tip blocks fitted (2).jpg (74.08 KiB) Viewed 6 times
Then I added the tip blocks to the stab and shaped them to the right profile but have not done the rest of the shaping as the elevators need to be added before that gets done so that all will match up.
Stabilizer tip blocks fitted.jpg (59.92 KiB) Viewed 6 times
After that was done I temporarily fitted the rear fin support on top of the stabilizer and removed material from the bottom of the fin to fit to fuselage. The rear fin support will be permanently fitted once the stabilizer has bee glassed, sanded and glued to the fuselage.
Temorarily fitting rear supports.jpg (58.84 KiB) Viewed 6 times
Stabilizer tip blocks fitted (1).jpg (87.81 KiB) Viewed 6 times
Stabilizer tip blocks fitted (2).jpg (74.08 KiB) Viewed 6 times
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Checking fit again.jpg (73.82 KiB) Viewed 6 times 
Rudder bottom hinge and horn block laminating.jpg (72.13 KiB) Viewed 6 times
Then I laminated the bottom rudder hinge and horn block.
Then I added the tip blocks to the stab and shaped them to the right profile but have not done the rest of the shaping as the elevators need to be added before that gets done so that all will match up.
After that was done I temporarily fitted the rear fin support on top of the stabilizer and removed material from the bottom of the fin to fit to fuselage. The rear fin support will be permanently fitted once the stabilizer has bee glassed, sanded and glued to the fuselage.
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03-14-2017, 10:27 PM
#27
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No Idea what's going on with Avcom this morning, but preview does not match what I put in (order of pictures is wrong, but you will figure it out (mods please repair the system)
Tail end so far
Tail end so far (1).jpg (91.68 KiB) Viewed 5 times
Tail end so far (2).jpg (90.25 KiB) Viewed 5 times
And here is a size comparison on the pool table...this bird is BIG.
Size comparison with pool table (1).jpg (71.57 KiB) Viewed 5 times
Size comparison with pool table (2).jpg (88.94 KiB) Viewed 5 times
Here's the shavings just from the fin/rudder and stab, not huge feet, but size 9 for comparison to amount of shavings
...I love making hamster bedding 
Hamster bedding.jpg (86.31 KiB) Viewed 5 times
Tail end so far
And here is a size comparison on the pool table...this bird is BIG.
Here's the shavings just from the fin/rudder and stab, not huge feet, but size 9 for comparison to amount of shavings
...I love making hamster bedding
03-14-2017, 11:51 PM
#28
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Location: Pretoria South Africa
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03-15-2017, 10:40 PM
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Right, so i got home and to work, started by making an elevator skin template and cutting the four elevator skins.
Elevator skin template.jpg (69.09 KiB) Viewed 3 times
Elevator skins cut.jpg (69 KiB) Viewed 3 times
Then checked which elevator ribs fitted, had to replace two on each side, and glued the leading edge and ribs on the first elevator.
Elevator ribs that fit.jpg (71.29 KiB) Viewed 3 times
Ribs glued on first elevator.jpg (71.63 KiB) Viewed 3 times
Then I skinned the other side and added the trailing edge and then sanded it all and V'd the leading edge before having to fetch my son.
First elevator .jpg (68.62 KiB) Viewed 3 times
Then while driving there was something niggling in the back of my mind...I had forgotten to add the hinge support blocks
So I got back and cut a strip of the sheeting out, installed the hinge support blocks and the sheeted again with a strip of 3mm and then sanded.
First elevator after fitting Hinge support blocks.jpg (73.89 KiB) Viewed 3 times
Then I built the other elevator and taped them to the stab.
Bothe elevators.jpg (71.95 KiB) Viewed 3 times
Just need their tips.jpg (64.25 KiB) Viewed 3 times
Plan for tonight is to do their tips and then onto the spar boxes, I will be fetching the 1/4 x 3/8 White Beach spars that I have had cut by Wood At Ease in the east of Pretoria during the day...R30/strip 1.5m long which I don't think is bad considering the price of spruce strip the same size
Then checked which elevator ribs fitted, had to replace two on each side, and glued the leading edge and ribs on the first elevator.
Then I skinned the other side and added the trailing edge and then sanded it all and V'd the leading edge before having to fetch my son.
Then while driving there was something niggling in the back of my mind...I had forgotten to add the hinge support blocks
So I got back and cut a strip of the sheeting out, installed the hinge support blocks and the sheeted again with a strip of 3mm and then sanded.
Then I built the other elevator and taped them to the stab.
