acerc

Pictures my man pictures!

WacoNut

Ok here are a few pics,
I have been all over the place with the plane this morning. The landing gear needed the front belly pan former replaced. That was easy. All the landing gear will need now is a good sanding and repainted.

The top center sections needs both end ribs replaced. I stripped the covering and the false fuel tank and managed to tear a big piece of balsa sheeting off the top. No big geal I will just mark it out for a 3" wide sheet and trim it up and add new sheeting. It also gives me the opportunity to inspect the internal structure a bit better.

The fin has been removed from the old fuse and I will work on mounting it once the landing gear mounting holes have been drilled and the cabane wires have been installed and the top center section verified for the correct position.

Also a pic of the fuse box, it came out perfectly straight and square. Hard to mees up as it is very well engineered. I have it sitting up on it's nose as I have tri-stock epoxied to the back side of the firewall and I am waiting for that to kick before proceeding.
You can also see the new gel coat cowling sitting in the background, at $150 a pop you don't wanna break too many of these[&o]

Later!!
Anthony

WacoNut

I replaced the broken ribs in the top center section. Wasn't too bad of a job.

The bottom center section only has one broken rib. As the plane stalled it caught a wing tip and cartwheeled onto it's nose. This resulted in a bent bottom wing tube and breaking the end ribs. The tube was kinked at both sides of the center section and I had to cut the tube off at one side in order to remove the tube. That reminds me I need to order a new tube[:@]. The tube on the top wing did not bend as the cabane wires giving way absorbed alot of the energy.

I will install a new end rib and glue the sheeting back in place and do a patch on the covering and it should look good. Each of the outer panels have the root ribs broken in the same manner. I will also have to cut all the Robart hinges off and drill them out so I can re-hinge everything after covering.
Later!!
Anthony

WacoNut

The bottom center section is now repaired.
When you receive an AMR Waco kit the aluminum tubes are dropped shipped sepertely from TNT Landing Gear. I just checked their site and the replacement aluminum tube is $44 for the tube and sleeve. I will call them Monday and see if I can order just a tube as I do not need the sleeve.

The epoxy has kicked on the fuse so I can go back to working on it. I am going to drill the landing gear mounting bolt holes and install the blind nuts then install the cabane wires. I also removed the Smart-Fly power expander from the old fuse as will as the rudder servo and switches. I will install these into the new fuse.
Later!!
Anthony

acerc

Brother when you get started you get started. Looking forward to it being whole again.

WacoNut

My wife is leaving me alone today

The landing gear and the bottom center section have been mounted. The glue on the blind nust disc needs to dry before I can remove the gear and work on mounting the top center section.

As you can see in the pics there is plenty of tri-stock bracing behind the firewall. I will also add tri-stock to the front of the firewall.

Later!!
Anthony

WacoNut

I just realized it is not feasable to stitch the fabric on the Waco mostly due to the tail surfaces being built from sheet stock. Aslo I would have to contend with the wing tube. I do have enough 1/3 scale stitches from Scale Rib-Stitch to do the Waco again so simulated stitches it will be.

Always Something
Anthony

WacoNut

I started to mount the top center section and realized I needed to install the former that holds the cross brace wires.

This former pulled out during the crash I added some tri-stock to beefen it up a bit. This former does carry quite a bit of loading during flight. While I had a batch of epoxy mixed up I installed the Smart-Fly power expander and the dual switches. The switches will be accesable from the luggage compartment. One nice thing about a rebuild is you already know where to put everything so it makes it go so much faster.

After a 12hr marathon run on the Waco I am calling it quits for the night. I will let the epoxy cure and mount the top center section tomorrow.
Anthony

Cub Flyer Fresno

Twelve hours straight! Jeeze! You're an animal Anthony! You need to learn to take a break once in a while.

Your a hard worker, a fast worker and you really make it look easy. Great job!

Now get some rest!

WacoNut

The top center section is mounted.
During the crash the front 2 cabane wires were bent, they bent at the top lug that had been silver soldered on. It appeared to me that the metal had softened from being heated and not quecnhed so I heated the wire with a torch and bent back straight and then quenched it in water.

It took a bit of adjusting of the cross brace wires but the center seaction is sitting level left to right and the incidence shecks -0- to the top of the fuse box.

Now I can take it all back off and mount the fin. This part always make me nervous at it also set the stab at the same time. If i get it wrong the stab could be off leve left to right and the incidence.

