tag:blogger.com,1999:blog-45616636750084297012024-03-12T19:58:56.950-07:00Building the "new" Prowler Aviation, Inc.Hi. Thanks for joining us as we set out to re-build a small experimental aircraft company. We hope you enjoy watching our progress as we work to get this beautiful kit airplane back into production.Unknownnoreply@blogger.comBlogger100125tag:blogger.com,1999:blog-4561663675008429701.post-9523688547323940012023-12-17T08:50:00.000-08:002023-12-17T08:50:10.871-08:002023 Year End Update Hello Everyone,<br /><br />Well, hard to believe it's the end of the calendar for another year. I had a great summer and fall, but unfortunately, I lost my medical after AirVenture and have not been able to work since. I'm fine and going through the steps required now to get my medical back. If all goes as advertised and predicted, I will have a surgery in early January with a 90 day recovery period. After that, I can apply for a new special issuance medical and hopefully get an answer back on that by late May or early Jun (currently the FAA is running 12-15 weeks out on special issuance medicals). Then, I should be heading to re-qualification training in late June or early July of 2024 for my return to the line. The good news is that I should be getting a lot of time in the shop this spring to and be able to get lots of Prowler Aviation projects done (or at least, farther down the road). OK, enough about me, lets talk about Prowlers!<br /><br />So, I have a fairly short and straight forward update this time. This update is just going to cover these ownership and builder updates:<br /><br />A. Two completed Prowlers have changed hands;<br />B. Update on the French Prowler;<br />C. Update on Vaughn's Prowler Status;<br />D. Update on Bryan's Prowler plans;<br /><br /><b><u>A. Two completed Prowlers have changed hands:</u></b> <br /><span> </span><b><u>1. Kit #14</u></b> - This kit is completed and certified. In Summer 2019, Steve Rogers donated his airplane to the Port Townsend Aero Museum. I covered that in a previous update (<a href="https://prowleraviation.blogspot.com/2022/02/dude-its-been-likeover-year.html" target="_blank">here</a>) last year. Earlier this year, the museum turned around and put the plane up for sale and it was purchased by none other than our own Bryce Mitchell. You may recall Bryce also owns the Red, White & Blue plane (the first production kit an the 2nd completed Prowler built by the original Prowler Aviation in 1990's). So, now both Kit #1 and Kit #14 are owned by Bryce and they are both based at the Auburn, CA airport! Here is a pic that Bryce sent me when he got the airplane safely (trailer-ed) to it's new home in Auburn in Nov2023:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgtn7LYlEBlIYDUx39slW9WHfyYV1hJG4U1ubagjaAy9YHlsj4V_km7IHZIUJ7dhO1mfhWIygv0mhE6KHygLtKKKZoUWjeQcEc22cFrK1RDZaQztznxmegvKHdXlT1BU6_faeaAWoBW99SsNMhKM4npO-TTmlEzFlTV_yl30fXVWVO2wXyCx5zkWgG5Qv9/s2016/-2808672994750079532.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1134" data-original-width="2016" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgtn7LYlEBlIYDUx39slW9WHfyYV1hJG4U1ubagjaAy9YHlsj4V_km7IHZIUJ7dhO1mfhWIygv0mhE6KHygLtKKKZoUWjeQcEc22cFrK1RDZaQztznxmegvKHdXlT1BU6_faeaAWoBW99SsNMhKM4npO-TTmlEzFlTV_yl30fXVWVO2wXyCx5zkWgG5Qv9/s320/-2808672994750079532.jpg" width="320" /></a></div>I'm really glad you were able to get your second Prowler, Bryce! Bravo! And, I know you're looking forward to getting that plane in the air!<br /><br /><span> <u><b> </b></u></span><u><b>2. Kit #16</b></u> - I was talking to Ray last month, and he mentioned that Bud, too, had sold his airplane. I don't have a lot of details yet. But I hope to get in touch with Bud soon and find out about where his plane went. More to follow!<br /><br /><b><u>B. Update on the French Prowler -</u></b> Francis continues to be the most active Prowler builder (currently - at this time). He has been steadily completing parts and components over this past year. In my last update, I missed a few progress pictures that he sent me prior to the last update. Here he is showing the MLG with the hydraulic actuator and most of the linkage mocked-up and temporarily installed:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnWO2PEUGvdQ84gtw8p-Al86XdZKA5fAa8XL2xCBo41zHuA4a0jWAaGnVFbgDRdN-Vo7Ih7EeQ_2aYTGqMcbD7-_rl-4o36CcVkidPzbuyMOEx7PCnVN2HFHkfyeNQlWjo7zMFbMa61hz9eTVfKGLk8SU1D45qF496ocZzpnKH7HHiM3orkKVdf6UdZ1A_/s1815/20230530_145839.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="882" data-original-width="1815" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnWO2PEUGvdQ84gtw8p-Al86XdZKA5fAa8XL2xCBo41zHuA4a0jWAaGnVFbgDRdN-Vo7Ih7EeQ_2aYTGqMcbD7-_rl-4o36CcVkidPzbuyMOEx7PCnVN2HFHkfyeNQlWjo7zMFbMa61hz9eTVfKGLk8SU1D45qF496ocZzpnKH7HHiM3orkKVdf6UdZ1A_/s320/20230530_145839.jpg" width="320" /></a><br /></div>Here is another view:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhu6yN1dTHJl_yoEJXWRTkenzN9j8zxtiZ8TjqnRh_7JNphzD7SfH8NmSt8ygYnqPHLh98BHXQl9ggZccBVQCfjSyXMlZbl_V2C0sdOdxMZDgWTvxI5wBegTkDNBO03sFLWTiscdcXBl30tW6WHsl8UAe6FE_-ezdw1HUQIvoEGrXi9b16s7cuW1j2rLsuP/s1815/20230530_145821.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="882" data-original-width="1815" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhu6yN1dTHJl_yoEJXWRTkenzN9j8zxtiZ8TjqnRh_7JNphzD7SfH8NmSt8ygYnqPHLh98BHXQl9ggZccBVQCfjSyXMlZbl_V2C0sdOdxMZDgWTvxI5wBegTkDNBO03sFLWTiscdcXBl30tW6WHsl8UAe6FE_-ezdw1HUQIvoEGrXi9b16s7cuW1j2rLsuP/s320/20230530_145821.jpg" width="320" /></a></div>It is awesome to see the MLG going into your plane, Francis!!! After everything was fitted and functioning - it was "off to paint:"<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcd153nZtBIre0hg1ZCVEXFX5QRa1TwiBko7e21HKDFCHfCjL1Q4JE-c04COQ0OU7m-YX5mAiBSLZkCqHxAtpOI6sj_m67gFNl4MXpZD3nMX2TjTPF7AFiKkiDpJCmo_gxbAD7h-_yVdUeU9TWXftnFUIwqBPBmzjAORF_2ToCza8V-qHhaExBNAGdJX4F/s1600/IMG-20230826-WA0001.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="777" data-original-width="1600" height="155" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcd153nZtBIre0hg1ZCVEXFX5QRa1TwiBko7e21HKDFCHfCjL1Q4JE-c04COQ0OU7m-YX5mAiBSLZkCqHxAtpOI6sj_m67gFNl4MXpZD3nMX2TjTPF7AFiKkiDpJCmo_gxbAD7h-_yVdUeU9TWXftnFUIwqBPBmzjAORF_2ToCza8V-qHhaExBNAGdJX4F/s320/IMG-20230826-WA0001.jpg" width="320" /></a></div>Since then, I have gotten several more updated from Francis. In a previous update, I showed Francis' work on building his MLG uplocks. Here is a pic of those installed in his center section gear wells:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgx7TQC5nLMNXDBORQb5hjRJbxnFQqVw61ETVJ9sBLMmLM6uCWl7ZDEXEcLTZ_XCkgi1sjKavLdN36mmB6PiTmj0mzOXZvCWWINIjXjhBWA-olOA31bbCM0PTmG47PvYtvcq9FdUZMUTT-zpJ1IwnDTKP900EFx_NonMGeh_i30iFsd6YNgujmwupa46N3z/s1600/IMG-20230729-WA0002.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="777" data-original-width="1600" height="155" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgx7TQC5nLMNXDBORQb5hjRJbxnFQqVw61ETVJ9sBLMmLM6uCWl7ZDEXEcLTZ_XCkgi1sjKavLdN36mmB6PiTmj0mzOXZvCWWINIjXjhBWA-olOA31bbCM0PTmG47PvYtvcq9FdUZMUTT-zpJ1IwnDTKP900EFx_NonMGeh_i30iFsd6YNgujmwupa46N3z/s320/IMG-20230729-WA0002.jpg" width="320" /></a><br /></div>Francis designed his uplocks to use aftermarket auto door latches (followed Ray's lead on that) with posts mounted into the ends of the MLG yokes. It looks like a superb setup! Great craftsmanship, Francis!!<br /><br />Here is an outstanding idea that I have not seen used by any other Prowler builders yet. Francis fabricated some round pins onto some plates that fit into the center section wing spars (the same place that the outboard wings are mounted). Then, he fabricated a stand with receivers for those round pins at the top of two posts. This allows him to set the (nearly) completed center section on a stand that can be used to rotate the airplane to whatever angle he needs to work on his current project. Check this out:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirwoSPA3IYg4uXPN7U8Ob2bAxbr2ToAO0yQXn642-VuQ2QLkjiLb9scicOLywND55SYWlQSCBaMYq0VzeYRSH0OwqoyB6593OtRB4rfVkvdEhjAnDEQ88vDAqnvfzgan7ORoSZJlsadMYeuvaL9kygxg1moPiHUQUIqAjWLDM5kOmgmSptG59DnbjV0xg1/s4032/20231117_154259.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="1960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirwoSPA3IYg4uXPN7U8Ob2bAxbr2ToAO0yQXn642-VuQ2QLkjiLb9scicOLywND55SYWlQSCBaMYq0VzeYRSH0OwqoyB6593OtRB4rfVkvdEhjAnDEQ88vDAqnvfzgan7ORoSZJlsadMYeuvaL9kygxg1moPiHUQUIqAjWLDM5kOmgmSptG59DnbjV0xg1/s320/20231117_154259.jpg" width="156" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQdGe3WUP4FTxQq_aTFoeH6HTNwnfC0ERjnF9MKRqvpoSd76p9hyzzbC4tO8CoOxilmJXHZ3At0uhoQBCjCrih_xQLO1YXymyXlFkJqn7_NdMCIluEWpVDXNeQ03bh6w3g2Tm0VUje-yce0co8jM1u2ntuBuGtJEuHtjuSd9ueCoMWbDfBlqQ4ogHIP0u3/s4032/20231117_154306.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="1960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQdGe3WUP4FTxQq_aTFoeH6HTNwnfC0ERjnF9MKRqvpoSd76p9hyzzbC4tO8CoOxilmJXHZ3At0uhoQBCjCrih_xQLO1YXymyXlFkJqn7_NdMCIluEWpVDXNeQ03bh6w3g2Tm0VUje-yce0co8jM1u2ntuBuGtJEuHtjuSd9ueCoMWbDfBlqQ4ogHIP0u3/s320/20231117_154306.jpg" width="156" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8IAeIUsk_2jk96DYoUMkidp6_W8lpBXu8gFJOX_h4wEKbWk1DqudgLBecMwjW0rHlkUnTenXdiglOyReEhbd_2q9Yxtnwl9dZvVvwvyWpdnOTjmKBMgW561XX4PQ7ixa7o1n7xqP6et23q6BxsYKPY8aaDFivllOcIIahJehklBeTNARsyJyJZhU0PPkh/s4032/20231117_175039.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1960" data-original-width="4032" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8IAeIUsk_2jk96DYoUMkidp6_W8lpBXu8gFJOX_h4wEKbWk1DqudgLBecMwjW0rHlkUnTenXdiglOyReEhbd_2q9Yxtnwl9dZvVvwvyWpdnOTjmKBMgW561XX4PQ7ixa7o1n7xqP6et23q6BxsYKPY8aaDFivllOcIIahJehklBeTNARsyJyJZhU0PPkh/s320/20231117_175039.jpg" width="320" /></a></div>What an awesome idea! This will, no doubt, make it much easier to work on the landing gear, then flip the center section over and work on the cockpit floor, brakes, etc. Very good!<br /><br />Here are a few pictures of some of his work on the cockpit floor that ended with the temporary installation of his foot wells for the aft pilot station:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiR5CKmvIl-9D7KlPFqU7wns0eJcxWMwzTokm3Bjpzx1As_uqW492Tbz3yfEClBsEjw7Saio9mh-dDLVncat61g-v_T7Q_aMbDWZuUGp7j2QkSlTjebEggmh1UtWwAuvP1J76HlUXUlwv0fOUJgHG4W25vo10j81reoWaxCPHU4zoQvzGGE3VtVVODoUhjh/s1600/IMG-20230826-WA0004.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="777" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiR5CKmvIl-9D7KlPFqU7wns0eJcxWMwzTokm3Bjpzx1As_uqW492Tbz3yfEClBsEjw7Saio9mh-dDLVncat61g-v_T7Q_aMbDWZuUGp7j2QkSlTjebEggmh1UtWwAuvP1J76HlUXUlwv0fOUJgHG4W25vo10j81reoWaxCPHU4zoQvzGGE3VtVVODoUhjh/s320/IMG-20230826-WA0004.jpg" width="155" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCFKrMJTNxWM1w2nwCPNC7Bh5CQp3uif1Eykf1HuUnd2yxTn15JH2yP_W_w1yKxfgtx5aamjV9GT6TYH0k_QCQQ8Ysr2FczBFxCMK-mKStPxSKXZJWu5UBpBClSaJODJ3B6N__3CuSd2QFMf6tcLkWdwCrYfjcuf88YYoq-R6WadCRJ7fEHvDgSpWBnOoj/s1600/IMG-20230826-WA0006.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="777" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCFKrMJTNxWM1w2nwCPNC7Bh5CQp3uif1Eykf1HuUnd2yxTn15JH2yP_W_w1yKxfgtx5aamjV9GT6TYH0k_QCQQ8Ysr2FczBFxCMK-mKStPxSKXZJWu5UBpBClSaJODJ3B6N__3CuSd2QFMf6tcLkWdwCrYfjcuf88YYoq-R6WadCRJ7fEHvDgSpWBnOoj/s320/IMG-20230826-WA0006.jpg" width="155" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjlFdrWQro4lqLVhmzZRSFl9-9HjURsj7vlEs2awii4Fe0CU-hEvDgrjXjWmdWpyy8Lv-Kyzsp9-v5eoKWrcDkPAlX0xDNHogn1dDOyXYQ0NKOuiu2dy4t4I1Qtd3ELQDY_utTocjG-uGYCGqwwLD8vICyAU331OH075csQsYjcbur9l1f-SJKUT2N7n6DR/s1600/IMG-20230826-WA0008.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="777" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjlFdrWQro4lqLVhmzZRSFl9-9HjURsj7vlEs2awii4Fe0CU-hEvDgrjXjWmdWpyy8Lv-Kyzsp9-v5eoKWrcDkPAlX0xDNHogn1dDOyXYQ0NKOuiu2dy4t4I1Qtd3ELQDY_utTocjG-uGYCGqwwLD8vICyAU331OH075csQsYjcbur9l1f-SJKUT2N7n6DR/s320/IMG-20230826-WA0008.jpg" width="155" /></a></div>Looking great!<br /><br />I shared with Francis how I make the U shaped brackets that hold the lower end of the follow-up doors on the MLG. Here is his mandrel that he fabricated and used to make these brackets:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmdadyWpNxdf6YZxM5oNiKSYjprY1ZXpf9RbK7MWmwG30LhyphenhyphenB7Igjgxf4nW-q1I0hQPBoRNdoPSfkjL1n4GLstcWnQRwvbOay6qajOz7AW98V4IBa_zmenhQb8wXUPYxRNeRWE1qFc_Tu7QH1qeYWoslJ3v14jxDC6-OvSeW3uEPlRYtZ7igTU3PAhY4l6/s1600/IMG-20230927-03.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="777" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmdadyWpNxdf6YZxM5oNiKSYjprY1ZXpf9RbK7MWmwG30LhyphenhyphenB7Igjgxf4nW-q1I0hQPBoRNdoPSfkjL1n4GLstcWnQRwvbOay6qajOz7AW98V4IBa_zmenhQb8wXUPYxRNeRWE1qFc_Tu7QH1qeYWoslJ3v14jxDC6-OvSeW3uEPlRYtZ7igTU3PAhY4l6/s320/IMG-20230927-03.jpg" width="155" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiA0jEYoirAeJAHHIz6f70uMrqvRrGUeCOgzk_VwmVnmRkgPG92haHUjyYvRgg15qgvuxXkM0FVW0DW5meaIUhIuR0FxtSqSmrkoTilKRguezDzQ9XV9bwXlI3jNxWC9Yh3x8vNlu3LSiQK-yLz8UMwXMSGXvh32rt1Uv7cFFhFoXGcHwVEu30BA6NJWlXG/s1600/IMG-20231001-WA0000.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="777" data-original-width="1600" height="155" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiA0jEYoirAeJAHHIz6f70uMrqvRrGUeCOgzk_VwmVnmRkgPG92haHUjyYvRgg15qgvuxXkM0FVW0DW5meaIUhIuR0FxtSqSmrkoTilKRguezDzQ9XV9bwXlI3jNxWC9Yh3x8vNlu3LSiQK-yLz8UMwXMSGXvh32rt1Uv7cFFhFoXGcHwVEu30BA6NJWlXG/s320/IMG-20231001-WA0000.jpg" width="320" /></a></div>And, here is one of them installed on the door and holding it to the lower end of the upper strut:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbuCeufQWt1dbPZGChgvDs9OJJCxxkfMJEMT3fXxUMRusfeUhyphenhyphenJrmTnR0hcSEsCAS2Vr4tttuLm1y1PtKsj_QExdh-16ccF8SgbpaT6geBjtA556346X3HVu3OGRuaNhCymGLV6BThgpjW5YZlTRMuR-YxYy3Gp42dxr-YZp-e_uTuqf59g6T-lZjZEIBT/s1600/IMG-20231001-02.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="777" data-original-width="1600" height="155" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbuCeufQWt1dbPZGChgvDs9OJJCxxkfMJEMT3fXxUMRusfeUhyphenhyphenJrmTnR0hcSEsCAS2Vr4tttuLm1y1PtKsj_QExdh-16ccF8SgbpaT6geBjtA556346X3HVu3OGRuaNhCymGLV6BThgpjW5YZlTRMuR-YxYy3Gp42dxr-YZp-e_uTuqf59g6T-lZjZEIBT/s320/IMG-20231001-02.jpg" width="320" /></a></div>I think that his brackets turned out better than mine! Francis is an excellent fabricator and I have been sending a lot of information to him so that he can make his own parts for the plane. I've been doing this for a couple of reasons. The main reason is that it is time consuming and expensive (for him) to have me send him aircraft parts. Shipping is expensive and then he pays a premium to import "stuff" to France. If I send him the info he needs to make the parts himself, all he has to do is find the material there to make it from. The secondary reason is that several times I've been busy with other projects and I don't want to slow down his progress while he has to wait for me. And, maybe the final reason is what you see above - most times he does a better job than me! As always, outstanding work on your airplane, Francis!<br /><br /> <b><u>C. Update on Vaughn's Prowler Status -</u></b> Recently, Vaughn's focus has shifted to planning for (and working on) his FWF solution for his Prowler. He is going to install a rotary engine in his plane. He has this PowerSport rotary FWF setup installed on his RV-8:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1TLlgtoNwBcuQiDHrfLJDL-QW8DY3jz2bafV-7MDzJzck1jkposUGPN7piKQDmAbOz3q13asgL-uv0-OmyFZJKxYej_V_3_q2AOt4K-CMqjk1lt-ng6GbEq-_xHFAoAnSLFYJW5mX8RiCZDe229u6cWVS6A5IBKUXY08LY2v6Nbsi7M822nYaA1C_5aIY/s1600/RV8%20with%20Rotary.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1TLlgtoNwBcuQiDHrfLJDL-QW8DY3jz2bafV-7MDzJzck1jkposUGPN7piKQDmAbOz3q13asgL-uv0-OmyFZJKxYej_V_3_q2AOt4K-CMqjk1lt-ng6GbEq-_xHFAoAnSLFYJW5mX8RiCZDe229u6cWVS6A5IBKUXY08LY2v6Nbsi7M822nYaA1C_5aIY/s320/RV8%20with%20Rotary.jpg" width="320" /></a></div>This is a 2 rotor setup in his RV-8. He will be installing a 3-rotor engine in his Prowler. His mechanic is working on the engine and Vaughn has begun to plan for it's installation. We have been discussing W&B issues to try to determine how much more forward he will have to install this lighter engine + PSRU+ prop combo to get roughly the same CG range as the previous Prowlers.<br /><br />At the same time, he has begun to mock up his FWF with the longerons and horse collar that I fabricated for him (shown in a previous update). Check this out:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1k52TnMqJ0jdFjcn_daYP0tfooaxHCEtfapA8ejIfLChXpHtFHoxqSH5mLULtdfNLyuc7OscoSWp-Tpz5mNSNSYi93Qa4wzGWbvVqbB3pfCGjVcopP599fvk4lv7vhyDjxb9H6FOb8PPmpqqAjSZL5RzLDaTlt-syfWWPao-6jExih9ngxSeo9mnMwGAQ/s2048/4337041648937968646.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1536" data-original-width="2048" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1k52TnMqJ0jdFjcn_daYP0tfooaxHCEtfapA8ejIfLChXpHtFHoxqSH5mLULtdfNLyuc7OscoSWp-Tpz5mNSNSYi93Qa4wzGWbvVqbB3pfCGjVcopP599fvk4lv7vhyDjxb9H6FOb8PPmpqqAjSZL5RzLDaTlt-syfWWPao-6jExih9ngxSeo9mnMwGAQ/s320/4337041648937968646.jpg" width="320" /></a></div>He has decided to start with the motor mounts that George used. These will get modified, but he's going to try to begin with these as something to build off of.<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEMJHXkikAdvG7XAu2xfFTF-Yc_DkUgjy9DPnTmEtSR2-PYS1zYQVyhljDf_l3lIfIbEIlldAFrFoK4G0IyyaYd87973kBYiZEj9D64npgszXg5z4vJXuGexYcv99zS02t2J10RYJQff0KtH9D_CldWORGPHWUw_sKFoUP7grjPAj-8Yx0hp0WMPgnibc-/s1280/-5241701543103215319.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="1280" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEMJHXkikAdvG7XAu2xfFTF-Yc_DkUgjy9DPnTmEtSR2-PYS1zYQVyhljDf_l3lIfIbEIlldAFrFoK4G0IyyaYd87973kBYiZEj9D64npgszXg5z4vJXuGexYcv99zS02t2J10RYJQff0KtH9D_CldWORGPHWUw_sKFoUP7grjPAj-8Yx0hp0WMPgnibc-/s320/-5241701543103215319.jpg" width="320" /></a></div>Yup! It's beginning to look like a Prowler! <br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiH0uO7K48SgCiTw1AZ1u6d9yYQodsFQ3gSgmoFFwHY5wO9wpw7vIneHUtP1298y_-qB8KbUyFY21CJREucxr1a6X77ooo2ElPe2jAajjBQnyh49Ak-5iVT6_Ib-y8bjTNDceQbtMthqiqRY7_KfROPI3B3C2aVIvH_pJQlLh5KHVQiBBMpFsYFZbedcscj/s1600/4876255702624207276.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiH0uO7K48SgCiTw1AZ1u6d9yYQodsFQ3gSgmoFFwHY5wO9wpw7vIneHUtP1298y_-qB8KbUyFY21CJREucxr1a6X77ooo2ElPe2jAajjBQnyh49Ak-5iVT6_Ib-y8bjTNDceQbtMthqiqRY7_KfROPI3B3C2aVIvH_pJQlLh5KHVQiBBMpFsYFZbedcscj/s320/4876255702624207276.jpg" width="320" /></a></div>Excellent progress! Vaughn has told me that he wants to set up things with his "engine guy" so that he can make this FWF system available to other Prowler builders who might want to also install a rotary engine system. When the time comes, I'll also talk with the PowerSport folks so we can formalize a FWF package for the Prowler.<br /><br /><b><u>D. Update on Bryan's Prowler Plans -</u></b> Bryan has not been doing much on his Prowler the past several years. There are many reasons for it, but mostly it was due to his plans to use a diesel engine in his Prowler. He has sent me an update recently. Here it is:<br /><span style="background-color: rgba(0, 0, 0, 0); color: #ffa400; font-family: "Helvetica Neue"; margin: 0px;"><br /></span><span style="background-color: rgba(0, 0, 0, 0); color: #ffa400; font-family: verdana; font-size: x-small; margin: 0px;">It’s been twelve years since I signed a purchase agreement for the engine intended for my airframe. With encouraging promises every subsequent OSH visit, my airframe languished in a dusty garage. Last year as talks (for the engine) were nearing certification I reviewed my contract with the vendor to learn that some provisions had changed, principally the financial investment required to complete the installation. I pulled the plug on that opportunity and to their credit they reimbursed me for my deposit and wished me blue skies. <br /><br />Anticipating a realignment of my design goals I started the due diligence process of deciding just how best to proceed FWF. I liked what Viking Aircraft has engineered but their offerings were short of the thrust I desired for the Prowler. To rectify that issue, after consulting with several well founded suppliers I chose the Honda K20C4 engine. <br /><br />On auction (recently) was an old lady’s 2022 Acura RDX that she rolled in Texas. As a successful bidder I now had an extremely durable 275 HP turbo inline 4 cylinder that wont break a sweat pulling the airframe around. However, I was the one sweating as I learned that the factory ECU was not modifiable without all the cross talk that goes on in modern cars. Aftermarket?, hold that thought… This is a direct injected engine. Fortunately there is a supplier in New Zealand that has recently stepped onto that stage. <br /><br />Next issue was that being a new car Honda still considers their maintenance data like wiring diagrams etc proprietary data. You can look at it but you pay handsomely to play. So that’s where I am at the moment. I have to figure out just how the 14 sensor inputs relay data and create a basemap that runs the VTEC and VVT. Once that is done it will be a quick trip to Texas to pick up my PSRU and integrate it to the engine. <br /><br />I am excited about this setup. If I am successful this FWF package will weigh in at 320 lbs, 100 lbs lighter and approximately 50 more HP on takeoff than the original Olds V8 that George Morse offered. It fits with room to spare in the narrow cowling with substantial space behind the engine since the block is a mere 24 inches in overall length without the PSRU. This engine just happens to be the the most coveted design for all those drifters, racers and tuners out there. I just need to infiltrate their ranks…</span><span style="background-color: rgba(0, 0, 0, 0); color: #ffa400; font-family: "Helvetica Neue"; margin: 0px;"><br /></span><br />So, here is what Bryan's dusty plane looked like in the garage:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmo2_GRo7DaANtD60dHkmA4b3baL4fpKbULPyPlZeLYQoxpWq6hFPty-3RuAawZUPdsvf27Gr5OMD-3oFtQK5NT0lSO3keZQy2YlF9bXpXhBpsyxgEgfi2twp-GG5DyDk455OFTfEuWCWbPGE481PBofDnvgBLZ5KiVjZSGzw0aJ2KErwhy7mJfNr-ZVaH/s1024/IMG_20230221_142905.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="768" data-original-width="1024" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmo2_GRo7DaANtD60dHkmA4b3baL4fpKbULPyPlZeLYQoxpWq6hFPty-3RuAawZUPdsvf27Gr5OMD-3oFtQK5NT0lSO3keZQy2YlF9bXpXhBpsyxgEgfi2twp-GG5DyDk455OFTfEuWCWbPGE481PBofDnvgBLZ5KiVjZSGzw0aJ2KErwhy7mJfNr-ZVaH/s320/IMG_20230221_142905.jpg" width="320" /></a></div>And:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMKo_FtviAPzzfswMITkN2VmhqLLChgKhJ5ZKSyy_ACiJQHPQNVPp7x9cXJOyKo7mPZov7Hq63e13I80_WA4LrPe2nQsW86X_o7hHzda3hkj2Ef0fPX7qq1LhjfdttURYbeDqb0Ydef2AAJBbrjAB49UXqUji61r2WEt1aL6UrZW3A70iQQvxx7vxW9u3H/s1024/IMG_20230221_142913.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="768" data-original-width="1024" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMKo_FtviAPzzfswMITkN2VmhqLLChgKhJ5ZKSyy_ACiJQHPQNVPp7x9cXJOyKo7mPZov7Hq63e13I80_WA4LrPe2nQsW86X_o7hHzda3hkj2Ef0fPX7qq1LhjfdttURYbeDqb0Ydef2AAJBbrjAB49UXqUji61r2WEt1aL6UrZW3A70iQQvxx7vxW9u3H/s320/IMG_20230221_142913.jpg" width="320" /></a></div>Then, when he finished his new "man cave" the plane got "un-buried:"<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqFEbM6bBwnnCdShDZXgG0izg5N7Wqw_irN40xZGw-FAJIuNp2qlaeEhANQksiMfTz968b8fwT78FglJbMTTtYkQo4RzTB2Fb8Dhbx7se2Vd6xWCWg0C75tPFO7cBpTzNNGPLbIJVSFurFU0VJ5-qetPoQBsv9jlnp2d83Few_gLqoeIwSjxMqalmayQzx/s640/4BFE396B-49BD-41F2-BCC5-E25178887688.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqFEbM6bBwnnCdShDZXgG0izg5N7Wqw_irN40xZGw-FAJIuNp2qlaeEhANQksiMfTz968b8fwT78FglJbMTTtYkQo4RzTB2Fb8Dhbx7se2Vd6xWCWg0C75tPFO7cBpTzNNGPLbIJVSFurFU0VJ5-qetPoQBsv9jlnp2d83Few_gLqoeIwSjxMqalmayQzx/s320/4BFE396B-49BD-41F2-BCC5-E25178887688.jpeg" width="320" /></a></div>cleaned up:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHmuhtZFxNrx6Wh7LI5fbWOopHDS0qOI-ExOfUXNRg5RDtCWnFp9kXoicVZ7bzqxTfthcB_q0Btd8rztFoA3ZvvIsexYfYShwVeicx-eXUgOaBXiyGpgmqtjf82dYSRDSUsFrB379zttkU-nXAoJnnnt98sYRfsCss_H8tzto7A1qDt5cV0cvc6SrfeVoT/s640/1633CAA7-FB05-48A2-BBF7-8B08B0EB0C42.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHmuhtZFxNrx6Wh7LI5fbWOopHDS0qOI-ExOfUXNRg5RDtCWnFp9kXoicVZ7bzqxTfthcB_q0Btd8rztFoA3ZvvIsexYfYShwVeicx-eXUgOaBXiyGpgmqtjf82dYSRDSUsFrB379zttkU-nXAoJnnnt98sYRfsCss_H8tzto7A1qDt5cV0cvc6SrfeVoT/s320/1633CAA7-FB05-48A2-BBF7-8B08B0EB0C42.jpeg" width="320" /></a></div>photo- op'ed:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYKIHeI_LXei5M07PlcleyylHbIY7ubkFMS5vl5WcUswsiDDMZf9C4NjhXMH-n6AG4nB1owdosSwIxjlBYCF0lss2Pz3O1Zpx_MKmTnt45JeBut0E0WePhHsZJxkcX1EZI0mr13ws_BnboAjcqi5Z9VN_N99wRgcoI2EhWWue0XB2SRSJzwjOu_hYiXzvD/s640/2815F216-48C5-4B21-96FA-36F9F642D439.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYKIHeI_LXei5M07PlcleyylHbIY7ubkFMS5vl5WcUswsiDDMZf9C4NjhXMH-n6AG4nB1owdosSwIxjlBYCF0lss2Pz3O1Zpx_MKmTnt45JeBut0E0WePhHsZJxkcX1EZI0mr13ws_BnboAjcqi5Z9VN_N99wRgcoI2EhWWue0XB2SRSJzwjOu_hYiXzvD/s320/2815F216-48C5-4B21-96FA-36F9F642D439.jpeg" width="320" /></a></div>and moved into the new building spot in the new building:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYXaRGcVi4oih0QK9AiMCgbOXszHlnne0U97SsPmBEJ5SgqegV3vYxiln0XqFAkD-YxtvZf_bJERxQZkY6Uta8KtriDH-MQjI4RoGWDYJGBZ_HWSKDfPcT_V9H5R-YKhVQ9h9Nnp7We8jp_7WJ-EMnayfbxBXjulM2omCaLxXH80h8eJFkbvaE76SrVT93/s2048/IMG_20230221_142926.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1536" data-original-width="2048" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYXaRGcVi4oih0QK9AiMCgbOXszHlnne0U97SsPmBEJ5SgqegV3vYxiln0XqFAkD-YxtvZf_bJERxQZkY6Uta8KtriDH-MQjI4RoGWDYJGBZ_HWSKDfPcT_V9H5R-YKhVQ9h9Nnp7We8jp_7WJ-EMnayfbxBXjulM2omCaLxXH80h8eJFkbvaE76SrVT93/s320/IMG_20230221_142926.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2Q6N9NEPZUqTAz0MuLwCaOaEno6pUFVdt5z6D5UfsA-tuKuvxmLDZQ8-NuPuc8mWhboelvYJHp7mNWByaZYZZytwgi2hDa2d4mRk3kEd2Qcdx3PGNdGp5Ux1ochuEK-VApDp2r50hksYBAwpKIInelvk8dDafcy6VGiA6Y2a_bslSzu9Y-ZjpCUoEyo49/s800/IMG_20230222_152607.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="600" data-original-width="800" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2Q6N9NEPZUqTAz0MuLwCaOaEno6pUFVdt5z6D5UfsA-tuKuvxmLDZQ8-NuPuc8mWhboelvYJHp7mNWByaZYZZytwgi2hDa2d4mRk3kEd2Qcdx3PGNdGp5Ux1ochuEK-VApDp2r50hksYBAwpKIInelvk8dDafcy6VGiA6Y2a_bslSzu9Y-ZjpCUoEyo49/s320/IMG_20230222_152607.jpg" width="320" /></a></div>Here is a look at the donor car that was purchased at auction to supply his new engine for his Prowler:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4w2od4Twbl93pKZ31Ln51wrohy3q6BQLpNkGjo_ut50BgMC1sxKOzPZ2ZJnRPFxI60rdFKWwrgY7y21T9cp10lrMyBQmFIYogjB_hQfPIpG2M50rd1csdUgx8DyxZX8z0_5nO2SMQxw15K0D9EI3E1DlRL5dYHKR_CSwbPBXHk0N70OpI87DN4XPCsK-D/s640/IMG_0299.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4w2od4Twbl93pKZ31Ln51wrohy3q6BQLpNkGjo_ut50BgMC1sxKOzPZ2ZJnRPFxI60rdFKWwrgY7y21T9cp10lrMyBQmFIYogjB_hQfPIpG2M50rd1csdUgx8DyxZX8z0_5nO2SMQxw15K0D9EI3E1DlRL5dYHKR_CSwbPBXHk0N70OpI87DN4XPCsK-D/s320/IMG_0299.jpeg" width="320" /></a></div>The mechanic, extracting the engine from the donor car:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1wUYFvb6u74kMbaMkQ0DEk3bkP4TGKsPLFLKNhdAwE-eht4m4O9AeNRZcjTMCh-AJ5sugz45bQ4c1sm5PCwHyxLUmvgF4HYxY6avZdRN_-JCKm-s9gc1Ej_dFgS0eOPILF8ukaa0nqWwyFeEfdZNrQqlGQ0Uvrso_KUpT3ivyzhKmqL6IEFuzAp_KU-uY/s640/IMG_0310.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1wUYFvb6u74kMbaMkQ0DEk3bkP4TGKsPLFLKNhdAwE-eht4m4O9AeNRZcjTMCh-AJ5sugz45bQ4c1sm5PCwHyxLUmvgF4HYxY6avZdRN_-JCKm-s9gc1Ej_dFgS0eOPILF8ukaa0nqWwyFeEfdZNrQqlGQ0Uvrso_KUpT3ivyzhKmqL6IEFuzAp_KU-uY/s320/IMG_0310.jpeg" width="320" /></a></div>And, whoop, there it is!<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRb2-U_HP_Rjp6ZCVOBBJpYbyJgwWDpaUZTuGxKT82vL0jFT6KRL9pRMoJ_sp19RS9ND67qYXVSR0OiHl08XzgnOZb6egn685sRnWADSyEZqsg9s_65Z2pvShSnMZmvrGoVOu6F7WpbgXRRvJuZm0G1mE22GYSwhZZYsgEbC0RKsFGt3EpQpVw_K3YAVzC/s640/IMG_0315.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRb2-U_HP_Rjp6ZCVOBBJpYbyJgwWDpaUZTuGxKT82vL0jFT6KRL9pRMoJ_sp19RS9ND67qYXVSR0OiHl08XzgnOZb6egn685sRnWADSyEZqsg9s_65Z2pvShSnMZmvrGoVOu6F7WpbgXRRvJuZm0G1mE22GYSwhZZYsgEbC0RKsFGt3EpQpVw_K3YAVzC/s320/IMG_0315.jpeg" width="320" /></a></div>This is the torque and horsepower plots for this engine:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwu1eZsafbNfRySYL8DFirEbpedg4wpr1jR9eyChLKaUFIXuz2NDdIgQW7rWOEsgLkn72r3DhyphenhyphenmrGXYzJbihem_8b3Ade5-zhAJhbCIplr5cAgvAFzQid7Kg3shyBd8syexu9G4V1H2DOhEmqY0fHTFsZpoj6Has87d7bLeyMewZS_usBTrVkVkQ3FBZiy/s640/IMG_9643%202.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="640" data-original-width="480" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwu1eZsafbNfRySYL8DFirEbpedg4wpr1jR9eyChLKaUFIXuz2NDdIgQW7rWOEsgLkn72r3DhyphenhyphenmrGXYzJbihem_8b3Ade5-zhAJhbCIplr5cAgvAFzQid7Kg3shyBd8syexu9G4V1H2DOhEmqY0fHTFsZpoj6Has87d7bLeyMewZS_usBTrVkVkQ3FBZiy/s320/IMG_9643%202.jpeg" width="240" /></a></div>This looks like an excellent choice for a FWF powerplant! I'm not sure about the reduction ratio of the PSRU that Bryan is planning - but at about 1.6:1 the useful max RPM is around 4000-4500 RPM. If the reduction ratio is higher, you might be able to go to 5000 RPM. From this plot, (on this engine) the HP is well over 200. And, the torque curve is flat at 275 Ft-lbs from just over 2000 RPM all the way up to near the cross-over point which is just above 5000 RPM. The power band (flat torque curve) and the peak HP of this engine is gong to be very usable and definitely in the range that it needs to be for delivering the max power to the prop. Great choice!!<br /><br />Here is the engine mounted on a test stand that will be used to edit, modify, delete, test, streamline and generally prepare the engine for installation into the airplane:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjat3_2ecC5Nzj2VUTE1ayxMzI2tQg8A2EWFhUmSzInzNtCm4QYqh212IOHb6f39UvztznwGirpjEHxwH_NKKxILyBllJ9q-rfWNNOcC1DcdXcmHJ1Sic-bE019bJjf25tEIGe5CYc72j1ozRk4BXUNZcWbiqOUhWorofJAhKBgdT07pUIlpsJNjGdCie-T/s640/IMG_20231212_0563.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjat3_2ecC5Nzj2VUTE1ayxMzI2tQg8A2EWFhUmSzInzNtCm4QYqh212IOHb6f39UvztznwGirpjEHxwH_NKKxILyBllJ9q-rfWNNOcC1DcdXcmHJ1Sic-bE019bJjf25tEIGe5CYc72j1ozRk4BXUNZcWbiqOUhWorofJAhKBgdT07pUIlpsJNjGdCie-T/s320/IMG_20231212_0563.JPG" width="320" /></a></div>This will be the place to figure out all the "issues" BEFORE trying to install the new FWF system in his airplane:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnHjMvHw6dao4Z2oBSXaAvR80YNMf-khsk9rW0nUNM2knaQx_C9cHhniiAiOofKWJq5UTAiTLhUJhK-H5u8RhUU1mmFiEEaaSOqaBQVn9p2tZY88q9Kq_JugFIs_SeOuApbQiAGTdJy50it0rwjn4cshq41yxgjoYVPH9vgjfAe3tXllb0Ghr6KFnTpM4a/s640/IMG_20231212_0567.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="640" data-original-width="480" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnHjMvHw6dao4Z2oBSXaAvR80YNMf-khsk9rW0nUNM2knaQx_C9cHhniiAiOofKWJq5UTAiTLhUJhK-H5u8RhUU1mmFiEEaaSOqaBQVn9p2tZY88q9Kq_JugFIs_SeOuApbQiAGTdJy50it0rwjn4cshq41yxgjoYVPH9vgjfAe3tXllb0Ghr6KFnTpM4a/s320/IMG_20231212_0567.JPG" width="240" /></a></div>First, however, there is A LOT of wiring harness work that must be done:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtOSKXGclc7fqyEoACdnD3-pQ0hrL9NeX4q8RSM4ZIId9BziEhKsDB6X_I1WxYHkktlYSvfUPzfjLavudBbrMqkqD_Pf3D3Z0Mk2nZxTD68BmDtBKUZswcmncrtWJw421cCNhgB0wKWbERywYyP3c48eAu0Fu3brXX43xZodC8CvLrLWoow_uvdbLF6CBd/s640/IMG_20231212_0564.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="640" data-original-width="480" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtOSKXGclc7fqyEoACdnD3-pQ0hrL9NeX4q8RSM4ZIId9BziEhKsDB6X_I1WxYHkktlYSvfUPzfjLavudBbrMqkqD_Pf3D3Z0Mk2nZxTD68BmDtBKUZswcmncrtWJw421cCNhgB0wKWbERywYyP3c48eAu0Fu3brXX43xZodC8CvLrLWoow_uvdbLF6CBd/s320/IMG_20231212_0564.JPG" width="240" /></a></div>Yikes!! That's a lot of wiring to figure out!! I think Bryan told me that he has "a guy" that will help him sort that all out. That will be a major accomplishment when it is finished!<br /><br />Thanks for the update, Bryan!<br /><br />Well, that's all I have for this update. I have not (personally) gotten much done with Prowler Aviation lately. I've mostly been making it a priority to deal with steps I need to take to get my medical back. Most of that will be finished my mid January and after that I'll be able to get out in the shop and get some things moving.<br /><br />I hope that you all have a Merry Christmas and a Happy and Healthy New Year!<br /><br /><br /><br /><br /><br /><br /><br /><p></p><p></p><p></p><p></p>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-4561663675008429701.post-12819538618479600962023-12-03T11:51:00.000-08:002023-12-03T11:51:42.734-08:00AirVenture 2023 - It Was A "Hot Mess"!! As I put in the title.....the best way to describe this year's AirVenture 2023 experience is that it was, indeed,a "Hot Mess!" But, it was still a great show! And, as the saying goes...."The worst day of AirVenture is still way better than the best day anywhere else!!"<br /><br />The "mess" started pretty much from the very first day that Bryan and I showed up at Camp Scholler. Bryan arrived on the Sunday before the Sunday before the show - literally a week and a day prior to the show. We went to "stake out" or normal camping space only to find out that it had, sort of, been staked out by someone else. However, those stakes and ropes had been pulled up and rolled into a ball and shoved out of the actually corner that we like to park in. Huh!!<br /><br />As we stood there pondering the situation, a new friend showed up. Shawna had been camping nearby for a few days before us and said that one group had staked out "our" corner, but that the next day EAA Security came by, rolled up the stakes and the ropes and re-opened "our" corner. She said that they had done that with several staked out campsites along the old fence rows that make up "our" corner. Oh well, I guess if that's the case, let's move into our corner!<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEetO4hWCZGMNvmKzGthGK86tf-eHA5mhde5mBnVONILyABDJCFA3bHdYEeh81XyYgd8-T61Iij0cou5ubypvOMQ8WWOfzXnyqbYIG7K5Wh9p__xzk6fOXUgBV0jOahH-WG0yV3-VL6dU7duXLvWFhiHcb6BUVfSNQf5_nOUmI_HObHQOC2HpIIuTA0CZS/s1479/20230718_233722121.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="832" data-original-width="1479" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEetO4hWCZGMNvmKzGthGK86tf-eHA5mhde5mBnVONILyABDJCFA3bHdYEeh81XyYgd8-T61Iij0cou5ubypvOMQ8WWOfzXnyqbYIG7K5Wh9p__xzk6fOXUgBV0jOahH-WG0yV3-VL6dU7duXLvWFhiHcb6BUVfSNQf5_nOUmI_HObHQOC2HpIIuTA0CZS/s320/20230718_233722121.jpg" width="320" /></a></div>Bryan parked there a few days before I was planning to pull my rig to Camp Scholler, so we "staked out" enough space for me and a few tents too. Well, guess who paid him a visit the next day!?!? EAA Security removed our stakes and ropes and said; "If you are going to reserve space for someone, you have to post their camping credentials in the reserved space(s)." Really! What this really meant was you had to PAY for the extra days that you're "reserving" these spaces for your friends or family!!<br /><br />----------- CAUTION! ------------- SIDEBAR RANT!! --------<br />C'mon, Jack!! Really!?!? What about: " The airplanes bring us together, but the friendships keep us together" concept? The new enforcement of this policy in the middle of a farm field near the south gate (which typically fills up dead LAST during the "influx") seems to fly in the face of those of us trying to keep our friendships going each year at AirVenture!! I don't complain about paying $35/day to park in farm field with no RV hooks ups or any services - but this paying full rate to stake out space for our friends & family rubs me a little wrong! Please revisit this "policy". <br />----------------------------------------------------------------------------<br /><br />OK! Rant over. Ultimately, I paid for an extra day and Bryan and I got to park next to each other with a "common" space between our front doors.<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhR7u3nzy6FXnThlQdBb2FREMPa4Jr24_sKPth9azECPE1u_G5R36gX11kDakBUyrEXsREPzAT1r50KG2Yr9iPcvrpBn2XkbM8fPr56RSMDfkVuH31ttA9QUvdC2wdQCtigKAX_FmdhAR0BT4_KrmHsom-2FgdCrcCqoCzb0envRcDtBFcdAR4pCl_x545U/s1479/20230722_165154152.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="832" data-original-width="1479" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhR7u3nzy6FXnThlQdBb2FREMPa4Jr24_sKPth9azECPE1u_G5R36gX11kDakBUyrEXsREPzAT1r50KG2Yr9iPcvrpBn2XkbM8fPr56RSMDfkVuH31ttA9QUvdC2wdQCtigKAX_FmdhAR0BT4_KrmHsom-2FgdCrcCqoCzb0envRcDtBFcdAR4pCl_x545U/s320/20230722_165154152.jpg" width="320" /></a></div>Back to the "Hot Mess." So, it was pretty hot, humid and wet this year. It rained (showers, not steady) almost every day during the first 1/2 of the week. One good storm showed up at 1130pm when many of us had already turned in. Thanks for waking me up, Dave, so that we could batten down the hatches! Overall, the roads got a little muddy, but that's nothing new for AirVenture and it wasn't even close to the severity of "Sloshkosh".<br /><br />Another "mess" that we encountered this year was our neighbors to the east. This is the first year I have ever encountered such inconsiderate, rude, rule breaking neighbors! That just doesn't happen at OSH!! As a group, everyone is ALWAYS considerate and abides by generator hours, and quiet hours. Not this group! I won't be upset if they aren't near us ever again! Ugh!!<br /><br />So, continuing with the "Hot Mess" theme, there were also several cool new aircraft and vendors that made their debut at AirVenture this year. Here are just a few, in no particular order:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5iupzX_Nl_NVsmP-4eRQ8YnoUpCzqI_ocJBbD4HuV6j0jHcGjkUo-7u72k3qJ7Rcyg1OQXQocsH_h2-xtt41uIE2DzdMWWwxZxi08f8WfSH0iC9AlvnafoIqJPt8118iMroTGynLApxMaE-6i_A6Iafx0Cc6l6EXEndoZ95V2SEtDtoEREAgaa0306hEM/s1479/20230724_161756007.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="832" data-original-width="1479" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5iupzX_Nl_NVsmP-4eRQ8YnoUpCzqI_ocJBbD4HuV6j0jHcGjkUo-7u72k3qJ7Rcyg1OQXQocsH_h2-xtt41uIE2DzdMWWwxZxi08f8WfSH0iC9AlvnafoIqJPt8118iMroTGynLApxMaE-6i_A6Iafx0Cc6l6EXEndoZ95V2SEtDtoEREAgaa0306hEM/s320/20230724_161756007.jpg" width="320" /></a></div>This is the first time I remember seeing the DreamLifter at AirVenture. It might be the first time ever, I'm not sure. It's a big aircraft! There was a LONG line to go inside. Speaking of big.....<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTHyGEAl4T1uz0Bg0T12QnW54RVK_0lgOZ3n12aNjQPTJ7uc0XYBbV8qxss7fm6_x0nf-PrDHJ-gBkXDMo1wEsMxUGTTN9bW8XTn8FUxdAimDKnkrG8hiGkZZc3C9yzlbzbntsdc0giWcNYdHO41AwtlcHADEHt2GYw4KbmZj-XE3aLqqAva9xWxdL844t/s1479/20230724_161648537.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="832" data-original-width="1479" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTHyGEAl4T1uz0Bg0T12QnW54RVK_0lgOZ3n12aNjQPTJ7uc0XYBbV8qxss7fm6_x0nf-PrDHJ-gBkXDMo1wEsMxUGTTN9bW8XTn8FUxdAimDKnkrG8hiGkZZc3C9yzlbzbntsdc0giWcNYdHO41AwtlcHADEHt2GYw4KbmZj-XE3aLqqAva9xWxdL844t/s320/20230724_161648537.jpg" width="320" /></a></div>I don't know if the Super Guppy has ever been to the show, but, it's the first time I've seen it in person. They can get some big stuff inside that!<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgDaTjdZKebkUOetLAVFwcK9OJeeqEyNPnbG8J8PejCxgWgbGKOrtjnlKGwX4R8dYN_GKkfgxYrvNAX1MB_GUPK-JvoETNN1zwn0FoSB4azrfHJBGHy3WAgYr1SkYpFjKo1qT-li5BkzPYQcndSdZVz2B3EPSAqGH7E57KR7HZUGta2ajRAOrjXz0Y7gra1/s1479/20230723_163033565.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="832" data-original-width="1479" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgDaTjdZKebkUOetLAVFwcK9OJeeqEyNPnbG8J8PejCxgWgbGKOrtjnlKGwX4R8dYN_GKkfgxYrvNAX1MB_GUPK-JvoETNN1zwn0FoSB4azrfHJBGHy3WAgYr1SkYpFjKo1qT-li5BkzPYQcndSdZVz2B3EPSAqGH7E57KR7HZUGta2ajRAOrjXz0Y7gra1/s320/20230723_163033565.jpg" width="320" /></a></div>OK, so Boeing is not new to AirVenture - after all, the big piece of concrete in the foreground is called "Boeing Plaza." But, this temporary building/structure/facility is! It's HUGE! Like two story huge! And, it was mostly air-conditioned! I think they had 2 full motion flight simulators in there! <br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhM17aFrSrpHxMD2ADeDMLAPjQQAFMnR4H0lXY0YVL5ODKT1Wd2ltahhTcl0of6hpr2_jFv_jK6aAzf_hNxRm-5xp3t4Kq15aCxUzUnO3NdUSE0COgAqkSw3TtVm1FWqdK0Pf-Iw-4NBFlcc1_cwxwNdpdR7He952kVH28noA2EOHpubCRPgk3umzkYUL_M/s1815/Boeing%20New%20Building.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="817" data-original-width="1815" height="144" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhM17aFrSrpHxMD2ADeDMLAPjQQAFMnR4H0lXY0YVL5ODKT1Wd2ltahhTcl0of6hpr2_jFv_jK6aAzf_hNxRm-5xp3t4Kq15aCxUzUnO3NdUSE0COgAqkSw3TtVm1FWqdK0Pf-Iw-4NBFlcc1_cwxwNdpdR7He952kVH28noA2EOHpubCRPgk3umzkYUL_M/s320/Boeing%20New%20Building.png" width="320" /></a><br /></div>This pic is from Monday morning on the day after AirVenture 2023. Look all the shipping crates lined up to be filled, already!!<br /><br />Here is an aircraft that I've not seen at AirVenture before:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0ujKDeeimw_IAf53b4g-aDgX5X3GP5qcF8lxb-ru2qdwgWJKHxj8sLK0VQxcI0BS4xgGwXINceXQeX7R0VgU26qSkpXSzpj7VVrPDGefbf6-r5-jEs2xtwtc424_H0dwKmV6nHiePlRtSQ2FjXpI_A_xip98ZtIquC840eHOvCr-Eczr80vgvWKdaMh0H/s1479/20230723_155432849.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="832" data-original-width="1479" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0ujKDeeimw_IAf53b4g-aDgX5X3GP5qcF8lxb-ru2qdwgWJKHxj8sLK0VQxcI0BS4xgGwXINceXQeX7R0VgU26qSkpXSzpj7VVrPDGefbf6-r5-jEs2xtwtc424_H0dwKmV6nHiePlRtSQ2FjXpI_A_xip98ZtIquC840eHOvCr-Eczr80vgvWKdaMh0H/s320/20230723_155432849.jpg" width="320" /></a></div>I have been told that it was a Reno racer at some time in it's past. It's a beautiful airplane!<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFtL3GUXm656k_wcE5lUvojC_NMHPzSXj6PabU-tsMFs60A3i_SdYmr-ikIJRICj9f_9LCjRrLdWmPvPKYTByodOPQcdXCT9tQ8FluUjDLtCCEhrYHFDQDyFiDA8G2X2A3hXFAtPluep0659t_-Zg_u9uTRQduzT2A7-WkyQ3sKYAYA0E5bYU2rvr9RMae/s1479/20230724_170935589.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="832" data-original-width="1479" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFtL3GUXm656k_wcE5lUvojC_NMHPzSXj6PabU-tsMFs60A3i_SdYmr-ikIJRICj9f_9LCjRrLdWmPvPKYTByodOPQcdXCT9tQ8FluUjDLtCCEhrYHFDQDyFiDA8G2X2A3hXFAtPluep0659t_-Zg_u9uTRQduzT2A7-WkyQ3sKYAYA0E5bYU2rvr9RMae/s320/20230724_170935589.jpg" width="320" /></a></div>My favorite airplane, with oldest daughter. Just something about the F4U that beats all the rest!<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirRP4FCRtiJ26a3NNZF8UxfCI13M-rB9nb_HUZ4gXOeDtxYA_cma5vfoJKcdiFwNSfJ5Df1mqG507yS9PQPE7zwHM_TQQ4UxlVlMF7qDRp220fmwvtBac4HFb_AG2lp2SoZvuywBnh4wHOMgdBwjfji44RETR1DO1Swj9qWZRpY7T2_TAzi7yddVaott_1/s1479/20230723_195956199.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="832" data-original-width="1479" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirRP4FCRtiJ26a3NNZF8UxfCI13M-rB9nb_HUZ4gXOeDtxYA_cma5vfoJKcdiFwNSfJ5Df1mqG507yS9PQPE7zwHM_TQQ4UxlVlMF7qDRp220fmwvtBac4HFb_AG2lp2SoZvuywBnh4wHOMgdBwjfji44RETR1DO1Swj9qWZRpY7T2_TAzi7yddVaott_1/s320/20230723_195956199.jpg" width="320" /></a></div>If you've never seen this man and machine do their thing, you need to! Just type "Steven Henry Highlander" into your favorite browser and look for STOL videos. You'll see!!<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYExNiSbZmWLMjPZEBVTT3HO-TlWGxg5xI8d6V0d4tS8gZBaKvdBFv7uT8PURXGwHW6IUyHgMruiFEJE1tXXHRxYtCuop1mvcHv5QBsFL5XIhbWlLS_GGGFFzIOVWFebWqqYQBsGGyh-HreErincfgew38sNFVoTRe16VCL9xhuMGD07miJjg9EMxGYhRC/s1479/20230725_144928465.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="832" data-original-width="1479" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYExNiSbZmWLMjPZEBVTT3HO-TlWGxg5xI8d6V0d4tS8gZBaKvdBFv7uT8PURXGwHW6IUyHgMruiFEJE1tXXHRxYtCuop1mvcHv5QBsFL5XIhbWlLS_GGGFFzIOVWFebWqqYQBsGGyh-HreErincfgew38sNFVoTRe16VCL9xhuMGD07miJjg9EMxGYhRC/s320/20230725_144928465.jpg" width="320" /></a></div>In the theme of "Hot Messes" my friend Nicky got her indoctrination to AirVenture with an AirCam ride with Dave. Thanks, Dave.<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXY3Jf9-cS9SyUa34PW7eU83L8OjmEoyhYLTpMaPPkN80p4GqqvIMcT9bjIk3dVH2JQEWLFu655vlYVeiKjlFb-ViKNv4iq8w_Kk3lmkS9IDvDOGhrDYiz9PoHKEO2Lhg9yqw1-831SJzzvMcKOewzuYSro2tv-0vqD6nlZsCelXsYOwJo88uRlntOid_o/s1253/20230724_162751278.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="832" data-original-width="1253" height="212" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXY3Jf9-cS9SyUa34PW7eU83L8OjmEoyhYLTpMaPPkN80p4GqqvIMcT9bjIk3dVH2JQEWLFu655vlYVeiKjlFb-ViKNv4iq8w_Kk3lmkS9IDvDOGhrDYiz9PoHKEO2Lhg9yqw1-831SJzzvMcKOewzuYSro2tv-0vqD6nlZsCelXsYOwJo88uRlntOid_o/s320/20230724_162751278.jpg" width="320" /></a></div>The youngest daughter got hired at NetJets this year. So, the two oldest daughters had to stop by their booth to brag about their little sis - and score some "swag."<br /><br />This is a fairly new aircraft to AirVenture. It's the SW-51 all carbon fiber aircraft.<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTZzamJnOFl6NM1fhEqx45Na4E07_I2-NQMZe0eavgyrAzJndeUEHX9MdZQBVDfNs1dMMz178pDcARwTcImugCa03Bzp7rfYOObqIoYjLun9_rWORZqxheBpTG0ZIIw6LR5T4Ux8h1n6HjxzzCSiJ6PaIsJykL5umOdiXZuj8RMXWqGUyB5B1oSSD0jGpY/s1479/20230725_184012430.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="832" data-original-width="1479" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTZzamJnOFl6NM1fhEqx45Na4E07_I2-NQMZe0eavgyrAzJndeUEHX9MdZQBVDfNs1dMMz178pDcARwTcImugCa03Bzp7rfYOObqIoYjLun9_rWORZqxheBpTG0ZIIw6LR5T4Ux8h1n6HjxzzCSiJ6PaIsJykL5umOdiXZuj8RMXWqGUyB5B1oSSD0jGpY/s320/20230725_184012430.jpg" width="320" /></a></div>When you walk up to the plane you can see every rivet, every skin line and every fine feature of the plane's surface. But, it's all fake! It has all been meticulously carved into the molds used to make the carbon fiber pieces of the plane. It's pretty incredible to see and comprehend!<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0lXuUWapHWIszvaKgb7VcHX_DkGpAGHOKmdaqnFv6G6lCXyb8rjULQcWc4z2TQUyRLz3tWH11bj8GJvxOsXNZ9s3kVMIxR3rBGVcJOrb8BKUQxXGjDr7xZVY1Grhbl4VrHxlTkiqFdTXUDHJ_nx5tIw-dmQeQvGHJ3PRHEOwphUJX550nOv1jkBMSUikb/s1479/20230725_184021609.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="832" data-original-width="1479" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0lXuUWapHWIszvaKgb7VcHX_DkGpAGHOKmdaqnFv6G6lCXyb8rjULQcWc4z2TQUyRLz3tWH11bj8GJvxOsXNZ9s3kVMIxR3rBGVcJOrb8BKUQxXGjDr7xZVY1Grhbl4VrHxlTkiqFdTXUDHJ_nx5tIw-dmQeQvGHJ3PRHEOwphUJX550nOv1jkBMSUikb/s320/20230725_184021609.jpg" width="320" /></a></div>The Bally Bomber is for sale!<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3YXimkx7NZngA-iF83T6vPUlMqYxuIwoClVHpAlRmIXQMpbxhoMa4yAnEnVYJHNla7NnMZnc77I0_ewNQMxrQ7d2lrUzacGLJzcZ607jGDWbddieXmjLng0OkQ7GqZNoyOAEEUYADhxAFRDAdleC10em0iBeD2dZfqbeTrBoNx2rKU8ybzXsi5DDvozhj/s1479/20230727_144711223.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="832" data-original-width="1479" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3YXimkx7NZngA-iF83T6vPUlMqYxuIwoClVHpAlRmIXQMpbxhoMa4yAnEnVYJHNla7NnMZnc77I0_ewNQMxrQ7d2lrUzacGLJzcZ607jGDWbddieXmjLng0OkQ7GqZNoyOAEEUYADhxAFRDAdleC10em0iBeD2dZfqbeTrBoNx2rKU8ybzXsi5DDvozhj/s320/20230727_144711223.jpg" width="320" /></a></div>It's a bird, it's a plane.......actually, it's an RV!! A DC-3 RV:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBPHyCttSY82DX4bPM0T3t6RYOwbIRV_0VW0M9ztscHaS0NL3MbFL8czaccONcajIabXbuQ3g-YkwIJhdBDZuHC0SXRN4oNeWRKx_-ugbq2TNIgo9Dq2tMl_2y9VrkFtOT41VOQXJ2I5CsS_MJYaeIZqchN2z_ApFCRog0REt_Cl_Q-KAnmGaZN0s5CVH1/s1479/20230728_175440670.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="832" data-original-width="1479" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBPHyCttSY82DX4bPM0T3t6RYOwbIRV_0VW0M9ztscHaS0NL3MbFL8czaccONcajIabXbuQ3g-YkwIJhdBDZuHC0SXRN4oNeWRKx_-ugbq2TNIgo9Dq2tMl_2y9VrkFtOT41VOQXJ2I5CsS_MJYaeIZqchN2z_ApFCRog0REt_Cl_Q-KAnmGaZN0s5CVH1/s320/20230728_175440670.jpg" width="320" /></a></div>Like every year, there were many awesome flight displays at the daily airshows. Here's a small sample with the only privately owned Soviet Mig-29 fighter that I've seen (it was also at AirVenture last year). This year it flew with the MiG-17:<br /><div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dxVLOvGt0e-unS41roKnMfQJC1rSzR9YuY9LVEPbgX0tgfIW0IsKbnSk8BN5MP3CtUvZDcoF3NMZXzeVulZRw' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div>And, these guys are always fun to watch:<br /><div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dw9_SGxn3c-RrpHlJtskuG56xhH1iM9_TEwEvjbttIGmTzP1ejENPaRSz23cs2lXJ-3cwVrKn5SSyT-DEmK7w' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div>And, here's some Buck Rodgers stuff for you:<br /><div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dwSvrk9TBau9U4VsaIp-0r1qh7zw7KwKbcPsWocz0VBa6b8caJ_hQ85JGWdU4jiY5QKIsYW-r3vjAtVd8IlOQ' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div>Again, going with the "Hot Mess" theme, this year's fireworks displays were more on the messy side than the hot side. The weather for Wednesday's show had low ceilings and a strong west wind, so everything was trying to blow to the east and a lot got lost in the clouds. Then, on Saturday, there was myriad technical glitches and the "Big Bang" didn't go off until after everyone gave up and started walking out. But, the fireworks are normally outstanding EVERY year! So, I'll give them a pass this year. Here is part of the Wed night finale: <br /><div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dwE_UAoF-c5-0lu7oSqwIL5pF9jJuPIZrKrTW-xrpJsZQZdi-TGVQWAqsi8k3WqMdCnzsxn2v_lGOVYiQhDuw' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div><br />Overall, AirVenture 2023 was another great show. We were down several of our normal "crew", but the show must go on! Everyone still had a great time!<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYOoVqfdMsinKyIzdAG4oe8xZja59fEjPbMq8ON_dUAFr3kOd1UPToxghJ5Uy2_UF-ciwiXZzxzMSov4ZVJny5JFrbV5IDWJuTr0T9isn6gBxJOpxrn9bWf1nAmWnTfs1BkGlJ968SDFbsO7_Z4PAowRMh_b0gjmSxHHSOycebYHSERwWFoe9tipfEGkgL/s1175/20230731_163727776.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="1175" height="247" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYOoVqfdMsinKyIzdAG4oe8xZja59fEjPbMq8ON_dUAFr3kOd1UPToxghJ5Uy2_UF-ciwiXZzxzMSov4ZVJny5JFrbV5IDWJuTr0T9isn6gBxJOpxrn9bWf1nAmWnTfs1BkGlJ968SDFbsO7_Z4PAowRMh_b0gjmSxHHSOycebYHSERwWFoe9tipfEGkgL/s320/20230731_163727776.jpg" width="320" /></a></div>See ya next year!<br />Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-4561663675008429701.post-58939216949607775172023-07-03T22:44:00.005-07:002023-07-04T09:17:20.377-07:00Fabricating More Prowler Parts, Builder Updates and Some Shop Projects. Hello Everyone,<br /><br />Happy Independence Day to each of you!<br /><br />I hope your summer is off to a great start! As for me, I managed a quick trip to WI in early June to open up my property there, get the grass mowed and open up the RV for the summer. So far, I only found one big problem there - a 50 amp breaker that failed. Otherwise, the RV and the property are in OK shape!<br /><br />Well, AirVenture is just around the corner! I'm finishing my last few days of work (day job) for the summer and looking forward to having most of July and August off thanks to two strategically placed weeks of vacay! We won't have as large of a "crew" at AirVenture this year - but most of the family will make it for a day, or two. As always, I'll have an update this fall with pics and vids from the "Big Show" this year.<br /><br />On a recent trip out of SFO, I got a pretty nice view of Lake Tahoe. This is taken from the south looking north. The airport you see is the South Lake Tahoe Airport and Emerald Bay is just to the west of that.<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAovRzPTj49GiR0Twx9qkSc7z-utuzr-k5RyTig39640P1j4RHiabjv38wsxMEhksJjDJJZh8ZUt9_-U6yHLlXx_9kAo489mfKbMaWqy8R-4AicFYoIiAi5rlVAxhCzya6v5TXQA6EMw9auR3Idaw_SywZRm1j9AZoVTregbt5FpJSAzEYFZTWIWiaVe4N/s2688/20230603_191433379.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="2688" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAovRzPTj49GiR0Twx9qkSc7z-utuzr-k5RyTig39640P1j4RHiabjv38wsxMEhksJjDJJZh8ZUt9_-U6yHLlXx_9kAo489mfKbMaWqy8R-4AicFYoIiAi5rlVAxhCzya6v5TXQA6EMw9auR3Idaw_SywZRm1j9AZoVTregbt5FpJSAzEYFZTWIWiaVe4N/s320/20230603_191433379.jpg" width="320" /></a></div>Time is short for me right now, but I'm gonna try to pound out this one last update before summer takes over all of my time. Here's what I have for this update:<br /><br /><u>Prowler Stuff</u><br />1. Engine Compartment Mock-up (Longerons and Bulkheads) - <br />2. Builder Update From Francis - <br /><br /><u>Non-Prowler Stuff</u><br />3. Pexto G-52 Sheetmetal Shear - <br />4. Finally Finished The Hardinge CNC Lathe - <br /><br />Let's get right to it!<br />
<br /><b><u>1. Engine Compartment Mock-up (Longerons and Bulkheads) -</u></b> I have been trying for years now to get a final solution set up for the Prowler FWF package using AutoPSRU's products. Stuart and Larry have built an engine mount and placed it onto a Prowler firewall. But, the progress has stopped waiting for me to get them set up with a Prowler engine compartment. We need to have a close approximation to the engine compartment that I want to use, so that we can figure out exhaust routing, a possible cooling inlet and a few other structural issues.<br /><br />Well, the first steps to getting an engine compartment built (assuming the firewall is in place) are to get the forward engine compartment bulkhead formed and make the longerons (and associated brackets) that run from the firewall to the forward engine compartment. I recently had a request from Vaughn for both of these items - which I showed in a previous update. The forward bulkhead for my iteration of the Prowler is "complicated" and I'll cover that in a minute. But the longerons are pretty straight forward. <br /><br />While I was in that "mode" of forming the longerons for Vaughn, I used the last of the channel I had to make up a set of engine compartment longerons for the FWF mock-up. Actually, one of them that I am using for the mock-up set was one that I accidentally broke a flange on while forming them for Vaughn. When I got down to the last 2 longerons, I didn't have enough 2" channel left to make full length longerons. But, I did have some pieces that I could put together and make a couple longerons that are good enough for an engine compartment for the FWF mock-up. So, I made up some 2"OD channel and riveted the pieces I had together. Then, I shrunk the flanges to make the last two longerons. Here's one side of these:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfD0P4DaeSWgYmq2_2gisXUkGHCNmly0aLzdtGDAO5Xz1hjr8u1IVamiFGKFUjw-nfhT4hfWGpgfGvsJRNI3fqUMGiuwwSj8MGaB1VIx4t8YYyGdIAaPTCsW1VNSzcUpjHNFr0Ubw6sEnOkAVDksGEqZIW6b739Sz_o6eUuO1NeUz9FJJ2aoG-_An8QiDI/s1512/20230227_041745078.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1004" data-original-width="1512" height="212" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfD0P4DaeSWgYmq2_2gisXUkGHCNmly0aLzdtGDAO5Xz1hjr8u1IVamiFGKFUjw-nfhT4hfWGpgfGvsJRNI3fqUMGiuwwSj8MGaB1VIx4t8YYyGdIAaPTCsW1VNSzcUpjHNFr0Ubw6sEnOkAVDksGEqZIW6b739Sz_o6eUuO1NeUz9FJJ2aoG-_An8QiDI/s320/20230227_041745078.jpg" width="320" /></a></div>
And, the other side:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXD5X-RDiI8z9dEEapxqgFTW1k8JcWolZBAbjljfOK6e3NhonNeZs_Qz08ZGTlY-AhQvXfEC19vlwpUbuzCBfEvJ6Nttt9kV99Cb8ZFLMhpaB8EYk8SutGr55YWtNSA_zD774EqnFd_8RdZmLJrUS1SI_805W0-xVyysA0Y-7ab4170FX8uLxjwooPU9Ro/s1512/20230227_041826211.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1102" data-original-width="1512" height="233" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXD5X-RDiI8z9dEEapxqgFTW1k8JcWolZBAbjljfOK6e3NhonNeZs_Qz08ZGTlY-AhQvXfEC19vlwpUbuzCBfEvJ6Nttt9kV99Cb8ZFLMhpaB8EYk8SutGr55YWtNSA_zD774EqnFd_8RdZmLJrUS1SI_805W0-xVyysA0Y-7ab4170FX8uLxjwooPU9Ro/s320/20230227_041826211.jpg" width="320" /></a></div>
Here are all 6 longerons that will be used for the FWF mock-up engine compartment:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjnl4bmas9R168vcROUxcNQ1CbGuhP5YJGtzwAzaOscN_TVcewb02P-ohMa5HNfvRRBIZNNNxxYR18IcEAxB-RLffvN-JNnriJvHkJkSMDpQqmcRNH95JgAXeTff39NTkNUB26fV_xqA6CfpqUpO3EJZWfZcplPegYY_kP85t1ESBaDzBAegoGbCQnD0WWN/s960/20230227_041946189.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="911" data-original-width="960" height="304" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjnl4bmas9R168vcROUxcNQ1CbGuhP5YJGtzwAzaOscN_TVcewb02P-ohMa5HNfvRRBIZNNNxxYR18IcEAxB-RLffvN-JNnriJvHkJkSMDpQqmcRNH95JgAXeTff39NTkNUB26fV_xqA6CfpqUpO3EJZWfZcplPegYY_kP85t1ESBaDzBAegoGbCQnD0WWN/s320/20230227_041946189.jpg" width="320" /></a></div>
OK, that was the easy part. Now, about the forward engine compartment bulkhead (the part that I refer to as the "horse collar"). Here's the issue - I can't use the existing form block to make the horse collar, because in order to fit the AutoPSRU reduction gear into the engine compartment, I had to make it 1" taller than the ones that all the previous Prowlers have used. What this means is that I have to make a new form block that I can use to fabricate a horse collar that will work with the AutoPSRU gearbox.<br /><br />That, by itself, is pretty straight forward and can be done pretty easily if you're just fabricating one horse collar. But, the issues with fabricating this part get bigger when you think about trying to fabricate horse collars in a production environment. What technique is used to form the part, directs how you make the form block. The horse collar is actually a pretty complex part to form. The outer flange of the part varies in width and the angle it makes with the flat part of the bulkhead changes as you move from top of the part to the bottom. That makes it tougher to get it done right.<br /><br />I would like to form this part using 2024-T3 in my rubber pad press. The problem with that is, the outer flange would have to be "tabbed" in order to form it correctly in the press. The tabbed flange would not be a problem if it was permanently riveted to skin. The problem there is, all the panels of the engine compartment are removable and the tabbed flange of the horse collar would not be rigid enough to give the engine compartment the necessary strength it needs.<br /><br />I started down the road to making the new form block for the horse collar. I bought a piece of 1" thick HDPE sheet. Then, I printed the outline of the flat portion of the horse collar from my CAD drawings and traced them onto the material:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7OZIhZ_WdibncGMj3gdKzCGNVBWkvDNYa9yIaJBMrXPTZ0zsLvP7DRTKk3YRe-oO6WwUfde76fQpRAMvZ-GKaGKU_6ES-e40YX49i_-L4d5qRd20TYx-7WjC1ynJwTAoJZYfNtNTIdGr2OakJcsWXVpgjTGk6ApbXyph6cTKlRyq_UxQRt3CyFy6E0Uvl/s1438/20230225_184116751.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="882" data-original-width="1438" height="196" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7OZIhZ_WdibncGMj3gdKzCGNVBWkvDNYa9yIaJBMrXPTZ0zsLvP7DRTKk3YRe-oO6WwUfde76fQpRAMvZ-GKaGKU_6ES-e40YX49i_-L4d5qRd20TYx-7WjC1ynJwTAoJZYfNtNTIdGr2OakJcsWXVpgjTGk6ApbXyph6cTKlRyq_UxQRt3CyFy6E0Uvl/s320/20230225_184116751.jpg" width="320" /></a></div>Here it is in the mill:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwhLNxiW5FaXCNSOhEV2qrhDQBI9HPK6-apgggu4qU4d4cB6v7HiT_KRZQDKF5BoYu5qXJ0OlRrRbxGqz5ODs4_5YRfr1JJZ8cT397pcdVBZeCsPMw7PXWKEJ7BXeVxtHMzm5isJkfzRQTvq023B0DgCs-BeNouPnocCO0lNPkZjnS_KM6tGzCtReSbJzX/s1420/20230225_184216721.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="715" data-original-width="1420" height="161" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwhLNxiW5FaXCNSOhEV2qrhDQBI9HPK6-apgggu4qU4d4cB6v7HiT_KRZQDKF5BoYu5qXJ0OlRrRbxGqz5ODs4_5YRfr1JJZ8cT397pcdVBZeCsPMw7PXWKEJ7BXeVxtHMzm5isJkfzRQTvq023B0DgCs-BeNouPnocCO0lNPkZjnS_KM6tGzCtReSbJzX/s320/20230225_184216721.jpg" width="320" /></a></div>
Both halves traced onto the one sheet of HDPE:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi9XDATwsXjrJS1rjuhO0r0D-tpfe5hz0-cyE8e_xgkSjbH5BlzH03IQ0SX5MjQkt-3mgzMUdvsQFHJmp3Jo9VabeUVknfZi9LiufGHedGbK3G8i59IAXQc37d2V4ZYJnVTn5ZMsjYb2DshJVSZMF4wyfNXSJ131tezmIT7oVrXICfqXVskU_FTI_Y6Kilu/s1467/20230225_190254407.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1467" data-original-width="1102" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi9XDATwsXjrJS1rjuhO0r0D-tpfe5hz0-cyE8e_xgkSjbH5BlzH03IQ0SX5MjQkt-3mgzMUdvsQFHJmp3Jo9VabeUVknfZi9LiufGHedGbK3G8i59IAXQc37d2V4ZYJnVTn5ZMsjYb2DshJVSZMF4wyfNXSJ131tezmIT7oVrXICfqXVskU_FTI_Y6Kilu/s320/20230225_190254407.jpg" width="240" /></a> <br /></div>For now, that's a far as I've gotten. I still have to decide how I'm going to make these in production so that I can make the correct form block for that. Stay tuned.<br /><br />The alternative to form this part is to make it from 2024-O material - pressed and formed with a solid outer flange. But, then it would have to be heat treated. Heat treating is another logistical and financial step required to make each of these parts that I'd rather not have to do. Right now, I'm leaning toward forming the part from 2024-T3, tab the flanges, but then go back and rivet in a "liner"onto the part that would make the outer flange act like a solid flange. I'm still experimenting with this. More to follow.<br />
<br />Beyond the horse collar, there is one other bulkhead that is needed right behind the prop spinner. That bulkhead will need to be formed in the same manner that I decide to make the horse collar - because it too has a flange with a varying width and angle. This part is the same size that it has been for all Prowlers up to now. Here is the form block for that part that came from the original Prowler Aviation:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKMcL7ZEVfGBWXhPyE3Y26iA8uxFygwNgfPEjzuB2Ri4hJhS58cqysojBFKVhHgT2CSDdz4loNmfqA6cOHJGrpCgSCBsoX4rj_er0jmOU5SO2Y1vch28-djAF1_YzANGKr0Tsl--2QK8BBJ7EbFYPulkLXvJnMtLwNWkeCLqGPlyssS45qtJscsTFU5e4S/s1271/20230324_014449451~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="824" data-original-width="1271" height="207" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKMcL7ZEVfGBWXhPyE3Y26iA8uxFygwNgfPEjzuB2Ri4hJhS58cqysojBFKVhHgT2CSDdz4loNmfqA6cOHJGrpCgSCBsoX4rj_er0jmOU5SO2Y1vch28-djAF1_YzANGKr0Tsl--2QK8BBJ7EbFYPulkLXvJnMtLwNWkeCLqGPlyssS45qtJscsTFU5e4S/s320/20230324_014449451~2.jpg" width="320" /></a></div>I make a cardboard template for the blank that will need to be made using this form block:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRE8UoFbmY7sCcoQef5LdVnA3RSsP2GVJUoAwePEaeoDdrFS1_hVFnb4NxQLiS5EtuenYNBxAMnFk32saeWlFWweRn6pmeDn720mTfrFkexyTMhavttLSI3kOzhE_WP2naxRLDHa3s6wQIf_ibw0XIMWM-3yV8418t6esYu6Zfc3VmcVBqwx3SSPic5xGJ/s1421/20230324_160510596~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="775" data-original-width="1421" height="175" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRE8UoFbmY7sCcoQef5LdVnA3RSsP2GVJUoAwePEaeoDdrFS1_hVFnb4NxQLiS5EtuenYNBxAMnFk32saeWlFWweRn6pmeDn720mTfrFkexyTMhavttLSI3kOzhE_WP2naxRLDHa3s6wQIf_ibw0XIMWM-3yV8418t6esYu6Zfc3VmcVBqwx3SSPic5xGJ/s320/20230324_160510596~2.jpg" width="320" /></a></div>Making both these bulkheads will be on the top of the list, when I get back into the shop this fall. Stay tuned.<br /><br /><b><u>2. Builder Update From Francis -</u></b> Once again, Francis has been busy doing awesome work on his Prowler project. He has shared the following pics with me. I will do my best to explain what I think the work is that he's been accomplishing.<br /><br />Last March, Francis wrote me asking about forming the leading edge of the wing skins. I sent him the dimensions of the apparatus that George made for forming the wing skin leading edges. Here's the tool that I got from George for forming them:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhOtGwnrg0poOR0MnWc6ZtXYoWR1WMUglZ3wW_MRxqs4feaWPftqRx1l4IsIZfOQYP58O0xUuwb0EvsQ2uBTYjjkjk-lCpz2n2qq6rarkQ9sz5tZbiBZ_NnNzo2-vIL1hTg6Aa7eaePuyqQvUJxxC0KKOdGLhjF9yil38XrdyykYuT_oiE1ojmI_O4sJDPs/s2335/PXL_20230116_224144835~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="549" data-original-width="2335" height="75" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhOtGwnrg0poOR0MnWc6ZtXYoWR1WMUglZ3wW_MRxqs4feaWPftqRx1l4IsIZfOQYP58O0xUuwb0EvsQ2uBTYjjkjk-lCpz2n2qq6rarkQ9sz5tZbiBZ_NnNzo2-vIL1hTg6Aa7eaePuyqQvUJxxC0KKOdGLhjF9yil38XrdyykYuT_oiE1ojmI_O4sJDPs/s320/PXL_20230116_224144835~2.jpg" width="320" /></a></div>It's essentially two 9' long 4x4's with blocks mounted to one of the 4x4 on each end to prevent over clamping. I assume that he opened the clamp as wide as possible and then (with a helper) wrapped a flat sheet of skin material like a taco and stuffed it into the clamp. Then, it would have been positioned correctly and the nuts on the long threaded rods would have been turned down to clamp the material and form the leading edge bend.<br /><br />In the end, Francis decided that he wanted to try to use the vacuum forming technique. I have also used that technique to form the leading edge of the vertical stab skin in the past and it is a very effective way to make long, relatively sharp bends in 2024-T3. It really is amazing how much force a normal vacuum cleaner can make when the small differential pressure is leveraged properly!<br /><br />It looks like, to get started, Francis used various boards and metal to start to get the aluminum skins to form around a piece of tubing with the correct size radius that he wanted for the leading edge of the skins:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhD-y_gTd8etRJu91AFZfZgwT0nxJvtl-DqyHwtuCo934pWVZaNbaIJprLDXiAfZ4_S6ga_ISHe9hqBcnfEKrEL3r-D-7y_TXAry289D_n7SqmbJlO4-e3pKci5LIhGwsXjsrKoHXc-6e9Az2ilxKn20qby_0x67wANvUOnvi6CWNJ6rFNf77rEd6O9QlnT/s1600/IMG-20230313-WA0003.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="777" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhD-y_gTd8etRJu91AFZfZgwT0nxJvtl-DqyHwtuCo934pWVZaNbaIJprLDXiAfZ4_S6ga_ISHe9hqBcnfEKrEL3r-D-7y_TXAry289D_n7SqmbJlO4-e3pKci5LIhGwsXjsrKoHXc-6e9Az2ilxKn20qby_0x67wANvUOnvi6CWNJ6rFNf77rEd6O9QlnT/s320/IMG-20230313-WA0003.jpg" width="155" /></a></div>
Then, to apply more force and get it to be more uniform along the bend, he put several boards on the top of the skin and used a bottle jack to press the skins down along the piece of tubing:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxBi1ckj3Q1fVohlM7AFT2Un9VFickjDAtWZxJf5MouYgf6kRzRw0uaS2gEBZ671zSyrkGQen35pHIcY_pKnAq2Qjzy6cuNvmpPf1HUkJkI8iJt8MC4yS7jE394Z9R2IFLVlVrqAv3H1WhWMEpYrBFHG6_PIv5vydOz89ZZddjxN-5EqlmbUocJBtZrT72/s1600/IMG-20230313-WA0000.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="777" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxBi1ckj3Q1fVohlM7AFT2Un9VFickjDAtWZxJf5MouYgf6kRzRw0uaS2gEBZ671zSyrkGQen35pHIcY_pKnAq2Qjzy6cuNvmpPf1HUkJkI8iJt8MC4yS7jE394Z9R2IFLVlVrqAv3H1WhWMEpYrBFHG6_PIv5vydOz89ZZddjxN-5EqlmbUocJBtZrT72/s320/IMG-20230313-WA0000.jpg" width="155" /></a></div>
With that done, he could tape the ends, hook up the vacuum and pull the material down around the tubing to complete the forming of the leading edge:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgK2a10-8-ag0flTaWq26XBS1zyDrFfEsdNrDiJhjJdmBLZhXEHyAk4i7A7nVVZSWDYIZ1fLXPbjTrPyuqyopnOkXpsF5aerFuNxov1BV0a6FpbuxdPR4r9urGE3urut6mcG9ihc5o6hNh2yZnIDKn7RYTwUAb4lE6RAF-qK8oNGA-1QtdmXnIkTEEyHrfR/s1600/IMG-20230313-WA0002.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="777" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgK2a10-8-ag0flTaWq26XBS1zyDrFfEsdNrDiJhjJdmBLZhXEHyAk4i7A7nVVZSWDYIZ1fLXPbjTrPyuqyopnOkXpsF5aerFuNxov1BV0a6FpbuxdPR4r9urGE3urut6mcG9ihc5o6hNh2yZnIDKn7RYTwUAb4lE6RAF-qK8oNGA-1QtdmXnIkTEEyHrfR/s320/IMG-20230313-WA0002.jpg" width="155" /></a></div>
With the skins formed, the next step was to fit them and get them cleco'ed to the wings. Here is the right hand inboard skin (looking at the top):
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpFAku-XCoYmPDfN7SGF-nx67rCKdsCtG91edo6mUtHWEmZNQ1LJOwjlciG84z1daUm5Y_doQ7GzWVSr4UkPm-NIZnZ8pqDbT3uEh1slnSbvMKvC5-x6otZn84cTvvF3wRbGlphhqfbq90qEVa4NTNQti3e6opT2_AQX8x4-DAXgWkUFk15VaCGH37VofA/s1600/IMG-20230430-WA0005.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="777" data-original-width="1600" height="155" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpFAku-XCoYmPDfN7SGF-nx67rCKdsCtG91edo6mUtHWEmZNQ1LJOwjlciG84z1daUm5Y_doQ7GzWVSr4UkPm-NIZnZ8pqDbT3uEh1slnSbvMKvC5-x6otZn84cTvvF3wRbGlphhqfbq90qEVa4NTNQti3e6opT2_AQX8x4-DAXgWkUFk15VaCGH37VofA/s320/IMG-20230430-WA0005.jpg" width="320" /></a></div>
The right hand skin looking at the lower side:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiBHmb25eqIuUVvOJBL7FDAXjzSneBNnOV-9I0faJG7xH0VNvepe3usLAA7xoEENmu-i2VSaq73-R8jLXXILX0Nhb8Ne-ZeLdM42uBOlBR-N2ENxoCmyW1C1V8Kev251x3sbEaCwonDa1eS-U8C3IyW6yiOBwmWBHJkr_3vm91eN7-o3OtrQYHQGCbYrvp/s1600/IMG-20230430-WA0004.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="777" data-original-width="1600" height="155" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiBHmb25eqIuUVvOJBL7FDAXjzSneBNnOV-9I0faJG7xH0VNvepe3usLAA7xoEENmu-i2VSaq73-R8jLXXILX0Nhb8Ne-ZeLdM42uBOlBR-N2ENxoCmyW1C1V8Kev251x3sbEaCwonDa1eS-U8C3IyW6yiOBwmWBHJkr_3vm91eN7-o3OtrQYHQGCbYrvp/s320/IMG-20230430-WA0004.jpg" width="320" /></a></div>
The left hand inboard skin looking at the lower side:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRXww9ygOmZX8ftHePJVPBMqtI31T1rodP-LIaymQ_U-1NUNA7vY7sb2Z7sEvV261SCpsSqphtC7wZ_U2K4hxD7njhywb2xji57UJyYqA0IY7GTeMtt6ncFHNOddbgKP7t7jMgT_xCdJLg1wuSg5HSaAvDarNu39F9q2VL0WScLUou1uZPSXptzRH8s2tu/s1600/IMG-20230430-WA0003.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="777" data-original-width="1600" height="155" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRXww9ygOmZX8ftHePJVPBMqtI31T1rodP-LIaymQ_U-1NUNA7vY7sb2Z7sEvV261SCpsSqphtC7wZ_U2K4hxD7njhywb2xji57UJyYqA0IY7GTeMtt6ncFHNOddbgKP7t7jMgT_xCdJLg1wuSg5HSaAvDarNu39F9q2VL0WScLUou1uZPSXptzRH8s2tu/s320/IMG-20230430-WA0003.jpg" width="320" /></a></div>
And, the left and right upper side of both inboard skins cleco'ed in place:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgoMicd0bWiKFtGYFajUci-vleuTSzykeA9qbMvWCq3zevePWqiHp6HjuWycUGkmkMMgqWDziLVanyqGfNcPc7uI-YxPSQH5HCdZ6mK4GxuK0TvwRHt8vD3eJaeTon4XD3xA8tcl20HK0we5Pa5-5X461ZGYeYj1NoBpGM_zSoDOQWOn-zzpjPK9klddzDY/s1600/IMG-20230430-WA0002.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="777" data-original-width="1600" height="155" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgoMicd0bWiKFtGYFajUci-vleuTSzykeA9qbMvWCq3zevePWqiHp6HjuWycUGkmkMMgqWDziLVanyqGfNcPc7uI-YxPSQH5HCdZ6mK4GxuK0TvwRHt8vD3eJaeTon4XD3xA8tcl20HK0we5Pa5-5X461ZGYeYj1NoBpGM_zSoDOQWOn-zzpjPK9klddzDY/s320/IMG-20230430-WA0002.jpg" width="320" /></a></div>That is outstanding progress! I like the covering on the joystick! I wonder if it is there to protect the joystick, or someone's head?<br /><br />Next topic. Francis liked the uplock system that Ray designed using aftermarket automobile door latches. They really are a great choice for this application. (1) They are designed to hold a car door closed under pretty extreme forces; (2) They must be aligned when installed, but they sort-of self align while closing each time; (3) they are relatively inexpensive; and (4) they are fairly compact.<br /><br />Recently, he emailed Ray and I to ask about mounting the stud in the axle yokes that work with this uplock design. Ray was able to answer his questions and it looks like he got a successful installation. I believe what Francis is capturing in this first few pics is his set-up for fixturing a hardened drill guide in the correct location to drill the hold for the uplock stud in the end of the axle yoke. He clamped the end of the yoke to one flange of a large aluminum angle and then clamped his drill guide to the other flange:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIiXPSlZrmgGuLScf6g6FlU-ha_O23OJwOtgY05I5ukzKqXKojYdQIB5naoHD_4ldvToV0U2yX7hXvZtSur4puldqkxDKtaHSRmkTvGDeGBfrAsPbImpu8TiD3knrchDYZMIbfNy-j2gmMW_tu5ShGpPZe2pw5S8cdbVAg6yLUhQt5-xskGqGl-eIpDzHy/s1412/20230620_171222.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1412" data-original-width="686" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIiXPSlZrmgGuLScf6g6FlU-ha_O23OJwOtgY05I5ukzKqXKojYdQIB5naoHD_4ldvToV0U2yX7hXvZtSur4puldqkxDKtaHSRmkTvGDeGBfrAsPbImpu8TiD3knrchDYZMIbfNy-j2gmMW_tu5ShGpPZe2pw5S8cdbVAg6yLUhQt5-xskGqGl-eIpDzHy/s320/20230620_171222.jpg" width="155" /></a></div>Same thing, just a different angle:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-JFw7Li3_JGi5c1G-8wnHkOnz0RlgNb7nain-9MsVu1vCdUJj8OSNXMn_jB4ZJ9G2H_7GUyLoavo21uDHkruCaAfX8U8x9hRN3xAORKpdUgCOyoFWUr70RZ0Vr5mXGBcBY9v3JhL8JANQZoEMdeErFc5ZG38XZ-IPUldKU5KHt48PXjwXzHJfOJwfPLuu/s1412/20230620_171229.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1412" data-original-width="686" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-JFw7Li3_JGi5c1G-8wnHkOnz0RlgNb7nain-9MsVu1vCdUJj8OSNXMn_jB4ZJ9G2H_7GUyLoavo21uDHkruCaAfX8U8x9hRN3xAORKpdUgCOyoFWUr70RZ0Vr5mXGBcBY9v3JhL8JANQZoEMdeErFc5ZG38XZ-IPUldKU5KHt48PXjwXzHJfOJwfPLuu/s320/20230620_171229.jpg" width="155" /></a></div>
After drilling, he tapped the hole for the stud:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPswQ3o3ortdB69WyxlIg9Tub7avU54db0EtDkK70Mhny4ANGsWKmG1IYROxJ2AiHlA72d8QgOmda_uJeeAd6znr-YOF46lCBoNXgxu62lQ1OscTcSvCfgectJLra_D8YYs_99kTBW58g9xz5hZ_oZIW54KkfBw4RYV0q73G6Vgv4g7-ql5UZ8VHk51-cW/s1412/20230620_172829.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1412" data-original-width="686" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPswQ3o3ortdB69WyxlIg9Tub7avU54db0EtDkK70Mhny4ANGsWKmG1IYROxJ2AiHlA72d8QgOmda_uJeeAd6znr-YOF46lCBoNXgxu62lQ1OscTcSvCfgectJLra_D8YYs_99kTBW58g9xz5hZ_oZIW54KkfBw4RYV0q73G6Vgv4g7-ql5UZ8VHk51-cW/s320/20230620_172829.jpg" width="155" /></a></div>
Here it is with the uplock stud installed:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjEkVsmqfNc2Qg2PY8T81_CLjn043fAQl3qKH8zRC73-5JZZia4XzaFiY5dhhlKplF_-o2l0w9WPptUqT8yhjb4NDAUNeSKFEcnfN-IStqiBOrFPgZkqAeTPDp0r_VTpTy-lwW6zF9LSFax4gDhbbbR7U9zGfCZ9VCbHnLkV_Djfniq6q98MfEbIK_F0ly/s1412/20230620_173518.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="686" data-original-width="1412" height="155" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjEkVsmqfNc2Qg2PY8T81_CLjn043fAQl3qKH8zRC73-5JZZia4XzaFiY5dhhlKplF_-o2l0w9WPptUqT8yhjb4NDAUNeSKFEcnfN-IStqiBOrFPgZkqAeTPDp0r_VTpTy-lwW6zF9LSFax4gDhbbbR7U9zGfCZ9VCbHnLkV_Djfniq6q98MfEbIK_F0ly/s320/20230620_173518.jpg" width="320" /></a></div>And, here is the latch placed over the stud roughly like it will sit in the gear well:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXFH0tshpy1uV9CaH68wQqr2KfOkGI6SMZ6SSsh1cyrRCqZqYqANuoh09BJNf1Ava44XSEzxeWckznkdNbtwe0sVPzlvwVg077a2TLfuzcta5Y3bYYWZMCVqZBOoJwMxo345wb1kA0zULowQAVf4jq89Q_1e_8oUhXDRkN0NWOHEstQqEZhi_O1AozehRW/s1412/20230620_173539.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1412" data-original-width="686" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXFH0tshpy1uV9CaH68wQqr2KfOkGI6SMZ6SSsh1cyrRCqZqYqANuoh09BJNf1Ava44XSEzxeWckznkdNbtwe0sVPzlvwVg077a2TLfuzcta5Y3bYYWZMCVqZBOoJwMxo345wb1kA0zULowQAVf4jq89Q_1e_8oUhXDRkN0NWOHEstQqEZhi_O1AozehRW/s320/20230620_173539.jpg" width="155" /></a></div>Nice work! Soon, we should see pictures from Francis of his landing gear struts mounted in the wings!<br /><br />Actually, maybe he already has!?!? Because, this next pic slows the
marking paint that he put on the ends of the anti-torque links:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8uChdvAgUiDZx0vkFzBL8HxSERwKD-Ob6zOnFpBWiuStQ4l1eGAD7anaedhPwRXKfwVsccCgpXgfu8JPcugIT631RvP_fmgCikhWKwwpsRZMRVprrP9Wf2bsy23TC307C5C7nstOAd75iAc6N3yvZO2CyK8ef1PU1oLbKMVsYbRsA3KACoAE1VRXrEEgx/s1412/20230620_173741.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1412" data-original-width="686" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8uChdvAgUiDZx0vkFzBL8HxSERwKD-Ob6zOnFpBWiuStQ4l1eGAD7anaedhPwRXKfwVsccCgpXgfu8JPcugIT631RvP_fmgCikhWKwwpsRZMRVprrP9Wf2bsy23TC307C5C7nstOAd75iAc6N3yvZO2CyK8ef1PU1oLbKMVsYbRsA3KACoAE1VRXrEEgx/s320/20230620_173741.jpg" width="155" /></a></div>
And, it looks like he used this marking paint to leave a mark on the inside skin the of upper side of the wing so that he would know where that point on the anti-torque links would need more room to keep from hitting the skins. Then, it looks like he pressed some aerodynamic "bumps" that he is going to place into the upper wing skins so that the MLG struts will fit without pushing up on the wing skins. Have a look:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvci0KQyKlw6WnY3OUNVZlCrpQgAnUGggm7u2dVLw9cmzXJHb3G8in8gTD60X5wfWTwS9cDMcP7OoVLaooLBLJWPLy_okdT3b7suykuSUW6SWJh7qLypznWCBqJEs0Bke76tDPGL8BoThMAZHDY_jOXiIXt8QEupveVGdkSgOVciyTzk0I0_BFc6KqjUco/s1412/20230620_173750.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1412" data-original-width="686" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvci0KQyKlw6WnY3OUNVZlCrpQgAnUGggm7u2dVLw9cmzXJHb3G8in8gTD60X5wfWTwS9cDMcP7OoVLaooLBLJWPLy_okdT3b7suykuSUW6SWJh7qLypznWCBqJEs0Bke76tDPGL8BoThMAZHDY_jOXiIXt8QEupveVGdkSgOVciyTzk0I0_BFc6KqjUco/s320/20230620_173750.jpg" width="155" /></a></div>It looks like he has already roughed in a hole in the skin for the anti-torque links to go into. Here is a closer view. It looks like he also made himself some kind of a form block and press plate to make those "bumps". Nice work!