Plan for tonight is to do their tips and then onto the spar boxes, I will be fetching the 1/4 x 3/8 White Beach spars that I have had cut by Wood At Ease in the east of Pretoria during the day...R30/strip 1.5m long which I don't think is bad considering the price of spruce strip the same size
03-16-2017, 09:18 PM
#33
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03-17-2017, 12:18 AM
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No sooner got home and got the elevator tips glued ready for shaping...then the little bugger Murphy arrived and I was called to go rescue my sister with car trouble, so all that was done last night was the elevator tips and glued the spar box sides together The stab and elevators are now ready foe glassing.
Elevator tips glued waiting to shape (1).jpg (64.13 KiB) Viewed 13 times
Stab and elevator done waiting for glassing.jpg (76.59 KiB) Viewed 13 times
Spar box sides setting.jpg (88.1 KiB) Viewed 13 times
I will glass both side of each spar box side before adding the spars and joining the sides together.
The stab and elevators are now ready foe glassing.I will glass both side of each spar box side before adding the spars and joining the sides together.
03-19-2017, 09:28 PM
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03-20-2017, 10:33 PM
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Yip, is only joint reinforcing really as I had 9 x 6mm White Beach spars cut and once they're in I will probably wrap the boxes in carbon tow as well. This is a big bird and it's a customers so I definitely don't want a wing failure on a customers plane...especially one as expensive as this
03-21-2017, 07:04 AM
#40
Yip, is only joint reinforcing really as I had 9 x 6mm White Beach spars cut and once they're in I will probably wrap the boxes in carbon tow as well. This is a big bird and it's a customers so I definitely don't want a wing failure on a customers plane...especially one as expensive as this
03-21-2017, 09:17 PM
#41
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Between waiting for dope to dry on the Super 60 I'll be building up the center spar boxes today. Had White Beach spars cut...they work out a hell of a lot cheaper than spruce by the way, R180 for 9 off of 9 x 6mm at 1.6m long.
03-21-2017, 10:04 PM
#42
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I had some of the parts for my Ryan SC projects laser cut and I really appreciate the guy who did the cutting. The main spar was a think plywood with spar doublers on both sides. He use a thinner plywood (easier to cut I'm sure) in multiple layers and staggered the joints so once the spar was laminated into one piece no two joints lined up. I hadn't been smart enough to think about that but was grateful he was! Obviously it wasn't his first rodeo.
03-22-2017, 05:04 AM
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Once dope ran out for the Super i moved over to the Bonnie and cut spars for the rear spar box. These were glued using 1/2 hour epoxy. Before the other side is glued I have to make up the spacers that go inside the spar box to allow the joiner plug to slide in. I will first fit the plugs as well to make sure there is no movement and all is a snug fit.
Spars being glued to spar box side (1).jpg (76.64 KiB) Viewed 25 times
Spars being glued to spar box side (2).jpg (78.61 KiB) Viewed 25 times
Spars being glued to spar box side (3).jpg (84.24 KiB) Viewed 25 times
And here's the rear spar box ready for the spacers.
And here's the rear spar box ready for the spacers.
03-23-2017, 12:55 AM
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Made up the front spar box the same as the rear one last night.
Front and rear spar boxes waiting for spacers.jpg (73.84 KiB) Viewed 11 times
Still waiting for their spacers but getting the fit right in the fuselage.
Fit in fuselage (1).jpg (94.4 KiB) Viewed 11 times
Fit in fuselage (2).jpg (73.73 KiB) Viewed 11 times
Fit in fuselage (3).jpg (87.71 KiB) Viewed 11 times
Still waiting for their spacers but getting the fit right in the fuselage.
03-26-2017, 09:46 PM
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Instead of getting joiner plug spacers cut I decided to laminate them and sand them on the disc sander...quicker and cheaper than waiting for them to be made 
I also redesigned the spar box a bit. The joiner plugs end abruptly at rib 3 so there is no spread of loads. Instead of making the spacer more complicated I just added another piece of 9 x 6mm White Beach that extends past the wing/fuselage joint line and angled it down so that the loads are spread along the spar. I will have the joiner plugs cut though as I don't have a circular saw right now and they aren't simply straight plugs. They will be slightly over size so that I can sand them to snug fit for either side of the box.
Original design of spar box.jpg (72.57 KiB) Viewed 40 times
Joiner plug spacers drying.jpg (82.16 KiB) Viewed 40 times
Redesigned spar box.jpg (80.46 KiB) Viewed 40 times
Redesigned spar box 2.jpg (78.55 KiB) Viewed 40 times
Today it's the main spar box
I also redesigned the spar box a bit. The joiner plugs end abruptly at rib 3 so there is no spread of loads. Instead of making the spacer more complicated I just added another piece of 9 x 6mm White Beach that extends past the wing/fuselage joint line and angled it down so that the loads are spread along the spar. I will have the joiner plugs cut though as I don't have a circular saw right now and they aren't simply straight plugs. They will be slightly over size so that I can sand them to snug fit for either side of the box.
Today it's the main spar box