I have a couple more days to work on the Waco then it will have to get set aside while I fill a previous commitment. I am going to build 2 Sig Wonders, one for me and one for a buddy in the club. I should be able to knock them out in a week or so then get back on the Waco.

acerc

Take your time on that Waco. Work's of art is never to be rushed. As long as it is on the road to recovery all is good.

WacoNut

No problem Robert,
This is the easy work. Once the fabric start going on then it will drop to a snails pace. The Waco will be back in it's original shape if not better this time around.

The Fin is epoxied in place. Had to so a little surgery to the bottom end of the fuse to allow clearance for the Robart tail gear. I will mount this once the epoxy has cured on the fin.

Going to watch some football then work on repairing the outer wing panels.
Later!!
Anthony

WacoNut

I didn't get too much more work done on the Waco yesterday(lazy day). The Robart Tail Wheel strut has been installled. The fork had bent during the crash so I had to heat, bend and quench to get it back into shape.

I may work on intstalling a false floor in the front end for holding the gas/smoke tanks. The old one split. The fuse is basically ready to install all the formers and stringer. I have yet to order the stringer material so I need to sit down and figure out how much wood I need to order.

I will have to rearange the tables in my hobby room as I will have to mount the fuse on a rotisary which will make the job of adding the formers, stringer and covering much easier.

I went back and looked thru the build thread on my 1st go around and to complete the fuse to the point I have this one now was 6 weeks. Due to having the landing gear complete, cabane setup complete, tail surfaces built and other odds and ends this time it took 5 days It is amazing how much I remember about doing little odd things to work around solving problems that just makes it so much easier this time.

Later!!
Anthony

WacoNut

I just ordered all the wood needed to complete the rebuild. I decided to give National Balsa a try. They carry 48" stock and have reasonable prices. The stringers for the fuselage are 3/16x3/8 and are up to 60" long so splices are required. They have a minimum order of $25 so I ordered some extra just in case and some sheeting to get over the $25 mark.

Tomorrow I start building the Sig Wonder so I am going to knock out the one for my buddy and get back to work on the Waco ASAP. I will build my Wonder later as I want to get the Waco completed.
Later!!
Anthony

WacoNut

Well I moved my tables around to make room for the Waco on the rotating fixture and free up the big build table for my buddies plane. He was supposed to bring the engine by today and I was going to get started. Well he was a no show(Brandon your missing out)

I decided to go ahead and install all the fuselage formers. Now it's starting to look like something. I figure I can add stringers while I am building the Wonder and waiting for parts to dry.


Here are a few pics of how it's shaping up. Back to work tomorrow so the fun is over.
Anthony

VincentJ

Took me awhile to catch up. Man you are really moving. Must feel good to get her back together again. Nice work Anthony!

sensei

Very nice work on the rebuild.

Bob

WacoNut

Thanks Guys,
Will be nice to see it back in flying condition again.
Anthony

Lins

All this activity has convinced me to start my Waco finally. I hope to get the wing panels mostly done before I go back to work the 7th. Good luck on the rebuild!

WacoNut

Hi Lins,
Good luck with your Waco build, which kit are you building?
Later!!
Anthony

Lins

It's an original Genesis 1/3 kit.

WacoNut

Ahhh, Nice!!!
Hopefully this thread will help, the AMR is an updated version of the Genesis kit. You will love how the plane fly's just don't get too slow on final

Post some pics as you go.
Anthony

Lins

Just wondering if you put shear webbing on one or both sides of the front spar (top wing). I have both the Genesis and AMR manuals and the Genesis says both sides but AMR says only rear side of front spar. Your mishap should demonstrate if only one side is sufficient . Cheers

WacoNut

Lins,
In the center sections I would put it on both side and on all the bays where the wing tubes reside on the outer panels. This plane carries alot of weight and in a sudden stop it puts alot of stress on the entire airframe.

The root ribs shattered on all 4 outer panels and I discovered cracks on several others. All the parts carried over to the rebuild are getting a full inspection and repairing anything that needs it.

My wood order is due to arrive on Saturday. I will be hunting Saturday thru Tuesday unless I tag out early then I will get back to work on the Waco.

Enjoy the build!!
Anthony

Lins

Good idea, thanks. I am just temporarily starting the Waco while on time off until the 7th. I'll be back to finishing my Nosen cub before I go full speed on this. The only reason I'm not finishing the cub now is because I need a couple things at work and don't want to go . I have been shopping around for a Moki already, though .