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnn2dErFngUT5RyDU0CW8QKA6BIyCD6XIYbwyPC2BRIpT1GBqUEiY0bSVKwOvd5JntOhT3xleIlZL9HBTO8uExniK9rLiOwaKrTuVBFUMbZM2FzdG7PQmRe-wfPUhyFtyqwdLCCpUEOa9TStRTE5yNrdIQnAUR2Qy7E6kfsGg3-D2kRO_N1qzsoZ0ODOI9/s1412/20230620_173737.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1412" data-original-width="686" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnn2dErFngUT5RyDU0CW8QKA6BIyCD6XIYbwyPC2BRIpT1GBqUEiY0bSVKwOvd5JntOhT3xleIlZL9HBTO8uExniK9rLiOwaKrTuVBFUMbZM2FzdG7PQmRe-wfPUhyFtyqwdLCCpUEOa9TStRTE5yNrdIQnAUR2Qy7E6kfsGg3-D2kRO_N1qzsoZ0ODOI9/s320/20230620_173737.jpg" width="155" /></a></div>
As always, thank you for the updates, Francis. I really appreciate you sharing this info with me so that I can share it with the rest of the folks interested in Prowler construction.<br />
<br />That's it for the Prowler related stuff in this update. The info below is not directly related to Prowler building. So, feel free to depart the AOA now if you're not interested in some of my shop projects.<br />
<br />
<b><u>3. Pexto G-52 Sheetmetal Shear - </u></b> I have had this Pexto sheetmetal shear for well over a decade now and for all that time, it has not been usable. I got this shear pretty inexpensively, but it was set up to be used as a pneumatic shear and it was not operating. This is what it looked like when I got it off the trailer and into the shop: <br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFlkuyI4pr52B6_Pbhs_NxXRYrn4byTa0o-99nJ4diovYVDR_LPjy5ruS4XWsxMTYONv6HW66vp0gxviAa25lEjARkOS7C59zoT6lpTZXnd_yOAxMeWINlUQ9_POSVCfOoa5iZJ8rz0F4hVd3GphkUrjIOMYLY0pjj8L9Ra1XJVqvactO3Tk4EApMuaPjH/s744/IMG_20140608_071155_231.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="744" data-original-width="703" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFlkuyI4pr52B6_Pbhs_NxXRYrn4byTa0o-99nJ4diovYVDR_LPjy5ruS4XWsxMTYONv6HW66vp0gxviAa25lEjARkOS7C59zoT6lpTZXnd_yOAxMeWINlUQ9_POSVCfOoa5iZJ8rz0F4hVd3GphkUrjIOMYLY0pjj8L9Ra1XJVqvactO3Tk4EApMuaPjH/s320/IMG_20140608_071155_231.jpg" width="302" /></a></div>Right after getting it into the shop, I stripped nearly all of the pneumatic operating components off of the it and started laying plans to rebuild it as a manually operated shear (actually, foot operated) - which is the way it was originally designed and intended to be used. More on that in a bit.<br /><br />Well, it didn't take long to figure out that this thing was HEAVY and moving it was gonna be a pain. Things in my shop need to be mobile so that I can shuffle things around if I need to. So, the first time I needed to move it out of the way, I went all-in and built a mobile platform for it and mounted it on the mobile base. I'm pretty sure I covered that in an update at some point - a long time ago. Here is what it looked like after installing it onto the mobile base:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjE0TQg7_RH0awqmhJiabiCQK3MgCEgjCd0jOCd8hQNkp1qGlT8spRCNaQxjkqL9rt9u40RhEdIriqgkL-me2gPU1sEX3IJx1S2R6gWj0sB0nC3Zgv7UMILX4YctKJ7C_F7Sp5hiMtxM3aIDgZF8_LlKsLWlpnEGd2lLhJEII3JwXb5ad2Wq5ODmfuDdZgt/s1078/20151218_121159.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="806" data-original-width="1078" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjE0TQg7_RH0awqmhJiabiCQK3MgCEgjCd0jOCd8hQNkp1qGlT8spRCNaQxjkqL9rt9u40RhEdIriqgkL-me2gPU1sEX3IJx1S2R6gWj0sB0nC3Zgv7UMILX4YctKJ7C_F7Sp5hiMtxM3aIDgZF8_LlKsLWlpnEGd2lLhJEII3JwXb5ad2Wq5ODmfuDdZgt/s320/20151218_121159.jpg" width="320" /></a></div>At this point, I could move the shear around the shop but it was not much more than a huge paper weight. When it was converted to a pneumatic shear, the foot treadle (bar that you step on with your foot to operate the shear) had been removed (and was not anywhere to be found in the shop that I moved it out of). Also, the springs that allowed the blade on the shear to move back up after a cut were removed and gone. In addition to that, the clamp bar across the front had been modified and the original manual handles that clamped the material down to the table were yarded off and gone. So, all this was going to have to be replace. But, with what?<br /><br />During the last 10+ years, I have been doing Google searches and scouring equipment auctions and FleeBay for a similar cheap and "ratted out" shear that I might be able to rob parts off of. But, there just aren't any out there - at least not that I could find. So, I could never make any progress to get this project done. [Incidentally, I also found out that you can buy this exact same shear from Roper Whitney (they bought this line of shears from Pexto). The cost of one of these new, right now, is merely, roughly, about $20K!!] <br /><br />Well, this spring, I really needed to cut some 4 ft pieces of aluminum. And, I couldn't use this thing! Out of sheer frustration I just said: "I'm gonna make it work,-now!" The first step was to run up to the local steel place and buy some 1/2" x 2" flat bar to make the side arms for a new treadle. The pockets in that torque tube assembly were made for just that size steel. Here is the 1st piece I cut to make the new treadle:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjztpM6-hSBcb4fbSAEXLVLZPLIF9nbaaRkStzOGR6bqwMxFgeVMzM_eGNLpjqDgDCbOFi2Kxh5WG6zrJ4n03spASxaEsui9wryJWl0Z8DNL1cDFf-xvAPiMGdyQfaSLZrYVckR6UsvsV1sqhJwQ51Jd6ytdY_MrdTNRUDx6ZmG8VZF8HI1KV2L0FqMj00F/s1016/20230228_004451461.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1016" data-original-width="932" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjztpM6-hSBcb4fbSAEXLVLZPLIF9nbaaRkStzOGR6bqwMxFgeVMzM_eGNLpjqDgDCbOFi2Kxh5WG6zrJ4n03spASxaEsui9wryJWl0Z8DNL1cDFf-xvAPiMGdyQfaSLZrYVckR6UsvsV1sqhJwQ51Jd6ytdY_MrdTNRUDx6ZmG8VZF8HI1KV2L0FqMj00F/s320/20230228_004451461.jpg" width="294" /></a></div>
Here is the left side arm after fabricating it with the blade in the down (finished cut) position. Notice the "kink" in the arm that I had to make to allow this thing to work around the mobile base that I put it on. Unfortunately, I didn't think far enough ahead when I was making the mobile base that it might interfere with a future new treadle some day! Well, ya can't think of everything. Here it is:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhugpaQrh4rAhSWCETg-pJ7LLDh6fwgbNrnjJekBQQED3TiSB2evxteD3Ewge8mZBq1Y_RtQqIZ606S3tm6oHCNbFVj940-E4JnpaBNMK4R5vZr_Iz-OdsiKxY47Y9sdqS1dGcCu-Zq7KFg-IDJ79ppjNzuNzkgs5NqLIiKU_WxzZGlcJRHbQAie28evfpD/s1210/20230305_212607053.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="853" data-original-width="1210" height="226" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhugpaQrh4rAhSWCETg-pJ7LLDh6fwgbNrnjJekBQQED3TiSB2evxteD3Ewge8mZBq1Y_RtQqIZ606S3tm6oHCNbFVj940-E4JnpaBNMK4R5vZr_Iz-OdsiKxY47Y9sdqS1dGcCu-Zq7KFg-IDJ79ppjNzuNzkgs5NqLIiKU_WxzZGlcJRHbQAie28evfpD/s320/20230305_212607053.jpg" width="320" /></a></div>
Here is the left side arm in the up (before cut) position:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgwIM3q3iRrpPB4Y2TcqxB2wmcQrtadbMnOnAkaTmEIzOavPSH0ky9Gb-YydvbpWGVjDY0zo1_ISfRw7py2EN_xd1S56wrcA-jtjb4EqzY4oMI6FDaXyWUbCubXuNPXMOmIRBPR60WcTj9Dj2bjCH5eRogP0Hp8ELUtgYUFPnbjUh2xqsOugzeJl_KcSLKl/s1059/20230305_212954715.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="866" data-original-width="1059" height="262" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgwIM3q3iRrpPB4Y2TcqxB2wmcQrtadbMnOnAkaTmEIzOavPSH0ky9Gb-YydvbpWGVjDY0zo1_ISfRw7py2EN_xd1S56wrcA-jtjb4EqzY4oMI6FDaXyWUbCubXuNPXMOmIRBPR60WcTj9Dj2bjCH5eRogP0Hp8ELUtgYUFPnbjUh2xqsOugzeJl_KcSLKl/s320/20230305_212954715.jpg" width="320" /></a></div>
With both side arms ready, I scrounged around the shop to find something to make the foot pedal out of. I settled on a piece of angle iron with the apex down and some tread plate welded across the flanges horizontally:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEBqqR5sYGUFLyyfpiEmGgS7Uc4BamzwVy9Tv5VY7cDXtj4oHBh3arWsMQgpIxYV_z6mGfAH3uCbZ3qeYloO4JFgq6ighKmZNpe4b23hCK2d6g00I6l3r8xSA--6uwGD3PHaHi5MG2mLPpgrCe8OyUEZ5fKaWna8vi567_GjEc-TwXdjeplYeYjIaYZFGK/s978/20230306_003024554.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="978" data-original-width="892" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEBqqR5sYGUFLyyfpiEmGgS7Uc4BamzwVy9Tv5VY7cDXtj4oHBh3arWsMQgpIxYV_z6mGfAH3uCbZ3qeYloO4JFgq6ighKmZNpe4b23hCK2d6g00I6l3r8xSA--6uwGD3PHaHi5MG2mLPpgrCe8OyUEZ5fKaWna8vi567_GjEc-TwXdjeplYeYjIaYZFGK/s320/20230306_003024554.jpg" width="292" /></a></div>
Here is the finished "new" treadle installed on the shear and in the down position:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQD1fBA60EP-dhSNQfiWv63P__Tdmj4geq8rv8fIlqUS0yr_HWc8AzU-30hWh40WDlWqoW5C-XhW3Tucwp-piXqWiy1Dp0Q0MOdOzJmXxWYQWOcidztmQZDj_UJ3nYuSblXcTV3xIRcN9ox-2gTNNlRIwgBhs9M-ZPd7xLDQwn7-K0ckBqhRFSIKIaVzll/s1113/20230306_174045660.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1113" data-original-width="677" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQD1fBA60EP-dhSNQfiWv63P__Tdmj4geq8rv8fIlqUS0yr_HWc8AzU-30hWh40WDlWqoW5C-XhW3Tucwp-piXqWiy1Dp0Q0MOdOzJmXxWYQWOcidztmQZDj_UJ3nYuSblXcTV3xIRcN9ox-2gTNNlRIwgBhs9M-ZPd7xLDQwn7-K0ckBqhRFSIKIaVzll/s320/20230306_174045660.jpg" width="195" /></a></div>
Same thing with the treadle in the up position:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEBlSyjgevCXiEQO5f3gajmtqnQY2JxB7Jt654hXdy5jCxQ64uvwzq-RjZhlncUyNvrXmqzvALvPxCSvqDg5NhHe4ICX-w35rPl3l24FI5a1Vlx5rGcbsvbW2m6gQ9CxB8psqZsrNRmvyA1WWsrRIZPdUlM6PEZcXp5nXKKpEXxof6oJGEuRPmZX7-qy6F/s1056/20230308_040225076.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1056" data-original-width="822" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEBlSyjgevCXiEQO5f3gajmtqnQY2JxB7Jt654hXdy5jCxQ64uvwzq-RjZhlncUyNvrXmqzvALvPxCSvqDg5NhHe4ICX-w35rPl3l24FI5a1Vlx5rGcbsvbW2m6gQ9CxB8psqZsrNRmvyA1WWsrRIZPdUlM6PEZcXp5nXKKpEXxof6oJGEuRPmZX7-qy6F/s320/20230308_040225076.jpg" width="249" /></a></div>Then, I added paint and reinstalled:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMto3GnjBmxa-LzD4fqHI0UKOk8pfEmaOjfiL0b51ht0fg2rJTg4CGhXu19QpqF2o__XujqoCEWb5D7LLQqYAJAcjgDO8pHbz60SbZ4ZY8velXes_cFF8EJm_jy8wy0aFY5jC8Hno3v_IwJFHaBDcNB0ig3WD3ZtF3gWkvpgcViwP8p4mKIeXmHNtH0yFs/s1090/20230308_234006138.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="765" data-original-width="1090" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMto3GnjBmxa-LzD4fqHI0UKOk8pfEmaOjfiL0b51ht0fg2rJTg4CGhXu19QpqF2o__XujqoCEWb5D7LLQqYAJAcjgDO8pHbz60SbZ4ZY8velXes_cFF8EJm_jy8wy0aFY5jC8Hno3v_IwJFHaBDcNB0ig3WD3ZtF3gWkvpgcViwP8p4mKIeXmHNtH0yFs/s320/20230308_234006138.jpg" width="320" /></a></div>
So, now I had a way to move the blade down to cut material (stomp it down). But, there was no way for the blade move back up. All that operating gear had been removed. Sourcing these springs and hardware would be expensive if I went to Roper Whitney. Trying to cannibalize an old press was not working out. So, out of nothing more than desperation (and lack of any better idea), I went to a "Big Box Store" and bought a set of the old style garage door springs. I cut them in half, made brackets to hold each end of them (as needed), welded lugs where I figured that they would work best and then I strung them all together. Here's what it looked like before I put tension on the springs:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhISTgRa6IemQX8mSMu1hCjClLsu-6kYCWomo_zekbIz2P0EOD9ghp2gfXxXwvrS3urhEktBmuLxNf4VDlcoPQmn7CJD_ndTvMWRnBHTqHYh62lMhMZfCJVGr4pilnGuX8ubNT6pXpb1PBN8ZJG_AWo7EWm6h3vuqjTP27fAJ9r4BKhgaqqKFhL0vtCVrvy/s1043/20230307_210232004.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1043" data-original-width="477" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhISTgRa6IemQX8mSMu1hCjClLsu-6kYCWomo_zekbIz2P0EOD9ghp2gfXxXwvrS3urhEktBmuLxNf4VDlcoPQmn7CJD_ndTvMWRnBHTqHYh62lMhMZfCJVGr4pilnGuX8ubNT6pXpb1PBN8ZJG_AWo7EWm6h3vuqjTP27fAJ9r4BKhgaqqKFhL0vtCVrvy/s320/20230307_210232004.jpg" width="146" /></a></div>
Notice the plate at the bottom with the all-thread coming up between the springs. I put a nut above the plate and just tightened it up to put more tension on the springs. It took every turn of the nut to get enough tension on the springs, but in the end, it was just enough (with this setup on each side) to lift the treadle and blade of the shear back up - after a cut. Here it is with the springs tensioned as much as possible:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJvq35SI9nKQsAaVZzwKgNpXZytlbejp5B_23iuI62HkKh0zr8z0c6-1zPlIzMbPq1uUXgBKyaBzcexiz9oItYmPBPfMntN-2NU9qdjUnLSskwgWMwt_PLf5VagN6y-Xe1XYwS5afZpD_qj5lrJuGXM6KNAagYQFZNY53jsXt8Fj5VQysYTpSwRcPdKYtP/s944/20230308_004331754.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="944" data-original-width="660" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJvq35SI9nKQsAaVZzwKgNpXZytlbejp5B_23iuI62HkKh0zr8z0c6-1zPlIzMbPq1uUXgBKyaBzcexiz9oItYmPBPfMntN-2NU9qdjUnLSskwgWMwt_PLf5VagN6y-Xe1XYwS5afZpD_qj5lrJuGXM6KNAagYQFZNY53jsXt8Fj5VQysYTpSwRcPdKYtP/s320/20230308_004331754.jpg" width="224" /></a></div>Here's a quick video of the shear operating:
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<div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dzna3Lm9BDpJwvXZ8DtETzOP_ixX5xe_ksecFGq5OFXF22OlB0wq2dx6rJXWWFPSIRneeAwryvOYJ9fmoY7ow' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div>Nice. But still not ready to use! The last piece of this puzzle is the material clamp that holds the sheet of metal down to the table while the cut is happening (so that it doesn't move). Originally, this shear was designed to have a 1.5" round bar that goes from side-to-side above the clamp. Then, there were two eccentric handle operated rings that would move the clamp down an hold it in place. Here's what those looked like:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIWLVh3ZgDAW-H_aeJjGIyVSdHVNDAimoGoWM51DKxspTNbQg20v_3Ds1z95_iQFWw8v2oY9aqgykwR8_Zlit7lSgQ0qh9WJwiUp44NmRxHYOvUL-yAwEHK2cUV-ZHLobMMRIQzCKwkvAwjcPlIyPpaSovnXz04vybHmc-ACRHb7xuSPEFbpeJgzBCSg3s/s1328/20141114_124856.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1328" data-original-width="747" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIWLVh3ZgDAW-H_aeJjGIyVSdHVNDAimoGoWM51DKxspTNbQg20v_3Ds1z95_iQFWw8v2oY9aqgykwR8_Zlit7lSgQ0qh9WJwiUp44NmRxHYOvUL-yAwEHK2cUV-ZHLobMMRIQzCKwkvAwjcPlIyPpaSovnXz04vybHmc-ACRHb7xuSPEFbpeJgzBCSg3s/s320/20141114_124856.jpg" width="180" /></a></div>There was no way I was ever going to find a set of these to put onto my shear. I was going to have to come up with another way! I started by turning 2 pins in my lathe so that they would fit snugly into the holes in the frame for operating the clamp. Here is a pic with the pins in the holes on each side. Laying across the table is the square tubing that I later mounted between the two pins:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj631KtCF0y44HApOCEqCNcozrz7DTucx_HU0UU6eNGWNP2boUT5qumfy3FnlZHm1he7c5QfCsp4JZSzU6sn1cS3skBhGjyd100WFFhFkXGwLxnHakMTeHZMV2wCy4pccLMNTjnmkVgV3_gv3JIKG75VHJqyVwoLRYJN4ef24AiKnixSiz543oDHUHuq0xf/s1176/20230308_233123651.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1176" data-original-width="888" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj631KtCF0y44HApOCEqCNcozrz7DTucx_HU0UU6eNGWNP2boUT5qumfy3FnlZHm1he7c5QfCsp4JZSzU6sn1cS3skBhGjyd100WFFhFkXGwLxnHakMTeHZMV2wCy4pccLMNTjnmkVgV3_gv3JIKG75VHJqyVwoLRYJN4ef24AiKnixSiz543oDHUHuq0xf/s320/20230308_233123651.jpg" width="242" /></a></div>
Here is the 1/4" wall tubing mounted into position:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQwdDgBGwC3xCJiVoqIP8Whnd6NqsFUcMbTQb85KwZbmqQzmugi4XbmVODxotIJN9LmOdjnKU4RXe7IEzsPBRXnUjWDwKINn4GYN_94babi19lebDTQCY2xqL1cNtrDYznvPmksse54sgp7YKLscsXONN-ZWVXH6-Zpuscbnkva1a-8V3CgJHx3XLmIVv8/s1106/20230308_233209227.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="986" data-original-width="1106" height="285" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQwdDgBGwC3xCJiVoqIP8Whnd6NqsFUcMbTQb85KwZbmqQzmugi4XbmVODxotIJN9LmOdjnKU4RXe7IEzsPBRXnUjWDwKINn4GYN_94babi19lebDTQCY2xqL1cNtrDYznvPmksse54sgp7YKLscsXONN-ZWVXH6-Zpuscbnkva1a-8V3CgJHx3XLmIVv8/s320/20230308_233209227.jpg" width="320" /></a></div>
Next, I fabricated some lugs that would fit into the holes in the clamp bar that were designed to lift it up and down:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTBMjVV7GIggap_XgyEzlpRaED4jTwx8yqWGLej0YGz_oR67dPZyA3XaYzKcj_K_bZYOgBmF1PYHJCUBs9zKvIrAYZ6_tWJfOnoAGTS8vejMEFkClq-g20ITHBZL_Ke9Q3b6_eZ9xQpfS_pJ4xqFUOpELJmRSJ_MKmucC7oQK3ZaBY4gzKL-LOXINdW7nO/s861/20230309_013930772.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="861" data-original-width="710" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTBMjVV7GIggap_XgyEzlpRaED4jTwx8yqWGLej0YGz_oR67dPZyA3XaYzKcj_K_bZYOgBmF1PYHJCUBs9zKvIrAYZ6_tWJfOnoAGTS8vejMEFkClq-g20ITHBZL_Ke9Q3b6_eZ9xQpfS_pJ4xqFUOpELJmRSJ_MKmucC7oQK3ZaBY4gzKL-LOXINdW7nO/s320/20230309_013930772.jpg" width="264" /></a></div>
Here is the shear with the lifting lugs mounted in position. Before I mounted these lifting lugs, I put 1/2" threaded holes into the tops of the lugs so that a long bolt could be threaded down into them:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4-ydgYNCry-QiecddN0Z4vxpIljNku-BAsGztT4UdkcxbSRU5RGmkY7gDV6tBdQs6lvHGM5VwTrm1tDnMGDHfPwE-3AtJ8qRdmL84F0gxiy8NvdPDSqp6FVneOKu7Rx6Zfih1eFIaTLKEILARIq_Kc4DDKBLj_K-cAWUlQl-dyYxBv5m4T7v5a8Zityqo/s864/20230309_014102485.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="847" data-original-width="864" height="314" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4-ydgYNCry-QiecddN0Z4vxpIljNku-BAsGztT4UdkcxbSRU5RGmkY7gDV6tBdQs6lvHGM5VwTrm1tDnMGDHfPwE-3AtJ8qRdmL84F0gxiy8NvdPDSqp6FVneOKu7Rx6Zfih1eFIaTLKEILARIq_Kc4DDKBLj_K-cAWUlQl-dyYxBv5m4T7v5a8Zityqo/s320/20230309_014102485.jpg" width="320" /></a></div>
Now, I found a couple of long 1/2" bolts that would go down through the tubing, and thread into the lifting lugs - just a little ways. The concept here is that turning these bolts will lift and lower the clamp bar using the threads in the top of the lifting lugs. For that to work, I had to fabricate collars (drilled out nuts) that I slid up onto the long bolts and pressed against the bottom of the tubing. Then, I welded them into position there. Now, turning the head of the bolts clockwise (righty-tighty) raises the clamp bar. And counter-clockwise (lefty-losey) forces the clamp bar down - and holds the material in place. Here is the arrangement without the welded collars in place:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUGhZKmyu428KDiINAgyMcZk6F4lIbp-jmxfh-jURNIS5b8ZRUm66sdG2HOD-eB8O-ZM-Igz4fzZmiuCqPYPM1rugPCO5e5hvBK0F5nOCnkaKkYTVmITY-MZwOhyuucyDMCmuSv7eN6OQE2J1tPnPVc9oWqpMOdpQ-1f0EgC97lx3qVGlBPMJ6iyYYpx66/s1185/20230309_064746590.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1185" data-original-width="744" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUGhZKmyu428KDiINAgyMcZk6F4lIbp-jmxfh-jURNIS5b8ZRUm66sdG2HOD-eB8O-ZM-Igz4fzZmiuCqPYPM1rugPCO5e5hvBK0F5nOCnkaKkYTVmITY-MZwOhyuucyDMCmuSv7eN6OQE2J1tPnPVc9oWqpMOdpQ-1f0EgC97lx3qVGlBPMJ6iyYYpx66/s320/20230309_064746590.jpg" width="201" /></a></div>
With that done, I welded some handles onto the tops of the clamp bolt heads and painted them yellow. Here is the shear is it is now:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-OkcW_9Rr5QdYfBKuSAKjJ0Rver8CLAuo4DxPXB8XZYNLVX3BfCDAohVUaaCWGcvXWiQooqqXn3Vw2-_3Zp0if3XR-dGqhTie6KEf--jbS0cwhMUWY2xkmzaZmZaG5AARwRTJD-NjgHcHygoAfYmBb4pvZRroSvX9THRiktZbDlM-NaeC0jyDhHLFyoGJ/s986/20230318_021509859.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="876" data-original-width="986" height="284" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-OkcW_9Rr5QdYfBKuSAKjJ0Rver8CLAuo4DxPXB8XZYNLVX3BfCDAohVUaaCWGcvXWiQooqqXn3Vw2-_3Zp0if3XR-dGqhTie6KEf--jbS0cwhMUWY2xkmzaZmZaG5AARwRTJD-NjgHcHygoAfYmBb4pvZRroSvX9THRiktZbDlM-NaeC0jyDhHLFyoGJ/s320/20230318_021509859.jpg" width="320" /></a></div>
Last thing to do was give it a test cut. I put a 4 ft piece of 2024-T3 (0.040" thick) and gave it a stomp. It sheared off a thin strip and cut it very nicely! I checked both sides of the cut for signs of imperfections in the blades and found none. The cut looks the same from end-to-end.
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJaazIiwppfJZHZBUsF6DNOGLF8H3A4Tob-U_AI8uV2UZER3yAqrUeOnflUUuZZzttYfHiElOmZEkphVj7jPYRBmr4kpvInsdxkWABu4b9WEYui_lCJmRehGr33F6KCdjhQJ-r9OYQ9_uPR9APVSV4I2amyPxWOP3kFoQKPSfyF7vhhhTO5CVs5t8MriJ0/s1982/20230314_201633226.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1982" data-original-width="361" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJaazIiwppfJZHZBUsF6DNOGLF8H3A4Tob-U_AI8uV2UZER3yAqrUeOnflUUuZZzttYfHiElOmZEkphVj7jPYRBmr4kpvInsdxkWABu4b9WEYui_lCJmRehGr33F6KCdjhQJ-r9OYQ9_uPR9APVSV4I2amyPxWOP3kFoQKPSfyF7vhhhTO5CVs5t8MriJ0/s320/20230314_201633226.jpg" width="58" /></a></div>
The shear works great! And, I am really happy to finally have a convenient way to cut 12' long sheets of aircraft aluminum down into 8' long sheets. Awesome! It took a long time to get this project done. But, it's now completed and it works great!<br /><br /><b><u>4. Finally Finished The Hardinge CNC Lathe -</u></b> So, if you have followed my blog posts for any length of time, you know how long I have been reporting on this project! Well, I'm happy to report that this should be my last update on this machine. Yay!! Mechanically and electrically, it has be finished for a while now. I have really just been waiting for time to get some aesthetic things completed. Namely, get the plexiglass back into the canopy bows and finish the cart that the controller is mounted to. Well, this spring I finally took the time to get these parts of the project finished.<br /><br />Here's the lathe with the canopy bows removed and just after I painted and reinstalled the black tubing that runs between the two end frames on the top. These two heavy tubes are what the top of the canopy sections ride along to stay square and move freely. <br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhslfLQ6WBdZrX2_tQNN1epsCDrQLZAvIViVAVKxePR9C_hPxE--65kxIEOtyqnw0J7I932IP3vEW7-SQf-fqvJEwJm-AqSszPH88Qso52flerIVGQTapZXZRZjb1b77NXFRxzsnuJCBWhPukyvtr6Y5hK1SWy6QkPjuam6vcHF2UKlXzNZP8xNarIHoQWS/s884/20230125_035122408.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="884" data-original-width="824" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhslfLQ6WBdZrX2_tQNN1epsCDrQLZAvIViVAVKxePR9C_hPxE--65kxIEOtyqnw0J7I932IP3vEW7-SQf-fqvJEwJm-AqSszPH88Qso52flerIVGQTapZXZRZjb1b77NXFRxzsnuJCBWhPukyvtr6Y5hK1SWy6QkPjuam6vcHF2UKlXzNZP8xNarIHoQWS/s320/20230125_035122408.jpg" width="298" /></a></div>The other parts that the canopy sections run along are two steel rods mounted to the vertical side flanges of the main machine table. Here's what those look like:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5Y2sEZHXZYj2331Xeu6Zm30slbjbPC5jRkMoResgfWiv_jz7-OKdbI5KVV6jX_D8f7DjK18xozXGRu7S4wemDNtqq8tv4AgeFOfgUETyGOJPCIrn0Tcw79qEfZ-N8Nhx9Ul3hgQmzkCYRQUmUXf1OcIfr4QW18uLaZ5Z8NanfjjHj6WeSjQ54kIo2O8mv/s773/20230125_223329814.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="739" data-original-width="773" height="306" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5Y2sEZHXZYj2331Xeu6Zm30slbjbPC5jRkMoResgfWiv_jz7-OKdbI5KVV6jX_D8f7DjK18xozXGRu7S4wemDNtqq8tv4AgeFOfgUETyGOJPCIrn0Tcw79qEfZ-N8Nhx9Ul3hgQmzkCYRQUmUXf1OcIfr4QW18uLaZ5Z8NanfjjHj6WeSjQ54kIo2O8mv/s320/20230125_223329814.jpg" width="320" /></a></div>For the canopy bows, I found some fairly inexpensive plexiglass at a
local shop that I figured would work for this application. It had to be flexible enough to bend into the slots on the frames of the canopy sections. But, it had to be thick enough and rigid enough to stay in place - so that a small bump between the rails wouldn't knock the plexiglass out of the frames. Anyway, I settled on some 0.190" stuff that seems right. The first step was to give each of the sections a good cleaning. <br /><br />In order to get the plexi into the canopy sections, I had to take on of the side frames loose, install the plexi and then put the side frame back on and re-rivet the frame back together. It was a little tedious, but it worked out OK in the end. Here is one of the side frames after the plexi was installed and I re-riveted the frame onto the section.
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3R-zL3dkMM-E8GL9W8URgmBpafhob1NDNeyJNYCWdlMsX2dc7MIh6g_-Bu-jUw79fwyTXRn5XIKIir9spqIQ7LxidVQX3u9J4L9CfrNwid5xCMxxQhneKrh-TU41dQniFuc36gawoOLg1fQSngDuUXTfpEJPr4Z94la4i6gxsiOVmy7n-t3Oce8eBZ9lt/s831/20230131_232611592.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="826" data-original-width="831" height="318" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3R-zL3dkMM-E8GL9W8URgmBpafhob1NDNeyJNYCWdlMsX2dc7MIh6g_-Bu-jUw79fwyTXRn5XIKIir9spqIQ7LxidVQX3u9J4L9CfrNwid5xCMxxQhneKrh-TU41dQniFuc36gawoOLg1fQSngDuUXTfpEJPr4Z94la4i6gxsiOVmy7n-t3Oce8eBZ9lt/s320/20230131_232611592.jpg" width="320" /></a></div>Here is one of the sections after cleaning, side frame removed, plexiglass installed, frame reinstalled and riveted. It is ready to be painted. I left the blue plastic film covering the plexi on it for now so that I could paint the frames and the canopy sections and not have to mask off the plexiglass itself.
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiY3n1hbBdJjgjISdGQ_BeVST7u4dqdFFz28fPzfM_cmKosUWvPsOV5OHjg4o-PprUnr8yh5h6R21Ej8shvPo7fiwiBZ9f6I7ldDCnyi6vXw4f-bEi0Hz1Vxu7QeHA91OCS8HOtg9jNMbhPGKJFT21aqdnC4Oiz43pR7XSYaUjYJymgtZl7-1nzKfF6PTwb/s898/20230131_233547799.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="898" data-original-width="864" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiY3n1hbBdJjgjISdGQ_BeVST7u4dqdFFz28fPzfM_cmKosUWvPsOV5OHjg4o-PprUnr8yh5h6R21Ej8shvPo7fiwiBZ9f6I7ldDCnyi6vXw4f-bEi0Hz1Vxu7QeHA91OCS8HOtg9jNMbhPGKJFT21aqdnC4Oiz43pR7XSYaUjYJymgtZl7-1nzKfF6PTwb/s320/20230131_233547799.jpg" width="308" /></a></div>
Here's a section after painting:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj46lPMxYqiro_NcZgiNADFi1CgECMnkv6vIoodrglfINYbLdRr3ATEPmhx3DEPvEvJJAzEj5oYhi1vPQmmSdCSPKSk2c21CtiYsGQZkuIrGZcSIFDnO5zJrhVjx4ud-PdW9vwqyXVxFX_1dcIlIhg5BvvBPI1NkdFI5lwMqszRCeSyc-dd0gvIPgDtjQYy/s893/20230201_000807113.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="876" data-original-width="893" height="314" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj46lPMxYqiro_NcZgiNADFi1CgECMnkv6vIoodrglfINYbLdRr3ATEPmhx3DEPvEvJJAzEj5oYhi1vPQmmSdCSPKSk2c21CtiYsGQZkuIrGZcSIFDnO5zJrhVjx4ud-PdW9vwqyXVxFX_1dcIlIhg5BvvBPI1NkdFI5lwMqszRCeSyc-dd0gvIPgDtjQYy/s320/20230201_000807113.jpg" width="320" /></a></div>Here is the first canopy section reinstalled onto the machine:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgH_6V2GHYuMy5l1AS6Vhns2EuCJ46KI1RDRZT93I1S_JJVmCKNpVjhxtmHCIUZf3lE3HI7R47-qWh3Z6BKBsTq8jue0aHl1u6Lxz0yecZE2qFCyqHnTY6ovvOFyo3q7NGKYaaqY9OEUGdajXWB78oCXeUSoEF07AGwcL45P-trkRcmLfMJrACIgtaXRDrV/s1066/20230201_041035090.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1066" data-original-width="866" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgH_6V2GHYuMy5l1AS6Vhns2EuCJ46KI1RDRZT93I1S_JJVmCKNpVjhxtmHCIUZf3lE3HI7R47-qWh3Z6BKBsTq8jue0aHl1u6Lxz0yecZE2qFCyqHnTY6ovvOFyo3q7NGKYaaqY9OEUGdajXWB78oCXeUSoEF07AGwcL45P-trkRcmLfMJrACIgtaXRDrV/s320/20230201_041035090.jpg" width="260" /></a></div>
Another section finished and installed:
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgA6osJ0XODR70VWYPXaHzbomrG4KtLrQbToyJ01W1B9YUtRWnfH_3jjsMTvJNyvmwz3mpKVen6b5VMCo7wpJ6FdfCbL2G_GDnkvAdRtk8w9MXXW8guUu2tA7-3Wzbhi5WwHS0EqYQsslD6CAw4SAK-bXyMZIxbpl9j_hcvBR1ut3qc-YhZb8kP1A6slyMu/s1090/20230202_000649093.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1090" data-original-width="918" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgA6osJ0XODR70VWYPXaHzbomrG4KtLrQbToyJ01W1B9YUtRWnfH_3jjsMTvJNyvmwz3mpKVen6b5VMCo7wpJ6FdfCbL2G_GDnkvAdRtk8w9MXXW8guUu2tA7-3Wzbhi5WwHS0EqYQsslD6CAw4SAK-bXyMZIxbpl9j_hcvBR1ut3qc-YhZb8kP1A6slyMu/s320/20230202_000649093.jpg" width="270" /></a></div>
While the paint was drying on the canopy sections, I was working on the controller cabinet too. I wanted to get a decent floor in it so that it could be used to store the manuals and boxes of spare parts for the machine. Git'er Done - Gotter Did!
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhES-iSRXmm6IApt3Ppqlqlw4X0LaHQZKnoDjwtW6mjDcSio-l7Wu26Ao1hEyTR3cZfYqO1Y9rY0cWi1PyEhA3-hKtFBeZj4JPHugyWzW5sRbmFiWnUvq3bHys0rj1Lrr0x71NuAkAnxktBxeucoMId74JqQgBA8NYodfoAlfTYqa7QbZ6cv8GFrvss6fzx/s958/20230228_000152980.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="958" data-original-width="946" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhES-iSRXmm6IApt3Ppqlqlw4X0LaHQZKnoDjwtW6mjDcSio-l7Wu26Ao1hEyTR3cZfYqO1Y9rY0cWi1PyEhA3-hKtFBeZj4JPHugyWzW5sRbmFiWnUvq3bHys0rj1Lrr0x71NuAkAnxktBxeucoMId74JqQgBA8NYodfoAlfTYqa7QbZ6cv8GFrvss6fzx/s320/20230228_000152980.jpg" width="316" /></a></div>
With that done - all that was left for the controller cabinet was to get some rattle can black on it to make it uniform in color and match the parts of the machine.<br /><br />Finally, here it is all done and ready to go!<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiyGFbZZftdwAuqzzf4ZwgwSIvxkwuBHEZmSaB_xMUJPDsqQ27aD6abvSJUWUzVyCQAbxHi37R9YVDWPxKg9cyHpE-RNLj-SmHVpWxx7Xb-AxCkgzqJgC3SFVO3jIcmzK6l1wxxFBL2REuWiLWG9LZvmcQK4uhVQIgDrq5qMXp2gg0CJnBesP6pmHBPbzrs/s1154/20230318_001329730.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="913" data-original-width="1154" height="253" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiyGFbZZftdwAuqzzf4ZwgwSIvxkwuBHEZmSaB_xMUJPDsqQ27aD6abvSJUWUzVyCQAbxHi37R9YVDWPxKg9cyHpE-RNLj-SmHVpWxx7Xb-AxCkgzqJgC3SFVO3jIcmzK6l1wxxFBL2REuWiLWG9LZvmcQK4uhVQIgDrq5qMXp2gg0CJnBesP6pmHBPbzrs/s320/20230318_001329730.jpg" width="320" /></a></div>
I think I might try to sell this machine now. I really wish that there were Prowler parts that I could make with it. But, there really aren't. I need to get this space back into my shop - it's gonna have to do. I still have the blue film on the plexiglass. I'll let the new owner remove the blue film. What a huge project this turned out to be! Not entirely sure it was worth it. But, once you start making things nice on a machine - it becomes hard to draw a line and stop. Anyway, onward and upward, now!<br /><br />Well, that's a wrap for this update. I'm glad I could get this published before I head back to WI and summer and AirVenture get into full swing. Happy 4th to you all - hope to see you back for the next update!<br /><p></p>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-4561663675008429701.post-5000204640643826492023-02-23T07:14:00.003-08:002023-02-23T07:18:08.611-08:00Fabrication of Radiator Fairings, Engine Compartment Longerons & An Update From Bryan Hello Everyone,<br /><br />I made a few parts for Vaughn and his Prowler lately. So, in an effort to make good on my resolution on do more blog updates more frequently, I am just gonna do it. <br /><br /><b><u>In This Update:</u></b><br />A. Radiator Fairings;<br />B. Engine Compartment Longerons;<br />C. An Update From Bryan<br /><br />Before I move onto the update, I had a couple of pics to share from the "day job." For those of you that do not get around Oshkosh, WI, except for during AirVenture - here's a look at what the place looks like in January:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwcdQGK0mbPA-S6ItKAJsOCUfJj6pU1Q2ow3TrxE8wTdf9fSJApk5jldgxADfHmWAPqhzZzJe98GaeqkVSMLZgQKgoFCIH_-1pFp093WtGXeEtgGtPvsjtrMIxIoYeCgxyzY-7-_mPhsRRuitpnkKGc6OC1O54vGHgjpMuEVIaS3gWo1s0RyjZRQP0Kg/s1882/20230204_185020117-2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="826" data-original-width="1882" height="140" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwcdQGK0mbPA-S6ItKAJsOCUfJj6pU1Q2ow3TrxE8wTdf9fSJApk5jldgxADfHmWAPqhzZzJe98GaeqkVSMLZgQKgoFCIH_-1pFp093WtGXeEtgGtPvsjtrMIxIoYeCgxyzY-7-_mPhsRRuitpnkKGc6OC1O54vGHgjpMuEVIaS3gWo1s0RyjZRQP0Kg/s320/20230204_185020117-2.jpg" width="320" /></a></div>Notice that Lake Winnebago is frozen over and snow covered (awesome for ice fishing!!!). I have also pointed out the approximate locations of Camp Scholler and the KOSH airport.<br /><br />I also got a neat picture of a moon rise recently. It's near full moon and what makes this picture neat is that it's taken just after sunset (behind the photo). If you've never had an opportunity to experience a sunset from higher altitudes, the darker strip along the eastern horizon is where the sun is no longer illuminating the sky. The yellowish band (and above) is where the sun is still illuminating the sky. Here, there is a mostly smooth undercast layer below the horizon. So, the sun has just set and the moon is just rising - which means that they are essentially 180 degrees apart when this picture was taken:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhc9JAevI8G1voqdGLNxQh4ya6VBnK05fuRyhnxvwXPonyh-2XyifVlw4EOtaWEs8cGQ7tzFca5Tf9ejbABETMo_6ep4H-pGUEdUpaGsa-7iEEeIX2zFn4zJDENYG7uKXddkKIcfNUfoipEsSJ6HGtUN7VYwuWolt4MP3iyOk2pW4nZnfLHvtvPvtqmUw/s942/20230206_002855081.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="942" data-original-width="908" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhc9JAevI8G1voqdGLNxQh4ya6VBnK05fuRyhnxvwXPonyh-2XyifVlw4EOtaWEs8cGQ7tzFca5Tf9ejbABETMo_6ep4H-pGUEdUpaGsa-7iEEeIX2zFn4zJDENYG7uKXddkKIcfNUfoipEsSJ6HGtUN7VYwuWolt4MP3iyOk2pW4nZnfLHvtvPvtqmUw/s320/20230206_002855081.jpg" width="308" /></a></div>OK. Let's get to the "good stuff!"<br /><br /><u><b>A. Radiator Fairings</b></u> - As the title of the update implies, Vaughn only got one set of radiator fairings for
his Prowler and needed another. So, I fabricated a set of those for
him. The first step in the process of making the radiator wall fairings was to locate the pattern and the forming blocks (aka forming dies). Here is the pattern, and I have traced and cut out two matching blanks to be formed:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1NtAvch7CnZStULbLbNWu-kMr92Nn5f4NPHORsXGuQKIHGSUpiuI0V4yASIiBujrhAtaLUMUJDqO5wX2URDsb4tiZ7aaTNt3Me1jBzVuYsHGjOTRGY9rn0mufeJlZbvR-O61GUFrz2l2XvXMuLT8eErXUsqU1gHGwpjOFgzqsXj1vVgZkziJE6iF-aw/s1434/20221223_014925509.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="977" data-original-width="1434" height="218" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1NtAvch7CnZStULbLbNWu-kMr92Nn5f4NPHORsXGuQKIHGSUpiuI0V4yASIiBujrhAtaLUMUJDqO5wX2URDsb4tiZ7aaTNt3Me1jBzVuYsHGjOTRGY9rn0mufeJlZbvR-O61GUFrz2l2XvXMuLT8eErXUsqU1gHGwpjOFgzqsXj1vVgZkziJE6iF-aw/s320/20221223_014925509.jpg" width="320" /></a></div>Here are the forming dies that I got from George to make these parts:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJCkuz2fg2uyQ80jifmWwbsx9qhpjoWlT4sOPn4e8toRk7ku1TaJB5cIhGtj9FFRgQ9wpBixYFF3vPErHSZNyW8qTfaiVOzkZYNfO5hkmfIoaSOKuqpGDqpNoiSxWw3WaC8J-Hs0dIOdPEeA_FkOF8HBIepjHdeh4KQg7HwnAFMBSpxClqDodRbx3KUQ/s2056/20221223_015213031.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="830" data-original-width="2056" height="129" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJCkuz2fg2uyQ80jifmWwbsx9qhpjoWlT4sOPn4e8toRk7ku1TaJB5cIhGtj9FFRgQ9wpBixYFF3vPErHSZNyW8qTfaiVOzkZYNfO5hkmfIoaSOKuqpGDqpNoiSxWw3WaC8J-Hs0dIOdPEeA_FkOF8HBIepjHdeh4KQg7HwnAFMBSpxClqDodRbx3KUQ/s320/20221223_015213031.jpg" width="320" /></a></div>Here, I have placed the blanks to be formed between each half of the forming dies. You'll see it better in the pictures below, but one half of each of the forming dies has the shape that the blank will be hammered to. The other half is simply a backing block that holds the blank in place and helps the material form accurate and sharp bends where they should be:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZjfw1IGdKESuPPhBkUCNDO814IX78l3QfbVa1ubpcPxYcnv5cJumGzJ2xKwtGsSJO6vApECTBWkQsJwqWFlkW3gNRCCk4Utu8-d3DkPadHOCsBxGil29j12ZlIksElzlbfPrK_af9Mi_fl6aUYDy9FT3fhgIhSW8xKAFnlmGsmtV5jlt08U6Tdi7Pog/s2000/20221223_030949337.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="989" data-original-width="2000" height="158" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZjfw1IGdKESuPPhBkUCNDO814IX78l3QfbVa1ubpcPxYcnv5cJumGzJ2xKwtGsSJO6vApECTBWkQsJwqWFlkW3gNRCCk4Utu8-d3DkPadHOCsBxGil29j12ZlIksElzlbfPrK_af9Mi_fl6aUYDy9FT3fhgIhSW8xKAFnlmGsmtV5jlt08U6Tdi7Pog/s320/20221223_030949337.jpg" width="320" /></a></div>In the pic below, I have started forming the flange that will fit the curve of the bottoms of the radiator wall. I use a two sided hammer that has hard rubber (red) on one side and nylon (yellow) on the other side. I use the nylon side when I am trying to move the metal around initially and get the wavy shape you see in this pic:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4d6epsizHkZsEWZpz5Lv5vjUj95vY6SYnNAQ8Xnb0DOmM_fGXFWdWLBroCGQaFcAa791Lce6FNSmjhVeQbBRbcB9eScsx2PootoYOYcWLzl1aAQ6Nh8ETwf61PERLUV9iUun9fWnwqDftyTZFGjuSy4gQ_ea6OSgnZVLsos0FxrwYmkW_bNdN3C0YMg/s1460/20221223_031705565.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="771" data-original-width="1460" height="169" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4d6epsizHkZsEWZpz5Lv5vjUj95vY6SYnNAQ8Xnb0DOmM_fGXFWdWLBroCGQaFcAa791Lce6FNSmjhVeQbBRbcB9eScsx2PootoYOYcWLzl1aAQ6Nh8ETwf61PERLUV9iUun9fWnwqDftyTZFGjuSy4gQ_ea6OSgnZVLsos0FxrwYmkW_bNdN3C0YMg/s320/20221223_031705565.jpg" width="320" /></a></div>Once the metal is closer to the final shape, then I use the hard rubber side to try to get the metal to form as closely to the die as possible. On the outside radius forming (above) I start in the middle of the radius and try to move the metal towards the ends. This is because the metal will have to shrink most at the top of the radius. The more you can move the metal away from that area, the less shrinking will be required there. So, working the middle towards the ends helps with that.<br /><br />Again, the metal has to be "shrunk" [or "shrinked", or placed in a shrinker"??] in order to get the wavies out of the edge of the flange. That is done using a shrinker. It doesn't take a lot, and more small shrinks is better than a few large ones, if you want to end up with the best finish. Once I shrink the flange a little, I put it back into the former and where the flange fits tight with the form block, I put an X on the flange with a Sharpie marker where it does not need any more shrinking. I put an O where it still needs a little more. Once the flange fits snugly around the entire radius, the forming on that flange is done:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKlQ_Ja8zF2h0T1FfqOSkuVzZfxp3aa1_9PorRwMEiOewLrPRvpMreJdwhW8VV3QGYA0ln8lzdrUNgznajeAoulslbh428DM-qpPEaiN88evzeM_HE1JZAhd62c7BMrbTcYUocMwmgdBw1EgKj3wi9FHGkJ6IREOfw9htjCcfFA1McEONiEVjp-q159w/s1367/20221223_040808420.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1367" data-original-width="1031" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKlQ_Ja8zF2h0T1FfqOSkuVzZfxp3aa1_9PorRwMEiOewLrPRvpMreJdwhW8VV3QGYA0ln8lzdrUNgznajeAoulslbh428DM-qpPEaiN88evzeM_HE1JZAhd62c7BMrbTcYUocMwmgdBw1EgKj3wi9FHGkJ6IREOfw9htjCcfFA1McEONiEVjp-q159w/s320/20221223_040808420.jpg" width="241" /></a></div>Incidentally, if you shrink the flange too much, the fix is pretty easy. You just flex the flange while you place the part into the form blocks again. Then, using the hard rubber side of the mallet, just hammer the flange a little and it will help the flange form nicely to the die!<br /><br />Inside radius bends are pretty much done the opposite way - and you don't really even need to take the part out of the form blocks. In forming an inside radius, the flange will naturally want to stretch on the outside edge. So, I start hammering at the ends and try to move the metal towards the middle as much as possible. This reduces the thinning of the outside edge of the flange material.<br /><br />Here, again, taking more small hammer strokes instead of fewer larger strokes will yield better results. The flange will come out smoother and you'll be less likely to split the outside edge of the flange while working the material. Here is the inside radius flange, about 1/2 formed:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_c7uqid0zrDcFOIszeudSTeiBhL_4rxNDJ9_nsC3RyyVSuGH3G1azdMgxIxeCgapv8TTq55oR0HfRm2bYuuTN_AsvRsDOGFw7DexagOo4VKoO4D3crjULWZ0Yb1C_FNHlDXDZOh68mz1tz2t34TUrgok26ARGIRm2vzNQiVBDvmn1wOSp4wwRIrQ8hg/s1137/20221223_041037517.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1137" data-original-width="944" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_c7uqid0zrDcFOIszeudSTeiBhL_4rxNDJ9_nsC3RyyVSuGH3G1azdMgxIxeCgapv8TTq55oR0HfRm2bYuuTN_AsvRsDOGFw7DexagOo4VKoO4D3crjULWZ0Yb1C_FNHlDXDZOh68mz1tz2t34TUrgok26ARGIRm2vzNQiVBDvmn1wOSp4wwRIrQ8hg/s320/20221223_041037517.jpg" width="266" /></a></div>Same operation from a different angle:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgb_KmwtxgvVNxp8MboHKxGioq3uOo-zuMCJHQzJ2h5pUUGp0fOwzaBngB8nmZBydPP20l1t7dwYX_s7AFR0ES4uDg_XmJCkQQmrUTGQ4wf3hY6x00AFj7gE9OeCVenm04jtPmaVdZepAb3ygC9HM7VTI9_K8kVbnPkGi8yMRdnH6EIieLDaLgS8qwoyg/s1417/20221223_032236752.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1417" data-original-width="751" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgb_KmwtxgvVNxp8MboHKxGioq3uOo-zuMCJHQzJ2h5pUUGp0fOwzaBngB8nmZBydPP20l1t7dwYX_s7AFR0ES4uDg_XmJCkQQmrUTGQ4wf3hY6x00AFj7gE9OeCVenm04jtPmaVdZepAb3ygC9HM7VTI9_K8kVbnPkGi8yMRdnH6EIieLDaLgS8qwoyg/s320/20221223_032236752.jpg" width="170" /></a></div>Here is the final product:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJ4UsGWEUXTe5Uqd0OwWR8kZ9HgJQOhU_TTZOFKB34ApymwDwtEhcAhWZWX4mkeYeod8vrrP8B-AGQ-pKqkcLSLr08lKoaHteX1tK1ifL9k4GghXG6dZ7-PQIi9hjniGrZgLD3Ydsih0goyxCymasjEG9934FkqJsL99PvTqQbCfr2_Pvglo_0dyJaxg/s1400/20221223_042702355.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="470" data-original-width="1400" height="107" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJ4UsGWEUXTe5Uqd0OwWR8kZ9HgJQOhU_TTZOFKB34ApymwDwtEhcAhWZWX4mkeYeod8vrrP8B-AGQ-pKqkcLSLr08lKoaHteX1tK1ifL9k4GghXG6dZ7-PQIi9hjniGrZgLD3Ydsih0goyxCymasjEG9934FkqJsL99PvTqQbCfr2_Pvglo_0dyJaxg/s320/20221223_042702355.jpg" width="320" /></a></div>The one thing that is hard to capture in a picture is checking the part for warping. As you form these flanges, they can pull on the metal and cause the portion that is supposed to be a flat wall out of shape and give it a twist. If that happens, you have to look at the part and decide where a little extra shrink or stretch will allow the part move back to more flat and take the twist out. There is no easy way to tell someone how to do that - it just comes from experience and trying. Here is the finished part with a (more-or-less) flat wall between the flanges:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKbHlSMoPldVZao3OCvVel_gerA8sQfpyKEaeXGrYD_iZ4XAUFhjKBSnwUJ-cm9imnVE_0MOpuTYC-Nf8CAL_nyFdKMiuhPkRkNLBD1XOocI0dkO4KT1ywdFAnYmBaC-IT2lvdEB5UW3WpGBm11uvsK43hMqFoxwfsbd95mu7w32m7ZGCAr7kzbZj3dQ/s1420/20221223_042814521.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="407" data-original-width="1420" height="92" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKbHlSMoPldVZao3OCvVel_gerA8sQfpyKEaeXGrYD_iZ4XAUFhjKBSnwUJ-cm9imnVE_0MOpuTYC-Nf8CAL_nyFdKMiuhPkRkNLBD1XOocI0dkO4KT1ywdFAnYmBaC-IT2lvdEB5UW3WpGBm11uvsK43hMqFoxwfsbd95mu7w32m7ZGCAr7kzbZj3dQ/s320/20221223_042814521.jpg" width="320" /></a></div>After that, I traced a line on each flange to get a uniform flange width and then cut off most of the access with a pair of shears. I finished trimming the flanges to the lines using the flat portion of my combination disk & belt sander to get a nice edge on the flanges:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjj8vDoEqeQH27IW0kS8xi7eu7fUaeXvA0srrCSTIKu4qxU5yL_ibQmD3U0hvpnDGUrG7RwjKAWU8YahxsuduU1WE5ePGzvUoeYtu07tABy5pCiGzqhMh8opJliBvzHcnxrE7gYcvCM9RWnjpj119oILBNt29Sruo8wLDf1KtOH20mFYtBRT9kvMhBQyw/s906/20221223_043100580.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="906" data-original-width="799" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjj8vDoEqeQH27IW0kS8xi7eu7fUaeXvA0srrCSTIKu4qxU5yL_ibQmD3U0hvpnDGUrG7RwjKAWU8YahxsuduU1WE5ePGzvUoeYtu07tABy5pCiGzqhMh8opJliBvzHcnxrE7gYcvCM9RWnjpj119oILBNt29Sruo8wLDf1KtOH20mFYtBRT9kvMhBQyw/s320/20221223_043100580.jpg" width="282" /></a></div><br /><u><b>B. Engine Compartment Longerons</b></u> - Vaughn is also going to get started laying out his FWF package and
wanted to get the parts together to start framing in his engine
compartment. He is going to be installing a PowerSport package on
his Prowler. This is based on a Mazda rotary engine. This engine will
be lighter than the George Morse package, so he is going to have to
move things forward a bit to get the W&B and CG to work into the
range of the 6 (almost 7) airplanes that have been certified.<br /><br />In order
help Vaughn with that, I made him a forward engine compartment bulkhead
(horse collar) that I covered in a previous update. Now, I have
fabricated the longerons to connect between the firewall and the horse
collar. Here's how that went.<br /><br />There are 6 longerons that make up the engine compartment. There are two on top, two on the sides and two lower ones. They are kinda important from the standpoint that these longerons set the basis for the shape of the front of the Prowler (what the silhouette of the airplane looks like from the top down and from each side). So, I kinda want to get that right!<br /><br />The first step to making these longerons is, again, finding the material and finding the pattern. The pattern that I use is one that I made from Ray's engine compartment longerons. All I did was tape some paper grocery bags together, lay his longerons down (on edge) onto the paper, and then traced them out. I was trying to get the proper curvature of each set.<br /><br />The longerons are made from 2024-T3 aluminum that is cut into 8 ft strips and then I form them into a C or U shaped channel with 3/4" flanges. A few years back, I was working on forming some of the aileron and flap hinge supports on the rear spar of outboard wings and while doing that, I also made several extra of these C channels. I found them and cut them into the correct lengths for each of the 3 sets of engine compartment longerons. Here is the pattern taped to the work bench and the pieces that I used to form the longerons:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPBPUDoKROoo1nbB9-kK8dAeVwE2zqnBfwT0WSXMSxpSjsFlYIYO1zVOD3ZpgYsD_3oH9wrR3PMX6uq6Od7YZPkvKlfBk46C-nAmGpEcrf6EgPO135KQRGlUSTQ2H50QRO8cO1coiu_UdYEgjtq1l40vBL9AS3sFXcDnGCzJQ5OKvJQHy7TSBscehkjA/s2169/20230208_014637290.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="818" data-original-width="2169" height="121" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPBPUDoKROoo1nbB9-kK8dAeVwE2zqnBfwT0WSXMSxpSjsFlYIYO1zVOD3ZpgYsD_3oH9wrR3PMX6uq6Od7YZPkvKlfBk46C-nAmGpEcrf6EgPO135KQRGlUSTQ2H50QRO8cO1coiu_UdYEgjtq1l40vBL9AS3sFXcDnGCzJQ5OKvJQHy7TSBscehkjA/s320/20230208_014637290.jpg" width="320" /></a></div>You probably can't see it, but the tracings of the longerons are on the brown paper!<br /><br />I started with the top longeron set. I started by placing the straight channel on the pattern and then marking the 1st place where it needed shrinking on the fwd end. After the 1st shrink, I set the longeron on the tracking and mark where the next place that needs shrinking. Here is the first top longeron after several iterations of this:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhDx1QH1hdl3K-0LM5E9MnjHh8FV7eqyTjOJZq9WznsXHEUA7iJyxd7DRdM_2RBS4ClD7rlwN8h6CIpuYFqrQhqQ3v86eGYcUKv0lHvuvNRP25w8mFjfSZ4oOQWpe00sXB6vivh8SQis0nQxWuf0QjZRq5ODGg-RRUDgbMMv_KP8RCN_7kneY0TWejpA/s2639/20230208_202404292.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="608" data-original-width="2639" height="74" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhDx1QH1hdl3K-0LM5E9MnjHh8FV7eqyTjOJZq9WznsXHEUA7iJyxd7DRdM_2RBS4ClD7rlwN8h6CIpuYFqrQhqQ3v86eGYcUKv0lHvuvNRP25w8mFjfSZ4oOQWpe00sXB6vivh8SQis0nQxWuf0QjZRq5ODGg-RRUDgbMMv_KP8RCN_7kneY0TWejpA/s320/20230208_202404292.jpg" width="320" /></a></div>Here is the top longeron in the shrinker:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXQRpHjwxGBdFgm0CaM-6imK0aR0vaiJI_VzRGAb9r2fX019mLHgimbILbV7LPobelqEhaFxqwKt1A8r7x39e0si3-1KcejMuzqAQhcttCuGCBtPwcfkjlFE7FFoV8ZSBdnoh15D1hqZxVq-nj4ePzoANADtEkOvQFYWK6q4JZGUTUqlcUachCIdRRZg/s1626/20230208_202606847.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1626" data-original-width="984" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXQRpHjwxGBdFgm0CaM-6imK0aR0vaiJI_VzRGAb9r2fX019mLHgimbILbV7LPobelqEhaFxqwKt1A8r7x39e0si3-1KcejMuzqAQhcttCuGCBtPwcfkjlFE7FFoV8ZSBdnoh15D1hqZxVq-nj4ePzoANADtEkOvQFYWK6q4JZGUTUqlcUachCIdRRZg/s320/20230208_202606847.jpg" width="194" /></a></div>And, eventually, the longeron fits the curve for the top longeron all the way to the back (firewall end):<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgynV_GvExQt8l_kSiFP7IZPsVQbJGgdpz8LYXCkSHPSxk_LxqAvNdzTt-gKURDXLy1OO_W1G9rwb3oS-U-tPLcdP3agOo6TrLfWcbsJSrbY8r6TDiS0OAQQkry8j1l2ZUXXgKf9YwRh-ExqA-XOpbRYV3mczITfCE-NYM7A798Qn0qXCw3fwnrL0GkcQ/s1608/20230208_203526503.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1608" data-original-width="472" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgynV_GvExQt8l_kSiFP7IZPsVQbJGgdpz8LYXCkSHPSxk_LxqAvNdzTt-gKURDXLy1OO_W1G9rwb3oS-U-tPLcdP3agOo6TrLfWcbsJSrbY8r6TDiS0OAQQkry8j1l2ZUXXgKf9YwRh-ExqA-XOpbRYV3mczITfCE-NYM7A798Qn0qXCw3fwnrL0GkcQ/s320/20230208_203526503.jpg" width="94" /></a></div>There are two tricky parts to this process for fabricating these longerons. The first tricky part is trying to shrink both flanges in the same place the exact same amount. If you can do this, the longeron will be curved, but it won't get a twist in it. Well, try as you might, it is virtually impossible to not shrink one flange more than the other and eventually it will develop a twist. The only way to fix it is to determine which flange needs more shrinking or needs to be stretched a bit and take the twist out. <br /><br />This leads to the second tricky part, trying to stretch a flange that
has had too much shrinking. I made the same mistake that I have made once before with these longerons. I tried to use the strecther device to take out some of the shrink in one of the flange. Well, it does not work. As you shrink the flanges, you work harden the 2024-T3 even more. So, when you try to stretch it, even just a little, SNAP! It breaks the flange. Here is the longeron with the broken flange after I drill-stopped the crack and cleaned it up a little:<br />
<a> </a><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9l8dQJdmmsH-AY_GaYmSt5ATY_N2Z6YKvKpqe25TSQTLjxDsqvozfrlgdNWkZ-AF2eT7BiOyGOvSz7y_G3EVgcqVnxhBRW_vxS0efvzeo9YFzKZJXobfeSpVjm0Xm_ItLhnT_dJBtVmT-Lq1kyTQ28fkeu0rZqJamlf4dBy44CIZXfXvwQAm7NydaAQ/s1457/20230208_222546432.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="943" data-original-width="1457" height="207" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9l8dQJdmmsH-AY_GaYmSt5ATY_N2Z6YKvKpqe25TSQTLjxDsqvozfrlgdNWkZ-AF2eT7BiOyGOvSz7y_G3EVgcqVnxhBRW_vxS0efvzeo9YFzKZJXobfeSpVjm0Xm_ItLhnT_dJBtVmT-Lq1kyTQ28fkeu0rZqJamlf4dBy44CIZXfXvwQAm7NydaAQ/s320/20230208_222546432.jpg" width="320" /></a></div>I moved on to the side longerons and left this one with the broken flange lay on the bench for a while. (Later, I riveted a patch on this one so that I can use this longeron for my FWF mock up - a project that I hope to get started on, again, soon!) Here is the repair:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpdRJd_Egr7sBUE2t1Q5GaFnc-G0a0LAjwI1Gpbjy2yxHV4hqYErk2rCySbZPmvEduQotWypwz9lTR9l5a_fq7CDTodS6Bc35zd8OO-KnylZaxI-AHQDul1lb3JPraqm6na7fb5kPZLUzQFE5G8lRgUlbANtDdS-QchIwVHsrbiSMmXliwbde915GAPg/s1137/20230223_003454046~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="798" data-original-width="1137" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpdRJd_Egr7sBUE2t1Q5GaFnc-G0a0LAjwI1Gpbjy2yxHV4hqYErk2rCySbZPmvEduQotWypwz9lTR9l5a_fq7CDTodS6Bc35zd8OO-KnylZaxI-AHQDul1lb3JPraqm6na7fb5kPZLUzQFE5G8lRgUlbANtDdS-QchIwVHsrbiSMmXliwbde915GAPg/s320/20230223_003454046~2.jpg" width="320" /></a></div>It will work fine for the FWF mock up work.<br />
<br />So to prevent breaking any more of the longerons, what I decided to try, instead of using a stretcher device, was to hammer the flanges. I put a radius on the square end of my anvil, and then clamped it to the welding table. Here is what that looked like:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfzUKyAunNtk_gFksQQVslJoFScZD6yhDu1W4NSGNXuajVaEyGiS9MCXIdm7bgkSnTnl8LeXJDhRigv7J1chnnjRHFulvj5RnPhMat16aDkt-67HIorP10uvQZwFiuuBPFuXMpS72cSFhpaNPw7bwscZgII6Rwadpc8TMHY6T_BQzcJIyYqZK5cuwWCw/s1221/20230222_144850986~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1221" data-original-width="749" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfzUKyAunNtk_gFksQQVslJoFScZD6yhDu1W4NSGNXuajVaEyGiS9MCXIdm7bgkSnTnl8LeXJDhRigv7J1chnnjRHFulvj5RnPhMat16aDkt-67HIorP10uvQZwFiuuBPFuXMpS72cSFhpaNPw7bwscZgII6Rwadpc8TMHY6T_BQzcJIyYqZK5cuwWCw/s320/20230222_144850986~2.jpg" width="196" /></a></div>I found my steel forming hammer that has the polished face and I put the
flange on the anvil and then hammered the edge of the flange in several
places, lightly. Several, light hammer strokes in the areas that
needed stretching would cause the flange to open up slightly and take
out some of the "extra" shrink. <div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikBvxTEXXnhzG63X71y_uKdvzBP3T5X-owqfFpYgQhAJPHZK_B_rlhbZx5BUWEvHQiPGVR9f6bVeWEK3aanP_gdHi1iyLZIBM4krF_fP1hE1cCItCfw4VSshvhUXPENSmnmi1i5WA4IcFJDovsc7G1aRKj_KDyTj1lEj4YemXtYjxmXKC99G65tematQ/s795/20230222_145038004~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="795" data-original-width="760" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikBvxTEXXnhzG63X71y_uKdvzBP3T5X-owqfFpYgQhAJPHZK_B_rlhbZx5BUWEvHQiPGVR9f6bVeWEK3aanP_gdHi1iyLZIBM4krF_fP1hE1cCItCfw4VSshvhUXPENSmnmi1i5WA4IcFJDovsc7G1aRKj_KDyTj1lEj4YemXtYjxmXKC99G65tematQ/s320/20230222_145038004~2.jpg" width="306" /></a></div>It worked much better than cracking the flanges trying to use the stretcher! In fact, you can see some of the hammer marks in the flanges on the cracked longeron in the picture above. I used the cracked longeron to try the hammering technique to see if it worked. Better to mess up a part that is already damaged!<br /><br />Moving along, here are the two side longerons completed:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhRtjtT4zJy_nQEqKmkgvo7kuHSuMea8XFxWa8QagFHAocYC6N-RzHM1VD3PAVno_vNimgIM8jsnwoFFfrvu6ZkxfRS1R8_k2mAwVKypSXpriIu_ZCP0F8E2poGkiCMYTJ5d1bmHgxUnYB9ARZDEilxfKNmt8Ay-kcWs9tUmg3mR187OURVLIsEIONmg/s1302/20230208_213813852.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1302" data-original-width="558" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhRtjtT4zJy_nQEqKmkgvo7kuHSuMea8XFxWa8QagFHAocYC6N-RzHM1VD3PAVno_vNimgIM8jsnwoFFfrvu6ZkxfRS1R8_k2mAwVKypSXpriIu_ZCP0F8E2poGkiCMYTJ5d1bmHgxUnYB9ARZDEilxfKNmt8Ay-kcWs9tUmg3mR187OURVLIsEIONmg/s320/20230208_213813852.jpg" width="137" /></a></div>And, here are all the longerons completed, except for the one top longeron that I broke. <br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbPExJZjhGVn7UmOlFuhSuUlWjz_VEPtVGrwBL0LxmiU4rlyLcOByp1YU-B6qgwVW3rbpGLvCyc0wJ9W1v9r-IKjrBTxymSSe0VAGe1jigTDv426z56kvoR_4MxKOIJi9jcjNiIca-c6uwb3p-ZhILoWy1pHg78loqWSX7DErElvYKxAlK8Eh-IlhlHQ/s1338/20230208_222324074.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1338" data-original-width="581" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbPExJZjhGVn7UmOlFuhSuUlWjz_VEPtVGrwBL0LxmiU4rlyLcOByp1YU-B6qgwVW3rbpGLvCyc0wJ9W1v9r-IKjrBTxymSSe0VAGe1jigTDv426z56kvoR_4MxKOIJi9jcjNiIca-c6uwb3p-ZhILoWy1pHg78loqWSX7DErElvYKxAlK8Eh-IlhlHQ/s320/20230208_222324074.jpg" width="139" /></a></div>Later, I scrounged around found some more C channel and I was able to get the 2nd top longeron completed. Here are all of the longerons, completed (in order from left to right - top set, side set and lower set):<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhT3jjQzpwroVcBvbJsARdNciKn_W0qcQXTGrlcx-ExFNpUCMLkPCnx45ncfxYc21qltQ7Cg4SoWd1Oq9CqDmXtFoQGI4W74zKX6zH8jdk0f_asFAd4u0gqn3yFL3po30a6k8ramMZJvZoE87hEKz6p7_tDuVDw33WIbBh79FSNEgRZG3Pz5LjDVe_SEA/s1314/20230208_232611309.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1314" data-original-width="576" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhT3jjQzpwroVcBvbJsARdNciKn_W0qcQXTGrlcx-ExFNpUCMLkPCnx45ncfxYc21qltQ7Cg4SoWd1Oq9CqDmXtFoQGI4W74zKX6zH8jdk0f_asFAd4u0gqn3yFL3po30a6k8ramMZJvZoE87hEKz6p7_tDuVDw33WIbBh79FSNEgRZG3Pz5LjDVe_SEA/s320/20230208_232611309.jpg" width="140" /></a></div>In the end, it is a tedious process to form these longerons from straight pieces of C channel. But, having done it again, I have found that if you take your time, only shrink the parts one step at a time - you can get a set of them done in 3-4 hours (not including the time to make the 8ft sections of C channel - that's a whole different animal).<br /><br />With Vaughn's longerons completed, I just had to figure out how to ship them to him. I wanted something sturdy, that would protect them and keep them from getting crushed. I finally decided that an 8" diameter cement form from Home Depot would work the best. Here are the longerons and the radiator fairings ready to ship:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMaf6Rjz9y_AJFuCiuz71xBS7HM40IIGevkGez8h9nlCmjS_24coDI_OGRhnRokScrLDZhmbpsAepYe4bcl5CfyP6iKGibzhdwhuidooHkMsKzMXUdbarO4J4A7p3CeC0FhzLasJEV9V-OXNKMozwVQnz6gwZOCg-nnpyrWZ9yd7NbW05kTnRiLuPU5g/s1910/20230215_024805664~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1910" data-original-width="643" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMaf6Rjz9y_AJFuCiuz71xBS7HM40IIGevkGez8h9nlCmjS_24coDI_OGRhnRokScrLDZhmbpsAepYe4bcl5CfyP6iKGibzhdwhuidooHkMsKzMXUdbarO4J4A7p3CeC0FhzLasJEV9V-OXNKMozwVQnz6gwZOCg-nnpyrWZ9yd7NbW05kTnRiLuPU5g/s320/20230215_024805664~2.jpg" width="108" /></a></div><br /><u><b>C. An Update From Bryan</b></u> - So, Bryan retired about 3-1/2 years ago. After that, he started working on several projects around the house, including: a new back yard with large retaining wall, an new deck, and a new, detached garage/man-cave to use while completing his Prowler. Of course, CoVid slowed the progress to a slow crawl at times, not to mention the battles with the local building department. But, just recently, Bryan sent me some pics and announced that he had gotten the go-ahead from the building department to move into some of the new garage. It's actually an RV garage, a hangar, and a workshop combined - with a man-cave above the hangar. Here's the front view (house is on the right and new garage on the left at the end of the drive):<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMcFlEJD3BYza39XG-FWmaHTV_iUOenf5XXyeQ55LXqcyNhsQ6-nZPnskxfkdrOsrfdjIgdjdfdbhQurvux44nIsFyyZcNK40A6pfkx4JA6TGxToVdkIQ47_ApkDF0LLs39KrrMJ0ygcUE8A3c7P4CVhRsthxw0iJMjNZPDWgPQRR06BTujevftT5XEg/s640/IMG_20230222_152557.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMcFlEJD3BYza39XG-FWmaHTV_iUOenf5XXyeQ55LXqcyNhsQ6-nZPnskxfkdrOsrfdjIgdjdfdbhQurvux44nIsFyyZcNK40A6pfkx4JA6TGxToVdkIQ47_ApkDF0LLs39KrrMJ0ygcUE8A3c7P4CVhRsthxw0iJMjNZPDWgPQRR06BTujevftT5XEg/s320/IMG_20230222_152557.jpg" width="320" /></a></div>With all the work that he'd been doing on other projects, the Prowler got relegated to the back of the "pile" temporarily:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_zQD7oroofs6zKSZLVF6chBYo2PUFTVwHsdRkPrBL9ofLWHAzm2fpK97aoeZinq2ecIrVNg8gY4voXqz2iJgliIyyiWNNWhgu6rAQrfSD2TLGp1-RtOSk2BJVYsyePMI_20b-IM2wynawaA1vo4hq_suERaJ-P71Bbbctd2GhNWEnCvIYeL1lZPYHww/s1024/IMG_20230221_142905.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="768" data-original-width="1024" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_zQD7oroofs6zKSZLVF6chBYo2PUFTVwHsdRkPrBL9ofLWHAzm2fpK97aoeZinq2ecIrVNg8gY4voXqz2iJgliIyyiWNNWhgu6rAQrfSD2TLGp1-RtOSk2BJVYsyePMI_20b-IM2wynawaA1vo4hq_suERaJ-P71Bbbctd2GhNWEnCvIYeL1lZPYHww/s320/IMG_20230221_142905.jpg" width="320" /></a></div>and:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilFgC0bL2UVbFSWrXEbgTAYEd0YxAFPfCbHj47tgqdUIhwGvS5ozZdpekld588x8E7Zkze748irexA1UR4TwEv5Ia6sl7y0FuVz4zl0YnamJsG_Pm0PDcsnujyZoSAtE_ZXmGqO_awrlUJl1JvlxzZFa-QvhksIRxIkn-pyDuyHds0eQyxSkmzYy4UiA/s1024/IMG_20230221_142913.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="768" data-original-width="1024" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilFgC0bL2UVbFSWrXEbgTAYEd0YxAFPfCbHj47tgqdUIhwGvS5ozZdpekld588x8E7Zkze748irexA1UR4TwEv5Ia6sl7y0FuVz4zl0YnamJsG_Pm0PDcsnujyZoSAtE_ZXmGqO_awrlUJl1JvlxzZFa-QvhksIRxIkn-pyDuyHds0eQyxSkmzYy4UiA/s320/IMG_20230221_142913.jpg" width="320" /></a></div>In the interest of full disclosure, the Prowler project has also gotten put on the back burner because Bryan had been waiting for DeltaHawk to provide a diesel aircraft engine which Bryan had put a fairly large deposit on. DeltaHawk never came through and Bryan eventually got his deposit back.<br /><br />Now, the Prowler has a new home of it's own in the "hangar bay":<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYN3d2iMZ2OgOuHvRvEuguY6LuGIbb1bkKFO1whzz3afAfYEIt56aabQ5zSCFKq2-B_C8tfkJlgHxoIIq8Xl8_NgTmTQLL2lXUduTvacyHeVJnW0e5pMSX3XQ4nsT4e8rXO9cRTh5YPW7QFllBwce2jGlLmnJ9v__JfUT2JdHNXW6S0ckVZkGSxacNyQ/s2048/IMG_20230221_142926.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1536" data-original-width="2048" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYN3d2iMZ2OgOuHvRvEuguY6LuGIbb1bkKFO1whzz3afAfYEIt56aabQ5zSCFKq2-B_C8tfkJlgHxoIIq8Xl8_NgTmTQLL2lXUduTvacyHeVJnW0e5pMSX3XQ4nsT4e8rXO9cRTh5YPW7QFllBwce2jGlLmnJ9v__JfUT2JdHNXW6S0ckVZkGSxacNyQ/s320/IMG_20230221_142926.jpg" width="320" /></a></div>and:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAASstFNLAjoD8CMtGsGuxMhLHcb1-cTnJ9IN4Eu034EaO6tdSednCGkKU39ZurqoLA8CeuxCLPTbXiggnEYU5CdHfTCKOkrPt0bsHqAM-XerDveTL-iyYkuTcDWuVmKk-lv0jZiE43PvluxYb8HX1nnR-F8T9EayGRdvDbqZZgdoi5nDBt3K65xjqqw/s800/IMG_20230222_152607.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="600" data-original-width="800" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAASstFNLAjoD8CMtGsGuxMhLHcb1-cTnJ9IN4Eu034EaO6tdSednCGkKU39ZurqoLA8CeuxCLPTbXiggnEYU5CdHfTCKOkrPt0bsHqAM-XerDveTL-iyYkuTcDWuVmKk-lv0jZiE43PvluxYb8HX1nnR-F8T9EayGRdvDbqZZgdoi5nDBt3K65xjqqw/s320/IMG_20230222_152607.jpg" width="320" /></a></div>On the right side of the hangar bay is the new workshop:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIIClQzvKEDRfX7s0SIEp4eAkxJRVsmp3HTdVncMuyHZNUYN5H6JCzkrWSmbmPZkUMR9XBcfjhWBnQe64diGf1i-YsEjFRAKxyELPzlAi-0UAW8UjTWR1EwcjHM4fYvqoj3LqXqgU0PtbH-GoMWVsHpy00jqOkKU6ikLzLTY02y3Atf9dRWbYteeZNFQ/s800/IMG_20230222_152612.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="600" data-original-width="800" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIIClQzvKEDRfX7s0SIEp4eAkxJRVsmp3HTdVncMuyHZNUYN5H6JCzkrWSmbmPZkUMR9XBcfjhWBnQe64diGf1i-YsEjFRAKxyELPzlAi-0UAW8UjTWR1EwcjHM4fYvqoj3LqXqgU0PtbH-GoMWVsHpy00jqOkKU6ikLzLTY02y3Atf9dRWbYteeZNFQ/s320/IMG_20230222_152612.jpg" width="320" /></a></div>And, here is the soon-to-be man-cave above the hangar bay and workshop:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLsn0lBNNHJXJ-SOMLgIsbLLH6KURNQaLpg09kOTiM-8COrjEnT9b4USdmD-akDboPM6IOZfeJGruw4FaJIsbUWm9rBV-aDzbvNkOJrdtnmcZgN6f5N8Jy_LDU3wNlUngmtzvbM7ay4rhNzB0zR7wZOKPi9YpTFNidSW9Ir5_G3m99b_GaPT9C4qePBQ/s800/IMG_20230222_152623.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="600" data-original-width="800" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLsn0lBNNHJXJ-SOMLgIsbLLH6KURNQaLpg09kOTiM-8COrjEnT9b4USdmD-akDboPM6IOZfeJGruw4FaJIsbUWm9rBV-aDzbvNkOJrdtnmcZgN6f5N8Jy_LDU3wNlUngmtzvbM7ay4rhNzB0zR7wZOKPi9YpTFNidSW9Ir5_G3m99b_GaPT9C4qePBQ/s320/IMG_20230222_152623.jpg" width="320" /></a></div>Nice work, Bryan. It looks awesome. I hope I'm not the only one feeling a little envious of your new "digs." I'm sure it's going to a great place to finish up your Prowler. Thanks for sharing!<br /><br />Well, that's it for this update. I have a bit more Prowler work in the works right now. I'll report on that soon. Thanks for stopping by to check out the update.<br /><br />Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-4561663675008429701.post-50102708840738738962023-01-30T16:06:00.000-08:002023-01-30T16:06:23.276-08:00Another "Catch-up" Blog Post - AirVenture 2022<p></p> Well, as promised, here is the update on AirVenture 2022. <br /><br />Bryan got to Camp Scholler first this year, so he roped off an area to save space for all of us. We tried a new location this year. We tried the NW corner of a field that was on in the SE part of Camp Scholler. There is a pic of the area that Bryan roped off:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhV5Eg5KHqci8drHe4i2PaTrmwXdYBZdKcHpGOPpiKrX-KCHgtyJC5DMfKroFG9N_JaAofEzdAhutBwADHE9vZSjqoKNUAzSrlTkcoNTcagkNugY6I6RUHDdhPKYlrtiZ2Gmp2W2E6MZLAkPW7parbzdpdRVtASny1m4noV1o2U7yRHa5EKsgN5XXJHOQ/s1749/20220719_192212028.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="654" data-original-width="1749" height="120" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhV5Eg5KHqci8drHe4i2PaTrmwXdYBZdKcHpGOPpiKrX-KCHgtyJC5DMfKroFG9N_JaAofEzdAhutBwADHE9vZSjqoKNUAzSrlTkcoNTcagkNugY6I6RUHDdhPKYlrtiZ2Gmp2W2E6MZLAkPW7parbzdpdRVtASny1m4noV1o2U7yRHa5EKsgN5XXJHOQ/s320/20220719_192212028.jpg" width="320" /></a></div>I pulled my RV in the following day:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKmOnXqZ_HsJcRR9fwicCPONvjSIETPvmhRN1KPHNrc0-x6dpw2NWmdj--ISnVUT03Y82_rKedhHslsIOq8I6iZt9RiuntIoysL-plhiHrV_3ofVcC3XQVWNIpuvik9gRNnOz_h5HYeTx3wGHv7R7hRC77btH-A3onh33c9Q7iIBq2tHLIBABmtUuz0g/s1344/20220721_005753814.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1344" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKmOnXqZ_HsJcRR9fwicCPONvjSIETPvmhRN1KPHNrc0-x6dpw2NWmdj--ISnVUT03Y82_rKedhHslsIOq8I6iZt9RiuntIoysL-plhiHrV_3ofVcC3XQVWNIpuvik9gRNnOz_h5HYeTx3wGHv7R7hRC77btH-A3onh33c9Q7iIBq2tHLIBABmtUuz0g/s320/20220721_005753814.jpg" width="320" /></a></div>We had an even bigger crew this year, than we did last year! We had
about 25 in all. Not all were able to be there for the entire week, but
almost everyone got there for a few days, at least. This year, my wife
and I had all three daughters with us. That was awesome! The oldest
daughter even bought her own bumper pull travel trailer earlier in the
year and she towed it to Camp Scholler from MT. She and her 3 dogos
made the trip in the travel trailer and it worked out really well for
her! Here she is with her dog, Whiskey, shortly after arriving:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbAUILpyQIMY8mxNSnWSvu3g_EiEgZEzCBUdx9auDSCyvLORli5upOLOBUXauSaiFwF61noUXi9KSAro6uAS9yP1Fr88k5j6ExBsZdjLy0w2uAMAn-nKlFjVOYzUlSPeIOJfnzEKxXI2DLLnRJaJEGcKxOg0X9OwpNDKCLxUN2dgVKqzZt2xcewyMIeQ/s994/KB%20Rig.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="715" data-original-width="994" height="230" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbAUILpyQIMY8mxNSnWSvu3g_EiEgZEzCBUdx9auDSCyvLORli5upOLOBUXauSaiFwF61noUXi9KSAro6uAS9yP1Fr88k5j6ExBsZdjLy0w2uAMAn-nKlFjVOYzUlSPeIOJfnzEKxXI2DLLnRJaJEGcKxOg0X9OwpNDKCLxUN2dgVKqzZt2xcewyMIeQ/s320/KB%20Rig.png" width="320" /></a></div>The weather for AirVenture 2022 was THE BEST weather I have ever seen for the actual days of the show (Mon to Sun). However, on the Sat before the show started, there was a massive gust front and storm that moved through the area. Have you ever heard "If the sky turns green, it's going to be a bad storm?" Well, check this out:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJ1dVLxzKj0_eIwO0XJGIAJPeIopiVhktGRMnG8ElQXVHJ46DJfcE_1R7recgMgXGggcnOMuppj18wpW4IodhgEqp1xxGSZ_0vpQuf5mPWp5tAUW3Y2PsnWbr_Rf--GeaH4c-qHCG-NLNNHI6YyZp9uhljkdYFJClVK4BNylfhhB9mjYUqa_bvxEsgUA/s1425/20220723_223938433.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="802" data-original-width="1425" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJ1dVLxzKj0_eIwO0XJGIAJPeIopiVhktGRMnG8ElQXVHJ46DJfcE_1R7recgMgXGggcnOMuppj18wpW4IodhgEqp1xxGSZ_0vpQuf5mPWp5tAUW3Y2PsnWbr_Rf--GeaH4c-qHCG-NLNNHI6YyZp9uhljkdYFJClVK4BNylfhhB9mjYUqa_bvxEsgUA/s320/20220723_223938433.jpg" width="320" /></a></div>Here is a little video of the approaching storm:<br /><div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dx-ZkV4JHMj8EmstE4GNmk9NUrDpF601mOigz-LCkc7dQe0kDVjZGEhC0kT8hNigAeZz1-cyE_DPMywiOUdCA' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div>It poured down rain for about 40 minutes! I am so thankful that there was very little aircraft or other damage. Sunday, the sun came out and it was breezy - so most of the roads dried out and it wasn't too muddy. The weather stayed clear, cool and sunny the rest of the week! Beautiful weather for this year!<br /><br />Here's a few pics of about 1/2 of the crew this year. This is on the flightline on Wed night before the night airshow:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjud8wDxZ68mrcjp76gYP4u-5gn6WoO4evif8YXRbz5CzIsSM47bAzpoBtG9uh_4HUUhr97zP3vbQCyPZuXiwnDTdtshIP8-xf_qfA4vHbQ8E5nOfMieEkcUUeDozixLbb0_ZloOU-aGTMUOFOIIwyx-XxU93XCexH72H13llCo3mTapxBui-PAB9JAYw/s1210/IMG_0535.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="1210" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjud8wDxZ68mrcjp76gYP4u-5gn6WoO4evif8YXRbz5CzIsSM47bAzpoBtG9uh_4HUUhr97zP3vbQCyPZuXiwnDTdtshIP8-xf_qfA4vHbQ8E5nOfMieEkcUUeDozixLbb0_ZloOU-aGTMUOFOIIwyx-XxU93XCexH72H13llCo3mTapxBui-PAB9JAYw/s320/IMG_0535.jpeg" width="320" /></a></div>And, our immediate family and friends at the "Brown Arch":<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTt2TQ_UXDIDr3wGjzJlT7s1Wtu99Y18MKQQ0RIyJGfjvD61jlUypQYTo__yQHjl_0tJKlkep5QtRFXsRjKBl9kwlcaDAyY2n2cd9d0LMMBgcu9HEB5LuChPKHRI_XXa1-O0mZGR_a2QXXh-KwkFrMdS9L_leELnWKo9NcmPurUCipt37gKNAHnG7sKw/s973/IMG_0584.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="888" data-original-width="973" height="292" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTt2TQ_UXDIDr3wGjzJlT7s1Wtu99Y18MKQQ0RIyJGfjvD61jlUypQYTo__yQHjl_0tJKlkep5QtRFXsRjKBl9kwlcaDAyY2n2cd9d0LMMBgcu9HEB5LuChPKHRI_XXa1-O0mZGR_a2QXXh-KwkFrMdS9L_leELnWKo9NcmPurUCipt37gKNAHnG7sKw/s320/IMG_0584.jpeg" width="320" /></a></div>When the show opened on Monday, I found a new plane I'd never seen before parked on Boeing Plaza:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4P1CEq-pcVBoEUERbUjqWZfoSR8Kv6Q0FGgIBvXAvU70G2cxNKdur4pIvCk1NKNWOhVH2nFB20oA7t4oYnx3So8wgEzdI8Zdqa__Mm9UkLPYwIFnJTu9kHAnFD1NxqZea0eXDllaW1xcd-K3rnfaKTtDstlMGiirxsFeGwVaeToD1dl1JLK75ry_HiA/s1193/20220725_161600892.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="546" data-original-width="1193" height="146" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4P1CEq-pcVBoEUERbUjqWZfoSR8Kv6Q0FGgIBvXAvU70G2cxNKdur4pIvCk1NKNWOhVH2nFB20oA7t4oYnx3So8wgEzdI8Zdqa__Mm9UkLPYwIFnJTu9kHAnFD1NxqZea0eXDllaW1xcd-K3rnfaKTtDstlMGiirxsFeGwVaeToD1dl1JLK75ry_HiA/s320/20220725_161600892.jpg" width="320" /></a></div>Interesting plane, and an interesting mission. Here's some details:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXwMbRIi9w5n7b213R4MSp-Q8avSKFeevoMYG475s2a4MG3qg22gF3CMwLM8sKJ1YWCmLYAFGVbsSZBGXdaqcCbTXliMtb81hWR-c5HvS2CYQblgewhKkCqIXkG6dwvX0FgY_UWlDsr5BvVMAykdD9Z8JUFZHACl4yeILDL1UDWc-usE0bcMBAuR8rPQ/s1236/20220725_161719104~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="1027" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXwMbRIi9w5n7b213R4MSp-Q8avSKFeevoMYG475s2a4MG3qg22gF3CMwLM8sKJ1YWCmLYAFGVbsSZBGXdaqcCbTXliMtb81hWR-c5HvS2CYQblgewhKkCqIXkG6dwvX0FgY_UWlDsr5BvVMAykdD9Z8JUFZHACl4yeILDL1UDWc-usE0bcMBAuR8rPQ/s320/20220725_161719104~2.jpg" width="266" /></a></div>My "once per week" check of the warbirds ramp netted sightings of this beautiful F7F Tigercat:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrQ7NiKpD6hxncrdCTHnlHFMyyGgVE7h9heWGJj_0CGyBX0yAJN4FToCCipSlhiJvgDIs8ZTgXsUpG-tr3sdS25WKNonX5Zia9xZoyVvnZme2aT2msgTM6QDFvWdUBuM99E_ZG3RYPV-TB8fLTkjqXpOTYPJnmNMZ3TnHN2SUtPHunEGJF4tBJY6114Q/s1371/20220729_183135132.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="869" data-original-width="1371" height="203" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrQ7NiKpD6hxncrdCTHnlHFMyyGgVE7h9heWGJj_0CGyBX0yAJN4FToCCipSlhiJvgDIs8ZTgXsUpG-tr3sdS25WKNonX5Zia9xZoyVvnZme2aT2msgTM6QDFvWdUBuM99E_ZG3RYPV-TB8fLTkjqXpOTYPJnmNMZ3TnHN2SUtPHunEGJF4tBJY6114Q/s320/20220729_183135132.jpg" width="320" /></a></div>And, this Marine Corps version of the same aircraft:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhknWaXwXpsM3SOWdvFPhVBngIH1RS215Noxdh1tn6SIjKEo-UXeEtRS28stQhFtCPA56ViCh7LNHBIms082ShGHcsLkJvwn4Wqep5VhzW4WzYRxnhpZKp3YeH45dnFeZ4EzxoUj0O8j4CcB0uWxrjfVrTf176KYL8nSk3zIKf2GqrYUMJjzsU4173w0w/s1451/20220729_183434530.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="815" data-original-width="1451" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhknWaXwXpsM3SOWdvFPhVBngIH1RS215Noxdh1tn6SIjKEo-UXeEtRS28stQhFtCPA56ViCh7LNHBIms082ShGHcsLkJvwn4Wqep5VhzW4WzYRxnhpZKp3YeH45dnFeZ4EzxoUj0O8j4CcB0uWxrjfVrTf176KYL8nSk3zIKf2GqrYUMJjzsU4173w0w/s320/20220729_183434530.jpg" width="320" /></a></div>I also found this F4U Corsair:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiyM94c7W3RzVwtWUmBH9gkXu0f2ez6EUTebMzYRraBQXnPjGw5fMdFGQiUNBgc1_B4-NF_n4-6wv9la7L3ltSXGrZbZz7Bxd2Rcf4ME0-PxOuraPReR59pMP9hjzJHtUy-72uEx6zUTLEr_qfyPckcao5MvL8EaQRdjkyKBQUZhtrtDuvcfPmwSdiyfg/s1045/20220729_185026608.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1045" height="232" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiyM94c7W3RzVwtWUmBH9gkXu0f2ez6EUTebMzYRraBQXnPjGw5fMdFGQiUNBgc1_B4-NF_n4-6wv9la7L3ltSXGrZbZz7Bxd2Rcf4ME0-PxOuraPReR59pMP9hjzJHtUy-72uEx6zUTLEr_qfyPckcao5MvL8EaQRdjkyKBQUZhtrtDuvcfPmwSdiyfg/s320/20220729_185026608.jpg" width="320" /></a></div>Beauty:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYvJaQem67S9lcpclEjZFZfbBiy351u4Ufi-mHoqIdO2LCsUlMkp_AFe_ZXeoOhVt2fU83dW2AVtO-FjrV_Vb0BcBkqqquk0fwm2wUT_o0q3iHV4ZJhXuCfYRRDkUNysQutsCYmlvCVHgHTKfaX_q6nMJEodHJqN4uGRV28bl6c0TUENhJfB_Su-X2Qw/s1190/20220729_185044827.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="837" data-original-width="1190" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYvJaQem67S9lcpclEjZFZfbBiy351u4Ufi-mHoqIdO2LCsUlMkp_AFe_ZXeoOhVt2fU83dW2AVtO-FjrV_Vb0BcBkqqquk0fwm2wUT_o0q3iHV4ZJhXuCfYRRDkUNysQutsCYmlvCVHgHTKfaX_q6nMJEodHJqN4uGRV28bl6c0TUENhJfB_Su-X2Qw/s320/20220729_185044827.jpg" width="320" /></a></div>Here is another 1st for me. At the daily air show on Sat, a privately owned Mig-29 Fulcrum did a demonstration flight:<br /><div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dxc4CIt_gb0v2nLXqcz7aoJ_hj3uofd_7DPxFpHJkOAgWt-o5O969NHTfb6yAC3rp17bEFPqy5DmlkxIHXspQ' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div>Anyone else think this airplane looks a lot like an F15 Eagle? <div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitsN7u25UItCf26GBS8rhS1nn6yvr_Ga9rgEBgjoBtmEZAF4EX1xYF5yif8v3j7EjOM_anWRwwuZ7Thn0pX5I1s9QgC5ZEh1rMR8oY3yQRFBMJdYTIo0TFLCIe6S6jC8SDdHT0xKoar4LTM518Lx2YqGoc_MPcozYRwsVC3yj4rHBDyvdJjHdR44UzoQ/s1327/20220730_220707691.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="726" data-original-width="1327" height="175" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitsN7u25UItCf26GBS8rhS1nn6yvr_Ga9rgEBgjoBtmEZAF4EX1xYF5yif8v3j7EjOM_anWRwwuZ7Thn0pX5I1s9QgC5ZEh1rMR8oY3yQRFBMJdYTIo0TFLCIe6S6jC8SDdHT0xKoar4LTM518Lx2YqGoc_MPcozYRwsVC3yj4rHBDyvdJjHdR44UzoQ/s320/20220730_220707691.jpg" width="320" /></a></div>The best part of AirVenture, for me, happened after AirVenture 2022. Dave got me an opportunity to join him and Justin while they were helping EAA get an AirCam (that EAA constructed) certified in the Experimental Category. This work was happening at the Kermit Weeks Hangar. Here is the hangar from the flightline side, with the AirCam on the right:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9sN8xcqWCNNiX59yiayGzysiAFBckDo5ke48RVR43wqrybGrzCNYLrciyPaEiJrwRz8zrHpsElGFC1r2H6cGEmOzhomy5njN4MVhvDsoQdekKr_6kxZOWTlg9hPdWXQCf8zhzv4SzI6wT86ospIjbwbw2_UW-TVr-U8fz9sABi4W9ATCM340pnXGaCg/s1613/20220803_140451826.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="1613" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9sN8xcqWCNNiX59yiayGzysiAFBckDo5ke48RVR43wqrybGrzCNYLrciyPaEiJrwRz8zrHpsElGFC1r2H6cGEmOzhomy5njN4MVhvDsoQdekKr_6kxZOWTlg9hPdWXQCf8zhzv4SzI6wT86ospIjbwbw2_UW-TVr-U8fz9sABi4W9ATCM340pnXGaCg/s320/20220803_140451826.jpg" width="320" /></a></div>When the AirCam was out flying, I got an opportunity to "wander" around the Kermit Weeks Hangar. Wow! There are so many fantastic aircraft here! Remember that F7F Tigercat above? Well - I had no idea that it was part of the Kermit Weeks collection:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsmlhVaxqLucL3KS2kqgY1CfpNtjT7N_vgBBciJpdlHJ8VxH9IgSZ70-trhn6aDqVd3cz68VPUDrmdAg2ywqgx5DquzirYJ_KScXT2WzC9tr_GJysBMn2s0SzRX66SY8WHzCTz7RtHUQHzgOz-vglBd1qgHa3xcNfxgian7Iff0JHIJUFGNoejXu6i2Q/s1613/20220802_142731168.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="1613" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsmlhVaxqLucL3KS2kqgY1CfpNtjT7N_vgBBciJpdlHJ8VxH9IgSZ70-trhn6aDqVd3cz68VPUDrmdAg2ywqgx5DquzirYJ_KScXT2WzC9tr_GJysBMn2s0SzRX66SY8WHzCTz7RtHUQHzgOz-vglBd1qgHa3xcNfxgian7Iff0JHIJUFGNoejXu6i2Q/s320/20220802_142731168.jpg" width="320" /></a></div>I have seen this Mustang at AirVenture many times:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhESRfia4GE4M5tAM-XcpAB3ddrR0utjMzDv8Ry_tnqX-BI13H_oebbLCKly0pHyEXeIxhedB4AmGjgG4lKAr2TqLBiRMyuXJMOal69Bci41-pTfL43pMLlRg3XXnOHHLql-EMzaEFblkOtRY4WF7vx_3BLhtQ7SFrDwEKKK6g6UgXHWnkrRff3HzD3JQ/s1613/20220802_142612996.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="1613" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhESRfia4GE4M5tAM-XcpAB3ddrR0utjMzDv8Ry_tnqX-BI13H_oebbLCKly0pHyEXeIxhedB4AmGjgG4lKAr2TqLBiRMyuXJMOal69Bci41-pTfL43pMLlRg3XXnOHHLql-EMzaEFblkOtRY4WF7vx_3BLhtQ7SFrDwEKKK6g6UgXHWnkrRff3HzD3JQ/s320/20220802_142612996.jpg" width="320" /></a></div>And, remember that F4U from above? Again, I didn't know it was part of this collection:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjGHKChpy3W0t3MCLvE6f3gMJZa-rn6CnNBkneCLX6TaA_9St8IioX1t1aiK-ycSQQbBLezUoyaF0jmIyFqg1dh9B99N-0VY3KScNHsaYbbix5r8q1a-eXL74BSvNw3UIuCUpY1zlt0kYbdYPp12fdmb0MQX7WQEB-fXgAtLLZAqM-HE8i0vOojDAuRdA/s1477/20220802_142629131.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="1477" height="197" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjGHKChpy3W0t3MCLvE6f3gMJZa-rn6CnNBkneCLX6TaA_9St8IioX1t1aiK-ycSQQbBLezUoyaF0jmIyFqg1dh9B99N-0VY3KScNHsaYbbix5r8q1a-eXL74BSvNw3UIuCUpY1zlt0kYbdYPp12fdmb0MQX7WQEB-fXgAtLLZAqM-HE8i0vOojDAuRdA/s320/20220802_142629131.jpg" width="320" /></a></div>Another view of the F7F Tigercat - what a beautiful airplane:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipNClTMxQNEcZ0PNjsmETnev_Bl0lDVrC0V7Pe8e-8ZgIWQVCDhvWKmhrvssjKCq-dONYWRHBZ30njhRnRaFMTC-qEkBTeHl9x03fK8Fjx_L6bPUlLG1DwiacwSB55RKUsb4Xv07XtGHEqXMroLufD95pcWMNq7p--AfSs5jwetrQZpXUTODT361SWVA/s1613/20220802_142703003.