ianober

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Well construction is underway!! Tonight I cleaned off my table and got everything organized and then got the jig assembled and setup nice and level. The parts fit together nice and tight so everything is solid and ready to go. I have already pre-cut the aluminum alignment tubes to the proper length earlier. Below are some pics of the jig.

ianober

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Next I laid out all my bulkheads and got them in the proper order so they would be easier to grab and slide on the tubes. The shot of all the bulkheads on the table is only about half of the total number, I just don't have a big enough table for all the parts. You can see that I had the laser etch the bulkhead letter on each piece so it was much easier to tell one from another.

ianober

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Next I marked out the locations on the aluminum tube for each of the bulkheads. These were all taken directly from the drawing I made to scale up the plane.

ianober

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After the bulkhead locations were all laid out it was on with some structure. In no time it was actually looking like a plane already, so awesome!! I used a laser level line to align all the bulkheads to each other. The laser level was mounted on a tripod and raised up so the laser would hit the top of all the bulkheads. When I laser cut all the bulkheads I had vertical alignment lines etched into them so I would be able to do this. So far it is working out great. Once I had on all the preliminary bulkheads on I slid the second aluminum tube into place and secured it to the first bulkhead for the second level tube. I then secured the tube in the rear towers of the jig and checked for level, lookin pretty good so far!!!

David Searles

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Ian,

That looks AWESOME!

Put my name on the squadron list for when you're done with this puppy!

David S

invertmast

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looking good ian.. is that a 1" electrical conduit tube?

NickC5FE

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Ian, looks great, keep up the good work.....BTW- are you filling in between the formers with foam? If not, what material?

ianober

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David, thanks!

Thomas, I am using aluminum tube from a local metals supplier so the tolerances are much closer than conduit. I think the actual diameter is something like 1.001 inches. I thought about conduit and it ended up being tons more weight compared to the aluminum tubing. Not to mention the Aluminum tubing was quite reasonably priced.

Nick, I am still indecided on that one. I am thinking more about strip planking it right now and the reason for this is because the distance between the bulkheads is all pretty much different. I think I will end up doing mostly strip planking and some foam in the more complex areas.

NickC5FE

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That was the problem that my old roommate and i had, because we used the same plans......We ended up using expandable foam in between the bulkheads, you do this by taking wax paper on one side of the jet, whethor it be top, bottom,,,etc. Put the wax paper and tape it to the bulkheads, and spray the foam in. It is MESSY, but quick, you dont have to worry about getting it perfect, when the foam is dry, take a razorsaw and hack most of the excess away. BE CAREFULL, A LITTLE BIT OF FOAM GOES A LONG WAY! You dont want to distort the bulkheads, also a good idea is the make some cross-connectors out of wood, it can be 1/4 by 1/4 balsa just to connect the bulkheads to one another, inside the plug, it will help from distortion....Just an idea.

After planking my Ziroli F-9 years ago, i will do anything in my power to never have to do that again!!!!!! It was like building a friggin boat man!

ianober

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Yeah, I know what you mean. Thomas did bring up one good thing with planking and that was the natural curve from bulkhead to bulkhead is retained. I am with you though, I am not a fan of strip planking. I am going to put my head to the grindstone and see if anything else catches my fancy. I should have the rest of the bulk heads on tonight though and you guys will be able to see how long its going to be.

ianober

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***NOTICE***
[hr]
I just wanted to post this since I got some emails regarding the matter

Please do not email me asking for my drawings or any materials that I have taken the time to create for this project. I have spent several hours doing the drawings and working out some of the details and to ask me for drawings or materials before my project is even finished, to me, is not cool. If you need advice or help locating things I am more than happy to help out but I will not turn over any of my drawings that I have done, at least not yet, thanks!

Ok, back to the thread, hope you guys enjoy!

mr_matt

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Hey Ian can I have all of your drawings?

ianober

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Yes, you may Matt, since you had the gusto to ask in a public forum

mr_matt

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Seriously Ian this is cool. Does this place you are a member of have any rapid prototyping gear? (stereo lithography SLA, not the 3d printer stuff)

Thanks. also there is a good online article from Mike James that used the foam technique that Nick is referring too.

EDIT: Here is a link:

http://www.nextcraft.com/plugmaking.html

ianober

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They just have the 3D printing, Dimension model. Nothing rapid prototyping. All parts are made from ABS plastic.

Awesome article Matt, this is right up my alley, thanks buddy!

DocYates

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Ian,
Awesome project. I wish there was a place like that around here with access to such awesome equipment, and training. What a novel concept.
Tommy

pkevinb

Looks like a great project of my all time favorite medium jet bomber.

invertmast

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Im working on it! I'll have an update later this evening, after i cook and eat dinner

ianober

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Nice Thomas, you and me both!!

Billy

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You are my hero Ian! Keep up the good work.

Billy

ianober

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Oh Billy, I cant wait till its done, a little Hog Escort with the Intruder......HOT!!!

David Searles

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Ian,

Have you decided if it's going to be twin or single turbine powered?

David S

ianober

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I am going to try and make both options possible David. Once I have a shell pulled I will take some measurements and see if a bifurcated pipe will be doable, I think it will be.

Boomerang1

Hi Ian, I'll be watching this closely. I'm a scratch builder & the methods I use for prop driven models do not lend themselves to jets very well. Time for some new techniques. - John.

ianober

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Thanks for tuning in John, I will try not to disappoint!