SunDevilPilot

Unfortunately in the world of ARFs and Foamy airplanes wood to build with is a little difficult to come by locally. Most have the standard balsa but not a great selection of quality ply. I could drive across town but decided to order some instead. Needing some windshield material anyways I placed my order with Balsa USA. For now I have one root rib created but I will need to wait for the 1/16th ply I just ordered to arrive.

Nothing is glued yet.....

I have also created the plywood discs for the wing bolt hardpoints and the rear plywood anti-rotation support.

A little more work needs to be done on each part but we're on your way!

SunDevilPilot

knucklebutt

Hey Phil I have your windshield material, you need it :????? No need to order more

SunDevilPilot

Something to note...

While working on the damage on the wings I had a chance to see how well the glue held up. The vast majority of that structure was glued with regular wood glue. All the glue joints survived and it was the wood that failed allowing the root rib to rip out upon impact.

Just an observation for those looking at using regular PVA type woodglue.

SunDevilPilot

SunDevilPilot

You keep that, I gave it to you.

I ordered some more at a total cost of about $5.00. No big deal. I needed the plywood from them anyways.

SunDevilPilot

knucklebutt

O.K. then I'll stop talking crap about you at the flying field


Thanks Buddie

SunDevilPilot

And.... I dont want to slow down any progress on the Fairchild. That one is going to be fun to watch fly.

Phil

SunDevilPilot

Im still waiting on the wood order to build the other root rib but for today I went ahead and fitted the one I already have to the fuselage. It still needs the balsa doubler but the part now fits onto the fuselage and mates perfectly with the spars and the wing bolt holes. The upper edge of the piece is a little large while the bottom, which is my reference point, is perfect. This will allow the part to be glued on flush with the bottom edge into the wing, setting the incidence, and sanded true at the top.

The main spar is just stuck in the fuselage. That piece broke in the crash so it too will need to be remade. The spar will be permanently installed after covering and painting, makes that process a little easier.

SunDevilPilot

I got my order from Balsa USA today and was able to create the root rib for the left wing. Next weeked I should be able to reinstall the ribs into the wings then move onto the struts.

SunDevilPilot

The root rib for the right wing is ready to be installed. I glued up the wing bolt hard points, balsa doubler, and rear ply doubler this morning. I am planning on putting a light coat of epoxy on the wings inner edge then run a bead of epoxyaround the ribs inner edge then put the two together. By gluing both sides I all but guarantee a good glue joint between the wing and rib.

In the photo the rib is just placed on the wing, the fit is really nice.

SunDevilPilot

cannonball200

My Feedback: (36)

Looking good again Sun!!!!!!!!!!!!!!!!!!!!!!!!!!! Be flying again soon.......maybe be flying for years we hope!!!!

SunDevilPilot

I was hoping for many years the first time. So far I am happy with the repair process. There will be almost no difference between when it was new and after the repair. All the damaged is starting to be gone.

SunDevilPilot

SunDevilPilot

Right Wing, Repaired.

Zor

SunDevilPilot,

As I wrote on 23 Sept "you are an inspiration for many".

The good results are self-rewarding ; enjoy them.

I remember the days wewere encouraging you to repair this model in which you had put so much love in building.

I am quite sure you now realize it wasthe proper thing to do.

Some fellows might think I am crazy but I believe that models we build have a personality oftheir own.
They can never be replaced with an equivalent.

It is nice to follow your progress.

Zor

SunDevilPilot

My intentions were to finish the Nieuport 28 then fix the Cub. However, I just cound't stand seeing the poor Cub sitting in my airplane room all broken and sad. So, I halted work on the Nieuport so I can focus on the Cub. So far the repair has not been too bad and I am having some enjoyment going through the process.

Again, don't crash to "Enjoy the Process" but repair is very similar to buiding a plane for the first time, something I really enjoy.

This morning I sanded / blended the left wings root rib which was glued in late last night.

Looks good as new.

Next up, struts then onto covering.