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="1613" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipNClTMxQNEcZ0PNjsmETnev_Bl0lDVrC0V7Pe8e-8ZgIWQVCDhvWKmhrvssjKCq-dONYWRHBZ30njhRnRaFMTC-qEkBTeHl9x03fK8Fjx_L6bPUlLG1DwiacwSB55RKUsb4Xv07XtGHEqXMroLufD95pcWMNq7p--AfSs5jwetrQZpXUTODT361SWVA/s320/20220802_142703003.jpg" width="320" /></a></div>Here is a 100% authentic restoration of the German Bf-109 Messerschmitt. I believe this aircraft won several awards:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTGMqkCFdPhDkHoh7hd4kVCit5Af1ldZKHw8PznU_U6R07ADIj4kyl9_s4vPzuU1G27Sow0_cT7_Dt7RszkXCtcUHUKjVSIiLSJUxNznKG9ctGhhmOzMeFW3b2usWL1mUsIL0Wq2HF-daICZ2qejM6BAkG8WY2nIIXPbpmmdSa42KlSbZt2iFrlmndVw/s1613/20220802_142810995.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="1613" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTGMqkCFdPhDkHoh7hd4kVCit5Af1ldZKHw8PznU_U6R07ADIj4kyl9_s4vPzuU1G27Sow0_cT7_Dt7RszkXCtcUHUKjVSIiLSJUxNznKG9ctGhhmOzMeFW3b2usWL1mUsIL0Wq2HF-daICZ2qejM6BAkG8WY2nIIXPbpmmdSa42KlSbZt2iFrlmndVw/s320/20220802_142810995.jpg" width="320" /></a></div>Beautiful restoration!<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfTsx7UwuxwwnPHP_g_abodNipz9T379RWWODnGefsp83KhGOxeflDS_Zuvr3SEbm5cz4CwRgF2xOxRqy9trSNJUTgTw3jJyDj2zvsFXHNErqjscUiX7QaIgFeYtFaurv5o_so2QpzW2BP9k0kQnRFil5C2x0Ynsj00saOBFRBetN5uY5NUwvDhTU4Cw/s1613/20220802_142851009.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="1613" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfTsx7UwuxwwnPHP_g_abodNipz9T379RWWODnGefsp83KhGOxeflDS_Zuvr3SEbm5cz4CwRgF2xOxRqy9trSNJUTgTw3jJyDj2zvsFXHNErqjscUiX7QaIgFeYtFaurv5o_so2QpzW2BP9k0kQnRFil5C2x0Ynsj00saOBFRBetN5uY5NUwvDhTU4Cw/s320/20220802_142851009.jpg" width="320" /></a></div>They were all carefully put away in the hangar:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHjx1zbh5CU6dP4ObUUwTrzJ2jf6ITu9wQ1aEp_wWbAy-gKR0XNVAh8Gucm-_8CVVFwXZylPuTGfbPcSZ0DknPU9_2OSWlZ4YGr4G_TwFbzktZZHf0h4pE-UDrAJKnYRhthbqAQXAvxh2Hn38rEnKplqjk7rXlZq_p9u-2si_AmdJynzfQGx8yb333Mw/s1613/20220802_142912515.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="1613" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHjx1zbh5CU6dP4ObUUwTrzJ2jf6ITu9wQ1aEp_wWbAy-gKR0XNVAh8Gucm-_8CVVFwXZylPuTGfbPcSZ0DknPU9_2OSWlZ4YGr4G_TwFbzktZZHf0h4pE-UDrAJKnYRhthbqAQXAvxh2Hn38rEnKplqjk7rXlZq_p9u-2si_AmdJynzfQGx8yb333Mw/s320/20220802_142912515.jpg" width="320" /></a></div>Here you can see the Ford Trimotor that the EAA "borrowed" to do the rides at AirVenture this year. EAA's Trimotor was out of service and not able to fly the "Trimotor Rides" this year. The maintenance guys were changing tires, brakes and other maintenance work to get it all spiffy-ed up before they gave it back:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8e_L3E7SreLOhm2CzglTh5xNRaWW8IRcE0SvrDJL3Uw68JMY5ZytXhjVOUNDFybTyhiyAwweDMAQ7b2n-t4iW6TaigypVqNJEbiasTOOG2uVGJrm2uwvMz7ju87mN93XHzt4srFu7rR-6hN81WZbwIv2bO58QMvVVEBW_i4D74kFZLo2SWtscpFP-8w/s1957/20220802_142315108.PANO.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="846" data-original-width="1957" height="138" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8e_L3E7SreLOhm2CzglTh5xNRaWW8IRcE0SvrDJL3Uw68JMY5ZytXhjVOUNDFybTyhiyAwweDMAQ7b2n-t4iW6TaigypVqNJEbiasTOOG2uVGJrm2uwvMz7ju87mN93XHzt4srFu7rR-6hN81WZbwIv2bO58QMvVVEBW_i4D74kFZLo2SWtscpFP-8w/s320/20220802_142315108.PANO.jpg" width="320" /></a></div>Here is EAA's Trimotor that is being worked on and was not able to fly this year:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZfFC9Vo8RF8adA-eHosDOJXitz1-W5j7utORONAptOGImsADIK5L9OYLOMe6e3gmhxzGuSsNctJ2KhGr9PRhzau8c5h6eeLU9Hyd4hBWT2yAGjDl0Eg32ev55Y_0C1OZWeVoB7GvpElVjuJIpBGBoM8FY3_adKcqCoiN-pwDEQ2fo0jbtx6DElgsCvQ/s1613/20220802_142713036.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="1613" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZfFC9Vo8RF8adA-eHosDOJXitz1-W5j7utORONAptOGImsADIK5L9OYLOMe6e3gmhxzGuSsNctJ2KhGr9PRhzau8c5h6eeLU9Hyd4hBWT2yAGjDl0Eg32ev55Y_0C1OZWeVoB7GvpElVjuJIpBGBoM8FY3_adKcqCoiN-pwDEQ2fo0jbtx6DElgsCvQ/s320/20220802_142713036.jpg" width="320" /></a></div>Thanks to Dave and EAA for the opportunity to check out the Weeks hangar. What an amazing collection of awesome aircraft!<br /><br />Sorry, no pics or video of the fireworks or finale this year. I was on a special mission and not able to take pics or vids those nights. But, it was still a great as it ever was!<br /><br />Well, I am getting caught up on my blog updates. I think I have a few things to share when I made some Prowler parts recently. Will update on those soon. Thanks for checking out the blog. See you next time.Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-4561663675008429701.post-78724898508699583462023-01-21T05:53:00.000-08:002023-01-21T05:53:42.797-08:00"Catch-Up" Blog Post - AirVenture 2021 Hello Everyone,<br /><br />In the past, I have always included pictures and info from AirVenture each year. In the last 2+ years I have been delinquent on keeping up with and getting any updates posted in a timely fashion. Anyway, I'm on a crusade to right the ship and I have a little more "stuff" in the backlog to get cleared out. A recent work trip had me in a hotel for 30+ hours, so I decided to use the time to get another "catch-up" blog update posted.<br /><br />What I'd like to share in this blog post is "stuff" from our week at AirVenture 2021. This was the 1st AirVenture after CoVid forced the cancelling of AirVenture in July 2020. In the next blog post, I'll cover "stuff" from AirVenture 2022 and that will get me caught up - at least with regard to AirVenture updates.<br /><br />For years now, I have been relying on my dad to use his GMC dually to pull my 5th wheel RV rig to Camp Scholler (and back) every year during AirVenture. I decided it was time to get my own truck to do that job. I started looking for something of my own. But I did not want to put a lot of $$$ into what had become very expensive items (Remember? With CoVid came supply shortages, and with supply shortages, vehicles became harder to find - and way more expensive to buy).<br /><br />Well, I managed to find a listing for an old 1989 Ford F350 Dually that was really reasonably priced. Where we live in the CA north state, everyone wants to have a 4wd dually diesel truck. Well, this was an old, rear wheel drive, gas truck. Not a huge market for those here, so it was priced accordingly. Now, another reason that I didn't want to put a huge pile of $$$ into a truck like this was that I plan to only use it, literally, ONCE every year - just to pull the RV from my property in WI to OSH for AirVenture and then back (about 70 miles, round trip). This one might be perfect for that!?!?<br /><br />I went to see the truck, and decided that it would work for what I needed. It was going to need some fixes, as you might imagine. First, I was told that the rear fuel tank (the bigger one) was not working and, of course, the air conditioning didn't work (go figure). Also, it had a goose neck ball mounted in the bed, but I'd need a 5th wheel hitch mounted. There were a few other "issues," but these were the biggest things. The only other "issue" was that if I bought it here at home, I would have to get it to WI somehow and pay for the fuel to get it there. But, since I had the time to work on it here at home (where I had the tools and the time), I decided that it was a fair trade for having to eventually drive it cross-country to AirVenture.<br /><br />A week or so later, I went to get the truck and got it home without any hiccups. It actually drove fairly well! I got it home and parked it on a slab in front of the garage and put a canopy over it for shade so that I could work under it during the day:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHLkLanbOyFNo7mBXry76oxUhkN5QbxbtHj8Y4-bY7ecbimRbYA9C8jCyXf3VIqhhvJr-JM6z2ss4DnHCwsLfw1zXedkMMjcPAn_CrMIGFKyZGs0DCGUKjzb6Oik5IimAVZplsRUgDN7BGk9DqaM4CTrBHBYxepevSEXjHBBsm-Fve6771I0Wqn8YfWQ/s1056/20210504_185412060.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1056" data-original-width="908" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHLkLanbOyFNo7mBXry76oxUhkN5QbxbtHj8Y4-bY7ecbimRbYA9C8jCyXf3VIqhhvJr-JM6z2ss4DnHCwsLfw1zXedkMMjcPAn_CrMIGFKyZGs0DCGUKjzb6Oik5IimAVZplsRUgDN7BGk9DqaM4CTrBHBYxepevSEXjHBBsm-Fve6771I0Wqn8YfWQ/s320/20210504_185412060.jpg" width="275" /></a></div>I'll try not to bore you with too many details, but here is a pic from the install of a new fuel pump in the aft fuel tank:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhaOdaaciVz3PYYFuB4-Kg8Wz9I8gBD1WqXfRMRSEzPFD__z07Ys7qG4TCSzPu_zNLqgq0JPFHGabAvPyyUGh44-f1OhBDiPBDTiflaGyElaAkVsYjFyZs8kAhpzMAMTfVGvrJkr5f-iJv4RqT101QHNaQczSq7Y4ewDtqTNHwdOfxC6yspl5wZSv49Lw/s861/20210502_164847293.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="856" data-original-width="861" height="318" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhaOdaaciVz3PYYFuB4-Kg8Wz9I8gBD1WqXfRMRSEzPFD__z07Ys7qG4TCSzPu_zNLqgq0JPFHGabAvPyyUGh44-f1OhBDiPBDTiflaGyElaAkVsYjFyZs8kAhpzMAMTfVGvrJkr5f-iJv4RqT101QHNaQczSq7Y4ewDtqTNHwdOfxC6yspl5wZSv49Lw/s320/20210502_164847293.jpg" width="320" /></a></div>And, a pic of the "magic" fuel selector that needed to be replaced:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAywpngVoohrf1s9RcmWgnwgaAY4cA4VRgmZftuZPtyizLi-wbNBHHLz2kdQNACr9yeocaYpVjCjv44V9hQ9aRllrpp0_o2KzDT7sD-z9PpSqxbGXGDksZlFRyiHGoHBHTeRKUbAarjjJCHGjLE9iPqV-4w-JpZOKYcyrXBgnhVlhFqyCGA4CUg96v-g/s830/20210503_015306561.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="830" data-original-width="727" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAywpngVoohrf1s9RcmWgnwgaAY4cA4VRgmZftuZPtyizLi-wbNBHHLz2kdQNACr9yeocaYpVjCjv44V9hQ9aRllrpp0_o2KzDT7sD-z9PpSqxbGXGDksZlFRyiHGoHBHTeRKUbAarjjJCHGjLE9iPqV-4w-JpZOKYcyrXBgnhVlhFqyCGA4CUg96v-g/s320/20210503_015306561.jpg" width="280" /></a></div>And, here is an "in progress" look at the install of a 5th wheel hitch that I installed over the top of the gooseneck ball hitch:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2mAklt3W915kL04jyVNQaF_ETxYjq3RStDllatwC3xtxRmHpu5D59zO_eEVZgHyOOEYgXyj2SRH6t_AcgV5tIZqHrbEjz88udJaHEXCq0XPqXHlm1KTN2iGN6pPzB-fEv3CVnTTi5jQa-34uQOFEhV7d6lrl_2rF0ekcLhV4jTUxcwmab3fpGIkVcYw/s1190/20210504_232948314.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="682" data-original-width="1190" height="183" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2mAklt3W915kL04jyVNQaF_ETxYjq3RStDllatwC3xtxRmHpu5D59zO_eEVZgHyOOEYgXyj2SRH6t_AcgV5tIZqHrbEjz88udJaHEXCq0XPqXHlm1KTN2iGN6pPzB-fEv3CVnTTi5jQa-34uQOFEhV7d6lrl_2rF0ekcLhV4jTUxcwmab3fpGIkVcYw/s320/20210504_232948314.jpg" width="320" /></a></div>I picked up that 5th wheel hitch from an machine shop auction a few months earlier. No one really wanted it, so I got it for a little more than the minimum bid - I think I paid $40 for it! The nice thing about this hitch is that it is removable. Just pull 4 bolts, and the top part of the hitch comes off the rails mounted to the bed and the gooseneck ball is exposed and usable. Nice to be able to switch back-and-forth easily - if necessary!<br /><br />I finally had the truck ready to go by Jun of 2021. I started my trek to AirVenture by first driving up to visit our oldest daughter in Montana. I figured if the truck made it to her place, then I'd probably be able to make it the rest of the drive to WI with this old truck. It was quite the journey, and I did have a few issues along the way. But, suffice it to say, I did make it to the property in WI for AirVenture. Here is the "beast" with the RV hooked up and ready to make the 35 mile journey to Camp Scholler in Jul of 2021:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHXiMi0dJc5XgSGdPuM7eL-leVvZ2fe3lxcqjPLkT5knTNM4rI9V5vZheSlQHH69Uexm-l9oIpZS6TRL9O2wahhjwtv6z9jQ0YgAPrtXe5yWTLkSfCM3Gn3UXhysVgNOhRxlF__cEZGO1h92icTYeRuE058Oy3Mp4MhIljA-dFY0Ho7PmsrGOnD0z7RA/s2688/20210722_121822834.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="2688" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHXiMi0dJc5XgSGdPuM7eL-leVvZ2fe3lxcqjPLkT5knTNM4rI9V5vZheSlQHH69Uexm-l9oIpZS6TRL9O2wahhjwtv6z9jQ0YgAPrtXe5yWTLkSfCM3Gn3UXhysVgNOhRxlF__cEZGO1h92icTYeRuE058Oy3Mp4MhIljA-dFY0Ho7PmsrGOnD0z7RA/s320/20210722_121822834.jpg" width="320" /></a></div>And, here is the beginning of our our "camp" at AirVenture 2021:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjClEEUS8ea96JHnmONqI8rYuMMQlngg-pbiHOVBoHXn4xbhpmP0RUhY55VwnVtE2InwBoap-iY9tl6Yvo-jCHmQGSPaXcX4QWgIGfy7b5IIiXikUGbj3C8LH3H0YOS5mseQUKt3B4xMIW3wSeWxuJnnnvtkmoJzG1yQzcp5bgZS5eS9QrRxZ-suB0hKg/s2688/20210722_151148898.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="2688" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjClEEUS8ea96JHnmONqI8rYuMMQlngg-pbiHOVBoHXn4xbhpmP0RUhY55VwnVtE2InwBoap-iY9tl6Yvo-jCHmQGSPaXcX4QWgIGfy7b5IIiXikUGbj3C8LH3H0YOS5mseQUKt3B4xMIW3wSeWxuJnnnvtkmoJzG1yQzcp5bgZS5eS9QrRxZ-suB0hKg/s320/20210722_151148898.jpg" width="320" /></a></div>Either Bryan, or I, get to Camp Scholler early the week prior to AirVenture starting. Whoever does, ropes off space for for the rest of the crew to park and camp. Eventually, our camp grew to include the all the "regulars" plus several more. We had the biggest crew that we ever had in 2021! It included kids, kids boyfriends and girlfriends, kids boyfriend's friends and their friends & family. Here is one evening back at camp when we were celebrating the birthday of one of the crew:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbMK_T_gRvxgBkejeXikQ3QwIQsW0aM9KBm0xIGwE-4IHrGMVzA2rUTsdqhcbTjVO_P-C6lHWh2MM0T3dk8AP9-LCYrmY-jUZRUKklMuGEEElv8m22KU9-Q-DWnqhpOyBX3ntGfE2BbKoCD23wRMca5sfl1t3GpONo_lMFQT45z2N9yKholBoWNNZEFw/s2688/20210728_001406283.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="2688" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbMK_T_gRvxgBkejeXikQ3QwIQsW0aM9KBm0xIGwE-4IHrGMVzA2rUTsdqhcbTjVO_P-C6lHWh2MM0T3dk8AP9-LCYrmY-jUZRUKklMuGEEElv8m22KU9-Q-DWnqhpOyBX3ntGfE2BbKoCD23wRMca5sfl1t3GpONo_lMFQT45z2N9yKholBoWNNZEFw/s320/20210728_001406283.jpg" width="320" /></a></div>Happy birthday, dude in orange!!! Here, his son is presenting him with a birthday cake:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEjbm6EGqML5dRQosD4otO3NkBHSsSDQmWfnbpGhgMHuSdCenPH9aFSJxUW97J8fsZANsfQl-FoNT5mliENIeLMfMkU8FnF0e521kgeWb8qd-E_a8vI52MC6UQYSyU6muGhHKDHnn0_kSZu2LHGhDPnCKZMnzuZbvA8v7XyhVAeJroH-BxYPTYrhoK9A/s2688/20210728_002948285.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="2688" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEjbm6EGqML5dRQosD4otO3NkBHSsSDQmWfnbpGhgMHuSdCenPH9aFSJxUW97J8fsZANsfQl-FoNT5mliENIeLMfMkU8FnF0e521kgeWb8qd-E_a8vI52MC6UQYSyU6muGhHKDHnn0_kSZu2LHGhDPnCKZMnzuZbvA8v7XyhVAeJroH-BxYPTYrhoK9A/s320/20210728_002948285.jpg" width="320" /></a></div>Here's the cake!<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVVCRXJEnsn9yBz74dBxKKHSKogBvs7fvjYtsMd-943DnpDEWOuviP-E8jFfJKkgCQtowUuPWs7i7sH1mJxkaLRNPgl514jarvh4uWtTD84UaX4NPcnjJAOJK_LzLjHu09gyoOZyj4_KvYGC2FZREGS-ZyqyTdeZGHnu00utcwb-yUq2tliuiMc2yv4g/s2688/20210728_003010338.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2688" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVVCRXJEnsn9yBz74dBxKKHSKogBvs7fvjYtsMd-943DnpDEWOuviP-E8jFfJKkgCQtowUuPWs7i7sH1mJxkaLRNPgl514jarvh4uWtTD84UaX4NPcnjJAOJK_LzLjHu09gyoOZyj4_KvYGC2FZREGS-ZyqyTdeZGHnu00utcwb-yUq2tliuiMc2yv4g/s320/20210728_003010338.jpg" width="180" /></a></div>
The bakery that provided the cake also had these cookies that I couldn't resist buying:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhezNsnchM3BM-nwBJIUXm4l9iqnaZRxNt452zIcPZoqbTmp5-2-bea6xO7cx_vBJU6bDX_FH41IcBYZ7L2XwJ6ZTK0ydcna2p7UgkupbzieIZ1mUKgiFCOKq9O22hvODIeYGNHAp3d3JghYHdbwyceokraKQ5ViZt-fGxQ-i_f6wPM3gv7sSuFhylCaQ/s1608/20210727_231356925.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1167" data-original-width="1608" height="232" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhezNsnchM3BM-nwBJIUXm4l9iqnaZRxNt452zIcPZoqbTmp5-2-bea6xO7cx_vBJU6bDX_FH41IcBYZ7L2XwJ6ZTK0ydcna2p7UgkupbzieIZ1mUKgiFCOKq9O22hvODIeYGNHAp3d3JghYHdbwyceokraKQ5ViZt-fGxQ-i_f6wPM3gv7sSuFhylCaQ/s320/20210727_231356925.jpg" width="320" /></a></div>We had been on a mission since the previous AirVenture (the one before CoVid) to get our friend (the south gate security guy) up on a flight. This was the year. Here he is going up with one of the Dave in the AirCam:
<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJpBPezl9dFdXYwpXIfpRtj7imJGDEQsFFUSzfVkF9AmOa6H9B_byUcy1mHdQZHnpVtkgH0R4NOBF-kutb6FyAqqqieZ3G2gkGY_0H3J4t4GJxrbXJ_6-p09YZol_yf0b705baNJFCz_yOKFqHx51jZ2Oc5CO20J-UfQ_4A8dbu01l4tBrIbMnuxyD1g/s2688/20210726_234233762.NIGHT.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="2688" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJpBPezl9dFdXYwpXIfpRtj7imJGDEQsFFUSzfVkF9AmOa6H9B_byUcy1mHdQZHnpVtkgH0R4NOBF-kutb6FyAqqqieZ3G2gkGY_0H3J4t4GJxrbXJ_6-p09YZol_yf0b705baNJFCz_yOKFqHx51jZ2Oc5CO20J-UfQ_4A8dbu01l4tBrIbMnuxyD1g/s320/20210726_234233762.NIGHT.jpg" width="320" /></a></div>And, the happy return:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjSw6LGZAcCiQ1G8mBzoJlFyIzfGVm-ONXEirNQV7kvAqCmPF82tqIkXWESQs5HhSsRykK8G15ZVVzYcFBaZ7lQHV0yBQOQyE3ejp5nvqAGA70hl9rWBYQqS7bJWOK6qnQObxoUCHjDUpjsqfT8ghdyfF5XoHzVf8MmrdErOQXVcEwLReFdCdAJ2XYQzg/s2688/20210726_234312924.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="2688" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjSw6LGZAcCiQ1G8mBzoJlFyIzfGVm-ONXEirNQV7kvAqCmPF82tqIkXWESQs5HhSsRykK8G15ZVVzYcFBaZ7lQHV0yBQOQyE3ejp5nvqAGA70hl9rWBYQqS7bJWOK6qnQObxoUCHjDUpjsqfT8ghdyfF5XoHzVf8MmrdErOQXVcEwLReFdCdAJ2XYQzg/s320/20210726_234312924.jpg" width="320" /></a></div>My wife hadn't been to AirVenture for many years. She had other family commitments that always overlapped with AirVenture week. That has passed and she was able to join us AirVenture in 2021. So, Dave and Laura helped get her up on an intro ride too:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqNDv2IPCQkY8HIQljxRpmrLgJlJrK0i4no12vznzWUH1eW3ASo8o1Me9tJdFN4FLP4Z9gu6D0uWP-5ZKyX29NQmi3sBelCZUoSDfEuMYt4kC_DSf-sJ7e4Ivm-PBQOF-TW1CHKfb5oVzfArTdt1y25x5WJeYiTDeerNI37VSki1_Gdh34jzy8j9xpcw/s2688/20210726_234510467.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="2688" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqNDv2IPCQkY8HIQljxRpmrLgJlJrK0i4no12vznzWUH1eW3ASo8o1Me9tJdFN4FLP4Z9gu6D0uWP-5ZKyX29NQmi3sBelCZUoSDfEuMYt4kC_DSf-sJ7e4Ivm-PBQOF-TW1CHKfb5oVzfArTdt1y25x5WJeYiTDeerNI37VSki1_Gdh34jzy8j9xpcw/s320/20210726_234510467.jpg" width="320" /></a></div>There was a new and interesting new aircraft that got a lot of attention in 2021. We all referred to it as the coffee bean. I think it is technically called the Blackfly eVTOL by a company called Opener, I believe. Interesting concept and design:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTKOLe6iHYYfOZVazrDnepuIXi9QiB-N9N0Acg2SrqFCI8kK-VB6H6iNF4vmO7PYMOeQFPgp9UdNpg3bc18dmsKkWA-WlJefnm8FpoJGQeGlVBivjFI7q0EOF2Rhr5SjB1YOp4C1Cyo2bZqJ11nYmd6UO_GwaXvG7-zMl9TR2PHKZqMrFOoSqseWJNmQ/s2688/20210731_164629740.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="2688" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTKOLe6iHYYfOZVazrDnepuIXi9QiB-N9N0Acg2SrqFCI8kK-VB6H6iNF4vmO7PYMOeQFPgp9UdNpg3bc18dmsKkWA-WlJefnm8FpoJGQeGlVBivjFI7q0EOF2Rhr5SjB1YOp4C1Cyo2bZqJ11nYmd6UO_GwaXvG7-zMl9TR2PHKZqMrFOoSqseWJNmQ/s320/20210731_164629740.jpg" width="320" /></a></div>You can check out more about it: HERE<br /><br />On one afternoon, I stopped by the Blue Barn: <br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdfWDLlzrCZ3B_aC4kDDY8kom5ThVC_E7YfAs8fNCpQeJca8M-lD5XGZVYimmVr2_BsZ4KKmGPhlgfs29MH8Hi3VtYzKGYg0v4oXKUa3ijh1IOmWEZYOleC8sboyXS7QfTMdADmgIWJNdTqde6HcSZw6frJjROwA2fO8BKbicrotkwdLOcCAvMIuj6eQ/s2688/20210731_175250344.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="2688" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdfWDLlzrCZ3B_aC4kDDY8kom5ThVC_E7YfAs8fNCpQeJca8M-lD5XGZVYimmVr2_BsZ4KKmGPhlgfs29MH8Hi3VtYzKGYg0v4oXKUa3ijh1IOmWEZYOleC8sboyXS7QfTMdADmgIWJNdTqde6HcSZw6frJjROwA2fO8BKbicrotkwdLOcCAvMIuj6eQ/s320/20210731_175250344.jpg" width="320" /></a></div>And stuck some push pins into the map for my two EAA chapters: Chapter 157 - Benton Airpark and Chapter 1148 - Corning Airport:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgoeosqohrxCStqISh3i4Yflm3JNtAnCr3mktKOeVCpKNoflnNIrEoO5b5knPjHalMN4PTf_hPaKDONo2zCfLcQytcTiA7nnMA3pqzs8M88O_Jm3CsaZ-InpHaIN_iG-1iVn37O8r4ihfXLo-GvTFhwDLZTDidWqTMNcrk7FxZlAJQ5TEUqrhIHIuCSQ/s2688/20210731_174908259.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2688" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgoeosqohrxCStqISh3i4Yflm3JNtAnCr3mktKOeVCpKNoflnNIrEoO5b5knPjHalMN4PTf_hPaKDONo2zCfLcQytcTiA7nnMA3pqzs8M88O_Jm3CsaZ-InpHaIN_iG-1iVn37O8r4ihfXLo-GvTFhwDLZTDidWqTMNcrk7FxZlAJQ5TEUqrhIHIuCSQ/s320/20210731_174908259.jpg" width="180" /></a></div>No AirVenture would be complete without checking out the old favorites. The P-38 Lightning:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYiCEinMyi64P2lHJjNMadpdIVmQqC_uANG-FihFWu6zqAtj1KmslG9-7nLjeAyS22YOCZ7nhiFPk2P-YMsJDA9vaTaDJfO48qLUGhww7GBgVKfYzIxH3EFpyY-UudH_CVOF8ExGz6YTdR5lLhDDWo7SH-Wm2EFgVcwBtLfKeTq5O0S1M2S0mYcqf8DA/s2688/20210731_180105586.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="2688" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYiCEinMyi64P2lHJjNMadpdIVmQqC_uANG-FihFWu6zqAtj1KmslG9-7nLjeAyS22YOCZ7nhiFPk2P-YMsJDA9vaTaDJfO48qLUGhww7GBgVKfYzIxH3EFpyY-UudH_CVOF8ExGz6YTdR5lLhDDWo7SH-Wm2EFgVcwBtLfKeTq5O0S1M2S0mYcqf8DA/s320/20210731_180105586.jpg" width="320" /></a></div>The F-4U Corsair:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6C6ULIGsnQPldJhvR9BNl87pxPtmKKWCRxPiQHZ0gGdHf16SAzpVWHyI46_1Ath_gq7e9AyEV0ouuEyKpHk47TZ6hKPBkNOH_SxufBtATb6WWszVFZlXAr926ehKWomXNsk-sCbkVJ7r2H__mROyyvhLj4k3FAjAse8GuO1MIhjvmZ_IZTp2U_BzrZQ/s2688/20210731_180133810.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="2688" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6C6ULIGsnQPldJhvR9BNl87pxPtmKKWCRxPiQHZ0gGdHf16SAzpVWHyI46_1Ath_gq7e9AyEV0ouuEyKpHk47TZ6hKPBkNOH_SxufBtATb6WWszVFZlXAr926ehKWomXNsk-sCbkVJ7r2H__mROyyvhLj4k3FAjAse8GuO1MIhjvmZ_IZTp2U_BzrZQ/s320/20210731_180133810.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiU9sYtU7a1rrW6P8L8FnE1gnWmECTzdfyuGU7GKjpQiSJ2I-fgUIb6bTLRqcTjy7zK7MKq6pFenFnAGz4OhVlKM8DwumpOx6OfroU_hPsNL6KElIB30DhwhUukmKPJ6r6l3TbDAluWU_8l39CJJhNCBNHKODcgKD78raPrlMiuXVRt0oDZ6rnluvYFSQ/s2688/20210731_180402960.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="2688" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiU9sYtU7a1rrW6P8L8FnE1gnWmECTzdfyuGU7GKjpQiSJ2I-fgUIb6bTLRqcTjy7zK7MKq6pFenFnAGz4OhVlKM8DwumpOx6OfroU_hPsNL6KElIB30DhwhUukmKPJ6r6l3TbDAluWU_8l39CJJhNCBNHKODcgKD78raPrlMiuXVRt0oDZ6rnluvYFSQ/s320/20210731_180402960.jpg" width="320" /></a></div>The P-51 Mustang:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigqtRSIcK3ep1t0ja0SPssAgBsm5Vikl4izqLHnKb5OJd2mxfEFNZkt6uajT5c4VraPgj7JJa3WcHQVpY2MC_xLIKYst6ksFuSoes_M2MyaHkTabc5DGE-PmgHBcv5n7iVe0Qbxa4X4Cpm13YSkvMhUeZIzbVXzPzY36hWLs-dbMBTbFoLpoOzvm91vA/s2688/20210731_180716706.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="2688" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigqtRSIcK3ep1t0ja0SPssAgBsm5Vikl4izqLHnKb5OJd2mxfEFNZkt6uajT5c4VraPgj7JJa3WcHQVpY2MC_xLIKYst6ksFuSoes_M2MyaHkTabc5DGE-PmgHBcv5n7iVe0Qbxa4X4Cpm13YSkvMhUeZIzbVXzPzY36hWLs-dbMBTbFoLpoOzvm91vA/s320/20210731_180716706.jpg" width="320" /></a></div>And, the P-40 Warhawk:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxYCDCoOXtgUURD__L7g4kc0rKLePNm6R3LkQGs3cSzyW8hUnCgVl41JD7nEjnqY5aNKauvbMwQXZa0ru3C8ShwA-JLGofmF0_GYw4Ep96KdQv4NM40O2Nu30QI9NA879elbYSe5weDOUYJ-oWg44-8wMsjUh0w7w9HGDi70UelMt8y1Ko32Jcmeg6DQ/s2688/20210731_180757181.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="2688" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxYCDCoOXtgUURD__L7g4kc0rKLePNm6R3LkQGs3cSzyW8hUnCgVl41JD7nEjnqY5aNKauvbMwQXZa0ru3C8ShwA-JLGofmF0_GYw4Ep96KdQv4NM40O2Nu30QI9NA879elbYSe5weDOUYJ-oWg44-8wMsjUh0w7w9HGDi70UelMt8y1Ko32Jcmeg6DQ/s320/20210731_180757181.jpg" width="320" /></a></div>Here's a new one (for me) to see up close - It's an RAF Hawker Hurricane, I believe:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJjqmHWUa4hsnd6dAXuWLH7SIgzTEacSJJTqbGlasN9b9msd1u-YYDc4munTvMHa-3ztdMRBEAduDnrm4Tvs_MQSLQZ2QbVRqLA72ezzoSEYuyCiLiZzfF7iiEBLsqST0YlKEyx_Bie9fLmVvKcthkRZwiEQTqXvN43aHREuG4IuvS8VwnNWQI5Fl5mw/s2688/20210731_180912394.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="2688" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJjqmHWUa4hsnd6dAXuWLH7SIgzTEacSJJTqbGlasN9b9msd1u-YYDc4munTvMHa-3ztdMRBEAduDnrm4Tvs_MQSLQZ2QbVRqLA72ezzoSEYuyCiLiZzfF7iiEBLsqST0YlKEyx_Bie9fLmVvKcthkRZwiEQTqXvN43aHREuG4IuvS8VwnNWQI5Fl5mw/s320/20210731_180912394.jpg" width="320" /></a></div>Of course, the Spitfire:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-diu6aql6cOcSp2cjrRqL7LQjJctf8i9nG2hCg5D7sW2g6jZKVcVU6ONauP-vUi0H0tDgu7bxoqhkCzALqEwcMO6myUTJJrMslfwDbW8dz2Q6NpgTlNB6nzhfv3yNWf7Hj3J1GLohaLVRmtWeKXI_W-yfi4HFVGsLrEXPcZ_5cEKQGTDAD3y-nM_hKA/s2688/20210731_180939626.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="2688" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-diu6aql6cOcSp2cjrRqL7LQjJctf8i9nG2hCg5D7sW2g6jZKVcVU6ONauP-vUi0H0tDgu7bxoqhkCzALqEwcMO6myUTJJrMslfwDbW8dz2Q6NpgTlNB6nzhfv3yNWf7Hj3J1GLohaLVRmtWeKXI_W-yfi4HFVGsLrEXPcZ_5cEKQGTDAD3y-nM_hKA/s320/20210731_180939626.jpg" width="320" /></a></div>Cockpit of the Spit:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8MYysDWlFXF6Ve0j_Shrd_7TgMALX3KKNum3H6hvFSNDM4M07H6IfYdWN-LP0FQ9U_ESxygET63mSJjLaRHVOC044AzbvqTGeFuZZxQ6LOgB9svYeQMvWEACcTO6o5TglR7futTalmag6Hfi_27yBPCpIIx8qAUavmYbIGB5DPezPkqUthdq1szHnkQ/s2688/20210731_181213463.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2688" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8MYysDWlFXF6Ve0j_Shrd_7TgMALX3KKNum3H6hvFSNDM4M07H6IfYdWN-LP0FQ9U_ESxygET63mSJjLaRHVOC044AzbvqTGeFuZZxQ6LOgB9svYeQMvWEACcTO6o5TglR7futTalmag6Hfi_27yBPCpIIx8qAUavmYbIGB5DPezPkqUthdq1szHnkQ/s320/20210731_181213463.jpg" width="180" /></a></div>This next display was very interesting. It's a Navy SBD Dauntless (aka Army Air Corps A-24) that was raised out of Lake Michigan in 2009. This is a cooperative project involving several groups to restore this aircraft that was lost on a training mission . As you can see, below, a lot of the fuselage has already been restored.<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDoZFoZxpl2kCBTo9t_KMIFQiO1JbzHaxi_kS-59WHRLvnILrdn_zotalID6SJNBhnlSP2X7JHHIzZMe9H0lWPsS265qZmooVBbp5iXt_tVbiLwircqHPYXk20s521nZJK54-kmlbgBOeMjV6AZXzX5VdolWxUI-Memz5nvEJiOeLUHcC1T5bbd8hNdA/s2688/20210731_181427105.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="2688" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDoZFoZxpl2kCBTo9t_KMIFQiO1JbzHaxi_kS-59WHRLvnILrdn_zotalID6SJNBhnlSP2X7JHHIzZMe9H0lWPsS265qZmooVBbp5iXt_tVbiLwircqHPYXk20s521nZJK54-kmlbgBOeMjV6AZXzX5VdolWxUI-Memz5nvEJiOeLUHcC1T5bbd8hNdA/s320/20210731_181427105.jpg" width="320" /></a></div>Restoration work began on the aircraft in 2011. Here is a photo of the raising of the plane from Lake Michigan in 1994.<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEge19AyWACd5OIAbnVzoxu8WxatoBlXbxUYcZh0RFkqJqWbk35WvQBrTpOWEB-bwhNgRuu84GtQlm5v8ZTI0SwhP30m83KMAFj19SfaPZuT1ky4mn4SFk0bZYuxAYo-ahYnKxJpJWG0utKJTPRpe1p-SbRmMQdyE_dJYxDYLNFQjmHJJMSxzXAx2OkxUQ/s2688/20210731_181504653.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="2688" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEge19AyWACd5OIAbnVzoxu8WxatoBlXbxUYcZh0RFkqJqWbk35WvQBrTpOWEB-bwhNgRuu84GtQlm5v8ZTI0SwhP30m83KMAFj19SfaPZuT1ky4mn4SFk0bZYuxAYo-ahYnKxJpJWG0utKJTPRpe1p-SbRmMQdyE_dJYxDYLNFQjmHJJMSxzXAx2OkxUQ/s320/20210731_181504653.jpg" width="320" /></a></div>The US Navy Bureau of Aeronautics report on the loss of the aircraft:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhX_Pkq5fjSVhKwUVnKjh2clRGbreUHb-9r2V76TWAMelffhdjOqPPYsgFqNyZjGSqZn4dWUQwaRD36jkhc2llwbSL1efuu-sOirKFJA15hS4i4i1j_E44LVCHqIffsE7Tgfm7lIqkydxOD91_YdatWmTv5E_vD1joJi9tKNDCDHiBK1T7FPk4vGQ970g/s2688/20210731_181516288.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="2688" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhX_Pkq5fjSVhKwUVnKjh2clRGbreUHb-9r2V76TWAMelffhdjOqPPYsgFqNyZjGSqZn4dWUQwaRD36jkhc2llwbSL1efuu-sOirKFJA15hS4i4i1j_E44LVCHqIffsE7Tgfm7lIqkydxOD91_YdatWmTv5E_vD1joJi9tKNDCDHiBK1T7FPk4vGQ970g/s320/20210731_181516288.jpg" width="320" /></a></div>
Here is the list of the groups involved with this cooperative restoration effort and some history of the aircraft use in WWII:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCVvN7r-tgP3R0cwMJcX2X2O0QlmY7Jq3PKM1nS3A07e1o2IifmJrsmv2lx57V_e9mIbZSP82-gs2cY9oZeRVjHv1QvR0Iwj_PF2Z7a6rPotfOFHNSXJVYKegR7Gg7dXgzZcqmXYOc1GVvyQO5FOee0nft7LbhiWSebNsCAEE7WbCxgvGgple8Bj0Rrg/s2688/20210731_181458790.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2688" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCVvN7r-tgP3R0cwMJcX2X2O0QlmY7Jq3PKM1nS3A07e1o2IifmJrsmv2lx57V_e9mIbZSP82-gs2cY9oZeRVjHv1QvR0Iwj_PF2Z7a6rPotfOFHNSXJVYKegR7Gg7dXgzZcqmXYOc1GVvyQO5FOee0nft7LbhiWSebNsCAEE7WbCxgvGgple8Bj0Rrg/s320/20210731_181458790.jpg" width="180" /></a></div>The original engine that came out of the lake:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLTHcWIsslmSeTHS3z07lBDs-Ayi9ZquW--96_ERJcsFw0Ky8KG-XrJUJ_vNmTy77PSlEby8L8SZuSXLDWxgjefY0hLR6ipdWnah6Y_ronk2FghS2rz1XBH_Ce6LRHDsQTO_aw-NKlRNuvyQBvE_lUv61aOd7rUGw_RyT6J_YAUfvOSoiXqeeuBytF1Q/s2688/20210731_181527746.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2688" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLTHcWIsslmSeTHS3z07lBDs-Ayi9ZquW--96_ERJcsFw0Ky8KG-XrJUJ_vNmTy77PSlEby8L8SZuSXLDWxgjefY0hLR6ipdWnah6Y_ronk2FghS2rz1XBH_Ce6LRHDsQTO_aw-NKlRNuvyQBvE_lUv61aOd7rUGw_RyT6J_YAUfvOSoiXqeeuBytF1Q/s320/20210731_181527746.jpg" width="180" /></a></div>And, here is an overview of the entire aircraft and it current state of restoration:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhdtRU0gp48IbDQLwR8xVHgq0ennP8UWTjnmwheYhWU_83r7GH7dHPz7p6Bu72FQ_k2ZPUk-bBJ7LYYrSQ3nK40aC1W5RZqEMrDhcUWxdO9JbYZfZGrAfaF0s9YauhdFPYssRfytsozK5j6RSOPlEWe7xjUBFcqbITa2yp9eK6yZxH2Uc77VDyn0PaZ1A/s2688/20210731_181637985.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="2688" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhdtRU0gp48IbDQLwR8xVHgq0ennP8UWTjnmwheYhWU_83r7GH7dHPz7p6Bu72FQ_k2ZPUk-bBJ7LYYrSQ3nK40aC1W5RZqEMrDhcUWxdO9JbYZfZGrAfaF0s9YauhdFPYssRfytsozK5j6RSOPlEWe7xjUBFcqbITa2yp9eK6yZxH2Uc77VDyn0PaZ1A/s320/20210731_181637985.jpg" width="320" /></a></div>This is an awesome project! For more information about this aircraft and the restoration, check here: Air Zoo<br /><br />Where else in the world will you see this many flying Gooney Birds all lined up in a row??<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivAhSdiTwpsqj7ZMVKn5tKpZ5AfuaHgAYqS0NSrQ3EuWZ-ibwMBonZlRnGOKHoTv3kmWPjT07KEQtkUgR2aRJPzDMVFCHbBFMHsZwqt3HUsxi6aYxKawlcPIeFqFsurqYhdQLbr3yBQ3X3XVwmOxTou9JZQ0OOwILAvBvgY8CfCFK5eJdj7BYOgULTYQ/s2688/20210731_190257263.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="2688" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivAhSdiTwpsqj7ZMVKn5tKpZ5AfuaHgAYqS0NSrQ3EuWZ-ibwMBonZlRnGOKHoTv3kmWPjT07KEQtkUgR2aRJPzDMVFCHbBFMHsZwqt3HUsxi6aYxKawlcPIeFqFsurqYhdQLbr3yBQ3X3XVwmOxTou9JZQ0OOwILAvBvgY8CfCFK5eJdj7BYOgULTYQ/s320/20210731_190257263.jpg" width="320" /></a></div>Of course, no AirVenture would be complete with out the night air show, the incredible fireworks show and the grand finale! Here's what I caught that year!<br /><div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dxeO0GNoTyXmjykIZCyA7aLhtjZbCHYSWzI_fxgOr3n4XaQLVAb7-jsBiDWX_I7EnWhO4Y63fZC5yF6CIBexQ' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div>It was an outstanding AirVenture in 2021. After the cancellation of AirVenture 2020, there was a lot of folks ready to get back to normal. There was a really strong turn out (numbers wise), but I think the head counts could have been a lot higher. I say that, because, during AirVenture 2021 international air travel was still being restricted by CoVid policies and there was almost no international presence that year. One example in particular, the South African group that normally takes up a whole city block in Camp Scholler was not there in 2021. And, I'm sure that there were many other groups from outside the US that did not make it because of that. It's too bad, because it might have been a truly record setting attendance that year.<br /><br />AirVenture 2022 recap is up next!<br />Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-4561663675008429701.post-23338861132413909422023-01-01T20:27:00.012-08:002023-01-02T07:31:07.507-08:00______Happy New Year - 2023!_______ Big Update on the "FRENCH PROWLER" Progress!<p></p> Happy New Year Everyone!<br /><br />I hope you all had a happy holiday season. The "Bomb Cyclone" made for a pretty cold and snowy holiday season this year over most of the country. If you were affected by this weather, I hope you were able to get through it safely. My favorite stat from that storm was the temp drop in Cheyenne,WY on the Wed before Christmas. The temp dropped 30 deg F in 10 minutes! The 30 min temp change was 39 deg F. That's more than 1 deg F per minute fall in temp. (<span style="color: #4c1130;"><span style="background-color: #fcff01;"><a href="https://kgab.com/cheyenne-temperature-dropped-32-degrees-in-10-minutes-wednesday/" target="_blank">Check it out</a></span></span>) Pretty crazy!!<br /><br />We've been getting a bit of rain in the California North state area. In fact, I think we have already gotten more rain this Nov/Dec than we got in the whole winter last year. It's helping relieve the drought conditions a little (or will in the spring). It had been raining most of the week before I took off recently from the SFO airport headed to JFK and I snapped this pic of Lake Tahoe area:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEim5NAktfkRLYQ0v6iNrwpDTOK0vCmslWC-HVhcHHtc9Aawk_Z1z6wgGNHZaVlGhE50mTiVMXdQXF8gC2Aqnn7zddhU_WOLcuLmT2Z1n4JMaRfJUVXIMzTix3KitTknp-_2NUvpdv697EkdWjCr3plOkshtPgSJWZc9SsMKlAneAeV3B7HJJmTlnzRARg/s1613/20221212_204424122.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="1613" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEim5NAktfkRLYQ0v6iNrwpDTOK0vCmslWC-HVhcHHtc9Aawk_Z1z6wgGNHZaVlGhE50mTiVMXdQXF8gC2Aqnn7zddhU_WOLcuLmT2Z1n4JMaRfJUVXIMzTix3KitTknp-_2NUvpdv697EkdWjCr3plOkshtPgSJWZc9SsMKlAneAeV3B7HJJmTlnzRARg/s320/20221212_204424122.jpg" width="320" /></a></div>Nice to see snow in the Sierras again!<br /><br />As I mentioned in the last blog update, I am going to dedicate this update completely to bringing you all up to date on the progress that Francis has made on building their Prowler in France. My last update on the French Prowler included work up until March 2020. Since then Francis has been sending me a lot of awesome pics and messages on how he is doing building their Prowler. I want to share that all with you now. To keep a sort-of timeline, I'll break this update into approximately 6 month periods. I have one update that should have been included in a previous blog post covering Dec 2020. I'll post that and then jump up to continue with May-Dec to 2021. So, here's the itinerary:<br /><br />A. Dec 2020 - Parts for Francis<br />B. May-Dec 2021 - Wing Work (Ailerons, Flaps & Radiators)<br />C. Jan-Jun 2022 - Wing Work (Outboard Wing Skins & Flap Actuator Work)<br />D. Jul-Nov 2022 - Completing Wing Work (Flap Actuators & Radiator Door Actuators)<br />E. Dec 2022 - Cockpit Floor & Cockpit Framing Prep Work<br /><br />Here we go!<br /><br /><b><u>A. Dec 2020 - Parts For Francis</u></b> - After finishing the dies (form blocks) for the stringers under the aft cockpit floor, I needed to make a set for Francis. I fixed a bad spot that had caused all the previous builders to do a lot of shimming to get skin to lay flat under the aft cockpit area. Since I knew that Francis hadn't gotten to this part of his build yet, I wanted to get a set of them made and sent out to him. I happened to have two of our daughters at home one weekend, so I cut out some blanks and had each one take a turn and do the pressing operation to form the two stringers for Francis. Here they are holding their finished products:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiczVvCDa7h6OerE2Uoddrm2zTHcrUGaqPB9HWalh1SG9GQvYC7bJBemmX_QeHj14TKr1mGxWBmRMIRBaVjwOuXOeEKKoRVWXke8oRjf2w8R0C3XjLjdBPEBFKAbUTy6ysY297kTm53SWw-sDrGTrLh9cagk0-O27lOwnz8v5-92eFyNFiSFuxUGw7Y2g/s1236/20200301_154635~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="1236" height="235" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiczVvCDa7h6OerE2Uoddrm2zTHcrUGaqPB9HWalh1SG9GQvYC7bJBemmX_QeHj14TKr1mGxWBmRMIRBaVjwOuXOeEKKoRVWXke8oRjf2w8R0C3XjLjdBPEBFKAbUTy6ysY297kTm53SWw-sDrGTrLh9cagk0-O27lOwnz8v5-92eFyNFiSFuxUGw7Y2g/s320/20200301_154635~2.jpg" width="320" /></a></div>
Then, I made a shipping box out of wood so that they would not get damaged on the trip to France. Here they are, ready for shipping:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilqUXWIa8wkjLXQkcCecUJLISrLfG0jTiWS_EQzLkWMB0svVfXsIYxxh3J0dhhkUk9mA5doiP3UoCFSIRo5BuOQMnh_PAG2wvOtwwMU43wT055ysImRL0BwbIS66p6e3KNaBQnowLzkeHP64PCQ5FWI3nS7sBHfDbHIzVX2SmDNsWnwRKeV2hGqt1Dnw/s1831/20201202_181519948~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="746" data-original-width="1831" height="130" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilqUXWIa8wkjLXQkcCecUJLISrLfG0jTiWS_EQzLkWMB0svVfXsIYxxh3J0dhhkUk9mA5doiP3UoCFSIRo5BuOQMnh_PAG2wvOtwwMU43wT055ysImRL0BwbIS66p6e3KNaBQnowLzkeHP64PCQ5FWI3nS7sBHfDbHIzVX2SmDNsWnwRKeV2hGqt1Dnw/s320/20201202_181519948~2.jpg" width="320" /></a></div>
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAvx_ZasWBSzt2Yi6QT1pQscpl39-p5Xa8Q1miUlM6SU-a3Ivut4wb9EwuGNP7o9h5ira1tWzyX9lQN5BhE3lEe_wjilSaVs5pXEP-N5U7eF8gZGFkIi7Vs5R2sZGQw_gDlS-Dc1cUjzX5QHYSwfnUGdA6JdF8ETelx-dT9kpfWjlOkCks0TgxBf47ww/s2077/20201202_201750562~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="720" data-original-width="2077" height="111" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAvx_ZasWBSzt2Yi6QT1pQscpl39-p5Xa8Q1miUlM6SU-a3Ivut4wb9EwuGNP7o9h5ira1tWzyX9lQN5BhE3lEe_wjilSaVs5pXEP-N5U7eF8gZGFkIi7Vs5R2sZGQw_gDlS-Dc1cUjzX5QHYSwfnUGdA6JdF8ETelx-dT9kpfWjlOkCks0TgxBf47ww/s320/20201202_201750562~2.jpg" width="320" /></a></div>
A little while later, I also pulled a set of aft flap hinge support brackets from inventory (that I had made some time ago). Francis needed a set, so I put them in a sturdy triangular tube and put that together with the aft floor stringers and shipped them at the same time:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOIaKQrBZY56MYH35N7DbRzG_YRtogS3B1t1r3sS5W5LZnDsqeRHy3aTu3gvEcIF2PYxHTioJ-NpGaMiUrlDLYlqN7OUsEt-WqJbDhaF-yEoHfm0fLZU9jpToDVaviAMW8I9gSkSu2VVWypWd1qncrp-Pw-g9D7KhhUBRYY0CloJH0RwEJeCQWmR33Xg/s2688/20201130_004726907~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="382" data-original-width="2688" height="45" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOIaKQrBZY56MYH35N7DbRzG_YRtogS3B1t1r3sS5W5LZnDsqeRHy3aTu3gvEcIF2PYxHTioJ-NpGaMiUrlDLYlqN7OUsEt-WqJbDhaF-yEoHfm0fLZU9jpToDVaviAMW8I9gSkSu2VVWypWd1qncrp-Pw-g9D7KhhUBRYY0CloJH0RwEJeCQWmR33Xg/s320/20201130_004726907~2.jpg" width="320" /></a></div>These were Francis' Christmas present from me last year! As you will see in the next sections of the blog update, Francis has already installed the flap hinge support brackets and is working on installing the floor stingers soon. Thanks for the help, Ladies!<br /><br /><b><u>B. May-Dec2021 - Wing Work (Ailerons, Flaps and Radiators)</u></b> - My last update on the French Prowler showed the work Francis was doing on the center section of the aircraft wing. He was working on the framing and skins of that section. In the second half of 2021 the focus shifted to the trailing edges of the wings and the radiators. Here is the trailing edge of what looks like the left wing of their aircraft and some lay-out marks that Francis has done.<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOKKZ3vXU7DB9nArmQ90W2M3Mxxjtcg-nKiMZB9beVztvBiz0M_5IzZrNoiUK-qCt70bYDzId8t2pbmj1-GCwdiRycZfRQCwQsC2FBPNEm5t-sidbZvHnik1ufrcExXeYRylhHowTOA1q7KW_xzwEFopFoggv8-BCi0jtFK_Mt_huSaWjWILzqBUvQYg/s1210/20210507_173619.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="1210" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOKKZ3vXU7DB9nArmQ90W2M3Mxxjtcg-nKiMZB9beVztvBiz0M_5IzZrNoiUK-qCt70bYDzId8t2pbmj1-GCwdiRycZfRQCwQsC2FBPNEm5t-sidbZvHnik1ufrcExXeYRylhHowTOA1q7KW_xzwEFopFoggv8-BCi0jtFK_Mt_huSaWjWILzqBUvQYg/s320/20210507_173619.jpg" width="320" /></a></div>In the pic below, you can see one of the flap hinge support brackets that I mentioned shipping to Francis (above). This is a long, tapered channel with approx 45 deg flanges formed into it. This provides an angled support to the skin that comes off of the aft spar and allows a rigid place to attach 1/2 of the hinge that supports the flap segments. This is the right wing, and the top of this tapered support bracket (on the left side) attaches to the rear spar near the top. Then, it angles back to join the skin aft of the rear spar (that's the flange you see farthest to the right pointed up (aft):
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3NTbS6uuMTFGbTJPr9FVUsa1Mxaxkm-QWITyWVcYBbt40revgJWD34V6Qz9azO6um2F4W-_VocCORLhZeUHOF2LaPMYQsCac1v43XZQHVoTJLCo426XreocOE65js30jqZhGCkoo5bxv9iM5qr32fElY-R3qhFMoHz4HOdX4TkSyg40SHYB_0uBqsJw/s1210/20210507_173704.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="1210" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3NTbS6uuMTFGbTJPr9FVUsa1Mxaxkm-QWITyWVcYBbt40revgJWD34V6Qz9azO6um2F4W-_VocCORLhZeUHOF2LaPMYQsCac1v43XZQHVoTJLCo426XreocOE65js30jqZhGCkoo5bxv9iM5qr32fElY-R3qhFMoHz4HOdX4TkSyg40SHYB_0uBqsJw/s320/20210507_173704.jpg" width="320" /></a></div>This pic below is the same wing, taken from the wingtip looking in. You can just see the flange of the support bracket pointing up. The bottom skin is not on the wing yet, but when it does get put on, it will be attached on the aft edge to the flange coming off of the angled support bracket (with one hinge tab which is 1/2 of the hinge that will allow the flap attachment):
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhs12lyV1_QEwAk9zJHmfiLGsTPy63b8jGN4C1TOz8F5Qd0Ey01po4HON_aVZ6GdUawBZkCjysABpxGirHELyZ4iDSY5qBGOCGyqeTMJk-muFWqQVaQcvtuo548dW-rVpS9lvcEKGlGjeRQ82-gFa3y5V_nLEvTgv5tfD2_v1lN9Y4CaUQrJS2YF_zYPw/s1210/20210507_173725.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="896" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhs12lyV1_QEwAk9zJHmfiLGsTPy63b8jGN4C1TOz8F5Qd0Ey01po4HON_aVZ6GdUawBZkCjysABpxGirHELyZ4iDSY5qBGOCGyqeTMJk-muFWqQVaQcvtuo548dW-rVpS9lvcEKGlGjeRQ82-gFa3y5V_nLEvTgv5tfD2_v1lN9Y4CaUQrJS2YF_zYPw/s320/20210507_173725.jpg" width="237" /></a></div>Francis found a bad spot on one of the radiators that came with his kit (I think that George used to pre-attach the aluminum blocks for the plumbing onto the radiators on his kits). Being an aircraft welder (by trade), the repair was an easy step for him:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKLB6OVTzXdZ_PKrNh4tU9WETbyXhF66K4mGamc-eHkhZg42tmK9zLRUZ0BjU-4VZXRgcVoxBJXe-zqHZi4egwgarRlN0jWo9EAY-hYQ4oW9Euh8VmNv1MyDpdWVkFRnJYe507cUJlTFaIeQFc4vxvNKGTSWkOFkHEISCGqSFSjOAWPa5eGoJ4GCgXTw/s908/20210628_150500.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="908" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKLB6OVTzXdZ_PKrNh4tU9WETbyXhF66K4mGamc-eHkhZg42tmK9zLRUZ0BjU-4VZXRgcVoxBJXe-zqHZi4egwgarRlN0jWo9EAY-hYQ4oW9Euh8VmNv1MyDpdWVkFRnJYe507cUJlTFaIeQFc4vxvNKGTSWkOFkHEISCGqSFSjOAWPa5eGoJ4GCgXTw/s320/20210628_150500.jpg" width="320" /></a></div>
Here are three more pics of work that Francis did while working on the flaps, and radiators.....one:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjf7uc9yGwKUXwhvttklZHRpNZy82aWIaXG0GEW4hYxr6irBYq5UZ0uycC2EMleSZBAaXRMFo7Wi88MifHhElP539cjiut7eQyw7ELQEZqslcWftl_Cq2rtecbaU2ghTad-lDwPV3ykA2iR7eVuj-zx1QeNJtjxIvUWtQU43JVmbUKKLCJnu-TCJRF3Lw/s908/20210717_183801.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="908" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjf7uc9yGwKUXwhvttklZHRpNZy82aWIaXG0GEW4hYxr6irBYq5UZ0uycC2EMleSZBAaXRMFo7Wi88MifHhElP539cjiut7eQyw7ELQEZqslcWftl_Cq2rtecbaU2ghTad-lDwPV3ykA2iR7eVuj-zx1QeNJtjxIvUWtQU43JVmbUKKLCJnu-TCJRF3Lw/s320/20210717_183801.jpg" width="320" /></a></div>
two:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6yXbePYUptpLbqvh9HJ1bZM3Ft1k1KmLqf0UGeUiME-SmuQPOdnNcySDh4Qeoq3KnMPYUhaWuPQqAZWi8fhlgoGppziGXfqzIAt7jqhdmxBuiTVNs45T53bSsSd2o5Y4FtCmNMQPPdQ11EEIxoIJVWpLSHEvE6z4KJbroxwE69XtdTqusb3PaRY0fug/s908/20210717_184104.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="908" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6yXbePYUptpLbqvh9HJ1bZM3Ft1k1KmLqf0UGeUiME-SmuQPOdnNcySDh4Qeoq3KnMPYUhaWuPQqAZWi8fhlgoGppziGXfqzIAt7jqhdmxBuiTVNs45T53bSsSd2o5Y4FtCmNMQPPdQ11EEIxoIJVWpLSHEvE6z4KJbroxwE69XtdTqusb3PaRY0fug/s320/20210717_184104.jpg" width="320" /></a></div>three:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMYGWPt63D0VlnbRTtr4r78cWEUd8scV0sjak3mCWdUUscSeA1rBHobFdLW7tAG8NPqkoybVJepJL2s7X-tu9kG03YwaY-7NxVZOz_UdJARy4pCpfJ8dYgp85e9IvSfqMzZmBUPtZMF5xqQJ83oSZ2wAfbTwMtyP59KEcIRXe3vPvam7TwU6f3e_dw9Q/s908/20210717_184638.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="908" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMYGWPt63D0VlnbRTtr4r78cWEUd8scV0sjak3mCWdUUscSeA1rBHobFdLW7tAG8NPqkoybVJepJL2s7X-tu9kG03YwaY-7NxVZOz_UdJARy4pCpfJ8dYgp85e9IvSfqMzZmBUPtZMF5xqQJ83oSZ2wAfbTwMtyP59KEcIRXe3vPvam7TwU6f3e_dw9Q/s320/20210717_184638.jpg" width="320" /></a></div>
<br /><b><u>C. Jan-Jun2022 - Wing Work (Wing Skins & Flap Actuator Work)</u></b> - With the flaps, ailerons and radiators installed on their airplane, the focus shifted to installing the actuating system for the radiator doors and beginning fabricating the wing skins in preparation for the finish installation. Here is the linear actuator that Francis has installed for moving the radiator door linkage:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhk8Cbcw0eQmwafj6ig57R6MDuDGCTEX2C3HUxePDS4fSR32k2UUfx30VAxlq6k8xQXPVxU4Q4CminWF7AxwGDEEyg2flwPehTU9XBhcbPIFR-5y1W8AaU9MMICh5seWQDzY3qdL7Mdh6GuAMK4gCM65EcviZao8gIwEYJIEcee1tu1AD3Ek7UOAUNb_w/s1512/IMG-20220526-WA0000.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhk8Cbcw0eQmwafj6ig57R6MDuDGCTEX2C3HUxePDS4fSR32k2UUfx30VAxlq6k8xQXPVxU4Q4CminWF7AxwGDEEyg2flwPehTU9XBhcbPIFR-5y1W8AaU9MMICh5seWQDzY3qdL7Mdh6GuAMK4gCM65EcviZao8gIwEYJIEcee1tu1AD3Ek7UOAUNb_w/s320/IMG-20220526-WA0000.jpg" width="320" /></a></div>Same thing from another angle where you can better see the limit switch that he incorporated to stop the travel at the max extension point:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSsgt3YlADUtCLh4g2LJmSJ0n1-FXsYN5_zXTlaJbtP3omtJTL_w9fJ_yCjjDJ-rqtBHVoYZwU_caaNC9Cnl424asLoignCdBHazPY46eTcI2_lmL9rL9Yhu1fV7nbM8r0uS388DO1sKB_ETfCmIp1wHvE3HdGIYR61TRFZzLnMWEgDjXtUvhM5EY24g/s1512/IMG-20220603-WA0000.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSsgt3YlADUtCLh4g2LJmSJ0n1-FXsYN5_zXTlaJbtP3omtJTL_w9fJ_yCjjDJ-rqtBHVoYZwU_caaNC9Cnl424asLoignCdBHazPY46eTcI2_lmL9rL9Yhu1fV7nbM8r0uS388DO1sKB_ETfCmIp1wHvE3HdGIYR61TRFZzLnMWEgDjXtUvhM5EY24g/s320/IMG-20220603-WA0000.jpg" width="320" /></a></div>
More close up of the limit switch:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1ZIJfRLwSEJCPDzpTtbjHdK8FAPXWjAILs0rGSEk7Z4qdb5hFoiIx4FAilu36vUWMKNPyLf8zmD-YYTkmuu30lkfqQ5PzubR5xbk2hNLbgWNG79EqEsIsCvRw1Ts8n8Rslwd4Z4oYHXgRyxg2ua8B9oA1rTR9PDnsyHKVJeyFlG3XhrXrZE-29-HGXQ/s1512/IMG-20220603-WA0001.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1ZIJfRLwSEJCPDzpTtbjHdK8FAPXWjAILs0rGSEk7Z4qdb5hFoiIx4FAilu36vUWMKNPyLf8zmD-YYTkmuu30lkfqQ5PzubR5xbk2hNLbgWNG79EqEsIsCvRw1Ts8n8Rslwd4Z4oYHXgRyxg2ua8B9oA1rTR9PDnsyHKVJeyFlG3XhrXrZE-29-HGXQ/s320/IMG-20220603-WA0001.jpg" width="320" /></a></div>
I am not certain what this pic below is showing, but it appears to be some kind of electrical connectors that I assume will power the linear actuators for the radiator doors and the flaps. Or, since this is at the wing junction (where the outer wing is attached to the center wing section) this might be part of his fuel level sensing system - as the forward tanks in the outer wings are close to this area when the outer wings are on the plane:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGG4XMIRYNqnUvHwJ99_TWjo-6jBWpzbi6a_rdfo1_l6pyE4FRZkE8I8-4oahkWpW3-f4_W-HAfnspPrq8_DL5DAw7uZpFJ1spnap5wYpYgdR4W-8qa-EONnayMuxaPC1RBDj2_9sdp4TlprbVtOKZypLB-nJYp6EvEZ7jx_t10FLY47CM_DLPSYv2ww/s1512/IMG-20220603-WA0002.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGG4XMIRYNqnUvHwJ99_TWjo-6jBWpzbi6a_rdfo1_l6pyE4FRZkE8I8-4oahkWpW3-f4_W-HAfnspPrq8_DL5DAw7uZpFJ1spnap5wYpYgdR4W-8qa-EONnayMuxaPC1RBDj2_9sdp4TlprbVtOKZypLB-nJYp6EvEZ7jx_t10FLY47CM_DLPSYv2ww/s320/IMG-20220603-WA0002.jpg" width="320" /></a></div>It looks like Francis in this pic has breadboarded some kind of control system for the radiator door system:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzDNkAjpI-gq95N1Nr7u7Dm3e9RqC63UPEGKlft-Z2PJlPOAIcWDrN0lzoX-WaM7AN0dCWnXknl9J3oFzB0LCFGcoF65d0tfUoN8eTyyRjoSenkcAiLURkKSnZczWS2O9xKryZiTwsaBqfUL3O8bFM5USr9U8w8VzAMn-wVKKyFBXa-C3otl6efkQO2g/s2048/IMG-20220619-WA0003.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2048" data-original-width="1536" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzDNkAjpI-gq95N1Nr7u7Dm3e9RqC63UPEGKlft-Z2PJlPOAIcWDrN0lzoX-WaM7AN0dCWnXknl9J3oFzB0LCFGcoF65d0tfUoN8eTyyRjoSenkcAiLURkKSnZczWS2O9xKryZiTwsaBqfUL3O8bFM5USr9U8w8VzAMn-wVKKyFBXa-C3otl6efkQO2g/s320/IMG-20220619-WA0003.jpg" width="240" /></a></div>In conjunction with the radiator door actuator work, Francis was also fabricating the inboard and outboard wing skins. Here is the installation of the wing skin stiffener on the center wing section. The hole on the right is the access panel that Francis put into the skin that will allow access to the top of the torque box, in case of possible maintenance in the future:
<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmBouWZ2oNmk6jj6D232Ys6cZsSdyCcK3Bvz1BAwjt9Uj4B7X9tcKgfEOelxMty9EUDiXTubqiCI1PFMc-MKrkn6IhYkApQnp--wiQCn818YMdDudk-kiMwFyTXUGxKdvEsGpLaxsEH6fAVfruExcSeJsOkWJNPhHyUbNOkz5COtc-CXWlHi_tNRlitw/s908/20220226_151358.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="908" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmBouWZ2oNmk6jj6D232Ys6cZsSdyCcK3Bvz1BAwjt9Uj4B7X9tcKgfEOelxMty9EUDiXTubqiCI1PFMc-MKrkn6IhYkApQnp--wiQCn818YMdDudk-kiMwFyTXUGxKdvEsGpLaxsEH6fAVfruExcSeJsOkWJNPhHyUbNOkz5COtc-CXWlHi_tNRlitw/s320/20220226_151358.jpg" width="320" /></a></div>Same panel, installed onto the top of the center wing section:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi09YJJaerwl1gvRKmcQDPkMfMHzZAkUrvUsCa9EOgdya5w-Jl1geAwuVipayxS34JxUZkGLlnBq6UWNG2NTY2xOZdXfa0fcNNZkn2-dSp1QRP1nxSv3Bs8nB1EBk1dBH8AmDGHiGHJM3toAjJPvHGVLusNyRhCD5PbpZxSboyB_kx_EK5Q2GNJ0YvmOg/s908/20220227_152117.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="908" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi09YJJaerwl1gvRKmcQDPkMfMHzZAkUrvUsCa9EOgdya5w-Jl1geAwuVipayxS34JxUZkGLlnBq6UWNG2NTY2xOZdXfa0fcNNZkn2-dSp1QRP1nxSv3Bs8nB1EBk1dBH8AmDGHiGHJM3toAjJPvHGVLusNyRhCD5PbpZxSboyB_kx_EK5Q2GNJ0YvmOg/s320/20220227_152117.jpg" width="320" /></a></div>Looks awesome:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjCHkm2MosAlDWr2JN9Slbozs0Lmc45_mGqog5jHs3rBFcI4wpRJUcA8LqhYGCkCPbT1-g79DAH0m-jArjE1sCZLT0GMgd5S-lTVa_YGVCIHnGmG9Jt4ZhYZTLFAxUNwk8HyzPL2rUpyLXlpaFh0YoE2cftbZcmVjvs7jugt2Lf3S8Wbqk7-dhk924mBw/s908/20220227_152133.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="908" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjCHkm2MosAlDWr2JN9Slbozs0Lmc45_mGqog5jHs3rBFcI4wpRJUcA8LqhYGCkCPbT1-g79DAH0m-jArjE1sCZLT0GMgd5S-lTVa_YGVCIHnGmG9Jt4ZhYZTLFAxUNwk8HyzPL2rUpyLXlpaFh0YoE2cftbZcmVjvs7jugt2Lf3S8Wbqk7-dhk924mBw/s320/20220227_152133.jpg" width="320" /></a></div>This is the setup that Francis made for dimpling the outboard wing skins:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgwZDXCmPLwCQmZaK7Gwi7jPAOSmaeRJkteQ-vvqvYAqaxDDeMFuyAv16lMengpWj4JazkrHeOfpKRc6auebR6s0KGDC7lKnTdHVJTOMCOqYkMubAvmY21XzGrQCND7hd7nLU5Av5AIJqdjzu-AFUyjT5r8WlfsJt67NgEqKAOOoVjZxSSZkGY6VT0UTw/s908/20220314_133429.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="908" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgwZDXCmPLwCQmZaK7Gwi7jPAOSmaeRJkteQ-vvqvYAqaxDDeMFuyAv16lMengpWj4JazkrHeOfpKRc6auebR6s0KGDC7lKnTdHVJTOMCOqYkMubAvmY21XzGrQCND7hd7nLU5Av5AIJqdjzu-AFUyjT5r8WlfsJt67NgEqKAOOoVjZxSSZkGY6VT0UTw/s320/20220314_133429.jpg" width="320" /></a></div>Same thing, with the access panels and doublers added:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOX7N0mpfocG2sGyn5rF06m0KZ4DyagEDW2z7VJMkJY9VYtrK4JBaNvP4MnnPjwECTcz7T1ON4GgHKEkruDjHZiXXt0KfmWc3lKhPtoUdHWXxaW7iNPt_CtyZH_DAVsc0vN3Dk25ZtTwCkawIYHykeCuh9mkb3gYUPFdBfhGDah7mirHeAFKruvz6mSg/s908/20220318_172037.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="908" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOX7N0mpfocG2sGyn5rF06m0KZ4DyagEDW2z7VJMkJY9VYtrK4JBaNvP4MnnPjwECTcz7T1ON4GgHKEkruDjHZiXXt0KfmWc3lKhPtoUdHWXxaW7iNPt_CtyZH_DAVsc0vN3Dk25ZtTwCkawIYHykeCuh9mkb3gYUPFdBfhGDah7mirHeAFKruvz6mSg/s320/20220318_172037.jpg" width="320" /></a></div>I believe this is the lower outboard wing skin where the pitot static tube will be installed:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLmo-7E9VWRE645dqlTuhfqAxlZgP79WwXq6WBXhLYWcZqdIkY5BwmavysDDyH84arauz5GAQ5kUJEJ_4TgvB7U0W-IHMnzcbgMux1dBh8j6c3wENaJg9Do6WJUGYe1SapWknWJ6fx-OPcKbdP9xe3XPlPafwcbJKlmcQ0GuZIbU1nGRQMSTtPZgQ_JQ/s908/20220318_172154.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="908" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLmo-7E9VWRE645dqlTuhfqAxlZgP79WwXq6WBXhLYWcZqdIkY5BwmavysDDyH84arauz5GAQ5kUJEJ_4TgvB7U0W-IHMnzcbgMux1dBh8j6c3wENaJg9Do6WJUGYe1SapWknWJ6fx-OPcKbdP9xe3XPlPafwcbJKlmcQ0GuZIbU1nGRQMSTtPZgQ_JQ/s320/20220318_172154.jpg" width="320" /></a></div>One outboard lower wing skin ready to install:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0IYIZ25EBneTE2C39W9skY8cANKOQH0CAh-zySJAfLTWXvkuTPHy5RWQrZZ_KPbk0tTQI_5aK25OoW7t-qQ0BaKlXt3k5-AmH96vqsovHfm5wMaUzoNjcZal7-bBWMlqaiwvHM0KqV9V0qZYDtUS2uroPPTxKeJES7fQk-JOlWloIPk-L0b3LwYVsLg/s908/20220319_161346.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="908" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0IYIZ25EBneTE2C39W9skY8cANKOQH0CAh-zySJAfLTWXvkuTPHy5RWQrZZ_KPbk0tTQI_5aK25OoW7t-qQ0BaKlXt3k5-AmH96vqsovHfm5wMaUzoNjcZal7-bBWMlqaiwvHM0KqV9V0qZYDtUS2uroPPTxKeJES7fQk-JOlWloIPk-L0b3LwYVsLg/s320/20220319_161346.jpg" width="320" /></a></div>Here was a tip that Francis passed on to me. He used this removable tape to hold the doubler in place while riveting:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNnzAD9WbIlrdMiAL6sCn9xc_eXgXfE_azm5wzG6Vp59ECFJ4Qzj_oNvIsOGrj1YdBzhiArmgoGTlqeEuvolNCoY8PhAmlNXPq9NOqFZ7K1sJePb3ZN-wZZTo0s0XPgU3xBsEdF1qYVBJq9gA3icI_5pfyq0n-9hzhy9pDqh-VLrhQiu0frudkVlCdFQ/s908/20220325_133159.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="908" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNnzAD9WbIlrdMiAL6sCn9xc_eXgXfE_azm5wzG6Vp59ECFJ4Qzj_oNvIsOGrj1YdBzhiArmgoGTlqeEuvolNCoY8PhAmlNXPq9NOqFZ7K1sJePb3ZN-wZZTo0s0XPgU3xBsEdF1qYVBJq9gA3icI_5pfyq0n-9hzhy9pDqh-VLrhQiu0frudkVlCdFQ/s320/20220325_133159.jpg" width="320" /></a></div>And; one mostly completed outboard wing:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg79N3uVjWtpr9i2dpVGgNitBE0peBpJYA2sZdVo2EFMXUbZdJza5_QUHAacXSrA_cRDhBoGO2PS1FzDEr_Vqs7LRzpk2oNT5Fwll7rnVogSfe73PNHRaWkrsJWsrcWFLCxrbQ-HCfaZitwRnTqGVQVTNTEjYtc95ho3Sd0_QfXaiq4IQ6GvO6K-0KfJA/s1512/IMG-20220919-WA0004.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg79N3uVjWtpr9i2dpVGgNitBE0peBpJYA2sZdVo2EFMXUbZdJza5_QUHAacXSrA_cRDhBoGO2PS1FzDEr_Vqs7LRzpk2oNT5Fwll7rnVogSfe73PNHRaWkrsJWsrcWFLCxrbQ-HCfaZitwRnTqGVQVTNTEjYtc95ho3Sd0_QfXaiq4IQ6GvO6K-0KfJA/s320/IMG-20220919-WA0004.jpg" width="320" /></a></div>Francis made a tube to submerge angle brackets into for alodine treatment and then clamped it upright in his vise. I think these are wing skin stiffeners:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVeXpgWjb-1p7f_jCIZqVbTYrR-ciun5PPxtgO2xIu40rMuNC6CId1l0hTsAaLN_D_Z55k333oizoxAPXXMpDI78nXAPZHmdkXyI-xxEkv3i2eLm_2AZT7gCUUaRHd6UvMtIuboz6d_G1TE8xH_C0D39eSq3aetylhh-FsrLg3o19liV8hsb3vzBEB5A/s908/20220318_173743.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="908" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVeXpgWjb-1p7f_jCIZqVbTYrR-ciun5PPxtgO2xIu40rMuNC6CId1l0hTsAaLN_D_Z55k333oizoxAPXXMpDI78nXAPZHmdkXyI-xxEkv3i2eLm_2AZT7gCUUaRHd6UvMtIuboz6d_G1TE8xH_C0D39eSq3aetylhh-FsrLg3o19liV8hsb3vzBEB5A/s320/20220318_173743.jpg" width="320" /></a></div>Here are the treated angles:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_mDVYy9v9s2yZ5n6WZTvheWp3LkdDNctXRSm1s6ue2QCEtpWCsWt1rcv3d21FWwatG7XfgUd1zRkGsk657dnJOAC1oGUi_3aV0z-lxU61XK8XmcAytIVkybJKnQ5-9hOpKbGN1ZSrlXZXxyc6jqvAVNcqXANx1mjigo_Q0B61uMl0Aag2qx5B_TNwYA/s908/20220318_173755.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="908" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_mDVYy9v9s2yZ5n6WZTvheWp3LkdDNctXRSm1s6ue2QCEtpWCsWt1rcv3d21FWwatG7XfgUd1zRkGsk657dnJOAC1oGUi_3aV0z-lxU61XK8XmcAytIVkybJKnQ5-9hOpKbGN1ZSrlXZXxyc6jqvAVNcqXANx1mjigo_Q0B61uMl0Aag2qx5B_TNwYA/s320/20220318_173755.jpg" width="320" /></a></div>
<br /><b><u>D. Jul-Nov 2022 - Completing Wing Work (Flap Actuators & Radiator Door Actuators)</u></b> - in the second half of this year, Francis continued on completing his center wing systems. This is either a revision to the actuator control for the radiator doors that was shown above, or it's a different controller used for the flap controller:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrgundrZEMI1k9YtkEmjto9E8M911-sYtiwDRiJFXukHq6kffNt-YWZwBm4tNjH8k0Q89Ixm4TyFTRVkSC9x1H6mYEm3QQq2R7liECGVJQ3fYXBB4MmZZJi2PFjMyB9bq_HoRWLysEPesE_tbVQLOValQP8eaQsJ3oVJq05W8i_FYHr1sZL69cA8iCAA/s1600/IMG-20220810-WA0000.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1600" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrgundrZEMI1k9YtkEmjto9E8M911-sYtiwDRiJFXukHq6kffNt-YWZwBm4tNjH8k0Q89Ixm4TyFTRVkSC9x1H6mYEm3QQq2R7liECGVJQ3fYXBB4MmZZJi2PFjMyB9bq_HoRWLysEPesE_tbVQLOValQP8eaQsJ3oVJq05W8i_FYHr1sZL69cA8iCAA/s320/IMG-20220810-WA0000.jpg" width="320" /></a></div>
I'm not certain which it is for, but I'm assuming it is for the radiator door actuators. The reason I think that is because these pictures came at the same time that he finished the radiator installations. Here is the right wing radiator with the door installed:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGdouWwIDJQ2nT2Ou7oVxim6U_9XSGfwkrwRcKbJRjctq56RgizEIMSQs5rQB5YtgUf3FPQvVCMDRjdiDhWs0M8So5YnEeGxAHGq2DX6rp5raOWcc3QvOiEGVkEm5gpBf6vHU2pcRvgAUodj14JQcZB1YzU-6pxTEi5I4cDtAxUotGQ3XFwEzuHONPAg/s1512/IMG-20220919-WA0000.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGdouWwIDJQ2nT2Ou7oVxim6U_9XSGfwkrwRcKbJRjctq56RgizEIMSQs5rQB5YtgUf3FPQvVCMDRjdiDhWs0M8So5YnEeGxAHGq2DX6rp5raOWcc3QvOiEGVkEm5gpBf6vHU2pcRvgAUodj14JQcZB1YzU-6pxTEi5I4cDtAxUotGQ3XFwEzuHONPAg/s320/IMG-20220919-WA0000.jpg" width="320" /></a></div>
Here's the same radiator looking outboard with the door open:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGUIQ3YpKStB1ZWiaDtQsFA20cHr_t000lDDDEhVkOdTRPvtn4aOa76qpyj51MlddPQJb2YHjN4DsWje5PB9N7xRrSHbE014UJVriMneEbkC18KSs4NKPbHcxq0VukctWCPPSsGsbvhxfYlCD9uBKvPwHfshrblNWHwY8JBv_eSMH13ELY34LNeW8L0Q/s1600/IMG-20220919-WA0001.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="900" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGUIQ3YpKStB1ZWiaDtQsFA20cHr_t000lDDDEhVkOdTRPvtn4aOa76qpyj51MlddPQJb2YHjN4DsWje5PB9N7xRrSHbE014UJVriMneEbkC18KSs4NKPbHcxq0VukctWCPPSsGsbvhxfYlCD9uBKvPwHfshrblNWHwY8JBv_eSMH13ELY34LNeW8L0Q/s320/IMG-20220919-WA0001.jpg" width="180" /></a></div>And same view with the door closed:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQM5OKsuVBhQjr-SkTSRUaNkal-PC77ti97umNKFOkkmd6jQK9GgIqXNtvx_gDw3ZGGp1MHZpHtnlqSPpbGmYGMlbSSucx2B8vmCu6R5Dh7S5aknvPsbsJx7ReJW7DyiMMChzDOBIynBwFM_L3Ak6pFwwdLRrCYM0E8zEjE_ItGFfCKuAdenj_p6Dmxg/s1512/IMG-20220919-WA0003.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQM5OKsuVBhQjr-SkTSRUaNkal-PC77ti97umNKFOkkmd6jQK9GgIqXNtvx_gDw3ZGGp1MHZpHtnlqSPpbGmYGMlbSSucx2B8vmCu6R5Dh7S5aknvPsbsJx7ReJW7DyiMMChzDOBIynBwFM_L3Ak6pFwwdLRrCYM0E8zEjE_ItGFfCKuAdenj_p6Dmxg/s320/IMG-20220919-WA0003.jpg" width="320" /></a></div>And, finally, video proof that both radiator doors work properly demonstrated in person by the star of the show.....Francis himself!!!!! <br /><div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dwnX7N95HKCfZIwcnmU15SvpdCJWduhy9ctx0WZhfLlhtk7_Mh4xnkaTYkaGWXQJ1jwvmzun-ib-YMMQxpBLA' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div>Nice job, Francis!! That's outstanding work.<br /><br />Moving on to the flap actuator, I think this was an initial mock-up piece that Francis made to test the fit of this design to actuate the flap extension limit switch. It looks like he cut this piece from a square extruded aluminum tube and fashioned a tab that would impact the limit switch when the flaps were fully extended:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3fYCT_nQGYILlaw65qkpbxb8aUeLS0ytfq1ae_4w50jvKl3yl42gZJjaOlbKm9YXGQp7t8mysi3nPOyA1lnWPwomYUF3Lh1d92V759gt47L0b96bvHthCLFpaiEgc8LN3hhwo0_FfBVl31pAgpN3SmvM58Jc5VjuhkVWVbwtbOgb-kOWFh-f4540sPA/s1600/IMG-20221008-WA0002.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="900" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3fYCT_nQGYILlaw65qkpbxb8aUeLS0ytfq1ae_4w50jvKl3yl42gZJjaOlbKm9YXGQp7t8mysi3nPOyA1lnWPwomYUF3Lh1d92V759gt47L0b96bvHthCLFpaiEgc8LN3hhwo0_FfBVl31pAgpN3SmvM58Jc5VjuhkVWVbwtbOgb-kOWFh-f4540sPA/s320/IMG-20221008-WA0002.jpg" width="180" /></a></div>
Here's that part attached to the flap actuation torque tube. Notice that Francis also incorporated Ray's design for the 3-piece flap actuator torque tube: <br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbZ2sjhtDQfckWG2gg9IJmTcEe5aa2OpaYaE5xqICMVjTLcMldJSkFP6k5VPXHH_P1Uv6-B-tO29NcfQstxf-s_wS9lvMZxX1ylSjqqZl3fnwMKneE7HZq4ur_5h0N9QcQ4-1FLwKDnFLjXN6FVyccLAyf8za-le82XXfyC9WBM1zG0NL7ye_PuTbjig/s1512/IMG-20221008-WA0000.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbZ2sjhtDQfckWG2gg9IJmTcEe5aa2OpaYaE5xqICMVjTLcMldJSkFP6k5VPXHH_P1Uv6-B-tO29NcfQstxf-s_wS9lvMZxX1ylSjqqZl3fnwMKneE7HZq4ur_5h0N9QcQ4-1FLwKDnFLjXN6FVyccLAyf8za-le82XXfyC9WBM1zG0NL7ye_PuTbjig/s320/IMG-20221008-WA0000.jpg" width="320" /></a></div>And, a side view:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXHtkjWlsrUQNfXEVkzQ-lnWanIjOYr5FyIejzN0RVGqZdyclXzx665Xai83ZmCHyqNOv_Dd16sP7zAT-Q36rdLFfy6K6nZid_OpgKXWoSsnFpNf3AKl3QliayUB5PfbL7-cndB6end9z0fMEp6Dt3tXHZ1bz-MdPsAbyoVO2iPmqAAb0Iq0QVMsAmug/s1512/IMG-20221008-WA0001.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXHtkjWlsrUQNfXEVkzQ-lnWanIjOYr5FyIejzN0RVGqZdyclXzx665Xai83ZmCHyqNOv_Dd16sP7zAT-Q36rdLFfy6K6nZid_OpgKXWoSsnFpNf3AKl3QliayUB5PfbL7-cndB6end9z0fMEp6Dt3tXHZ1bz-MdPsAbyoVO2iPmqAAb0Iq0QVMsAmug/s320/IMG-20221008-WA0001.jpg" width="320" /></a></div>Then, it looks like in this pic below, that he fabricated a new part from heavier aluminum to actuate the limit switch:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3ZDx_7kj64BX693Hy7glA0O6nZC_C5DYfYf0K8o_mFd6rC8xq-alUSlq6dAOWYi7sOWrHloRT-JiSunFxNes7rdVilXvJz3xjFIndqdWG7isKNQ-IyFsQ0T4VNKIA9PZciUTGjQsOGDTQTwMXlp29TvNPFAOBSAs3HGu8kzkmcjeBn9AzsxJO8CDLrQ/s1600/IMG-20221119-WA0005.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="777" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3ZDx_7kj64BX693Hy7glA0O6nZC_C5DYfYf0K8o_mFd6rC8xq-alUSlq6dAOWYi7sOWrHloRT-JiSunFxNes7rdVilXvJz3xjFIndqdWG7isKNQ-IyFsQ0T4VNKIA9PZciUTGjQsOGDTQTwMXlp29TvNPFAOBSAs3HGu8kzkmcjeBn9AzsxJO8CDLrQ/s320/IMG-20221119-WA0005.jpg" width="155" /></a></div>
Nice work on that! It is a fairly simple, clean design!<br /><br /><b><u>E. Dec 2022 - Cockpit Floor & Cockpit Framing Prep Work</u></b> - Now, most recently, Francis has sent me the pictures below where it looks like he is beginning to frame up the cockpit floor. Even though he just sent me these pics, I think they were taken sometime earlier before he finished the radiator installations. The reason I say that is because in these pics, the lower skins (and doors) are not installed on the radiator boxes. In any event, remember those parts that the girls helped me make for Francis?? Well, here they are:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKYzlgxl9CnHpm8rdXT7NIktS1QS1yrDdYMrLEL6o9ArAYlsrWk222IFcc_vvn4tA4fIDTGM32dxdML34r4ccS2bwEePUsxY4gdJO6peaj6zBOmpt7haQbswdM3cL3pUBsrQ280LV6ui4cLJ2hC6_H2YbV9n8KEf1-oArg4r7LtKCca9zyoE7-G8T8A/s1600/IMG-20221119-WA0001.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="777" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKYzlgxl9CnHp-m8rdXT7NIktS1QS1yrDdYMrLEL6o9ArAYlsrWk222IFcc_vvn4tA4fIDTGM32dxdML34r4ccS2bwEePUsxY4gdJO6peaj6zBOmpt7haQbswdM3cL3pUBsrQ280LV6ui4cLJ2hC6_H2YbV9n8KEf1-oArg4r7LtKCca9zyoE7-G8T8A/s320/IMG-20221119-WA0001.jpg" width="155" /></a></div>
That's them, on top, attached to the rear spar. In the picture below, they are probably cleco'ed in place and have the cockpit floor clamped in place as well:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjA_28YLRDjLYUa6OcYN7wgM1B3-OxnoxmKuvj8XGdZI3W1DCp3csJ4ZZ8rjad9xZ8CVpEH3dhBAP8T3XT0iPAQuEckCaOjwfpzoKM2TG6lh9SF3MdD5dkUmEPgSFYsIXfbYLONkkBzhhlyidC-8GiFUZblTH3vajdMljMNnlQkDWUnyoXsstZrTAFS-Q/s1600/IMG-20221119-WA0003.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="777" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjA_28YLRDjLYUa6OcYN7wgM1B3-OxnoxmKuvj8XGdZI3W1DCp3csJ4ZZ8rjad9xZ8CVpEH3dhBAP8T3XT0iPAQuEckCaOjwfpzoKM2TG6lh9SF3MdD5dkUmEPgSFYsIXfbYLONkkBzhhlyidC-8GiFUZblTH3vajdMljMNnlQkDWUnyoXsstZrTAFS-Q/s320/IMG-20221119-WA0003.jpg" width="155" /></a></div>Another view:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgL2xnLso2ZaNP0SmpoH3qveWlTl4AEJVOukNtdZNfqoUJgOMa2DMbbyxVt92z30ntHS3QSdJU0bWxBSGsqnXHKcm-HTRan9I3Gm_1pRFZvTO-Lxug4sJUexlZS4_yYhqB_OWmFDldR2NP7obXbQ9P-wUAevoYV2iLWgjzSZQWeEh5OpItLXXyJk7jaEA/s1600/IMG-20221119-WA0004.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="777" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgL2xnLso2ZaNP0SmpoH3qveWlTl4AEJVOukNtdZNfqoUJgOMa2DMbbyxVt92z30ntHS3QSdJU0bWxBSGsqnXHKcm-HTRan9I3Gm_1pRFZvTO-Lxug4sJUexlZS4_yYhqB_OWmFDldR2NP7obXbQ9P-wUAevoYV2iLWgjzSZQWeEh5OpItLXXyJk7jaEA/s320/IMG-20221119-WA0004.jpg" width="155" /></a></div>Here is the cockpit floor from the top side. He even has the flight control sticks in place!! Looks great:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgk90YrbIulXY_-FvRYTQlxf3Va3r57oYjOUem2a-gz0ZtWVKGhzgdW_GWbjIC2Q4kP2nan1s_gVhP0WazY5pASTrOEZsx42fSNm5whZ_2ji1tfIhLOSHoxYmg7A5ASkUNQ8mzqZFMfkDEtxfc6x15IbCGtl_t-b45nOadGr3lVz7zUcOpBZiCRx_mkBQ/s1600/IMG-20221119-WA0006.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="777" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgk90YrbIulXY_-FvRYTQlxf3Va3r57oYjOUem2a-gz0ZtWVKGhzgdW_GWbjIC2Q4kP2nan1s_gVhP0WazY5pASTrOEZsx42fSNm5whZ_2ji1tfIhLOSHoxYmg7A5ASkUNQ8mzqZFMfkDEtxfc6x15IbCGtl_t-b45nOadGr3lVz7zUcOpBZiCRx_mkBQ/s320/IMG-20221119-WA0006.jpg" width="155" /></a></div>Here is the cockpit floor, back off of the wing jig and laying upright on a bench (or saw horses) so that he can begin the floor layout and fabrication:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaKdErbg1Yjnm9xGhmFIToB7QKV5APt8QarfUVVuT4D4DF60ByTLGB8jHVNFvmQ8TAniAOxPXamw4cE6IFUGp9FH7L6EDAG_aeyB1lnYCLhgiSysuvV33EjooF5RavpYnw30DwI3OhW4PPYCdj2M4-gMM_YmF6IYUvF3y2hJ6hepNEa6jCTZk-1OHp2w/s1600/IMG-20221205-WA0001.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="777" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaKdErbg1Yjnm9xGhmFIToB7QKV5APt8QarfUVVuT4D4DF60ByTLGB8jHVNFvmQ8TAniAOxPXamw4cE6IFUGp9FH7L6EDAG_aeyB1lnYCLhgiSysuvV33EjooF5RavpYnw30DwI3OhW4PPYCdj2M4-gMM_YmF6IYUvF3y2hJ6hepNEa6jCTZk-1OHp2w/s320/IMG-20221205-WA0001.jpg" width="155" /></a></div>Here is a footwell for the cockpit floor - with some of Francis' humor included on it:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6oTGWhAeOjwwTcKWAMEe4NoQSme4Mm9IwRgTE7wwqS3MNRUzML68YvmfvAWoBVcP9Jd6ttKlpGZhd8XHpwc3kyIB7aWGdDoduXycG61PknmA9bgYmfIbyIHUkIIRv5_rXy6jn5eTRskPEsaxSXcS1dY-NiQKTgadMRpYQqLZzWATKxVLdLEYpSnKnHA/s1600/IMG-20221212-WA0007.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="777" data-original-width="1600" height="155" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6oTGWhAeOjwwTcKWAMEe4NoQSme4Mm9IwRgTE7wwqS3MNRUzML68YvmfvAWoBVcP9Jd6ttKlpGZhd8XHpwc3kyIB7aWGdDoduXycG61PknmA9bgYmfIbyIHUkIIRv5_rXy6jn5eTRskPEsaxSXcS1dY-NiQKTgadMRpYQqLZzWATKxVLdLEYpSnKnHA/s320/IMG-20221212-WA0007.jpg" width="320" /></a></div>
And, here is the floor with a footwell and on of the side channels in place:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7Uj5suCNtlcUp_rWVEPnLDIYkqTsSQI10kv1KYfmeObrILtHCbzito1_sekNbuHEwfDLaXEJjnrzkkJ3CBygnCn5Y-e1CPCBKGiwG5Zs8hZaJalKR73sFuYUPAA8oQRTJAhA_wQPtEvWh4iJkXxYjtxdMdoRs-MJCIOVoSgIInYN9GYNbdG5sJ8MtTw/s1600/IMG-20221205-WA0000.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="777" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7Uj5suCNtlcUp_rWVEPnLDIYkqTsSQI10kv1KYfmeObrILtHCbzito1_sekNbuHEwfDLaXEJjnrzkkJ3CBygnCn5Y-e1CPCBKGiwG5Zs8hZaJalKR73sFuYUPAA8oQRTJAhA_wQPtEvWh4iJkXxYjtxdMdoRs-MJCIOVoSgIInYN9GYNbdG5sJ8MtTw/s320/IMG-20221205-WA0000.jpg" width="155" /></a></div>
Another view:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinBEsfmhd5Qd5kjnu11Kqpq-QGkjtrnJGd1sieEcPdbcbV6tAQ8jYItY1QmNubRqschlWLr97FdziNawVN2lpr9Plqje1_0PkhdjljcNs1GcyLLLOZuGQDFFn2y8Mim9TbtTv1tTgZc4fSImMOKuM8_8wWD_GJhoPRvv9IoUdk3I4TnFKTnralhpAbtQ/s1600/IMG-20221205-WA0002.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="777" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinBEsfmhd5Qd5kjnu11Kqpq-QGkjtrnJGd1sieEcPdbcbV6tAQ8jYItY1QmNubRqschlWLr97FdziNawVN2lpr9Plqje1_0PkhdjljcNs1GcyLLLOZuGQDFFn2y8Mim9TbtTv1tTgZc4fSImMOKuM8_8wWD_GJhoPRvv9IoUdk3I4TnFKTnralhpAbtQ/s320/IMG-20221205-WA0002.jpg" width="155" /></a></div>
Here Francis is laying out the steel to make another set of the gusset plates for the negative G mod for the wing spar. He had one set that came with the kit, but there is actually one set on the front of the fuselage former above the main spar, and another set that attaches to the aft side. Here he is copying the dimensions and laying out for cutting another set:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjP3IiCCFKiRO9coGk2snMuviJGEjONQAmXJ2WR-cUKEYdhg0hqKBxKhqS-6WGsiha_UnZrp1c-C6CUbXJvmiWQ-WKHzJ0Uv3iUewENm4njK-t7-mADl7BpbXVD-lO7Ff9gDZHnnU0kv2CJXbAVOZu0sMIDWOvcrCrDT4cqSY5wJPmGDWQuru6zZrUOnQ/s1600/IMG-20221210-WA0001.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="777" data-original-width="1600" height="155" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjP3IiCCFKiRO9coGk2snMuviJGEjONQAmXJ2WR-cUKEYdhg0hqKBxKhqS-6WGsiha_UnZrp1c-C6CUbXJvmiWQ-WKHzJ0Uv3iUewENm4njK-t7-mADl7BpbXVD-lO7Ff9gDZHnnU0kv2CJXbAVOZu0sMIDWOvcrCrDT4cqSY5wJPmGDWQuru6zZrUOnQ/s320/IMG-20221210-WA0001.jpg" width="320" /></a></div> Here is the new set and the original set: <br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3Vr2Ssz-9QVI0sJb08-ZLIvPxQW1iemBPeCJE5VYeE4Qs0dcMKKHFH1qkrLd1NgyyzaGxSbc8TxcA_-dqL2KH_lanMSJsP4MT65rNqSA4tUC4i8uPXJ-6_eDePXwQ_zNpjNSliKPQqGEh2Vvu56C58so7xfIHBl0Sn2gN_yUnwblv9nvjos1rNzsAZg/s1600/IMG-20221210-WA0002.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="777" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3Vr2Ssz-9QVI0sJb08-ZLIvPxQW1iemBPeCJE5VYeE4Qs0dcMKKHFH1qkrLd1NgyyzaGxSbc8TxcA_-dqL2KH_lanMSJsP4MT65rNqSA4tUC4i8uPXJ-6_eDePXwQ_zNpjNSliKPQqGEh2Vvu56C58so7xfIHBl0Sn2gN_yUnwblv9nvjos1rNzsAZg/s320/IMG-20221210-WA0002.jpg" width="155" /></a></div>This next picture is Francis laying out the cockpit framing on the forward end of the cockpit floor. Here he has the left side steel engine mount bracket laying on the floor (mounted inside the forward end of the left floor channel) with another piece of aluminum clamped on to simulate the back side of the firewall:
<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijgN2zCeJNntj1IsPMU7XPqZ7BgBafcFxmj5-kReH4fWVha2m57Tu0RcHHCLiHACeFmD6CBdpYGydcAWddMKZPO8xaPjZakFKt5lASWJhWlOPaRW7ic3YnxUdu2krh3Z_8XcVkyHgaCpIht0VgGF40glRPb9qIW9aNCa66VF4lsYU0aqr5dnxUQPyHnw/s1600/IMG-20221212-WA0009.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="777" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijgN2zCeJNntj1IsPMU7XPqZ7BgBafcFxmj5-kReH4fWVha2m57Tu0RcHHCLiHACeFmD6CBdpYGydcAWddMKZPO8xaPjZakFKt5lASWJhWlOPaRW7ic3YnxUdu2krh3Z_8XcVkyHgaCpIht0VgGF40glRPb9qIW9aNCa66VF4lsYU0aqr5dnxUQPyHnw/s320/IMG-20221212-WA0009.jpg" width="155" /></a></div>Here are both engine mount brackets in place on the front end of the cockpit floor inside of the two floor channels with the upper floor attach angle between the two engine mount brackets:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-kb3JREDCLyYPdbGVUzeItZdkrC-9J6BvCjIeHyLH3Ed3J_gIE-PDDhG7_uj2VOigI9OZuNSoFambx-yHBpLbL1qR2Tn5DrHLehBzCSGrOmHKuBf8qce8D7wH0oMoHECPby0UdhZXyPEcakHp3czdY7z31BSmIpkSY10e11uxUXZ7fzqHHv3pffKc1w/s1600/IMG-20221212-WA0010.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="777" data-original-width="1600" height="155" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-kb3JREDCLyYPdbGVUzeItZdkrC-9J6BvCjIeHyLH3Ed3J_gIE-PDDhG7_uj2VOigI9OZuNSoFambx-yHBpLbL1qR2Tn5DrHLehBzCSGrOmHKuBf8qce8D7wH0oMoHECPby0UdhZXyPEcakHp3czdY7z31BSmIpkSY10e11uxUXZ7fzqHHv3pffKc1w/s320/IMG-20221212-WA0010.jpg" width="320" /></a></div>
Eventually, the firewall will be riveted to the upper and lower floor angle brackets and the engine mount brackets (that are on the forward side of the firewall) will be bolted to these steel brackets mounted in the floor channels. This transmits the tractor forces from the engine mount to the firewall and the floor channels and out to the skin all around the fuselage (aft of the firewall) - exactly where it should go!<br /><br />I'm not certain what we are seeing in the next pic. It looks to me like it is the aluminum 90 deg angle brackets that came with the kit that will go on the top and bottom of both ends of the cockpit floor and attach the floor to the firewall in front, and the large fuselage former in the back. Looks like he found a crack that formed in one of the angles while bending it:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqcqZRVbEfrsG10_iR9VB87k7cfqZ5kqH_AW7u-5_bPl8YpFo0KdWlTfuwZv9tPx2vVLGFb1n4pq_4cqy_pbSQgS-nETqIizaBpzmRh2sG9OEygJgKi1aCkETQ4m0Awy_Jo7e4HADZgtx9rH86z0tTfVDYoXmADyzT4WO0izEjeVooygA-S0rzVlNlYw/s1600/IMG-20221212-WA0014.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="777" data-original-width="1600" height="155" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqcqZRVbEfrsG10_iR9VB87k7cfqZ5kqH_AW7u-5_bPl8YpFo0KdWlTfuwZv9tPx2vVLGFb1n4pq_4cqy_pbSQgS-nETqIizaBpzmRh2sG9OEygJgKi1aCkETQ4m0Awy_Jo7e4HADZgtx9rH86z0tTfVDYoXmADyzT4WO0izEjeVooygA-S0rzVlNlYw/s320/IMG-20221212-WA0014.jpg" width="320" /></a></div>I think the pic below is of a previous builder's firewall, but it shows the hole patterns cut into it. The double row of holes about 1/4 the way up from the bottom will hold a 2" channel on the front side of the firewall and will also be used to hold the cockpit floor angles on the back side. This will help to stiffen the firewall and transfer some of the forces from the motor mount into the firewall and into the skins:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhb4185jF1apc5SeFklPE3K3BkAZZ3HWHvuPkM3XrLgdDPBQ4pHu-qGZEm_M3F2c82b5MiBzW0DZYh1h5U_rEjwqa7X5VHBhwm7780AyeuqFqqSTv7VBlAFI8bK15kz2rLs2JWjbLvXiqOztaA-9wVrQfa9LyCGV2fFTDL-XqyZ6nNDBY6BL8uIdDwmw/s640/IMG-20221210-WA0004.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="640" data-original-width="480" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhb4185jF1apc5SeFklPE3K3BkAZZ3HWHvuPkM3XrLgdDPBQ4pHu-qGZEm_M3F2c82b5MiBzW0DZYh1h5U_rEjwqa7X5VHBhwm7780AyeuqFqqSTv7VBlAFI8bK15kz2rLs2JWjbLvXiqOztaA-9wVrQfa9LyCGV2fFTDL-XqyZ6nNDBY6BL8uIdDwmw/s320/IMG-20221210-WA0004.jpg" width="240" /></a></div>Here is Francis' firewall getting ready for the hole pattern layout:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgk79D7laaKnBwu0-nxKHSMEXNOraqzwbVTStTJYJT48Xcm7iyBqzd1VPkKZa8seU7W4tDGdEC6snfO3asE1NB1suJwnD9uZkk_LSwJOmK27i0NSiGJNhbTFp9ytVAPYnSSiMqNngAcftC-RvcwzLfjeGrz_77Ddm2dncnqTajbUIwByf6ljZoWRCRHsQ/s900/IMG-20221214-WA0002.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="802" data-original-width="900" height="285" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgk79D7laaKnBwu0-nxKHSMEXNOraqzwbVTStTJYJT48Xcm7iyBqzd1VPkKZa8seU7W4tDGdEC6snfO3asE1NB1suJwnD9uZkk_LSwJOmK27i0NSiGJNhbTFp9ytVAPYnSSiMqNngAcftC-RvcwzLfjeGrz_77Ddm2dncnqTajbUIwByf6ljZoWRCRHsQ/s320/IMG-20221214-WA0002.jpg" width="320" /></a></div>The floor channels are used to (obviously) stiffen the cockpit floor, but they also help to transmit the tractor forces of the engine mount into the cockpit floor and to the skins that are riveted to it all down the side of the fuselage. These floor channels are parallel on opposite sides of the cockpit floor for about 2/3 of the length of the floor. Then, just about where the aft stick is mounted, the channels become angles and bend in slowly as you travel aft down the cockpit floor. Here is a 3D CAD drawing of this part to better show how the part goes from a 2 flange channel to a single flange angle bracket:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgeDO6k_OZIuXMqT_1azsxTxyU3Nq0UK8nfdWq71F_IWNdMm7LmALb85zdRSM4tIrAAiobvUILSqfw8g-XUmnspQ32NeDmQCCHsUhKdoy8yMbmHiD8ooA_MnUZWiIbYiKVowpccSrhhVW6hi4kG94-mjvdiwuYrFroihu5Uv_Scg-6apsxKZNG6F9HgSw/s1434/FFA20&21_3D.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="744" data-original-width="1434" height="166" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgeDO6k_OZIuXMqT_1azsxTxyU3Nq0UK8nfdWq71F_IWNdMm7LmALb85zdRSM4tIrAAiobvUILSqfw8g-XUmnspQ32NeDmQCCHsUhKdoy8yMbmHiD8ooA_MnUZWiIbYiKVowpccSrhhVW6hi4kG94-mjvdiwuYrFroihu5Uv_Scg-6apsxKZNG6F9HgSw/s320/FFA20&21_3D.png" width="320" /></a></div>This is how the fuselage in a Prowler transitions from a mostly rectangular tube up front (from the firewall back to about where the aft stick is located) to more of a tapered cone shape of the aft fuselage at the empenage. This pic below is showing where the inside flange of the floor channel has been removed and the slots have been cut into the flange that will attach to the cockpit floor. These slots will allow the angle to bend slightly and conform to the shape of the aft cockpit floor. Here's what the slots look like:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhsna3E3aP7-bxdk__yl3r_bLFCQn9jDUqB4dOeNVTpmTD2QHULtOPQhF5jWk57ed7OWhUOTiWxhcY3iCoK2qDq5EaHTsj_0XkdiLzLS74f84Llq2FBXZqCr02uiI6thgFkO0Ac7tV3_YGtl-duK3at3EIUKlpexxyWl9sP6dZ17ljuR42076pT76eeyw/s1600/IMG-20221212-WA0011.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="777" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhsna3E3aP7-bxdk__yl3r_bLFCQn9jDUqB4dOeNVTpmTD2QHULtOPQhF5jWk57ed7OWhUOTiWxhcY3iCoK2qDq5EaHTsj_0XkdiLzLS74f84Llq2FBXZqCr02uiI6thgFkO0Ac7tV3_YGtl-duK3at3EIUKlpexxyWl9sP6dZ17ljuR42076pT76eeyw/s320/IMG-20221212-WA0011.jpg" width="155" /></a></div>
