Upper Wings #4 and other misc.

It's been a couple of weeks since I added a post, so I thought it was time to update on what's been going on.  I've made some good progress,  just not much to show for my time as it has mostly been time-consuming component work.  I decided to build both upper wings at the same time.  Should save time, but has added more work up front.

Here's what I've been working on the last couple of weeks...

Plywood strips have been cut and glued to the webs of the ribs.  Provides considerable strength since as you may recall, these ribs are made from basswood.

The spars have been drilled for all the fittings that will eventually be attached. The rectangular plywood pieces are where the aileron hinges attach.

These are the plywood compression ribs.  A 1/4" by 3/4" spruce strip has been glued on each side to give them the necessary compressive strength.

All the fittings that go on both upper wings have been painted.  Why black?  Well, the common aviation primer for many years was zinc-chromate, but was not yet available in the '20's, or if it was, not used in the aircraft industry.  If you look in old aviation supply catalogs from the '20's, like Nicholas Beazley, lacquers and enamels were readily available and used.  I can really find no signs of any paint on the original fittings, but certainly don't want to leave them bare steel.  So, with black being a common color, that is what I went with.  Plus it just looks right.

I also wanted to get the other 7 cylinders nickel-plated.  Most custom platers get pretty busy over the winter and I wanted to make sure these got done in a timely manner.  In this picture, the cylinders have been blasted to remove any old nickel and all the holes/ports plugged to keep the nickel out of unwanted places.

I have wanted to build a magnet charger for magnetos for a long time.  My friend, Mark also wanted one for the Ford Model T's he restores.  So, we decide to build one together.  He can use it on his Model T's, and I can use it on the Berling for the OX-5 and other mags I do.  This pictures shows the coils we recently wound, one with the motor-winding tape already wrapped around it.  When we have it finished, I'll put in a detailed post about it for anyone who may be interested.




Just about ready to start attaching ribs to the spars, that will probably be my next update in a week or so.  Hope everyone has a great Thanksgiving!

Upper Wings #3

The upper wing fittings are done...except for a few minor things like drilling holes for the wire terminal fittings and painting them.  Lots of cutting, grinding, filing, bending, welding, etc., etc.!!

Certainly better than the originals:  the originals were crudely cut out, and the new ones made from 4130 will have better strength properties than the low carbon steel previously used.

Detail pictures and descriptions of the fittings follow.

Weld detail

Most of the fittings have a doubler welded on the top to increase the thickness to .200" where the terminal fittings and struts attach.  These were all TIG welded which is my preferred method of welding. 

Cabane, landing wire - rear spar

Interplane strut and flying wire attach - rear spar

Cabane, landing wire - front spar

Interplane strut and flying wire attach - front spar

Aileron pulley brackets

Aileron hinge fittings

I'll get these finished up and painted in the next couple of days, it will then be time to start the actual wing assembly - Finally!

Tomorrow, we are heading up to Fond du Lac, WI for the annual Midwest Antique Airplane Club (MAAC) banquet.  Always a nice gathering and good time!  

Until next time...