SunDevilPilot

SunDevilPilot

Thanks Zor!

SunDevilPilot

I was having a little struggle with this one.

Last time I made the parts for the struts I used my scroll saw. It is an old tool, which was cheap to start with, and if I broke it I would upgrade it. The problem with the scroll saw is the up and down motion of the blade is always trying to take the workpiece and rip it up and off the table. This makes for some exciting, if not totally dangerous situations.

My next choice of tools was my bandsaw. Much safer as the tool is always pulling the work down into the table. However, my saw is a woodworking saw and not a metal cutting one.

I did some searching on the internet and the general consensus is soft nonferrous metals were ok my saw. I found a video where a builder of aluminum homebuilt aircraft frequently cuts aluminum on his woodworking bandsaw. His recommendation was when cutting aluminum, which likes to become sticky and clog the blade, was to take a piece of sacrificial wood and run it under the aluminum. As the blade cuts through the aluminum then into the wood the blade gets cleaned off.

With much hesitation I made my first cut. The bandsaw cut through the aluminum and wood backer like butter. About 1000 times easier than my struggles with the scroll saw.

I was able to use my fence and get perfectly cut parts right off the saw. Before I would cut rough then come back with the belt sander, file, and sandpaper and true up the edges.

After cutting the aluminum parts I throughly cleaned all the shavings out of the saw.

Everything looked just fine and the blade, a 1/8" blade with 14 TPI, remained razor sharp.

There are still some more cutting, drilling, and bending to do on the parts but at least I have begun the strut construction.

FYI, the strut material is some T6 6061 aluminum. Last time I built these struts I accidentally figured out Tower Hobbies sells T6 made by K&S. You have to know to look for it but this type of metal is far superior to the standard "Hobby Grade" aluminum. The part # for the aluminum I am using is K&S 3070.

SunDevilPilot

VincentJ

Nice Job, your almost there! Should be easier the second time around...

acdii

I'm glad to see you took it out of the trash can. I have seen much worse get rebuilt. My friend put his 1/4 scale through a tree and is rebuilding it.  His is barely recognizable as a cub, wouldn't know if it wasn't still yellow.     Heck even my 4* will get rebuilt some day, and it was smashed REALLY good! Only the tail survived unharmed. 

SunDevilPilot

Today was a little trying.

I was making some of the easiest parts and it took three tries!

The forward aluminum piece under the gear is just a spacer. The rear one is the mounts for the struts. I made the front one no problem. The darn rear one was giving me issues and the part is so simple.

First I made one but I did not like how close the strut mounting holes were to the fuselage. Simple, make another one. Everything went well until I had to cut it to length. One side was cut fine but when I cut the other I lost my focus and cut the strut mounting tab off the part, oops. The cut was good but down the line marking the bend and not the end of the part. So, I made a third... This one turned out fine.

Took about an hour to make a part that should have taken 15 minutes.

After that I stopped for the day, I must be a bit off for some reason.

SunDevilPilot

cannonball200

My Feedback: (36)

Sun-they say 3rd time is a charm!! Looks as though it's true. Looking good!

SunDevilPilot

Despite my earlier issues with focus I forged ahead and got the wing joiner replaced. Thanks to my friend Ed I was able to source some 1/4 ply for the part.

knucklebutt

GO ED !!!!!!!!

SunDevilPilot

Now... If only I can get him to build that Pup!

SunDevilPilot

SunDevilPilot

Weather finally turned nice around here for fall so I moved the workbench back into the garage. Once that was done I finished up the struts. Holes were drilled, pieces bent, and the main strut components shaped and sized. Next I will mount the wings, mount the struts, check their alignment, and glue them up.

Creation of the new set was not too difficult using the first pair as a guide.

Should be on to covering shortly.

The white fluffy thing is not mine. I dont know who he is. Just showed up and hung out in the garage for a few hours.

SunDevilPilot

Flyitorcrashtrying

Ihave a challenge for you. When you are finished...you can scratch build one blindfolded.