Here are the forward ends of these floor channels clamped together. I think he is comparing the length and width of the channels here:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4HQwn-vBDVcw9X1sslDssTZqLHv9RgRSCv5L4wnussyO8eOneNzbp_Q7InB5PS9mBgkMDLwS6HtQe6_kHJHqmO1CahV9mPUWl7zbrRlX2wzKM3r_zx35KnBqxbiDGGAykpL97BcbpxUIzA3LwmoK_iSrKcNY_XzJuAsg8wXnHemS6azXnM760iDdDow/s1600/IMG-20221212-WA0012.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="777" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4HQwn-vBDVcw9X1sslDssTZqLHv9RgRSCv5L4wnussyO8eOneNzbp_Q7InB5PS9mBgkMDLwS6HtQe6_kHJHqmO1CahV9mPUWl7zbrRlX2wzKM3r_zx35KnBqxbiDGGAykpL97BcbpxUIzA3LwmoK_iSrKcNY_XzJuAsg8wXnHemS6azXnM760iDdDow/s320/IMG-20221212-WA0012.jpg" width="155" /></a></div>
At the aft end of the cockpit floor, the upper and lower angle brackets get riveted to the large fuselage former:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj83W7Z0LEugON4cxbbDGDak4ZlDp69-YwfUNQ88F3M62Xh3d1fKurqPdKA9SqPj9xNFkUp4F670IPb3V6BTNStCR9CT1kAVJzQxcFEjEl5MnNpwr0CgCldorN15p92-LSOKSFNDIiHAfuf79j68NEJBfg8pFnO053dpVnwIBK2VdmSuZS-cFAgWroUaA/s1600/IMG-20221217-WA0000.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="777" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj83W7Z0LEugON4cxbbDGDak4ZlDp69-YwfUNQ88F3M62Xh3d1fKurqPdKA9SqPj9xNFkUp4F670IPb3V6BTNStCR9CT1kAVJzQxcFEjEl5MnNpwr0CgCldorN15p92-LSOKSFNDIiHAfuf79j68NEJBfg8pFnO053dpVnwIBK2VdmSuZS-cFAgWroUaA/s320/IMG-20221217-WA0000.jpg" width="155" /></a></div>
Same fuselage former viewed from the front:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEir9M8nClQussPvkd8K5FN8Xw8ygcqKUKGt9Ns1rLr4lyeOJrxByIlo6-ZUrwbCuP5l_ssvCFYqHNrnVzTi0YqqQpzxSxsk75qIrnWqpgjeTr_Fl54hHChcjITNRgjK_se-xLyk4m655-R_MeGl2z7QjHbZ18zXj0AFb3CaxDfikUZ9xH7p1YqKZ_N6IA/s1600/IMG-20221217-WA0002.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="777" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEir9M8nClQussPvkd8K5FN8Xw8ygcqKUKGt9Ns1rLr4lyeOJrxByIlo6-ZUrwbCuP5l_ssvCFYqHNrnVzTi0YqqQpzxSxsk75qIrnWqpgjeTr_Fl54hHChcjITNRgjK_se-xLyk4m655-R_MeGl2z7QjHbZ18zXj0AFb3CaxDfikUZ9xH7p1YqKZ_N6IA/s320/IMG-20221217-WA0002.jpg" width="155" /></a></div>This fuselage former that is just aft of the cockpit floor is mounted in place and then the fuselage side longerons are added to frame in the cockpit. These longerons have to have the same contours formed into them that the aft ends of the floor side channels have. Then, when the side longerons are completed and attached to the aft fuselage former, the top of that large fuselage former is trimmed off even with the top of the cockpit side wall. Then, the sloped baggage compartment door frame is added from there. We will see that develop as Francis gets farther along in the near future.<br /><br />Awesome progress, Francis!! I really, really appreciate you sharing pictures of your progress so that I can share it all with the other Prowler builders and enthusiasts! <br /><br />OH!! I forgot to mention earlier, Francis has told me that he is now retired. Congratulations on your retirement, Francis!! I expect that I will be getting more and faster updates from him now! I will be happy to post that info here in the blog. He has also mentioned that he wants to come to AirVenture in 2023 to meet more Prowler builders. That would be great! I'll have more on this later - stay tuned! <br /><br />Again, Happy New Year Everyone!! I am already getting started on a couple more blog updates to catch everyone up on a few more events that happened during "CoVid". I hope to get those posted over the next couple of weeks. <br /><br />Unknownnoreply@blogger.com1tag:blogger.com,1999:blog-4561663675008429701.post-50370662943327249942022-12-24T11:13:00.000-08:002022-12-24T11:13:34.916-08:00Merry Christmas!! Sorry It Has Been So Long Since The Last Update!! Hello Everyone,<br /><br />Merry Christmas to all - Florida style:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgugl897eKZ6waSsbuu-yHEEX_p9zdcYMQFBo6q2sdFUopuIQ9RhfCPb8ZQdp6xaKTkWG05vxtyIFjdfixrebCtb-EdO751Ah2YkUnKKuJVBE8WmP2gLtqoqIcAduesJdWRpYfkfWDkCyFROOdiWop-iqDobvokZIpiWyhDaT5EhRkfyGkY-fVYnun3Dg/s1047/20221121_071403949.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1047" data-original-width="698" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgugl897eKZ6waSsbuu-yHEEX_p9zdcYMQFBo6q2sdFUopuIQ9RhfCPb8ZQdp6xaKTkWG05vxtyIFjdfixrebCtb-EdO751Ah2YkUnKKuJVBE8WmP2gLtqoqIcAduesJdWRpYfkfWDkCyFROOdiWop-iqDobvokZIpiWyhDaT5EhRkfyGkY-fVYnun3Dg/s320/20221121_071403949.jpg" width="213" /></a></div>This display was located just inside security checkpoint at the JAX airport this year.<br /><br />Yup! I'm still around, and I'm still doing Prowler Aviation work. However, now I am back to the normal "day job" and it has been a fairly busy year at work. I really want to start to get back to doing more of these Prowler blog updates, but it seems like I always have something higher on the priority list, so it ends up getting pushed to the right. I will endeavor to do better. Let's say that I will make that my New Year's resolution for 2023!<br /><br />The last blog update was dedicated solely to the work I have finished on restoring an old Hardinge HCNC lathe that was in need of some updates. I don't have a lot more to update on machines and such. However, I do have a bit of Prowler related material that I have been holding onto while waiting for an opportunity to get going with a blog update for it. Most of the Prowler related update info that I have is on one of the following topics: 1) work done to the "Sea Prowler"; 2) Updates on Francis' progress on the French Prowler; and 3) Parts that I have made to support the work that Vaughn is doing, or updates on his project's progress.<br /><br />For this blog update, I think I will address the "Sea Prowler" items and the work that we have been doing for Vaughn's Prowler project. Then, I'll put all of the pics and updates that I have gotten from Francis into a single blog post of it's own - which I will do right after this update. I will shoot to get this current blog post done by Christmas and then get the next one posted by New Year's.<br /><br />So, let's go........<br /><br /><u><b>Vaughn's Prowler Project (Kit #13) - </b></u> I introduced Vaughn and his project in a previous update (<span style="background-color: #fcff01;"><a href="https://prowleraviation.blogspot.com/2022/02/dude-its-been-likeover-year.html" target="_blank">here</a></span>). This kit was originally bought and partially built by Mr. Ron Chamblin of Jacksonville, FL. Ron sold all of his Prowler projects to Rick Pelliciotti in 2008/2009. Some years later, Rick sold this kit to Roy in Indiana. Roy had it for sale for a while until Vaughn purchased it in late 2020. Here is a pic from about the time that Roy bought the partially completed kit:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHLZwavoAXkznJZlDcA0RXrTvFnguEaJ8CsfLFxrbQT_ktkyCunqAG0zX30WMJ7NreMzmBozuOFfm3oymsfewxqgWD5ISRvSpuyDR04y0B2B3s1wBWByW69VcJ9OKrwdc2NNB-bC5-1Xngy-EiuszyA0DUD3kVotbHNLE2BK8fnRCPP9tnCs-KiZ-cwA/s792/Kit%2013_2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="594" data-original-width="792" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHLZwavoAXkznJZlDcA0RXrTvFnguEaJ8CsfLFxrbQT_ktkyCunqAG0zX30WMJ7NreMzmBozuOFfm3oymsfewxqgWD5ISRvSpuyDR04y0B2B3s1wBWByW69VcJ9OKrwdc2NNB-bC5-1Xngy-EiuszyA0DUD3kVotbHNLE2BK8fnRCPP9tnCs-KiZ-cwA/s320/Kit%2013_2.jpg" width="320" /></a></div>Once Vaughn got the airplane in his hangar and got familiar with the airplane, he started to make a list of things that needed to be fixed, modified or just needed finishing. Here are a few of the first items on the list.<br /><br /><u>MLG Alignment Mods to Torque Box</u> - One of the first things on that list was the alignment of the MLG. Vaughn
noticed that the wheel on one side was not tracking correctly and when
retracted into the wheel well, the strut was not parallel to the spar in
the gear well. After some discussions, we determined that the torque box was possibly mis-aligned during wing construction and the easiest "fix" would be to move the pivot link inside the torque box. After taking some measurements, Vaughn determined that the strut was approx. 1/4" too far forward in the gear well. With that info, all we had to do was the math:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhh8-BfBd_puJqy1_f_tx8z--B_9mVEBMjJNzvbRNgMJ6hnVBb1Csk0immj9FL8PrmanNWWvZFeW08y-9lhcTDYU29Ao8E_d4q69gSFQleQHDE-B5uFcwZtOTujGvsc8t6MlNH0gRBhagPLQUMeYRzEmplsXz6ld1WD29lqejUTlENQHAeB4OJ6VffWFQ/s1008/image0.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1008" data-original-width="756" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhh8-BfBd_puJqy1_f_tx8z--B_9mVEBMjJNzvbRNgMJ6hnVBb1Csk0immj9FL8PrmanNWWvZFeW08y-9lhcTDYU29Ao8E_d4q69gSFQleQHDE-B5uFcwZtOTujGvsc8t6MlNH0gRBhagPLQUMeYRzEmplsXz6ld1WD29lqejUTlENQHAeB4OJ6VffWFQ/s320/image0.jpeg" width="240" /></a></div>
What the math told us, is that the pivot link support inside the torque box was going to have to move about about 0.054" (rounded off to a 0.050" piece of steel plate). That would be possible to do by placing a shim on one side of the pivot link support. But, first, the torque tube would have to come out - that is a more difficult task. The first step to remove the torque tube was to make room for it to come forward into the wing, past the transverse bulkheads between the nose ribs in the center wing. Here was the ruff removal to accomplish that:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWR2fqMdJp5ESPtZMf3Ug7TtMjSrvgd7FpKGaw-nAO9Fr29dSEBRjF33KE655KCs3b6hKKQVaWEILZgFVZtlTgLthcRhixEC4aYnAw9cYCfm7KNeIenH0v_Jh6HF7joRiOEMjsq8nZY9dlto2QX1GYFFNNwpMrZ_5UBxmzhOxdUtdu6xXlOAiSDipN0Q/s960/-1996954670662506214.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="720" data-original-width="960" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWR2fqMdJp5ESPtZMf3Ug7TtMjSrvgd7FpKGaw-nAO9Fr29dSEBRjF33KE655KCs3b6hKKQVaWEILZgFVZtlTgLthcRhixEC4aYnAw9cYCfm7KNeIenH0v_Jh6HF7joRiOEMjsq8nZY9dlto2QX1GYFFNNwpMrZ_5UBxmzhOxdUtdu6xXlOAiSDipN0Q/s320/-1996954670662506214.jpg" width="320" /></a></div>With more room to pull the torque tube forward, the next step was to cut into the top of the wing and the top of the torque box and remove the bolts holding the pivot link to the aft end of the torque tube. Then, after removing a bunch of bolts on the wing joint plates, the torque tube could be removed from the torque box (the spherical bearing has to come along with it). Here is the tube removed:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh51BYegsA2M1ZQeSb5EMwLXz0lKKVIBcxHXjj-k8mT51rXE_Wxfq1QeWGVbBMCUI6bo6b7fhkpoW4EG2qjA2s0Om2fO5NnspyeAATFAT_kw0Q-5UbF37ClKXzsYpr63JAfnY0Y6IkFxQ3Hh0W5sWm4dHcv6bz4NcHT1KofA37vuNSUPAeumBgHlZod3w/s960/8471da2f-4314-4663-98da-fecd8f9aa9ee.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="720" data-original-width="960" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh51BYegsA2M1ZQeSb5EMwLXz0lKKVIBcxHXjj-k8mT51rXE_Wxfq1QeWGVbBMCUI6bo6b7fhkpoW4EG2qjA2s0Om2fO5NnspyeAATFAT_kw0Q-5UbF37ClKXzsYpr63JAfnY0Y6IkFxQ3Hh0W5sWm4dHcv6bz4NcHT1KofA37vuNSUPAeumBgHlZod3w/s320/8471da2f-4314-4663-98da-fecd8f9aa9ee.jpg" width="320" /></a></div>
With the torque tube removed, he could remove the bolts that held the pivot link bracket and remove it. Here is the bracket with the new shim installed in place:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxvFhGzVECooEXWhHZUxE_L37yQ2bGCTnTtmVmTBBVCmflqaE4yodq_Zjihdnuug_LOfdOZSIHjNLMmIW5GaICYUa41_6xOZuUUBZzjofY3Xa1QRmZBBX-QKguf2zgce3H-MRU2CGbsR5ijN2QAzGqsM_FvZBDZYIR8Du5knLlTIykfF8xfyPSGpsp2g/s960/8e6aca52-5f3a-43f3-8abf-cc0e04916586.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="720" data-original-width="960" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxvFhGzVECooEXWhHZUxE_L37yQ2bGCTnTtmVmTBBVCmflqaE4yodq_Zjihdnuug_LOfdOZSIHjNLMmIW5GaICYUa41_6xOZuUUBZzjofY3Xa1QRmZBBX-QKguf2zgce3H-MRU2CGbsR5ijN2QAzGqsM_FvZBDZYIR8Du5knLlTIykfF8xfyPSGpsp2g/s320/8e6aca52-5f3a-43f3-8abf-cc0e04916586.jpg" width="320" /></a></div>Another view:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiI5gErEl6ltR9NFtSbPrVtc94mpFpp2lzzbn01z1fDE2v5nXiXSjGustqxvXy12Yj4YkyC7rhtwZCYh3lefx-lWzBVmKAYuGwr4RfMZphLKl3sFsmgsTQl1cVNC8pZfz7aYOk__wZIMLCrCj3t0j-4QDzwp_7K_IdyLSRbr6jO4GehceiNaPpFzNguOA/s960/ec509c0c-f0bc-4212-b09e-ecfa37f7da69.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="720" data-original-width="960" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiI5gErEl6ltR9NFtSbPrVtc94mpFpp2lzzbn01z1fDE2v5nXiXSjGustqxvXy12Yj4YkyC7rhtwZCYh3lefx-lWzBVmKAYuGwr4RfMZphLKl3sFsmgsTQl1cVNC8pZfz7aYOk__wZIMLCrCj3t0j-4QDzwp_7K_IdyLSRbr6jO4GehceiNaPpFzNguOA/s320/ec509c0c-f0bc-4212-b09e-ecfa37f7da69.jpg" width="320" /></a></div>
Here is the pivot link that was removed, inspected and replaced into the torque box. If I remember correctly, Vaughn had to modify some of the bolts in the pivot to take out some backlash that was in the clearance holes in the pivot link and the threaded holes in the torque tube. Here is what that looked like:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhS3-rZqYPhmOsqdG4i1j3ML9uHnSvMT8TmqUG9TULeDK6oYVLtAqmQ7__LRG0uCh79yklZIafr0YTQQvR20yaZUzkazN7VfVe2ByApclv6FmBMyL5-72pWtVjS1aNXkuCi6rmU2JvJouKYJr2bSd4g7Hu4VSvVWyK4C_3OFiubtUVdmeJJjyyzT1aeKQ/s960/bb4f5241-835c-4609-a3d5-1b4a6e80208c.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="720" data-original-width="960" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhS3-rZqYPhmOsqdG4i1j3ML9uHnSvMT8TmqUG9TULeDK6oYVLtAqmQ7__LRG0uCh79yklZIafr0YTQQvR20yaZUzkazN7VfVe2ByApclv6FmBMyL5-72pWtVjS1aNXkuCi6rmU2JvJouKYJr2bSd4g7Hu4VSvVWyK4C_3OFiubtUVdmeJJjyyzT1aeKQ/s320/bb4f5241-835c-4609-a3d5-1b4a6e80208c.jpg" width="320" /></a></div>After getting it all back together, Vaughn was much happier with the operation of the MLG.<br /><br />
<u>MLG Uplocks</u> - With the MLG struts properly aligned and tracking into the gear wells properly, the next item on Vaughn's hit list was to install MLG uplocks. He copied Ray's work here and installed a stud to the MLG yoke that engages with an automobile OEM door lock unit. This design works great, it's reliable and can hold up multiple times the weight of the MLG during during G loads on the airplane. Here is Vaughn's installation:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7kiJTg0mnYiybkoxBIUBpd5c49v0uM2eC-coZGy0HBH-STL3BRRrBXNtY03F9n8bnQa6iRdzLeFukDkyL1GT3it6JrR_d1Q-oUC8z--hSGY9RlPhFhUp6DsRJ4eJjZYWQ6c4Wy_Df7cIploff9mxMEz_XHe52Zwctwscb3iIM3QjP6mgppG0tn3WbMA/s960/-2161659698032796866.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="720" data-original-width="960" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7kiJTg0mnYiybkoxBIUBpd5c49v0uM2eC-coZGy0HBH-STL3BRRrBXNtY03F9n8bnQa6iRdzLeFukDkyL1GT3it6JrR_d1Q-oUC8z--hSGY9RlPhFhUp6DsRJ4eJjZYWQ6c4Wy_Df7cIploff9mxMEz_XHe52Zwctwscb3iIM3QjP6mgppG0tn3WbMA/s320/-2161659698032796866.jpg" width="320" /></a></div>Nice work!<br /><br />
<u>Radiator Mods </u>- While working on the MLG (and while I was fabricating radiator parts), Vaughn was simultaneously planning his FWF installation and what he would need for systems to support that. He is planning on using a PowerSport rotary engine package for his Prowler. He determined what he would need for heat rejection with this PowerSport FWF package and had the proper sized radiators made for this. Once I got the radiator parts shipped out to him, he was able to start putting it all together. <br /><br />Here is a pic of some of his fabrication work on the radiator boxes:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWJ8d6FbntFb3as7b-Gpg07IeSNUAQfFtCHw2qK47d5r9S9fMp-dPgvH5C8amty2CGEOW1Rf0s5yQxtepdRklyagvt1UnXRc8qY6uNv3lvMJMhNM6uvVDqyefPithyzgTcAsf3xQTRfBSGiHNhIadaPiL243ODsM0mcGHoChhnK_04QgzNghNSd5M_3Q/s960/48fcae9e-8f31-4f9d-b591-145e17218c0a.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="720" data-original-width="960" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWJ8d6FbntFb3as7b-Gpg07IeSNUAQfFtCHw2qK47d5r9S9fMp-dPgvH5C8amty2CGEOW1Rf0s5yQxtepdRklyagvt1UnXRc8qY6uNv3lvMJMhNM6uvVDqyefPithyzgTcAsf3xQTRfBSGiHNhIadaPiL243ODsM0mcGHoChhnK_04QgzNghNSd5M_3Q/s320/48fcae9e-8f31-4f9d-b591-145e17218c0a.jpg" width="320" /></a></div>Since his FWF setup will not need as much heat rejection as a large V8 engine, and because he had very efficient, multiple flow radiators made, his radiators had a much smaller cross section than was needed for the old George Morse design. So, notice the baffles that Vaughn made to surround the radiators and, yet fit into the original channels: <br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtEvCIzZJBFZKh9h5mCyN9cqQDd6NgV_Xp1DHe2WpkTxJLelE89PCVOhvN3gy1a7t9zXUc6UtpM_MiNpzDOjDCrWmcEW8FIljdAYuaKrTqcp7RwQQVXAsS05gazkr-frA6SlPjzQTMsJUHVuSAUhwnUA9WgxeLPBCaXWta5BxXCi-Vn-k3MFFjVBPHCQ/s960/57891a58-26e2-41f3-a9b6-d8c9a7b42ca2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="720" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtEvCIzZJBFZKh9h5mCyN9cqQDd6NgV_Xp1DHe2WpkTxJLelE89PCVOhvN3gy1a7t9zXUc6UtpM_MiNpzDOjDCrWmcEW8FIljdAYuaKrTqcp7RwQQVXAsS05gazkr-frA6SlPjzQTMsJUHVuSAUhwnUA9WgxeLPBCaXWta5BxXCi-Vn-k3MFFjVBPHCQ/s320/57891a58-26e2-41f3-a9b6-d8c9a7b42ca2.jpg" width="240" /></a></div>Nice radiators! Here is what the (somewhat) final installation will look like:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhskJKUPY0mbT9OLpfDovVaK_QkmD2bHsLXFKana0FDWLj5N-CoOTaFlcMKiRfHBM9Aeb0YGWdm4ByJE5pfxgZLqDzqP3x8MVh9Z2C7SVqVqvs-b1cUFcxlI-nO__omfSL1B1TADr3ennBKtE5jYW17ZZL3bya8Q0Nwzh7NyZ-oojj54JU5Oo3k2C7_KQ/s960/5421590803593133218.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="720" data-original-width="960" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhskJKUPY0mbT9OLpfDovVaK_QkmD2bHsLXFKana0FDWLj5N-CoOTaFlcMKiRfHBM9Aeb0YGWdm4ByJE5pfxgZLqDzqP3x8MVh9Z2C7SVqVqvs-b1cUFcxlI-nO__omfSL1B1TADr3ennBKtE5jYW17ZZL3bya8Q0Nwzh7NyZ-oojj54JU5Oo3k2C7_KQ/s320/5421590803593133218.jpg" width="320" /></a></div>Same view here, except notice the part of the follow-up door installed on the MLG strut!<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhfGmF4scaL_4vGcRowwi_xwgE-GDNAF9wo7u4HlfbvK1ZvW9tyP33KpbTueLKJp6WUXKH6PefbW2jQier4Zg6QhDnJCZGXw0qWPXUefHKYhKSLgo8IPHuhWwWQmK-da3nqlXgApXM3HLT2aOBzQfQp8a8t0NNRFQjRvqn3PMQyGK9jJqgBTZ1_7swQfg/s960/-7114975895069972692.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="720" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhfGmF4scaL_4vGcRowwi_xwgE-GDNAF9wo7u4HlfbvK1ZvW9tyP33KpbTueLKJp6WUXKH6PefbW2jQier4Zg6QhDnJCZGXw0qWPXUefHKYhKSLgo8IPHuhWwWQmK-da3nqlXgApXM3HLT2aOBzQfQp8a8t0NNRFQjRvqn3PMQyGK9jJqgBTZ1_7swQfg/s320/-7114975895069972692.jpg" width="240" /></a></div><u>Parts #1</u> - I have been fabricating parts for Vaughn in several rounds. This first batch of parts that I shipped to Vaughn included MLG wheel well framing parts:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHpTauqdrZKl_Dk8COAhk5ldfwa7TIxlWAujGKcwEwSuIEfsFbtFJvA3kV5SNqjSB8QvleEzDeBm0R3HZslEe8R-gTCRF-5CoBTqU2DuEaSeXuYcYPsBvmJERHJp6OqtRirbGzVM3-U1GVthce8MVPbktPJWnXe4ABYHLqC3YajaN7s4pRQiAAlcBbfA/s2356/20210531_185005509~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="595" data-original-width="2356" height="81" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHpTauqdrZKl_Dk8COAhk5ldfwa7TIxlWAujGKcwEwSuIEfsFbtFJvA3kV5SNqjSB8QvleEzDeBm0R3HZslEe8R-gTCRF-5CoBTqU2DuEaSeXuYcYPsBvmJERHJp6OqtRirbGzVM3-U1GVthce8MVPbktPJWnXe4ABYHLqC3YajaN7s4pRQiAAlcBbfA/s320/20210531_185005509~2.jpg" width="320" /></a></div>Cockpit framing parts, including the back seat setback and seat pan, instrument panel frames and brackets:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg6CI8Xj_i1i3K2uT6QcO0gisn-XW6FPvEL80NBDsvw--8gPZxNAvN93-DtLOq3z6B1WiZoCPqGVVBVjYMMDiVT5R8dkQri7BgU_DkkwC3yG2puOm0sLXB-PKWMZEJN9NOmXorpjzT7ifvccxmmWM0xsFTB7VYaBCDUHVN_I9DoJmZ4r4ZNfoGcWjxEPg/s1722/20210601_001717133~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1722" data-original-width="1394" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg6CI8Xj_i1i3K2uT6QcO0gisn-XW6FPvEL80NBDsvw--8gPZxNAvN93-DtLOq3z6B1WiZoCPqGVVBVjYMMDiVT5R8dkQri7BgU_DkkwC3yG2puOm0sLXB-PKWMZEJN9NOmXorpjzT7ifvccxmmWM0xsFTB7VYaBCDUHVN_I9DoJmZ4r4ZNfoGcWjxEPg/s320/20210601_001717133~2.jpg" width="259" /></a></div>Radiator mounting flanges, door linkage brackets and radiator doors:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihAfuyDfGnkslVl3zl0XJc4fnUKavqyH0GkxXeLT3sF4g4G3QqXH4ZVkhCTNTI2nsXIL8gIVlCHOO7PtMUg-HwMFaLvuAYVi8w-XondbGaqxtdZKGJ87DmUy3F9dBgKgWaotV5UlwA42rlQgKCVClnzJfWOV7L1rIlVKIF-tsk67gJd4731iEuzgJ06A/s1460/20210601_003907301~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="755" data-original-width="1460" height="165" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihAfuyDfGnkslVl3zl0XJc4fnUKavqyH0GkxXeLT3sF4g4G3QqXH4ZVkhCTNTI2nsXIL8gIVlCHOO7PtMUg-HwMFaLvuAYVi8w-XondbGaqxtdZKGJ87DmUy3F9dBgKgWaotV5UlwA42rlQgKCVClnzJfWOV7L1rIlVKIF-tsk67gJd4731iEuzgJ06A/s320/20210601_003907301~2.jpg" width="320" /></a></div>More MLG parts including hydraulic actuators, actuator mounting brackets and some more framing pieces:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0uqTBeU24eScQ-vHUyqNQ75TSjuO6q33jo1wJX_7L-VsUog_ruHglSCJGCNrxrXqt8kBDFjB3XLkNvN-eR2mZQseKS-NirAjNzf3Wib8_HPQ78ESBOvQfAYByYh6CZ8IUm92eeezBpPDEa28pgeF4zH5GUFbebs0s7zI_XvSLYGwGmmhrD89rCdPExQ/s1423/20210601_040146911~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1147" data-original-width="1423" height="258" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0uqTBeU24eScQ-vHUyqNQ75TSjuO6q33jo1wJX_7L-VsUog_ruHglSCJGCNrxrXqt8kBDFjB3XLkNvN-eR2mZQseKS-NirAjNzf3Wib8_HPQ78ESBOvQfAYByYh6CZ8IUm92eeezBpPDEa28pgeF4zH5GUFbebs0s7zI_XvSLYGwGmmhrD89rCdPExQ/s320/20210601_040146911~2.jpg" width="320" /></a></div>I got most of the above parts shipped out to Vaughn in May 2021. Then, I started working on the next batch:<br /><br /><u>Parts #2</u> - Because of the size/length of the radiator attach angles and the instrument panel flange, I did not send those with the first shipment. After I fabricated the radiator lower skins for Vaughn, I included those with the previous parts and got them shipped out to him in June 2021. Here they are:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3fEBN3ekLBd41iH2k6YZZxjiqDZKu6briyaOCKvpAGzm_mKkEXTbLrTZ1Kw6rxBkeOHagRYXv9KVJ7wl9y42pbkCvGvFUGFbT2lIPEhnezR22KHd7V4cFf-WNAY7wHA48YwrffO9L93HOWpLjAUzB3Wqe4dOx_9xC5P5OphAhoAJc3tnXVwaHiZVgig/s1849/20210901_173203714~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="983" data-original-width="1849" height="170" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3fEBN3ekLBd41iH2k6YZZxjiqDZKu6briyaOCKvpAGzm_mKkEXTbLrTZ1Kw6rxBkeOHagRYXv9KVJ7wl9y42pbkCvGvFUGFbT2lIPEhnezR22KHd7V4cFf-WNAY7wHA48YwrffO9L93HOWpLjAUzB3Wqe4dOx_9xC5P5OphAhoAJc3tnXVwaHiZVgig/s320/20210901_173203714~2.jpg" width="320" /></a></div>Here is a quick pic of part of the lower radiator skin fabrication. This gets the proper radius bend on the forward leading edge of the radiator lower skin.<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh69QMmtsSkdr2Q8BFt_bvc3_xJkz4CZsG10SaXGLVrbgBoc0BNBUcUyJl7kVvG8RZHi0dFpUSOAKAWZpQ8xOx39OfThugWxYcs3nP_y-sj8E94R28pi4zsaimh5SQ9FRoD--C9VBYm0vipEdOig5sMPmfaFVmrTR2NggLS4sdx3CvrBbiD-uIUaukrhA/s940/20210912_202122766.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="940" data-original-width="786" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh69QMmtsSkdr2Q8BFt_bvc3_xJkz4CZsG10SaXGLVrbgBoc0BNBUcUyJl7kVvG8RZHi0dFpUSOAKAWZpQ8xOx39OfThugWxYcs3nP_y-sj8E94R28pi4zsaimh5SQ9FRoD--C9VBYm0vipEdOig5sMPmfaFVmrTR2NggLS4sdx3CvrBbiD-uIUaukrhA/s320/20210912_202122766.jpg" width="268" /></a></div>It is kinda low tech - but, it works good!<br /><br /><u>Parts #3</u> - The third batch of parts that I made for Vaughn was a set of radiator door side formers. To make these, I needed to cut the blanks that were to be formed. Then, they are clamped between the two form blocks. You bend the flanges one way for one side of the door, and bend the flanges the other way for the other side of the door. Here is the pattern, a forming blank and the forming blocks:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRWyYYxomNDvvUkfwKurY9R9oFhD7lmHVwy2SdzYZduGm1m7ruC11zRCtuiwr2bNsOlnSxwICLGn5lVHKTMTyocmnF9K2dZV8FcR0rq2-MlSvAP5ZvN2jtlmbVcXaHGvEpFt8ZRU0u4DEz/s958/20211021_152807443%257E2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="958" data-original-width="569" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRWyYYxomNDvvUkfwKurY9R9oFhD7lmHVwy2SdzYZduGm1m7ruC11zRCtuiwr2bNsOlnSxwICLGn5lVHKTMTyocmnF9K2dZV8FcR0rq2-MlSvAP5ZvN2jtlmbVcXaHGvEpFt8ZRU0u4DEz/s320/20211021_152807443%257E2.jpg" width="190" /></a></div>Here is the paper pattern, a metal pattern, and 4 forming blanks:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcQiI0FKeKEw2-LaKq4eMnDC36j1KtevcpKIdBETrO2wKlXaIoVbLGD4TqjWTWoTS8_pffwCFnCq90hIDffnPSucxfBLg4MT_CBsAgu6XkuCY2JIUZAlOtt_8WwwbSdQx1KhFfHojkUY5b/s939/20211021_160131182%257E2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="809" data-original-width="939" height="276" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcQiI0FKeKEw2-LaKq4eMnDC36j1KtevcpKIdBETrO2wKlXaIoVbLGD4TqjWTWoTS8_pffwCFnCq90hIDffnPSucxfBLg4MT_CBsAgu6XkuCY2JIUZAlOtt_8WwwbSdQx1KhFfHojkUY5b/s320/20211021_160131182%257E2.jpg" width="320" /></a></div>Drilling the tooling holes:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPJkTQcIV7629Ar4d3bbryMIqoHDAU17Qe5YVeQ7mmztlQwkMgtdU4WOlpsTaAkE-5e4XupXBtlJkxE9QJW_gDXt96V-VKGADqwD17pVMNVwR6SGkp4B_QXY1WcDlAdzzgvQv16x_Spuwd/s1083/20211021_160414993%257E2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="577" data-original-width="1083" height="170" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPJkTQcIV7629Ar4d3bbryMIqoHDAU17Qe5YVeQ7mmztlQwkMgtdU4WOlpsTaAkE-5e4XupXBtlJkxE9QJW_gDXt96V-VKGADqwD17pVMNVwR6SGkp4B_QXY1WcDlAdzzgvQv16x_Spuwd/s320/20211021_160414993%257E2.jpg" width="320" /></a></div>First blank in the form blocks and bending (forming) the flanges:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhurfrZkLOfYxuYxzkae5HRPn9cQ3L6PsTgwvsBqhH0pdoe1hsWMu4TEBvKQkbjYZRwXFcxLBEmHscmffvJaPvBnpXo_R88MwVRXWD_qoSYEoWVuYkixNwXHI33xB6RYm74Oguk7_uZKSpW/s1055/20211021_162710505%257E2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1055" data-original-width="908" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhurfrZkLOfYxuYxzkae5HRPn9cQ3L6PsTgwvsBqhH0pdoe1hsWMu4TEBvKQkbjYZRwXFcxLBEmHscmffvJaPvBnpXo_R88MwVRXWD_qoSYEoWVuYkixNwXHI33xB6RYm74Oguk7_uZKSpW/s320/20211021_162710505%257E2.jpg" width="275" /></a></div>One completed radiator door former:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiS4601UqMpbJNoEPPs2KgCLZasQMAMAd45A4RbSGELyMB9olPDmmbSOCzsL4Ne6h1BHxR7eYBFoXYvaZA7xuhmuvuDvu2YB8VFjWfArLx1Z5VYagIpAC5KbQeZQWwh8Y97B50GdeXCnuh_/s1334/20211021_162942220%257E2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="818" data-original-width="1334" height="196" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiS4601UqMpbJNoEPPs2KgCLZasQMAMAd45A4RbSGELyMB9olPDmmbSOCzsL4Ne6h1BHxR7eYBFoXYvaZA7xuhmuvuDvu2YB8VFjWfArLx1Z5VYagIpAC5KbQeZQWwh8Y97B50GdeXCnuh_/s320/20211021_162942220%257E2.jpg" width="320" /></a></div>Here are two complete sets of radiator door formers:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2x_6oMQbGhbQz61ixsNVf7PvMlxwYxehuC9Sjd7ydJE__Pky76yNDJixwDvGZlonsEtqm0SL_6rjKhvlTYNZui58C-rSrOpMQ2S8MB0We_wxN5YOxRRGD3xD6DwCORSaAOd3JqZbhSCJf/s1439/20211021_184021630%257E2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="634" data-original-width="1439" height="141" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2x_6oMQbGhbQz61ixsNVf7PvMlxwYxehuC9Sjd7ydJE__Pky76yNDJixwDvGZlonsEtqm0SL_6rjKhvlTYNZui58C-rSrOpMQ2S8MB0We_wxN5YOxRRGD3xD6DwCORSaAOd3JqZbhSCJf/s320/20211021_184021630%257E2.jpg" width="320" /></a></div>Ready to ship:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8QJ4Rvd9sab1iozUj2V0v6Ud-m5-lKfMY8_0yL3kXurXQtDxnX_v_T_f1dkjVM4I38AwAi_yd7BGgkxbg7kUQ6pT3_F4pbS22C8ZhBg40JldktkNpXzm278UdWFU2lGvuu6RAaBhklbst/s1262/20211021_184406214%257E2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="762" data-original-width="1262" height="193" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8QJ4Rvd9sab1iozUj2V0v6Ud-m5-lKfMY8_0yL3kXurXQtDxnX_v_T_f1dkjVM4I38AwAi_yd7BGgkxbg7kUQ6pT3_F4pbS22C8ZhBg40JldktkNpXzm278UdWFU2lGvuu6RAaBhklbst/s320/20211021_184406214%257E2.jpg" width="320" /></a></div>With radiator parts now finished....time to move on to the flap actuator.<br /><br /><br /><u>Parts #4</u> - I don't think that Kit #13 was built with the flap actuator installed onto the forward side of the aft bulkhead beneath the cockpit floor. At least, it was not there when Vaughn bought the kit. So, the first step for me was to fabricate all of the parts to make an actuator:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgl7CR1Z2V00YQTHP5zuetjpwlWECp0w-ZOoEHW1bWEFCePJT6rVYSn1bd0s1wlwjp5nCaSQf1sEbmA36Z_KtSUMt1KMnYE-grpg0jt2jJqXB_KZ9bOxiI7E3i-tN1298xuD2IYODIEatJVNMkThqKM-oj4wU0xU9sQGuJTkigXcHocXcXA7PaMUxogzA/s1156/20211102_032424346.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="759" data-original-width="1156" height="210" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgl7CR1Z2V00YQTHP5zuetjpwlWECp0w-ZOoEHW1bWEFCePJT6rVYSn1bd0s1wlwjp5nCaSQf1sEbmA36Z_KtSUMt1KMnYE-grpg0jt2jJqXB_KZ9bOxiI7E3i-tN1298xuD2IYODIEatJVNMkThqKM-oj4wU0xU9sQGuJTkigXcHocXcXA7PaMUxogzA/s320/20211102_032424346.jpg" width="320" /></a></div>Then, I jigged them all up in the fixture that I made several years ago:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyYrCT_JDcopZ3ql3ogdX3240Gc84KOx36mdpMqhZjBBph8Rpav9PyvHyaQmREhxfEspjHrj5isDSQghwK0SC-WuJl5_8YBfcrMRxon7gxjKP74WFfjBEhiwrK0HwsKBH4NZqk-8r9GqBAIl-YqNmIaPkaGcUn1ASk4nR4TRw0n1q2UURfAsFkfZYzVA/s824/20211102_194516956.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="819" data-original-width="824" height="318" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyYrCT_JDcopZ3ql3ogdX3240Gc84KOx36mdpMqhZjBBph8Rpav9PyvHyaQmREhxfEspjHrj5isDSQghwK0SC-WuJl5_8YBfcrMRxon7gxjKP74WFfjBEhiwrK0HwsKBH4NZqk-8r9GqBAIl-YqNmIaPkaGcUn1ASk4nR4TRw0n1q2UURfAsFkfZYzVA/s320/20211102_194516956.jpg" width="320" /></a></div>I tack welded each of these parts well enough to hold them in place and got this:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihvAeUUWW3bNV8eT9llMYhoJPH2svm14xnVoY5eBcve255kJfti9hRTuQ5WGK8q7G95pc3bxr6deRSe-zLExTU4MyB4CuTCUmCMKw21iPZ9imfr6HSlt5KJuXWOJ1sqA979FCusN4srhMLTLB1qwfapoMwZah3VoOw_0t8HzVR_5Sk6xgxG_smDCRvfg/s1510/20211213_020644179.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="683" data-original-width="1510" height="145" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihvAeUUWW3bNV8eT9llMYhoJPH2svm14xnVoY5eBcve255kJfti9hRTuQ5WGK8q7G95pc3bxr6deRSe-zLExTU4MyB4CuTCUmCMKw21iPZ9imfr6HSlt5KJuXWOJ1sqA979FCusN4srhMLTLB1qwfapoMwZah3VoOw_0t8HzVR_5Sk6xgxG_smDCRvfg/s320/20211213_020644179.jpg" width="320" /></a></div>Because Vaughn's kit is mostly assembled, he doesn't have much room to install this actuator. So, to make it easier (to make it even possible) I was going to have to use another of Ray's proven modifications and divide the actuator up into 3 pieces. Here is the fabrication of 2 sets of triangular parts that will make it possible to install this actuator in 3 pieces and then bolt them all together:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzreaYjH2R3w78zQlc1jp1quMndfjHJ62s44LqKGno__XFZtIExo_WQ73Xw3RMBqJi6wZ90XMn_ZRzYKG26Ru3yD4Vd1dQq55ivLkVCIiOxqps-t983i95BArS7hQsJYn6mewwIzCSs6EnYekbaUawhcCt6_CpoTOZffTJuf6M2_CTta-pdBTzpKiZVg/s1436/20211213_222743817.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="660" data-original-width="1436" height="147" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzreaYjH2R3w78zQlc1jp1quMndfjHJ62s44LqKGno__XFZtIExo_WQ73Xw3RMBqJi6wZ90XMn_ZRzYKG26Ru3yD4Vd1dQq55ivLkVCIiOxqps-t983i95BArS7hQsJYn6mewwIzCSs6EnYekbaUawhcCt6_CpoTOZffTJuf6M2_CTta-pdBTzpKiZVg/s320/20211213_222743817.jpg" width="320" /></a></div>Three pieces plus the flanges:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1bP0fzJd82GJepb_1vgaUclNfTZ2-3uboWYnmIYBt27CXM_bnWVP1W_BxeXnIv4VAr_cQ5ZOLLb7nNL4--nHOonvXZa6igirPBWjA-UkGXdqudLWOmBpYJnetfWRdvLjJuZzdJeV2N-V2LQqVbNdRTBkNrridfhqbhkC6gbYHSi2SlAH1TnnawtuKJg/s1509/20211213_234011114.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="551" data-original-width="1509" height="117" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1bP0fzJd82GJepb_1vgaUclNfTZ2-3uboWYnmIYBt27CXM_bnWVP1W_BxeXnIv4VAr_cQ5ZOLLb7nNL4--nHOonvXZa6igirPBWjA-UkGXdqudLWOmBpYJnetfWRdvLjJuZzdJeV2N-V2LQqVbNdRTBkNrridfhqbhkC6gbYHSi2SlAH1TnnawtuKJg/s320/20211213_234011114.jpg" width="320" /></a></div>Back into the jig/fixture for more tack welding:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWtdmu7b3S5MDy2e90iBdAGmGaLFh2LzTPazphaL8MvpcGvi-PVAtYFvpuGvfk_fiiRKrekYkd6LDvhxuCuPFPWz-Fmr2oJgo9bxW66CNK5jmYTQzXsZl9FiWUEcRIjcxiBjhruE-P2-MDc4Qaj050PSe2tUms4rJ24PlWGxcXzGN7_wBQ9hIXYVkkDA/s1388/20211214_020107080.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="611" data-original-width="1388" height="141" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWtdmu7b3S5MDy2e90iBdAGmGaLFh2LzTPazphaL8MvpcGvi-PVAtYFvpuGvfk_fiiRKrekYkd6LDvhxuCuPFPWz-Fmr2oJgo9bxW66CNK5jmYTQzXsZl9FiWUEcRIjcxiBjhruE-P2-MDc4Qaj050PSe2tUms4rJ24PlWGxcXzGN7_wBQ9hIXYVkkDA/s320/20211214_020107080.jpg" width="320" /></a></div>Here is the final product that is tack welded together.<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYr5PV2lV7rWQpHYnmNvwPjH-OLj2azwv4k5KXLSeUrWNhATGPUNuD1bKwlN49ndTSEZD5Ni7Nt2_gYGrUTRrX403rSXJtfBjyjJUt565U9nMNNnM1Jtebnl9xAuKukr0Bm7DAxG09CiG7YMLxCx3VhYFZxZPmaKqWHrFfQF-jAySHgh7XFBVqVTQXDw/s1375/20211214_021300183.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1265" data-original-width="1375" height="294" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYr5PV2lV7rWQpHYnmNvwPjH-OLj2azwv4k5KXLSeUrWNhATGPUNuD1bKwlN49ndTSEZD5Ni7Nt2_gYGrUTRrX403rSXJtfBjyjJUt565U9nMNNnM1Jtebnl9xAuKukr0Bm7DAxG09CiG7YMLxCx3VhYFZxZPmaKqWHrFfQF-jAySHgh7XFBVqVTQXDw/s320/20211214_021300183.jpg" width="320" /></a></div>Since I lost my TIG welder (he up and moved his family clear across the country!), it is hard for me to get airplane parts welded. I was able to tack these parts together for Vaughn and he has a welder that will do the final welding on this actuator. Here are the parts ready to put in the box:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgVz0RpMJeV661Dwo8iX4h51fP7NX5XZiny8g5cKchg2Wgk19QKVsMNJNoGUmVSw4g_ftvRz2Ld0eVJRKfyd6KdwHjwt_klqX9-usNal-5CDcIuR5azdQkEimHNrC9amlVE4SiyzsBRhAXbyVS3roimqtXn26ZS_Cfkjh_dPhd8aF6Lpz-3BR1s9Pydw/s1463/20211214_021917304.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="817" data-original-width="1463" height="179" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgVz0RpMJeV661Dwo8iX4h51fP7NX5XZiny8g5cKchg2Wgk19QKVsMNJNoGUmVSw4g_ftvRz2Ld0eVJRKfyd6KdwHjwt_klqX9-usNal-5CDcIuR5azdQkEimHNrC9amlVE4SiyzsBRhAXbyVS3roimqtXn26ZS_Cfkjh_dPhd8aF6Lpz-3BR1s9Pydw/s320/20211214_021917304.jpg" width="320" /></a></div>I also included 3 sets of radiator door actuator brackets that Vaughn needed:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrKHzYuA6psbo9PLjp1UnhNN9rCXZcVXxs9L_JVpT0ZV-8MokThdh-e-q9suYCheRjXPVx2o9zbjkpV0eQ4ax5oZA5wCzuK1l7ce_860FGWeKwhz86jgIchfFnKINcuTHtN0xQZN26wWDOnG-eME8JjvOAPON7AL_KkIXST5O9OHWqh74sVUG0RD1dSQ/s1138/20211215_024444644.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1138" data-original-width="1018" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrKHzYuA6psbo9PLjp1UnhNN9rCXZcVXxs9L_JVpT0ZV-8MokThdh-e-q9suYCheRjXPVx2o9zbjkpV0eQ4ax5oZA5wCzuK1l7ce_860FGWeKwhz86jgIchfFnKINcuTHtN0xQZN26wWDOnG-eME8JjvOAPON7AL_KkIXST5O9OHWqh74sVUG0RD1dSQ/s320/20211215_024444644.jpg" width="286" /></a></div>Vaughn plans to use these to devise his own door actuators from small linear electric actuators. I'll update you on his design here. If it works well, I may adopt it as the new system for this on the Prowler. More to follow.<br /><br /><u>Parts #5 </u>- The most recent part I fabricated for Vaughn was the forward engine compartment bulkhead. I refer to this part as the "horse collar" - cuz that's what it looks like to me. Others have said it looks more like something you find attached to nearly every toilet in the world. You decide.<br /><br />Anyway, Vaughn is starting to plan out his engine installation and he needs this part to be able to begin to mock up his FWF project. There is a bit of a story behind finding the former for this part, but let's just say thanks to Cabi for providing this form block for making the horse collar for the original (smaller) Prowler. This is the former that was used to make the "horse collar" for the very first (smaller) Prowler. Here is the form block for making this part:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirFINPI61z3Edd_96NPZ6uzHSEQHX-gL8T0F_Dx2lsWuinbv5Xxa7ffp_lBSm_LArFQgiY8viSisY-xlc3Be6XbeGLmzomh0nMmw9YBp8t1RZH7bl2TeOuWvDGn3U9HuPTrRTtU9D_XQHgGFIfiklZn6hRzyfWNH_z1WpoSn-0MWXPQcF5WaXKdrMsYQ/s1126/20221124_192754884~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1087" data-original-width="1126" height="309" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirFINPI61z3Edd_96NPZ6uzHSEQHX-gL8T0F_Dx2lsWuinbv5Xxa7ffp_lBSm_LArFQgiY8viSisY-xlc3Be6XbeGLmzomh0nMmw9YBp8t1RZH7bl2TeOuWvDGn3U9HuPTrRTtU9D_XQHgGFIfiklZn6hRzyfWNH_z1WpoSn-0MWXPQcF5WaXKdrMsYQ/s320/20221124_192754884~2.jpg" width="320" /></a></div>[Sidebar - Vaughn chose to go with this smaller sized part because his FWF package weighs less
and has a smaller cross-section size up front. It is very likely that
he will have to move his whole FWF package forward some to keep the CG
in the range of all the current Prowlers. By going with this slightly
smaller front bulkhead former for the engine compartment, it should keep the side-view silhouette
of the airplane looking like it should for a Prowler (keep the same "lines"). We reasoned that the larger fwd bulkhead of the production Prowler moved forward might give his plane a more noticeably blunt front end, right behind the spinner. I think he/we made the right choice.] <br /><br />Here's a side view of the former that shows the angle of the flange that varies as you go around the outside perimeter of this part:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinnFlvyUnU1X2gF--CQzrM8ZJYrN8t9scxfOavF5mjiUFAl3dOR94Bd9QT_uE5is7bOV9wqdZ7aTLKPmsjsxmJPWFQlwzrGAeDAR63ZTuRKWodyK0JtsQTryJ0H_XEtylyXJX5pdxtAAzSuUP22IGr2m1OQaez84nLPbNRfCmePtHhl-qxtllVzl3xEA/s1343/20221124_193008284~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="311" data-original-width="1343" height="74" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinnFlvyUnU1X2gF--CQzrM8ZJYrN8t9scxfOavF5mjiUFAl3dOR94Bd9QT_uE5is7bOV9wqdZ7aTLKPmsjsxmJPWFQlwzrGAeDAR63ZTuRKWodyK0JtsQTryJ0H_XEtylyXJX5pdxtAAzSuUP22IGr2m1OQaez84nLPbNRfCmePtHhl-qxtllVzl3xEA/s320/20221124_193008284~2.jpg" width="320" /></a></div>I did not have a pattern for making this part. So, I made one from the form block backer. I traced the backer onto cardboard and then added a 1" flange on the outside and an 1/2" flange on the inside:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOj2gkR8nxxeeuHg_yjgVkLX5MCyS-4-rXCOsp4JfV3g-F5PNU84i5Iliq_-YUvAyqXZf0gHmutfMaXi9dRN_n176tfk8fKg0DjNiC5iLCoPWwc9iU0Rx9XdMaxqHRarVwVdq0hcy87WJafDSSGFOnFFjbkNxkNGr2g3_WmDuTfB-xe45FFpMZH5M-Xg/s1486/20221129_213310875~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1466" data-original-width="1486" height="316" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOj2gkR8nxxeeuHg_yjgVkLX5MCyS-4-rXCOsp4JfV3g-F5PNU84i5Iliq_-YUvAyqXZf0gHmutfMaXi9dRN_n176tfk8fKg0DjNiC5iLCoPWwc9iU0Rx9XdMaxqHRarVwVdq0hcy87WJafDSSGFOnFFjbkNxkNGr2g3_WmDuTfB-xe45FFpMZH5M-Xg/s320/20221129_213310875~2.jpg" width="320" /></a></div>Then, I used that pattern to cut out a forming blank. Notice how "wrinkly" the 2024-O material looks. That's just from holding/moving the piece while using a shears on it. It flattens back out once it is in the form block and you start to hammer, stretch, shrink and move the metal during forming:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWtEoDVn42rW2eWvx-hq-OkvurXtqnbZG4LpEnZM5zTcBic-_gJNY6T6OrssOoCDEGKRIeOXLppmpQA79D0n5WObbnDeRSvj3LpZPTeQ6d3Q5RHjPWNOa0M7c3uRql4wRS_mFSX2j0PLpOUKYAAi0y4ZbYKLUxNv4XICQHZc7mabpm1z6xqMOV0W8bdA/s1247/20221129_213410875~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1087" data-original-width="1247" height="279" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWtEoDVn42rW2eWvx-hq-OkvurXtqnbZG4LpEnZM5zTcBic-_gJNY6T6OrssOoCDEGKRIeOXLppmpQA79D0n5WObbnDeRSvj3LpZPTeQ6d3Q5RHjPWNOa0M7c3uRql4wRS_mFSX2j0PLpOUKYAAi0y4ZbYKLUxNv4XICQHZc7mabpm1z6xqMOV0W8bdA/s320/20221129_213410875~2.jpg" width="320" /></a></div>Then, sandwiched the blank between the form block and the backer:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIa704ZQw5ThfK1WbdDieV052OrDhdDVNE72jy0tMVu_SbPvkFqpYlRRYFE9B5eAxWW_725Tyhbk9_NfML_HYln7ptLsOTuTHIMxIZ_uF4wwSM6AlkZRejfpxhc-TOFEI-MkcX2B11UnrWDOqHbiQG0I4WM8iLz7iBeNN8LBp4WG2mTbdLYBTXdJX0DA/s1263/20221129_231017072~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="712" data-original-width="1263" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIa704ZQw5ThfK1WbdDieV052OrDhdDVNE72jy0tMVu_SbPvkFqpYlRRYFE9B5eAxWW_725Tyhbk9_NfML_HYln7ptLsOTuTHIMxIZ_uF4wwSM6AlkZRejfpxhc-TOFEI-MkcX2B11UnrWDOqHbiQG0I4WM8iLz7iBeNN8LBp4WG2mTbdLYBTXdJX0DA/s320/20221129_231017072~2.jpg" width="320" /></a></div>Here's another side view:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqZOVI6HFHwrUDfT8EcP43vbGKFwfXxXeWYKZ2FJJn-h785Lc8S7gJ61GPrdqyPbQkfz1Vo0RPBwxCTF4nVhS135sHqWWxOB9J7qxIOItJrlWSqDQy2_ypTzkl25XXLFKRnclwzfIcKZLYK6-ZtnoGh3k04J5_pX5YDI2IMFkCvbXx8wfrnBD6YWWE-Q/s1312/20221129_231111971~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="795" data-original-width="1312" height="194" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqZOVI6HFHwrUDfT8EcP43vbGKFwfXxXeWYKZ2FJJn-h785Lc8S7gJ61GPrdqyPbQkfz1Vo0RPBwxCTF4nVhS135sHqWWxOB9J7qxIOItJrlWSqDQy2_ypTzkl25XXLFKRnclwzfIcKZLYK6-ZtnoGh3k04J5_pX5YDI2IMFkCvbXx8wfrnBD6YWWE-Q/s320/20221129_231111971~2.jpg" width="320" /></a></div>Once the blank is in the form block, you simply start hammering the edges down. As you do that, the outer perimeter gets wavy:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYmNSGL4Z4HMThQWSR8kwsMfNK3oKE0UPzK47lqIobhKmL2f4uEnI_51-pthfZ2xszwiMYEitBUAA6djMuBxbtAQLvLflxpAFoIZIvV8XRjM8q7NVTSh0cLB-4deya471amGCBQdqdnvC2FjqXDbuN72FkiAhISQ1jHjvLMVqLwG5dDWfs7vxTp_8wxQ/s1247/20221129_232854894.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="695" data-original-width="1247" height="178" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYmNSGL4Z4HMThQWSR8kwsMfNK3oKE0UPzK47lqIobhKmL2f4uEnI_51-pthfZ2xszwiMYEitBUAA6djMuBxbtAQLvLflxpAFoIZIvV8XRjM8q7NVTSh0cLB-4deya471amGCBQdqdnvC2FjqXDbuN72FkiAhISQ1jHjvLMVqLwG5dDWfs7vxTp_8wxQ/s320/20221129_232854894.jpg" width="320" /></a></div>The flange gets wavy because the outer perimeter of the flange must get smaller (shorter) as you form the flange. You are essentially making the outside edge of the flange form a smaller, concentric contour. The metal in the outer perimeter of the flange must "come together". The best way to do that is to take the blank back out of the former and use a shrinker to take the "wavies" out of the flange:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjh68NC9jYLSJoC6X3sisLUzztUozpGS4KqRAgEJPjV-Y-OOChfzIV4RoHyGbRdu1r5c8C2slDLQWfSVB5frg6BeyeHZoUsfk4VcDmGc4nTuuJ0SULz976mLR2JBxHaLaj7WJgUFB07m34Qn0aLAgtoWhWSBEZeQZxbsIOizQO1_C1S4vi4l9v9ioNa-g/s1173/20221129_234301059.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1173" data-original-width="996" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjh68NC9jYLSJoC6X3sisLUzztUozpGS4KqRAgEJPjV-Y-OOChfzIV4RoHyGbRdu1r5c8C2slDLQWfSVB5frg6BeyeHZoUsfk4VcDmGc4nTuuJ0SULz976mLR2JBxHaLaj7WJgUFB07m34Qn0aLAgtoWhWSBEZeQZxbsIOizQO1_C1S4vi4l9v9ioNa-g/s320/20221129_234301059.jpg" width="272" /></a></div>Then, you have to put the part back into the former and hammer the edges down more until they fit tightly to the form block. As you do that, the material will get wavy again. In this picture below, I put X's on the flange where I do not need to shrink it any more:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgX0JambqeNsWENr27UH_756HQdEKHYxcFEHLGWU9mFXV6XtCbvd0E1EK7XNVKJFnYC0pP3unK9pVmI4GHkLW4IZVIpg5Bf71wb64QFsoB0yg6d-E_mdRDsaWNu8xuIX2bkjoqJkFtPMXoXMrM8-AFw2UjHNcJBZT-zuHC6BbvVI9Bx7c5KaT_PEzCyQ/s1335/20221129_235818813.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="684" data-original-width="1335" height="164" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgX0JambqeNsWENr27UH_756HQdEKHYxcFEHLGWU9mFXV6XtCbvd0E1EK7XNVKJFnYC0pP3unK9pVmI4GHkLW4IZVIpg5Bf71wb64QFsoB0yg6d-E_mdRDsaWNu8xuIX2bkjoqJkFtPMXoXMrM8-AFw2UjHNcJBZT-zuHC6BbvVI9Bx7c5KaT_PEzCyQ/s320/20221129_235818813.jpg" width="320" /></a></div>Each time you hammer the flange it will get wavy again, so you take it out and shrink the outer edges more. It is an iterative
process that you go through until you get the flange to form snugly to the form block without any waves, gaps or buckles. Eventually, you get the flange to fit nicely.<br /><br />Once the outer flange was done, I cut the center out of the part and hammered the inside flange. Unfortunately, I forgot to grab a pic of that. The inside flange is easier because you do not have to shrink the edges-the metal on the outer perimeter of the inside flange actually has to stretch to make the inside curves. The danger there is that you have to be careful not to hammer the inside flange too much, too fast - especially in the corners. Otherwise, the material will try to stretch too fast and it will fracture. Lots of little hammering operations is best. And, you try to hammer the metal from the straight flanges toward the curved areas.<br /><br />With the inside flange formed, all that is left to do is check the part for warping. If the part does not sit flat on a table, you have to carefully shrink the outer flange in the right places to take the warp out. Usually, a little bit in just the right places is all you need. Then, you trim the flanges to make them uniform. With that, you get the finished product:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRRCovgmIAJtwte4peaEei394BdZkZ2hiItBexb1PZ3wcELkcRGL2kzNkFSoxRZR0J71AnDPwAIpeUKSAwHGFW6GdDt3Tds6-ccBNpKq9lv8Vg5pj3B7KfIXTxGtsBzy3KNmvx5SUD3ZJNnTuZtUrXn1OSf8saD0-gZFCuY4Z1SzKiXAVkO9ewz5KX7A/s994/20221130_015320131.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="776" data-original-width="994" height="250" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRRCovgmIAJtwte4peaEei394BdZkZ2hiItBexb1PZ3wcELkcRGL2kzNkFSoxRZR0J71AnDPwAIpeUKSAwHGFW6GdDt3Tds6-ccBNpKq9lv8Vg5pj3B7KfIXTxGtsBzy3KNmvx5SUD3ZJNnTuZtUrXn1OSf8saD0-gZFCuY4Z1SzKiXAVkO9ewz5KX7A/s320/20221130_015320131.jpg" width="320" /></a></div>I also use a combination of files, sandpaper and Scotchbrite rol-lock disks to clean up where the shrinker mars the metal. You can get some of the lines out, but I don't try to get it all. You'll thin the metal too much. Then, give it a clean up with a Scotchbrite pad on the faces. Here is the back side:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEia6okOGO84p2K444bTe8-DYHjEnT9-l5-c0zrcWEVGLJT-Jm4NEqa9ezeBGhgK6FJJe_SpMwGF_nR8SBF3Ox2BPO9AYTIgGg1bB7-6a_QZBe4sG26CL1GJVBmYo9UkW-L-sUrXogttokxmCSmY4okP6HGyr2NARTjCMH9-lJuYevoh0_oj4WQ7zxp2zA/s1287/20221130_015400367.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="749" data-original-width="1287" height="186" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEia6okOGO84p2K444bTe8-DYHjEnT9-l5-c0zrcWEVGLJT-Jm4NEqa9ezeBGhgK6FJJe_SpMwGF_nR8SBF3Ox2BPO9AYTIgGg1bB7-6a_QZBe4sG26CL1GJVBmYo9UkW-L-sUrXogttokxmCSmY4okP6HGyr2NARTjCMH9-lJuYevoh0_oj4WQ7zxp2zA/s320/20221130_015400367.jpg" width="320" /></a></div>You can still see the lines from the shrinking. But, this is not a part that is visible on the plane without removing the skin panels. So, I don't try to get all the lines out. If you need to get it looking perfect, you'd probably want to use some filler material and then sand it real nice for painting. It is up to the builder to make it as clean looking as is desired. Here's a quarter view:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjivwF3jEOE10KRWton4b_tCL0jmlMlqhFiMtPGDJqERBduiUx1Tutn-PVGFpZ9WSnlw2scCImXYxLfyJEVRySVYhn2ATeomyMciiFAANm5DOJsMf7Vzgh7EZF8oonVnIDtGL3Aba9dQ6sYMTaOptXaExdDsYqV8OdmuEg7yosfsCOanrKRWNdeMEcFMg/s1304/20221130_015501207.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="586" data-original-width="1304" height="144" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjivwF3jEOE10KRWton4b_tCL0jmlMlqhFiMtPGDJqERBduiUx1Tutn-PVGFpZ9WSnlw2scCImXYxLfyJEVRySVYhn2ATeomyMciiFAANm5DOJsMf7Vzgh7EZF8oonVnIDtGL3Aba9dQ6sYMTaOptXaExdDsYqV8OdmuEg7yosfsCOanrKRWNdeMEcFMg/s320/20221130_015501207.jpg" width="320" /></a></div>After some final clean up, I fabricated a hard sided shipping container for this part. The part is formed from soft 2024-O material and must be heat treated before installing in the plane. Vaughn is going to take care of that. So, I wanted a shipping box for it that would protect it better so that it wouldn't get bent, or damaged:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWsa3yCUCZ9pvLLsHDYO_rV9JKRmIZoj3EVEE99_iV6kRKeuPMFS8T_egpI3t5lxKwFZOQZ8Ou7nBYrn0bVOxsu8o_QxB24wYGXMFdez-B8HFMCn4_IJZxfFlkUFRVjR6Dtq9eIxe6eln3hjNQo5rYB7iA94-W2cZ_1aOA4MHzmKZBTmhaM2T8HoGQTA/s695/20221202_183002988.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="642" data-original-width="695" height="296" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWsa3yCUCZ9pvLLsHDYO_rV9JKRmIZoj3EVEE99_iV6kRKeuPMFS8T_egpI3t5lxKwFZOQZ8Ou7nBYrn0bVOxsu8o_QxB24wYGXMFdez-B8HFMCn4_IJZxfFlkUFRVjR6Dtq9eIxe6eln3hjNQo5rYB7iA94-W2cZ_1aOA4MHzmKZBTmhaM2T8HoGQTA/s320/20221202_183002988.jpg" width="320" /></a></div>Off it went to Vaughn:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtjwQd8k36YbFgjgMxIoX4UAON_AJjv0SZhEzQnX1Wyu0lzvVN-XjECqoDcayv_P3IXmYCU9Cq-KdvtHOrHOgrTip8XsPQVyBniS3LkKR06H9eXUm_6WQ--67jYbU7Aw0LPpCsRvEA5L_udgj8WM2OrL8sZayASFFPbdFJsFUXzRd8iEyEXPksfnnndQ/s788/20221202_183015302.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="758" data-original-width="788" height="308" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtjwQd8k36YbFgjgMxIoX4UAON_AJjv0SZhEzQnX1Wyu0lzvVN-XjECqoDcayv_P3IXmYCU9Cq-KdvtHOrHOgrTip8XsPQVyBniS3LkKR06H9eXUm_6WQ--67jYbU7Aw0LPpCsRvEA5L_udgj8WM2OrL8sZayASFFPbdFJsFUXzRd8iEyEXPksfnnndQ/s320/20221202_183015302.jpg" width="320" /></a></div>The next items on Vaughn's wish list are radiator side fairings and a set of engine compartment longerons. More on this in a future update.<br /><br /><br /><u><b>The "Sea Plane" Work -</b></u> For those that are new to the blog, this is the airplane that formerly belonged to Ernest ("EZ") up in Seattle. Several of us have begun to refer to it as the "Sea Plane" or the "Sea Prowler" because of it's ultimate salt water demise. After EZ's forced landing, this plane sat off the beach of McNeil Island in Seattle for 4 days and was submerged by the tide, twice a day. This is possibly bad humor, and no one is intentionally being disrespectful (or making light) of what happened to EZ - but it is a fairly accurate way to describe this plane. Here is an older pic I have of it in my yard (you can see the outboard wings laying along side the plane):<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVArTp_n3NyP-e5ljGcZD-O3OpzXGM3JG-kkurXDxrDV36VYyp46uoVG61hiVOvPenBZBjJoEVDMJf7hRYf3W2rBWgWP7r_gGfZu3YWzbpwPieOfbs0DBv37yRAkVh3f-eSuiLfoaTPtwc5R9AY5VrHppXRpS32EyqNGUNzVhxCxSRMcaZWhXxStTfVQ/s1344/20181019_182447.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1344" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVArTp_n3NyP-e5ljGcZD-O3OpzXGM3JG-kkurXDxrDV36VYyp46uoVG61hiVOvPenBZBjJoEVDMJf7hRYf3W2rBWgWP7r_gGfZu3YWzbpwPieOfbs0DBv37yRAkVh3f-eSuiLfoaTPtwc5R9AY5VrHppXRpS32EyqNGUNzVhxCxSRMcaZWhXxStTfVQ/s320/20181019_182447.jpg" width="320" /></a></div>In a previous post I described making and installing hitch receivers that will eventually support the airplane in it's next roll as either a Prowler Aviation billboard, or possibly as a "Prowler on a post" that will greet folks that arrive at an airport somewhere (yet to be determined). Here's a pic of the mounting points I installed:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJ3YvrOxBLD2bhnu2UTi_V97xkbVu0YJFrLiJWpzC5bbuU9HJ_dyPK84Rd1eUHwz1rSTGFVY2eyiOb69N6GxIdjTlM8VFBg1MLpyiyvV4e5pOpkI-ABU1Arqk5GVMs4vFHjuvzx1uCDGcN6V9ayb4T4NiIKx8X-RjOVcPy-_2srIp3pSKsRzneBOZiOA/s2688/20200624_164030.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="2688" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJ3YvrOxBLD2bhnu2UTi_V97xkbVu0YJFrLiJWpzC5bbuU9HJ_dyPK84Rd1eUHwz1rSTGFVY2eyiOb69N6GxIdjTlM8VFBg1MLpyiyvV4e5pOpkI-ABU1Arqk5GVMs4vFHjuvzx1uCDGcN6V9ayb4T4NiIKx8X-RjOVcPy-_2srIp3pSKsRzneBOZiOA/s320/20200624_164030.jpg" width="320" /></a></div>Next, I have two tasks to complete for the Sea Prowler - I need to fabricate one more mounting point on the keel of the plane aft of the cockpit to complete the 3 point mount that I am envisioning. The other is to re-skin and re-mount the inboard flap segments that got badly damaged when the airplane was being salvaged out of the Seattle harbor. The salvage company just put slings under the airplane and lifted it out of the water with an excavator onto a barge. The slings damaged the wing fairings and inboard flap segments extensively.<br /><br />I have removed the inboard flap segments. One side came off pretty easily by pulling the hinge pin of the hinge that holds it in place. The other side, I could not get the hinge pin to pull out - no matter what I tried. So, I ended up having to drill the rivets out of the entire hinge on one side. Here is the LH flap after I got it off the airplane and on the bench in the shop. You can see the damage:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgA-3lTW_w5eyXXC-jiLOU_3LQ8cBy8JjcGF6UhXugKVJ_bZ7aszn2Et64AViKFirbNBFB-hVOArAeZvLOmNxRrodEEgc3vzjJgAHoWSumQvCmY7fTjvsvXsezlddKXIxZbdEkS7GLyT4oUcyN7oJkOgVCakLOXIC5KhLuZW2YyR0DFDfsUXshU6xTSuQ/s980/20211110_035222936~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="882" data-original-width="980" height="288" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgA-3lTW_w5eyXXC-jiLOU_3LQ8cBy8JjcGF6UhXugKVJ_bZ7aszn2Et64AViKFirbNBFB-hVOArAeZvLOmNxRrodEEgc3vzjJgAHoWSumQvCmY7fTjvsvXsezlddKXIxZbdEkS7GLyT4oUcyN7oJkOgVCakLOXIC5KhLuZW2YyR0DFDfsUXshU6xTSuQ/s320/20211110_035222936~2.jpg" width="320" /></a></div>Here is a picture of both inboard flap segment frames with the skins removed:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8TWSQ37Zfa-1_u7l6P0bVyRb-7qRVGNb00vXFKrqOg6BduLLpH_ywSbg6jG0iP_JVlxyVxG_U99NqqZo5we86B4FDL8R-fcLbZk4aAUaIRCV7zm44Q6imbJ46T2s0AF1T-TRpA9u8w5xSTYp1IrDDGquP51jCFVBRVlKUaW8h_1F0D_t1PJh3WaR0ug/s923/20211110_065649297~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="923" data-original-width="890" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8TWSQ37Zfa-1_u7l6P0bVyRb-7qRVGNb00vXFKrqOg6BduLLpH_ywSbg6jG0iP_JVlxyVxG_U99NqqZo5we86B4FDL8R-fcLbZk4aAUaIRCV7zm44Q6imbJ46T2s0AF1T-TRpA9u8w5xSTYp1IrDDGquP51jCFVBRVlKUaW8h_1F0D_t1PJh3WaR0ug/s320/20211110_065649297~2.jpg" width="309" /></a></div>The inboard flap frames are salvageable and I am going to keep them and re-skin them. I'll have more pics in a future update when I am finished with the re-skin of them.<br /><br />While working on the Sea Prowler flaps, I decided that it will not be able to live the rest of it's life in my front yard next to the pumphouse. At some point, it will have to be moved to a new home - wherever that may be. I have a trailer [that I bought from EZ, (who got it from George) that is now with Ray carrying his Prowler] that I can use to move a Prowler airplane. But, since the Sea Prowler does not have any landing gear, I was going to have to find another way. I decided to......wait for it......BUILD ANOTHER TRAILER!! Ha! Bet you didn't see that coming!?!? <br /><br />OK, maybe you did - given my historical penchant for trailer building. Anyway, I had some old axle spindles laying around that I cut from an damaged trailing link axle that my neighbor had given to me. Here is a pic of one of the spindles still as it was cut from the trailer (on the left) and one that I had cut up to get ready to modify to install into a new axle tube:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyezN_VabQvQfvuh7DVWpV1B_7NlPi-_pcbljctIhhA1P2-uxIe8RECp-caou0Zp1t5R22Jfsl8wuwC8lKPTd56gwYs1SY_wCEYPkrCR64S3POd0a7KT4RrS02BMwH28tER3_Ua-dDleK1fxNzQslQEmaoZJLmZFWhW2eH4aYXIIJCiiyJoa9XD61r-Q/s1299/20210218_200522499~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="820" data-original-width="1299" height="202" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyezN_VabQvQfvuh7DVWpV1B_7NlPi-_pcbljctIhhA1P2-uxIe8RECp-caou0Zp1t5R22Jfsl8wuwC8lKPTd56gwYs1SY_wCEYPkrCR64S3POd0a7KT4RrS02BMwH28tER3_Ua-dDleK1fxNzQslQEmaoZJLmZFWhW2eH4aYXIIJCiiyJoa9XD61r-Q/s320/20210218_200522499~2.jpg" width="320" /></a></div>By trimming the trailing link down to a six sided piece, it would be easier to put in the lathe and machine down to a clean plug that could be fitted into the new axle tube. Next step was to find some steel to make the axle tube from. I found some surplus drops at the local steel place that I was able to weld together to make a new axle tube. Here is a pic of both spindles mounted in the new axle tube:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcoAMYXqVe14AOySSbVYvQgzj6UXm80mIGEioIsv7d2_MBtVBXI6_tVlwvYUV9zjv2iVGhS0jNE0R5ZNqq1XlSPr3Du5QdDsIS_CQQzqDSYaFnnARMDg91WgI_9SoaAXR52hCZmOWFg_AAHktP7fna690qoopRJP7ktYHRJHrOVO6L4GeTf61OueR3eQ/s1127/20211030_011916398.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="547" data-original-width="1127" height="155" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcoAMYXqVe14AOySSbVYvQgzj6UXm80mIGEioIsv7d2_MBtVBXI6_tVlwvYUV9zjv2iVGhS0jNE0R5ZNqq1XlSPr3Du5QdDsIS_CQQzqDSYaFnnARMDg91WgI_9SoaAXR52hCZmOWFg_AAHktP7fna690qoopRJP7ktYHRJHrOVO6L4GeTf61OueR3eQ/s320/20211030_011916398.jpg" width="320" /></a></div>Here's a closer shot of the way that I mounted the spindles in the new axle tube. I machined the cylindrical ends of the spindles so that they would just slip into the ends of the tube. I drilled several holes in the end of the tube so that they would line up with the steel on the inboard ends of the spindles. This would allow for a fillet weld around the end of the tube to the square plate, and also several plug welds (aka rosette welds) around the inner ends of the spindles. Here's what each end looked like before welding: <br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjiHV8QLlatANHyK3oZegQFrgj9nXuxIcCmZgfsTLUB86-G7THSN6E90b-iAP_v3DnV09ZGYxnRRnrSxx31PvBt3-qn5fKYIElEZQbpGkuYP1X6-HqkvzNVUow_JcfY5H1KPXU9xfLUDVa0XOsKnR2aLwhJybtlg9OBz0jZqGRn1j7aBdthLCG7r6icA/s1169/20211030_011931027.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="771" data-original-width="1169" height="211" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjiHV8QLlatANHyK3oZegQFrgj9nXuxIcCmZgfsTLUB86-G7THSN6E90b-iAP_v3DnV09ZGYxnRRnrSxx31PvBt3-qn5fKYIElEZQbpGkuYP1X6-HqkvzNVUow_JcfY5H1KPXU9xfLUDVa0XOsKnR2aLwhJybtlg9OBz0jZqGRn1j7aBdthLCG7r6icA/s320/20211030_011931027.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEuYuGnzo1w-fURa_XUrRH2GTGayAi_zQ6TnsaHfT-CLxk5ud7Ie-Nwewum6Poj6FfZ9JHIw6lrtqTGW6wEKcQB40c3ejEUYT9dksxt6TgnU57T5nPaqyS_nLYmrIabNUQVG83QO6wFP_9epbgC97xlhKqpuDKBWvD_Ryq8h21euaR1ii9ki2SYxMHBw/s1307/20211030_011923693.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="713" data-original-width="1307" height="175" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEuYuGnzo1w-fURa_XUrRH2GTGayAi_zQ6TnsaHfT-CLxk5ud7Ie-Nwewum6Poj6FfZ9JHIw6lrtqTGW6wEKcQB40c3ejEUYT9dksxt6TgnU57T5nPaqyS_nLYmrIabNUQVG83QO6wFP_9epbgC97xlhKqpuDKBWvD_Ryq8h21euaR1ii9ki2SYxMHBw/s320/20211030_011923693.jpg" width="320" /></a></div>With everything lined up and straight, I welded everything up. I did the plug welds first thinking that the heat from these was less likely to warp the spindles out of alignment with the
tube. Once the rosette welds were done, I welded the end of the tube to the square flange on the spindles.<br /><br />Since each
axle spindle is only rated for 1250 lbs, I am stripping the Sea Plane of everything heavy and building the trailer to haul a max load of 2,500 lbs. With the trailer limited to a max load of 2,500 lbs, I can use lighter materials to build it. I had a bunch of tubing that I had salvaged from some old tractor shipping skids several years ago. I used that to make the basic frame and deck of the trailer. <br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEja_UGhy3CeL2hjfqsARI5phxQiubAtlRCp1PkESQlr-sBPcmAiMClCbZWgclfShEmWLI-PB9LHFRtm3dBt56oKDoed9-ux3IA6lMpCRsRy4pahdnNn30Ez36Fz_NRY24_bE29nil3eOAkLCA_6JvRzIR6dWhFErA_wB6gK02Ly7k3ixA1gsjmX2nlDLA/s1239/20211122_200230901~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="863" data-original-width="1239" height="223" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEja_UGhy3CeL2hjfqsARI5phxQiubAtlRCp1PkESQlr-sBPcmAiMClCbZWgclfShEmWLI-PB9LHFRtm3dBt56oKDoed9-ux3IA6lMpCRsRy4pahdnNn30Ez36Fz_NRY24_bE29nil3eOAkLCA_6JvRzIR6dWhFErA_wB6gK02Ly7k3ixA1gsjmX2nlDLA/s320/20211122_200230901~2.jpg" width="320" /></a></div>So far, the only things I have needed to buy for this trailer were the springs, wheel fenders, a hitch coupler and a jack stand. I was able to order a set of 1,500lbs springs fairly inexpensively and added those to the build (above).<br /><br />Since there will be several special requirements to haul the Sea Prowler, I designed this trailer specifically for that purpose. However, after this trailer has served that purpose, I have made some provisions to do some fairly easy modifications to make it into a general purpose utility trailer. The biggest special requirement is the distance between where the weight of the plane will bear onto the trailer (affecting the weight and balance of the trailer) and the spinner on the front. I had to build a long tongue on the trailer to allow room so that the spinner will clear the back of a truck that is pulling it. Here is the trailer just after fabricating and adding the tongue:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5rGMgskkJlNGlyg_ZNEBm8yuPth3HMSH4dvVoa1MBLd9H16JDfke0ZCV5z_T5TUncVgvz3RBuXuKDOwhEkmaT1jXpxuLuSN10WkaVg6XogDYGboQ7nyof26VcTBorwQMVhNFK_IXEzX5Xps5C3f81nn6S2oTq_hD1tE5fOK6jAhX-sn1K2us0eWcFOw/s1657/20211212_005814186~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="679" data-original-width="1657" height="131" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5rGMgskkJlNGlyg_ZNEBm8yuPth3HMSH4dvVoa1MBLd9H16JDfke0ZCV5z_T5TUncVgvz3RBuXuKDOwhEkmaT1jXpxuLuSN10WkaVg6XogDYGboQ7nyof26VcTBorwQMVhNFK_IXEzX5Xps5C3f81nn6S2oTq_hD1tE5fOK6jAhX-sn1K2us0eWcFOw/s320/20211212_005814186~2.jpg" width="320" /></a></div>With the underside welded and finished with paint, I flipped it over and put on some wheels to see what it was going to look like:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJa6alrft6iqvFsWT3H1woAP3KtWtuN8tLhiHs5b5oI80Hl_zr3kDlMYiXWSWWKNC0tvoH9QJrZ5OWS4JE9VkpIi4OVFE6yXvbGrRLuU9LaxW1miTVrGJgJjBDobwe5mp9F9vUvnKi6o1HiPTcO13c0zXABdJQQ-TUE4mUkoEv8PSajZcg6aEdBJjU3Q/s2072/20220324_182429441~2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="730" data-original-width="2072" height="113" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJa6alrft6iqvFsWT3H1woAP3KtWtuN8tLhiHs5b5oI80Hl_zr3kDlMYiXWSWWKNC0tvoH9QJrZ5OWS4JE9VkpIi4OVFE6yXvbGrRLuU9LaxW1miTVrGJgJjBDobwe5mp9F9vUvnKi6o1HiPTcO13c0zXABdJQQ-TUE4mUkoEv8PSajZcg6aEdBJjU3Q/s320/20220324_182429441~2.jpg" width="320" /></a></div>Here is the Sea Prowler trailer project as it currently exists. Those fenders are just sitting on the wheels right now as I try to figure out the best way to permanently attach them to the trailer:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihx8Edq2doQCboOTMsLHnx2uG57NYgZMwMRqfyJ-v3rQLTDR7IPbDGh5ibQ-p84HjAK_SmsImzHG97lLrbRToL2UKi5frRDvI6uBPQ-o6J989u7QknRwQtSuE3X0Rm5ypEsymKgtmc2x7Q8-Kna1PtRIeHrwayJ6Z7C5lQuxguZ5d29mgJjtgcLVt0ZQ/s1512/20221220_233152752.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="719" data-original-width="1512" height="152" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihx8Edq2doQCboOTMsLHnx2uG57NYgZMwMRqfyJ-v3rQLTDR7IPbDGh5ibQ-p84HjAK_SmsImzHG97lLrbRToL2UKi5frRDvI6uBPQ-o6J989u7QknRwQtSuE3X0Rm5ypEsymKgtmc2x7Q8-Kna1PtRIeHrwayJ6Z7C5lQuxguZ5d29mgJjtgcLVt0ZQ/s320/20221220_233152752.jpg" width="320" /></a></div>I am also reconsidering the wheels. Those are 15" wheels with trailer tires on them in the pic above. They really don't need to be that big. I have a set of smaller 14" wheels that I might find some trailer tires for and use those. And, that will change where I mount the fenders. So, this is a kind "engineer it as you go" type of project. But, that's what you have to do when you're trying to not spend a bunch of money and use what you have on hand.<br /><br />So, that's it for this update. I hope you all have a Merry Christmas this year. Thanks for following along with me as I work to get this airplane closer to a limited production status. I am going to get started right away on the next blog update that will feature all the work that Francis has been getting done on the French Prowler. See ya next year.<br />Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-4561663675008429701.post-48803659928801721932022-02-25T14:28:00.000-08:002022-02-25T14:28:06.827-08:00Hardinge CHNC Lathe Project Catch-up Update - Part 2Hello Everyone,<br /><br />As I mentioned in the last updates, there was not a lot going on in the Prowler world between late 2020 and early 2021. Also, I was not working the "day job" because of CoVid. So, I took advantage of the time to get some machine fixing done. <br /><br /><span style="color: #990000;"><span style="background-color: #fcff01;"><u><b>CAUTION !</b></u> - This blog update does not contain any Prowler related material. If you don't care to see me talk a lot about repairing old machines, you might want to skip ahead to the next blog update.</span></span><br /><br /><u><b>The (Seemingly Never Ending) Hardinge CNC Lathe Project</b></u> <br />This machine has been sitting in the shop bay where I normally work on projects for so long, that it starting to become a permanent fixture. I really need to get this machine out of the shop! (I need the space!) So, I put my head down and charged forward on several "hit list" items on this never ending repair/remodel/restore project. <br /><br /><u><b>Tool Turret</b></u> - This CNC lathe originally had an 8 position tool turret that could automatically be lifted up, rotated to a new tool, and then locked back down into position. There were an amazing amount of special parts that worked in concert to accomplish this seemingly simple function. When the F8025T control was retrofitted to this machine, the old control was removed and this rendered the automatic tool selection turret unusable. <br /><br />The retrofit installer's solution was to bolt a bar of steel to the turret and turn it into a gang bar style tool setup. That did work, and there are many gang bar style tool machines out there. However, the range of motion of this machine in the X axis is a little limited (short). So, it cuts down on the number of tools you can mount onto it.....depending on the size of your stock, etc. The other problem was that air was no longer ported to the side of the piston to hold the turret down firmly, so it allowed for some tool movement - affecting accuracy.<br /><br />I really didn't like this idea of a gang tool bar and I wanted to figure out a way to make the tool turret usable again. However, to get this to work again automatically with the F8052T control was going to be a real challenge. But, even if it wasn't automatic, if I could just get the turret to pop up and rotate by hand, that would be a huge improvement. After some more tear-down of the cross-slide and tracing some air channels in there I decided it might be possible. Using a small number of the original parts, and adding an "air switch" the turret could maybe be used again to select new tools in a manually selectable fashion.<br /><br />In it's original form, what made the turret lift up and lock down was simply air pressure ported to a piston that was integral and attached to the tool turret. If I could figure out a way to get air routed properly to that piston, I could make it move again. The hole in the cross slide in the picture below is essentially the "cylinder" of a pneumatic actuator:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEjmlD2N5mbFFIEHhPqSCOCivLbkx8PwdpOmAVWluyHlVNj7sn_hWHsAAfoWzKDZCtVk-s7N3K8a8SFMg0mSR6JxGZirZtBC-A3MDYdc5Kmr0Kpx16lRborgmS6AQs_LHb19e-swo1f7gIKwElBdecLlFhq4zU22Dmy-5Te7aeqGcr36Qsv9EKQmrZRGEQ=s1559" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1559" data-original-width="773" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEjmlD2N5mbFFIEHhPqSCOCivLbkx8PwdpOmAVWluyHlVNj7sn_hWHsAAfoWzKDZCtVk-s7N3K8a8SFMg0mSR6JxGZirZtBC-A3MDYdc5Kmr0Kpx16lRborgmS6AQs_LHb19e-swo1f7gIKwElBdecLlFhq4zU22Dmy-5Te7aeqGcr36Qsv9EKQmrZRGEQ=s320" width="159" /></a></div>This (below) is the air piston that is integral to the turret. The tool turret plate is attached with the nut on the right side. The black stripe around the edge of the piston is the large O ring that seals the piston inside the cylinder:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEhSKHINh7qrfTzhYnhAVW1c0FQxfy6mO_GmJXuk7XOvB6T1w-UPRmKg_uBxdpy6N9e7gKlmHPhUXJ8uaJ-ql_o2eRU-f0YW41sjBznZ46IA4IOmYcuy_0lzdT-X1okz5loCC1q0ngnjTLeHws-bsjrUTcoPT62w9gh-vwPcVYABY6lzeFDLCmMr9M1dDg=s1023" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1023" data-original-width="741" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEhSKHINh7qrfTzhYnhAVW1c0FQxfy6mO_GmJXuk7XOvB6T1w-UPRmKg_uBxdpy6N9e7gKlmHPhUXJ8uaJ-ql_o2eRU-f0YW41sjBznZ46IA4IOmYcuy_0lzdT-X1okz5loCC1q0ngnjTLeHws-bsjrUTcoPT62w9gh-vwPcVYABY6lzeFDLCmMr9M1dDg=s320" width="232" /></a></div>Here is the piston mounted into the cylinder. The tapered dogs on the left and the right are what align the turret plate to the lathe and help hold it in position when air pressure pushes the piston down. The turret plate rotates using the bearing on the inside diameter you see here:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEhslpJDAqJR1drwd-46Se3JsGoRZOHrWVUtDVjXlKxwNLLt1DCVLk8-w30Ih_dYCGx4mauhcm7RFmVb7PRjzGXsSX16V2Oyudd3-ZuNdByLUm79Z61A7uDpt6-DNEO_f2g7ejcGv_g4LG4hoPQ7vdRWTji-YkiqoIoTZes4DOk5b_n9caCICuyo8btffQ=s1448" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1448" data-original-width="724" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEhslpJDAqJR1drwd-46Se3JsGoRZOHrWVUtDVjXlKxwNLLt1DCVLk8-w30Ih_dYCGx4mauhcm7RFmVb7PRjzGXsSX16V2Oyudd3-ZuNdByLUm79Z61A7uDpt6-DNEO_f2g7ejcGv_g4LG4hoPQ7vdRWTji-YkiqoIoTZes4DOk5b_n9caCICuyo8btffQ=s320" width="160" /></a></div>Put it all together and you get this:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEgnHvgzt3UOlxtxNclFcB76qbJ5KcbDqikux1TQjm-AxU2R9kV2dLVHYzVnS06HkyW5WJ0vMvgqUVwxHmQgRnUtQ9KBWCHJFH-kCckv_Ne02Ny3WsosKTyDOh9LXuF5wSn2M4SiHrm2_LDtcInjFXg5VTvqdcn1v_cTtj0L7MbDZrWhQaS0q3A0UEojBA=s1245" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1245" data-original-width="800" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEgnHvgzt3UOlxtxNclFcB76qbJ5KcbDqikux1TQjm-AxU2R9kV2dLVHYzVnS06HkyW5WJ0vMvgqUVwxHmQgRnUtQ9KBWCHJFH-kCckv_Ne02Ny3WsosKTyDOh9LXuF5wSn2M4SiHrm2_LDtcInjFXg5VTvqdcn1v_cTtj0L7MbDZrWhQaS0q3A0UEojBA=s320" width="206" /></a></div>Now, to move the turret up or down, air pressure has to be applied to either the bottom and vented off the top, or vice-versa. That required finding the original ports that would take the air pressure to the top side and bottom side of the air piston. Once i found those, I simply had to plumb them to this special "air switch" that I found online:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEiwzwA0mRKbjIK2EO8UiEIgkA4VPXtbcPcq7Hs4wq8-AHdXposywqRjKjwOYKx53wl3R1KEw1wgTSH8Rln3UyoC0lnHkD7NcFKFr75RQp9fv3pWVzb4lqpRCxVZ1kB0bHE-vyHVKn5N5Y4En7z2zoFIaaQig3KDM9J7h1wb0DRwFHsG5xkTLa90U7B2Dw=s1600" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1600" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEiwzwA0mRKbjIK2EO8UiEIgkA4VPXtbcPcq7Hs4wq8-AHdXposywqRjKjwOYKx53wl3R1KEw1wgTSH8Rln3UyoC0lnHkD7NcFKFr75RQp9fv3pWVzb4lqpRCxVZ1kB0bHE-vyHVKn5N5Y4En7z2zoFIaaQig3KDM9J7h1wb0DRwFHsG5xkTLa90U7B2Dw=s320" width="320" /></a></div>This switch has 3 positions: 1- a position that just vents all the lines; 2. - Port A pressurized and port B vented; and, 3. - Port B pressurized and port A vented. Here is the air switch mounted into the machine (before paint):<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEhv9WO7qgDXKZRHS1AQVLglZ8rWLmaQ1XYRgITpSDWnj7ivz-9RPRJdfFpGIforbCoGhohApNMoljM9KtCxhMC6EoHDdWaihbHg048jBFJ0vOeb9izkzgNEQfB04kW0VdeUGKUDnXAO1JMKQXJy_FtnJmH4zKlnnkOEP6-F1bZIR97br8j5cElRXkZ-dQ=s1229" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1229" data-original-width="900" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEhv9WO7qgDXKZRHS1AQVLglZ8rWLmaQ1XYRgITpSDWnj7ivz-9RPRJdfFpGIforbCoGhohApNMoljM9KtCxhMC6EoHDdWaihbHg048jBFJ0vOeb9izkzgNEQfB04kW0VdeUGKUDnXAO1JMKQXJy_FtnJmH4zKlnnkOEP6-F1bZIR97br8j5cElRXkZ-dQ=s320" width="234" /></a></div>I added pressurized air to the machine and got this:
<div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dw7MURSWy7s8nJooaepUpe18-FKEwv43ZP-B7LPWOiauuHN8Ub6-1XVgeY7xozI9ckwwQkMXKOn5YuwhpJHZA' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div>YES! It works!! With this setup, the machine can now be programmed to work with one tool, then use a pause routine with a message for the operator to select the new tool, then press the cycle/start button to continue operation. Sweet!<br /><br /><u><b>Spindle Encoder Cover</b></u> - A spindle motor encoder is a device which sends feedback information from the spindle motor back to the machine control (computer). It is a rotatory device that is mechanically linked to the spindle motor and always turns whenever the spindle motor turns. It essentially sends a stream of electrical pulses to the control computer and the computer can count these pulses and accurately determine the spindle speed, direction of rotation and angular position. Here is the spindle encoder on this machine:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEgVzcgw_9AlfcgyG9-oKPLbcIyqj-IpUE7M5hPqREtoXYSsjjK7_-NCvuKeTYQZETiX3DJ6IiTMEVVeRzKAwT78l1DnlCKaGpr0GOkCdgjmfbHt9fLfdMHLkK-HKGnoZH6925p62eXJ78YHuyZE8EjDyRvq2LtakfFWCMu9X5ywjSmz-ezEl0bFFVaTPw=s1291" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="868" data-original-width="1291" height="215" src="https://blogger.googleusercontent.com/img/a/AVvXsEgVzcgw_9AlfcgyG9-oKPLbcIyqj-IpUE7M5hPqREtoXYSsjjK7_-NCvuKeTYQZETiX3DJ6IiTMEVVeRzKAwT78l1DnlCKaGpr0GOkCdgjmfbHt9fLfdMHLkK-HKGnoZH6925p62eXJ78YHuyZE8EjDyRvq2LtakfFWCMu9X5ywjSmz-ezEl0bFFVaTPw=s320" width="320" /></a></div>As was the case with so much of this machine, when the new control was
installed, many of the original supporting components were left in place
and just disabled. The spindle encoder system was no different. In
fact, as I started to troubleshoot this system, I found the spindle
encoder cable cut in half and the ends of the cables simply stuffed into
cable way tubes! The other thing I determined while troubleshooting this system was that the original encoded was not working correctly (probably why the cable was cut). <br /><br />The encoder you see in the picture above was an older, used unit I found online to replace the original. Once installed and working, it needed a cover. The original cover could not be found, so I decided to fabricate a new one. The first step was to make a plate to fit the mounting surface on the machine. Using a picture of the pad and scaling it in the CAD software, I was able to use the CNC mill to cut this plate out:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEgbDlCbp9Jw89jlbbiVuz7jafPX8D5RGEz3_sjNPCeUn_Pmeeq7tchWps0nFHlzyCqZG0PWCU4NrUfkRP1tNyfVydgdvMMicqAhP-QzZMkrAy87ogJBFThnH3bjrtpv77UU-oVFHpko9v6CdJepG4UG1AOCJ5G2SyaaFf7Yr4Tv0KWDDMa_0zw-Ad1dFA=s1456" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="967" data-original-width="1456" height="213" src="https://blogger.googleusercontent.com/img/a/AVvXsEgbDlCbp9Jw89jlbbiVuz7jafPX8D5RGEz3_sjNPCeUn_Pmeeq7tchWps0nFHlzyCqZG0PWCU4NrUfkRP1tNyfVydgdvMMicqAhP-QzZMkrAy87ogJBFThnH3bjrtpv77UU-oVFHpko9v6CdJepG4UG1AOCJ5G2SyaaFf7Yr4Tv0KWDDMa_0zw-Ad1dFA=s320" width="320" /></a></div>Then, I found a piece of aluminum tubing the correct size and cut a piece to the right length. The one mounting hole in the flange was going to get partially covered by the piece of round tubing, so I used the mill to cut a partial hole (groove) in the right place:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEggSK1-3cvnOML3hXlVHj5zjHyr6FKpy8rQBK7J7tCGAEesPPakTjcDE47DbT_WH59q8EHg1t-amfgtEWrkPNJMCFux3INfvzpcVTdWiilog3uE53ytFlDsgfxAwt6yKTJ5JG7m0ZwBA8noOlDgzi-2KBcQXZ59_8SZOzKWWl-MJo366wrN84a0AMgiCA=s828" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="828" data-original-width="771" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEggSK1-3cvnOML3hXlVHj5zjHyr6FKpy8rQBK7J7tCGAEesPPakTjcDE47DbT_WH59q8EHg1t-amfgtEWrkPNJMCFux3INfvzpcVTdWiilog3uE53ytFlDsgfxAwt6yKTJ5JG7m0ZwBA8noOlDgzi-2KBcQXZ59_8SZOzKWWl-MJo366wrN84a0AMgiCA=s320" width="298" /></a></div>So far, so good:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEgMVD9hhx-PnDrxD5X1OH1MzH956cqUAchNGDwVfCgCSwxRrXHlhHH8p0zJHYjQoHbjzkov4FN63fGEdI6I0BCXdCQC8SY32fcSO4ob2PvQEOg9EftUH0U1hM6FwvJKFc6VEBKfEXaRv3KZlIR6jA5hbNqFbaHPZPx4CCaulZ7fLyDgHtcMDYgWCRBqzg=s1200" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="880" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEgMVD9hhx-PnDrxD5X1OH1MzH956cqUAchNGDwVfCgCSwxRrXHlhHH8p0zJHYjQoHbjzkov4FN63fGEdI6I0BCXdCQC8SY32fcSO4ob2PvQEOg9EftUH0U1hM6FwvJKFc6VEBKfEXaRv3KZlIR6jA5hbNqFbaHPZPx4CCaulZ7fLyDgHtcMDYgWCRBqzg=s320" width="235" /></a></div>Add a cover and here is the result tack welded together:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEgkDgxw0BCXGt6e-DN-c713cdl-dXGTN9sQNkox6ZlwbOm2WPoYKwNBPGcdNXzOS1YrUuPijHXcqkdvyYr-VmWpUQu6l5zSOTaH7fmf6XK-vDpeH4rEyM4yMOhw_02oc5nv9HI6G4HxzIxZhZwJQhE-ZgV3trybODpRG3vT-C_vKPexFYG26EbuLqM5DA=s1227" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="810" data-original-width="1227" height="211" src="https://blogger.googleusercontent.com/img/a/AVvXsEgkDgxw0BCXGt6e-DN-c713cdl-dXGTN9sQNkox6ZlwbOm2WPoYKwNBPGcdNXzOS1YrUuPijHXcqkdvyYr-VmWpUQu6l5zSOTaH7fmf6XK-vDpeH4rEyM4yMOhw_02oc5nv9HI6G4HxzIxZhZwJQhE-ZgV3trybODpRG3vT-C_vKPexFYG26EbuLqM5DA=s320" width="320" /></a></div>
I will get this welded up soon and finally get it installed on the machine.<br /><br /><u><b>Collet Closer</b></u> - The next system on this lathe that needed attention was the collet closer system. This machine was designed to use 5C collets and the are tightened by an air diaphragm system pictured below.
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEhOECp22D5G0VNUg6XTqEEphdnmEJkLdwC_vdujYIBmxL9QJ1w2uyj2kydDyAjgmlPuZrLE-NOK802HJSAR_XLbJ4toKTjhXKFOlAWk88cSJek2Muf43BgG287hQcRJMgAYqv3EnmMXBfIXPB86EnXwJkGuVgpIBJoYpu4_1QmrUzfKtOVyp2QxSLTfrQ=s1522" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1522" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEhOECp22D5G0VNUg6XTqEEphdnmEJkLdwC_vdujYIBmxL9QJ1w2uyj2kydDyAjgmlPuZrLE-NOK802HJSAR_XLbJ4toKTjhXKFOlAWk88cSJek2Muf43BgG287hQcRJMgAYqv3EnmMXBfIXPB86EnXwJkGuVgpIBJoYpu4_1QmrUzfKtOVyp2QxSLTfrQ=s320" width="318" /></a></div>When I bought the machine, the parts V & X shown in the picture below were missing. Fabricating these parts was going to be a pretty big job. <br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEifULO9KrQec4WylIhCIEYkCyT7immIZ1yMQX796R0JYBr6XSx9p_HGN3DT-fgLr9FeIYkUeMyF8KSW9H0HLfQrF7LOBqYKduCegAhpYGxzC3wMtPYbktlFE7Z3XEW8emvzUzRz0OfmWo94dSRY4RpycyG3ldqlqsOmxM3S5m0WTwvqeWLQ4Ll42qtJMQ=s1509" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1284" data-original-width="1509" height="272" src="https://blogger.googleusercontent.com/img/a/AVvXsEifULO9KrQec4WylIhCIEYkCyT7immIZ1yMQX796R0JYBr6XSx9p_HGN3DT-fgLr9FeIYkUeMyF8KSW9H0HLfQrF7LOBqYKduCegAhpYGxzC3wMtPYbktlFE7Z3XEW8emvzUzRz0OfmWo94dSRY4RpycyG3ldqlqsOmxM3S5m0WTwvqeWLQ4Ll42qtJMQ=s320" width="320" /></a></div>Fortunately, the buddy I bought the machine from was converting one of
his other Hardinge lathes over to a newer style collet system and could
give me these parts off of his machine. So that part of the system was
taken care of. Here they are installed on my machine:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEjbXf8gPc_WNSwr38oy6j_fTHdaqHEPwhzUloSRl9PVbMbA2Sc7XSAnDvzqLMDya8jHbeDHcvyvuzcA6KN-_dFHcoa4L00dmxY5-J0twyEX-zMNEEJs3FB0znCNeXXf66HEsbM2u_CzCaKJaSvADlw_cLiW5GS8XnoLQUBm5Q9gZTOwHau1Ch51Xfp2bQ=s1905" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1905" data-original-width="1321" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEjbXf8gPc_WNSwr38oy6j_fTHdaqHEPwhzUloSRl9PVbMbA2Sc7XSAnDvzqLMDya8jHbeDHcvyvuzcA6KN-_dFHcoa4L00dmxY5-J0twyEX-zMNEEJs3FB0znCNeXXf66HEsbM2u_CzCaKJaSvADlw_cLiW5GS8XnoLQUBm5Q9gZTOwHau1Ch51Xfp2bQ=s320" width="222" /></a></div>
With that done, I turned my focus another part of this collet closer system. The air glands and piston. While researching this part of the lathe, I learned that this model of collet closer uses a lot of air - even when they are new and working correctly. The reason is that there are not any seals in the system between the rotating and stationary parts of the closer - only tight tolerance air glands that are located in part where the air lines attach in the picture above (on the left side of part Q). I decided to go through the entire part Q and replace all the seals, just to make sure it won't give any problems later. So, here is a picture of the closer piston taken apart:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEiQe4Qx5DD4a-vOLsUuuC4kQ-9P-ZEOJmPEMi27QixQaopK5DadCfvMLdI3jcozoiGznO-PDcFWIEuok4n8neqEpXS26DxBxQSvdVSfdzfrJzlYcUP5gU9-u0W83m2Ay4H7hM-ZdwrQ70jbpkRX3UQLoCnua-f6yZoPk7CriEO8uyimgwnQBdz1AILJFQ=s2145" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1429" data-original-width="2145" height="213" src="https://blogger.googleusercontent.com/img/a/AVvXsEiQe4Qx5DD4a-vOLsUuuC4kQ-9P-ZEOJmPEMi27QixQaopK5DadCfvMLdI3jcozoiGznO-PDcFWIEuok4n8neqEpXS26DxBxQSvdVSfdzfrJzlYcUP5gU9-u0W83m2Ay4H7hM-ZdwrQ70jbpkRX3UQLoCnua-f6yZoPk7CriEO8uyimgwnQBdz1AILJFQ=s320" width="320" /></a></div>I actually posted a YouTube video of this work, in case it might help someone else refurbish their unit some day. If you are interested, you can see it here: <span style="color: #990000;"><span style="background-color: #fcff01;"><a href="https://www.youtube.com/watch?v=lUYE82lBPXk" target="_blank">Vari-Grip Collet Closer</a></span></span><br /><br />With the unit re-sealed, I installed it back onto the machine and hooked up the air lines:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEgD6rFDFW8X2XKmgXCRnsqlAp-5rdcTWgqnmUZeDIpMel-iqcwYBSLTMFIK0UNA-RD6Q9eeoOXdzVrX2JOw0NXuO6lmSm95J2Q1fpsBgKzHoX8MDRNkQ62lda39BLFMiDInmHarsDv1GweUMSYpnR0INDUPZXiVEvmTJxYAQyrTd8EPY6W9RbmLn3SaWg=s2688" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2688" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEgD6rFDFW8X2XKmgXCRnsqlAp-5rdcTWgqnmUZeDIpMel-iqcwYBSLTMFIK0UNA-RD6Q9eeoOXdzVrX2JOw0NXuO6lmSm95J2Q1fpsBgKzHoX8MDRNkQ62lda39BLFMiDInmHarsDv1GweUMSYpnR0INDUPZXiVEvmTJxYAQyrTd8EPY6W9RbmLn3SaWg=s320" width="180" /></a></div>Now, I had to resurrect the part of this system that applied the air to the closer to get it to open and close. In it's original form, this collet closer was controlled by a switch on the old, 1970's vintage controller console - which is long gone. What that switch did, was control two solid state relays that I had earlier relocated to the new electronics cabinet. You can see the bank of relays in this picture:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEgMIliR2I7t_kLU5nUv8fsQvjJzUEXYfII8llizqmnFBP6M5pGCqB4wXf9RO7gCovDsIiRjDrHnTsbPo-E4fOp3h-He6yK9EIUoXFoT6_bneXlZXxJgeQFeyhCvbnpZhfgmjRtWCBTyYQqkQjcu0mHfbQ2C8mpXP235MCXX3XzE4anDFGCSdNjFZUejkQ=s2688" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2688" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEgMIliR2I7t_kLU5nUv8fsQvjJzUEXYfII8llizqmnFBP6M5pGCqB4wXf9RO7gCovDsIiRjDrHnTsbPo-E4fOp3h-He6yK9EIUoXFoT6_bneXlZXxJgeQFeyhCvbnpZhfgmjRtWCBTyYQqkQjcu0mHfbQ2C8mpXP235MCXX3XzE4anDFGCSdNjFZUejkQ=s320" width="180" /></a></div>So, all I had to do was to source a new switch and wire it to control those same 2 relays. Then, I would have to mount the switch in a convenient place for the operator to control. I ended up finding a rotary switch and then fabricated a switch box with a switch guard to mount to the front of the machine. Here are the parts that I fabricated and the switch:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEiBqaXujRymkQBv4tllKcLTWIisLNetY28EW-bxertc-XlbtOSPHRjG-ozriahfy8bs7iYGQZxFn3L3UIWDQWQGSihHymP1A-irYrXb0nZjUQbsfd8aWZWjMNE8j6Fi55ilyBE5G2M6MGnN9eaq8OkgN78jUwIVKtJkUuoU86Pb1zkhQc_hrRGFzHjqdQ=s1586" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1586" data-original-width="1499" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEiBqaXujRymkQBv4tllKcLTWIisLNetY28EW-bxertc-XlbtOSPHRjG-ozriahfy8bs7iYGQZxFn3L3UIWDQWQGSihHymP1A-irYrXb0nZjUQbsfd8aWZWjMNE8j6Fi55ilyBE5G2M6MGnN9eaq8OkgN78jUwIVKtJkUuoU86Pb1zkhQc_hrRGFzHjqdQ=s320" width="302" /></a></div>
The parts assembled and before paint:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEjdx-i-dOPQWI2gi5YJ_6e5e3nqwWGxH9oI54qVDMAKkdY4RimSz9gmT4eeFrxM4OJGXueWCLyb0a8atwgNuThz4_ELpgvd70hvyBzRvsWUm2Tqabvkr6vLSg2k9qKABofXqsqmXyXJaT1cV7BrwIrSrDZwj8qgDX09SEbX9NNN9h_jAWbwdb20ivAg_A=s1423" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1423" data-original-width="1319" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEjdx-i-dOPQWI2gi5YJ_6e5e3nqwWGxH9oI54qVDMAKkdY4RimSz9gmT4eeFrxM4OJGXueWCLyb0a8atwgNuThz4_ELpgvd70hvyBzRvsWUm2Tqabvkr6vLSg2k9qKABofXqsqmXyXJaT1cV7BrwIrSrDZwj8qgDX09SEbX9NNN9h_jAWbwdb20ivAg_A=s320" width="297" /></a></div>And, here is a picture of the switch box mounted to the front of the machine:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEhRavuIJpi2LSom0LWvDE4q_XUIICO_aKh3_uTx2LoHc49u6QKZXZ9knLpPQuxqHrx-FuHUcfWO6sZyGvls-QhO3COcE-nilInUMlGJ2bcm88VYVw2ssMNtd1DhxjtwNw5rVS9WPRMG0v5NjC0CaZKY2uO1GDWOokB_TG-uJ8DBHdZE3QkxZ09ZlWPplw=s2688" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2688" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEhRavuIJpi2LSom0LWvDE4q_XUIICO_aKh3_uTx2LoHc49u6QKZXZ9knLpPQuxqHrx-FuHUcfWO6sZyGvls-QhO3COcE-nilInUMlGJ2bcm88VYVw2ssMNtd1DhxjtwNw5rVS9WPRMG0v5NjC0CaZKY2uO1GDWOokB_TG-uJ8DBHdZE3QkxZ09ZlWPplw=s320" width="180" /></a></div>Just below this new switch is the solenoid compartment. Each of the two solenoids controlled by the new switch are in this compartment (pictured below). This system is called "Vari-Grip" and what it means is that it can adjust how tightly the collet clamps down on the parts being machined. The "Vari" in this systems simply comes from an air pressure regulator that controls the amount of air pressure sent to the "Grip" part of the system. You can see this pressure regulator in the upper left of the picture below.<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEhVJdyJSTar3xXgy1N9ecs3Jq0k-PVzmf4WzEBdxcVk1kwCoKstWVUknt6LOiphirimQSaheTNej1uNXGG1MU1Opl6NFQVBq1fAcvDyCUJLT0aGQ7xn1zWOMdULKTMwwId99e8Hmti4qQQuWmGU8cG9gkohzwWQACjSI8OBROMllinmZ03pq1nnLYptjw=s1345" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="810" data-original-width="1345" height="193" src="https://blogger.googleusercontent.com/img/a/AVvXsEhVJdyJSTar3xXgy1N9ecs3Jq0k-PVzmf4WzEBdxcVk1kwCoKstWVUknt6LOiphirimQSaheTNej1uNXGG1MU1Opl6NFQVBq1fAcvDyCUJLT0aGQ7xn1zWOMdULKTMwwId99e8Hmti4qQQuWmGU8cG9gkohzwWQACjSI8OBROMllinmZ03pq1nnLYptjw=s320" width="320" /></a></div>The solid state relays control two solenoids that are located the the
far bottom left of the pic above. The two larger black air hoses in
the far left side of the picture are the air lines that pass through the
machine walls and end up coming out behind the headstock and go to the
collet closer shown in a picture (several) above. This was my first experience dealing with a collet closer system and I learned a great deal about it. I'm also happy to have it rebuilt and done!<br /><br /><u><b>Coolant Tank and Pump</b></u> - Well, of all the repairs to this machine so far, it was this coolant tank system that almost broke me! In order to get the old tank out of the machine, there is a sleeve between the catch pan and the top of the tank that must be pulled upward. In order to pull that sleeve up, I had to remove a plug that had been welded into the bottom of the catch pan. Removing that plug was a bear!! I played hell trying to get that thing cut loose and pulled up, out of the way. I heat it, beat it, ground on it, pried on it, and it wouldn't budge. Finally, I had to weld bolts to the inside and then block up a strong back to pull it up with 3/8" nuts. Just look at this thing:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEh2ep3Rpmc7gXah7I0RU7EFgvJL0yu1JTM6AtKfFmu0k5xCoEuvurIEjh5Esg4Agj2BZ82jpicS-KQleyR7fPIe_zNc3iJxPJswxqUW_s-_ZNTDtR-uhgcFPyrMG8T8xRPRk58w8jMLT_FTus3P6AwZsWc1PJr-sVXpd6L_kn_lGtb0wuy6SoUPqxcEIw=s1022" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1022" data-original-width="903" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEh2ep3Rpmc7gXah7I0RU7EFgvJL0yu1JTM6AtKfFmu0k5xCoEuvurIEjh5Esg4Agj2BZ82jpicS-KQleyR7fPIe_zNc3iJxPJswxqUW_s-_ZNTDtR-uhgcFPyrMG8T8xRPRk58w8jMLT_FTus3P6AwZsWc1PJr-sVXpd6L_kn_lGtb0wuy6SoUPqxcEIw=s320" width="283" /></a></div>BTW - wrestling with this thing was made worse by the fact that it was directly under the bed of the lathe. Once I got the the plug removed from the catch pan, I was able to remove the sleeve from the hole in the top of the coolant tank can see in this pic below. This pic is of the coolant tank after I remodeled it to about 1/3 of it's original size and welded some fittings into it. The fitting with the hose on it is the pump pick-up. The one below that is for a drain valve. Here is the tank while testing my welds for leaks with water:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEhDO-l0o8xCc7GmghcTsCoS3neORV6uWSmCtwDhGwibtaerExG8O5MIDO7nJfUwqrAjAQAz9H2HSTbphBRiQeHqQmzJsCgQn297agioZOBs6-6AhpyWf-tLFTx3NTLrEQZmvfZEbDtORYI9dS0rHDAwRu1WmMddpRE70sFYCcxmnOcvqwzbtzmI576ECw=s1469" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="807" data-original-width="1469" height="176" src="https://blogger.googleusercontent.com/img/a/AVvXsEhDO-l0o8xCc7GmghcTsCoS3neORV6uWSmCtwDhGwibtaerExG8O5MIDO7nJfUwqrAjAQAz9H2HSTbphBRiQeHqQmzJsCgQn297agioZOBs6-6AhpyWf-tLFTx3NTLrEQZmvfZEbDtORYI9dS0rHDAwRu1WmMddpRE70sFYCcxmnOcvqwzbtzmI576ECw=s320" width="320" /></a></div>The same tank after some clean-up and some paint:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEhaw9QGUKrADPHTEOMSDztC8QjyTJ8I5kkblwRezAQy7J9iCyBzslZKNoqQlwroAIk1JV8nE_fiJLlLpjv4yXvTZ4KAa5Cw6DCv1UgfBAqThhSfEDKnhwUpEF_paKFgEfzkbK8xigk0cgNLSR8mwoWX2jNU01ZReR7WIGgh6H6YrlXXzYuqY15hJnmqLA=s1468" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1121" data-original-width="1468" height="244" src="https://blogger.googleusercontent.com/img/a/AVvXsEhaw9QGUKrADPHTEOMSDztC8QjyTJ8I5kkblwRezAQy7J9iCyBzslZKNoqQlwroAIk1JV8nE_fiJLlLpjv4yXvTZ4KAa5Cw6DCv1UgfBAqThhSfEDKnhwUpEF_paKFgEfzkbK8xigk0cgNLSR8mwoWX2jNU01ZReR7WIGgh6H6YrlXXzYuqY15hJnmqLA=s320" width="320" /></a></div>Here is the tank put back into the machine with the coolant level indicator that I made viewable from the back of the machine:. There will eventually be a panel in place to cover this tank access with a window for viewing the coolant level:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEjRPxlxQbQb7F0mYwhq9V3nVIZcQ_N7MyqcX9wafRtoVywbCiZ9R_ZFBPdIMtgo-d9c7hBLa_saHpc7r6iIpVnTmrEaIifSNHK-vOLbEhlL44SmHI-TO99ur_rM3LC8HNLC5lQGav8hldCfhu3HAJrtrFnAiVi3D_i6OBsEby0uWhbhdcqSrkJUdAWa_g=s1621" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1621" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEjRPxlxQbQb7F0mYwhq9V3nVIZcQ_N7MyqcX9wafRtoVywbCiZ9R_ZFBPdIMtgo-d9c7hBLa_saHpc7r6iIpVnTmrEaIifSNHK-vOLbEhlL44SmHI-TO99ur_rM3LC8HNLC5lQGav8hldCfhu3HAJrtrFnAiVi3D_i6OBsEby0uWhbhdcqSrkJUdAWa_g=s320" width="298" /></a></div>Here is another view of the tank installed in the machine. The pump is on the right side and the lower left side has a drain valve on the bottom and a tank suction for the pump just above. You can also see the sleeve that comes down from the catch pan and seals into the hole in the top of the tank:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEiiCka4mxHl4HgBi4BYKyKqV5D1o2N5BMOA-Orq_98ZE_3qxM7DtCrqRR76MboXZPVJq3BOrrXwI0H1_GTdXN3-tDrEro42sWSYgPQJx8FtW8dB0w-AYcHJRu2GrtpWr2nbzSigs6etBvmCujaGOse2jfHrRgRnwrAB1tt-c49kSsR165ypRAt4ljJ63g=s1321" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="844" data-original-width="1321" height="204" src="https://blogger.googleusercontent.com/img/a/AVvXsEiiCka4mxHl4HgBi4BYKyKqV5D1o2N5BMOA-Orq_98ZE_3qxM7DtCrqRR76MboXZPVJq3BOrrXwI0H1_GTdXN3-tDrEro42sWSYgPQJx8FtW8dB0w-AYcHJRu2GrtpWr2nbzSigs6etBvmCujaGOse2jfHrRgRnwrAB1tt-c49kSsR165ypRAt4ljJ63g=s320" width="320" /></a></div>To get the coolant pump to work both in manual and automatic (activated by the part program) - I had to find the control wires and route them to one of the solid state relays in the servo control cabinet. In this case, it is 5CR, the relay in the top right that is wired to the coolant pump:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEg9o1QV1f3soYqVV_8oba6OfvvYGzwKtRqj0PlrYi3ja8gNZW39tqJU5ZHTkH2k40PU9D-gZBfy1AVASpfIKnVrBiBevjsmdMsnAFCuLltUKCIDh1uvS5yrzAuYvcOGPGl7cpWsU6bQia4SA21P5EzXbxeYdNqojZs0cqA_iqVk63HkebMWWfOR_q2Kgw=s1613" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="1613" height="180" src="https://blogger.googleusercontent.com/img/a/AVvXsEg9o1QV1f3soYqVV_8oba6OfvvYGzwKtRqj0PlrYi3ja8gNZW39tqJU5ZHTkH2k40PU9D-gZBfy1AVASpfIKnVrBiBevjsmdMsnAFCuLltUKCIDh1uvS5yrzAuYvcOGPGl7cpWsU6bQia4SA21P5EzXbxeYdNqojZs0cqA_iqVk63HkebMWWfOR_q2Kgw=s320" width="320" /></a></div>
With that wiring completed, I did a test of the system in this video:<br /><div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dzK8aZG_vBdAXhPzcmTEgSBlp8-luBUv2PThAYMPy_zFL8n9tSgtC5E8Tw2TwcJkxXdCEhmgUAyot6CkMaoJA' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div>The last step to the coolant tank work was to fabricate a new screen to put in the bottom of the catch pan (instead of a plug) to catch fine chips from making their way into the coolant tank. I found a piece of pipe the correct size, welded a steel screen to the bottom and put it in place:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEhg-kcO0XFEVFFKcLsdqexq9nZEeB-DQz52nHNROV_MezPORfXq3Bksb1tJ57TT82VwysHt3VPrXY_JC-elGaZs8O74O5JJ3YiBGImZvLa6vSEX-a-Vr4iIQzEXX16GRZ6fQ_5FayN_VKiO_LQLONdlblyGQ6AhNq6eBgbOKYDuLDgkONfzvHaiO30U1g=s2688" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2688" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEhg-kcO0XFEVFFKcLsdqexq9nZEeB-DQz52nHNROV_MezPORfXq3Bksb1tJ57TT82VwysHt3VPrXY_JC-elGaZs8O74O5JJ3YiBGImZvLa6vSEX-a-Vr4iIQzEXX16GRZ6fQ_5FayN_VKiO_LQLONdlblyGQ6AhNq6eBgbOKYDuLDgkONfzvHaiO30U1g=s320" width="180" /></a></div>After getting the plug out of this system, the all was academic after that. Glad to have this system working again.<br /><br /><b><u>Control Cabinet</u></b> - There were several modifications that I wanted to make to how this control was mounted and located. The first one was that I wanted to install a PC that could be used to transfer programs to/from the F8025T. The second thing I needed to do was to move where the control was mounted to the machine, because 2 of the main cables running to the servos stuck out of the side of the control cabinet in a way that the door by the operator's station could not be closed all the way. Then, as I got more into this part of the project, I also decided that the control needed to be mounted to a rolling cabinet that could be disconnected when the machine had to be moved, and then moved as needed.<br /><br />As I worked on a lot of the parts of this machine that I've discussed earlier and in previous updates, I was keeping my eye out for an enexpensive PC and LCD monitor. I eventually found both and set out mount them to the existing control box. I made a bracket that fit the monitor and used that to mount it to the top of the box. You can see that here:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEj3epxcpU0dWzDWW-hmCcXnT7jSYY7zVMTlhxgqnjxoDvCC--wMUKwle-xWsT4bZt_NqRwDgm30pE2ywQKpsoX1-vRQmmP2NfUedJFbAE2vbYwBzX6_XMoMIkItsASa2JbBerXiLUO9x_rwwGxlN7K5lJnTMW8i8Nx74jFcRLVxRyfVpASExh3poJZCCw=s2688" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2688" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEj3epxcpU0dWzDWW-hmCcXnT7jSYY7zVMTlhxgqnjxoDvCC--wMUKwle-xWsT4bZt_NqRwDgm30pE2ywQKpsoX1-vRQmmP2NfUedJFbAE2vbYwBzX6_XMoMIkItsASa2JbBerXiLUO9x_rwwGxlN7K5lJnTMW8i8Nx74jFcRLVxRyfVpASExh3poJZCCw=s320" width="180" /></a></div>I also found some sheet metal and formed up a keyboard tray that I mounted at an angle and put a small flat shelf for the mouse pad. It turned out pretty nice and it all worked when I plugged everything in and tried it:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEjlG58h8hv72nJFVGqsmow5xnXUn9PgUF0PdQEIXBE3K15Jrw5zj32RzrVNAW5XHcRWuQfpJRJMqBhTaU-g9oJURnEJrmTG35eZm7Y-dgGuYRKAPqNYH1DoucXYIuN2Qx4n331C7hZqrJtndp8sME4RFca9WfBxmNQ3ejJ3elg3azcuYHWz3Mc0R7SrMA=s2688" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2688" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEjlG58h8hv72nJFVGqsmow5xnXUn9PgUF0PdQEIXBE3K15Jrw5zj32RzrVNAW5XHcRWuQfpJRJMqBhTaU-g9oJURnEJrmTG35eZm7Y-dgGuYRKAPqNYH1DoucXYIuN2Qx4n331C7hZqrJtndp8sME4RFca9WfBxmNQ3ejJ3elg3azcuYHWz3Mc0R7SrMA=s320" width="180" /></a></div>Once I had this finished, I started thinking about moving this machine. With all this "stuff" attached to the control box, how do you move it? How do you set it down, without breaking something off or having to take it all apart? I had to find a better way.<br /><br />About that time, I came across an old steel cart that was like a podium on wheels. I looked it over and decided that if I could cut it off the right height, weld the right plates and brackets to the top, then I could mount the control on it permanently. With this design, moving the machine would be much easier - just removed a few canon plugs, pull a few power wires and remove a couple of bolts and the whole control cabinet would be able to be rolled away from the main machine. Then, the main machine could be lifted with a forklift and moved as needed. I liked the idea. After some cutting, heating and beating, I had this:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEgq-qzRNCjjGjQtujborsV2bd1eCCTD1u05-0RQdsdLTOxvuq9EsLsyNl1qvvI9BzsVVyT5jM1CYhVwBZO3CaeEJs8QN0ZwXsdsO69ZAxu8LZAD2xAxtDF7inXq8fFQyaud4aFKIlq8uUY_G_QGri8uqXYflSrdnepQ354iMCVkMbuBxrAaEkPd6IVMOw=s2688" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2688" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEgq-qzRNCjjGjQtujborsV2bd1eCCTD1u05-0RQdsdLTOxvuq9EsLsyNl1qvvI9BzsVVyT5jM1CYhVwBZO3CaeEJs8QN0ZwXsdsO69ZAxu8LZAD2xAxtDF7inXq8fFQyaud4aFKIlq8uUY_G_QGri8uqXYflSrdnepQ354iMCVkMbuBxrAaEkPd6IVMOw=s320" width="180" /></a></div>I even put in a shelf to mount the small footprint PC to inside the cabinet. The other nice thing about this plane is that there will be storage in this rolling cabinet to put machine manuals and spare parts etc.:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEjD6ZeY8D1wMsEVP16by18rGf_BFqo2PFYvqXJufvC-TxNXEu23yTD43gKl0jzxz5WxC-Pg285o18R28V79O54Y0cfreR6V78daDLpRWKGgDXRE8I7bTXv5cT1_5rDiMHn1jHM8TLx_vGBdJcl4LW53Ltb3q04P041UQZ1_A5KYUsjZ_Ay3Wew-P0l8TQ=s2688" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2688" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEjD6ZeY8D1wMsEVP16by18rGf_BFqo2PFYvqXJufvC-TxNXEu23yTD43gKl0jzxz5WxC-Pg285o18R28V79O54Y0cfreR6V78daDLpRWKGgDXRE8I7bTXv5cT1_5rDiMHn1jHM8TLx_vGBdJcl4LW53Ltb3q04P041UQZ1_A5KYUsjZ_Ay3Wew-P0l8TQ=s320" width="180" /></a></div>When, I put it all back together again, this is how it looked:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEg1_77DtwsdauqZAgwFjEKSM3EkeIL4talUv3wWXb3PVDl-YNEuss2QAxhCVI5yhny7y-pAiIF72tpcoc11Qj5GYm4ciIZ6OSF1qkuVxfza-ZTAMK4x46_evoR8VMgvT4-JYh7VkFpAdH0CpzrBmWuk3bqeB5qOSSPs1grZNLB7F7Svc6a7e8RAYdNjOA=s2688" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2688" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEg1_77DtwsdauqZAgwFjEKSM3EkeIL4talUv3wWXb3PVDl-YNEuss2QAxhCVI5yhny7y-pAiIF72tpcoc11Qj5GYm4ciIZ6OSF1qkuVxfza-ZTAMK4x46_evoR8VMgvT4-JYh7VkFpAdH0CpzrBmWuk3bqeB5qOSSPs1grZNLB7F7Svc6a7e8RAYdNjOA=s320" width="180" /></a></div>Nice! So, now that I could move the control around more easily, I wanted to work on positioning it so that the control cables to the servos would not interfere with the doors on the machine. I rolled the control back about 8 inches an now the cables to the servos will pass behind the canopy on the machine. You can see in this pic where the control cables plug into the blue connections on the control box:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEiG2S1uXV2EkvqCXW1sD0EhN0S6T0-vUmXJpyYQ8Dv3Dw92JAXTZKWdNBALK7gSZDavqI0iqgSSb1Y9p_6uUxKzrzVX3OgDIMAtg5S0FOkm_Saj0rv_86DRrMMgeWzEyUdtx2iupQmcXfBAK-QDvCDMIy0OQoRiOa_cST6OzLUpymPSQa8zyEsCHFvkqg=s2688" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2688" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEiG2S1uXV2EkvqCXW1sD0EhN0S6T0-vUmXJpyYQ8Dv3Dw92JAXTZKWdNBALK7gSZDavqI0iqgSSb1Y9p_6uUxKzrzVX3OgDIMAtg5S0FOkm_Saj0rv_86DRrMMgeWzEyUdtx2iupQmcXfBAK-QDvCDMIy0OQoRiOa_cST6OzLUpymPSQa8zyEsCHFvkqg=s320" width="180" /></a></div>The only modification needed to make the control stay in this position can be seen in this picture: <br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEiR79lDG1JwMc55V9b8s1eIa3sNszeIt0RI9rt-BQ0jV0i3dva6_vZNKc3tpSocD4-Qo7hlNVjVOeCgpH0plq1UTX_QJGld0pC0T9_u-ss0jQzZKq8SFHwTSckObnGysWbDo9WLXS9912wCTie013_3mI_pGm4Xfx_ynkCC5_x0txbK-YgoDVriqdvhPw=s2100" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1274" data-original-width="2100" height="194" src="https://blogger.googleusercontent.com/img/a/AVvXsEiR79lDG1JwMc55V9b8s1eIa3sNszeIt0RI9rt-BQ0jV0i3dva6_vZNKc3tpSocD4-Qo7hlNVjVOeCgpH0plq1UTX_QJGld0pC0T9_u-ss0jQzZKq8SFHwTSckObnGysWbDo9WLXS9912wCTie013_3mI_pGm4Xfx_ynkCC5_x0txbK-YgoDVriqdvhPw=s320" width="320" /></a></div>The black square tube with the flange on the right is connected to the control box, the holes in the machine base on the left is where it used to be bolted together. All I would need to do is fabricate a plate with hole patterns in the right places and bolt it all together. Since the weight of the control was no longer supported by this steel tube, it did not have to be very beefy or strong. All it would do is hold the cart in place, essentially. Here it is, also painted up in black:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEiOG-KzVXdjTOsUshYi0Ds_SncuiA9ryYPz6749HAq8AVhlnG-NkUNSu7Y-Ti9ZpWty9Dh0uMr2fvAFUjvkPmLnJiahpCkvIEiL9CZsaNYgJfkb9WqpQPR2lgL4YTKeM-6KNcDhtFRg9lLzt9GbPVucxtNROAIupCT83obKUqAch9aGuskMRX3lrgg2aA=s988" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="988" height="245" src="https://blogger.googleusercontent.com/img/a/AVvXsEiOG-KzVXdjTOsUshYi0Ds_SncuiA9ryYPz6749HAq8AVhlnG-NkUNSu7Y-Ti9ZpWty9Dh0uMr2fvAFUjvkPmLnJiahpCkvIEiL9CZsaNYgJfkb9WqpQPR2lgL4YTKeM-6KNcDhtFRg9lLzt9GbPVucxtNROAIupCT83obKUqAch9aGuskMRX3lrgg2aA=s320" width="320" /></a></div>Now, the control is positioned well and sits pretty much like you saw 3 pictures above.<br /><br /><u><b>Paint and Panels</b></u> - With the bulk of the repairs done to this machine, it was time to start putting the panels back on and I wanted to put a coat of paint on the base to clean it up a little. I did not have all the missing panels, several were removed and not on the machine when I got it. But, I did have a little collection of panels that I'd gotten off of other machines in the past or found various places. I was able to find enough to replace all the panels on the machine - except one. Here's the front of the machine:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEj6FtNNtaPZUkdNxZkOnEEGr8p4BOgKSVoY1f3s04NJX2GGiWJZF-oXhYExTn3lsR6Uuol63oS9GD9X65rdP2Pk7PDAYEFenpSihNMEWw5E4vMKZEAU983dTzqvY1qhr1tUfD3gBeLXczhIdZT_kGdK-lhl3s9Zxyf-3A923lI78DoQMRSmKKvMo5zPiw=s2187" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1419" data-original-width="2187" height="208" src="https://blogger.googleusercontent.com/img/a/AVvXsEj6FtNNtaPZUkdNxZkOnEEGr8p4BOgKSVoY1f3s04NJX2GGiWJZF-oXhYExTn3lsR6Uuol63oS9GD9X65rdP2Pk7PDAYEFenpSihNMEWw5E4vMKZEAU983dTzqvY1qhr1tUfD3gBeLXczhIdZT_kGdK-lhl3s9Zxyf-3A923lI78DoQMRSmKKvMo5zPiw=s320" width="320" /></a></div>There was a panel that covered the main spindle motor originally, but it has long since been removed and lost. I decided to leave the machine without replacing that one cover. Here is that end:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEjBBXfWN4RobWcApFRrlD-k5Eb0j7UKOfcVJsZNot5Lj60xI3Rwr9_sofR-VV4dfpE0icTu-l_FXzJKOv6Tp8eN1mHszDvMU4TNFUySvHvLydT3ey7S-RTz5f3CceDhn5RhdIjfN7N320bMFVvOEMsJJshyexDlssYE00e-G4TgQI0rGaG12KVU5wrThw=s1652" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1506" data-original-width="1652" height="292" src="https://blogger.googleusercontent.com/img/a/AVvXsEjBBXfWN4RobWcApFRrlD-k5Eb0j7UKOfcVJsZNot5Lj60xI3Rwr9_sofR-VV4dfpE0icTu-l_FXzJKOv6Tp8eN1mHszDvMU4TNFUySvHvLydT3ey7S-RTz5f3CceDhn5RhdIjfN7N320bMFVvOEMsJJshyexDlssYE00e-G4TgQI0rGaG12KVU5wrThw=s320" width="320" /></a></div>Here is the right end of the machine and the back with all the panels in place and painted. The panel that covers the coolant tank in the back was the last to be fabricated, painted and put on the machine:<br /><br /><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEjIXQiG0pJtBk3gM1IASTYXUJuijLMtZMkLQXrg7G1wqgss1WRCf7dhkGLzh-NYDKRx5tcYdOs8TgYYVneKonZfK3RI7F_TrnpNuxAd5AwLvxNic62G-cHqG-pBoAc9Lpx4lyBZVk1eE9WOY-5gBuypCOl7rf9ct_HjDXCAQ8G2vAt0mQTpr04x3DI5LA=s1366" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="848" data-original-width="1366" height="199" src="https://blogger.googleusercontent.com/img/a/AVvXsEjIXQiG0pJtBk3gM1IASTYXUJuijLMtZMkLQXrg7G1wqgss1WRCf7dhkGLzh-NYDKRx5tcYdOs8TgYYVneKonZfK3RI7F_TrnpNuxAd5AwLvxNic62G-cHqG-pBoAc9Lpx4lyBZVk1eE9WOY-5gBuypCOl7rf9ct_HjDXCAQ8G2vAt0mQTpr04x3DI5LA=s320" width="320" /></a></div>So, as the machine currently sits, I have a little painting to do - I want to paint the uprights on each end of the machine and repaint the doors black (they are sitting on top of the machine, up-side-down in this picture):<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEj-Z8wn-vBD73VnZKM_r8lLPofrPKOlXQBCpfnfE_duHC2dKFIow-OpxaxE5jg5MyZlSG3zpQG0JuUdSs3H0Bx7Wm4BSXS2fokztMhekowPde5VLJTF7ODDdXgJgvFABClZJ1WgfhFlU_YyAg2-gyLaDEFyLf9yrxnd9k38wZFyIuJrdkQpSf5iRql43g=s2688" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2688" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEj-Z8wn-vBD73VnZKM_r8lLPofrPKOlXQBCpfnfE_duHC2dKFIow-OpxaxE5jg5MyZlSG3zpQG0JuUdSs3H0Bx7Wm4BSXS2fokztMhekowPde5VLJTF7ODDdXgJgvFABClZJ1WgfhFlU_YyAg2-gyLaDEFyLf9yrxnd9k38wZFyIuJrdkQpSf5iRql43g=s320" width="180" /></a></div>I have to decide if I want to spend the money to put plexiglass back in the doors. That'd be a little expensive, and I only want to do it if there is real need for it. I have more thinking to do on that topic.<br /><br />There is also a little more sheet metal work to do on the control cabinet and that needs to be painted black. I want to add some shelves in the cabinet for the machine manuals and paperwork. I also would like to have a space to put some of the old/spare parts from the machine.<br /><br />I will report on these items in a future update. Thanks for checking out this project. I hope it was informative and maybe a little entertaining.<br /><br />
Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-4561663675008429701.post-37393689219345369792022-02-23T09:00:00.005-08:002022-02-23T09:34:21.362-08:00Hardinge CHNC Lathe Project Catch-up Update - Part 1Hello Everyone,<br /><br />Thanks for checking out the blog. This update is going to be dedicated to the seemingly never ending Hardinge CHNC lathe project. First off, a warning!<br /><br /><span style="background-color: #fcff01;"><span style="color: #990000;"><u><b>CAUTION !</b></u> - This update is completely dedicated to my work on this Hardinge CHNC Lathe projetct. There is no Prowler related material in this update. So, if you are only interested in Prowler "stuff" - you might want to skip ahead to other updates.</span><br /></span><br />With that said, I will also say that some of the information in this update may have been mentioned in previous blog updates. My intention here is to go over some of the work that I have done to this machine that I did not want put in my normal Prowler updates. It's a lot of info, and I try to not "clutter up" the Prowler blog updates with too much non-Prowler related info.<br /><br /><u><b>Power Switch</b></u><br />One part of this project that I've not mentioned before is the power supply for the spindle system. After I moved all of the electrical components into the smaller compartment, I wanted to be able for the operator to turn it on from the front operator's station. So, I sourced an appropriate switch and a box and mounted them to the front of the machine. Here is what that turned out to look like:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDg3r1Xpapg7ET9BF3VCq44U3nSPSpy3TJgFwIPW4nQgOEwdZL1pQptunXEcTx780M6G67Fp727DTL0X8ebauDCa3yE_8cxNJnoOzLHHe6rdrMFIecuqE3on2adRqOaaOjaGdRn5XyFWMn/s1600/20190830_202832%257E2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="965" data-original-width="903" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDg3r1Xpapg7ET9BF3VCq44U3nSPSpy3TJgFwIPW4nQgOEwdZL1pQptunXEcTx780M6G67Fp727DTL0X8ebauDCa3yE_8cxNJnoOzLHHe6rdrMFIecuqE3on2adRqOaaOjaGdRn5XyFWMn/s320/20190830_202832%257E2.jpg" width="299" /></a></div>
<br /><u><b>F8025T Control Cooling</b></u><br />Another important change I made was adding ventilation to the F8025T. Heat is the enemy of every electrical component - I cannot believe that this control cabinet was not cooled in any way. Especially, considering that the Fagor control is in a box already - then whoever did this retrofit mounted that airtight box INISDE of another airtight box (you'll see it in few pics below). That's a formula for certain electronics failure! So, I found some fan screens and found an appropriate place to locate it:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKlyCdfMekzWhpP0aXmUAOv8E2z78NUWjz6j7wrMUAr6To5oUXMPkBt5vkj6cvv3fvpQWeMmP5-NabQCreeK0dehRdXyqvsl1lf9UcV9dPNaQZrxUZDvW4mq76Sbe64x4eBerqwFd8d94_/s1600/20190919_083913.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="710" data-original-width="748" height="303" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKlyCdfMekzWhpP0aXmUAOv8E2z78NUWjz6j7wrMUAr6To5oUXMPkBt5vkj6cvv3fvpQWeMmP5-NabQCreeK0dehRdXyqvsl1lf9UcV9dPNaQZrxUZDvW4mq76Sbe64x4eBerqwFd8d94_/s320/20190919_083913.jpg" width="320" /></a></div>
Marked the mounting holes:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj12u3wjZdbp2c3ODL1ZXGetOF4QZav0fy5ZsXyhYZuR4PX4hmHVyIhdKXZrRoWkVKVfPHWK9Og_UEX3d1RAK9uX9xN5Do02ca6W3yk_2uNw5KwsRllgPLX2D57VtOeJUG_4UbmUgYIW4HS/s1600/20190919_084029.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="805" data-original-width="756" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj12u3wjZdbp2c3ODL1ZXGetOF4QZav0fy5ZsXyhYZuR4PX4hmHVyIhdKXZrRoWkVKVfPHWK9Og_UEX3d1RAK9uX9xN5Do02ca6W3yk_2uNw5KwsRllgPLX2D57VtOeJUG_4UbmUgYIW4HS/s320/20190919_084029.jpg" width="300" /></a></div>Then, cut air flow holes:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcNPEWbQ3_jH1e340eItPIVnGDs9xaRCXPgoxFX3LQfEMoGnGAn3RQZ4-EDMHQ7PhgWrmpCtRKFUxz4RhDgssPlvNM_MDtlfPGzRAplSpGTHMYlVkuv_ZLOcgae4zSWc2NVQGAlBtgOKSU/s1600/20190919_094141.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="609" data-original-width="756" height="257" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcNPEWbQ3_jH1e340eItPIVnGDs9xaRCXPgoxFX3LQfEMoGnGAn3RQZ4-EDMHQ7PhgWrmpCtRKFUxz4RhDgssPlvNM_MDtlfPGzRAplSpGTHMYlVkuv_ZLOcgae4zSWc2NVQGAlBtgOKSU/s320/20190919_094141.jpg" width="320" /></a></div>
Test fit:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiG3kXFDg9Qrd7ThcHXGOecPp2PFN_oLAiJTyfguIdLnsa_ISXXzQSh6tGqare4E71doh3dg4X4rDVELeUb2G3cpGKtDEwAGgZdyE76at4cVc6ljrV9JK1lOr9etO3ALOF1lK1TiwrVC-1E/s1600/20190919_094318.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="625" data-original-width="756" height="264" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiG3kXFDg9Qrd7ThcHXGOecPp2PFN_oLAiJTyfguIdLnsa_ISXXzQSh6tGqare4E71doh3dg4X4rDVELeUb2G3cpGKtDEwAGgZdyE76at4cVc6ljrV9JK1lOr9etO3ALOF1lK1TiwrVC-1E/s320/20190919_094318.jpg" width="320" /></a></div>
And, finally put it all together:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLuJhKA1ptzI4A4k1m_2H8yI53dTOyNjlwX09L2QDU77Xh_fsnx2NjmRqaAqIbreHIDKzjwWwBQq8jUaNOeWsIQLHSxbPzqdc-jdNrr_VYwR8_z1TD_1jokmP1ANQFgq-nM-DKJKG3Fzew/s1600/20190919_101126.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="653" data-original-width="756" height="276" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLuJhKA1ptzI4A4k1m_2H8yI53dTOyNjlwX09L2QDU77Xh_fsnx2NjmRqaAqIbreHIDKzjwWwBQq8jUaNOeWsIQLHSxbPzqdc-jdNrr_VYwR8_z1TD_1jokmP1ANQFgq-nM-DKJKG3Fzew/s320/20190919_101126.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7Hr-T3qWeZgyqpu7NPsbSDsKgJp48tBBIZCpSUwBZeMeglrq2TeQNBREzNZMTM9_wFngfWCNuSlp-KOLvHW1rgI4Hj8b1VnXsBXey83fCLKDJWsKIG_b_sB5zp-fogP0K2pEP-fhMzl6K/s1600/20190919_101138.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="805" data-original-width="756" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7Hr-T3qWeZgyqpu7NPsbSDsKgJp48tBBIZCpSUwBZeMeglrq2TeQNBREzNZMTM9_wFngfWCNuSlp-KOLvHW1rgI4Hj8b1VnXsBXey83fCLKDJWsKIG_b_sB5zp-fogP0K2pEP-fhMzl6K/s320/20190919_101138.jpg" width="300" /></a></div>This setup in the back cabinet door was merely a vent for the fan air to exhaust out of the cabinet through. I created a similar vent on the bottom of the cabinet and mounted the fan on the inside above it:
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8Y3PaWVJPDEfJh7ScvjuiUoyQukorJ8_D3LlqwiprLKmcfan5S5P7NI9kW8Zt82QSY3MgLs94ulRHTRiIthhKBiMAnmuCwwJKFG1r80TiLfKCYG3NsUTsFKtA5LbdtDLrjzJkOiXWz8_Q/s1600/20190919_101226.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="918" data-original-width="756" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8Y3PaWVJPDEfJh7ScvjuiUoyQukorJ8_D3LlqwiprLKmcfan5S5P7NI9kW8Zt82QSY3MgLs94ulRHTRiIthhKBiMAnmuCwwJKFG1r80TiLfKCYG3NsUTsFKtA5LbdtDLrjzJkOiXWz8_Q/s320/20190919_101226.jpg" width="263" /></a></div>This allows the fan to blow directly up onto the control and then vent out the back of the outer control box. Here you can see the heat sink on the back of the actual control (computer) box that is mounted inside of the outer box (which holds the rest of the servo control components):
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxGMqgdvZOIVaKvfdHWa7-NelAyRsJP0cZJyXR1wHIDy3Yc8YjputB9zwmkmkhEjz2pwUol9KAkumDd2TSWTYVguipTdHYylXg3urM6bnMx5FIY_4n3CnaheReJb9x6lnpcEdRUbR_kp8c/s1600/20190919_101220.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="706" data-original-width="756" height="298" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxGMqgdvZOIVaKvfdHWa7-NelAyRsJP0cZJyXR1wHIDy3Yc8YjputB9zwmkmkhEjz2pwUol9KAkumDd2TSWTYVguipTdHYylXg3urM6bnMx5FIY_4n3CnaheReJb9x6lnpcEdRUbR_kp8c/s320/20190919_101220.jpg" width="320" /></a></div>
This should help this F8025T last much longer - and the door won't have to hang open on the back of the control anymore!<br /><br /><u><b>RS232 Serial Connection</b></u><br />Here is another little facet of this project that has big returns. The connection for the serial cable that is used to hook the control to a laptop or PC was always laying inside the back door. I wanted to have this passing through the control wall so that it could could be connected to a PC without having to have the back door open. All that took was a drill bit, a small grommet and about an hour with a soldering iron to make it happen. Here was the final result:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHw7ncQGj27Ra47xRMlOHhWC7PSWyTS1IQiF-yogaNnSD_NKCihirGnXJ_eiNuOw9qKntXAV_Ngbt9dJGgeoFZSxkFzVLeROJVK2czYfJj5js323s2E6GTSM9HHfo3yEtWl7wmoRXjlTPP/s1600/20190919_101351.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="602" data-original-width="573" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHw7ncQGj27Ra47xRMlOHhWC7PSWyTS1IQiF-yogaNnSD_NKCihirGnXJ_eiNuOw9qKntXAV_Ngbt9dJGgeoFZSxkFzVLeROJVK2czYfJj5js323s2E6GTSM9HHfo3yEtWl7wmoRXjlTPP/s320/20190919_101351.jpg" width="304" /></a></div>
In the next update you'll see how this serial cable is used to hook the control to a PC full time so that part files can be transfer to/from the control with ease.<br /><br /><u><b>Z Axis Homing Switch</b></u><br />Something else that was a pretty important part of this refurbish project was designing a new Z axis home switch. When the F8025T retrofit was done to this machine, they used one of the old limit switches that was original to the 1970's CHNC design. That switch finally became unusable (years of soaking in oil and coolant) and it was mounted in a difficult area to access. So, I wanted to move it to a more serviceable location and replace it with a new, reliable switch. <br /><br />I sourced a good limit switch. But, there was no convenient place to locate it where a part of the cross-slide could contact the switch as needed to set the home position. So, I picked another convenient place to mount the switch and had to fabricate a long, rigid arm that would do the contact work: <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitaX2rK_q31NGew2E_Wf8tkk7TWConEOAlZnChg6ki4f3UrTpjGyGO3b47cRYMYnNVoM6_gjuTInDkpjIfZjBkgGN5HrDgkGub-clfMqiNaTzTL4ILNGOjU_MErFlIdLJDwiLCjHb96JgE/s1600/20191002_143740.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="797" data-original-width="681" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitaX2rK_q31NGew2E_Wf8tkk7TWConEOAlZnChg6ki4f3UrTpjGyGO3b47cRYMYnNVoM6_gjuTInDkpjIfZjBkgGN5HrDgkGub-clfMqiNaTzTL4ILNGOjU_MErFlIdLJDwiLCjHb96JgE/s320/20191002_143740.jpg" width="273" /></a></div>Another view:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiH5wFoz3_89SnMJ8sqoZ_Y-7mFNGtum0z88YSMFwQ3ZsbfJL52QK-cXC3IA0fDP24ijBG_bieQlnVmXJdyvBElGW_zoqE61gfB_Rlv4DrDEvWEW9oFwVbCfv-zwjqF-CC1LRbioMibvta7/s1600/20191002_143751.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="815" data-original-width="672" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiH5wFoz3_89SnMJ8sqoZ_Y-7mFNGtum0z88YSMFwQ3ZsbfJL52QK-cXC3IA0fDP24ijBG_bieQlnVmXJdyvBElGW_zoqE61gfB_Rlv4DrDEvWEW9oFwVbCfv-zwjqF-CC1LRbioMibvta7/s320/20191002_143751.jpg" width="263" /></a></div>This Z homing setup works excellent now. It should provide reliable homing for many years. Seems like a simple thing, but the amount of work and time it takes to do these little things can really add up.<br /><br /><u><b>New X Axis Mechanical Setup</b></u><br />When I bought this project, the X axis servo motor and belt system was a cobbled together, hacked up mess. The main plate was not long enough to cover all the servo motor mounting bolts holes and an add-on plate was hacked away to allow for belt clearance. The 48 tooth cogged belt pulley was corroded and worn until the belt would skip and slip. All the this may not be clearly evident in this pic, but you'll get the idea:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEjvoGU_6t2QWG0TwbNKLCP-09RXktTWF0rmDG5QP_MiNlg05q09cz-oPGGJlEqr4t_7OCwNxOAjs5i4_1nOqhNIMxnkTpKICneAdywwmGEPnuAydj_qvQ9PrZFT1JrxkRA5O9-O6Ydv4h4LOVdXP5ZB1I0MY-NJcFxJi7YQPMpZyLpr-3Gtpkp9Z23Y9w=s1024" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="768" data-original-width="1024" height="240" src="https://blogger.googleusercontent.com/img/a/AVvXsEjvoGU_6t2QWG0TwbNKLCP-09RXktTWF0rmDG5QP_MiNlg05q09cz-oPGGJlEqr4t_7OCwNxOAjs5i4_1nOqhNIMxnkTpKICneAdywwmGEPnuAydj_qvQ9PrZFT1JrxkRA5O9-O6Ydv4h4LOVdXP5ZB1I0MY-NJcFxJi7YQPMpZyLpr-3Gtpkp9Z23Y9w=s320" width="320" /></a></div>You can really see the bad condition of the big pulley here:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEj5aLn2vbSeWcn-TyNwIwr-XTFQLiBNBPICrLC6FIcUo1k4gjLOueUgDoNNkuyWKUaywjsUwEBpOhB1d36JmN5QBABscBf9g3ZpT2qlXQXyYDOcuBQn5lFFbNsIcAHbJ3B-JBniCjpwEaBiPRcFc-w8wTfIdflBMz7xhTRlXUWWWnAP6y3oYAOrnQ4sTQ=s914" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="786" data-original-width="914" height="275" src="https://blogger.googleusercontent.com/img/a/AVvXsEj5aLn2vbSeWcn-TyNwIwr-XTFQLiBNBPICrLC6FIcUo1k4gjLOueUgDoNNkuyWKUaywjsUwEBpOhB1d36JmN5QBABscBf9g3ZpT2qlXQXyYDOcuBQn5lFFbNsIcAHbJ3B-JBniCjpwEaBiPRcFc-w8wTfIdflBMz7xhTRlXUWWWnAP6y3oYAOrnQ4sTQ=s320" width="320" /></a></div>All that I really wanted to do with this was to find a 1-1/2" long piece of 48 tooth cogged bar so that I could machine it to fit the existing hardware, then make a new plate for mounting the servo to the X axis cross-slide and put it together. Well, it was not going to be that easy. I beat up the internet for days looking for a piece of 48 tooth stock - but all I could find were wholesale vendors that wanted to sell me a 10 foot bar of this stuff at a pretty hefty cost. That wasn't going to work.<br /><br />Eventually, the best and most cost effective solution I could come up with was a retail pulley that I thought I might be able to adapt to the existing set up. So, I took the old part that you see on the left in the picture above and cleaned it up and shortened it a bit. Then, I put it back onto the machine:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj07-OuV28Y62G3NQuUe1Jfe3S9OZQbG_d-CBFZrie2lxLNlhqoPJrf3f15Hh1IP9UZtDSMMko7e05U5bue0vKWEc6MxDA4-5ky8BniyD_jZU3sr7ei93r5doVAEx90E6WkRi-EMzbUOoGF/s1600/20191003_220920.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1034" data-original-width="749" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj07-OuV28Y62G3NQuUe1Jfe3S9OZQbG_d-CBFZrie2lxLNlhqoPJrf3f15Hh1IP9UZtDSMMko7e05U5bue0vKWEc6MxDA4-5ky8BniyD_jZU3sr7ei93r5doVAEx90E6WkRi-EMzbUOoGF/s320/20191003_220920.jpg" width="231" /></a></div>Next, I had to machine a sleeve that would fit over the part above on the inside end, and fit the new pulley on the outside end. This is what I came up with, initially:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKtk7sm234_RNhiXNL6F3lN7bl7QQ5ufKp-M2IRDwnRAUGPzB09QcXBf6WJdbyANIbupdwpBfzPUfHeXbSC6lJH7jOBqOElCYJTiWVPmv3O2rnxvx-L3YXack-p8-GNNHe-KCNGO5WKN_s/s1600/20191003_220940.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="875" data-original-width="723" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKtk7sm234_RNhiXNL6F3lN7bl7QQ5ufKp-M2IRDwnRAUGPzB09QcXBf6WJdbyANIbupdwpBfzPUfHeXbSC6lJH7jOBqOElCYJTiWVPmv3O2rnxvx-L3YXack-p8-GNNHe-KCNGO5WKN_s/s320/20191003_220940.jpg" width="264" /></a></div>Then, I fitted the pulley onto the sleeve:
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixSjKYt8QHoapttOqUvYPtSxg1XdxHbTWDrOR_crRERe11mmOyRgz8YVgm75EmoMY7IsgwdfycCBLfNbway6AD7YfPA0IQhu9GJ8CaU3NmB20j-DvEhuaBDDN4Ow_q5sGaVJoVLLREhOAL/s1600/20191003_221046.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="737" data-original-width="684" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixSjKYt8QHoapttOqUvYPtSxg1XdxHbTWDrOR_crRERe11mmOyRgz8YVgm75EmoMY7IsgwdfycCBLfNbway6AD7YfPA0IQhu9GJ8CaU3NmB20j-DvEhuaBDDN4Ow_q5sGaVJoVLLREhOAL/s320/20191003_221046.jpg" width="296" /></a></div>
After that, I started on the new servo motor mounting plate. Here it is, cut to size and shape and getting the hole cut in for the new pulley sleeve to pass through:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9qhMm_sVYYJFBekFd1TU0Ov39uGpvrf2zcgXUKExGsUqbDluP1javjC6x8DDpb8rHX8E8Hx3tkPf9DF35YiYK6WW-OujSx7NVe9Ox1TTx0FUPkuLNmrxpmUre-TT7bxtUn1q2bU0dlXvX/s1600/20191004_133211.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="698" data-original-width="990" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9qhMm_sVYYJFBekFd1TU0Ov39uGpvrf2zcgXUKExGsUqbDluP1javjC6x8DDpb8rHX8E8Hx3tkPf9DF35YiYK6WW-OujSx7NVe9Ox1TTx0FUPkuLNmrxpmUre-TT7bxtUn1q2bU0dlXvX/s320/20191004_133211.jpg" width="320" /></a></div>
And, here is the test fit up:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzSPB8Vq08j3WdFDZnvchNzjv6yYOG2dQJSJsVrGFd5vocxdpzrtYBsvMViJpOmTQ09RoN4DDo3jroSwAq0yrGUSTICpK1WyuDPw3YpC3YPSjiY_W8k6cimYkK9CvtjBGnN5eOk91N0RPz/s1600/20191004_135650.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="870" data-original-width="946" height="294" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzSPB8Vq08j3WdFDZnvchNzjv6yYOG2dQJSJsVrGFd5vocxdpzrtYBsvMViJpOmTQ09RoN4DDo3jroSwAq0yrGUSTICpK1WyuDPw3YpC3YPSjiY_W8k6cimYkK9CvtjBGnN5eOk91N0RPz/s320/20191004_135650.jpg" width="320" /></a></div>
Now, for the holes and slots to mount the servo motor:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhoSzyC6ieblS4HVAUPhJ45JdCnMI1WGYcrGPo6e_A307OQPnroVVgKUFxCpKEw6kyDjuGILnVRg3r3YoWbDstZy9-V5dJthRkYbiYWojjdc5KL3C203LWwF70y3mJiR0qyDCfZJcwnIs-5/s1600/20191005_131818.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="749" data-original-width="704" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhoSzyC6ieblS4HVAUPhJ45JdCnMI1WGYcrGPo6e_A307OQPnroVVgKUFxCpKEw6kyDjuGILnVRg3r3YoWbDstZy9-V5dJthRkYbiYWojjdc5KL3C203LWwF70y3mJiR0qyDCfZJcwnIs-5/s320/20191005_131818.jpg" width="300" /></a></div>Next, I had to make a sleeve to mount the small pulley to the servo motor shaft. Then, putting it all together got me to this:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvlPEmbTPJihLG77HosfohnixHmwVjAsBRg9VKIioCJ8jSikWyEdQntA3GqxW9NTy0WD7Y3M84E3PHYZMHjiAIyJ7A9qyIZgnEJn4Xt0j3D8n7-epWYzsWu7BaIK6JBhwfZkm521BuMK0B/s1600/20191005_163531%257E2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="738" data-original-width="681" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvlPEmbTPJihLG77HosfohnixHmwVjAsBRg9VKIioCJ8jSikWyEdQntA3GqxW9NTy0WD7Y3M84E3PHYZMHjiAIyJ7A9qyIZgnEJn4Xt0j3D8n7-epWYzsWu7BaIK6JBhwfZkm521BuMK0B/s320/20191005_163531%257E2.jpg" width="295" /></a></div>This was looking and working great. But, I decided that the pulleys were sticking out too far. I took it all back apart and shortened the necessary pieces. Then, I put it all back together and now, it looked "right."<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEgtFjbqlYm3tSUArPKHWp31s47q_mupuiZWtLlWXtY5Zo1qjzydfBeVWx059dyUeH6iDfyiHpoDRNXw8C_rfqEZJatYtBPQVEPgg8KXE9BhX-zKJoMFp2I0Z9gaKk8ZaJwl-fSgV6OO3b6WQOiUW7mgnPbnNfvI5UA7d7mJ3EfDZMKRKUH5Q95EfNWBiA=s1137" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="705" data-original-width="1137" height="198" src="https://blogger.googleusercontent.com/img/a/AVvXsEgtFjbqlYm3tSUArPKHWp31s47q_mupuiZWtLlWXtY5Zo1qjzydfBeVWx059dyUeH6iDfyiHpoDRNXw8C_rfqEZJatYtBPQVEPgg8KXE9BhX-zKJoMFp2I0Z9gaKk8ZaJwl-fSgV6OO3b6WQOiUW7mgnPbnNfvI5UA7d7mJ3EfDZMKRKUH5Q95EfNWBiA=s320" width="320" /></a></div>This was much better. (You might notice that I also put a larger pulley on the servo motor shaft. I did that so that the servo shaft could pass all the way through the pulley and shorten the overall length. However, this required some re-programming of the control to account for the new gear ratio between the servo pulley and the X axis ballscrew.) Now, all that was left to do was make a cover to protect the belts and pulleys from coolant, etc. I'll cover that in the next update.<br /><br /><u><b>Spindle Electronics Cabinet Door</b></u><br />Here is a quick picture of the servo control cabinet after I fabricated and mounted a door to cover the components:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzuLt4unUSKXcZEa7QvL5A_XJk-w83db4Q6wnDUgOHebjCCUrIMpRaIUnHNwYcSFRiiTKlG4DbgPf9YRbW3W3lBE4KQs6rM0VSSNBuH-KqBd0_MOO1I044B3QUAeIwmEI_U5e7U_x8fZ3q/s1600/20191005_165009%257E2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1016" data-original-width="697" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzuLt4unUSKXcZEa7QvL5A_XJk-w83db4Q6wnDUgOHebjCCUrIMpRaIUnHNwYcSFRiiTKlG4DbgPf9YRbW3W3lBE4KQs6rM0VSSNBuH-KqBd0_MOO1I044B3QUAeIwmEI_U5e7U_x8fZ3q/s320/20191005_165009%257E2.jpg" width="219" /></a></div>
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That's gonna do it for this part of the lathe project update. Part 2 will be out soon and bring us up to where the project currently is as it sits in the shop. Thanks for checking this out. See you in Part 2, coming up next.<br />
Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-4561663675008429701.post-79479675584362911092022-02-23T08:23:00.005-08:002022-02-23T08:35:38.151-08:00Ganesh CNC MillHello Everyone,<br /><br />As I mentioned in the last blog update, there was not a lot going on in the Prowler world during late 2020 and early 2021. So, I took advantage of the time to get some machine fixing done. <br /><br /><span style="color: #990000;"><span style="background-color: #fcff01;"><u><b>CAUTION !</b></u> - This blog update does not contain any Prowler related material. If you don't care to see me talk a lot about repairing old machines, you might want to skip ahead to the next blog update.</span><br /></span><br />One project that has been nagging at me for years was my Ganesh CNC mill. From the time that I bought the machine, it had damage on the top of the spindle motor. You can see it here:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEiz_-VHKbf1C-3jHzy3LWD3eH88Y9Nf4nQzEOqxyWaOCwZNSyrpoDGc4ChW4c38qwPBEHFoFlpERInOvji08vTXoix6BrPZxBJLwrqFycq0YuW8CuAudhA6x_DZXnytLX1lcdCAoHufSG-VLADsONXOduxdt7r1yDxFbOwyqpMiRrSiY5229Kew9bPI6g=s2848" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2134" data-original-width="2848" height="240" src="https://blogger.googleusercontent.com/img/a/AVvXsEiz_-VHKbf1C-3jHzy3LWD3eH88Y9Nf4nQzEOqxyWaOCwZNSyrpoDGc4ChW4c38qwPBEHFoFlpERInOvji08vTXoix6BrPZxBJLwrqFycq0YuW8CuAudhA6x_DZXnytLX1lcdCAoHufSG-VLADsONXOduxdt7r1yDxFbOwyqpMiRrSiY5229Kew9bPI6g=s320" width="320" /></a></div>It appears that during a previous move, it was run into a door overhead or something. All of the bolts holding the plate on top had been sheared off and was just sitting loose on top of the motor frame. That slotted circular plate holds the cooling fan for the spindle motor. So, I have always wanted to repair the damage and get the spindle motor cooling fan re-mounted properly. First step was to remove the top of the motor frame:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEjX7PMoAzRSw_QpiPRm2HCWqCqCu9xMJjcrVC6kC8M843L95ebpRfFSba1Sd5BxSMDEb2bkRvpiTh_2rvFcV7ioUxggdXjFCRe43llQPb7D9AKe86AOzE-ufbzfsbw4UG3YXoZKDMc88h3ojUHt9rbXh0lM0qTchvj5OPceVUNUsS_4GxmsUYt4AdlYbA=s987" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="948" data-original-width="987" height="307" src="https://blogger.googleusercontent.com/img/a/AVvXsEjX7PMoAzRSw_QpiPRm2HCWqCqCu9xMJjcrVC6kC8M843L95ebpRfFSba1Sd5BxSMDEb2bkRvpiTh_2rvFcV7ioUxggdXjFCRe43llQPb7D9AKe86AOzE-ufbzfsbw4UG3YXoZKDMc88h3ojUHt9rbXh0lM0qTchvj5OPceVUNUsS_4GxmsUYt4AdlYbA=s320" width="320" /></a></div>You can see more of the damage better here. I checked on just buying a new motor frame, but it was going to be over $400. I didn't think that was an acceptable cost. So, I set out to fix it, or make a new motor top frame. If I had the missing pieces, I might have tried to weld the frame back together. But without those, it was going to be a lot of work. If I tried to fabricate a whole new piece, I would have to design something with the webbing and bearing pockets that are integral to this part. The last option was to try to re-make just the cylindrical portion that actually had the damage.<br /><br />This option would require keeping the webbed part of the frame that holds the upper motor bearing and centers the motor shaft, and then fit and attach a new cylinder to the webbed plate. That might work! I thought I remembered having a large diameter aluminum tube from an auction a while back. I dug it out of the storage shed and, sure enough, it was the right size!
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEiILH8Yi2gxwGJcUHYQ1lw1FqxNPElzIaJl6T-3tZdDDBdP3EXQNGRZM9UUzibIW8oR3foN8L37Rq6iMhMEhPNM86ZHhDpsLuiv5sTpM6GoPc1mH2QPbfSX3kKl9dHMSsNr16gsRDQOcMN94CdlfaNjIgck00VBzoTNXFxkC-kEQBrppcUOYyQafrxvJg=s1090" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1090" data-original-width="537" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEiILH8Yi2gxwGJcUHYQ1lw1FqxNPElzIaJl6T-3tZdDDBdP3EXQNGRZM9UUzibIW8oR3foN8L37Rq6iMhMEhPNM86ZHhDpsLuiv5sTpM6GoPc1mH2QPbfSX3kKl9dHMSsNr16gsRDQOcMN94CdlfaNjIgck00VBzoTNXFxkC-kEQBrppcUOYyQafrxvJg=s320" width="158" /></a></div>Cool! I cut a piece off the right length:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEi6vonji9iGEqYgNrWlte2Fbv0czGLrSWoQQ3ScrjCpeIn1UDz9cBXCOlae8NL6myCDpD3nci16miUBr4LDrVue2OTB6Y7ImMjiPlK3iLLpX8Lzhd3-gPiJ7Yf8lB8gFPttcNlZT1rZrHlbAQs0vXCT6YOJh8fNTVTIX62mBwaqzHRsA51GBxM3mWBKAA=s1041" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1041" data-original-width="822" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEi6vonji9iGEqYgNrWlte2Fbv0czGLrSWoQQ3ScrjCpeIn1UDz9cBXCOlae8NL6myCDpD3nci16miUBr4LDrVue2OTB6Y7ImMjiPlK3iLLpX8Lzhd3-gPiJ7Yf8lB8gFPttcNlZT1rZrHlbAQs0vXCT6YOJh8fNTVTIX62mBwaqzHRsA51GBxM3mWBKAA=s320" width="253" /></a></div>Looks good!
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEg7KLSDNVdHDIfVW-Ue55h9KG70XwIZCvp3MsfnH_2Ek8AhZLhszRFAj7mp5Y9-FwKuQ1pm1Ke4tA9IPRS4CZOWTTzWbKQZohTuPR6yKyulIv6e9aTd_zqofxS8311Ec9yMH_AQIijX2fiqR51pWGNZ8WMvf_2DSU3RjA6_T6SbSZPVM7eGQAIzqPPwDQ=s1251" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1058" data-original-width="1251" height="271" src="https://blogger.googleusercontent.com/img/a/AVvXsEg7KLSDNVdHDIfVW-Ue55h9KG70XwIZCvp3MsfnH_2Ek8AhZLhszRFAj7mp5Y9-FwKuQ1pm1Ke4tA9IPRS4CZOWTTzWbKQZohTuPR6yKyulIv6e9aTd_zqofxS8311Ec9yMH_AQIijX2fiqR51pWGNZ8WMvf_2DSU3RjA6_T6SbSZPVM7eGQAIzqPPwDQ=s320" width="320" /></a></div>Next, I had to true it up in the Bridgeport mill to make sure the cylinder was square. I did that in the Bridgeport mill by fixturing the cylinder in the super spacer (set vertically) and then rotate it 360 degrees against an end mill (on both ends):
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEig-tkaOtQ5Xzolygo7oHOhSPTl7PbB8rebbTosfG-Xfyiim2y1KcYKz94Gta5U5F2I9Czbk1oPGLe4f_lPokaiFH9_YHFY1r6m7tKxGrWp9c5NdSBTmQFJIvn-eAuXlSeCs3D5kglnrxuGV-02VnVL5-rBqF8WA1aZBgbFa1c4gycIfW9Q3daki9487w=s826" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="826" data-original-width="819" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEig-tkaOtQ5Xzolygo7oHOhSPTl7PbB8rebbTosfG-Xfyiim2y1KcYKz94Gta5U5F2I9Czbk1oPGLe4f_lPokaiFH9_YHFY1r6m7tKxGrWp9c5NdSBTmQFJIvn-eAuXlSeCs3D5kglnrxuGV-02VnVL5-rBqF8WA1aZBgbFa1c4gycIfW9Q3daki9487w=s320" width="317" /></a></div>The next step was to remove the cylinder portion to be replaced off of the motor frame and leave just the webbed plate. Some cut-off wheel work with an angle grinder got it started:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEg2QRbBiV4AC6lb5hHhg7Rxhzt1EAu-7SlVswp-DF-0kaAK8zOOZNswpSqX6trqfdVg_pnjWlH-nQXvJkydBpxJwWxoo8K_skwv0N-zyq6qMBGZGr2PpKQysvCzaPgdrnDZnBCQNteZcuzyni5zZBt_TTVIKzh5pMGWAuWT8tyGgK4HGRXlozDvCYO0nQ=s915" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="915" data-original-width="897" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEg2QRbBiV4AC6lb5hHhg7Rxhzt1EAu-7SlVswp-DF-0kaAK8zOOZNswpSqX6trqfdVg_pnjWlH-nQXvJkydBpxJwWxoo8K_skwv0N-zyq6qMBGZGr2PpKQysvCzaPgdrnDZnBCQNteZcuzyni5zZBt_TTVIKzh5pMGWAuWT8tyGgK4HGRXlozDvCYO0nQ=s320" width="314" /></a></div>So far, so good:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEi6auXrcvvzWXyDJ4NE5_4F5-tbM01OOiA7LsbnxzBgPb9EMThd45IlnNjavbo5VuPur12wq2CczX4-1p9-rjYQMQfhRnUwjc8ajMXIchvAb4xe9y05ldL1mdxNd9rqW9jSz3OtOlsoSsCX2d62x7YPWIILiq4gmKFoZ6B71sccEMWuMZs5LoTz4EzoPA=s1192" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="992" data-original-width="1192" height="266" src="https://blogger.googleusercontent.com/img/a/AVvXsEi6auXrcvvzWXyDJ4NE5_4F5-tbM01OOiA7LsbnxzBgPb9EMThd45IlnNjavbo5VuPur12wq2CczX4-1p9-rjYQMQfhRnUwjc8ajMXIchvAb4xe9y05ldL1mdxNd9rqW9jSz3OtOlsoSsCX2d62x7YPWIILiq4gmKFoZ6B71sccEMWuMZs5LoTz4EzoPA=s320" width="320" /></a></div>Now, back to the Bridgeport mill to clean up and true-up the webbed plate for the new cylinder. Here is the webbed portion of the motor frame fixtured in the Bridgeport mill. I ran an endmill around the perimeter of the part to get it flat and true so that the new cylinder could be bolted to it:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEgk6C4N-4R7u976mqCne7VJWkW05KGEMXPBKROeRVBoeI-4FlPWNDsf2JP9qxJSJu-JminlberFxZVwfJwnNIzh-q34Ug05kjFlgU3Blku1YMn7p5r_50P7CiyO_KnHP6wTjDhVZ85vII_azoVhQse9VYhfrs3irBZztKjQgCftfq1XLvBKGni44atnYw=s1210" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1043" data-original-width="1210" height="276" src="https://blogger.googleusercontent.com/img/a/AVvXsEgk6C4N-4R7u976mqCne7VJWkW05KGEMXPBKROeRVBoeI-4FlPWNDsf2JP9qxJSJu-JminlberFxZVwfJwnNIzh-q34Ug05kjFlgU3Blku1YMn7p5r_50P7CiyO_KnHP6wTjDhVZ85vII_azoVhQse9VYhfrs3irBZztKjQgCftfq1XLvBKGni44atnYw=s320" width="320" /></a></div>Then, I flipped it over and drilled a proper hole pattern for mounting the new cylinder. In this pic (below) you can see the bearing pocket and the centering shoulder that keeps the spindle motor armature aligned. You can also see the counter sunk holes I put into the frame to use to mount the new cylinder:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEhKFCmFJk-6nKU8iHJ_0grCA1voqOpkUtVifx0CYsMNq0ICkwW9Pls_UksgZNzT-AaljJd-75DkXgOA7egLydJ_luZHQsX9DeJRI87McK4ALgBHx5I0tZZSjszcxGCVp8C10QVQKWyXq-uF2f-N0YgAZyIRczbPtvcIFqMVQnjryhVRVaMbj9X0tlWI8A=s1006" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1006" data-original-width="994" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEhKFCmFJk-6nKU8iHJ_0grCA1voqOpkUtVifx0CYsMNq0ICkwW9Pls_UksgZNzT-AaljJd-75DkXgOA7egLydJ_luZHQsX9DeJRI87McK4ALgBHx5I0tZZSjszcxGCVp8C10QVQKWyXq-uF2f-N0YgAZyIRczbPtvcIFqMVQnjryhVRVaMbj9X0tlWI8A=s320" width="316" /></a></div>Then, I drilled the same hole pattern in the bottom end of the new cylinder. On the top end of it, I drilled the correct hole pattern needed for the fan plate on the top. Then, I bolted the webbed plate to the new cylinder. Here it is put together:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEjdHsabQB4htbuDvzbHg7SGT0LXR4UNpR5szIKpSWWaA9Zg_g58QKn_HTGmYK02wo24KpslaEQ4ptcMNEIfJV-NOeAZkXfGlDL3ujGZPL3HX0Tq28QmY4ugJeIH0LkKjrvCPCH_P_l32GGM4O6JYj1RzrowQcC90Alu7yAjCqbauav1or98GVJavcBDeg=s837" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="782" data-original-width="837" height="299" src="https://blogger.googleusercontent.com/img/a/AVvXsEjdHsabQB4htbuDvzbHg7SGT0LXR4UNpR5szIKpSWWaA9Zg_g58QKn_HTGmYK02wo24KpslaEQ4ptcMNEIfJV-NOeAZkXfGlDL3ujGZPL3HX0Tq28QmY4ugJeIH0LkKjrvCPCH_P_l32GGM4O6JYj1RzrowQcC90Alu7yAjCqbauav1or98GVJavcBDeg=s320" width="320" /></a></div>After that, it could be fitted back onto the spindle motor:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEj2eH6ahnOShhEvEdCFJLestD5gv2ab_KUETGOj6-ugsSogCkSQB3vfEZOLaos5G6OVzNeax3qcuBGXdZdM-53QEtajtpw_zACPrFHNEtAocdhTiuLIGD1U0wYb-EE5Wk17iqr3FLGNNcImtPPIpCL1_cPHSPstCcU4xbqQQPn1JxI0RGgzbDkBRwfxLg=s1234" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1234" data-original-width="904" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEj2eH6ahnOShhEvEdCFJLestD5gv2ab_KUETGOj6-ugsSogCkSQB3vfEZOLaos5G6OVzNeax3qcuBGXdZdM-53QEtajtpw_zACPrFHNEtAocdhTiuLIGD1U0wYb-EE5Wk17iqr3FLGNNcImtPPIpCL1_cPHSPstCcU4xbqQQPn1JxI0RGgzbDkBRwfxLg=s320" width="234" /></a></div>It worked perfectly! A quick test run of the spindle ensured that the motor was working properly.<br /><br />Next, I was going to need to fabricate a new slotted plate for the spindle motor cooling fan to mount onto. Here is the old part placed on top of the new aluminum plate stock to make sure it would be big enough to cover the new cylinder top:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEiKc2ww020kNiL2lQxE-fPUExx64sGE5pcECvSqdepJemkt8ESNM-XexFXXTN6RDUeC_sqwhRo9R1wNThRjZS4A9ysFznSAYVWkjGAXJsB3RW3FEUfgzDxlh069wPZ6_k54GwZWAVvxwEoSx1F9R49xo1F-6o2lLHiSqvY4Rb_rf8bgECeSnHMt5mKHbg=s880" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="828" data-original-width="880" height="301" src="https://blogger.googleusercontent.com/img/a/AVvXsEiKc2ww020kNiL2lQxE-fPUExx64sGE5pcECvSqdepJemkt8ESNM-XexFXXTN6RDUeC_sqwhRo9R1wNThRjZS4A9ysFznSAYVWkjGAXJsB3RW3FEUfgzDxlh069wPZ6_k54GwZWAVvxwEoSx1F9R49xo1F-6o2lLHiSqvY4Rb_rf8bgECeSnHMt5mKHbg=s320" width="320" /></a></div>Since the spindle motor on the CNC mill could now be used, I mounted the new fan motor plate stock into the CNC mill, wrote a program, and cut it out:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEhr5I9SNMqQH5HTfZG1iIWZcmQI5KufZkcf9lkhQCCWkAAo8D2cBrS7Hh201XpX_N60-ysD7tir4YluTIo16x-KYnriQ1eYwLR5POZnGvjBZXf-vqO4Qz3Avip5ZraYEn8R-kLT9x7mGxbBENKehHXCZsT_h8O6QQzX0lYOsDBGDWab_laEnUDqbCygjA=s1333" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="886" data-original-width="1333" height="213" src="https://blogger.googleusercontent.com/img/a/AVvXsEhr5I9SNMqQH5HTfZG1iIWZcmQI5KufZkcf9lkhQCCWkAAo8D2cBrS7Hh201XpX_N60-ysD7tir4YluTIo16x-KYnriQ1eYwLR5POZnGvjBZXf-vqO4Qz3Avip5ZraYEn8R-kLT9x7mGxbBENKehHXCZsT_h8O6QQzX0lYOsDBGDWab_laEnUDqbCygjA=s320" width="320" /></a></div>Here is the whole unit put back together:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEiF2-AKSVWo-gX6uJ3xF50xCVXB0x8GJ4k3mXrvT2v-Bi_z6NTGUtgR5AdmUj7MkXx1Dm3lqaZt9tayFyiSEVrt0zBC3mKs4eQTYZTslJ9gmyJwUi6cpDb8bmSMgZQkrTPSbqAWqkWlY4K7DIV4tcYOWRBiPmxIuy0LEl86w7NMzXoFTXuMfxXDljF_Fg=s1278" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1278" data-original-width="710" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEiF2-AKSVWo-gX6uJ3xF50xCVXB0x8GJ4k3mXrvT2v-Bi_z6NTGUtgR5AdmUj7MkXx1Dm3lqaZt9tayFyiSEVrt0zBC3mKs4eQTYZTslJ9gmyJwUi6cpDb8bmSMgZQkrTPSbqAWqkWlY4K7DIV4tcYOWRBiPmxIuy0LEl86w7NMzXoFTXuMfxXDljF_Fg=s320" width="178" /></a></div>All that was left was a coat of matching paint.....well, close to matching:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEhQWGqPbkXcTrXQj-hTyPHWC_V1pPpT5R3CQAWy-OqL4s-o1XYKa8Rd22yCdW4ZGs5DiQns_2ZxpA_1coBt86Fc-k7z4jpinjHktHMvEVUJKa2aBBxvYDfyk4PlpR4BBgcy98pVLm8jEvy06owPuANdRfihjdbh84hmT-pIkZ6kk1xg2edACdEXt3ikyQ=s1102" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1102" data-original-width="742" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEhQWGqPbkXcTrXQj-hTyPHWC_V1pPpT5R3CQAWy-OqL4s-o1XYKa8Rd22yCdW4ZGs5DiQns_2ZxpA_1coBt86Fc-k7z4jpinjHktHMvEVUJKa2aBBxvYDfyk4PlpR4BBgcy98pVLm8jEvy06owPuANdRfihjdbh84hmT-pIkZ6kk1xg2edACdEXt3ikyQ=s320" width="215" /></a></div>Oh, and put the data plate back on:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEjCFi337qJQTFmuRBRIwfGYpqtyU6bUxzrBGsTGpadRa__E_GC21y8sFiDJ4FtRDq5O9Me_3WU6cR4qstRc0PyIOQ34qAgw-ytxmqin4Zw9HrmhOd73uXms1m13ImyPfk_EtBR25bvV3KyM__MGZxCRDKsFSutKKb68O9eFiWnTilb7rNv10z_UnEeFLQ=s1382" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1382" data-original-width="769" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEjCFi337qJQTFmuRBRIwfGYpqtyU6bUxzrBGsTGpadRa__E_GC21y8sFiDJ4FtRDq5O9Me_3WU6cR4qstRc0PyIOQ34qAgw-ytxmqin4Zw9HrmhOd73uXms1m13ImyPfk_EtBR25bvV3KyM__MGZxCRDKsFSutKKb68O9eFiWnTilb7rNv10z_UnEeFLQ=s320" width="178" /></a></div>Happy to have this repair project done!!<br /><br />Thanks for checking out this repair job. Next up, more of the work I've done on the never ending Hardinge CHNC lathe project.<br /><br />Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-4561663675008429701.post-3980041191773477472022-02-20T19:18:00.002-08:002022-02-23T07:02:51.426-08:00Prowler Aviation Blog Update (Dec 2020 - March 2021) - Francis Was Busy !Howdy All !!!<br /><br />As the title indicates, Francis was busy building during this period. Actually, Francis is always busy actively building on their Prowler project. He has been great (for years now) sharing his progress and his accomplishments while building their aircraft.<br /><br />Anyway, during this period of Dec2020 - March 2021, there was not a lot of Prowler related work going on in my shop, or anyone's shop - except Francis. So, the bulk of this update will be based on Francis and his updates to me.<br /><br />Right now, I believe that there are 3 active builder: Francis (France), Eric (Montreal), and Vaughn (Fort Worth). As I said, Francis keeps me pretty up to date on his progress. I don't hear much from Eric. Starting in summer/fall 2020, Vaughn has become really active on his Prowler project. I stay up to date with Vaughn through the phone calls and texts we share in discussing the issues and plans that he has for his Prowler project.<br /><br />In late 2020 and early 2021, Francis was busy putting the skins on the center wing section of the airplane. Here is the area on the lower side of the wing, under the cockpit:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEhNI-SFi2z9l2r5c_iruX_UU_0rjwkYuxFbujdm_i4QqL-G-VMfZC1pGDB83yhBJhu-WAz-KohEntkU_80vSwI-vEGyrIkTgJOv13MHZ6xOOzbF7DHA0fg0jnovSNPhFO1wtFk0PwtpjKnMf00ZgtZDzRKdpaioOEOdE0wlvP8rn1Wn7N4wteSWQO1h0A=s1208" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1096" data-original-width="1208" height="290" src="https://blogger.googleusercontent.com/img/a/AVvXsEhNI-SFi2z9l2r5c_iruX_UU_0rjwkYuxFbujdm_i4QqL-G-VMfZC1pGDB83yhBJhu-WAz-KohEntkU_80vSwI-vEGyrIkTgJOv13MHZ6xOOzbF7DHA0fg0jnovSNPhFO1wtFk0PwtpjKnMf00ZgtZDzRKdpaioOEOdE0wlvP8rn1Wn7N4wteSWQO1h0A=s320" width="320" /></a>
</div>It appears that he has slightly shrunk outer edges of the center panel. Also, note that initially he only had the one central access panel installed. In the next picture, the panel on the lower side of the left wing is being fitted:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEj306eJS5Yd87AFaU1WswWDXhRnC5uSiokQdPO5iJ7_OeazJ5XkyyHK0ZEhtHWwh33W1jvmm1xqJOI1-mEfsjbUvfN1NB0K0wuKAjjEtM2ytu4-BPcVFvVAgwolFQ2JC5_3IlOcxzJgGO85vTFgPMAIQfR6MwFZdQ-IbEfWtU4btARHcXYsRBSZHqv0fg=s1210" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="864" data-original-width="1210" height="228" src="https://blogger.googleusercontent.com/img/a/AVvXsEj306eJS5Yd87AFaU1WswWDXhRnC5uSiokQdPO5iJ7_OeazJ5XkyyHK0ZEhtHWwh33W1jvmm1xqJOI1-mEfsjbUvfN1NB0K0wuKAjjEtM2ytu4-BPcVFvVAgwolFQ2JC5_3IlOcxzJgGO85vTFgPMAIQfR6MwFZdQ-IbEfWtU4btARHcXYsRBSZHqv0fg=s320" width="320" /></a>
</div>What the skin joint looks like a little closer up:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEiRO4ldkLBZhNpoISt5-EXnyWyDVfTcaOD80Tpq3HmYQMT9a4be_QlsAacFjVmn-QPW2rDitdWyIXFWVdbjf5RWVKDsTUISaCHj34kOQMbn4h53cUOugbdEXm3VlA8L5SJLgr342eS7Zj2kwx_XoG5Xq0cUdopo7McLavotmD3GWczi5KndZm2zN_grUg=s1210" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="979" data-original-width="1210" height="259" src="https://blogger.googleusercontent.com/img/a/AVvXsEiRO4ldkLBZhNpoISt5-EXnyWyDVfTcaOD80Tpq3HmYQMT9a4be_QlsAacFjVmn-QPW2rDitdWyIXFWVdbjf5RWVKDsTUISaCHj34kOQMbn4h53cUOugbdEXm3VlA8L5SJLgr342eS7Zj2kwx_XoG5Xq0cUdopo7McLavotmD3GWczi5KndZm2zN_grUg=s320" width="320" /></a></div>Now, more access panels have been added to the center skin to be able to get into each bay under the cockpit floor:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEijCG3cLq3E-4f6R36luSF1JuiiRTzPwdSHIBR4VdgIJOVe-laL7HmuvzpmGHJyxLQTB1IgD0PjV3_FglAQ1aNeuoUZKxQ_XDbmYsjwltz2BWV3PJWg-96AD-xWQmT0K3dpEEtLcwwrFV2cJBxeCG8AfNjab4nt8QfeEUBJUruFs7oApUsIsltmMJiTAw=s1210" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1174" data-original-width="1210" height="310" src="https://blogger.googleusercontent.com/img/a/AVvXsEijCG3cLq3E-4f6R36luSF1JuiiRTzPwdSHIBR4VdgIJOVe-laL7HmuvzpmGHJyxLQTB1IgD0PjV3_FglAQ1aNeuoUZKxQ_XDbmYsjwltz2BWV3PJWg-96AD-xWQmT0K3dpEEtLcwwrFV2cJBxeCG8AfNjab4nt8QfeEUBJUruFs7oApUsIsltmMJiTAw=s320" width="320" /></a></div>At this point, Francis was commissioned to do more work on the Yak-3 that he made the spinner backplate and other parts for in the Nov 2020 update. This time, he was working on the landing gear doors. I beleive he needed to form some fairly thick steel and he needed to "beef up" his english wheel in order to get the job done. Here is the frame stripped down with a new stiff-back added to it:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEhlaY6_i4O4FtXppnimfiddMX8nD78zdNjZDHpIIIPqT3s111ouKAPto0LBgMzJeJ6YajYjg87-6VQB_gf59V77HQtikmEL5OfvDaKCfhiMN4jM2YYoQEeLHDZwC4D1nLhvLx8HgNSY8uk2pHlGcThFlwyJtyJkDwZdRh-8RqVMN5DBqY5_VJ3ZivENLw=s1512" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEhlaY6_i4O4FtXppnimfiddMX8nD78zdNjZDHpIIIPqT3s111ouKAPto0LBgMzJeJ6YajYjg87-6VQB_gf59V77HQtikmEL5OfvDaKCfhiMN4jM2YYoQEeLHDZwC4D1nLhvLx8HgNSY8uk2pHlGcThFlwyJtyJkDwZdRh-8RqVMN5DBqY5_VJ3ZivENLw=s320" width="320" /></a></div>And, here it is with a new paint job and the parts back:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEii8ShtuP1YbFQC9xk1aF6moVwo2sHjyiT5hKLHpYfynjLOOQNaRETvqk6wg54CeQQ65H83ASoieWeoj7XWbp9u_0hBgdjN_S-iDpQcwe9wf5VFbybqmsld08k2mSyXlOn83UmuzNImP951EuXMiFagA7H-ihZiFSrgVIulNLKgR3LwGLoUOf43Aw6z7w=s1512" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEii8ShtuP1YbFQC9xk1aF6moVwo2sHjyiT5hKLHpYfynjLOOQNaRETvqk6wg54CeQQ65H83ASoieWeoj7XWbp9u_0hBgdjN_S-iDpQcwe9wf5VFbybqmsld08k2mSyXlOn83UmuzNImP951EuXMiFagA7H-ihZiFSrgVIulNLKgR3LwGLoUOf43Aw6z7w=s320" width="320" /></a></div>I believe that he used the supped up english wheel to form the steel bracket you see in this pic:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEiQJ2KtoKxwcjQjC9Usk6FDobZQMqXCX6D41Wuj0KosaDcqcyupUjRVbHckUxjrEWn5wr87dUDCbtqPR0mdXF6vHc3qliEWiB1QuIf8PhVrviRgYGeF2HQiHMoD-c4WrRJC2zLl6L7Wt7XPLYMlz_eo9ZGPlGbPy-8s7EuBxzdo3gEAKac-y8MjgdYoAA=s1512" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEiQJ2KtoKxwcjQjC9Usk6FDobZQMqXCX6D41Wuj0KosaDcqcyupUjRVbHckUxjrEWn5wr87dUDCbtqPR0mdXF6vHc3qliEWiB1QuIf8PhVrviRgYGeF2HQiHMoD-c4WrRJC2zLl6L7Wt7XPLYMlz_eo9ZGPlGbPy-8s7EuBxzdo3gEAKac-y8MjgdYoAA=s320" width="320" /></a></div>There are two of these on each door and they got a small tab welded onto them so that the could attach to the gear door operating mechanisms:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEiZIXyuXhKATNEFlVtnWzaL-apZNnXhaj51ID39HhKHDqoRYgH6aJ5pTs4k99WcJqCt4hhEzqQphIldbrIfiLXt6txxlJIBP9fHnc9kB4iDW7pYZ1xRYn4t4RO1nz4CcNl5I_FsgwOKaZfDMR_flvS1YbmAHb0hUSz0cn__AZD-ey_vm2PBsRRJHDLiiQ=s1512" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEiZIXyuXhKATNEFlVtnWzaL-apZNnXhaj51ID39HhKHDqoRYgH6aJ5pTs4k99WcJqCt4hhEzqQphIldbrIfiLXt6txxlJIBP9fHnc9kB4iDW7pYZ1xRYn4t4RO1nz4CcNl5I_FsgwOKaZfDMR_flvS1YbmAHb0hUSz0cn__AZD-ey_vm2PBsRRJHDLiiQ=s320" width="320" /></a></div>I am not sure if Francis fabricated the doors themselves, but I am inclined to think that he did, also, make the doors (they look great - that's the kind of work he does!!). Here's the outsides of the doors:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEh9WiXZ8NK5A_ZSifhE_DaQEQ2Ru9p56LQ7Goey0kuLotYilFzUrlv067CacHtr-ozscxIfcgYAKUBVf1xJvCBiv_JH1LAjPROmXiXP8YNsPbfJqlCn-ieW37DSoxl5Sm5Bj0l47YUYCqFnHKMKcOK7AbYwrkuCJxpzjsm-n6jeGDSaEBTmGCE87nGVww=s1161" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1161" data-original-width="852" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEh9WiXZ8NK5A_ZSifhE_DaQEQ2Ru9p56LQ7Goey0kuLotYilFzUrlv067CacHtr-ozscxIfcgYAKUBVf1xJvCBiv_JH1LAjPROmXiXP8YNsPbfJqlCn-ieW37DSoxl5Sm5Bj0l47YUYCqFnHKMKcOK7AbYwrkuCJxpzjsm-n6jeGDSaEBTmGCE87nGVww=s320" width="235" /></a></div>Looks like everything is primed for paint:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEidJR0jt25tx4Bg-9vD_Ye_uWC5QYU-L2bwmCmCgodDFfHyTFm-iZZW7MIl5Jw_PqXPVYfIpMO6Xx_tM2Z82kZYsersYanIfpk7LWfxJXQ9YboA8-6VUsY52Qs1g0gagNhpNwkp78uM-4ncVHxTAKvE7mZ25RUphpFwSdECaYz7o78Ot87XUeUvAUJU6A=s1181" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1070" data-original-width="1181" height="290" src="https://blogger.googleusercontent.com/img/a/AVvXsEidJR0jt25tx4Bg-9vD_Ye_uWC5QYU-L2bwmCmCgodDFfHyTFm-iZZW7MIl5Jw_PqXPVYfIpMO6Xx_tM2Z82kZYsersYanIfpk7LWfxJXQ9YboA8-6VUsY52Qs1g0gagNhpNwkp78uM-4ncVHxTAKvE7mZ25RUphpFwSdECaYz7o78Ot87XUeUvAUJU6A=s320" width="320" /></a></div>These pictures show a test fitting of the door. It looks like this was done before the primer was put on, so these might have been a little out of order. But, they look great!!<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEhVyDozInZoaor60uled2Z0mpCi7D8NubGizXCmKCdyaQfsh8ol5LKswflA6SL7PWY6eyorJrUEkIYuOsh8S_cJT1nWzjIlUKyxwWOXgu9k0P8Bs5kI5psMLyMilsoZ4-Ho_vrLzZ8ml6QNhekRZ79ErGtSPE9lg4z9_YdDp8ythb_feKLTygim2KuoVA=s1210" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1197" data-original-width="1210" height="317" src="https://blogger.googleusercontent.com/img/a/AVvXsEhVyDozInZoaor60uled2Z0mpCi7D8NubGizXCmKCdyaQfsh8ol5LKswflA6SL7PWY6eyorJrUEkIYuOsh8S_cJT1nWzjIlUKyxwWOXgu9k0P8Bs5kI5psMLyMilsoZ4-Ho_vrLzZ8ml6QNhekRZ79ErGtSPE9lg4z9_YdDp8ythb_feKLTygim2KuoVA=s320" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEhSgbfPBEwyeRdMjs8BRnCgBP8yQXdhVdt6t1KPuHy35dqMH3F3IZwDI2l0Xi04Qiem5zf5rmMZa-2EsPYx6aGgMGJZF155WW2WzWTBswRS2FsADnXGkAFaUfEQ0PW5peKcAnmgdIIrF6nPIPX0sTACHbJ4Z4VGb3asytAHRRZXiew_-eSuWbRQMVdK0g=s1210" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="971" data-original-width="1210" height="257" src="https://blogger.googleusercontent.com/img/a/AVvXsEhSgbfPBEwyeRdMjs8BRnCgBP8yQXdhVdt6t1KPuHy35dqMH3F3IZwDI2l0Xi04Qiem5zf5rmMZa-2EsPYx6aGgMGJZF155WW2WzWTBswRS2FsADnXGkAFaUfEQ0PW5peKcAnmgdIIrF6nPIPX0sTACHbJ4Z4VGb3asytAHRRZXiew_-eSuWbRQMVdK0g=s320" width="320" /></a></div>Nice job, Francis!! You do great work!! I will have more of his Prowler project in another "catch-up" update that is coming soon!<br /><br />That will do it for this blog update. Thanks for checking in!<br /><p></p>Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-4561663675008429701.post-11347725106043336572022-02-19T14:39:00.021-08:002023-12-17T08:53:49.696-08:00DUDE!! IT'S BEEN LIKE....OVER A YEAR!!Hello Everyone,<br /><br />
I must apologize for my lack of Prowler blog updates over the past couple of years. I could blame it on a lot of things, but mostly it's me. In the past, I've always used downtime sitting in a hotel or other time on work trips to type up these blog updates. They do take a fair amount of work to write, insert pics, write captions, spell & grammar check and then publish. <br /><br />So, when I have the time in a hotel with no other good use for the time, it works out great. But, since I haven't been working all that much for most of the past 2 years, I just find it hard to sit down while at home and commit that much time to do the "busy work" of making these blog updates - when I could be out in the shop or working on other projects around the house, yard, property, friends, etc., etc. (It's kinda like when you're a kid and your stuck inside doing homework when you really want to be outside riding your bike!)<br /><br />
Anyway, the past 4-5 months, I've been back to the "day-job" and the daily grind is getting back to mostly pre-CoVid normal. So, I am going to endeavor to get my butt in gear had get you all caught up on what has been going on with Prowler Aviation (and around the shop). I'll try to do these updates in smaller updates and post more of them - to prevent them from getting overly large. I'll also try to do the updates in chronological order when it works. But, I might group some related topics into updates and post it a little out of order - where it makes sense to do that.<br /><br />
To finish out this blog update, I'd like to catch you all up on some family news, both my personal family and the Prowler family. On the personal side, we have reached a new familial milestone. All the kids are officially "out of the house."<br /><br />
I reported on the oldest daughter in the last blog update in Nov 2020 that she purchased her 1st house and the work we did to get her set up there. She is still living happily in Superior, Montana. Last fall she attended Top Tier Academy and got certified as a Pet Dog Trainer, then started her own (new) business called "<span style="background-color: #fce5cd;"><a href="https://www.superior-k9.com/about" target="_blank">Superior K9</a></span>". Things are going pretty well with the new business launch and she is building a great customer base.<br /><br />
The middle daughter is working on finishing her undergraduate degree in Math & Physics at Humboldt College in the Eureka/Arcata area in CA. Early on in her studies, I was able to help her a little with math and physics problems. But, in the last few semesters, I cannot help anymore..... because, now she's smarter than me! She's doing great in a Linear Math class, that I only remember getting a "D" in during my college days. I'm not sure if I should feel old, dumb or bested!?!? Mostly, I think I just feel proud that she is doing so well!<br /><br />
I have also reported on the youngest daughter in the past. She has gotten bitten by the flying bug and has taken up flying as a career choice. I last posted that she had passed her Private Pilot checkride and had started working on her instrument rating. Since that update she has passed her Instrument Rating, Commercial Single, CFI, and Multi-engine Rating checkrides. She has also gotten her tailwheel endorsement and some multi-engine float plane hours. Currently, she is living in Salt Lake City and working as an Instrument Fight Instructor at Randon Aviation located on the South Valley Regional Airport.<br /><br />
So, all the kids are doing great!<br /><br />
Now, for the Prowler family news. There have been a few Prowler kits and airplanes that have changed hands that I have not reported in any blog updates yet. This includes 3 kits and/or aircraft: Kit #8, #13 and #14. <br /><br />
<u><b>Kit #8 - </b></u>This kit has not changed hands recently, but I have only recently "discovered" the location of this kit. The "Kit List" that I got from George many years ago, never had any owner listed for Kit #8. It was only within the past year that in a conversation with Bryan, that I "found" kit #8. It turns out that this kit was owned by Curt Hughes in N.C. You my recognize Curt as the owner of the original Prowler (I refer to it as Kit #01A). In fact, Curt owned the original Prowler and <u><b>two</b></u> additional kits (Kit #7 and Kit #8).<br /><br />
Bryan purchased his kit (Kit #7) from Curt quite some time ago - before we purchased Prowler aviation from George. Well, Bryan always assumed that I knew that Curt owned those two additional kits. I was only aware of the one that Bryan bought from him. So, during a passing conversation one day, Bryan referred to Curt selling the "other kit". Huh!?!? "What other kit," I asked. And, the ensuing discussion "caged my gyro" with respect to Kit #8.<br /><br />
Well, the next logical question that I asked was, "So, who owns Kit #8 now?" Bryan checked with Curt and it turns out that it is now owned by a gentleman in GA. I have not personally contacted the owner of Kit #8 yet - so I don't want to use his name until I know that he's OK with it. But, at least now, I have some contact info for this kit. That leaves only 1 original (George Morse produced) kit that I do not know the location of (Kit #2). It's last known location is Missoula, MT!<br /><br />
<u><b>Kit #13 - </b></u>This kit was most recently owned by Roy in Indiana. This past year, I was contacted several times by Mr. Vaughn Proffitt from Keller, TX asking about this kit, the Prowler airplane and my support. In late 2020, Vaughn and Roy came to an agreement and Vaughn moved the airplane to it's new home in his hangar in the Fort Worth area. In fact, here it is in Vaughn's hangar:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEiXzueON4HGRsNxx-7lTT0jbxygd57Y6CFtKpt6FmHNP66_WXhO2XbHyLm2PqN-k0_VGpnw0hIIw28XYTSTHHBeaDnpMExdP7uT_gLJrY7C_9ELV3IV61WsK-7V-v4ZHiXDQsWgoWTpj2Ern0XFWJb_qXnrBwGmGXm9UafhnLpsAPABCr-tw0cynFwbiA=s2592" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1944" data-original-width="2592" height="240" src="https://blogger.googleusercontent.com/img/a/AVvXsEiXzueON4HGRsNxx-7lTT0jbxygd57Y6CFtKpt6FmHNP66_WXhO2XbHyLm2PqN-k0_VGpnw0hIIw28XYTSTHHBeaDnpMExdP7uT_gLJrY7C_9ELV3IV61WsK-7V-v4ZHiXDQsWgoWTpj2Ern0XFWJb_qXnrBwGmGXm9UafhnLpsAPABCr-tw0cynFwbiA=s320" width="320" /></a>
</div>Since then, I have made several parts for Vaughn. Here is a quick sample:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEgSy6siy0jSSFDgD36wfnguYq0e2eX2hyG7zP0Nvq6A5XebZ_PihlZdXC1vz2GlIik_-rhA-nF15k7z4-r0VGWAuS_GSTa6IFEgFVQFHUIF7AsOYR2We9IiMd-mZBLOXRYqJgMTHWm7-AK_EzeeRRi5vATz4p7B_YnXohE9HtDWE47ewosKIxM4V-K8Pg=s1722" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1722" data-original-width="1394" height="320" src="https://blogger.googleusercontent.com/img/a/AVvXsEgSy6siy0jSSFDgD36wfnguYq0e2eX2hyG7zP0Nvq6A5XebZ_PihlZdXC1vz2GlIik_-rhA-nF15k7z4-r0VGWAuS_GSTa6IFEgFVQFHUIF7AsOYR2We9IiMd-mZBLOXRYqJgMTHWm7-AK_EzeeRRi5vATz4p7B_YnXohE9HtDWE47ewosKIxM4V-K8Pg=s320" width="259" /></a></div>
I will have more info on Vaughn, his project, his plans and the parts I have made for him in the blog updates that I will be working on over the next couple of months. So, look for those in a future update. <br /><br />
<u><b>Kit #14</b></u> - This kit was purchased new from George's Prowler Aviation and was built by Dr. Rogers and his son Steve Rogers in the Anchorage, AK area. At some point, Dr. Rogers lost his medical, gave the airplane to Steve and hired George to move the airplane to Paine Field, north of Seattle in 2006. In fact, here is a picture from that move:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEhOdWhwmg2_GBSO-BYEcEtWgNKWyd0oWIOwy6r-KVsm6bQj6aFnRprJAcBBuSG9jicn-kp3VSPQxLsx249Y_OFWHAyALASI79I4yDa7Zg_k011JGVve8hevLJcknQ3QiTrhsVVN9mBDHeYDqicCvEd0kPEHolnfgbOURLDIavbD4GuBi5XUTMuoWPH5vw=s921" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="551" data-original-width="921" height="191" src="https://blogger.googleusercontent.com/img/a/AVvXsEhOdWhwmg2_GBSO-BYEcEtWgNKWyd0oWIOwy6r-KVsm6bQj6aFnRprJAcBBuSG9jicn-kp3VSPQxLsx249Y_OFWHAyALASI79I4yDa7Zg_k011JGVve8hevLJcknQ3QiTrhsVVN9mBDHeYDqicCvEd0kPEHolnfgbOURLDIavbD4GuBi5XUTMuoWPH5vw=s320" width="320" /></a></div>
I remember when this happened. George told me that he was going to be gone for several weeks on a drive to AK. I didn't even know that this was what he was doing! Steve eventually completed the airplane and the 1st flight from Paine Field was done sometime around 2008 - I believe. Here are some pics from that day:<br />
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I know that Steve hired someone to do this 1st flight. I believe it was someone from the Reid-Hillview airport.
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After that, Steve flew the airplane a few times and worked on it quite a lot. He did PSRU work and designed and built a new oil cooler system to name a few. In the summer of 2019, Steve made a "life" decision and instead of trying to sell his Prowler, he ended up donating it to the Port Townsend Aero Museum in Port Townsend, WA. So, Kit #14 has a new home there. <br /><br />Here is a link: <span style="background-color: #fce5cd;"><span style="color: #fcff01;"><a href="https://ptaeromuseum.com/visit/" target="_blank">Port Townsend Aero Museum</a></span></span><br /><br />The museum intends to do some repairs to the airplane and get it into full flying condition. Then, it will remain on display there. I hope to get up there to check it out, when the airplane is on display, sometime. <br /><br /><span style="background-color: #ffa400;"><< UPDATE: IN 2023 THE PTAM PUT KIT #14 UP FOR SALE. IT WAS PURCHASED BY BRYCE MITCHELL AND MOVED TO THE AUBURN, CA AIRPORT IN NOV 2023.>></span><br /><br />So, that will do it for this update. I will start another blog update as soon as I publish this one and I hope to keep the updates coming every week, or so, until I get you all caught up on the status of Prowler Aviation. Thanks! See you again soon!<br />Unknownnoreply@blogger.com1tag:blogger.com,1999:blog-4561663675008429701.post-65153900034713565412020-11-26T09:27:00.004-08:002022-02-22T07:41:47.187-08:00Year 2020 - What The Hell Happened!?!?Hello Everyone!! And, Happy Thanksgiving!!<br /><br />Well, COVID happened!!! <br /><br />I cannot imagine that there is a person alive in this country, at least not anyone with any cognitive skills at all, that hasn't heard about the Covid (aka: Corona Virus, Covid-19, China Virus, etc.) I also cannot imagine that there is anyone in this country (probably the world) that hasn't been affected by it in some way or other.<br /><br />So, before I go any further let me say that if you have lost anyone close to you because of this virus, please accept my condolences, and condolences from my family and our Prowler family. We are very sorry for your loss. There is no dispute that what this virus does, in the worst case, is tragic and very sad.<br /><br />Next, I will tell you that, so far, my immediate and extended family have been very, very fortunate with regards to Covid. We all know friends, or friends of family, that have had Covid and/or tested positive - but no one has been lost to this thing. That may change, but for now my family and I are very grateful and thankful for this good furtune.<br /><br />Unfortunately, I haven't updated the blog for almost a year!! I have no excuses - just been busy. And, honestly, I haven't had a lot of Prowler news to update on, except for Francis. He continues to be the "Energizer Bunny" of the Prowler building world this year. So, most of this update (Prowler Stuff) will be about his progress. <br /><br />Here is what I have for you in this update:<br /><div style="margin-left: 40px; text-align: left;">
<b><u>Prowler Items</u></b><br />1. The French Prowler Progress<br />2. The Static Display Prowler<br />3. Ruff Cutting Prowler Part Dies<br />4. George's Early Prowler Drawings<br /><b><u>Non-Prowler Items</u></b><br />5. Oldest Daughter Bought Her 1st House<br />6. Youngest Daughter Solo Flight, Then Private Pilot<br />7. New Porch/Deck On The House<br />8. Trailers, Trailers, Trailers<br />9. New Wisconsin Property<br />10. Hardinge CHNC Lathe Progress<br /></div><br />
If you follow my blog, by now you know that my day job is flying for a major US airline. If you follow any business news then you are probably also aware that every US airline has been all but decimated by this Covid thing. My airline's stats for 3rd quarter 2020 showed revenue (money coming in) that is barely 25% of what it was in 2019. After major changes to the airline in the 2nd and 3rd quarters to try to stem the flow - the company's cash burn is still $6M a day as we start the 4th quarter!! It doesn't take a rocket scientist to see that this is not sustainable for too long. You can move the numbers up and down a bit, but every major airline is in the same state - cash burn is far outpacing revenues right now (and has been since late Feb and March of 2020).<br /><br />
The two greatest costs to every airline are fuel and pilots. Depending on what point you look back in history (depending on the cost of a barrel of oil at that time) pilots and fuel trade places for the top cost at any airline. Currently, Covid has also hit the oil industry and fuel costs right now are fairly low. So, if you're an airline looking to cut cash burn as much as possible and fuel is not on top of the list - well, you know what's next. Except, that hasn't happened to a great degree - yet!! Yes, there are some airlines that have sent out furlough notices as of this date, but not in any numbers that match the loss of revenues (75%). I think this is largely for two reasons: 1) Rebound; and 2) Qualification and Currency. These are actually different topics, but they are closely linked.<br />
<br /><u><i>Rebound</i></u> - From the minute the bottom fell out of flying demand in March 2020, the airlines have had their best prognosticators trying to guess when and how demand for flying would return. We've heard about V shaped curves, U shaped curves, W shaped curves, etc., etc. (I personally think it's a check-mark curve [ |/ ] with the very steep drop and wiggly tail to the right that is pretty flat.) But, who knows!?!? The reason this is important is that an airline (as in any business) wants to be there to provide service when there is demand for it, right? So, you don't want to be the "only guy" out there who isn't ready. Ah, but what does it take to be "ready"?<br />
<br /><u><i>Qualification and Currency</i></u> - What it takes to be ready is (very simplistically): an airplane, fuel, and a flight/Inflight crew. A lot of airplanes got parked in the desert this year, and it does take a little while and a little work to get them up and running again. But, it is manageable and not a huge cost. You can get fuel with a phone call. But, your flight crew has to be qualified and CURRENT! Depending on the type of training program at an airline, the crew has to pass a checkride every 6, 9 or 12 months to be qualified (this might also include some OE and line checks). And, every pilot must have had 3 takeoffs and landings in the past 90 days to remain current in that type of aircraft. So, if an airline decided to furlough 75% of its pilots (to match the reduction in revenue) and then the passenger demand for flying suddenly returned - you'd be caught without your ability to provide the service until you get your flight crews re-trained and current - and that takes TIME. In some cases, it can take a long time. That's why you haven't see huge numbers of furloughs at the major airlines - yet.<br />
<br />The point of all this is that most airlines have been trying to come up with creative ways to reduce the cost of keeping pilots around as much as possible - but they are bearing the brunt of the cost of NOT doing widespread furloughs. So, now the airline industry is basically in a situation similar (but for much different reasons) to the late 80's and early 90's where airlines are taking on huge debt and "burning the furniture" to try outlive "the other guy" and be one of the few to survive and be able to provide the airline service to customers when demand returns. It's a cut-throat game. But, "to the victor go the spoils." And, the spoils are sizable -just look at Delta's <u>profits</u> in 2019 ($<u>1B each quarter</u>!!!). That's $1B per quarter left over after you've paid all your payroll, bills, taxes, etc.!! Nice work, if you can get it.<br />
<br />The "creative ways" I mentioned above is what has applied to me for most of this year. My airline started to offer what they call a VIL (Voluntary Incentive Line). What that means is you can volunteer (on a monthly basis) to stay home and get paid 2/3 of your monthly guarantee (base pay check). [That equates to roughly 1/2 of a "normal" paycheck, or even less, depending on how much a given pilot chose to work each month during "normal", "non-Covid" times.] Financially, for me, that was enough to stay afloat and tread water for a while - so, sign me up!! Starting in April this year I was basically "off of work" until just recently (Nov) when I had to head back to the schoolhouse and get re-qualified and re-current. <br /><br />So, what did I do with all this time? Well, unfortunately, not a lot of Prowler related work. I still worked hard, nearly every single day. But, it was a lot of work done to help my kid(s) and to finish some major projects that have been hanging fire around here that are not related to rebuilding Prowler Aviation - as you will see. But, by getting a lot of this stuff off my plate now I'm hoping that when work (the day job) goes back to normal in the future, I'll then have more time to work on Prowler related projects with my days off. <br /><br />On to the update. First, the Prowler stuff - then, the other stuff:<br /><br />
<span style="font-size: large;"><b><u>Prowler Stuff</u></b></span><br /><br /><b><u><span style="font-size: medium;">1. The French Prowler Progress - </span></u></b> Francis is currently the "rockstar" of the Prowler building world. He has been making great progress and sending me lots of updates as he does. I really appreciate him sending me updates with lots of pictures that I can share with you all. (Eric in Montreal is the only other currently active builder that I know of, unfortunately I don't know the status of his Prowler project).<br /><br />Francis started the year finishing his torque boxes. He made the mods to the boxes that Ray designed when he built his torque boxes. Ray added some access ports that he built into the tops of his boxes over the pivot link so that if he ever needed to get in there he would be able. [Turned out, Ray did have a failure in one of torque boxes and he ended up needing to make repairs in each torque box. Good thing he had those acess holes available! I covered this in a previous post,<span style="color: #ffa400;"> <span style="color: #ffa400;"><a href="http://prowleraviation.blogspot.com/2018/11/prowler-aviation-summer-2018-wrap-up.html">Section 2.C here</a>.</span></span>] Anyway, Francis liked this idea and did the same with his torque boxes:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjV0XQ2M8E7DSCIG7PvFzjwg2A8JqCaaAhuZoCyC9WstJAmFTxRqP30z3enLIaaVDSgP0Hy54GgI-muVA3CaTvMQ3fDuF5bm64GQUd9siunxq9p8kQjLVWTpHMb-HSVRSDyxwQ_R8jAA8M9/s1613/20200104_132135.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1613" data-original-width="784" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjV0XQ2M8E7DSCIG7PvFzjwg2A8JqCaaAhuZoCyC9WstJAmFTxRqP30z3enLIaaVDSgP0Hy54GgI-muVA3CaTvMQ3fDuF5bm64GQUd9siunxq9p8kQjLVWTpHMb-HSVRSDyxwQ_R8jAA8M9/s320/20200104_132135.jpg" /><br /></a></div>That looks great! It looks like he has the cover to the torque box access held above with some of the screws in the box access, and the cover hanging by yellow tape is probably the access and cover that will go into the wing skin. (I think I got that right!?!?) <br /><br />In March, Francis turned to working on his forward outboard wing sections (fuel tanks). Here are his wing tanks getting ProSeal and assembled:<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVkjHJDo2QI9ragV4AroP8w4EDOjiKszbzn_XTw0e7B72Irhx5n_QZ5NpVrfO05P8c4wTKUdXLy8zADHT9xWiOjMgRqG0-wx0AfjzQwosYKvSBYLp7mHWps-MdwEMRTHasSZwfwKNcwTrT/s1210/20200414_191344.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="1210" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVkjHJDo2QI9ragV4AroP8w4EDOjiKszbzn_XTw0e7B72Irhx5n_QZ5NpVrfO05P8c4wTKUdXLy8zADHT9xWiOjMgRqG0-wx0AfjzQwosYKvSBYLp7mHWps-MdwEMRTHasSZwfwKNcwTrT/s320/20200414_191344.jpg" /></a></div>Here are the fuel tanks after he got them sealed up and riveted together:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLO9V4juAZsFFpNw7uThYngKgG1C2ka6PWSlWlW-ZTKjm5zwnBdn7bMAm0WcPeYmxmhJNJrRbx9FVSTegQFzNGNYTZ5dL3zQVtY9GowFpIqR3bZf6c6b3IsEk_6_h9tVqVUTutMx342zF5/s1210/20200301_191444.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="1210" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLO9V4juAZsFFpNw7uThYngKgG1C2ka6PWSlWlW-ZTKjm5zwnBdn7bMAm0WcPeYmxmhJNJrRbx9FVSTegQFzNGNYTZ5dL3zQVtY9GowFpIqR3bZf6c6b3IsEk_6_h9tVqVUTutMx342zF5/s320/20200301_191444.jpg" /></a></div>Outstanding!! After getting the tanks together, he realized that he forgot to put the screens on the fuel pick-up lines. So, he had to use a little ingenuity to get them on. Here is one of the screens:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEWYIheDIW3C95F85SiDWHL28z-uh-z4srt8TYQpqn8wVfDEVguQfNpF-OQxRqhw39gLR5GsyPRJs_edC6LZhhcfpKnVXCg96I4rBVtjZS-yBwf6nCpbnr9uky7RurLD9-mEGUdOENj2R4/s1210/20200503_151331.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="1210" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEWYIheDIW3C95F85SiDWHL28z-uh-z4srt8TYQpqn8wVfDEVguQfNpF-OQxRqhw39gLR5GsyPRJs_edC6LZhhcfpKnVXCg96I4rBVtjZS-yBwf6nCpbnr9uky7RurLD9-mEGUdOENj2R4/s320/20200503_151331.jpg" /></a></div>Here is his setup for guiding the screen in place:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJ__0QO9GT3SOmnkJsMD0O1ojJr5ZJPZq4f50E806MN6NklAo2GDirxc9WZAWMcY4LHeaMA2MLnzhHDJn6MntWZVRCV5xbr3ffjg3w3RaBbh3wiIxWehT8tMRNtN0fNCE_6MFa5A7PC-WK/s1210/20200504_140316.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="1210" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJ__0QO9GT3SOmnkJsMD0O1ojJr5ZJPZq4f50E806MN6NklAo2GDirxc9WZAWMcY4LHeaMA2MLnzhHDJn6MntWZVRCV5xbr3ffjg3w3RaBbh3wiIxWehT8tMRNtN0fNCE_6MFa5A7PC-WK/s320/20200504_140316.jpg" /></a></div>And, here is the screen mounted in place and visible from the access hole for the fuel level sending unit:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbUkc3qj42TgONQzruAWna1z0YxTw1r7Ln_6CUFmKdHi68xusXFf_oJrHtwLC0ddGkeKDjZTvxytmH0WAzCbZOplU9t9MYUJCrv75eRKKzCirUTxXzk3F7cTvNH-coexZumU6SaBR0AEoC/s1210/20200504_140552.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="1210" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbUkc3qj42TgONQzruAWna1z0YxTw1r7Ln_6CUFmKdHi68xusXFf_oJrHtwLC0ddGkeKDjZTvxytmH0WAzCbZOplU9t9MYUJCrv75eRKKzCirUTxXzk3F7cTvNH-coexZumU6SaBR0AEoC/s320/20200504_140552.jpg" /></a></div>He must have gotten a clamp around that screen to keep it in place. Nice recovery! After leak testing his tanks, he found a few small ones. Here he is fixing a leak that he found around his tank sump:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQsYj4QPUvLsIkXdeIUkhJo_x8eTOUqcY7VjQFdjz2qxhS9R6nYRJ8xfCdfCYlyTZTLVVzTkBeutmL18_fx1dkYaO1sQdCEDshFVk29Jj-RNeV3QAR-b8axKOUWfU2OBtqESbdVTo7ptdp/s1210/20200521_165635.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="1210" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQsYj4QPUvLsIkXdeIUkhJo_x8eTOUqcY7VjQFdjz2qxhS9R6nYRJ8xfCdfCYlyTZTLVVzTkBeutmL18_fx1dkYaO1sQdCEDshFVk29Jj-RNeV3QAR-b8axKOUWfU2OBtqESbdVTo7ptdp/s320/20200521_165635.jpg" /></a></div>With the outboard wing tanks done, Francis turned to completing the rest of the wings. Here is the wing in June:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi42TPv4x5yFdIgTbPgFGkxizd0n6mBGnJqNMUuELz1l9gjTrHafRxni-JCpdy-uLkruZ9_T-JAj3TpOccrxTzVw0Rx-cmgX-HdpIagIq891v7HVMVM12pX-mu9SjVeGqNCvO751vZGfwrY/s1210/20200608_175219.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="1210" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi42TPv4x5yFdIgTbPgFGkxizd0n6mBGnJqNMUuELz1l9gjTrHafRxni-JCpdy-uLkruZ9_T-JAj3TpOccrxTzVw0Rx-cmgX-HdpIagIq891v7HVMVM12pX-mu9SjVeGqNCvO751vZGfwrY/s320/20200608_175219.jpg" /></a></div>Here he is putting the lower wing skins on:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiarTUGlEGNhy4KYNV45lwBbqBUZwCYvq8q6I_1KM11AXwx1tYNcqAzvA4S5zEhGNqt6tVmy3u513oEsjonL8JKWr4HUVWXX2FhOTDoJV_jDIm_EC60PUVrJd8XzQPiebR_suEUjSLwNhgm/s1512/20200613_162008.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="1512" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiarTUGlEGNhy4KYNV45lwBbqBUZwCYvq8q6I_1KM11AXwx1tYNcqAzvA4S5zEhGNqt6tVmy3u513oEsjonL8JKWr4HUVWXX2FhOTDoJV_jDIm_EC60PUVrJd8XzQPiebR_suEUjSLwNhgm/s320/20200613_162008.jpg" /></a></div>and<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhobIZ3MBP4OYwuW47OhAK2Q5VFc9Y5E1-7Y51xh1it_7Fmt0fr3ZJ3ucLFTMJoKnFQsNHopO1gINEA57A4ziGrfsYEHmi3C3A1HvBQhFeJFROfRHXSZ5jcFHRomcrTC-iPAMJrf1voYu3v/s1210/20200613_182529.jpg" style="margin-left: 1em; margin-right: 1em;">c<img border="0" data-original-height="1210" data-original-width="1210" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhobIZ3MBP4OYwuW47OhAK2Q5VFc9Y5E1-7Y51xh1it_7Fmt0fr3ZJ3ucLFTMJoKnFQsNHopO1gINEA57A4ziGrfsYEHmi3C3A1HvBQhFeJFROfRHXSZ5jcFHRomcrTC-iPAMJrf1voYu3v/s320/20200613_182529.jpg" /></a></div>Note the tool he uses to apply pressure to the wing skin. The long wooden board had foam taped to it and it is hinged off the wing jig on the bottom. At the top the blue strap goes over the top (aft edge) of the wing.<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXu8zkkFxmh01nVJwRAEeTc0EC6g9AZP0HTjDLtqdLNJnOTxC6t6ZMKO9eEOXlvxPVPUpsAvuteOvVylw2MIiabWsGmi-OKqeEPiLWrzM_oJMCiRwqTX2228REnlF8n1dzxfgSHPHBskLm/s1210/20200711_163145.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="1210" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXu8zkkFxmh01nVJwRAEeTc0EC6g9AZP0HTjDLtqdLNJnOTxC6t6ZMKO9eEOXlvxPVPUpsAvuteOvVylw2MIiabWsGmi-OKqeEPiLWrzM_oJMCiRwqTX2228REnlF8n1dzxfgSHPHBskLm/s320/20200711_163145.jpg" /></a></div>With the blue strap, he can pull and apply pressure to the wing skin while working from the top (inside) of the wing:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9NjBKFQv6Rv6EGXeeY64t65OPuR_xL8Yx6DKhgrd0xChyphenhyphen10lv6DqOlNz62LM7h1oS1_x1oDCbgiYv4C_JO3oEMOu1d0KJgPpXzb3Vx5dYa6MtIx9lpSGUBmwZMhKb-qb2ZTjcWZfBY-hd/s1210/20200711_163310.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="1210" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9NjBKFQv6Rv6EGXeeY64t65OPuR_xL8Yx6DKhgrd0xChyphenhyphen10lv6DqOlNz62LM7h1oS1_x1oDCbgiYv4C_JO3oEMOu1d0KJgPpXzb3Vx5dYa6MtIx9lpSGUBmwZMhKb-qb2ZTjcWZfBY-hd/s320/20200711_163310.jpg" /></a></div>Here are the L & R wings with the lower skins completed:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkzrZOZAl96wZGu1sDH9g-X4QonoY5oWufWLmDr5e_U-ikMQk0d8AUzv1GenZJEpGXEx8d84MpGHFJ7AeK5ZvtYwKB1TNToym0QLYDNBBadKt2JybO4_xU1c0dgM2QKsOPBSSK2fAKNNZJ/s1210/20201109_173548.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="1210" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkzrZOZAl96wZGu1sDH9g-X4QonoY5oWufWLmDr5e_U-ikMQk0d8AUzv1GenZJEpGXEx8d84MpGHFJ7AeK5ZvtYwKB1TNToym0QLYDNBBadKt2JybO4_xU1c0dgM2QKsOPBSSK2fAKNNZJ/w320-h320/20201109_173548.jpg" width="320" /></a></div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhOlbz7b2zEZBz9fo0NkiPJU-91iGlzEny775TqRoUWJikw1X3l1veyrKlEfsFRakxBAgafWyzidEVGcmsgBAvFlz5nVwQDFoRdEBwLRUOh0Twyt1J0EKTQ1TvxDKRl9D1VHu_7C4rv4eT1/s1210/20201109_173541.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="1210" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhOlbz7b2zEZBz9fo0NkiPJU-91iGlzEny775TqRoUWJikw1X3l1veyrKlEfsFRakxBAgafWyzidEVGcmsgBAvFlz5nVwQDFoRdEBwLRUOh0Twyt1J0EKTQ1TvxDKRl9D1VHu_7C4rv4eT1/s320/20201109_173541.jpg" /></a></div>In Sept, with the skins mounted, he turned to cutting the holes for the access panels. He used a router with guides made from pieces of thick polyurethane. Here's the router:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkkjxQcxwcQV6b6ludBo9zzcM9W0iLDrtWWEkX5HQUsDZ6Tp1zRVi4EaF5UBzI6pvbM4B-t8J1kFtBMQPoWM2z9PdIh_XJSAAdDgn0v4aP3s9pnoi9CESeetnTDn0TnwyzqzRw-Hs3To__/s1210/20200904_150652.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="1210" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkkjxQcxwcQV6b6ludBo9zzcM9W0iLDrtWWEkX5HQUsDZ6Tp1zRVi4EaF5UBzI6pvbM4B-t8J1kFtBMQPoWM2z9PdIh_XJSAAdDgn0v4aP3s9pnoi9CESeetnTDn0TnwyzqzRw-Hs3To__/s320/20200904_150652.jpg" /></a></div>And, the router guide mounted in place with clecos:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjE6PxMjBIRBjgAh-hHtRxuG8yFUScPZKSgQzZsem1CEBvlbUkDbcPW08hG0ACvT3IMeIhzA1CxYPQW1yfT3NpMsc_gcnHfmoCRwVraZctXF2yuWX82ok4b06P5IMj4jVCLq7UGdXyLpyJG/s1210/20200904_150656.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="1210" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjE6PxMjBIRBjgAh-hHtRxuG8yFUScPZKSgQzZsem1CEBvlbUkDbcPW08hG0ACvT3IMeIhzA1CxYPQW1yfT3NpMsc_gcnHfmoCRwVraZctXF2yuWX82ok4b06P5IMj4jVCLq7UGdXyLpyJG/s320/20200904_150656.jpg" /></a></div>Here is the beginning of one of the hole cuts:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgzaEB6i3-xoSH5vnKgwklj4VwzZepRSNuTZfOrOJcv_XpJA0SgtZmbLeVw-l52x-kiv_OfEhfzhpjVZu6u_nIGr2UIF4O30EKLxym_lXd-EvXM8qm-LcZ6IsKgCkO1q7DjfGnje9rdx98/s1210/20200904_150710.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="1210" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgzaEB6i3-xoSH5vnKgwklj4VwzZepRSNuTZfOrOJcv_XpJA0SgtZmbLeVw-l52x-kiv_OfEhfzhpjVZu6u_nIGr2UIF4O30EKLxym_lXd-EvXM8qm-LcZ6IsKgCkO1q7DjfGnje9rdx98/s320/20200904_150710.jpg" /></a></div>I believe that this is a pic (below) of an access hole that he is locating to put in the wing skin. I believe that he mounted the access cover with the two clecos on the inside and then centered/placed the red guide around the access cover panel. Then, he installed the clecos all around the guide to hold it in place while using the router to cut it out:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWGNunI7vinR8GF5nDLhSNSXisvRJyUV-rHt4WLBLDZyxsLHp-Z3K9Kcr9vhdkcx5foPw8gfksUTROdwW1AwHK7ydmVxR2WA2KxMjKVj1Ko8FfxRM8U2_UFQthWRzpb0It8Ikgv2Pn6VeD/s1210/20200904_144821.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="1210" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWGNunI7vinR8GF5nDLhSNSXisvRJyUV-rHt4WLBLDZyxsLHp-Z3K9Kcr9vhdkcx5foPw8gfksUTROdwW1AwHK7ydmVxR2WA2KxMjKVj1Ko8FfxRM8U2_UFQthWRzpb0It8Ikgv2Pn6VeD/s320/20200904_144821.jpg" /></a></div>Here are a few pics of the doublers under the wing skins and panels in place from the other side:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPZdaX7lK8EKdTH4iW5d231_Af_wiqoNMEhVz0LypZfWXBk2NLfVIKhCl8XDUtsB-9Zy6yRi_7P1rvtWTtmCGK8ibunctU1FEIGe6ZVBDMSqbXLBsD22JrBsnGBl3NDzrPfeNaHBv3lJpD/s1210/20200725_171807.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="1210" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPZdaX7lK8EKdTH4iW5d231_Af_wiqoNMEhVz0LypZfWXBk2NLfVIKhCl8XDUtsB-9Zy6yRi_7P1rvtWTtmCGK8ibunctU1FEIGe6ZVBDMSqbXLBsD22JrBsnGBl3NDzrPfeNaHBv3lJpD/s320/20200725_171807.jpg" /></a></div>And, the outside:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFe7mL_kLyD0MJpmY1FuZB2dt6TgZ7CqDHDjHyAKNL0BgAufF0cEtCy1CL4FIk1Yyjx7NwRM5V8Fy2Wf9THosL-iZUQKjfEbQbjIXb4GF26CXHS7ADKKLp5_aClBy5aeZI5UuXRHYnIgyS/s1210/20200725_171753.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="1210" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFe7mL_kLyD0MJpmY1FuZB2dt6TgZ7CqDHDjHyAKNL0BgAufF0cEtCy1CL4FIk1Yyjx7NwRM5V8Fy2Wf9THosL-iZUQKjfEbQbjIXb4GF26CXHS7ADKKLp5_aClBy5aeZI5UuXRHYnIgyS/s320/20200725_171753.jpg" /></a></div>Here are a few pics of another circular access hole being cut and the subsequent perfect hole:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbrp0GGXrIPWQ1KqIazqHK5iBvMV7Vtlj8YBUAyQ3KlMABSWDcVXbjT-T6OjL9j6g46YF38_1uj6bufykio9i_7DBZXsmGwjFBGubulxeNIENmf-doI5nnmOsaqRZpQEoDnCh6h_jzuQ5Q/s1210/20201010_175646.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="1210" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbrp0GGXrIPWQ1KqIazqHK5iBvMV7Vtlj8YBUAyQ3KlMABSWDcVXbjT-T6OjL9j6g46YF38_1uj6bufykio9i_7DBZXsmGwjFBGubulxeNIENmf-doI5nnmOsaqRZpQEoDnCh6h_jzuQ5Q/s320/20201010_175646.jpg" /></a></div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5_9FkFD2T6liSoZKYqGmUkEMiVGWP3tdtruehvaPQ140QRHyUBwq2I_BUIFHK_3daAaUUYHReUApuXlL04o6ja0CXiQjO_mttxxXZpgJ5v_xqVNk_Q-uYAvicNn9FIneLBp1pEDkhqbca/s1210/20201010_145427.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="1210" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5_9FkFD2T6liSoZKYqGmUkEMiVGWP3tdtruehvaPQ140QRHyUBwq2I_BUIFHK_3daAaUUYHReUApuXlL04o6ja0CXiQjO_mttxxXZpgJ5v_xqVNk_Q-uYAvicNn9FIneLBp1pEDkhqbca/s320/20201010_145427.jpg" /></a></div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNdFV1n266Eo6jMPp-H0HM6miSPq629iiriyQmiX2bX8n8o1yw4SIFd37wc6rR2ghx7-_nZ9bmbdwqdF6Wo3zi-lPGtTo2m5GLwPS8XLMrCf3hqyc8KccRn43QvUmly4Hdh8h6fPQ0aKIa/s1210/20201010_145417.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="1210" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNdFV1n266Eo6jMPp-H0HM6miSPq629iiriyQmiX2bX8n8o1yw4SIFd37wc6rR2ghx7-_nZ9bmbdwqdF6Wo3zi-lPGtTo2m5GLwPS8XLMrCf3hqyc8KccRn43QvUmly4Hdh8h6fPQ0aKIa/s320/20201010_145417.jpg" /></a></div>Here are more pics of the skins with the access panels:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_dN3vw-sg16SxqvyjHCB9HwCvsrMyj2HepLCNZBWjjorogPB8wmwf2fscyrC2TpU0_m_ElRHDttVESLkVWLJ1vXZJnvdlfyD8KNGRl-qw4AoFhL9lwbyEo0paKqKmTdTXCc5YrIDfTMgU/s1210/20200911_170438.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="1210" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_dN3vw-sg16SxqvyjHCB9HwCvsrMyj2HepLCNZBWjjorogPB8wmwf2fscyrC2TpU0_m_ElRHDttVESLkVWLJ1vXZJnvdlfyD8KNGRl-qw4AoFhL9lwbyEo0paKqKmTdTXCc5YrIDfTMgU/s320/20200911_170438.jpg" /></a></div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjH6l0RY1fzcW-lPtVDPMxdlbnx7rXhqRLXqv2tOksopcTaXcIKN4s1oXwpihye7_EsFIIdetWnxTQGgp9x0K4deZSzS_G0hEMuulAy6MoNzQ_wSE1LuTXS5D620Fw3RST0kF2uadBeoNJJ/s1210/20200911_170430.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="1210" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjH6l0RY1fzcW-lPtVDPMxdlbnx7rXhqRLXqv2tOksopcTaXcIKN4s1oXwpihye7_EsFIIdetWnxTQGgp9x0K4deZSzS_G0hEMuulAy6MoNzQ_wSE1LuTXS5D620Fw3RST0kF2uadBeoNJJ/s320/20200911_170430.jpg" /></a></div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRtYFremsx7AmvBV0v5YiqUIsigWJjgfBMhbTO-qvXnKp4UdyI2UILxaQVHC28TK_UYsjTWipw8Kn5ZP1QSoi8-gTlJoHpBU6NYs0kypiJA1SmlQ3QM3qzoL_vzx7fjm8J7-aHDNKOi6Ci/s1210/20201031_175737.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="1210" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRtYFremsx7AmvBV0v5YiqUIsigWJjgfBMhbTO-qvXnKp4UdyI2UILxaQVHC28TK_UYsjTWipw8Kn5ZP1QSoi8-gTlJoHpBU6NYs0kypiJA1SmlQ3QM3qzoL_vzx7fjm8J7-aHDNKOi6Ci/s320/20201031_175737.jpg" /></a></div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0W_sslbly1hRKwoDX_i-INJcFdsLByWQed8AnC_VEvVuNr6oKkXqnLeziRKRXznbGD51aYFg8MQD9x9R6erY0KD5_aLFodQTCLzvgy9k6L37cgkVlIZEaLmnXoSyFAaySuYh2lyd5gtwQ/s1210/20201030_145531.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="1210" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0W_sslbly1hRKwoDX_i-INJcFdsLByWQed8AnC_VEvVuNr6oKkXqnLeziRKRXznbGD51aYFg8MQD9x9R6erY0KD5_aLFodQTCLzvgy9k6L37cgkVlIZEaLmnXoSyFAaySuYh2lyd5gtwQ/s320/20201030_145531.jpg" /></a></div>Awesome work, Francis!! <br /><br />As if all of that were not enough, Francis picked up some side work this year helping the owner of a Yak-3 aircraft to get the airplane flying again. In his email, Francis said that the owner asked him to do some welding and riveting on the spinner and backing plate. Here are a few pics of the work in progress:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEij2kvMtBoQKYATnEFNJlfQ1D5jRuG6qcKz0_9uhij7zoe3Wf7568JmsNpZX0k7QDnFDaMn1rTaMqkvsWfue1s7-y-ckndveQIhRMd3MOZIFtunY9UkvO8Hn1h56YphxLkFITtG7RXccy/s1083/20200705_143002.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1059" data-original-width="1083" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEij2kvMtBoQKYATnEFNJlfQ1D5jRuG6qcKz0_9uhij7zoe3Wf7568JmsNpZX0k7QDnFDaMn1rTaMqkvsWfue1s7-y-ckndveQIhRMd3MOZIFtunY9UkvO8Hn1h56YphxLkFITtG7RXccy/s320/20200705_143002.jpg" width="320" /></a></div>The inside:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAOv4vxbQ4_VFi9TUMTIALMZf0HyjADYTjAh8lPRYJh1MLXdJ3BDx48W-TgFNCsSbyeq56H4AoG1RHOepFqnRBKYlb5PCqwR24BT_2CsFkZig5CbCsG6Rbmv0VmN_DKKtpnHc9yhlqSiO3/s1059/20200705_143229.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1059" data-original-width="1059" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAOv4vxbQ4_VFi9TUMTIALMZf0HyjADYTjAh8lPRYJh1MLXdJ3BDx48W-TgFNCsSbyeq56H4AoG1RHOepFqnRBKYlb5PCqwR24BT_2CsFkZig5CbCsG6Rbmv0VmN_DKKtpnHc9yhlqSiO3/s320/20200705_143229.jpg" /></a></div>The finished spinner:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEin5a17okrTSJ7o7-K3xItNI4V80PdbAEO1dsi-FeemA0oxauiyKForEClfIMpGg6yBSC8bQoDOQqZ3_YC8H1uATq_jVTU93WNH3uDfXHwiyunmzVrDHEya9inVnnzv-9PpGgJexxuo8EZp/s1059/20200707_163628.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1059" data-original-width="1059" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEin5a17okrTSJ7o7-K3xItNI4V80PdbAEO1dsi-FeemA0oxauiyKForEClfIMpGg6yBSC8bQoDOQqZ3_YC8H1uATq_jVTU93WNH3uDfXHwiyunmzVrDHEya9inVnnzv-9PpGgJexxuo8EZp/s320/20200707_163628.jpg" /></a></div>and backing ring:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRdeyGBzQVLQ47ZlLMm2mgmT5tGj6g8UGdz4otrvo4rTOzqVW6wm9A4lJBAJ4nEnIfo5xR9iaF_l-1kl8RZxemLW5UwnjslCwn6X4W8nflbOEzWYKELa5nADQ_Mi6IC9KURtRZij8r7fnt/s1059/20200707_163631.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1059" data-original-width="1059" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRdeyGBzQVLQ47ZlLMm2mgmT5tGj6g8UGdz4otrvo4rTOzqVW6wm9A4lJBAJ4nEnIfo5xR9iaF_l-1kl8RZxemLW5UwnjslCwn6X4W8nflbOEzWYKELa5nADQ_Mi6IC9KURtRZij8r7fnt/s320/20200707_163631.jpg" /></a></div>Here is the finished product in flight:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJ9nL6FytyRC77GnsmrUSmkJ7OGCaT__vnTvQZ6GfUOdV0JO34I_7GcFkJYdUOTAYBmxhQ_R0PPBJsq1DdjCAb8L8iAtwYefveRm2Mn9cAidBaB52fndttQgc4753SyKjBLU-voKvGzSfW/s1600/IMG-20200913-WA0002.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1067" data-original-width="1600" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJ9nL6FytyRC77GnsmrUSmkJ7OGCaT__vnTvQZ6GfUOdV0JO34I_7GcFkJYdUOTAYBmxhQ_R0PPBJsq1DdjCAb8L8iAtwYefveRm2Mn9cAidBaB52fndttQgc4753SyKjBLU-voKvGzSfW/s320/IMG-20200913-WA0002.jpg" width="320" /></a></div>Well done, sir!! That is awesome that you can say that you played a part in restoring that beautiful aircraft.<br /><br />
<span style="font-size: medium;"><b><u>2. The Static Display Prowler -</u></b></span> Well, I've had this Prowler sitting in my yard on wing jacks for a couple years now:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTLLdN43ctMfMfNXWOqnvpLIe6Bl3exi8wQ-jiFljDRUdguuZ63dIn_YqnjVo2zThgoZVONPr3Qlmy16vN1D2IRKANmzvbYey-lsS6CFfShz1zgNrw-jw2gVR6B555CeZxsM1o_S3JvVEc/s1203/IMG_20181019_182514.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1203" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTLLdN43ctMfMfNXWOqnvpLIe6Bl3exi8wQ-jiFljDRUdguuZ63dIn_YqnjVo2zThgoZVONPr3Qlmy16vN1D2IRKANmzvbYey-lsS6CFfShz1zgNrw-jw2gVR6B555CeZxsM1o_S3JvVEc/s320/IMG_20181019_182514.jpg" width="320" /></a></div>I want to have a way to get ahold of this thing so that it can be mounted on a trailer, or a stand, or even a pole. After thinking it over for a while, I decided that the brackets that attach the MLG hydraulic actuator to the spar are held by 6 bolts through the main spar caps. Since the static display won't have landing gear, this might be a good place to grab a hold of the main spar for mounting hardware.<br /><br />I happened to be in HFT one day and saw that their hitch receivers are not real expensive and are heavy duty enough to hold the weight of the airframe - a couple of times over. That should be a satisfactory safety margin! So, I found some 3/8" steel plate and cut them into shapes that will cover the 6 mounting holes:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8k1Jyu-oZKGolh2kbuSoZNZW_T_sQQCevHJcaV-BWJuyBwjwmFoXGG-rmdGj2Mjb1xtsU99Yf7xmnB3Gl8JsRfd1l9gglfWKKrAJBJGLBOWI03knBJjbt2nUIimdFSm0uzEI76LJCdxia/s2302/20200621_165139%257E2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1123" data-original-width="2302" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8k1Jyu-oZKGolh2kbuSoZNZW_T_sQQCevHJcaV-BWJuyBwjwmFoXGG-rmdGj2Mjb1xtsU99Yf7xmnB3Gl8JsRfd1l9gglfWKKrAJBJGLBOWI03knBJjbt2nUIimdFSm0uzEI76LJCdxia/s320/20200621_165139%257E2.jpg" width="320" /></a></div>Then, figured out the angles so that the hitch receivers will be perpendicular to the cockpit floor and mounted them to the plates:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixCp6iDnj0TY1td8Y1i1CQBfz5CnpSa84KortI5IXHm7aFjyOa4ug7FQoJg1pEaHghlBf53AAraOw10ErbbpT_taxrjUgJt7TVfYZmAbWLgUILnu0RPovmdrMIm6ntxmxhXbL29uMA_Cbr/s1976/20200622_204856%257E2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1269" data-original-width="1976" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixCp6iDnj0TY1td8Y1i1CQBfz5CnpSa84KortI5IXHm7aFjyOa4ug7FQoJg1pEaHghlBf53AAraOw10ErbbpT_taxrjUgJt7TVfYZmAbWLgUILnu0RPovmdrMIm6ntxmxhXbL29uMA_Cbr/s320/20200622_204856%257E2.jpg" width="320" /></a></div>I had to open the holes for 5/16" bolts thru the spar caps, cut away some wing skin and then test fit the mounts. Here's the left wing:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigqP25kjFS_rZ2MvL9jt0J1GJZjuQ-UlMLOkiyMi-2jmCNsis_Djm8S9C6-hRM8F_e46ZPR41DzBH0c1i3XnHgLoBr68Dz3Ft5o0SXT_tdg5vRAcW2C_sLKVKGJrX7AXeXLjArUoz8pxP3/s2048/20200624_160526.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2048" data-original-width="1152" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigqP25kjFS_rZ2MvL9jt0J1GJZjuQ-UlMLOkiyMi-2jmCNsis_Djm8S9C6-hRM8F_e46ZPR41DzBH0c1i3XnHgLoBr68Dz3Ft5o0SXT_tdg5vRAcW2C_sLKVKGJrX7AXeXLjArUoz8pxP3/s320/20200624_160526.jpg" /></a></div>And the right wing:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmoucDlsaxzhSCMuHEL6s-EhjwXxByPaRxVlhQr8ml98Pb4p9733NAhR2W4kFHxWWw7Zuk7z0jIWfnsHH4qX2KaVsO22Q_WIKKoDk9dAsGe3n7zXGckqfqQV232Q5vSVj6l__ipn2rK2eO/s2048/20200624_160519.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2048" data-original-width="1152" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmoucDlsaxzhSCMuHEL6s-EhjwXxByPaRxVlhQr8ml98Pb4p9733NAhR2W4kFHxWWw7Zuk7z0jIWfnsHH4qX2KaVsO22Q_WIKKoDk9dAsGe3n7zXGckqfqQV232Q5vSVj6l__ipn2rK2eO/s320/20200624_160519.jpg" /></a></div>Here's what both mounts look like installed in place:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrCbESWSgBk2xixvLk0atab9gci6QRliglRmyS5f5ApwYvGZ0R3HfPVvmJ5ahtFvdYMd5eSIBbTviX-LGfKtIcDm2mQKPcZiWue-lUoIc7g9lcQdmD78y6WpjUUVEvbOlCh1OrHb4EMLnY/s2048/20200624_164030.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1152" data-original-width="2048" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrCbESWSgBk2xixvLk0atab9gci6QRliglRmyS5f5ApwYvGZ0R3HfPVvmJ5ahtFvdYMd5eSIBbTviX-LGfKtIcDm2mQKPcZiWue-lUoIc7g9lcQdmD78y6WpjUUVEvbOlCh1OrHb4EMLnY/s320/20200624_164030.jpg" width="320" /></a></div>The next step will be to find a good place and fabricate a 3rd mount that attaches to the fuselage aft of the cockpit. With three mounting points on the airplane, I'll fabricate a stand that can be secured to a trailer. Then, the plane can be dropped onto the mount points on the trailer for moving, etc. More to follow.<br /> <br />
<span style="font-size: medium;"><u><b>3. Ruff Cutting Prowler Part Dies - </b></u></span> Recently, I have begun managing the process of making a large number of dies (form blocks) for making Prowler parts. I started cutting what dies I could with the 1" thick aluminum bar stock that I had in the shop. Here is the ruff cut set of the largest mid ribs from the center wing section (just outboard of, and below, the cockpit walls):
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtcnK2gTINzuiwtZigXtAuBh2_0yihvKFk9QWiaFYYz5sDiFybz7HasKit2CgayG761FrF6aEfxMZAodQx2Ghh90ztsS6hymJoJStFJd7JU0JqFGdechXsW9yb-XsD1tUQ0UWezAQ9xo2w/s1325/20201120_183454283.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="819" data-original-width="1325" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtcnK2gTINzuiwtZigXtAuBh2_0yihvKFk9QWiaFYYz5sDiFybz7HasKit2CgayG761FrF6aEfxMZAodQx2Ghh90ztsS6hymJoJStFJd7JU0JqFGdechXsW9yb-XsD1tUQ0UWezAQ9xo2w/s320/20201120_183454283.jpg" width="320" /></a></div>(There is also an aluminum die stock under the wood pattern above.) This is a set of center section wing nose ribs:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5eh0UaNj0udiHDjVdvX5-3Q7T8DDoMKnulDp-IfDizu_6ZA2-HZbfwTWhH2Pq_mR0EGpEqYncPTnB23A5Jzs0R98wEo2JbBBzYtb0y0x6mUxniD7p0DzByT3tzKAoGSd4FSYVmLOKejWy/s975/20201120_183430545.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="780" data-original-width="975" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5eh0UaNj0udiHDjVdvX5-3Q7T8DDoMKnulDp-IfDizu_6ZA2-HZbfwTWhH2Pq_mR0EGpEqYncPTnB23A5Jzs0R98wEo2JbBBzYtb0y0x6mUxniD7p0DzByT3tzKAoGSd4FSYVmLOKejWy/s320/20201120_183430545.jpg" width="320" /></a></div>Remember, because of the forming technique I'm using, even though it's the same part, I have to make separate dies for the L wing and the R wing. This essentially doubles the die count and the associated machining and work to make each die!<br /><br />Here is the current stack of ruff cut dies waiting to get machined so that they can make Prowler parts:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj259ziqDez2tlxUYCoYUHPsxg8zWUMbhoUgj2IxHg7toiSIy6uEOc2_F8HEKi-FMnw2vA1sERxEYm8jQM56ZsWSs7ZUJtroxYLKepPIrtQ6F6CX0EPMvMVPtfda7IHp4G1cSHBqJsI3xfQ/s948/20201120_185249178.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="824" data-original-width="948" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj259ziqDez2tlxUYCoYUHPsxg8zWUMbhoUgj2IxHg7toiSIy6uEOc2_F8HEKi-FMnw2vA1sERxEYm8jQM56ZsWSs7ZUJtroxYLKepPIrtQ6F6CX0EPMvMVPtfda7IHp4G1cSHBqJsI3xfQ/s320/20201120_185249178.jpg" width="320" /></a></div> When I ran out of pieces large enough to cut the dies I wanted to ruff cut next, it became obvious that I was going to need to get more 1" aluminum stock. Buying more 1" aluminum bar is a somewhat expensive endeavor, so I set out to make a list of all the dies that I have left to make. Once I had the list, I had to figure out the overall dimensions of each part so that I could buy stock large enough. For example, here are 4 wing bulkheads that I need to make dies for and each one has to make a LH wing and a RH wing part. So, I'll need enough stock to make 8 dies from these 4 patterns and 6" wide stock will work:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxQ3UMpqDPQfKpMflyHmbMreQ82JvQLaU2YlBBk1AMmr7lDs9KRsSZYv-Mmtl6FphJDrYKTlVjF03BPI4fdL9D5dRAQU5b_g_CCNV8RBfU7Qck4_2BAZlPbZUOFD6lFRh2yaWPtmYeVI6Q/s1596/20201120_184902904.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="683" data-original-width="1596" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxQ3UMpqDPQfKpMflyHmbMreQ82JvQLaU2YlBBk1AMmr7lDs9KRsSZYv-Mmtl6FphJDrYKTlVjF03BPI4fdL9D5dRAQU5b_g_CCNV8RBfU7Qck4_2BAZlPbZUOFD6lFRh2yaWPtmYeVI6Q/s320/20201120_184902904.jpg" width="320" /></a></div>I also had to try to figure out the most efficient way to place the dies on each piece of stock to get the least amount of waste. Throwing big chunks of aluminum that I'm buying for $2.50/lb into the recycling bin that gets me $0.22/lb is not a super appealing proposition.<br /><br />Anyway, what I came up with was a list of 60 dies that will make the majority of the large parts that need to be formed for the wings and the fuselage. (Later on, there will be many smaller parts in the various sub-kits of the airplane that I will be able to make using a die and the press, but this current list will get the bulk of the wing and the fuselage finished). <br /><br />As of right now, I have 17 of the 60 dies already completed (mostly outboard nose rib dies). Added to
that, I have 14 of the 60 dies ruff cut and ready to start machining.
That leaves 29 dies that I still need get stock for and to ruff cut. Last week, I placed an order for 2 bars of 1"x6"x12' aluminum; and 2 bars of 1"x8"x12' aluminum (almost 400 lbs). These 4 sticks got here yesterday. Here they are in the shop:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEho1W_pYyxGm_w9W-CtBOmdoe6gmk4P5MOORXImDHD5HxbTmgfWmrzksrAULHmmLu9cZWLlILIjcDFWBqo4vj1is1Klk4d5SsNUdYz97hfrczA_jJpORvt-1mbUMRiI0ZpCdAK6ndVx3nKv/s1014/20201124_230441550.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="691" data-original-width="1014" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEho1W_pYyxGm_w9W-CtBOmdoe6gmk4P5MOORXImDHD5HxbTmgfWmrzksrAULHmmLu9cZWLlILIjcDFWBqo4vj1is1Klk4d5SsNUdYz97hfrczA_jJpORvt-1mbUMRiI0ZpCdAK6ndVx3nKv/s320/20201124_230441550.jpg" width="320" /></a></div>Next week, I'm going to get to cutting these sticks up and getting the remaining 29 dies on the list ruff cut and on the stack.<br /><br />Now for some quick machinist math. I have 42 dies left to machine just for the wing and aft fuselage. Assuming that I have all of the computer work done to convert the CAD drawings for each of these dies into files that the milling machine can use to cut the dies, I can usually get one large die done per day. [As a side bar: For each die, it usually takes me about a 1/2 day to get the cut files processed, written, tested and ready for the mill to start cutting. I can get a lot of this done while I'm working the day job and sitting around in hotel rooms, etc. But, the testing has to be done in the shop at the machine.] As I get more proficient at cutting these things, I could possibly cut 2 smaller dies done in one day. <br /><br />That means I'm probably looking at a minimum of 35-40 days of machine work to get these dies all made. With my normal work schedule at the day job, I can usually get 1 or 2 days a week in the shop. That means I could get roughly 4-6 dies made per month. At that rate, I'm thinking it will take 10-12 months to get all these made (in ideal conditions). Ugh!! It's going to be a long haul. Well, it will give my bank account time to recover from the aluminum purchase! Ha!<br /><br />
<span style="font-size: medium;"><b><u>4. George's Early Prowler Drawings -</u></b></span> In my last update, I posted about 3 drawings that I found that I believe were George's hand-drawn early concepts of the Prowler. At that time I had finished framing two of the drawings, but still had one left to find a frame for. Again, this was the first one I did using an "off the shelf" frame from Hobby Lobby:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYAEBFqMk_MbbYa5e2z2GdbbENpaFaJob5wR_3e97UEJbTE0_P7V_G-BJcy0N9NCnmdURrrPSody0Shd4vKIwUzn6wrUG6neNy0_aBspOQPNW7rxk9RmgFZG6Lic7UW4GJl9Ev4qJ-Ocjj/s1517/20191214_212623%257E2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1148" data-original-width="1517" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYAEBFqMk_MbbYa5e2z2GdbbENpaFaJob5wR_3e97UEJbTE0_P7V_G-BJcy0N9NCnmdURrrPSody0Shd4vKIwUzn6wrUG6neNy0_aBspOQPNW7rxk9RmgFZG6Lic7UW4GJl9Ev4qJ-Ocjj/s320/20191214_212623%257E2.jpg" width="320" /></a></div>
And, this was one that I built a frame for using a large canvas frame from Hobby Lobby and Lexan from HD:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzMoI-k7RrmyaXI1KrstfVNIAW4_inEN7sZzM8q0tn_cStj0ccHZs4WROGW5R2jK59xgWwJqAP4PFjyDjM7bAk7gNjolQ9czPDKf1G4i_G3bzgTys5GcaUr8uOVttZZOxkq9rjK-3TGB2Y/s1616/20191219_182313%257E2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1616" data-original-width="1387" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzMoI-k7RrmyaXI1KrstfVNIAW4_inEN7sZzM8q0tn_cStj0ccHZs4WROGW5R2jK59xgWwJqAP4PFjyDjM7bAk7gNjolQ9czPDKf1G4i_G3bzgTys5GcaUr8uOVttZZOxkq9rjK-3TGB2Y/s320/20191219_182313%257E2.jpg" /></a></div>
The final drawing was also pretty large, and I found an online website that you can order any size frame you want and they make it and ship it to you. This was a metal frame and it worked really well and was not hugely expensive. It turned out pretty well:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjeVxfbXpXlX7IXtpg6IrNg_GAw7Juxv1zfexNDZvXC7mz5qqzWCZQKcPizy7Y45TeSxggTzGdrPeTKaOjv_PM74BZOH1YjfV7k-2CdU5E3wIuiP3oMg3z9IAa17fcvffIqUToosZaR14nB/s1610/20201115_165949430%257E2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="797" data-original-width="1610" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjeVxfbXpXlX7IXtpg6IrNg_GAw7Juxv1zfexNDZvXC7mz5qqzWCZQKcPizy7Y45TeSxggTzGdrPeTKaOjv_PM74BZOH1YjfV7k-2CdU5E3wIuiP3oMg3z9IAa17fcvffIqUToosZaR14nB/s320/20201115_165949430%257E2.jpg" width="320" /></a></div>Sorry about the weird angle of this picture. I had to take the picture that way to avoid the glare and reflections from the natural light from the windows. Anyway, they are now all hanging on the office wall of my shop and look great!<br /><br />
<span style="font-size: large;"><b><u>Non-Prowler Items</u></b><br /></span><br />
<u><b><span style="font-size: medium;">5. Oldest Daughter Bought Her 1st House -</span></b></u> After graduating from Univ. of Montana last year, our oldest daughter got a job working for the State of Montana. She discovered the USDA - Rural Development program and got pre-qualified for a home loan. She searched long and hard and just before the pre-qualification was due to expire, found a home for sale that met most of her important requirements. She and her realtor made an offer and it was accepted! It is a 40 year old manufactured home in pretty good condition, but needed some work. It came on a lot and a half in a small town called Superior, MT and it also came with a small guesthouse and a nice sized shop! Here is a pic from the property listing:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpqTnujyu5FDLCqB-lH1Fe-2jZ16EWQuYWfmDSJu5I6CHDA7qr0Sp7-CXWfZrytIH5yKOUx4DxTU-TO4fa1RdCREHs9KrDb8QJ1hDqNNvA7GBtQqgwi727QfvFlabaOmEtLGK7-w8whHdn/s1536/1.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1152" data-original-width="1536" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpqTnujyu5FDLCqB-lH1Fe-2jZ16EWQuYWfmDSJu5I6CHDA7qr0Sp7-CXWfZrytIH5yKOUx4DxTU-TO4fa1RdCREHs9KrDb8QJ1hDqNNvA7GBtQqgwi727QfvFlabaOmEtLGK7-w8whHdn/s320/1.jpg" width="320" /></a></div>While waiting for escrow to close, we started making a plan for things that she was going to need. I/we starting collecting things around here that Kayla could use in her new place and we didn't need any longer, or we had more than one of. There was a lot on the list, fridge, dryer, beds - you know, the usual stuff. In addition to the normal stuff, if I was going to be able to help her fix the place up, we would need hand tools, work benches, table saw, ladders, wheelbarrow, air compressor, etc., etc. It became obvious that I was going to have a trailer full of stuff to bring up there!<br /><br />She also discussed wanting to be able to keep her horse there in the back yard, but was going to need a shelter for it. [She checked with the county and the laws do allow "riding stock" to be kept in residential areas.] I had some old steel pallet rack frames laying around that I scavenged from somewhere. I thought that they would work and I fabricated them into a steel frame that would make a shelter. By pre-assembling it in the shop, it could go together fairly quickly at her place and then all we would have to do is find boards to mount on three sides. After several day's worth of cutting and welding, here is what I came up with:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhlYIbhs9mlpCqh5n76vN5Y2479eSaWoCo3V_nMaUBt3xVcDBxnP4muSTIlAIFUJ8JYncNCKpVtXkeW5q1733Xtbon8ML7eNKPRCwB1Vv8l_Nuz5x7AZwVYHwhlsiWmTaWyhXXtPTzOVulp/s1138/IMG_20200516_175814%257E2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="905" data-original-width="1138" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhlYIbhs9mlpCqh5n76vN5Y2479eSaWoCo3V_nMaUBt3xVcDBxnP4muSTIlAIFUJ8JYncNCKpVtXkeW5q1733Xtbon8ML7eNKPRCwB1Vv8l_Nuz5x7AZwVYHwhlsiWmTaWyhXXtPTzOVulp/s320/IMG_20200516_175814%257E2.jpg" width="320" /></a></div>A few days before the closing, I loaded the trailer and got it ready to head north. Here is the truck and trailer on the morning we left the shop:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKfSvTK5NYEF9M_BLWCc-hN42TSspw932VFM63wWie_2_2-YEVcOs3hAy6dChrr_-qcrhQSr3nZs-6TzIpzKjn-vvETooN64R_3F7PsIQkHPAHLb1sTU94NwLURLoxU3RX6F-B81qDVrHg/s1344/IMG_20200520_201427.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1344" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKfSvTK5NYEF9M_BLWCc-hN42TSspw932VFM63wWie_2_2-YEVcOs3hAy6dChrr_-qcrhQSr3nZs-6TzIpzKjn-vvETooN64R_3F7PsIQkHPAHLb1sTU94NwLURLoxU3RX6F-B81qDVrHg/s320/IMG_20200520_201427.jpg" width="320" /></a></div>We drove the whole way to her new place in one, long day (16 hrs). Here is the trailer the next morning in the driveway of her new house:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijIVI15XFHNzpvUbB-6bIuionmculHHyJK3-cQPJR9RfmSTjw1v_-LSWZidg9L_futvey9Ee_-zJBl0sSM8PHdTbO97F-KBnbyiUXkoNChYaJb6TRP9D31E0pfPctMisARhpphvxZCycRj/s1344/IMG_20200522_080642.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1344" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijIVI15XFHNzpvUbB-6bIuionmculHHyJK3-cQPJR9RfmSTjw1v_-LSWZidg9L_futvey9Ee_-zJBl0sSM8PHdTbO97F-KBnbyiUXkoNChYaJb6TRP9D31E0pfPctMisARhpphvxZCycRj/s320/IMG_20200522_080642.jpg" width="320" /></a></div>We spent almost 5 weeks there helping her get a lot of demo and renovation done to the place so that it was set up for her to be functional and livable. The list of projects accomplished before we headed back home included: <br />=> new laundry walls & flooring;<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvOKsi2kBYTn_83fumsWqzu5hF5FQxsEGR0o7AaqzrVx_l1n_cu27prkLrKJ96yhEO9NsgatAwog68UrACwDCPDYCLxUjOep7soC6mo7H-zID1skFstBeDH-CNlsSa-2zIv1SmWSkT91Ye/s1344/IMG_20200526_190550.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1344" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvOKsi2kBYTn_83fumsWqzu5hF5FQxsEGR0o7AaqzrVx_l1n_cu27prkLrKJ96yhEO9NsgatAwog68UrACwDCPDYCLxUjOep7soC6mo7H-zID1skFstBeDH-CNlsSa-2zIv1SmWSkT91Ye/s320/IMG_20200526_190550.jpg" width="320" /></a></div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgDHH9dMnrYqm4phH1YhsS4xYLnJYU7N8QJw18PU8mr6fR1iTBh1Ho1GTIZ7jsiSAChuO0ba733K9pkFlR_2KdgyBrbKWiuo3TpHWexnKBI_7lw4SZoHj6vgRwC4d8VTBfQezA4tqWgsh_0/s1344/IMG_20200526_223508.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1344" data-original-width="756" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgDHH9dMnrYqm4phH1YhsS4xYLnJYU7N8QJw18PU8mr6fR1iTBh1Ho1GTIZ7jsiSAChuO0ba733K9pkFlR_2KdgyBrbKWiuo3TpHWexnKBI_7lw4SZoHj6vgRwC4d8VTBfQezA4tqWgsh_0/s320/IMG_20200526_223508.jpg" /></a></div>=> new vinyl flooring in kitchen and dining room;<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7WClZxYpsvVeivWGsNF1pt_1tbfov5J0qK0Yry0NYcOS9wREL-tgxVUkg8pG5NZ-ltpqi1cqKUlKgj8GjSHV3SuE6B-SENV6GA-8wFxT95cdyE6DPSXB7IbeCoTr5d1uG-bkJe70316N8/s1344/IMG_20200525_220520.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1344" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7WClZxYpsvVeivWGsNF1pt_1tbfov5J0qK0Yry0NYcOS9wREL-tgxVUkg8pG5NZ-ltpqi1cqKUlKgj8GjSHV3SuE6B-SENV6GA-8wFxT95cdyE6DPSXB7IbeCoTr5d1uG-bkJe70316N8/s320/IMG_20200525_220520.jpg" width="320" /></a></div>=> new kitchen cabinet paint;<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_Iy60p-LgT0pWUashnJC5qTXMIzqk0xoM5hQOQaGV_RL5tFRyU1RzUXoD23cvYNjqvvCzBK4zIMynMzUPAfmzoBJxOYfJB0RtH6I_ruK65qUewfwSgjQ3TyjNcAz8jDEY13GAlQjct6ra/s1344/IMG_20200602_223350.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1344" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_Iy60p-LgT0pWUashnJC5qTXMIzqk0xoM5hQOQaGV_RL5tFRyU1RzUXoD23cvYNjqvvCzBK4zIMynMzUPAfmzoBJxOYfJB0RtH6I_ruK65qUewfwSgjQ3TyjNcAz8jDEY13GAlQjct6ra/s320/IMG_20200602_223350.jpg" width="320" /></a></div>=> new range hood with new vent that actually goes through the roof;<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTkyJD_Ng_-XLSd72t_aQEKKIV7aiDh-DAaVgpkogS9T6lCC4JqioPUFxHqCUgUwxoKS2WYJkv41tONHb6WykAWAAocmvgn0W5hafvbHIr8f3-ManTs8eEUcZIz2T60urPOfxU52fPEvwR/s1344/IMG_20200604_132000.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1344" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTkyJD_Ng_-XLSd72t_aQEKKIV7aiDh-DAaVgpkogS9T6lCC4JqioPUFxHqCUgUwxoKS2WYJkv41tONHb6WykAWAAocmvgn0W5hafvbHIr8f3-ManTs8eEUcZIz2T60urPOfxU52fPEvwR/s320/IMG_20200604_132000.jpg" width="320" /></a></div>=> new vinyl flooring and new accent wall in the living room;<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLEhQJy-4Fg6hyfiYyU4Gyvn_9CJwtwNtJsTmYpaLwUNyaRl6CX65d7ipoM0ipIEtlvN5JlIST0yyK-Gs5zhY4CkAO8HHVJQEMPwGX3N0JcVNJCsofVUpUhKAV3JmFUShwWGEWwKPqhWcu/s1344/IMG_20200611_231959.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1344" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLEhQJy-4Fg6hyfiYyU4Gyvn_9CJwtwNtJsTmYpaLwUNyaRl6CX65d7ipoM0ipIEtlvN5JlIST0yyK-Gs5zhY4CkAO8HHVJQEMPwGX3N0JcVNJCsofVUpUhKAV3JmFUShwWGEWwKPqhWcu/s320/IMG_20200611_231959.jpg" width="320" /></a></div>=> new fenced in dog yard behind the house with a new pet door for her dogs;
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhhbrFxcDU1xwem0DIe5TjurgGKlr4oM2DFfFxs3gTHBo7GWu4mzx3oh7sHgtXMJF3wTNlVNSGxgf5jER4qkVf1NGA8fCrv5EJNgohL42b0DC9XeUu0rNNCnH_4nt5RuQrZjDdeWoYeoX_/s1344/IMG_20200612_064026.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1344" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhhbrFxcDU1xwem0DIe5TjurgGKlr4oM2DFfFxs3gTHBo7GWu4mzx3oh7sHgtXMJF3wTNlVNSGxgf5jER4qkVf1NGA8fCrv5EJNgohL42b0DC9XeUu0rNNCnH_4nt5RuQrZjDdeWoYeoX_/s320/IMG_20200612_064026.jpg" width="320" /></a></div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhH2ZpS5gshDeNFmMhCNrqrYGwSBDjwGWksA7KT3nnyKfDZkkOYB3T81iPArh8OlCMGXWnxrYZ143RMmyXQroWunMZJGZD8Ph88FiRMtZgKYtY8mHwhUI3hbKi7c0w0Qn5pl4wuO-kmOng7/s1344/IMG_20200528_124850.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1344" data-original-width="756" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhH2ZpS5gshDeNFmMhCNrqrYGwSBDjwGWksA7KT3nnyKfDZkkOYB3T81iPArh8OlCMGXWnxrYZ143RMmyXQroWunMZJGZD8Ph88FiRMtZgKYtY8mHwhUI3hbKi7c0w0Qn5pl4wuO-kmOng7/s320/IMG_20200528_124850.jpg" /></a></div>=> horse paddock set up and "horse house" put up and sided;<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghklvfyhZZTqeHD4eR5N3F89_VVRV3Avg2nilFZLH4hyphenhyphenL8ki-BfXAhqGeV2RVrGalI3M-iH07bEeZk2khDSd9ip_CJSmRnjCZ24-RSVQKc1JGjXNddRbzudLNC9ZJO1u4074CScDHohxbq/s1344/IMG_20200612_064019.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1344" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghklvfyhZZTqeHD4eR5N3F89_VVRV3Avg2nilFZLH4hyphenhyphenL8ki-BfXAhqGeV2RVrGalI3M-iH07bEeZk2khDSd9ip_CJSmRnjCZ24-RSVQKc1JGjXNddRbzudLNC9ZJO1u4074CScDHohxbq/s320/IMG_20200612_064019.jpg" width="320" /></a></div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_Ykia5OoKK55Hka5FIv3PI-SVgfoLLYlOn6CojVuek9bWHenpC7HfsBR315G5SqS_sbtr-YfMy2Qi4RWm1Sh_2CM_XWs7LiBYUuVbd05qSbz1HwEPq8dPimtQ-IhcOVgCGP2QfG_EIY-Y/s1319/IMG_20200609_201919.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="798" data-original-width="1319" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_Ykia5OoKK55Hka5FIv3PI-SVgfoLLYlOn6CojVuek9bWHenpC7HfsBR315G5SqS_sbtr-YfMy2Qi4RWm1Sh_2CM_XWs7LiBYUuVbd05qSbz1HwEPq8dPimtQ-IhcOVgCGP2QfG_EIY-Y/s320/IMG_20200609_201919.jpg" width="320" /></a></div>In addition to all this, there were contractors that showed up to put on a new roof:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiUD0QPqrq10zWckoeWorUytLFHaTiCEntpahEmDKM81aoCi3OT6TfIJ0CuPWJRuPhTsGIznAW-pWCiVqLcBIZMPuFueI1HOTQuI3fSGZa4URzS31WY2j9u1ccKshCURAVd7CTlO7_7MooN/s1344/IMG_20200602_205732.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1344" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiUD0QPqrq10zWckoeWorUytLFHaTiCEntpahEmDKM81aoCi3OT6TfIJ0CuPWJRuPhTsGIznAW-pWCiVqLcBIZMPuFueI1HOTQuI3fSGZa4URzS31WY2j9u1ccKshCURAVd7CTlO7_7MooN/s320/IMG_20200602_205732.jpg" width="320" /></a></div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikVxpJ3qRjJ6SHtqXiUb-k4KsEK3C570yHW8qNXpcry-2YLQG45VLKS2FpwVUzaJEUfOt-Zgmah5GXBzReX2JkYv97wJw_E7OeWJcK0lya-dc2MMIjHCp6Mx6Rom-JpNg1TcMNq5JSb45N/s1344/IMG_20200604_213120.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1344" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikVxpJ3qRjJ6SHtqXiUb-k4KsEK3C570yHW8qNXpcry-2YLQG45VLKS2FpwVUzaJEUfOt-Zgmah5GXBzReX2JkYv97wJw_E7OeWJcK0lya-dc2MMIjHCp6Mx6Rom-JpNg1TcMNq5JSb45N/s320/IMG_20200604_213120.jpg" width="320" /></a></div>
There were also contractors that completely removed the insulation from the attic, treated for mold and then re-installed all new attic insulation. There was also electrical and septic work that was required by the lender to be completed. Plus, we had to set up the shop with all the tools and equipment to get all this work done. It was a very busy 5 weeks of hard work. By the time we left her, she could put her dogs outside for the day, go to work, get home and cook, clean, and had a safe place to sleep. The end result was a happy kid!<br /><br />
<u><b><span style="font-size: medium;">6. Youngest Daughter Solo Flight, Then Private Pilot -</span></b></u> The youngest has been pursuing a flying career. She finished a year of college but has decided to delay the college for a while to get her pilot certificates and ratings. Here she is with her instructor right after her solo flight in early May:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcV30HFJOYbKleqkuCZYszxJdIuSov31v6Flx3dP8kSw6uR7QSdTqY4z9lDsk8C4wmVZBxUHTQHLBbVccfd4a5XJ6iO_A6wIsmmWzOrAQlZKse88zdTQReV-EyXXdX3XYp62SbwFmKGHI1/s2048/20200501_145942.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1152" data-original-width="2048" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcV30HFJOYbKleqkuCZYszxJdIuSov31v6Flx3dP8kSw6uR7QSdTqY4z9lDsk8C4wmVZBxUHTQHLBbVccfd4a5XJ6iO_A6wIsmmWzOrAQlZKse88zdTQReV-EyXXdX3XYp62SbwFmKGHI1/s320/20200501_145942.jpg" width="320" /></a></div>This was her 1st solo takeoff:<br /><div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dzzuzZv5_75U8xI7-NxeVYfmRyxA9I3AW_SZrJ3HEa983h-tBX31md4tFb2fM8jsNYRchGgKKu2UE_VkszfSQ' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div>And, her 1st solo landing:<br /><div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dxtjRhTNbeT49361Ip2wt9eBX-E4EjFwU0Ijh_Z-VNI_HbT6YVyjPG0gHk43T2PHSdqPEKRKkhZ3lf0TLSq9g' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div>After her solo, her (then) instructor was leaving for an extended time, so she "moved" her flying to the Lincoln Airport near SMF. Her boyfriend was working on his CFI certificate there so she went there to finish her PPL work. She took her oral exam in late Aug, but because of the smoke from the massive wildfires this year, they didn't have VMC conditions and were not able to do the practical portion of the checkride. Trying to get the practical rescheduled was problematic and went on for almost 2 months because of reduced visibility and DPE availability. But, FINALLY, on Oct 10, Crysta completed her checkride and became a Private Pilot! Here she is on that day with her temporary certificate:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEHZwQfEAQ87nJ3_uuHT-peAci-kH3HuZp5ULOsbEyyY-IErA8Yl2dQPGWa9nrficapkV0RErRmctGWd3fguOFpkLqzwHDrv9PRx4ru6XGXxAW_aEre_4qQbr3SxmPRLdoMtHHZ9_PItiY/s1600/20201010-WA0001.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEHZwQfEAQ87nJ3_uuHT-peAci-kH3HuZp5ULOsbEyyY-IErA8Yl2dQPGWa9nrficapkV0RErRmctGWd3fguOFpkLqzwHDrv9PRx4ru6XGXxAW_aEre_4qQbr3SxmPRLdoMtHHZ9_PItiY/s320/20201010-WA0001.jpg" /></a></div>Congratulations, kid!! Great job!! She's now started working on her instrument rating.<br /> <br />
<u><b><span style="font-size: medium;">7. New Porch/Deck On The House - </span></b></u> The east deck on our house finally reached the point of disrepair that I couldn't ignore it any longer. Feet were actually, literally going through the deck boards! So, between putting things together for the oldest daughter's new house, painting a trailer and fixing a cantankerous old CNC lathe, I ripped out the deck and put new pressure treated stringers and deck boards on it. Here is the demolition mess with the deck location in the background:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiJn8RTPPWxUVWwkcCEsTMy3pjg-F4Ma4fD_BPzmZemmhDk9_SBRXbu-jnvodWj-_3590Yg1KdU1k8Tl2L8h974YfEMj_23DnLLGzf1l4ZfcOtdzz-RzWqjECBQFGXNZoPkfdIMBBgFhFy/s1344/20200509_201151.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1344" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiJn8RTPPWxUVWwkcCEsTMy3pjg-F4Ma4fD_BPzmZemmhDk9_SBRXbu-jnvodWj-_3590Yg1KdU1k8Tl2L8h974YfEMj_23DnLLGzf1l4ZfcOtdzz-RzWqjECBQFGXNZoPkfdIMBBgFhFy/s320/20200509_201151.jpg" width="320" /></a></div>Here is the height of demo. I kept the posts and beams, then put in new cross bracing boards:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXn6ZH4TBdh4oFJPm2DyzTKxBiYco0RnTGLb3co5VipBqliPIFzFNdq-I7MiUHdzLaaOf4j5PCg9LnknqrfZX7-BjRSwiLoYWjT103bLroMhGBHKoZCdTTYwd4EfhhQVtFbWWXX73zWgOg/s1344/20200511_091935.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1344" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXn6ZH4TBdh4oFJPm2DyzTKxBiYco0RnTGLb3co5VipBqliPIFzFNdq-I7MiUHdzLaaOf4j5PCg9LnknqrfZX7-BjRSwiLoYWjT103bLroMhGBHKoZCdTTYwd4EfhhQVtFbWWXX73zWgOg/s320/20200511_091935.jpg" width="320" /></a></div>Here is the deck with the new pressure treated stringers and deck boards installed:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHp4VmY9iu7XOUVza0Tzk5D9-gQAlBzAy6igLLUegR18MlHOnGcQjXbb3GpGtkQ30k7GjC_zJJgcm0U_9_HK8SoBVXGeriq5jSF1kKqRVtXS4YyiPzMhlENJj_68mVid4zgiburq2qb-eU/s1344/20200513_164557.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1344" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHp4VmY9iu7XOUVza0Tzk5D9-gQAlBzAy6igLLUegR18MlHOnGcQjXbb3GpGtkQ30k7GjC_zJJgcm0U_9_HK8SoBVXGeriq5jSF1kKqRVtXS4YyiPzMhlENJj_68mVid4zgiburq2qb-eU/s320/20200513_164557.jpg" width="320" /></a></div>I wanted to put a new, wider stairs up to the deck which would need a larger concrete landing pad. So, I had to form-up and pour the new concrete:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjY4ndsyAIBiB-nO6ZLwOJkPx_af5fmh1fRe5Ch7irIUMpIH_7emVlPCijKks22DrH5Ync5LVimeBTL2d91P2V0H67hmz2xjWxY_W7Fp_qvefGM2rrVk1-Mle9Pcl_hsFWeAA_ocE_JxgUE/s1344/20200704_131738.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1344" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjY4ndsyAIBiB-nO6ZLwOJkPx_af5fmh1fRe5Ch7irIUMpIH_7emVlPCijKks22DrH5Ync5LVimeBTL2d91P2V0H67hmz2xjWxY_W7Fp_qvefGM2rrVk1-Mle9Pcl_hsFWeAA_ocE_JxgUE/s320/20200704_131738.jpg" width="320" /></a></div>I fabricated new steel staircase stringers (wooden ones rot too fast) Here is the new stairs with all the concrete poured in place:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEir0PxFFUIJEOE8ui5EN6ScZFZaweB5y-bmK16_EO1b1qx3oHuUkLf24zZPpTz-RxwcLopkoUYTq-UEqcg3mOn_wV2eJHaDkqfpGStiK4CcWlzH5APDjXBjWfAcmuSXM13G8Xb-caz4Mmlh/s1210/20201123_172047177.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="681" data-original-width="1210" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEir0PxFFUIJEOE8ui5EN6ScZFZaweB5y-bmK16_EO1b1qx3oHuUkLf24zZPpTz-RxwcLopkoUYTq-UEqcg3mOn_wV2eJHaDkqfpGStiK4CcWlzH5APDjXBjWfAcmuSXM13G8Xb-caz4Mmlh/s320/20201123_172047177.jpg" width="320" /></a></div>Handrails around the entire deck are next on the list. In fact, you can see the bottoms of the posts that I just installed in the pic above. I'm going to be working on the rest of it later today. Look for a completion pic in future update.<br /><br />
<u><b><span style="font-size: medium;">8. Trailers, Trailers, Trailers - </span></b></u> This has been the year of trailer work for me. I ended up with a total of 3-1/2 large trailer projects this year.<br /><br /><u><i>Trailer Project #1</i></u> - This project started in April when I got motivated to repaint my big tandem axle trailer that I use to haul my tractor and bigger loads. Take a look:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5iCwUa2DAxqlyQfjCo4DCgNsZPg4bctH9YSdAWY4Q7Z-XjUF59mgSoyIFoskRHpkCqEIXEDioZ_njz58ErKJqoGc-LoijkoV3WOfoOWP2nbGM0iK1Qzo1nOwCtMPPih-VGzHiNO7pEbPQ/s1745/20200407_124057.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="870" data-original-width="1745" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5iCwUa2DAxqlyQfjCo4DCgNsZPg4bctH9YSdAWY4Q7Z-XjUF59mgSoyIFoskRHpkCqEIXEDioZ_njz58ErKJqoGc-LoijkoV3WOfoOWP2nbGM0iK1Qzo1nOwCtMPPih-VGzHiNO7pEbPQ/s320/20200407_124057.jpg" width="320" /></a></div>The plywood sides that had been put on before I got it had all but rotted off and the rust was taking over, all over. It's been sorely in need of an update and this was finally the time. In addition to the repainting, this project was also going to include adding steel sheet to the sides, fabricating better tail light protectors and making a better spare tire holder. The first order of business was tearing off all the unwanted stuff and adding the steel sheets to the sides and front:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNbpEgPwMeqDSFzRcwUtETeiStGQ4EpBaEpaOEjOy-0mkVQhKM9kbBlIv5_9QR5A8WSyZi3J-QfBuYM3BgU60s7ub8c2hWGKRP5SGYC-zH0gq01qOHHjNKnEO0ACFGfGjGz2E4vUzolkc8/s1578/20200409_152820.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="823" data-original-width="1578" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNbpEgPwMeqDSFzRcwUtETeiStGQ4EpBaEpaOEjOy-0mkVQhKM9kbBlIv5_9QR5A8WSyZi3J-QfBuYM3BgU60s7ub8c2hWGKRP5SGYC-zH0gq01qOHHjNKnEO0ACFGfGjGz2E4vUzolkc8/s320/20200409_152820.jpg" width="320" /></a></div>With these steel sides on, I had to come up with a way to make tie-downs available on the inside of the trailer deck. I took off all the old stake pockets around the outside lower edge and added reinforcement plates in several places - then I drilled 1/2" holes through these plates and trailer frame:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEggFQd3G9rsV7kf02d0UMQT2U2WqWOpAvnytMy3Jkip2lYMnmd7hKSij-60EtO208UGpucVZ_TR443QZB1j7adh17NyHWKcuOqgkG6c1muUCMjQyAQk_lRIiwQfmZRpzxtr6anM9DdFb8cW/s914/20200413_171715.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="914" data-original-width="894" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEggFQd3G9rsV7kf02d0UMQT2U2WqWOpAvnytMy3Jkip2lYMnmd7hKSij-60EtO208UGpucVZ_TR443QZB1j7adh17NyHWKcuOqgkG6c1muUCMjQyAQk_lRIiwQfmZRpzxtr6anM9DdFb8cW/s320/20200413_171715.jpg" /></a></div>Then, I fabricated these anchors:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIjxbaOj4-pGxBTWdpgBLCi4Zab5JBlpgpHFPZwlfky-sn-OBU_4ahssz6rTXUvL2K8yCI1vK1FGUI9DnGa5a5_JsB9yKipfdqWCwy4-u33M4uTE4_9qTYdLfcz-TdNSRCJZ_UKD4CAB5z/s843/20200413_170148.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="778" data-original-width="843" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIjxbaOj4-pGxBTWdpgBLCi4Zab5JBlpgpHFPZwlfky-sn-OBU_4ahssz6rTXUvL2K8yCI1vK1FGUI9DnGa5a5_JsB9yKipfdqWCwy4-u33M4uTE4_9qTYdLfcz-TdNSRCJZ_UKD4CAB5z/s320/20200413_170148.jpg" width="320" /></a></div>
Now, when I need to move something inside the trailer and tie it down, I put these on and secure them with a nut on the outside of the trailer:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgId9zoH_Mg-WT9bR37jXcxZtwhbZ8t3_CPnbq2p9DA9enCgwfu8iFuZOm3TrNHziokudUhuBCe_8U89WbyMYyN1t1PgMVu2IlC9cUzjQgxDVXqjvWIkDMq2dU67mGtV7ZyGnguXR_drZAU/s860/20200413_171900.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="860" data-original-width="721" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgId9zoH_Mg-WT9bR37jXcxZtwhbZ8t3_CPnbq2p9DA9enCgwfu8iFuZOm3TrNHziokudUhuBCe_8U89WbyMYyN1t1PgMVu2IlC9cUzjQgxDVXqjvWIkDMq2dU67mGtV7ZyGnguXR_drZAU/s320/20200413_171900.jpg" /></a></div>And, I can hook ratchet straps or whatever to these anchors on the inside to tie down the load:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXJMvo5wMJK1URrB3wduUabn1QJa3wU3ZLlX-Dy7GKZpRkI-GSZUirQLZeSo3qEXle8QJHKWAomP8gW_KatZdvQT2lYSBqiGqv8Qe5Sql3B_4KFe40MmtedNvgGIdswye_jHqLNvyy5PLy/s1292/20200413_171845.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="910" data-original-width="1292" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXJMvo5wMJK1URrB3wduUabn1QJa3wU3ZLlX-Dy7GKZpRkI-GSZUirQLZeSo3qEXle8QJHKWAomP8gW_KatZdvQT2lYSBqiGqv8Qe5Sql3B_4KFe40MmtedNvgGIdswye_jHqLNvyy5PLy/s320/20200413_171845.jpg" width="320" /></a></div>With the sides added and the other mods complete, it was on to sandblasting. This is a tedious, hard, sweaty, witch of a job that requires a lot of PPE. But, there is no better way to prep large areas of steel for re-painting. Whoa.....this guy is scary!!
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHRK2bGicJigZN3sU4Sa734KoWs4uucdh26EY10Ek5gzeKaWDf8vlkVMCMXcVT4ARg8Cssn59YLKzXJdG1u67Qhu5xo67424xeHEHZzqA7IOMdWa55pbclrJeTqZbyb22kQ3EK5lhmDM4Y/s1031/20200419_195356.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1031" data-original-width="743" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHRK2bGicJigZN3sU4Sa734KoWs4uucdh26EY10Ek5gzeKaWDf8vlkVMCMXcVT4ARg8Cssn59YLKzXJdG1u67Qhu5xo67424xeHEHZzqA7IOMdWa55pbclrJeTqZbyb22kQ3EK5lhmDM4Y/s320/20200419_195356.jpg" /></a></div>Here is the trailer after some sandblasting:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxt1RWP1rKQc8dVmLEaCnPGsd5Cf70OediHg_LYEXTPM6GfVVH57IfwemVWAiXjUIJYSeGgQSq3_q9Xrfr9HXUzJgB3CB9zwp_8_cq2QJK4RnIgNX8Uaq854s4zJneKZeurdNqARFb1Ss_/s1286/20200419_195426.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="747" data-original-width="1286" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxt1RWP1rKQc8dVmLEaCnPGsd5Cf70OediHg_LYEXTPM6GfVVH57IfwemVWAiXjUIJYSeGgQSq3_q9Xrfr9HXUzJgB3CB9zwp_8_cq2QJK4RnIgNX8Uaq854s4zJneKZeurdNqARFb1Ss_/s320/20200419_195426.jpg" width="320" /></a></div>Here it is with a coat of primer:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7ZMSx6_T4orjQwX38SsZWiSmS7YZm_mpR191k1Dip6QJBu3biTG6uVaByBcUx3RFwWkJGwNS68-TKmXPKuvm3UeJDQozaEwk8pi4ax7OX1yjjAjOcvBGtzq1EXgh4f2mtvpXcU0SozVOC/s1576/20200421_182037.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="615" data-original-width="1576" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7ZMSx6_T4orjQwX38SsZWiSmS7YZm_mpR191k1Dip6QJBu3biTG6uVaByBcUx3RFwWkJGwNS68-TKmXPKuvm3UeJDQozaEwk8pi4ax7OX1yjjAjOcvBGtzq1EXgh4f2mtvpXcU0SozVOC/s320/20200421_182037.jpg" width="320" /></a></div>And, finally after new paint:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjyoQEKv_0_cO0ngtW7UfW4YGSAV4hKtzIFbsR-2DigU1PPalmvi595A3ISoy9rS9oHmGTJ4nj_RFa-CERtta79_n1B5SLfga_clhrAYQHbA9gWxGe5HxIN6XDVPBNdKsNr1uHdsaQ0a75u/s1563/20200502_165226.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="723" data-original-width="1563" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjyoQEKv_0_cO0ngtW7UfW4YGSAV4hKtzIFbsR-2DigU1PPalmvi595A3ISoy9rS9oHmGTJ4nj_RFa-CERtta79_n1B5SLfga_clhrAYQHbA9gWxGe5HxIN6XDVPBNdKsNr1uHdsaQ0a75u/s320/20200502_165226.jpg" width="320" /></a></div>It was a lot of work. These few pictures are capturing weeks of work. But, the trailer turned out looking really nice and now it will be protected for several more years of hauling work.<br /><br /><u><i>Trailer Project #2</i></u> - In August I needed to find a trailer that I could use to haul a bunch of equipment on a one way trip later in the year. After searching Craigslist for weeks, the only thing I could find was really old junky things that were way too expensive. But, I did find a fella that was selling a package of parts of trailer frames, trailer axles, springs, wheels and other stuff at a reasonable cost. It was a lot of stuff and there was enough to make at least two trailers, and maybe more. I worked the deal and got the stuff in the driveway in front of the shop. After surveying all the components, I started making the 1st trailer from a section of frame with a tongue attached, a pickup bed, and a lighter duty axle that didn't have trailer brakes. Here it is with the deck welded on and the springs and axle attached:
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTrJEWwOs5iQ6I79PZxTgg45jz4a9MAXeQX9nfWOOcDCUSZwOoiVhsVKkYnxJ5lYpooaEwTDwsxNH7hI0UJdywsSfeB5WHmJWWUId7l4ZiEZamlWjxDz8YTgq7gL4m4NZetN_j4G1KNai9/s1734/20200901_210312.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="666" data-original-width="1734" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTrJEWwOs5iQ6I79PZxTgg45jz4a9MAXeQX9nfWOOcDCUSZwOoiVhsVKkYnxJ5lYpooaEwTDwsxNH7hI0UJdywsSfeB5WHmJWWUId7l4ZiEZamlWjxDz8YTgq7gL4m4NZetN_j4G1KNai9/s320/20200901_210312.jpg" width="320" /></a></div>Someone had made that axle from hubs off of an old F-150 pickup truck (I think). And the springs were off of some old vehicle (They were not trailer springs). Here it is on it's landing gear with the fenders, tongue jack and lights added:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEisaymWtTQ_5mVewcZFPtj2nwpawAQ7LBTQRA5-NMiVp6atBvHIj7m02hmWKfkE8IuiaAqT65E2bX8Aapb-Kn5UOYsO9riMSeRjZoutF7tXg49hyphenhyphenjOcYrXTpNCxyOztW0inyQVEBOGYmNCA/s1360/20200907_151530.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="578" data-original-width="1360" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEisaymWtTQ_5mVewcZFPtj2nwpawAQ7LBTQRA5-NMiVp6atBvHIj7m02hmWKfkE8IuiaAqT65E2bX8Aapb-Kn5UOYsO9riMSeRjZoutF7tXg49hyphenhyphenjOcYrXTpNCxyOztW0inyQVEBOGYmNCA/s320/20200907_151530.jpg" width="320" /></a></div>Here it is after some paint:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgj0dN7kMUTYMVZbDc5d4SsEce78fjriJGw1ivoAu3z4u_6eshMKsXiIB8XKgxoCUhaKW03KW-Q75r5NGf7CGs_3Pvu5bVDPWDDGnmho_Wj9DdTJLeDe7R8mLObOu2lD58ww4mGa2Lz8V_a/s1397/20200925_105955.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="562" data-original-width="1397" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgj0dN7kMUTYMVZbDc5d4SsEce78fjriJGw1ivoAu3z4u_6eshMKsXiIB8XKgxoCUhaKW03KW-Q75r5NGf7CGs_3Pvu5bVDPWDDGnmho_Wj9DdTJLeDe7R8mLObOu2lD58ww4mGa2Lz8V_a/s320/20200925_105955.jpg" width="320" /></a></div>The oldest daughter came home for a visit recently and we added sides and a spare tire so that she could use it to move more stuff to her place. She's going to keep it for hauling hay for her horse and hauling the "processed" hay away, later up into the mountains. Ha! Here is the trailer with the new sides and new trailer tires attached to her truck and ready to go:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjwPApzGS0QbX5mdc8RQM79-H1zBojRGWnbBMqThahrRiFyB2asU-8-Mj4vNIu_FZkkp9NV3QzOhH2MEwr4AhVDlmOJhBV1vCMdl4uw-PyVhcVmMA5BYLA3nFgYW7KvCm_vHchKm82g1nd/s1344/20201111_212944435.PORTRAIT.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="658" data-original-width="1344" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjwPApzGS0QbX5mdc8RQM79-H1zBojRGWnbBMqThahrRiFyB2asU-8-Mj4vNIu_FZkkp9NV3QzOhH2MEwr4AhVDlmOJhBV1vCMdl4uw-PyVhcVmMA5BYLA3nFgYW7KvCm_vHchKm82g1nd/s320/20201111_212944435.PORTRAIT.jpg" width="320" /></a></div>This trailer turned out pretty well and I know that Kayla will get a lot of good use out of it.<br /><br /><u><i>Trailer project #3</i></u> - This trailer was the one that would be used to haul a load about 2,200 miles for me. It was going to need to be a pretty heavy duty single axle trailer. I picked out the 3,500lbs axle that I got in the pile of trailer parts (this axle also had trailer brakes that I could use for this trailer). I had also gotten a heavy duty boat trailer tongue with the load of parts I got. So, I started putting these together with some additional 4 inch channel iron that I had so that I could see what it would look like:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjM46v1GTYoKaxWSqqsZ9IcF9228TGk_bl3_1MSahaRjJeR_AruMTPN40ujtkqjYs4lhnaBKtJUOAOEJlEOIqpRZ1es6tkjXaB215l4Af4MZGvQsgr0k6E3YBcAi2DIDqbs-2catdE7psd5/s1228/20200909_115842.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="746" data-original-width="1228" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjM46v1GTYoKaxWSqqsZ9IcF9228TGk_bl3_1MSahaRjJeR_AruMTPN40ujtkqjYs4lhnaBKtJUOAOEJlEOIqpRZ1es6tkjXaB215l4Af4MZGvQsgr0k6E3YBcAi2DIDqbs-2catdE7psd5/s320/20200909_115842.jpg" width="320" /></a></div>I welded these all together and onto the tongue and made the main frame of the entire trailer out of 4" channel iron - all the way around. It made a really sturdy frame. Then, I had to fabricate the brackets to hold the axle springs and mount them to the bottom of the channels. Here are the spring brackets I made:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDaEnNVi0rDEsyGUE9UfMIqnNFSL_pAd2ufdP8RMWl3QlCf0vtT9Zb4DQ9n5NW_0N9NW5bkEsz5fsqvvlMs87lk3WF_KYCa1lQh-HP7W-k8SvP102YMNqnikikbCaHraKYNMjqGwgigoCP/s809/20200910_213335.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="809" data-original-width="742" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDaEnNVi0rDEsyGUE9UfMIqnNFSL_pAd2ufdP8RMWl3QlCf0vtT9Zb4DQ9n5NW_0N9NW5bkEsz5fsqvvlMs87lk3WF_KYCa1lQh-HP7W-k8SvP102YMNqnikikbCaHraKYNMjqGwgigoCP/s320/20200910_213335.jpg" /></a></div>And, here it is with the springs clamped in place. The brackets I made above take the place of the wood blocking you see in this picture:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgT_jWYKGBOA9JYZ78Gtj7ZY8r9T6uqTg9HQYhtrmYaQEaHwZbr8CPTGYVBwypxgdP51rRqe5cFac64cMS2mNCQ92T85ogtQeU62qY7y4FPBuZ_k8aWQ3gHxoEL8oSPla3Mos2B77oBBs04/s1597/20200909_192849.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="512" data-original-width="1597" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgT_jWYKGBOA9JYZ78Gtj7ZY8r9T6uqTg9HQYhtrmYaQEaHwZbr8CPTGYVBwypxgdP51rRqe5cFac64cMS2mNCQ92T85ogtQeU62qY7y4FPBuZ_k8aWQ3gHxoEL8oSPla3Mos2B77oBBs04/s320/20200909_192849.jpg" width="320" /></a></div>Then, I moved onto the axle. I had to tear down the brake assemblies and hubs to clean and inspect them. Then I put it all back together again, bought some new wheels (load range E from TSC) and put them on the trailer:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTzpLvyhohCxBuLyBfC21EDtCL2607H3cz2HXgclUefGeucrZa_OIx2bMBs4yXwUngxp-KUMjctkpHeYC8HTJkX0pCiNf5rL1CI8tVWFtoTiOmQl8OGaT4sNDh89IksGOgnJuDh1qqnyB-/s1446/20200920_170833.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="623" data-original-width="1446" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTzpLvyhohCxBuLyBfC21EDtCL2607H3cz2HXgclUefGeucrZa_OIx2bMBs4yXwUngxp-KUMjctkpHeYC8HTJkX0pCiNf5rL1CI8tVWFtoTiOmQl8OGaT4sNDh89IksGOgnJuDh1qqnyB-/s320/20200920_170833.jpg" width="320" /></a></div>I added the side rails and fenders while it was still upside/down. Then primed and painted the bottom sides of everything on the trailer. Then, I flipped it on it's landing gear and continued to paint the tops sides of everything:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYbsAB-XrEtKjbafL5umTh3W11IluVIs-5yXoANVbua7_urd39Ns2eChvK03uLSNsiMs99bRlE3VUm7Awvly6eIC7xVvE1b2OKEQU0KUYfozTsvRkzPXvtEDQ8lA-rRGt640Rsxzm5l5Jr/s1459/20200925_192025.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="621" data-original-width="1459" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYbsAB-XrEtKjbafL5umTh3W11IluVIs-5yXoANVbua7_urd39Ns2eChvK03uLSNsiMs99bRlE3VUm7Awvly6eIC7xVvE1b2OKEQU0KUYfozTsvRkzPXvtEDQ8lA-rRGt640Rsxzm5l5Jr/s320/20200925_192025.jpg" width="320" /></a></div>When the paint was dry, it was off to the lumber yard for a test drive and to pick up some 2x6 boards for the deck:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2aX5TDcdDSyYbETICloZ3bEwsaPJNnpR6pKiE8Kz3fm6hbdlKZSuJlQOgBax3wHVwGFCN6NnHe5zorSW6qSkpkQo_ciOCi3vYQuye1bvbpX9FvBOtHRUjPtwUQ1WKErSg42RGdQYUUrYG/s1277/20200928_170140.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="444" data-original-width="1277" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2aX5TDcdDSyYbETICloZ3bEwsaPJNnpR6pKiE8Kz3fm6hbdlKZSuJlQOgBax3wHVwGFCN6NnHe5zorSW6qSkpkQo_ciOCi3vYQuye1bvbpX9FvBOtHRUjPtwUQ1WKErSg42RGdQYUUrYG/s320/20200928_170140.jpg" width="320" /></a></div>Here is the end result:<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi9hULunLTj13aU8qQzfQRx52ZFgCoLcqEs1xOHM3KKUs1dBaGXn4SDRkiSP0JfhRf7979M7Bxmu9ugdZ70sKbVdIyvRSG7skuJNySftxBZ_s06S67HpuNYgVaelsk60LTdHaPIjMr_s8MU/s1333/20200928_192722.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="880" data-original-width="1333" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi9hULunLTj13aU8qQzfQRx52ZFgCoLcqEs1xOHM3KKUs1dBaGXn4SDRkiSP0JfhRf7979M7Bxmu9ugdZ70sKbVdIyvRSG7skuJNySftxBZ_s06S67HpuNYgVaelsk60LTdHaPIjMr_s8MU/s320/20200928_192722.jpg" width="320" /></a></div>The trailer is finished and ready to load. Oh, BTW, the Ford F150 is/was also going to be making the one way trip. What? Trip to where, you ask. Well, let's talk about that next! <br /><br />[Oh, yeah. <u><i>Trailer project #3-1/2</i></u>. This (1/2) project is currently a collection of parts that is eventually going to become trailer #3 that I build. I have all of the parts I need to build another trailer except the axle tube and the springs. I've already done a fair amount of work to get these parts prep'ed and ready to go together. So, once I buy an axle tube and find some springs all I have to do is find the time to weld it all together! Watch for that in a future update.]<br /><br />
<u><b><span style="font-size: medium;">9. New Wisconsin Property - </span></b></u> I spent 2-1/2 weeks in Wisconsin this July with my folks. I normally spend a little time with them before and after AirVenture each July, but with AirVenture cancelled this year I got to spend the whole time with them. I also got to do a little looking around for some land near them. (I had actually been looking online at properties for nearly a year, but this was a great time to finally go see some of them in person.) I was looking for something that did not have a house. I've already got one of those and have no desire for another one. I was also looking for some place where I might be able to store my RV (the other 50.5 weeks of the year that it's not being used in Camp Scholler). If it had a barn, or shop, or some kind of large building - that'd be a plus. And, if it had utilities - that'd be a home run! <br /><br />After beating up the real estate listings and doing a lot of driving around east central Wisconsin, I found a property that I liked. It met most of my requirements: It's within 35-40 mins of my folks place, it's within 35-40 mins from OSH, it's 5 acres in size, it's rural, it has a 40' x 60' pole barn, it has a septic system, 200 Amp service and a well for water! Sweet! Oh, also, the east end is along a small river. I made an offer on the property the day before I left WI to head back home in CA in early Aug. On the 1st day of my drive home I got a counter offer from the listing agent and I accepted it. Closing was set for 9/11/2020. Here is a bird's eye view of the property with the approximate lot lines:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhR2ShqwrOe6l5y5_OfFH1LQue5NESw-_s10B_hLkML1XsmQshAdXUCeNIx89wHTPiFa82m4cDMQdf5j7MEEGYvqVtJPxa3wvNza_o5kuggSAYFRq_SiyEQLR6Zm8V-5B_iAYrhqqYa0oI5/s1978/Top+View+-+Lot+Lines.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="527" data-original-width="1978" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhR2ShqwrOe6l5y5_OfFH1LQue5NESw-_s10B_hLkML1XsmQshAdXUCeNIx89wHTPiFa82m4cDMQdf5j7MEEGYvqVtJPxa3wvNza_o5kuggSAYFRq_SiyEQLR6Zm8V-5B_iAYrhqqYa0oI5/s320/Top+View+-+Lot+Lines.jpg" width="320" /></a></div>If you look closely in the pic above you can see a small single car garage in the woods along the south lot line. This panoramic pic (below) is taken from the north end of that building looking north (as the property was when I made the offer):<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2noyC_TdGoZHm6bDMEmSRnP8KkxyPIKdhXnM9si5Qq9-MKQttSLJGJ9yyYmlsfnG29f-mq0VtrT_ZWe7srWdTAQMcVZ1wwY54SNFcngz4g3UrywIhfNmakv1EacAOc19UqIckTJp6vAc-/s2542/20200807_095126.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="726" data-original-width="2542" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2noyC_TdGoZHm6bDMEmSRnP8KkxyPIKdhXnM9si5Qq9-MKQttSLJGJ9yyYmlsfnG29f-mq0VtrT_ZWe7srWdTAQMcVZ1wwY54SNFcngz4g3UrywIhfNmakv1EacAOc19UqIckTJp6vAc-/s320/20200807_095126.jpg" width="320" /></a></div>For the rest of the drive home and the next month and a half, I was planning another trip back to the property. I had a lot of things around the CA shop that I had duplicates of and other things that I didn't need in CA anymore and wanted to move them to the WI shop (lathe, work benches, file cabinets, hand tools, etc.etc.). That was the reason for finding another truck and building the 2nd trailer. I was hoping to make the trip back before it got too cold there so that I could stay in the RV while I cleaned up the property and got some things fixed up and/or set up around there. As soon as I got the 2nd trailer built and painted, I started loading it and getting ready to make the drive. I left home on Oct 7th and here is what the truck and trailer looked like the day I dropped the trailer in the yard on the new property on Oct 9th:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrK7DmtrkIgMV_6l_zHQgosXAKZpI1fiLtHNBrHj5VVsksFl9ESMLGl50ZaIV0sFGSwktGwut_aDrE3YB_DO00dlS_-7yWWWWn5pL_jUBg8qEsAF-44QzjHKFindTaCuuIs3l4o9BJi30m/s1532/20201009_182108027.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="634" data-original-width="1532" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrK7DmtrkIgMV_6l_zHQgosXAKZpI1fiLtHNBrHj5VVsksFl9ESMLGl50ZaIV0sFGSwktGwut_aDrE3YB_DO00dlS_-7yWWWWn5pL_jUBg8qEsAF-44QzjHKFindTaCuuIs3l4o9BJi30m/s320/20201009_182108027.jpg" width="320" /></a></div>The truck and trailer performed flawlessly on the trip. The trailer hauled 2,200 lbs of stuff on the 2,212 mile journey. I had the trailer weighed before the trip and it came in at 3,760 lbs gross weight (yeah, it was a little over gross!). With the 250-300 lbs I had in the back of the truck - the truck itself pulled and/or carried over 2 tons of stuff without any problems. I did the gas math and it got 13mpg average over the entire trip. That's not bad!!<br /><br />The day after I got there, dad brought my RV down and we got it set up and then started cleaning up. There was over 30 dead Scotch Pine trees on the property and myriad piles of trash all over in the woods that needed clearing out. Here is one of the days that dad and his tractor were on a roll and it was hard to keep up to them:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhc28X3ulg8ISJBBeVqADjpu7Y5hSThzzJKrBJyXAce0bOgVxxlfrOUY57O3gMUEq9trBLLxrNNfAwvWXNY8DyAhcgcp5MlgyqiZsr2rsLGB5lhRKxFlFLX-Aj9B-fnDHecXqPsPqrIHdNt/s1606/20201017_160047446.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="637" data-original-width="1606" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhc28X3ulg8ISJBBeVqADjpu7Y5hSThzzJKrBJyXAce0bOgVxxlfrOUY57O3gMUEq9trBLLxrNNfAwvWXNY8DyAhcgcp5MlgyqiZsr2rsLGB5lhRKxFlFLX-Aj9B-fnDHecXqPsPqrIHdNt/s320/20201017_160047446.jpg" width="320" /></a></div>He, and his tractor, did a great job and made short work of the dead trees. Later, we even harvested a few trees that he took to his sawmill to make into 4x4's. I eventually got the trailer unloaded into the single car garage that I will use as a workshop for now:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIYYF4tsc7ZOorbjgUDyhd3ugL9EeSlt9GCdA4t3M4rjVbsR9OE8ThwUNRX3VUDGh_jzEh85MijhmU2YsBRGBIEZs37H5sc0dJocvd0GtSdAPkDgX6BrbOdC-aa3xm0-0jM2zf8axdlUwT/s1613/20201011_194102954.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="1613" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIYYF4tsc7ZOorbjgUDyhd3ugL9EeSlt9GCdA4t3M4rjVbsR9OE8ThwUNRX3VUDGh_jzEh85MijhmU2YsBRGBIEZs37H5sc0dJocvd0GtSdAPkDgX6BrbOdC-aa3xm0-0jM2zf8axdlUwT/s320/20201011_194102954.jpg" width="320" /></a></div>Later, I dedicated one whole day to cleaning up a pile of over 100 tires. Someone had used this as tire dump at some point. I dug them all out, cleaned them off and loaded them on the trailer. I took them to a tire recycling plant about 65 miles away:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCpW_pndYocDA1aPSeHfJt_3GWzoe5OMQnuCbOHerKn0ro_CmOu3U9HY7Mten4UBpJa9OdVRaHrg7Db8nukEIJL4JPHkG07amHHGT4t4sq9sL4VVSQE5I1w3W8cN1-zY8l5dPSNxwTokrR/s1583/20201020_170119386.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="790" data-original-width="1583" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCpW_pndYocDA1aPSeHfJt_3GWzoe5OMQnuCbOHerKn0ro_CmOu3U9HY7Mten4UBpJa9OdVRaHrg7Db8nukEIJL4JPHkG07amHHGT4t4sq9sL4VVSQE5I1w3W8cN1-zY8l5dPSNxwTokrR/s320/20201020_170119386.jpg" width="320" /></a></div>I stacked over 2,500 lbs of tires on the trailer and, again, it performed flawlessly (yup, it passed another "over gross" stress test!). I burned what trash that I could from around the property, and the rest went to the dump/transfer station. Here's a load of steel stuff that I took one day:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgz_Pn7SXlTmNI5DVxd6gt6S-JSXPHlg4h13CtVDBfHHnN6uqSTQxwGD8dQBa_rHCrn7TBhOMrSj5Wmek8qMnyEzWgoZ4JCihwYKA8caIsrexUyVzwDJ9O34d4ZkBUea-APAD_3dwCAskcq/s1583/20201024_161858972.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="745" data-original-width="1583" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgz_Pn7SXlTmNI5DVxd6gt6S-JSXPHlg4h13CtVDBfHHnN6uqSTQxwGD8dQBa_rHCrn7TBhOMrSj5Wmek8qMnyEzWgoZ4JCihwYKA8caIsrexUyVzwDJ9O34d4ZkBUea-APAD_3dwCAskcq/s320/20201024_161858972.jpg" width="320" /></a></div>The very next day, it got cold and snowed:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3gCiC9yjreVdhf5ux0UUrW9imkmuOxJVM4vs4lbl49FCMRYA-NntCkKP2itFVLZcHZETZveop_iKcEApNWN6rZipAjXynpHghiOOrpqU6keAdR8MfIQxV1k8Zq_Vn6wHEz6sQsUg4TJMe/s1540/20201025_213212509.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="814" data-original-width="1540" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3gCiC9yjreVdhf5ux0UUrW9imkmuOxJVM4vs4lbl49FCMRYA-NntCkKP2itFVLZcHZETZveop_iKcEApNWN6rZipAjXynpHghiOOrpqU6keAdR8MfIQxV1k8Zq_Vn6wHEz6sQsUg4TJMe/s320/20201025_213212509.jpg" width="320" /></a></div>Over the 2.5 weeks that I was there I also got the well powered up and running with a pressure tank installed. I repaired the gutters on the pole barn and got the rain water draining away from it properly. I also planted trees along the north lot line and cleaned up dozens of piles of pallets and other junk from the woods behind the two outbuildings. Eventually, it got too cold to stay there living in the RV and I had to leave to head to work (yes, they finally cornered me into going back to work). So, I winterized the RV, finished some last details, locked everything up and headed back to work on Nov 3rd.<br /><br />I'll head back to the property in the spring. I want to investigate the septic system more and figure out a way to set it up so that the RV can dump into it. In fact, I plan to build another building that is tall enough for the RV to park inside (the pole barn just isn't quite tall enough). I also have some other ideas about using this property in the future to stage Prowler "stuff" for AirVenture. I will cover that more in future updates.<br /><br />
<u><b><span style="font-size: medium;">10. Hardinge CHNC Lathe Progress -</span></b></u> My last post about this project was several months ago and just after I got the necessary electrical components moved out of the huge, old cabinet and installed into the smaller, more compact one. I had also just gotten the ballscrew bearings on the Z axis tightened up, got the home switch on the Z axis relocated and had rebuilt the entire X axis belt drive system on the end of the cross-slide. Here is what
the machine currently looks like:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6yGIrg72ydQt4OvCoVoFLVlSLylR0Wfl2FFHmDTgpDWijKytDPROIx5uiN5lFdHYrgqJarU0liNcocIBjEvh-4bFYbNJc_C3nf6wc9-UlG7qCygafjyI-0SdGdJ0DtdUi4HTw0sA4ThXe/s1118/20201123_161923603.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="710" data-original-width="1118" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6yGIrg72ydQt4OvCoVoFLVlSLylR0Wfl2FFHmDTgpDWijKytDPROIx5uiN5lFdHYrgqJarU0liNcocIBjEvh-4bFYbNJc_C3nf6wc9-UlG7qCygafjyI-0SdGdJ0DtdUi4HTw0sA4ThXe/s320/20201123_161923603.jpg" width="320" /></a></div>With all of that done, I fired up the machine and tested everything. Everything was working great, except now (for some reason) the spindle wouldn't turn at the
proper speed (it had been working fine up to this point). What the heck!?!? I tried everything I could think of to get it working. It would turn, it just turned much slower than commanded (max speed should be 3K rpm, but it would only turn about 300-400 rpm at best - and the motor had an erratic buzz/hum). It frustrated me beyond words for months. I contacted the tech support for the company that makes the spindle motor amplifier (Servo Dynamics). One of their techs was very helpful and offered several suggestions, but nothing really helped.<br /><br />All along through troubleshooting this problem, I thought it was acting like it had an AC hum to me (interference from typical 120 Vac 60Hz power). But, I couldn't locate the source. I moved and re-routed some of the power wires, but nothing helped. Then, one day, I thought "What the heck." I would try to tune the amplifier one more time (tuning the amp is a process of electrically "matching" the motor to the amplifier to get the best electrical performance and response). <br /><br />Doing this requires reaching into the electrical cabinet and balancing my left hand over the tuning potentiometers while holding a small screw driver and "tweaking" these pots. As I did this, my hand slipped at one point and brushed against the group of control wires going to the amp. Suddenly, for a second or two, the spindle motor stopped buzzing and sounded "normal". So, I poked the wire bundle again, and sure enough, for a couple seconds the motor sounded normal. Whhhaaaattttt!?!?!? Here is what the area looks like:<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-c65pYljZZ54Can8qr8EvmJUcp2ATxT9X8izWdU-wz8ApD5tu6d4UYdqU3sK4xYJBIK6pZ2SbprdP12DwkVHcPhcr4NnXMTLD2zEgjjvCl0xPw7G6oL67A2ktzrAke23vBNmn20rdI4Cx/s1190/Blog_Update_Amp_Info.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1190" data-original-width="867" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-c65pYljZZ54Can8qr8EvmJUcp2ATxT9X8izWdU-wz8ApD5tu6d4UYdqU3sK4xYJBIK6pZ2SbprdP12DwkVHcPhcr4NnXMTLD2zEgjjvCl0xPw7G6oL67A2ktzrAke23vBNmn20rdI4Cx/s320/Blog_Update_Amp_Info.jpg" /></a></div>What I eventually discovered is that the cable that takes the control signal from the CNC (computer) to the spindle amplifier had lost it's ground on the cable shield. This control signal is a small +/- 10Vdc signal that the computer uses to tell the spindle motor which way to turn (pos = CW and neg = CCW) and how fast to spin (0 Vdc = stop, 10Vdc means max speed in whichever direction). Well, this small signal is sent via a two conductor, twisted pair cable that is shielded to prevent 120Vac interference. When the shielding lost is contact to ground, the spindle motor signal got corrupted with a lot of electrical interference and the amplifier was essentially amplifying a bunch of "garbage." That was the reason for erratic behavior and the buzzing/humming.<br /><br />This was a major....albeit accidental.....breakthrough!!! But, I'll take it. Sometimes it's better to be lucky than good!! Finally, the machine runs like it should.....mostly. <br /><br />While troubleshooting this spindle problem I also discovered that the spindle encoder was not working properly. In fact, someone had cut that cable completely in half!! Best I could figure out, the encoder stopped working (bad Zref channel) and it must have been causing the CNC to throw an error code. So, instead of fixing/replacing the encoder - they just cut it out of the system. Here is the old spindle feedback encoder mounted on the machine with the cannon plug removed:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXOtJsZXodBjKCkd57bqQ_SHmij4LT_9EPOzEyIlZi_v93G0mid35BUQ0DkldcHzXz29EOrXJmZWpX3VJH2XJ7TGOx-pKATAGVUXK8MIERktrDpvN-iUxThk1Lm_-bxNTMrHawAMIu-1xE/s1285/20200906_160035.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1285" data-original-width="796" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXOtJsZXodBjKCkd57bqQ_SHmij4LT_9EPOzEyIlZi_v93G0mid35BUQ0DkldcHzXz29EOrXJmZWpX3VJH2XJ7TGOx-pKATAGVUXK8MIERktrDpvN-iUxThk1Lm_-bxNTMrHawAMIu-1xE/s320/20200906_160035.jpg" /></a></div>Well, the machine is more accurate and reliable with an operating spindle encoder. So, I set out to splice the feedback cable and find a replacement encoder. Sounds easy, but, it's not! First of all, this is 40+ year old equipment. Most of the parts for it are obsolete and not produced any longer. If you can find something used for sale that is still operating - it's cost prohibitive. Trying to find something new to replace the old with is difficult, at best, because mounting hardware changes constantly (usually gets smaller and more compact). Then, with these encoders, electronically, there are literally dozens of types with multiple versions of each type - and you gotta find that one that is "just right." Well, persistence pays off. I finally found a few on eBay that looked to me like they would be a suitable (almost direct) replacement. I made a few offers and finally got one at a reasonable cost. Once it showed up, I tested it and then installed on the machine:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUr1VLNs1P2FzfXl1ED-ejSlAsV-RJEjfekEHZzUpBdgxgJ3zweGAXCd84TXNCcOX1HOiI-t82a6iyBoqEDdfpsAc5_5wGNdSAZ_XzI8PqNXOwO71kKO0bOgvCRrlijeJETDXEDU8JX73m/s1023/20201123_161949999.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="744" data-original-width="1023" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUr1VLNs1P2FzfXl1ED-ejSlAsV-RJEjfekEHZzUpBdgxgJ3zweGAXCd84TXNCcOX1HOiI-t82a6iyBoqEDdfpsAc5_5wGNdSAZ_XzI8PqNXOwO71kKO0bOgvCRrlijeJETDXEDU8JX73m/s320/20201123_161949999.jpg" width="320" /></a></div>Another thing I wanted to do with this project was get the tool turret working again. The lathe was originally designed with an 8 position tool turret. Tool selection was fully automated on the original CHNC design, but I am hoping to be able to make it work again and be, at least, manually indexable (selectable). I dug into the maintenance manual that I have for this machine and found that essentially the tool turret table is mounted to an air piston that is below the turret. If I could find the air passages that the CNC used to pressurize the area under the piston and on top of the piston - then, I should be able to make the tool turret pop up and down. Well, I did, I found them:<br /><div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dwRhzWx5eDlvYiEFh9TV_tXeBXPhGIrGoQ0UshJpOqYM_-TFKeeC8gvcHN7FMOTlme3GHo8tevAkAOTRyiIDw' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div>I had to make the aluminum manifold that you see in the foreground. This gave me a place to attach air lines to and port the air to the correct passages machined into the cross slide. Next, I am going to source a 3 position air valve that will allow for 3 conditions: 1) pressure on the up air line and vent the down line; 2) vent both air lines; and 3) pressure on the down line and vent the up line. With this I will be able to get the turret completed. Mounting the valve and routing the air lines will be the biggest task here. More to follow on this.<br /><br />Next on the list was the automatic collet closer. I just got started on trying to get this system to work again on this lathe. Again, I started with the maintenance manual and figured out a part that I am missing. It's the black hub part that is labeled V in this pic:<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiuktJdcBI8odPA78WjodCGP23GUAKebAKPSQEmVlYu9V7PU3P7l7y2xj-f6B9SLaE7MvO0iqdQmE_v5lBh1rGpii1c0EsVy4Gw9QUvWuBSjEMEN7R289rChjnO041hitpI58vNsakUHLp1/s1502/20200830_092102%257E2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1331" data-original-width="1502" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiuktJdcBI8odPA78WjodCGP23GUAKebAKPSQEmVlYu9V7PU3P7l7y2xj-f6B9SLaE7MvO0iqdQmE_v5lBh1rGpii1c0EsVy4Gw9QUvWuBSjEMEN7R289rChjnO041hitpI58vNsakUHLp1/s320/20200830_092102%257E2.jpg" width="320" /></a></div>W & Y point to some set screws and ports on this same part. I'm also missing part labeled X, but I can fabricate that myself from a piece of steel plate. On a whim, I called the buddy that I bought this from to ask him if that part might still be sitting around. He didn't think so. Rats! But, later he called me back and told me that he did have that part on another machine of his. He has an aftermarket collet closer that he bought to put on his machine - which would mean that he would not need the part anymore that I want. So, shortly I will be heading over to his place to help him install his aftermarket system and bring home Part V that I need. More to follow on this too.<br /><br /><span>FINALLY - The End.<br /><span></span></span><br />Well, that's all I have for now. I think this is the longest blog update that I might have ever done! Well, heck - it's been almost a year!! Anyway, as always, thanks for checking in. If I don't get an update done before the end of the year, I hope you all have a very happy, healthy, (Covid free) holiday season.<br />Unknownnoreply@blogger.com2tag:blogger.com,1999:blog-4561663675008429701.post-9297702540502612072019-12-25T08:43:00.001-08:002019-12-25T08:43:06.394-08:00Merry Christmas & 2019 Prowler Year End Wrap-UpHello Everyone,<br />
<br />
Merry Christmas from Prowler Aviation. I had every ambition to get more blog updates done this year - but, before I knew it, the end of the year arrived and I wasn't able to get nearly as much done as I'd hoped.<br />
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The closest thing I have to a Christmas themed picture this year is from a recent BOS to LAX trip. We crossed the Rockies just south of DEN after a recent snow "event". I got a pretty good picture of the new snow on the Rockies:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8y70CBofgM4CwVItcMBbgyiAd4Jotlr6J3uhCUHRLoBi-3QLPFf2QAZdeLEsorjNGnm1vv22pBYHfc53IbF0hyphenhyphenR7zS9sCxTFVtuhuFj7cnyNR691Fp1sIa0KiaiOESED0PVkuJkeJL3i7/s1600/20191206_080454.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="813" data-original-width="1600" height="162" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8y70CBofgM4CwVItcMBbgyiAd4Jotlr6J3uhCUHRLoBi-3QLPFf2QAZdeLEsorjNGnm1vv22pBYHfc53IbF0hyphenhyphenR7zS9sCxTFVtuhuFj7cnyNR691Fp1sIa0KiaiOESED0PVkuJkeJL3i7/s320/20191206_080454.jpg" width="320" /></a></div>
Those folks know about snow! They know how to deal with it and how to have fun with it!<br />
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Well, to wrap-up 2019 for Prowler Aviation I only have the following few items:<br />
1. Making A Set Of Cockpit Floor Stringer <br />
2. An "Artsy" and Creative Prowler Project<br />
3. One Builder Update from Francis <br />
<br />Before I get started with the update, I wanted to rant a little and then do some follow-up on a project that I completed a few years ago. By now, many of you may have heard on the news about the power outages in CA. Well, that would be us! This fall, we had 4 of what PG&E calls "PSPS's" - that would be "Public Safety Power Shutoffs". I call them ridiculous and a result of decades of corruption at (and between) PG&E, CPUC, and the State of CA. For decades the profits have been sucked off of PG&E to pay huge bonuses and to pay off politicians and CPUC members. Nothing was ever put back into maintaining the infrastructure. Now, all the towers, wires and poles are falling down any time the wind blows and the customers are left to pay the cost - again. Soon, we will all have to endure significant rate increases to pay for infrastructure "upgrades." Just watch, in the near future, Gov. Nuisance will let PG&E off the hook and they will be allowed to charge significant rate increases. (So glad I bought a solar system!) That money should have come from properly managed maintenance funds over the past 4 decades, but instead went to myriad corrupt causes. OK, rant over.<br />
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Anyway, I am (now) really, really happy that I committed to spent the time, money and effort to build the backup diesel generator that I've mentioned several times in this blog. This is what it currently looks like installed in the "Gen Shack":<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTM8NrkALlI_BgaMfUf5nAceJwu-i6kUN0_LcbJQKJvtaOj04l8V_Yq0s0vmEpMnaBhXanxZKJqXEEGb3TaxVSi72QqTrpj4l4afP-M3NJuI2abruOhKQLUb1ueYSHSPvWJCSGRGQAjzP_/s1600/IMG_20190327_191301.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1211" data-original-width="756" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTM8NrkALlI_BgaMfUf5nAceJwu-i6kUN0_LcbJQKJvtaOj04l8V_Yq0s0vmEpMnaBhXanxZKJqXEEGb3TaxVSi72QqTrpj4l4afP-M3NJuI2abruOhKQLUb1ueYSHSPvWJCSGRGQAjzP_/s320/IMG_20190327_191301.jpg" width="199" /></a></div>
I never really thought that I'd be using this to keep us up and running when PG&E repeatedly fails so miserably. All I ever had in mind was having this system available for the family during the occasional power outages that happen when you live in a rural area. In particular, I wanted a system that the girls could run when I was gone on trips and not at home (sometimes for weeks).<br />
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Overall, it has worked flawlessly and provided us with great, perfect power during all of these PSPS's (most have lasted 2.5 - 3 days). Over the course of the past year, I've figured out that it burns about 1/2 gal of diesel fuel per hour and costs about $25 per day to run it. We usually run it from 5:30am until about 10:30pm and turn it off at night. At $25/day it is fairly expensive to run the gen, but it is worth it compared to the alternative of no power for 3 days! Between the week long power outage we had in Feb 2019 and these PSPS's this fall, this generator has REALLY earned it's keep!<br />
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On a related note (dry, windy, wildfire conditions), we finally got our winter rains in the CA north state during the 1st week of Dec. It's a great thing! All through Nov everything was crispy dry - everywhere! Even the animals were getting desperate for water. We had a lot of wildlife coming to the watering hole in the back yard:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgK3oZ3gRHGsVZioXTCgmwpP3yHKJtonOBf_8mhUfJ3W3ybNDjNfWvSNET_KJXFgDlc96Hk8ERhSBXDASKBKMRYA8s-6iOexP83NaA5dmRRWvN-Si4cWDrKJfZK3gzeB2cuWv816ZDV0ZVK/s1600/20191121_113543.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="834" data-original-width="1169" height="228" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgK3oZ3gRHGsVZioXTCgmwpP3yHKJtonOBf_8mhUfJ3W3ybNDjNfWvSNET_KJXFgDlc96Hk8ERhSBXDASKBKMRYA8s-6iOexP83NaA5dmRRWvN-Si4cWDrKJfZK3gzeB2cuWv816ZDV0ZVK/s320/20191121_113543.jpg" width="320" /></a></div>
The wildfire danger was really high and we had already had several close calls this past summer and fall. One particular fire, the Red Bank fire, started in early Sep from a dry lightning strike just west of Red Bluff, CA about 1130am. By midnight (roughly 12 hrs later) the fire had consumed 6,000 acres!! Fortunately, the winds died down the next day and CalFire was able to get control of it by the 3rd day at about 9,500 acres. But, it could have been much worse and our home and the shop would have likely been in the path of that fire - had they not gotten control of it.<br />
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All of this has gotten me to thinking more about wildfire prevention at home and helping to protect my house and shop. I have a few areas on my property that I never got around to clearing off the brush and undergrowth. They are mostly on the north side of the house and the shop. If we ever did have a wildfire come through our place, it would most likely approach out of the north. So, after this past fire season, I decided to clean up these parts of the property. I had a good block of days off before the Xmas trip that I'm on right now. So, I got busy with cutting, clearing and burning off the brush.<br />
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All in - I spend about 4 days on this effort.
CalFire recommends cutting tree limbs off from the ground to 8 ft up,
and then, cut and burn anything that is dead or anything that is laying
on the ground. Turns out, that is a lot of stuff!! But, by doing this,
you help prevent the spread of fire from embers landing in dry grass and propagating into the trees. And, if there is a fire, the CalFire
crews can get through the area much easier to do their thing and fight
the fires. It makes the property more "defensible" in case of a
wildfire - and CalFire is more likely going to be able to save the
structures (home and shop). Here is one burn pile (out of 6) that I got going while it was raining one day recently: <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1jmhNm0NlrwJqO-wD-bZcxsqPe5rauBpSjbopS11oMc60Iwi057lRj5sTVJSY1Vw_ho4xJpFPMngPjUZ63CCw9X-DkTjjTxGU8sk1WdfMtSNLG32LRpD98QYCht1JI6erjTfNc00GOAS0/s1600/20191211_091722.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1307" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1jmhNm0NlrwJqO-wD-bZcxsqPe5rauBpSjbopS11oMc60Iwi057lRj5sTVJSY1Vw_ho4xJpFPMngPjUZ63CCw9X-DkTjjTxGU8sk1WdfMtSNLG32LRpD98QYCht1JI6erjTfNc00GOAS0/s320/20191211_091722.jpg" width="261" /></a></div>
As I sat and watched these piles burn, it seemed odd to me that now it was no big deal - but, had I started a fire like this just 3 weeks earlier it would likely have burned down 1/2 of Tehama County!! However, now I can safely contribute to global warming, and my property will be better prepared for wildfire season next summer. Glad to have this done!<br />
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On with the update.<br />
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<u><b>1. Making A Set Of Cockpit Floor Stringers</b></u> - My new focus here in the shop is to try to get all of the parts fabricated that I need to complete Kit #18 that is inhabiting my shop office. I hope to get this kit sold in 2020. The next set of parts on the list was the floor stringers under the aft part of the cockpit floor. For reference, here is a pic of the under side of the Prowler showing the placement of these floor stringers:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEge3vkU7StMV1Ky4kphQh7AlwmcEumP5GMLwKqLisF-D-DywhbjaqjQAx4nbhsxNBV1hJheEbutUWU6nBO-oIfqHJXfkbYFTDQ28wogQ19S0_od7LMV0f04XQpCz8Qi7tsX5bSscA4O2A3I/s1600/FFA22%252623+Positions.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="826" data-original-width="1557" height="169" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEge3vkU7StMV1Ky4kphQh7AlwmcEumP5GMLwKqLisF-D-DywhbjaqjQAx4nbhsxNBV1hJheEbutUWU6nBO-oIfqHJXfkbYFTDQ28wogQ19S0_od7LMV0f04XQpCz8Qi7tsX5bSscA4O2A3I/s320/FFA22%252623+Positions.png" width="320" /></a></div>
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In the last update, I posted about mounting and fixturing these dies in the mill to prepare for machining them. But, then I determined that somehow I had cut the stock for these dies too small. (BTW - I figured out why I cut these die stock piece too small. I used the old part pattern to mark them for ruff cutting. The new parts are a bit larger because all the builders were having to cut shims to fill between these old parts and the skin. After seeing the work Ray had to go through to make the old parts work, I corrected the sizes/shapes of them and they should fit much nicer in the future).<br />
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I took these die stock pieces over to a buddy who added some aluminum weld to them in the areas where they needed it. Here is one of them with the added weld:
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Here is that die stock mounted to the fixture plate:<br />
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Here is the whole assembly back in the mill and after I'd centered it up and taken the 1st ruff cut around the die:<br />
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After the face cut and the 2nd ruff cut you can see that the welded area really helped fill in the needed material. But, it was still looking like it was going to be too small in that area. Yikes!!<br />
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Here is the die after the 3rd profile cut. Just the very top edge was looking too small:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFxzEvJSnS99FWIyPkyriVAWfe6yO0xvJXdLEm-HmLsOaIAZM7J0MZVK5W-xjmVsOoaD-9c75lnDyFboX5tIzRobdj0d1wRY_7kZC5SKgTerzw0Cf8y-F8BVaHWC1WTtmohy44iUl6OKpW/s1600/20191123_170215.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="678" data-original-width="1344" height="161" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFxzEvJSnS99FWIyPkyriVAWfe6yO0xvJXdLEm-HmLsOaIAZM7J0MZVK5W-xjmVsOoaD-9c75lnDyFboX5tIzRobdj0d1wRY_7kZC5SKgTerzw0Cf8y-F8BVaHWC1WTtmohy44iUl6OKpW/s320/20191123_170215.jpg" width="320" /></a></div>
Finally, after the round over cut there was only a few small voids that were still showing:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCwf9qbgxpYitv-b4ntFB9yZwQKzmQFJ6p89Y61l_sXSkpcWi6latVdLGLv_lVueJ580bwmzTR5ifUKUpjWVRf_RBcxdJRZV6pikVczpdNNGFB6ql5oIgir1JIUr_v32_R21kJhYZkfmoz/s1600/20191123_182535.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1344" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCwf9qbgxpYitv-b4ntFB9yZwQKzmQFJ6p89Y61l_sXSkpcWi6latVdLGLv_lVueJ580bwmzTR5ifUKUpjWVRf_RBcxdJRZV6pikVczpdNNGFB6ql5oIgir1JIUr_v32_R21kJhYZkfmoz/s320/20191123_182535.jpg" width="320" /></a></div>
Fortunately, these voids are not big enough to affect the part while pressing (these
voids are too small for the aluminum to flow into when under pressure). I might still take them to my buddy had have him TIG a little weld into these areas. Then, I'll just file them all flush with a good file. Here is the die with all the profile work completed:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqFmHXMD1kAebU-ap5EcW3hhTyMlntHWmWrVXHPqShYYHxg-D9m3vUH3wCnm3nQhD2WjWpTnCP6TW18JiFieHHUDYmGDUEmPv8s0Y15hV428_auRJy0sQ4pSPqXV0v2TFLkCRVz5YRHFn2/s1600/20191123_182647.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="815" data-original-width="1314" height="198" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqFmHXMD1kAebU-ap5EcW3hhTyMlntHWmWrVXHPqShYYHxg-D9m3vUH3wCnm3nQhD2WjWpTnCP6TW18JiFieHHUDYmGDUEmPv8s0Y15hV428_auRJy0sQ4pSPqXV0v2TFLkCRVz5YRHFn2/s320/20191123_182647.jpg" width="320" /></a></div>
The last step was to cut in the pockets for forming the flanges on the lightening holes. Here is cutting the 3rd pocket:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkP-8zd6rF2rRbaVMdvVkyt9d2XAvA5S_707JPkq9RM9WRXKOugHNJY-moFfdEa6GkhfQTzt1p6LRC-6J39udrcy9k6dCkzkPIVjtV6xdZvmHOmra7O4hhyWGpIo2mZAFzg5pU-IiWwAsa/s1600/20191124_161728.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="802" data-original-width="1342" height="191" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkP-8zd6rF2rRbaVMdvVkyt9d2XAvA5S_707JPkq9RM9WRXKOugHNJY-moFfdEa6GkhfQTzt1p6LRC-6J39udrcy9k6dCkzkPIVjtV6xdZvmHOmra7O4hhyWGpIo2mZAFzg5pU-IiWwAsa/s320/20191124_161728.jpg" width="320" /></a></div>
This is cutting the largest of the 4 pockets:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7NDrkH2v3PHtuLocBEWNTymQ2WSbyzum4FLBD93aWo2HlKc1gza_vokO-51rypbV6Iw3NTci2Fzf8ND29phEaeickQMzBAxHgQULaPTwA-0TGcTslUKZThb1TtufUhXnpSvz9QJmnsb0x/s1600/20191124_164830.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="836" data-original-width="1442" height="185" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7NDrkH2v3PHtuLocBEWNTymQ2WSbyzum4FLBD93aWo2HlKc1gza_vokO-51rypbV6Iw3NTci2Fzf8ND29phEaeickQMzBAxHgQULaPTwA-0TGcTslUKZThb1TtufUhXnpSvz9QJmnsb0x/s320/20191124_164830.jpg" width="320" /></a></div>
Once the die was out of the mill, I had to file down all the sharp edges and break the sharp corners, especially on the pockets (to make sure that the bends on the lightening hole flanges are not too sharp):<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgstpMSGh11Uzmnp5NwUGWmTJWAVI3sHswVr0ttvJind6CjQG9qZ2UsXl8IzOdg_TH8rRrNjY3H5EwsbMl-JGzG0N4oAYsARfvl1saOiKfGtw_TyDljvz8r6pJTDZ5xg6ni9ig2tKZpiJPy/s1600/20191124_175525.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="944" data-original-width="1188" height="254" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgstpMSGh11Uzmnp5NwUGWmTJWAVI3sHswVr0ttvJind6CjQG9qZ2UsXl8IzOdg_TH8rRrNjY3H5EwsbMl-JGzG0N4oAYsARfvl1saOiKfGtw_TyDljvz8r6pJTDZ5xg6ni9ig2tKZpiJPy/s320/20191124_175525.jpg" width="320" /></a></div>
The 1st of the two floor stinger dies completed:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg15DUN7f4096sEqhYYvW1yG_zHd08XisY4fKVsVnfY9K0DuujUlihDNKJDOYX4hntns1mDID7gOt-InHnbXOUiq9fpLbDJrGiQrrBQ9JIbYpLYM-NvLrVNsT4ScXAyGgHsL_greroswLt3/s1600/20191124_175955%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="488" data-original-width="1600" height="97" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg15DUN7f4096sEqhYYvW1yG_zHd08XisY4fKVsVnfY9K0DuujUlihDNKJDOYX4hntns1mDID7gOt-InHnbXOUiq9fpLbDJrGiQrrBQ9JIbYpLYM-NvLrVNsT4ScXAyGgHsL_greroswLt3/s320/20191124_175955%257E2.jpg" width="320" /></a></div>
At this point, I held up on cutting the 2nd die. This was because I have not yet made a part with lightening holes or formed the flanges for them. I came up with an educated guess to make the pockets for forming the flanges 3/16" deep and then leave a flange length of 1/4". In other words, the pockets cut into the die are 3/16" deep and 1/2" diameter larger than the actual lightening hole in the blanks. I wanted to test this recipe before I cut the other die. That way if it didn't work well, I'd only have to try to fix one of the dies - instead of both of them.<br />
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Next, I had to fire up the router and cut some blanks for forming over the dies. That took the better part of a day - I ran into several obstacles and had to re-CAM each of the cut files for the router control. Once I got that done, I grabbed the die and pressed the part. It came out awesome! Here is the formed part and the die below it:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZc2DKAcuhmOcdkaUgIlyyDxw0a2RSKrp-YQ0l-nCBswpllb7JE4zEAmz106MssDJhF8AsW93l2Ggh6hd-SaGTcmP3F1nQrPY2ShznQq_grYxmoynOnnYL2voFxxcYpMpWUpFMyNfFRyNZ/s1600/20191218_212256%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="902" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZc2DKAcuhmOcdkaUgIlyyDxw0a2RSKrp-YQ0l-nCBswpllb7JE4zEAmz106MssDJhF8AsW93l2Ggh6hd-SaGTcmP3F1nQrPY2ShznQq_grYxmoynOnnYL2voFxxcYpMpWUpFMyNfFRyNZ/s320/20191218_212256%257E2.jpg" width="320" /></a></div>
I was really happy with how this part turned out. Here is the inside of the part:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEik7tWyog5lr2Z9jmtG487hH1CsV58vn6taD4SRq_g-6oMRbnqAoUozYMtXCxaBK087jmw6ItCEeTIIwKJxqdNfgE6NvpBlgjjtCW9qKOY9idt9MiFW89cYssPeCG_YKGA4FTxRdypCAlqH/s1600/20191218_212349%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="472" data-original-width="1600" height="94" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEik7tWyog5lr2Z9jmtG487hH1CsV58vn6taD4SRq_g-6oMRbnqAoUozYMtXCxaBK087jmw6ItCEeTIIwKJxqdNfgE6NvpBlgjjtCW9qKOY9idt9MiFW89cYssPeCG_YKGA4FTxRdypCAlqH/s320/20191218_212349%257E2.jpg" width="320" /></a></div>
And the top side of the part with the tabbed edge along the bottom:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj9i0hINbT0lJpq0UtpIcRXp7EaZQ6IyOc2bh5c3w7u_xCD18haCcxA8bIGd0uWwSTygLddvfVHgipbwMO_q8IuFOx3i0YWRHlMW7UzyTey2joxhxanEUifiZJGvBkfcPOC4ALgrz2iPphU/s1600/20191218_212410%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="337" data-original-width="1600" height="67" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj9i0hINbT0lJpq0UtpIcRXp7EaZQ6IyOc2bh5c3w7u_xCD18haCcxA8bIGd0uWwSTygLddvfVHgipbwMO_q8IuFOx3i0YWRHlMW7UzyTey2joxhxanEUifiZJGvBkfcPOC4ALgrz2iPphU/s320/20191218_212410%257E2.jpg" width="320" /></a></div>
Satisfied with the lightening hole flanges (and totally satisfied with the part as a whole), I got right on cutting the matching die for the other part. Here it is mounted in the mill:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjSCN9baXw5VOjUBaLURicWt4hJRl3wo5k41h-imRVVfzNQW__Z_E4g3gX6v2v_U8CeC9YUqrN-gcnYcm1IYH1V83aLN_V7LlRnMM9lMHbd5zxfGPTfLDkwoNjqiSptaH6epUd8OiRbH5dA/s1600/20191219_230013%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="682" data-original-width="1600" height="136" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjSCN9baXw5VOjUBaLURicWt4hJRl3wo5k41h-imRVVfzNQW__Z_E4g3gX6v2v_U8CeC9YUqrN-gcnYcm1IYH1V83aLN_V7LlRnMM9lMHbd5zxfGPTfLDkwoNjqiSptaH6epUd8OiRbH5dA/s320/20191219_230013%257E2.jpg" width="320" /></a></div>
This die also came out with one area that had a void from the weld that my buddy added to the stock. Turns out, it is in an area that doesn't have a flange anyway - so no problem:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjK53GuXvGIbfW0KocHpKYf45023k-6Y7xooTvUq40Szsx_43zqMgL3oElms_2pcTlNpNvRWclUvWibz2DYolCQO4QAXUdJtxchH13sWR7fXFrYOsUBaCDgZyDodCOnzqrEUEy6gsUIOGp7/s1600/20191219_230022%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="619" data-original-width="1108" height="178" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjK53GuXvGIbfW0KocHpKYf45023k-6Y7xooTvUq40Szsx_43zqMgL3oElms_2pcTlNpNvRWclUvWibz2DYolCQO4QAXUdJtxchH13sWR7fXFrYOsUBaCDgZyDodCOnzqrEUEy6gsUIOGp7/s320/20191219_230022%257E2.jpg" width="320" /></a></div>
Here is the completed die:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCW9kW_ZEadhyphenhyphenCXSMWvUXWa0AY1rk63x3SjVChABjqms1zDYufjd87noPofT5Z2DqtCeuChXlTNU7phLFoJzchurYLJ0eYTfIjOYltOQFJarud5FE0hzpndXE2KIgC2Hpt1e1nf0Cm1zvU/s1600/20191220_134224%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="890" data-original-width="1600" height="177" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCW9kW_ZEadhyphenhyphenCXSMWvUXWa0AY1rk63x3SjVChABjqms1zDYufjd87noPofT5Z2DqtCeuChXlTNU7phLFoJzchurYLJ0eYTfIjOYltOQFJarud5FE0hzpndXE2KIgC2Hpt1e1nf0Cm1zvU/s320/20191220_134224%257E2.jpg" width="320" /></a></div>
Within minutes of completing the 2nd die, I grabbed the other blank cut from the router and pressed the matching part. Here are the dies on the left and the set of these parts on the right:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgeiOPEiCmKF-MOoegr6NkxMBMuJkaTsF7Hs5N9BrBlZjmmbCCFat4N11IdTLsRUY0PqsyZ5Y7Vt37F49S2ThYFdd8vCuVavg7D5bw0t7ZghAsKBCo7bTmz7UFCeB4WLhKSmmLJzj5llGqd/s1600/20191220_153250%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1325" data-original-width="1463" height="289" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgeiOPEiCmKF-MOoegr6NkxMBMuJkaTsF7Hs5N9BrBlZjmmbCCFat4N11IdTLsRUY0PqsyZ5Y7Vt37F49S2ThYFdd8vCuVavg7D5bw0t7ZghAsKBCo7bTmz7UFCeB4WLhKSmmLJzj5llGqd/s320/20191220_153250%257E2.jpg" width="320" /></a></div>
Here are the two parts (sort-of) oriented as the would be when mounted in the airplane:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHVaYQpx4vAdypTEWmgq3hiwf222hpELJk74AN6UOpu_HtTt4Q4pYoLo3k2tAL3fRKVuIDfngC5nHEGrIDqH6fdY6wAvOar_6W4SMoxk5pIMeISQkQesadnMjPMC7FJ3tsJIbalUyYuWDj/s1600/20191220_153545%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="852" data-original-width="1483" height="183" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHVaYQpx4vAdypTEWmgq3hiwf222hpELJk74AN6UOpu_HtTt4Q4pYoLo3k2tAL3fRKVuIDfngC5nHEGrIDqH6fdY6wAvOar_6W4SMoxk5pIMeISQkQesadnMjPMC7FJ3tsJIbalUyYuWDj/s320/20191220_153545%257E2.jpg" width="320" /></a></div>
Another view:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-BrIAuz6MqEd497XbGujAlieXMSyzch6cAgNBatet0WNWkFKhhlfCGEvv-3mCcxdy7wtDS4jmsaKG-Oe78WIO-O32ZctJoDAMUDvRiK6KTeen5es3TKKoQpRf6qUV5f7VIWos5dY9k1p4/s1600/20191220_153626%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1131" data-original-width="1161" height="311" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-BrIAuz6MqEd497XbGujAlieXMSyzch6cAgNBatet0WNWkFKhhlfCGEvv-3mCcxdy7wtDS4jmsaKG-Oe78WIO-O32ZctJoDAMUDvRiK6KTeen5es3TKKoQpRf6qUV5f7VIWos5dY9k1p4/s320/20191220_153626%257E2.jpg" width="320" /></a></div>
Overall, I am really happy how these parts turned out. I am getting a process down for machining these dies in the mill. I'm also thrilled with how the 400 Ton press is working. It's forming really nice parts. Now, I only have about 300 more dies to make!!<br />
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<u><b>2. An "Artsy" and Creative Prowler Project</b></u> - After George Morse passed away, I was in contact with his family and they ended up giving me a lot of Prowler related stuff that no one in the family wanted. One of the things I got was a large box full of aircraft and parts drawings. At some point, I went through all the drawings to see what was there. Most of the drawings were Prowler parts that I was already familiar with, but I came across 3 drawings in particular that really intrigued me. I am still not 100% certain what these drawings are. But, I believe that they are all hand-drawn by George and I believe that they are all concept drawings that he did when he was trying to come up with his idea for what eventually became the Prowler aircraft.<br />
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This first drawing is large (36" x 44") and is of a tricycle gear aircraft that has a turbo-prop engine in it. At first, it didn't strike me as being anything related to a Prowler - but, after looking more closely, the wing planform and the tail planform (top down) certainly gives the impression to that of a Prowler. The canopy also looks the closest (of the 3 drawings) to what the Prowler eventually included:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1jAEabWgo95sRGGqq-fTDK9rxSzW88kLl6qxzTFwVh5bx_8d3Et2gA5yYr-La5BX3XNs4j8TGOd2pQRa8ry-UW44bxX2A2yPIFNeSGQpmQsxgjOB7reLrNbyADgxE1JjZTXz3-hdMhYfu/s1600/20191214_211114.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1202" data-original-width="1552" height="247" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1jAEabWgo95sRGGqq-fTDK9rxSzW88kLl6qxzTFwVh5bx_8d3Et2gA5yYr-La5BX3XNs4j8TGOd2pQRa8ry-UW44bxX2A2yPIFNeSGQpmQsxgjOB7reLrNbyADgxE1JjZTXz3-hdMhYfu/s320/20191214_211114.jpg" width="320" /></a></div>
This 2nd drawing is 20" x 24" and is of a tail-dragger design with a folding wing and a flat aircraft engine. The wing folding hinge point looks to be very closely located to the wing joint location of the Prowler. The tail looks to be of P-51A design and the cockpit looks almost of a Mooney descent. However, look at the forward swept main landing gear and the engine compartment - those are clearly the silhouette of the front end of a Prowler!<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5S-UlwMQSbdgkEunj48DeKSNwa2fNE0L0NIuiud_Pzu_e3troJXdMHeDJvSCL2XwVEg3xbBBJ52FNv6vmJE2uJjG31BHgflnFuGD-3uiQgck6XoSYe9BQVB7tqeJAL96t1D02rSkeiAK4/s1600/20191214_212624.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="995" data-original-width="1285" height="247" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5S-UlwMQSbdgkEunj48DeKSNwa2fNE0L0NIuiud_Pzu_e3troJXdMHeDJvSCL2XwVEg3xbBBJ52FNv6vmJE2uJjG31BHgflnFuGD-3uiQgck6XoSYe9BQVB7tqeJAL96t1D02rSkeiAK4/s320/20191214_212624.jpg" width="320" /></a></div>
Here is the 3rd drawing. It is 24" x 42" and is also a tricycle design. The tail also has a P-51A look to it as well as the canopy area. The parts of this drawing that I can easily identify as Prowler are the windscreen and everything forward of that, except for the nosewheel landing gear. Look at the engine compartment and you see the George Morse PSRU and motor mount design. The wing tips, wing dihedral and the taper of the forward and trailing edges also indicate Prowler to me: <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHgtMG2zPVSvMeCxEa3s41rIuIRaSj0-UikhmPlY8fPg6Ee2RurgHCDL5SRnrTDnO0s0itggEZB7Zxj-H6j2Q6gzcjzc3g10DAhzFqQJFfPxk_rXgJIXILnbK4tKc4wwIj9eAw6Ih3TNdb/s1600/20191215_120953%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="950" data-original-width="1600" height="190" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHgtMG2zPVSvMeCxEa3s41rIuIRaSj0-UikhmPlY8fPg6Ee2RurgHCDL5SRnrTDnO0s0itggEZB7Zxj-H6j2Q6gzcjzc3g10DAhzFqQJFfPxk_rXgJIXILnbK4tKc4wwIj9eAw6Ih3TNdb/s320/20191215_120953%257E2.jpg" width="320" /></a></div>
I could not find any signatures or any other identifying markings on any of these drawings. But, I know that George did enjoy doing technical drawings. I think that these drawings have historical importance with regard to Prowler Aviation and the development of the Prowler aircraft. If any of you have any information or thoughts about these drawings - please send them to me.<br />
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I really want to preserve these drawings. So, recently, I got into a creative "mood" and found myself at Hobby Lobby looking for something practical and economical to frame these drawings with. I pretty quickly found an "off the shelf" frame for the 2nd drawing. Here is what it looks like after getting it framed up:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_u7j-jy6X0CUIsmMOhTAjiTdahqJkfk4eIi91xmIvapmwzPRGCWnHaErGWRpugsP96F0NPxc7M8fYwsklcsWjOzseCJUOJ-LvHivUR21D8PDFuaMe8M0fMfvZgig12bLhnehZ9tA9-X5-/s1600/20191214_212623%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1148" data-original-width="1517" height="242" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_u7j-jy6X0CUIsmMOhTAjiTdahqJkfk4eIi91xmIvapmwzPRGCWnHaErGWRpugsP96F0NPxc7M8fYwsklcsWjOzseCJUOJ-LvHivUR21D8PDFuaMe8M0fMfvZgig12bLhnehZ9tA9-X5-/s320/20191214_212623%257E2.jpg" width="320" /></a></div>
Unfortunately, "off the shelf" frames only go up to about 36" x 40". And, it turns out that getting a custom frame made for something that is 36" x 48" is pretty pricey. At this point, I was not inclined to invest almost a 1/2 day's pay into a frame for the large drawing. So, I set out to find another option. I was cruising thru the area of the store that had painting canvases and saw that they had "build-your-size" frames for making a painting canvas. I bought a set of 38" frame sides and a set of 48" sides ($14). Here they are:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIB9a9shb-OsZypIFg91O0AC-C4xjpD0soFSnzebs4KGB6zs5Bx6AmnaE7OikpF0H6sZmUtzhE6HdPAluFZTzmyzw3eO2NnoiCMjKGwS240m1WdoTk1yyOuMa0QgaJ4DwFHezvqKz1fK5X/s1600/20191213_185913.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="493" data-original-width="1600" height="98" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIB9a9shb-OsZypIFg91O0AC-C4xjpD0soFSnzebs4KGB6zs5Bx6AmnaE7OikpF0H6sZmUtzhE6HdPAluFZTzmyzw3eO2NnoiCMjKGwS240m1WdoTk1yyOuMa0QgaJ4DwFHezvqKz1fK5X/s320/20191213_185913.jpg" width="320" /></a></div>
I put them together in a rectangle and glued and nailed the corners. Then, I painted the frame. Next, I cut hardboard triangles and glued and nailed them to the corners to square the frame and stiffen it. Then, I cut down a large piece of foam board ($12) and fit it inside the frame. Here is what that all looked like from the back:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHj9l4ZCyEGyXhVTgBjSGmpuG5IHayP8ZFiLsPzSLwbMxmiDaCuCA1ih_IufAP_oD6XVd43bRmJBz-FeteWbRekWerzlFwesdirTx_CTKDN5kXDfZSDbsjQLsP_r2LqNH1-UsH5953vX3I/s1600/20191219_193623%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1305" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHj9l4ZCyEGyXhVTgBjSGmpuG5IHayP8ZFiLsPzSLwbMxmiDaCuCA1ih_IufAP_oD6XVd43bRmJBz-FeteWbRekWerzlFwesdirTx_CTKDN5kXDfZSDbsjQLsP_r2LqNH1-UsH5953vX3I/s320/20191219_193623%257E2.jpg" width="261" /></a></div>
With that done, I placed the drawing in the frame. Then, I found a 48" x 48" piece of acrylic plexiglass at Home Depot ($50) and cut it down to fit inside the frame. The last step was to cut down some screen molding pieces in the table saw to make some glazing strips that would hold the plexiglass in place. I painted them black for some contrast and nailed them into place to hold the plexiglass. Here it is:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJRXnl-Pbd8qEUERr2EsNDkRv_1PVJAc9CSE421ogXdPazh-ysCNQ2HaktEO4Y_ilw9tcXOd3gJPBFFEq2r3VjtFeVlvPawxHRD9uvB0Bi4oj9ZVz9tj_vMizKPIoXjNcoHyD0N72ZERfY/s1600/20191219_181928%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1273" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJRXnl-Pbd8qEUERr2EsNDkRv_1PVJAc9CSE421ogXdPazh-ysCNQ2HaktEO4Y_ilw9tcXOd3gJPBFFEq2r3VjtFeVlvPawxHRD9uvB0Bi4oj9ZVz9tj_vMizKPIoXjNcoHyD0N72ZERfY/s320/20191219_181928%257E2.jpg" width="254" /></a></div>
The final result turned out pretty nice, I think. I only had to spend about $75 for materials and about 2 hrs or time to make this frame. Sometime in Jan, I'll work on hanging these in the office. I still have to find, or make, a frame for the 3rd drawing. I'll update on that next time. <br />
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<u><b>3. One Builder Update from</b></u><u><b> Francis</b></u> - I've gotten a couple updates from Francis recently. His first was to let us know that he was working on the many access panels for the wings. Here are his panels after cutting them out:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilBV0NSsNnSNJzrJBRsCP5LDFuVPACCF4bTCmy2838DC0Da_SLV6WOAhA3jKVJ_OkeCLXJfplzcfQ1kMa8GkoukzaOO1G_BfW0S9YcMEpNKrcT-r9hqaTxnkeqWk_Y0HjGOXElaUcj1Wja/s1600/20191107_181213.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="778" data-original-width="1600" height="155" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilBV0NSsNnSNJzrJBRsCP5LDFuVPACCF4bTCmy2838DC0Da_SLV6WOAhA3jKVJ_OkeCLXJfplzcfQ1kMa8GkoukzaOO1G_BfW0S9YcMEpNKrcT-r9hqaTxnkeqWk_Y0HjGOXElaUcj1Wja/s320/20191107_181213.jpg" width="320" /></a></div>
And, here are his access panel doublers after he did an alodine process on them:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhm8wZU6pztq9dgJvr0nkhN8hws8wISqTC0vVZMV42T1o8-z9BKZbHCi-3-iEwvkHvS9EvXzGpM65uyhvy4DExNLk-FuTqi9JDZmz7AJIYKmU2SlhJ4EWZsjbdiBUC8kIYsAZ2gz5uS2-4_/s1600/20191130_135316.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="778" data-original-width="1600" height="155" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhm8wZU6pztq9dgJvr0nkhN8hws8wISqTC0vVZMV42T1o8-z9BKZbHCi-3-iEwvkHvS9EvXzGpM65uyhvy4DExNLk-FuTqi9JDZmz7AJIYKmU2SlhJ4EWZsjbdiBUC8kIYsAZ2gz5uS2-4_/s320/20191130_135316.jpg" width="320" /></a></div>
Looks like a great way to separate them and still hold them all together for the alodine process:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhzGsSz18vOLuOyuIygTudzdgfS4foCi18jWFMGz0MaXERcUwfkpWQ8W50L3GC1iX3KkuW6jo9KTzg2J0lns6Ge58FkcgLC_E1WCh82Yog-RCzSiEscajrKvUT-7TXllKc2BGbeIA2zsrEv/s1600/20191130_135338.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="778" data-original-width="1600" height="155" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhzGsSz18vOLuOyuIygTudzdgfS4foCi18jWFMGz0MaXERcUwfkpWQ8W50L3GC1iX3KkuW6jo9KTzg2J0lns6Ge58FkcgLC_E1WCh82Yog-RCzSiEscajrKvUT-7TXllKc2BGbeIA2zsrEv/s320/20191130_135338.jpg" width="320" /></a></div>
Then, just a few days before Xmas, I got an email from Francis telling me that he got his inspection and sign-off (thumbs-up) from OSAC (which I believe is the French form of the FAA). With that, he is now cleared to close up and put skins on his wing. Here is the OSAC stamp of approval on his wing spar:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJ2OpDiq9c5XaX6HUuxIKp9enmVvY3wQbpIdq2m2FaX8pfrAX13b0id-oDlDZP7cQdjohV4qD5rKpFpp4nGhvPv0nDgK_eM7IDMVkq1sB29Jb46LfC5Q7JC236SffDl-3YN3xp7UZr3HII/s1600/20191223_103902.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="778" data-original-width="1600" height="155" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJ2OpDiq9c5XaX6HUuxIKp9enmVvY3wQbpIdq2m2FaX8pfrAX13b0id-oDlDZP7cQdjohV4qD5rKpFpp4nGhvPv0nDgK_eM7IDMVkq1sB29Jb46LfC5Q7JC236SffDl-3YN3xp7UZr3HII/s320/20191223_103902.jpg" width="320" /></a></div>
That's AWESOME, Francis!! Great job!! Looks to me like Francis gave himself an excellent Christmas present this year!! Well done, my friend. <br />
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Well, that's all for this update. I hope you all have a safe, enjoyable holiday season and a happy, healthy new year in 2020.Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-4561663675008429701.post-60560340199998220062019-10-24T18:52:00.001-07:002020-11-26T09:37:51.730-08:00AirVenture 2019 Was AWESOME!!! Original Prowler For Sale & 2 Missing Prowler Kits Found!!Well, AirVenture 2019 was a great one! The XP-82 was outstanding and the Wed & Sat night airshow were typically excellent - with a new finale!!<br /><br />In this update:<br />
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<u>Prowler Stuff:</u></div>
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1. Original Prowler Is For Sale <br />
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2. Two Missing Prowler Kits Located </div>
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2. Builder Updates:</div>
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2.A. Francis Building & Sealing His Forward Fuel Tanks </div>
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2.B. Bryan Has Retired <br />
3. Making Cockpit Floor Stringer Dies </div>
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<u>Non-Prowler Stuff:</u></div>
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4. AirVenture 2019 </div>
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5. Fixing 5th Wheel RV's <br />
6. Hardinge CNC Lathe Progres<br /><br /> <br />
I hope everyone is having a great fall season. I've been trying to clear some projects off my "To-Do List" that have been hanging around for quite some time now. Not the least of which is the Hardinge CNC lathe project. With the kids all out of the house now, I'm able to devote more of my days off from the "Day Job" to getting some of these things done. The kids have been doing the holiday yard decorations for years now, but with them all moved out it's mom's job. But, I decided to have a little fun, too .... HAPPY HALLOWEEN!!<br />
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On with the update........</div>
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<b><span style="font-size: large;">Prowler Stuff:</span></b></div>
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<b><u>1. Original Prowler Is For Sale</u> - </b>In early Sep, I had a fella send me an email asking about the Prowler for sale on Barnstormers. What? I didn't know anything about it, so I went to the Barnstormers website and sure enough, I found this....<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrANcIhYBfbVaBklvSbvNRlBN_QkT7vTh0DxPNs0PxarG0qgtH1N1Yhrrsy2CVHe6pMfEpJUygSdyNfOGDPLOKZJtzNzqwbiaeRa0ZWje45wVR-EV9bzovKM7oSe5GmuVWkgTwx6vjQi_Q/s1600/Orig_Prowler_Barnstormers+Ad.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="295" data-original-width="589" height="160" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrANcIhYBfbVaBklvSbvNRlBN_QkT7vTh0DxPNs0PxarG0qgtH1N1Yhrrsy2CVHe6pMfEpJUygSdyNfOGDPLOKZJtzNzqwbiaeRa0ZWje45wVR-EV9bzovKM7oSe5GmuVWkgTwx6vjQi_Q/s320/Orig_Prowler_Barnstormers+Ad.png" width="320" /></a></div>
Turns out, this is the original Prowler that George Morse built and eventually sold to Curt Hughes in North Carolina. I have had a few email exchanges with Curt, but I have not talked with him. Bryan has talked with him on several occasions however. In fact, Bryan bought his kit from Curt. I have not heard if this Prowler was sold to anyone, but I checked Barnstormers again last night and there are no longer any Prowler ads posted. If anyone knows any more about this Prowler, please send me an email, <a href="http://www.prowleraviation.com/contact/contact.html" target="_blank">here</a>.<br />
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<b><u>2. Two Missing Prowler Kits Located</u> -</b> So, until early this past Sept, there were 3 of George's original 15 kits that I have not located or did have any contact with the last recorded owner. One of these kits (Kit #8) I had no information on at all. The other two I had sent letters to the last owners on record a couple of times and never gotten any response (Kit #2 & Kit #3). I am now happy to report that 2 of those 3 kits have been located!<br />
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First, during my discussion with Bryan about the original Prowler for sale (above), he mentioned that Curt had sold "the other kit". I always only knew that Curt had the original Prowler and the kit that Bryan had bought from him. So, I asked, "What other kit?" Turns out, that was Kit #8. Apparently, Curt had bought the original Prowler and TWO additional kits!! At some point, Kit #8 had been sold to a fella named Fred who lives in GA. Bryan just never knew that I didn't know about that "other kit!" So, one more missing piece of the puzzle had been found!!<br />
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Then, out of the blue I got another email from a fella named Darian in Vernon, BC, Canada. Turns out Darian now has Kit #3 that formerly belonged to Ed Radu in Calgary, Alberta Canada. Darian reports that this kit is still new in the crates and has never been opened or touched. He says he has the canopy and the MLG and everything firewall aft. This kit is <u>FOR SALE</u>, so if you are interested, please send me a note via the <a href="http://www.prowleraviation.com/contact/contact.html" target="_blank">feedback link</a> and I will put you in touch with Darian.<br />
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That leaves only Kit #2 that I have not located or have had contact with the owner. The last recorded owner of Kit #2 is Mr. Everett Reynolds in Missoula, MT. If anyone has any info on the status of this kit, please send me an email via the feedback link on our website, here:
<a href="http://www.prowleraviation.com/contact/contact.html" target="_blank">Feedback</a>
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So, right now, to the best of my knowledge, here is a list of the <br />
CURRENT PROWLER KITS / AIRCRAFT FOR SALE<br />
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Kit #A (Original Flying Aircraft), Curt, NC, USA<br />
Kit #3 (Un-assembled Kit), Darian, BC, Canada</div>
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Kit #16 (Flying Aircraft), Bud, FL, USA</div>
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Kit #18 (Un-assembled kit), Todd, CA, USA<br />
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Also, Kit #8 might possibly be for sale, but I have not been able to confirm this with the current owner yet. More to follow.</div>
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<b>2. Builder Updates:</b><br />
<b><b><u>2.A. Francis Building & Sealing His Forward Fuel Tanks</u></b></b> - Let me start out by saying that, currently, Francis continues to be the most active Prowler builder and that I really appreciate him sending me periodic updates with pictures to share. (Eric is probably also very active with his Prowler, but I don't have his latest status).<br />
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Most recently, Francis has been building and sealing his forward (outboard) fuel tanks. It looks like the first order of business was to locate fuel sumping fittings:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXpSdBFLUAtpdnbOz0ZalbskSjbZG3t6GSVCczin5Y-kEb1A3noxWKKXznAaI3zH-y9tj39Dpy4DZZaYrmSgpEn0wGjrerjFIWfmGHuZP2pRRromVPRsMRgpjp92ggU89X00OZgIb2EXWX/s1600/20190620_180433-.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="778" data-original-width="1600" height="155" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXpSdBFLUAtpdnbOz0ZalbskSjbZG3t6GSVCczin5Y-kEb1A3noxWKKXznAaI3zH-y9tj39Dpy4DZZaYrmSgpEn0wGjrerjFIWfmGHuZP2pRRromVPRsMRgpjp92ggU89X00OZgIb2EXWX/s320/20190620_180433-.jpg" width="320" /></a></div>
Then, he either had someone machine these for him or he did it himself (not sure). But here is his drawing and the stock to make the flanges shown on the upper left:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1M5bx2TQluPv_GbYrXXM9hUCS75yaU9gpBKLQLsJMGWOSPJxtzOqRjZna0W5ZugWko9xZFEEXBXZ6g_Ixqjv3dFP-68XESxR3-bEVcfB4QOLjuKqo0iMkq93nxDIUijKD-1ihqV0wfpg0/s1600/20190621_212510-.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1329" data-original-width="976" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1M5bx2TQluPv_GbYrXXM9hUCS75yaU9gpBKLQLsJMGWOSPJxtzOqRjZna0W5ZugWko9xZFEEXBXZ6g_Ixqjv3dFP-68XESxR3-bEVcfB4QOLjuKqo0iMkq93nxDIUijKD-1ihqV0wfpg0/s320/20190621_212510-.jpg" width="235" /></a></div>
Looks like the following pic shows him countersinking the flange mounting holes for installation into the wing skins:<br />
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And, here is one of them installed on the fuel tank skin:<br />
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Here is a fuel tank cap installed on the fuel tank skin:<br />
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And, here he is checking the fitment with the skin placed over the forward side of the outboard wing spar:<br />
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That looks awesome, Francis!! Then, the real fun began. In his August email to me Francis tells us again how much he likes his friend "ProSeal".....<br />
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<span style="color: #741b47;"><span style="background-color: #ffe599;"><span face=""trebuchet ms" , sans-serif"><span style="font-size: small;">Fuel tank drain<br />Fuel cap<br />And starting fu..🤬 sealant</span></span></span></span><br />
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And then, in early Oct his email to me with pictures was titled "A Day With My Friend...ProSeal" in the subject line. I'm not sure that I have the timeline of these following pictures exactly right, but here is where Francis sealed the forward side of the outboard spar with ProSeal:<br />
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And, the following pictures are showing the job he did getting the fuel tank skins cleco'ed to the nose ribs and sealed with his "friend"......<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVPLk6HHYEM040VoERcgOVpxtrIu1AqkhL4jEvboZEZmUQFQ2srI1CEFRKck_TSY631m6k07cMMKcd1RdsAoXpr1qHuoh406wYhTkM-umntwpmq505kL3yzZZmfgqQPEMpCaOonAUYcPAU/s1600/20191005_170057.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="778" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVPLk6HHYEM040VoERcgOVpxtrIu1AqkhL4jEvboZEZmUQFQ2srI1CEFRKck_TSY631m6k07cMMKcd1RdsAoXpr1qHuoh406wYhTkM-umntwpmq505kL3yzZZmfgqQPEMpCaOonAUYcPAU/s320/20191005_170057.jpg" width="155" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis_1yahMo81lNKgsLTZ7sLbwvdpib82HH9uDYy8CdWQB6FBVOdlcReO6xiXR9JfoTzvYSNjyTugazWuwJAOyIFj1LVfIVvzC6vXoKnwHi5_8LKOnKduuG4h0WLAe_eNgTwA54UO0WMKQRW/s1600/20191005_171121.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="778" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis_1yahMo81lNKgsLTZ7sLbwvdpib82HH9uDYy8CdWQB6FBVOdlcReO6xiXR9JfoTzvYSNjyTugazWuwJAOyIFj1LVfIVvzC6vXoKnwHi5_8LKOnKduuG4h0WLAe_eNgTwA54UO0WMKQRW/s320/20191005_171121.jpg" width="155" /></a></div>
In his own words, here is the current status of Francis' fuel tank assembly:<br />
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<span style="color: #4c1130;"><span face=""trebuchet ms" , sans-serif"><span style="background-color: #ffe599;">Hello Todd<br />Last Saturday I had Prosealed and riveted on fresh Proseal [on] one rib,so😬🤯🤬🤢🤮<br />[In] The time [it takes] to squeeze the rivets the Proseal is not useable (dry) for the other ribs, so I [had to] discard the 3/4 of material!<br />In accordance with advice of some "choumack" [French word for "a sheetmetal guy"] today I have Prosealed and clecoed the other ribs and waiting [for] them to dry! I [will] rivet [them] next Saturday.<br />Less dirty [messy]!</span></span></span><br />
<span style="color: #4c1130;"><span style="background-color: #ffe599;"><span face=""trebuchet ms" , sans-serif">Next Saturday, I hope that I can remove the clecos!😁<br />Thanks for all</span></span></span><br />
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Just last night, I got another quick update from Francis. He sent these pics:<br />
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It looks like those clecos did come out. The pic above shows the clecos out and rivets installed along the nose rib lines! Sweet!<br />
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From the side view above, it does not look like the rivet lines have any buckling or warping. It looks like the ribs that he did by just using Proseal and then putting in clecos to hold the rib in place until it was dry did well. Might be a technique to keep in mind. Thanks for sharing that, Francis. Here is his note with the latest pics:</div>
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<span style="background-color: #ffe599;"><span style="color: #741b47;"><span face=""trebuchet ms" , sans-serif">Hello Todd,
<br />In [while] waiting for the visit of OSAC inspection [French form of FAA] to close the spar I start[ed] the riveting of the leading edge [fuel tank]. I use ms20426 -4-3.5 instead -4-3 ,i think -3 are too short and -4 are too long!</span></span></span></div>
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Nicely done, Francis!! Thanks for the update. Great work, as always!!!<br />
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<b><u>2.B. Bryan Has Retired</u> -</b> Recently, while emailing with Bryan, he told me of his upcoming final flight. Specifically saying:<br />
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<span style="color: #741b47;"><span style="background-color: #ffe599;"><span face=""trebuchet ms" , sans-serif">Getting busy around here as the whole family is coming in for the final flight, even family I didn’t know I had... They will all be on the ramp parallel to the 9-27 Rwy awaiting the block in. I have a plan. Shoot an ILS to 9 circle to land 36. That should qualify as a fly by without registering a go around for performance metrics, I hope. Bryan</span></span></span><br />
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He later told me that the date was Sep 21st and that he was flying one of his shortest flight leg ever in the B777 for his last flight - OAK to MEM. I checked with him later via text about how it went and he reported this:
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<span style="color: #741b47;"><span style="background-color: #ffe599;"><span face=""trebuchet ms" , sans-serif">Ha! They closed the runway while we were enroute. However, I did overfly the 50 people that were on the ramp while landing on Rwy 18L and they were all impressed with the flyover. We have some awesome video. For one fleeting moment I had some emotion about the event. I'm over that now - on to a new life!</span></span></span><br />
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Bryan started working as a delivery driver for FedEx over 40 years ago. He worked as a FedEx driver while he built flight time and eventually got hired by FedEx's internal flight department. After getting hired to that job, he waited for the next application window for FedEx line pilots and was given an interview and hired to the line. He was also allowed to keep all of his longevity time as a FedEx employee! So, in total, he has flown the line at FedEx for over 31 years and retired with 42 years of longevity!!</div>
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<u><i><b>CONGRATULATIONS</b></i></u>, Bryan!!! You have had an incredible career! You have also been a wealth of help and information for me with regard to Prowler airplanes. You have also been a great friend! Enjoy your retirement!!<br /><br />Bryan had an engine for sale during AirVenture. He displayed it at the RFA building during the show. On the last day we had to get it back to the RV's so that he could put it on the trailer. We decided that the easiest way to get the engine back to camp was to have Bryan ride in the back of the golf cart and hold the cart that he had the engine mounted to and pull it back. Here's what that looked like:<br />
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It was slow going, but it worked great! And, Bryan eventually sold the engine!<br /><br />
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<u><b>3. Making Cockpit Floor Stringer Dies</b></u> - Last week, I was having a frustrating time in the shop trying to get some equipment projects finished. So, I decided to switch up to working on a Prowler project. The project currently at the top of the Prowler list is getting some floor stringers (part FFA22 & FFA23) made for Kit #18 that I have for sale. Before I can make the parts, I have to get the dies (form blocks) made. In a blog update in April I mentioned cutting the large pieces of 1" thick aluminum bar to make these dies. Here are the two rough cut dies on the bottom and the old pattern for the floor stringer part on top:</div>
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Eventually, the dies should look something like this:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj49OSNsL6-PyFtWwsAkwcaDTrgq53NwVfByM9MdgzIpN-tmQUKzRHgO4twyVT49gaCCXHUS2_f63fLaTBOTzb0XPl4Au5WAw6kF8paW9J7q7BYkbHSnQd6savtpzdgUxQuu45Cca6ZL8YT/s1600/FFA22%252623+Overall+Die+Dims.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="474" data-original-width="1504" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj49OSNsL6-PyFtWwsAkwcaDTrgq53NwVfByM9MdgzIpN-tmQUKzRHgO4twyVT49gaCCXHUS2_f63fLaTBOTzb0XPl4Au5WAw6kF8paW9J7q7BYkbHSnQd6savtpzdgUxQuu45Cca6ZL8YT/s320/FFA22%252623+Overall+Die+Dims.png" width="320" /></a></div>
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The circles represent pockets that will be cut into the top of the die to allow for forming the flanges on the lightening holes. These pockets will be slightly larger than the lightening holes in the parts and when placed in the press, the rubber will bend the center edges of these holes down into the pockets and form flanges around them.<br />
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In order to machine these dies, the first thing that has to be done is figure out a way to fixture and hold the die on the mill table rigidly. I have a fixture plate that I have been using to make all of my dies so far. I figured I could still use this fixture plate, but I was going to have to make some other provisions to hold the fixture plate to the mill table (since the die is so large and covers most of the fixture plate up). Here is RH die sitting on top of the fixture plate sitting on the mill table:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmQPGto0uRYPlKpmkRyT_K07eSVWzuL1bGRLDjPffWDCqIMupklDO-T-E_7CDmRGjZxDark1aSgt7B-bf-aRbm82T89m23e4f1Em6igZEoWIFk24-w9DbCxm-wSztZ5Itp_6Zvc7hnte9M/s1600/20191008_131309.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="819" data-original-width="886" height="295" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmQPGto0uRYPlKpmkRyT_K07eSVWzuL1bGRLDjPffWDCqIMupklDO-T-E_7CDmRGjZxDark1aSgt7B-bf-aRbm82T89m23e4f1Em6igZEoWIFk24-w9DbCxm-wSztZ5Itp_6Zvc7hnte9M/s320/20191008_131309.jpg" width="320" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmQPGto0uRYPlKpmkRyT_K07eSVWzuL1bGRLDjPffWDCqIMupklDO-T-E_7CDmRGjZxDark1aSgt7B-bf-aRbm82T89m23e4f1Em6igZEoWIFk24-w9DbCxm-wSztZ5Itp_6Zvc7hnte9M/s1600/20191008_131309.jpg" style="margin-left: 1em; margin-right: 1em;"></a></div>
It is not easy to see in the pic above, but there is just enough of the fixture plate exposed at the top (RH side) of the die to allow counter sunk screws to be put into T nuts in the top slot of the mill table. This will hold the top of the fixture plate to the mill table. However, the bottom of the die and the bottom of the fixture plate hang over the front of the mill table. I was going to have to devise some means to hold the bottom of the fixture plate (LH side as pictured) to the front of the mill table. So, I made up some steel blocks with thru holes for 3/8" bolts into T nuts in the front table slot and then have threaded holes vertically down through the blocks. Here is what those look like:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFrIrn8iN5UsGDQJwIpUWdtqjz5amqMerCbKRx1Qb6vcA1SdnZbLP_qvp6uqJxfsW7mo9-1742wBK0cMZBQ-Tb8K2owu0pI9Tha9RtQSe4P0RXC3sFYO9jn9pQ8M7uY_gdcH549zWIsiph/s1600/20191008_111347.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="678" data-original-width="1134" height="191" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFrIrn8iN5UsGDQJwIpUWdtqjz5amqMerCbKRx1Qb6vcA1SdnZbLP_qvp6uqJxfsW7mo9-1742wBK0cMZBQ-Tb8K2owu0pI9Tha9RtQSe4P0RXC3sFYO9jn9pQ8M7uY_gdcH549zWIsiph/s320/20191008_111347.jpg" width="320" /></a></div>
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The bolts through the fixture plate have to have flush heads counter sunk into the fixture plate, but for measurement you can see a regular hex head bolt on the left above. I figured out later that the die will cover the hole in the fixture plate on the right front corner. So, here below, I had to thread the 1/4" all-thread into the bottom of the fixture plate and locked it with a jam nut. Then the all-thread passes through a clearance hole in the steel block. A nut on the bottom of the block that is bolted to the front of the mill table pulls the fixture plate tight down to the mill:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgy2MjdQFtLf3wmEC-sNmqWdxnbAa0YjjUj7LxmQ8Bb0U5aEeIuc0FD6O5NFFa0sBWWUitWd9QCPUjnTfjo9MFJ4zGkoysR2SV70_NJIHpJXncnLofaqXvqYbnzepEQjNJEKWsOlRVshLXh/s1600/20191008_130947.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="716" data-original-width="732" height="313" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgy2MjdQFtLf3wmEC-sNmqWdxnbAa0YjjUj7LxmQ8Bb0U5aEeIuc0FD6O5NFFa0sBWWUitWd9QCPUjnTfjo9MFJ4zGkoysR2SV70_NJIHpJXncnLofaqXvqYbnzepEQjNJEKWsOlRVshLXh/s320/20191008_130947.jpg" width="320" /></a></div>
Here is pic of the left front side of the fixture plate showing that I did not have any flush head cap screws long enough to reach the anchor block:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-e-dbv2_LbF7XRk-sjzslwhTBc71TpW-2rBrXetU774mYB_TBpd43439al8ieYx_SHdeKLT4t87jyq9nI3t-ITMp8pzaAfbO3I9DKWL18sSwSvDZTdhz-HGGQ_fnLlTgqmgzZe1wnUClR/s1600/20191008_131028.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="839" height="288" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-e-dbv2_LbF7XRk-sjzslwhTBc71TpW-2rBrXetU774mYB_TBpd43439al8ieYx_SHdeKLT4t87jyq9nI3t-ITMp8pzaAfbO3I9DKWL18sSwSvDZTdhz-HGGQ_fnLlTgqmgzZe1wnUClR/s320/20191008_131028.jpg" width="320" /></a></div>
I would have to get longer bolts the next day, but I continued on with the mounting of the die onto the fixture plate. Here is the ruff-cut aluminum die clamped in the correct position onto the fixture plate:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqQiH-TR-_9A0qsjaydq_8tV71DT5CRUEgR9tZm6NHAJhNywF38p-ydCSWYtAdIfCdyaP_bxXvX-NzJSHHe-_viOrRUE_uYX4eVrlfd_d3akdL_7GfHK0TpFu7Wx8EbOPRkJ7zHBM7V88c/s1600/20191008_132150.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="713" data-original-width="1220" height="187" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqQiH-TR-_9A0qsjaydq_8tV71DT5CRUEgR9tZm6NHAJhNywF38p-ydCSWYtAdIfCdyaP_bxXvX-NzJSHHe-_viOrRUE_uYX4eVrlfd_d3akdL_7GfHK0TpFu7Wx8EbOPRkJ7zHBM7V88c/s320/20191008_132150.jpg" width="320" /></a></div>
Then, I flipped it over and put it on blocks so that the clamps cleared the top of the table:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinc5IGT5du42_zdRte8fxULK46V8pnhGAq6nieqC_WsNaQRaTX9wflCbJhhKT2XH3flYNozgfphdsDsjVvdQHwxDX1Pu34HtKQNKeZaLPiaeH20km1fnJZgpRntNG_B0ezhUPqgiFR-fWm/s1600/20191008_132423.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="552" data-original-width="1444" height="122" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinc5IGT5du42_zdRte8fxULK46V8pnhGAq6nieqC_WsNaQRaTX9wflCbJhhKT2XH3flYNozgfphdsDsjVvdQHwxDX1Pu34HtKQNKeZaLPiaeH20km1fnJZgpRntNG_B0ezhUPqgiFR-fWm/s320/20191008_132423.jpg" width="320" /></a></div>
That allowed me to transfer punch the holes in the fixture plate onto the back of the die:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8zWW40No3zIU5Li2cSIKlqBRSFUSYvZrAECXKMpEW71VuLVfTn8kBl0nFOaym543T-lnQqwIklxKxiqdgMxI-JNSxbOqLD7yEsL1RGdXfQpm_rAfL094HuZ16Abh74I1md2bOBNaYk9LG/s1600/20191008_132755.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="556" data-original-width="1476" height="120" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8zWW40No3zIU5Li2cSIKlqBRSFUSYvZrAECXKMpEW71VuLVfTn8kBl0nFOaym543T-lnQqwIklxKxiqdgMxI-JNSxbOqLD7yEsL1RGdXfQpm_rAfL094HuZ16Abh74I1md2bOBNaYk9LG/s320/20191008_132755.jpg" width="320" /></a></div>
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These are the transferred punch marks on the back of the die that will be used to drill and tap blind holes:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjsiWPFm4HgW3yt5ELz6xNVnruTMW8GFVVpObJEUOIXdLYXPK5MF9zlMpCiWywfzNm583UHd6iWkW8po_Rk2H8ta-HL53_3Oali0LArfrQ4ekECQeZJsx-ZpjVhlOvoEWduaBQLqhVkQYY/s1600/20191008_133055.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="502" data-original-width="1600" height="100" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjsiWPFm4HgW3yt5ELz6xNVnruTMW8GFVVpObJEUOIXdLYXPK5MF9zlMpCiWywfzNm583UHd6iWkW8po_Rk2H8ta-HL53_3Oali0LArfrQ4ekECQeZJsx-ZpjVhlOvoEWduaBQLqhVkQYY/s320/20191008_133055.jpg" width="320" /></a></div>
Once I completed drilling and tapping the holes, I mounted the die to the fixture plate. Then, I could mount the fixture plate onto the mill table. Here it is:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbiVWQwv01yhFPREfHNYTGTsh-jUDczGS88Yhtrybrm97Vpvr1eh0erWTfWFuvwuJEWg65RpGr1dwdzVpiVuNjddw61pk8ub6UxypKuagFdoZCY9qXsHiTb9hg-7GvsRHNfhzqDLA9j7nW/s1600/20191008_150357.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="711" data-original-width="1250" height="182" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbiVWQwv01yhFPREfHNYTGTsh-jUDczGS88Yhtrybrm97Vpvr1eh0erWTfWFuvwuJEWg65RpGr1dwdzVpiVuNjddw61pk8ub6UxypKuagFdoZCY9qXsHiTb9hg-7GvsRHNfhzqDLA9j7nW/s320/20191008_150357.jpg" width="320" /></a></div>
Now, the bad news. With the die mounted in the mill, I did the programming and did a test cut on the profile of the die. To do this test cut, I set the cut depth to zero and run the profile program. The cutting tool drops to the top of the part and then moves around the outside profile of the part. When I did this for the die, I found out that I ruff-cut these dies too small!!! Ugh!! More frustration!!<br />
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After making a few adjustments and running the program a few times I determined that one die was only too small along approximately 14 inches of the bottom curve. You can see it here: </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKrj_bd0xkUJRuS8vOxfLQ758CuGMKN-CUSxwczc4k9pI1ciNlR9EzwhFmRruuong5EKBhPzw4L8mWY_abf8gwyV36shJaKft5QVnPg_esMXXBSW7RIYaTFQs1E1_9p3nS7UqOaIKF75WK/s1600/20191014_123836%257E2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="451" data-original-width="1600" height="90" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKrj_bd0xkUJRuS8vOxfLQ758CuGMKN-CUSxwczc4k9pI1ciNlR9EzwhFmRruuong5EKBhPzw4L8mWY_abf8gwyV36shJaKft5QVnPg_esMXXBSW7RIYaTFQs1E1_9p3nS7UqOaIKF75WK/s320/20191014_123836%257E2.jpg" width="320" /></a></div>
Then, buy placing the other die on top of the one that I mounted, I found that the 2nd die was a little too short on the overall length by about 1/16" and that it was also too small on the bottom curve along about 16" near at the narrow end. I marked approx how much material needed to be added (see markings in the pic above) to these places. I took them over to buddy who is going to add aluminum weld to these dies for me while I'm on the road for the next several days. Next time I'm in the shop, I should get these dies cut out successfully. More to follow.<br />
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<b><span style="font-size: large;">Non-Prowler Stuff:</span></b><br />
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<b><b><u>4. AirVenture 2019</u></b></b> - For me, this year, AirVenture started the week prior to opening Monday. I headed back to WI a week early between work trips to get my RV and move it down to Camp Scholler. I wanted to get my/our campsite set up prior to my final work trip for the month of Jul. That way, once I was done with my last trip, I would be able to head back to OSH for the start of AirVenture and not have to worry about getting all set up. Turns out, that was a good call as the weather on Sat prior to AirVenture was crazy and definitely hindered the beginning of the show this year. It was well worth the cost of an extra few days to know that the rig would be all set up and waiting for me.</div>
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You might recall that last winter my dad's RV got crushed under a collapsed building that got a huge snow load from the harsh weather last winter. While his RV was out of commission, I offered my RV to him to stay in at his sawmill this season. He did use it until I needed it for AirVenture. So, the first thing we had to do was get up to his sawmill where he works in the summer months and unhook my RV from the parking spot where his RV normally is and pull it out of the way. Here is my RV after we got it moved out of the way:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8JMBg1phxVvlSG1gyhL8RDIT50KH5UIGedQJkgzkOnKQh2EhitxgP_5bQHLWp7EmzmqvNY6LAvMnvwZ_m13C1J0T1hyphenhyphenK-lcEiXM_lrd52FPen2OWeucVYME8MI4qRyhKYokzn6tb9RzmA/s1600/20190715_154708.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="727" data-original-width="1474" height="157" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8JMBg1phxVvlSG1gyhL8RDIT50KH5UIGedQJkgzkOnKQh2EhitxgP_5bQHLWp7EmzmqvNY6LAvMnvwZ_m13C1J0T1hyphenhyphenK-lcEiXM_lrd52FPen2OWeucVYME8MI4qRyhKYokzn6tb9RzmA/s320/20190715_154708.jpg" width="320" /></a></div>
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Then, we were able to drop my rig and move his RV back into its normal parking spot and get it hooked up. Here is his rig moved back in it's spot and all hooked up again:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg60aKFrjD5FlEz10BF5t-m8VNgTb7vD764ri3eIe2H3xpCUpQWHN7_FDoYKjk7pTw4rgrBYt-elpncH5uGbsW-gndKCivH_PNAEV7-P8_VbMjwarQ8sWboTEXc8YRaT5OtiNp9qLeOR2lB/s1600/20190715_154722.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="733" data-original-width="1571" height="149" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg60aKFrjD5FlEz10BF5t-m8VNgTb7vD764ri3eIe2H3xpCUpQWHN7_FDoYKjk7pTw4rgrBYt-elpncH5uGbsW-gndKCivH_PNAEV7-P8_VbMjwarQ8sWboTEXc8YRaT5OtiNp9qLeOR2lB/s320/20190715_154722.jpg" width="320" /></a></div>
Then, the following day, we pulled my RV down to Camp Scholler and got it set up in my favorite parking spot under the big Oak tree:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNXfqLiXjSjhpguF6n-AJhaY0EAwsZqnvtb4loJDqfm6d8AcvEJ1E8Agxv4MkCi90f_NpcLik-WH18sihkU-VX79myP616kTxdCURSUmKSsFQuVjmhzBgXHtH-AHccoKSpMD-V9Io9vpA_/s1600/20190717_073303.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="702" data-original-width="1584" height="141" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNXfqLiXjSjhpguF6n-AJhaY0EAwsZqnvtb4loJDqfm6d8AcvEJ1E8Agxv4MkCi90f_NpcLik-WH18sihkU-VX79myP616kTxdCURSUmKSsFQuVjmhzBgXHtH-AHccoKSpMD-V9Io9vpA_/s320/20190717_073303.jpg" width="320" /></a></div>
Notice how empty Camp Scholler is on the Tues before AirVenture begins!! It's crazy how quickly the campground fills up as it gets close to the Sun before opening Monday! In the pic above you might also see the stakes and tape I put up to save a spot for Bryan to park his rig next to me too!<br />
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With that done, I headed back to work for my last trip of the month. After that trip, I got back to my folks very late on Sat before AirVenture. On that Sat some very strong (65K ft) storms passed through central Wisconsin. When we woke up on Sunday morning (without power), this was how my folks yard looked:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWPDBEIWVD46WnjgHSOJfRPyRofmLFfIfOT8kF4Uw6DzMHNMS46_aQsBuN3kR7G9VtSaUOizieBou2DTBoDnnHaKfieB8F2dXPomVfN5KMLmiay5nvaRNr0ta55O-OPGoUAen8NA-ZllkW/s1600/20190721_073127.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1344" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWPDBEIWVD46WnjgHSOJfRPyRofmLFfIfOT8kF4Uw6DzMHNMS46_aQsBuN3kR7G9VtSaUOizieBou2DTBoDnnHaKfieB8F2dXPomVfN5KMLmiay5nvaRNr0ta55O-OPGoUAen8NA-ZllkW/s320/20190721_073127.jpg" width="320" /></a></div>
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In total, the storm broke the tops out of 2 dozen trees (or more) on my folks property. I spent the most of the day on Sunday clearing broken trees out of the yard and driveway. We finally loaded up and headed to Camp Scholler about 7pm. We (the crew and I) finally got to the RV about 9pm on Sun night. Here is a pic of this year's AirVenture "Crew": </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEit9dznYJg_Pez3ujs02VmAowD4yaOn0K5tnJ2UTAg-SZ4dYtsdjMPB8O9TjY6z2Jr3umFzOqhKslNfANDEHUv7jR1lvzjVrZ6hOsD1CsGuNQx6WeODflh9dcUlaXqv4h21RCxpsRfMFtCo/s1600/Crew+Pic+2019-07-22.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="734" data-original-width="1094" height="214" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEit9dznYJg_Pez3ujs02VmAowD4yaOn0K5tnJ2UTAg-SZ4dYtsdjMPB8O9TjY6z2Jr3umFzOqhKslNfANDEHUv7jR1lvzjVrZ6hOsD1CsGuNQx6WeODflh9dcUlaXqv4h21RCxpsRfMFtCo/s320/Crew+Pic+2019-07-22.jpg" width="320" /></a></div>
That's yours truly (front right), my daughter Alex behind me, a work friend, Jennifer (front left), and her boyfriend, Taha, behind her. By Monday afternoon, things at Camp Scholler were getting back to normal, except for the several "lakes" that were still standing in many places from all the heavy rain on Sat. Here is a picture of the flight line crowd on Tues afternoon:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIJMQLmrsooTGGUuj3DY224wsdi0Z0y9Hlv_nIHBrI08Ba7NJYYIiDk_RIJ4Xiwr2kSa2Fxo3uGmAFBSmi77-A3ihzTCE_q6e8xfbd4Fup95OGjzoKufuKBN2T3a9qsZ4_-jvkipJ_ND63/s1600/20190727_144102.vr.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="220" data-original-width="1600" height="43" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIJMQLmrsooTGGUuj3DY224wsdi0Z0y9Hlv_nIHBrI08Ba7NJYYIiDk_RIJ4Xiwr2kSa2Fxo3uGmAFBSmi77-A3ihzTCE_q6e8xfbd4Fup95OGjzoKufuKBN2T3a9qsZ4_-jvkipJ_ND63/s320/20190727_144102.vr.jpg" width="320" /></a></div>
That's the north end of the flight line on the left (above) and the south end of the flight line on the right end. Here is a picture of the Brown Arch for 2019:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWFrpulXIsH5wnMT3maPHJau2K4o7DZjnU9H8bRQEFRmnqX2WtE4wXl1m7MbIJoYO1fCUAEFouxjsJJt3ZqIu4EyZZk6ateKeQUSADGh4Ne2z2k4GIl-QhioGI3XY-2tWGrvpwGqNSzuFC/s1600/IMG_20190722_151345.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="803" data-original-width="1392" height="184" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWFrpulXIsH5wnMT3maPHJau2K4o7DZjnU9H8bRQEFRmnqX2WtE4wXl1m7MbIJoYO1fCUAEFouxjsJJt3ZqIu4EyZZk6ateKeQUSADGh4Ne2z2k4GIl-QhioGI3XY-2tWGrvpwGqNSzuFC/s320/IMG_20190722_151345.jpg" width="320" /></a></div>
Here is a 1st time aircraft for me (maybe ever at AirVenture, I'm not sure?). It looks a little like a Spitfire and I little like a Hurricane. It's actually a Fairey Firefly:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcD1IUjlzcvsjztAR9PdHaCr9SYpq60IK5CgniSW4kBBkUHM7ftZDssh_vCoFLBcK7bmcgk2P0bo65oV9xV0awt26mGjqnx0RmPE33laMFBhiWovmS9oEGflMAOhKj_d02WyOkRtGVbhHJ/s1600/IMG_20190722_153253.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="829" data-original-width="1600" height="165" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcD1IUjlzcvsjztAR9PdHaCr9SYpq60IK5CgniSW4kBBkUHM7ftZDssh_vCoFLBcK7bmcgk2P0bo65oV9xV0awt26mGjqnx0RmPE33laMFBhiWovmS9oEGflMAOhKj_d02WyOkRtGVbhHJ/s320/IMG_20190722_153253.jpg" width="320" /></a></div>
Here is the airplane that stole the show this year. It was supposed to be at AirVenture in 2018, but got held up. Well, it was definitely worth the wait!!! Definitely!!!<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiP64-z90tNS3f0khRNT3cZZcO3y3YoOf1uDdbWdqKY63P55mUroWdnYOVoYUXkHCP-vM41IeRducwqmwZ29QhUtkTg24XxQBird66V_bsf8oY5FPj8_BX2knrvb5HFjUc2EXsTK5lVDV14/s1600/IMG_20190722_153351.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="868" data-original-width="1579" height="175" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiP64-z90tNS3f0khRNT3cZZcO3y3YoOf1uDdbWdqKY63P55mUroWdnYOVoYUXkHCP-vM41IeRducwqmwZ29QhUtkTg24XxQBird66V_bsf8oY5FPj8_BX2knrvb5HFjUc2EXsTK5lVDV14/s320/IMG_20190722_153351.jpg" width="320" /></a></div>
It's the XP-82 and it is absolutely an incredible aircraft!! <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0QZVDX8GZ5p0ypbUoZ5oVNBZp6M96xu_dGVzuY-kinCAm6vrrKLXGPzpkwb-3nAugHfTdYfL3Q5yLL13b82207hxFexcPtkKOK3hY62MFPhyJrlpdjnd6baHbGno0jAWGGXX9QtRPMSSL/s1600/IMG_20190722_153408.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="901" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0QZVDX8GZ5p0ypbUoZ5oVNBZp6M96xu_dGVzuY-kinCAm6vrrKLXGPzpkwb-3nAugHfTdYfL3Q5yLL13b82207hxFexcPtkKOK3hY62MFPhyJrlpdjnd6baHbGno0jAWGGXX9QtRPMSSL/s320/IMG_20190722_153408.jpg" width="320" /></a></div>
It's stellar, from every angle:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJEYVKB7GAYZDt5lNEeEmCqPve9hU78KexUSn9UO7HJecyU-2zdloZRF9uAvoDM4GmRYNlmCOcn-24_YFwDCzP66-f5MZryBlSjbqvthupYYP0IQiIANXAhisd22tE0cWLKghhB669Wedb/s1600/IMG_20190722_153502.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="827" data-original-width="1563" height="169" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJEYVKB7GAYZDt5lNEeEmCqPve9hU78KexUSn9UO7HJecyU-2zdloZRF9uAvoDM4GmRYNlmCOcn-24_YFwDCzP66-f5MZryBlSjbqvthupYYP0IQiIANXAhisd22tE0cWLKghhB669Wedb/s320/IMG_20190722_153502.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPsS-cm3NGYWWEEgqjaOiBEXrtTXdRxIbhkKeTNKFXxGZjJPDENrBWlgJ_JTPYXUqXOqHMOvaUsPdOY3mvM-BuPubKs6EjnmsaVzZwoDSydGq9wSeDrjZTi2S9SRx_FdRljcj5SJ2Uja9a/s1600/IMG_20190722_153546.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="901" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPsS-cm3NGYWWEEgqjaOiBEXrtTXdRxIbhkKeTNKFXxGZjJPDENrBWlgJ_JTPYXUqXOqHMOvaUsPdOY3mvM-BuPubKs6EjnmsaVzZwoDSydGq9wSeDrjZTi2S9SRx_FdRljcj5SJ2Uja9a/s320/IMG_20190722_153546.jpg" width="320" /></a></div>
There is an incredible story behind the restoration of this aircraft. It's worth the read.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKs3eu167Vb0BmrqcKEaqizuSZscCppoi0DVJm9Vb_TAhldlA5S-O8ZEwnCgPpIOYVoSEaZ24HNUi54akT5Q-xUZ71nddgpSb1l1X3fsdF5gMwrculmxrs_hlknwtdQtNzqJHGtX6Niu0A/s1600/IMG_20190722_153640.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="901" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKs3eu167Vb0BmrqcKEaqizuSZscCppoi0DVJm9Vb_TAhldlA5S-O8ZEwnCgPpIOYVoSEaZ24HNUi54akT5Q-xUZ71nddgpSb1l1X3fsdF5gMwrculmxrs_hlknwtdQtNzqJHGtX6Niu0A/s320/IMG_20190722_153640.jpg" width="320" /></a></div>
Please check it out. A simple web search for XP-82 will provide tons of info.<br />
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It is as beautiful in flight as it is on the ground:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg9GKJ-eAmZBu50u7KaNMAME5D5Vt2WJFUUJVdJohAaPzfeDdcmFWH-SEYW14CfEAERwGC4sYyqvQNSVvQwTTZ1PnpZHu8Y9lkQ6aTmFKKpodvuc5m_hRU6ZS6BnEuVLOSV9LJGzVs16ddv/s1600/IMG_20190727_171741.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg9GKJ-eAmZBu50u7KaNMAME5D5Vt2WJFUUJVdJohAaPzfeDdcmFWH-SEYW14CfEAERwGC4sYyqvQNSVvQwTTZ1PnpZHu8Y9lkQ6aTmFKKpodvuc5m_hRU6ZS6BnEuVLOSV9LJGzVs16ddv/s320/IMG_20190727_171741.jpg" width="320" /></a></div>
Here is another fantasist airplane and always a crowd pleaser. It's the Mosquito:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxgLvRmVmr5URSl2bv5e_DKw-CXe0-HIK_Qyr6wjcNRnyR20w-ITlxL1SWotp46fjIjdXmnJw23vM208O6fYOLLpNi03rKYlnThLLo63A3glcAxxt2vqE2xGVIzXViBaqFtBZwoiocLu2p/s1600/IMG_20190724_102537.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxgLvRmVmr5URSl2bv5e_DKw-CXe0-HIK_Qyr6wjcNRnyR20w-ITlxL1SWotp46fjIjdXmnJw23vM208O6fYOLLpNi03rKYlnThLLo63A3glcAxxt2vqE2xGVIzXViBaqFtBZwoiocLu2p/s320/IMG_20190724_102537.jpg" width="320" /></a></div>
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Here is another favorite aircraft of mine. I've seen the Beech Starship many times, but it still grabs my attention every time. This is a Burt Rutan aircraft and there is so much history, mystery and intrigue that is associated with this airplane. Not many folks know that the building techniques and processes that were created by Burt and Scaled Composites to make the Starship actually laid the foundation for the building of every FAA certified composite aircraft EVER made since!!</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi73c4Hgi3j6_Wq7oMVZe7yCSrtnXMobfZlQXHSOB5FRAmNxo6Ie3PHhSFzVhyphenhyphensgG2Sh1WZp3Ko5u8RnV9NsooMf5cUbFKRv5ICer0u8zk_SKeMVmS0fk5JQKaZ23F4dZWORJ2JlftHf74l/s1600/IMG_20190724_170734.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="636" data-original-width="1600" height="127" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi73c4Hgi3j6_Wq7oMVZe7yCSrtnXMobfZlQXHSOB5FRAmNxo6Ie3PHhSFzVhyphenhyphensgG2Sh1WZp3Ko5u8RnV9NsooMf5cUbFKRv5ICer0u8zk_SKeMVmS0fk5JQKaZ23F4dZWORJ2JlftHf74l/s320/IMG_20190724_170734.jpg" width="320" /></a></div>
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This next airplane is no exception. It also benefited from processes and techniques learned during the Starship certification. It's the B787 and it's the largest certified aircraft that I'm aware of that is built largely of composites. [The Dreamliner has an airframe comprising nearly 50% carbon fiber reinforced plastic and other composites.] By all accounts (that I've heard from among the commercial pilot group) the B787 is an "evolutionary" step up in commercial aircraft design. This is one of United's B787's that was flown into AirVenture with an all female crew this year on Wed for the Women In Aviation meeting.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPdNB8Iph4kZ1cXs2_kbcSA77qVIFpMRggD0g0uNN_BuGX9RKey3xFcfF7YieXnLsrQgnU0APDmfU9RLpTPZa9nC_YpBQ_OR4NHVQ0li0fetlrmMzfxtJWW2iXEj_g60_fr5XF9yIp_wEv/s1600/IMG_20190724_170854.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="619" data-original-width="1600" height="123" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPdNB8Iph4kZ1cXs2_kbcSA77qVIFpMRggD0g0uNN_BuGX9RKey3xFcfF7YieXnLsrQgnU0APDmfU9RLpTPZa9nC_YpBQ_OR4NHVQ0li0fetlrmMzfxtJWW2iXEj_g60_fr5XF9yIp_wEv/s320/IMG_20190724_170854.jpg" width="320" /></a></div>
The F35 Lightning II flew a bunch this year! And, so did the F22 Raptor. Here's one of the F35's on Boeing Plaza:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEit19BZRZnMY3JSmjp2JRlJNzROxh-JGMnMchzc7YdbuVIN-bEiph4S_cvVffYHaA_QH8g7_2CdSAElADJaMkrE_4Ev10_9hXucSlbP98a6G88FmUa05S7HN2eZ9Ct52sBQqeqiZNKLUd2V/s1600/IMG_20190724_172416.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="702" data-original-width="1600" height="140" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEit19BZRZnMY3JSmjp2JRlJNzROxh-JGMnMchzc7YdbuVIN-bEiph4S_cvVffYHaA_QH8g7_2CdSAElADJaMkrE_4Ev10_9hXucSlbP98a6G88FmUa05S7HN2eZ9Ct52sBQqeqiZNKLUd2V/s320/IMG_20190724_172416.jpg" width="320" /></a></div>
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Here's a pic of the multiple military aircraft that flew A LOT this year at AirVenture. The F22's and the F35's flew every airshow, every day!! </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhOzQFy_ApWkkIeoiA8AHuRPPM0c2RxHZiGgqNySyawrmJKcgdUUT4Q1zYE5523Q96WCUIvXXymkLUjW3J05stfMqwvkvWZ04M4hFTEznnEI9qalHvJ9LBQukR3LJavtg03FvtCbIYgOXNJ/s1600/IMG_20190726_110821.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhOzQFy_ApWkkIeoiA8AHuRPPM0c2RxHZiGgqNySyawrmJKcgdUUT4Q1zYE5523Q96WCUIvXXymkLUjW3J05stfMqwvkvWZ04M4hFTEznnEI9qalHvJ9LBQukR3LJavtg03FvtCbIYgOXNJ/s320/IMG_20190726_110821.jpg" width="320" /></a></div>
The active military aircraft and flying at AirVenture this year stood in very stark contrast compared to the years following sequestration. The military burned A LOT of gas this year! By comparison, there was not one single active military aircraft on the field for two years during sequestration. I, for one, am glad their back! And, if anyone ever complains about the sound of fighter jets, please tell them: "It's not noise, it's the sound of FREEDOM!!!"<br />
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It was another GREAT show this year. The night airshow was phenomenal. As I have said before, if you can only get to AirVenture for one day - make sure it is a Wed or Sat. The night airshow (and the fireworks display in particular) is worth the price of admission all by itself!!</div>
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So, in years past, the fireworks was the finale for the night airshow, and the "wall of fire" was the fireworks finale. This year, the wall of fire was only the beginning of the finale. It's now the "ball of fire" that wraps up the show. Seriously! Check this out: </div>
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<iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dw3JtGIDphUxVkXAR3No4g8jwQzQ-l-zHa8S7XLl1DsOF6Geys8VgCnuOUWpAQ9l1aITVcGawlj6PdieAoHBA' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div>
Wowzer!!!<br />
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<u><b>5. Fixing 5th Wheel RV's</b></u> - As I mentioned above, over last winter dad's RV got crushed and in May this spring I went to help him dig it out of this mess:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTZIyKS3HxeZqZujvVxJrkV5xYuCEKzBO6U6KXTXcJz2lBljaBKtn2YczX3kubxK2XTVE5Nwzi5GFXyXJSqlbQDj7_pASWPR0lBDLhL9BpXmkh-w664xfLUut2dLKPCcK3l0ZEypsybFtO/s1600/20190502_161546.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="901" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTZIyKS3HxeZqZujvVxJrkV5xYuCEKzBO6U6KXTXcJz2lBljaBKtn2YczX3kubxK2XTVE5Nwzi5GFXyXJSqlbQDj7_pASWPR0lBDLhL9BpXmkh-w664xfLUut2dLKPCcK3l0ZEypsybFtO/s320/20190502_161546.jpg" width="320" /></a></div>
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After we got the RV un-buried, we pretty much tore a bunch of stuff apart on the inside to get at everything that we needed to get to so that he could start to fix it. For example, the bed and bedroom had to be pulled apart in order to fix the bump-out rack gear, the landing gear under the front of the RV, and then put in new carpeting. After AirVenture, I had some extra days off before having to get back to work. So, I could stay and help dad get his RV back together so that it would be livable again. The first order of business was to get the bedroom back together. Here is the bed going back together after fixing the bump-out gear (he already had the landing gear fixed and the carpet re-installed):</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcB0sGVOd_mOOaqL7T8jz3ji9lHDyumFYq15Kh6G4bOcMfumHtdU00b9bxDSFSbGvFtnFtBSi0FBKFEiv7nsfp1WZpMCsfcoWdsFaUSpMJhrlbCjEqcvKMHSIXbjtRw6OyATTPbg3mwq9e/s1600/20190730_150252.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1344" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcB0sGVOd_mOOaqL7T8jz3ji9lHDyumFYq15Kh6G4bOcMfumHtdU00b9bxDSFSbGvFtnFtBSi0FBKFEiv7nsfp1WZpMCsfcoWdsFaUSpMJhrlbCjEqcvKMHSIXbjtRw6OyATTPbg3mwq9e/s320/20190730_150252.jpg" width="320" /></a></div>
And, the bedroom all back together:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1aDMh7FsagB2MudRgCuGPOP_7Pnk05FtnKqqO4LPTho6pDEk1FMWByUtUBwJu6VLZXw8bR8zrhrkmQCuZmhAGaOnHDW5DVazW08eAmESPY8Uvvs7OqAYihVRlgWDPNKKeZKPJR1R_R6Xd/s1600/20190730_182322.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1344" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1aDMh7FsagB2MudRgCuGPOP_7Pnk05FtnKqqO4LPTho6pDEk1FMWByUtUBwJu6VLZXw8bR8zrhrkmQCuZmhAGaOnHDW5DVazW08eAmESPY8Uvvs7OqAYihVRlgWDPNKKeZKPJR1R_R6Xd/s320/20190730_182322.jpg" width="320" /></a></div>
You may also recall this pic of one of the building trusses that came down square on top of the air conditioner. You can see here how the RV roof was crushed down and pushed down into the living space by the truss and a/c unit:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjnT8PMR9wLFpDNJ8YHNjyhh7oVR7mq5CBwCMxVnbnn52U93rh5Cunf1cDfzVBI_CZj4mJNrESgyIHMinIiVLQa5_k8sTGlizFMBW21i87koW4OZ4druHbOgMmWQpDIM9UQp_AjcBF-jKKf/s1600/20190503_173748.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="901" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjnT8PMR9wLFpDNJ8YHNjyhh7oVR7mq5CBwCMxVnbnn52U93rh5Cunf1cDfzVBI_CZj4mJNrESgyIHMinIiVLQa5_k8sTGlizFMBW21i87koW4OZ4druHbOgMmWQpDIM9UQp_AjcBF-jKKf/s320/20190503_173748.jpg" width="320" /></a></div>
On the inside, we had to somehow "shove" the roof back up, and then do something to it so that it would stay up and not want to mush back down. To "shove" everything back up into position, we decided to make up and H frame on top of some screw jacks and use them to push the ceiling back up. Here's what we came up with:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjx0-ljD8HoAb0WjwN91zeT-jd6IPk-UAUmVPkX1sRpPAFw-biq8N1r517LD4HEkFyOp00OdDEan1khDso3bMtlrNHEKqTCApwtUFMqI5hmk-rivrwmT03dzpRYEa4QwedOQpDfCcxYVRaS/s1600/20190801_100718.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1344" data-original-width="756" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjx0-ljD8HoAb0WjwN91zeT-jd6IPk-UAUmVPkX1sRpPAFw-biq8N1r517LD4HEkFyOp00OdDEan1khDso3bMtlrNHEKqTCApwtUFMqI5hmk-rivrwmT03dzpRYEa4QwedOQpDfCcxYVRaS/s320/20190801_100718.jpg" width="180" /></a></div>
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Once we got the part of the ceiling that was in front of the hole (towards the front of the RV) pushed back up into position, we cut a heavy oak board to the right size and shape so that it would fit inside of the existing aluminum truss in the roof. Then, we glued and screwed it into place. By doing that, the broken roof truss and ceiling would stay up in position after removing the jacks. Here is what it looked like just before we took the H frame back down:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWEvJRXNJdfKv6hCmBUpqRxdHIvk1b3D5B60GUihem1Qv3HYXB0E_-I86O7QUQoBEnh_c9WxSJwJ8MUQIxcadwGoo3iMvNPOT_UNwCEjjioRTOkzy9nvfZ1mVQAYot1gzSEbdi1oyMoem0/s1600/20190801_132112.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="696" data-original-width="1600" height="139" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWEvJRXNJdfKv6hCmBUpqRxdHIvk1b3D5B60GUihem1Qv3HYXB0E_-I86O7QUQoBEnh_c9WxSJwJ8MUQIxcadwGoo3iMvNPOT_UNwCEjjioRTOkzy9nvfZ1mVQAYot1gzSEbdi1oyMoem0/s320/20190801_132112.jpg" width="320" /></a></div>
Then, we repeated the process on the part of the ceiling that was just aft of the hole (towards the back of the RV) and got the heavy oak board glued and screwed into place:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPTlaaEM6L6IoVST48i0ciQvHyAFyRP0zDNaQb2p6G8dS3O1elawvvM-UaruA60RwEkvoVOYnSAQpx7CDOSe2rdJzQpHvVqKKZ8Pds_8WwLmhzlOwXzKzc0uuhQwM1QENJ7lg_QowFov0x/s1600/20190801_152610.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1344" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPTlaaEM6L6IoVST48i0ciQvHyAFyRP0zDNaQb2p6G8dS3O1elawvvM-UaruA60RwEkvoVOYnSAQpx7CDOSe2rdJzQpHvVqKKZ8Pds_8WwLmhzlOwXzKzc0uuhQwM1QENJ7lg_QowFov0x/s320/20190801_152610.jpg" width="320" /></a></div>
This is how the hole looked after both trusses were pushed back up into position and the roof trusses were reinforced:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8qqauUVJ8jv9lXw_PpZbRkZbTUkLXqiXAlVVDwERkiksg1kIkLGakqpy7adQ1f7CBBUN6JBxtVNTzJieLnrtkuo77GFwspezRrAGbFc8c06qQ02lcr4jqxgby4713aZ_ZnxuptAdRh9Dv/s1600/20190801_164938.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1344" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8qqauUVJ8jv9lXw_PpZbRkZbTUkLXqiXAlVVDwERkiksg1kIkLGakqpy7adQ1f7CBBUN6JBxtVNTzJieLnrtkuo77GFwspezRrAGbFc8c06qQ02lcr4jqxgby4713aZ_ZnxuptAdRh9Dv/s320/20190801_164938.jpg" width="320" /></a></div>
Next, we filled the empty space with insulation and then put up a full sheet of luan plywood that we had pre-painted white to match the ceiling:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg9xU3acd6rt4xUwCfQ27Y7rfGIcBW-JPNYEfUlZbuFL1DP1ja-ENMHVaAYA88SkupMkCn8nTrDeqvR3lb7TrwHaa8Ee9dhG5MR6-ilr4tgbF9BBxCogUxXjWWZ-9oIllfdxdUxPMhih_Ro/s1600/20190802_070603.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1344" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg9xU3acd6rt4xUwCfQ27Y7rfGIcBW-JPNYEfUlZbuFL1DP1ja-ENMHVaAYA88SkupMkCn8nTrDeqvR3lb7TrwHaa8Ee9dhG5MR6-ilr4tgbF9BBxCogUxXjWWZ-9oIllfdxdUxPMhih_Ro/s320/20190802_070603.jpg" width="320" /></a></div>
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We left all of that to dry overnight. Then, the next day we went on top of the roof and put a heavy coat of roof tar all around the hole in the roof. Then, we layed down a 3/4" sheet of marine plywood and screwed it down to the roof trusses and all around the perimeter. When that was finished, we covered it all with several coats of white RV roof paint. I don't have any pics of that, but the repair came out great!</div>
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Speaking of white RV roof paint, during AirVenture this year, I climbed up on the roof of my RV and found that there was almost no roof paint left covering my rubber roof. I don't think that it had ever been maintained or re-painted since it was new (20+ years ago). So, while we were working on fixing dad's RV, and when we got tired of looking up, we'd take a break and go up on my rig and look down for a while. The first thing we did with my roof was to remove any covers or fittings that could be taken off and then replaced after painting. Then, we gave the entire roof a good washing and scrubbing to get all the loose junk off of it. Once it was cleaned, here was dad helping me cut in the roof paint around the edges of the roof and all the vents, etc. on the roof:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKWOkxanABabBlkauf40nNGOd1Ok37JntQDFwNv-C5TbTiVndVLx5qoazF8sCqzMIUxMcS6OXryWThqK1iFgAm-Y5ikzVYnh5wJJXjDxgDNRqvpWHw-F49AWHMTdcVm0KhRhL36TdsKezr/s1600/20190730_163649.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1344" data-original-width="756" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKWOkxanABabBlkauf40nNGOd1Ok37JntQDFwNv-C5TbTiVndVLx5qoazF8sCqzMIUxMcS6OXryWThqK1iFgAm-Y5ikzVYnh5wJJXjDxgDNRqvpWHw-F49AWHMTdcVm0KhRhL36TdsKezr/s320/20190730_163649.jpg" width="180" /></a></div>
After we finished cutting in around everything on the roof with 3 coats of paint, I went up and rolled on 3 coats of the while polymer roof paint everywhere else. It came out looking really good!<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjU-QAN7fEyhys62I7XKA1Jdz0h0gvrKMSTJYq0gLSAJfHeNLZcLdDuBk2wezJ7zYVDdPvjEGpd1dSWfinh516eikOtotK-m6HMP84PuiMHKX2eV7RGG7qAlzxXl8nq6fi1WujHuohFdcMQ/s1600/20190801_061900.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1344" data-original-width="756" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjU-QAN7fEyhys62I7XKA1Jdz0h0gvrKMSTJYq0gLSAJfHeNLZcLdDuBk2wezJ7zYVDdPvjEGpd1dSWfinh516eikOtotK-m6HMP84PuiMHKX2eV7RGG7qAlzxXl8nq6fi1WujHuohFdcMQ/s320/20190801_061900.jpg" width="180" /></a></div>
I removed the cover from the air conditioner to make it easier to paint around the unit. When I did, i found that it was deteriorated pretty bad and broken is several places. I ordered a new one and by now, dad has probably put the new one on. I'm really happy to get this job done. It looks great and the RV will be good to go for AirVenture for years to come now!!<br />
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<u><b>Z. Hardinge CNC Lathe Progress</b></u> - I had several days off recently and the biggest project that I have that is physically taking up too much room in my shop is this Hardinge CNC lathe. So, I got after it and tried to get as much done as possible.</div>
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I have a lot of information with this involved project, so I am only going to hit the highlights here.
One of the main objectives on this project was to move all of the spindle control electrical components out of a huge cabinet and condense them into a much smaller enclosure mounted on the side of the lathe. At this point, that has been completed and the spindle has been tested and works. Here is the new spindle components compartment:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIOrCDL8jUyr0US03fLNdcUgUvBG3ami_owO8ABMU4Wg-ys7WP-oWFgGPOVISb1GEnt2AU2lxO_tjEnumLsZS0J-tbLKeUcTVX0aYgJNRhyphenhyphenwLmngr7dMVCbVS7MFf-5xAIjeJW3O6Yfh0-/s1600/20190830_202401%257E2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1190" data-original-width="867" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIOrCDL8jUyr0US03fLNdcUgUvBG3ami_owO8ABMU4Wg-ys7WP-oWFgGPOVISb1GEnt2AU2lxO_tjEnumLsZS0J-tbLKeUcTVX0aYgJNRhyphenhyphenwLmngr7dMVCbVS7MFf-5xAIjeJW3O6Yfh0-/s320/20190830_202401%257E2.jpg" width="233" /></a></div>
Later, I added a door to the new compartment:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzuLt4unUSKXcZEa7QvL5A_XJk-w83db4Q6wnDUgOHebjCCUrIMpRaIUnHNwYcSFRiiTKlG4DbgPf9YRbW3W3lBE4KQs6rM0VSSNBuH-KqBd0_MOO1I044B3QUAeIwmEI_U5e7U_x8fZ3q/s1600/20191005_165009%257E2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1016" data-original-width="697" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzuLt4unUSKXcZEa7QvL5A_XJk-w83db4Q6wnDUgOHebjCCUrIMpRaIUnHNwYcSFRiiTKlG4DbgPf9YRbW3W3lBE4KQs6rM0VSSNBuH-KqBd0_MOO1I044B3QUAeIwmEI_U5e7U_x8fZ3q/s320/20191005_165009%257E2.jpg" width="219" /></a></div>
It still needs a handle, some body putty and some paint -but, the door works great.<br />
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Another big ticket item to get done was to install a cooling fan in the control cabinet as well as a vent to allow the hot air to escape. Here is the new installed fan:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8Y3PaWVJPDEfJh7ScvjuiUoyQukorJ8_D3LlqwiprLKmcfan5S5P7NI9kW8Zt82QSY3MgLs94ulRHTRiIthhKBiMAnmuCwwJKFG1r80TiLfKCYG3NsUTsFKtA5LbdtDLrjzJkOiXWz8_Q/s1600/20190919_101226.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="918" data-original-width="756" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8Y3PaWVJPDEfJh7ScvjuiUoyQukorJ8_D3LlqwiprLKmcfan5S5P7NI9kW8Zt82QSY3MgLs94ulRHTRiIthhKBiMAnmuCwwJKFG1r80TiLfKCYG3NsUTsFKtA5LbdtDLrjzJkOiXWz8_Q/s320/20190919_101226.jpg" width="263" /></a></div>
And, the new vent in the back door of the control:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLuJhKA1ptzI4A4k1m_2H8yI53dTOyNjlwX09L2QDU77Xh_fsnx2NjmRqaAqIbreHIDKzjwWwBQq8jUaNOeWsIQLHSxbPzqdc-jdNrr_VYwR8_z1TD_1jokmP1ANQFgq-nM-DKJKG3Fzew/s1600/20190919_101126.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="653" data-original-width="756" height="276" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLuJhKA1ptzI4A4k1m_2H8yI53dTOyNjlwX09L2QDU77Xh_fsnx2NjmRqaAqIbreHIDKzjwWwBQq8jUaNOeWsIQLHSxbPzqdc-jdNrr_VYwR8_z1TD_1jokmP1ANQFgq-nM-DKJKG3Fzew/s320/20190919_101126.jpg" width="320" /></a></div>
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The Z axis limit switch used to be in a very hard to reach place where it also interfered with other cables and parts of the machine. I moved the switch to this new location and fabricated a rigid actuator that I mounted to the back side of the cross-slide table:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEus6weqrnRvU1WzDv4kAfS0E0g04Xh9GR2k3vwZ2dIdcZfRrWA80wBPQC5dCBo-AmelRUlLg_HaRYaZ76S-FmCUUzmMtw2c7FH8TbgsEmRvO_ARzJDZLSuD9-Uy7hVIlmXzf8arT8zT66/s1600/20191005_164104%257E2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="736" data-original-width="726" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEus6weqrnRvU1WzDv4kAfS0E0g04Xh9GR2k3vwZ2dIdcZfRrWA80wBPQC5dCBo-AmelRUlLg_HaRYaZ76S-FmCUUzmMtw2c7FH8TbgsEmRvO_ARzJDZLSuD9-Uy7hVIlmXzf8arT8zT66/s320/20191005_164104%257E2.jpg" width="315" /></a></div>
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And, the most important modification - a new X axis drive belt pulley installation with a new servo motor mounting plate:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvlPEmbTPJihLG77HosfohnixHmwVjAsBRg9VKIioCJ8jSikWyEdQntA3GqxW9NTy0WD7Y3M84E3PHYZMHjiAIyJ7A9qyIZgnEJn4Xt0j3D8n7-epWYzsWu7BaIK6JBhwfZkm521BuMK0B/s1600/20191005_163531%257E2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="738" data-original-width="681" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvlPEmbTPJihLG77HosfohnixHmwVjAsBRg9VKIioCJ8jSikWyEdQntA3GqxW9NTy0WD7Y3M84E3PHYZMHjiAIyJ7A9qyIZgnEJn4Xt0j3D8n7-epWYzsWu7BaIK6JBhwfZkm521BuMK0B/s320/20191005_163531%257E2.jpg" width="295" /></a></div>
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The hardest nut to crack on this project is going to be to figure out how to re-install the 8 position tool turret and, hopefully, make it work again. I'm hoping I can use air pressure and some of the original parts and make it work again so that the turret can be rotated to select various tools and then be locked back down into position after the tool change. Here is what I'm starting with:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhd46oaNIzoNNCSvvx-hDUxBuVm6nnsp-CSUw_T9AfgyDNqM_SGjJmhWiWvmiG8iA5IbNXgwPNBwHIj1pVSREfqU7iQVPVQUJfnnxszR0sUiWxe2PknZmhAkJjYibVQAHSHradU_3j85lj1/s1600/20191005_165603%257E2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="925" data-original-width="866" height="320" save_image_to_download="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhd46oaNIzoNNCSvvx-hDUxBuVm6nnsp-CSUw_T9AfgyDNqM_SGjJmhWiWvmiG8iA5IbNXgwPNBwHIj1pVSREfqU7iQVPVQUJfnnxszR0sUiWxe2PknZmhAkJjYibVQAHSHradU_3j85lj1/s320/20191005_165603%257E2.jpg" width="299" /></a></div>
And, last, but not least..... Remember that big old huge electrical cabinet? Well, it became a very nice cabinet for storing my Second Amendment devices - after about a week of 10 hr days of work. Here is the cabinet as it was when I got it:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjskdS47AEVnkNCi4ilansWYjNfOZH5kVcU-fNpS-DkaROL12PvM29DO8NMfmqZB7JQI0XiJ6R8zl2xdP-vb-4PKRqxR2x8RgvM46sTOften8W4VnZ6d0m8oNRvCmFnmwImdS0RxQj-XLQr/s1600/20180523_135358.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="900" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjskdS47AEVnkNCi4ilansWYjNfOZH5kVcU-fNpS-DkaROL12PvM29DO8NMfmqZB7JQI0XiJ6R8zl2xdP-vb-4PKRqxR2x8RgvM46sTOften8W4VnZ6d0m8oNRvCmFnmwImdS0RxQj-XLQr/s320/20180523_135358.jpg" width="180" /></a></div>
After gutting the cabinet (accomplished while installing the spindle electrical components into the new cabinet), the first step was to grind off the steel bars welded to the back of it:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqw0k5MrXtvFL6Qe_Mq3ObSiRH_U9SZaVYCb8FoNudfgR3RlSHqwLBkQjE5ydEMNh1z-T7Un5-5CMuaiiuOCi7c3lxiWt8kK84f1tUvZ7EV1OLUuZgAQRR4sVw-q9jqThHLAFiQxNHMEsq/s1600/IMG_20190917_104646.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="708" data-original-width="1287" height="176" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqw0k5MrXtvFL6Qe_Mq3ObSiRH_U9SZaVYCb8FoNudfgR3RlSHqwLBkQjE5ydEMNh1z-T7Un5-5CMuaiiuOCi7c3lxiWt8kK84f1tUvZ7EV1OLUuZgAQRR4sVw-q9jqThHLAFiQxNHMEsq/s320/IMG_20190917_104646.jpg" width="320" /></a></div>
Cut plugs for over a dozen holes and weld in those plugs, then grind them off as flush as possible:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirVfTb7-f7yL584zEQieJMjVQqARdOJwV2EMA6pzL5XMDtDXwpqF_mqLDQFeov4X5Z8FiCfX7dsrR5CSoyzBD87Ex6eJO9l6Ep2U21-28PrtuAFRYpHfylNTG9v4bGXp9JHL_LfFtPjLM_/s1600/IMG_20190919_183635.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="683" data-original-width="722" height="302" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirVfTb7-f7yL584zEQieJMjVQqARdOJwV2EMA6pzL5XMDtDXwpqF_mqLDQFeov4X5Z8FiCfX7dsrR5CSoyzBD87Ex6eJO9l6Ep2U21-28PrtuAFRYpHfylNTG9v4bGXp9JHL_LfFtPjLM_/s320/IMG_20190919_183635.jpg" width="320" /></a></div>
Clean off over 40 years of gunk off the cabinet inside and out and prime after cleaning:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhyphenhyphenvHl_DHl18hY2PbLMKd1B26nkFPhyxblEZSy4fa8VBQOo6ZUoOTK-wlKsgLSZgXaHR8U4GyxfFujUD3EdXI8Sxoa-qHBjUhbBgUwXt2ygD8io2KHp5jU4rDH59fOOndsSpEDihB4fIzc/s1600/IMG_20190922_093020%257E2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1216" data-original-width="1372" height="283" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhyphenhyphenvHl_DHl18hY2PbLMKd1B26nkFPhyxblEZSy4fa8VBQOo6ZUoOTK-wlKsgLSZgXaHR8U4GyxfFujUD3EdXI8Sxoa-qHBjUhbBgUwXt2ygD8io2KHp5jU4rDH59fOOndsSpEDihB4fIzc/s320/IMG_20190922_093020%257E2.jpg" width="320" /></a></div>
Also, body putty, sand, and prime all the exposed welded up holes:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7pRzSBseRRTJC5R_Wz32TWcPkr4dI1KPbo5D0fSJWtHCmxt0BWQhF_MhqHc29Vhsf-Z0XdJWlCoUrg65D4tVn012_j0Vi3kup1uiGB8qjN9chkZRwQO8OztQOgQaqgw7KbBE_nKvR3yky/s1600/IMG_20190922_171451.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="914" data-original-width="669" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7pRzSBseRRTJC5R_Wz32TWcPkr4dI1KPbo5D0fSJWtHCmxt0BWQhF_MhqHc29Vhsf-Z0XdJWlCoUrg65D4tVn012_j0Vi3kup1uiGB8qjN9chkZRwQO8OztQOgQaqgw7KbBE_nKvR3yky/s320/IMG_20190922_171451.jpg" width="234" /></a></div>
Here it is after it was mostly primed and ready to paint:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRqU1-Vf9TC1dk7DxUBofTLnlWPSHekF9enuvhXXK_gCpzLv9daY7vcqEqfheAYI0D47oV3KatQD2zJqlZqholIqefltnGdIqQRfs_vzPcADlQsnlZO9rjzKytaaznw91XgQyFX_ugFrSM/s1600/IMG_20190922_184914%257E2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="868" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRqU1-Vf9TC1dk7DxUBofTLnlWPSHekF9enuvhXXK_gCpzLv9daY7vcqEqfheAYI0D47oV3KatQD2zJqlZqholIqefltnGdIqQRfs_vzPcADlQsnlZO9rjzKytaaznw91XgQyFX_ugFrSM/s320/IMG_20190922_184914%257E2.jpg" width="173" /></a></div>
After painting and installing some of the carpet:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZMlsTuAF02PhxQ6GfvQKRISRMG3eCaLl9rnq1h2lottdqM5WC7BJ7dGSRMyoEfNQC9bm_OkHqZvwxzPoLbOaMEsscOKkJ_BEF0zTiqHLW6OVcm3oGU096osLUyL5-UIOqXSj6WV-zxbdF/s1600/IMG_20190925_102000.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1205" data-original-width="756" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZMlsTuAF02PhxQ6GfvQKRISRMG3eCaLl9rnq1h2lottdqM5WC7BJ7dGSRMyoEfNQC9bm_OkHqZvwxzPoLbOaMEsscOKkJ_BEF0zTiqHLW6OVcm3oGU096osLUyL5-UIOqXSj6WV-zxbdF/s320/IMG_20190925_102000.jpg" width="200" /></a></div>
And, finally, the finished product - a cabinet to store my 2nd Amendment devices:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTiMO1lvQjRBt5XPiU4DQVS4HCBt7QTuudz4jaHdBLk83rmUNF-NKfdEDsLeiD-w-kBcFOPMp-8JWfrWEZvHu0Vg1goJmO9tLEbGFZ9r8JI3_r9KK_kTb6c6aD_l1lu4NIx9Gs0_l4ra2i/s1600/IMG_20190925_143942%257E2.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1193" data-original-width="1600" height="238" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTiMO1lvQjRBt5XPiU4DQVS4HCBt7QTuudz4jaHdBLk83rmUNF-NKfdEDsLeiD-w-kBcFOPMp-8JWfrWEZvHu0Vg1goJmO9tLEbGFZ9r8JI3_r9KK_kTb6c6aD_l1lu4NIx9Gs0_l4ra2i/s320/IMG_20190925_143942%257E2.jpg" width="320" /></a></div>
I think it turned out pretty good! Even if I do say so, myself! Ha!<br />
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That's it for this update. Thanks for joining me and checking out this update.</div>
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Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-4561663675008429701.post-70342267072668316412019-07-13T20:25:00.000-07:002019-09-12T08:34:35.584-07:00Prowler Spring (Pre-AirVenture) UpdateHey Everyone,<br />
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Well, summer is getting into full swing and AirVenture is just around the corner. But, I wanted to take a few minutes to recap the Prowler related news, happenings and other stuff that's gone on since the last blog update in April. I personally have not gotten much accomplished with Prowler this spring. I just have too many domestic things happening right now, not the least of which is the last 2 daughters are leaving the house (and the country) soon for college and a Rotary Exchange. But, I do have a fair amount of Prowler related news from several of the builders and owners to share with you. Here is what I have:<br />
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Prowler items in this update:</div>
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1. Ray Has Moved out of "Commie-fornia" </div>
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2. Bryan Has Purchased Kit #4 </div>
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3. Francis has completed paperwork for French FAA </div>
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4. Bud's Prowler is For Sale </div>
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5. Steve Has Donated His Prowler To A Museum<br />
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Before I get started on the blog update, I wanted to share something
pretty interesting with you. This spring, we had really strange, large,
cyclonic storm pass over our area. Here are a couple pics that I took:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_Fmifv1BU2S-MlW-0A98-WC6bdk-DaYQ1MMVUydRGz52a8-AH4Wz-GzDv-esb3NBwh1N0ZcdKCjWTf3I8s7Wht7_-9tEK7sy67iaG4D4RRijyGSRUKQtflbkO-OydDvSAILOLOMe1IqaT/s1600/IMG_20190524_203141.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="900" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_Fmifv1BU2S-MlW-0A98-WC6bdk-DaYQ1MMVUydRGz52a8-AH4Wz-GzDv-esb3NBwh1N0ZcdKCjWTf3I8s7Wht7_-9tEK7sy67iaG4D4RRijyGSRUKQtflbkO-OydDvSAILOLOMe1IqaT/s320/IMG_20190524_203141.jpg" width="180" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKVzXt7vGS8BevkkiG0ya0V0YglkPURpQ2mp2CBVkSlTeZbwYYQsCc26EbpMJ7Srl2Sgs10GjLZkbWhv7_jw5plYp9sBAf-MJdPU-W-pSz-YWB0R2OkQ31p-ZZCvSeC-pJV_nNj3_FwtBr/s1600/IMG_20190524_203127.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKVzXt7vGS8BevkkiG0ya0V0YglkPURpQ2mp2CBVkSlTeZbwYYQsCc26EbpMJ7Srl2Sgs10GjLZkbWhv7_jw5plYp9sBAf-MJdPU-W-pSz-YWB0R2OkQ31p-ZZCvSeC-pJV_nNj3_FwtBr/s320/IMG_20190524_203127.jpg" width="320" /></a></div>
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While you can sort-of see the cyclonic movement of this storm from these pictures, you really needed to be standing under it watching the whole storm spin to get the full effect. Then, my daughter found a video (with some time-lapse footage) that was made by a young guy in her class that makes drone videos. Check this out:</div>
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<iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dwtnSL38fqpcTFxf3uxaz6ZkZiiBcp87vEZngLIDW_wPz4bbUFRo_rhjgh5FIPSLUsAlu221rzCabRnj7LNbA' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div>
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That was a very crazy storm! Nice job on the video, Landon!!<br />
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On with the update.......<br />
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<u><b>1. Ray Has Moved out of "Commie-fornia"</b></u> - In my last update I reported that Ray had stopped by the shop on one of his trips to haul his Prowler and his hangar "stuff" up to the Bend, OR area. Well, recently he and his wife packed up what was left in the house and they made the final move up to Bend. Here is the email that he sent out to announce the move:<br />
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<span style="font-size: small;"><span style="background-color: #b45f06;"><span style="font-family: "georgia" , "times new roman" , serif;">This will be the final communiqué from this outpost. The southern border has now been overrun and the troops are rapidly infiltrating the local area. I suspect the fifth column may begin to activate for the final push. Also noted are more frequent intrusions along the coast, possibly probing operations to locate more weak spots for the final moves.</span></span></span></div>
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<span style="font-size: small;"><span style="background-color: #b45f06;"><span style="font-family: "georgia" , "times new roman" , serif;">We will be evacuating this location in the next few hours and will re-establish communications when we have located a more secure location to operate from. There will be no further transmissions…</span></span></span></div>
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Later, I got this email with the subject line "Return To Reality" and this announcement from the new "outpost":</div>
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<span style="background-color: #b45f06;"><span style="font-family: "georgia" , "times new roman" , serif;">The great escape is over. The return to reality occurred on 10 Jun 2019 @2004Z as I crossed the line in the lead vehicle. The high speed recce vehicle was close behind to complete the relocation convoy. A previous secret load had been pre-positioned with all the industrial tools and supplies and is still hidden in a secret location.</span></span></div>
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<span style="background-color: #b45f06;"><span style="font-family: "georgia" , "times new roman" , serif;">With great difficulty communications have been re-established and the location can now be revealed. [Street Address removed]. Map coordinates are still classified to prevent targeting the exact location by previous enemy officials.</span></span></div>
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<span style="background-color: #b45f06;"><span style="font-family: "georgia" , "times new roman" , serif;">Contact # XXX-XXX-XXXX. This # is classified and not available from any other source.</span></span></div>
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So, there you have it. Ray has really escaped from Commie-fornia. I'm hoping to get invited to visit the new outpost sometime soon. I'll have to make sure that I'm not followed by any previous enemy officials. I'll make a report with pics when I return. Thanks for the updates, Ray. Congratulations on your escape from CA.<br />
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<u><b>2. Bryan has purchased Kit #4</b></u> - Kit #4 was originally purchased by a gentleman named Lee Guiff from Indiana. Lee stuck with George and made payments on the 2nd half of his kit cost and eventually ended up with a mostly complete kit. Unfortunately, Lee passed away recently and his wife began looking for a way to dispose of this kit. I mentioned this to Bryan in one of our conversations. He became interested and eventually negotiated a deal with Lee's wife. Here is a pic from his trip to pick up Kit #4: </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgALUQ2KstLSQaCkaxIstaByX7B31R1dzMd0uSmYG4RJhf0AUTJTlxe_Aee-OP3KNKJVVrOvh9d46_ZdK9EeUl6RCDPUn6qthnGM4BEa6rbHIUyp0DJYeLBMPmxFFaZCiSeyVrNdFlZCKtl/s1600/Bryan+and+Lees+Wife.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="859" data-original-width="566" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgALUQ2KstLSQaCkaxIstaByX7B31R1dzMd0uSmYG4RJhf0AUTJTlxe_Aee-OP3KNKJVVrOvh9d46_ZdK9EeUl6RCDPUn6qthnGM4BEa6rbHIUyp0DJYeLBMPmxFFaZCiSeyVrNdFlZCKtl/s320/Bryan+and+Lees+Wife.png" width="210" /></a></div>
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Here is a write up of the transaction that Bryan sent to me recently:</div>
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<span style="background-color: #b45f06;"><span style="font-family: "georgia" , "times new roman" , serif;">You had mentioned Kit #4 being possible for sale. After the conversation life went on as usual and I had not given this opportunity a second thought. Then one morning out of the blue I had a distinct prompting that I should call and inquire about the status of their progress in reselling their kit. As it turns out not much had transpired since your initial consultation with them since the component pieces were uncrated and shelved in different locations in a barn on the family farm.</span></span></div>
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<span style="background-color: #b45f06;"><span style="font-family: "georgia" , "times new roman" , serif;"><br />After much communication on the subject we reached an understanding and I realized that it was time to borrow a trailer and head north to personally inspect the remnants of Kit #4. As an aside, the original purchaser was introduced to George in the early days of Auto Aviation when George was building F85 engines for other aircraft builders. When the decision was made to transition into building an airframe for the F85 engine, George put together the prototype Prowler. After the decision was made to make Prowler kits, the well known Red White and Blue Jaguar (production) version came to be. <br /><br />That was when Lee made the decision to acquire a position in the kit delivery schedule and kit #4 was assigned. As with all the other initial purchasers component delivery was an issue and diluted the initial enthusiasm associated with the purchase. Eventually a majority of pieces found their way to complement the collection of parts and kit #4 was pretty much complete (but without cowling and engine). Like other builders at the time work was started on the horizontal stab but not much happened after that. As delays were hampering delivery of components almost six years transpired before an engine arrived, then - there it sat for the last twenty-four years.<br /><br />Rolling back the barn doors I immediately began recognizing items that looked all too familiar (from my experience constructing my own kit #7). Remarkably the majority of parts were in good shape so we transitioned into conversing about perceived value and subsequent liabilities of transferring ownership. With those issues settled we loaded up my trailer, reminisced a bit and with smiles all around I became the new caretaker of a collection of salvaged parts. In all, this was a good thing for me as I needed quite a few component pieces to assist me in final assembly of my airframe. Some of the remaining parts will also go to supplement other builders who may need items.</span></span></div>
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Since then, Bryan has begun to process all of his new "stuff" and one
of his first orders of business is to sell the engine that he also
bought from Lee's family. Here are a few pics:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-TR9oBgoTahP77yF-HccrjUZZNhRf3ulYcbfjXmGSBPCqWmhmgAZL269iJhMSA9xnCW9miP0NhCqjB2pvzRXCde0OzzO16US9GwUdSkC-0AG1vSff8iAXV-0KGU2Nxg38f-lw0ShUgV3E/s1600/7832daba-46f3-48aa-bebb-429e6117ebd7.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-TR9oBgoTahP77yF-HccrjUZZNhRf3ulYcbfjXmGSBPCqWmhmgAZL269iJhMSA9xnCW9miP0NhCqjB2pvzRXCde0OzzO16US9GwUdSkC-0AG1vSff8iAXV-0KGU2Nxg38f-lw0ShUgV3E/s320/7832daba-46f3-48aa-bebb-429e6117ebd7.jpg" width="240" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCCy5d7XjepPu7zAKLSX1zaYH5LaPGMrAsx8guLl8V1esCxakWF_7VCZ8te6GrpkeOPgF4GltV_KVPk7D6IZQ7N7R9li-x_551DyHhN4qzT8LpvFG5RxC1O846Ig5ljTFRnAjLK5rStpZ4/s1600/a1983e01-8104-40f6-bb11-ab47ddb4d0e4.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="1280" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCCy5d7XjepPu7zAKLSX1zaYH5LaPGMrAsx8guLl8V1esCxakWF_7VCZ8te6GrpkeOPgF4GltV_KVPk7D6IZQ7N7R9li-x_551DyHhN4qzT8LpvFG5RxC1O846Ig5ljTFRnAjLK5rStpZ4/s320/a1983e01-8104-40f6-bb11-ab47ddb4d0e4.jpg" width="320" /></a></div>
This engine is for sale. If you are interested, please contact me and I will put you in touch with Bryan. If you get to AirVenture this year, you can see this on display!!<br />
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Update: 9/12/19 - The engine has been sold. <br />
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<u><b>3. Francis has completed paperwork for French FAA</b></u> - I recently got an email from Francis that contained a document in French. Here is what Francis sent me:<br />
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<span style="background-color: #b45f06;"><span style="font-family: "georgia" , "times new roman" , serif;">Sent: 6/15/2019 9:40:52 AM<br />Subject: Fwd: 2ème relecture<br />Hello Todd,<br />Some news of "dossier de calcul".<br />Asked by OSAC (French FAA)(they broke my bollocks!)😄🙄😵</span></span></div>
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I asked Francis if this report was good, if the Prowler passed the test with the "French FAA"?? Apparently, he doesn't know yet. His answer was:<br />
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<span style="background-color: #b45f06;"><span style="font-family: "georgia" , "times new roman" , serif;"><span style="font-size: small;">I dont know, but this allows the visit of OSAC to close the spar!</span></span></span></div>
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<span style="background-color: #b45f06;"><span style="font-family: "georgia" , "times new roman" , serif;"><span style="font-size: small;">But, I do not know when, the French bureaucrats are very slow!</span></span></span></div>
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Hopefully, it will happen soon!! Here is the first page of the report that Francis made for the OSAC:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEit0wTMwbopp_3o3znY_gYq_0MQYLqo6GDeK0R-JKvSBwWv344ImRFwGMydb6tDLAKhRrHikF9qqoguXiFOE9QeEuFpDrWPgitJc6S-zCagi2ntsMXhQ6N6Ngh1V9zHgu0Qi26WiuKyQbTg/s1600/Page+1+of+Report.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1165" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEit0wTMwbopp_3o3znY_gYq_0MQYLqo6GDeK0R-JKvSBwWv344ImRFwGMydb6tDLAKhRrHikF9qqoguXiFOE9QeEuFpDrWPgitJc6S-zCagi2ntsMXhQ6N6Ngh1V9zHgu0Qi26WiuKyQbTg/s320/Page+1+of+Report.png" width="233" /></a></div>
If anyone knows a french speaking mathematician that can translate this, please let me know. Thanks for the update Francis! I hope the inspection gets completed soon!<br />
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<u><b>4. Bud's Prowler is For Sale</b></u> - Bud has placed his Prowler For Sale. I created a blog page for him to use to send information to interested folks. See it here: <a href="http://prowleraviation.blogspot.com/2019/07/buds-prowler-is-for-sale.html" save_image_to_download="true" target="_blank">http://prowleraviation.blogspot.com/2019/07/buds-prowler-is-for-sale.html</a></div>
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<u><b>5. Steve Has Donated His Prowler To A Museum</b></u> - I recently emailed Steve to check on the status of selling his Prowler. Here is what Steve sent back to me:<br />
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<span style="background-color: #b45f06;"><span style="font-family: "georgia" , "times new roman" , serif;">Thanks, Todd! I wound up donating it to the Port Townsend Aero Museum at Jefferson County airport in Port Townsend. They picked it up a couple of weeks ago. They’re expanding their museum and envision it hanging in a new building they are preparing to build, gear up and banked; but in the meantime they say they want to fly it. They know they need to swap out the PRSU drive gear and fix the two or three squawks I had from my last flights; we’ll see if they can do it. I’m working on a liability waiver now. I think it will be cool when its all said and done. I told them about you; you might give them a call in case they ever want to consult with you.</span></span><br />
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<span style="background-color: #b45f06;"><span style="font-family: "georgia" , "times new roman" , serif;"><a class="" href="http://www.ptaeromuseum.com/">http://www.ptaeromuseum.com/</a></span></span><br />
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<span style="background-color: #b45f06;"><span style="font-family: "georgia" , "times new roman" , serif;">Cheers, Steve</span></span></div>
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So, the PT Aero Museum may seek some help to get the plane in the condition that they want. I also told Steve that I'd try to put together some kind of tribute to George that could be placed with his airplane. I'll keep you informed as I pursue that.</div>
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Well, that does it for the Prowler update for this time. While I haven't been doing a lot of Prowler work myself, I have still been busy. The following paragraphs outline some of what has been going on with me this spring.</div>
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__________________________________________________<u><b><br /><br />Dad's RV Mess</b></u> - Dad has an RV that he stays in when he is up at his sawmill during the summer. When my folks head for Phoenix each winter, dad puts his RV under a roof that he build many years ago to dry his fresh cut lumber under. This past winter, there was a lot of cold, wet, snow that piled up nearly 4 feet deep on the roof of this shelter. Well, it could not handle that size load and roof and trusses came down onto his RV. It did a lot of damage. I had a stretch of 5 days off at the beginning of May and went home to WI help him get this mess cleaned up. Here is what it looked like on the day we started:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJ9So-KZepThux_jijBXC_W7S_E6w222bIi9QRo89t92MDcvXVe0f1ppX7ZswmLpQhLahwtcBaX90GBFCt0iIHXSSs0LOwGmki1g1QAtLmWkXXDB-NpCmYu3v8Jvri8I5DpI9Ft9sw-9t8/s1600/IMG_20190502_161543.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="901" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJ9So-KZepThux_jijBXC_W7S_E6w222bIi9QRo89t92MDcvXVe0f1ppX7ZswmLpQhLahwtcBaX90GBFCt0iIHXSSs0LOwGmki1g1QAtLmWkXXDB-NpCmYu3v8Jvri8I5DpI9Ft9sw-9t8/s320/IMG_20190502_161543.jpg" width="320" /></a></div>
Here is the "pile" about 6 hours later after we got the sheathing off and the 1st couple trusses removed:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyUX3otLdBJHJ5sx5MWvCdz1AZYStqQrq9zhjld8qL60icFOHv-bEPFRKFZjbO9KAcrbEeBwmu6iO0izMyFk3iaGytsWvpjTs8EsCJZKXDvGpd0NwbEAFUymL7X_o1-9FSmhoAjuvS5crU/s1600/IMG_20190503_120942.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="901" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyUX3otLdBJHJ5sx5MWvCdz1AZYStqQrq9zhjld8qL60icFOHv-bEPFRKFZjbO9KAcrbEeBwmu6iO0izMyFk3iaGytsWvpjTs8EsCJZKXDvGpd0NwbEAFUymL7X_o1-9FSmhoAjuvS5crU/s320/IMG_20190503_120942.jpg" width="320" /></a></div>
Yeah, at 81 years old, that's dad up on the roof of the RV! About noon on the 2nd day, we exposed the truss that crashed down onto the RV air conditioner and shoved it down through the roof. Ugh!!<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhx5MX7b1V2uWsxcwy-VSxaQNNupdVh8YZDGIH4D0tQp-PegQhwpJb-Ma8fZ9BrC8kPgj5JUmKQcRjyGFmJqXU7OAkU6nofKXLmI7YvD8HHiU74ODWtObU5L92BCYMHgg-JI9OnwHcUDQbf/s1600/IMG_20190503_173748.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="901" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhx5MX7b1V2uWsxcwy-VSxaQNNupdVh8YZDGIH4D0tQp-PegQhwpJb-Ma8fZ9BrC8kPgj5JUmKQcRjyGFmJqXU7OAkU6nofKXLmI7YvD8HHiU74ODWtObU5L92BCYMHgg-JI9OnwHcUDQbf/s320/IMG_20190503_173748.jpg" width="320" /></a></div>
This is what was left to do on the last day - just take down the last section of sheathing and trusses:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjv6LW9ESO5d0AV-cMlu5f7kTanIIW4JQWob2ZdKH9KH2uPpuNwmYlCd-6i85vOl86Ji9S1jYIypE8xzaT37Mt9VTyYb3IcG3-gXT0tKPACp2WPEKicmcqF0M7MnJsW5yXEdimzTA6gNPTY/s1600/IMG_20190504_094115.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="901" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjv6LW9ESO5d0AV-cMlu5f7kTanIIW4JQWob2ZdKH9KH2uPpuNwmYlCd-6i85vOl86Ji9S1jYIypE8xzaT37Mt9VTyYb3IcG3-gXT0tKPACp2WPEKicmcqF0M7MnJsW5yXEdimzTA6gNPTY/s320/IMG_20190504_094115.jpg" width="320" /></a></div>
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In the end, we got the entire roof removed and got the RV jacked back up to level so that the landing gear could be removed:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg2bTpWay1zyrhj5CFNktf-gvpflxE_u1Vd0xD8AlFSNbYw2RH7Fo4WgP72V5UA_s4KH8x2FB1K01LaGsJBRZ95CE09lkHhA1gwqbeNPUYjS0YWCP7vBWkdN-vlPK5CsLSAqZYMo4Vusr5k/s1600/IMG_20190504_121901.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="901" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg2bTpWay1zyrhj5CFNktf-gvpflxE_u1Vd0xD8AlFSNbYw2RH7Fo4WgP72V5UA_s4KH8x2FB1K01LaGsJBRZ95CE09lkHhA1gwqbeNPUYjS0YWCP7vBWkdN-vlPK5CsLSAqZYMo4Vusr5k/s320/IMG_20190504_121901.jpg" width="320" /></a></div>
The weight of all that snow coming down onto the RV caused the pins in the landing
gear to shear off. That allowed the landing gear legs to shove up through the bedroom
floor and tore the hell out of the bed and the bump-out gear. Since then, dad has gotten the landing gear fixed and re-installed. Then, he moved the RV off of the slab. After AirVenture this year, I'm going to hang around and help him get the bedroom put back together and get it closer to livable again.<br />
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<u><b>Graduations</b></u> - So, this spring 2 of our 3 daughters had graduations. First, in mid May, our oldest daughter, Kayla, graduated from the University of Montana - Western:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBkMerM9uPISZ7LhTx93k4hsrcTmBBXCsHrDFRzBy3yGyiuYirLOxhJeZpm0A73Vr_m4Jdd6vclsY-jQauJgJz9JFtlR25JJVIVaR82Z25MGb9mdVCV4FJ3pKUUCvX0WmKqVKiX52XHovz/s1600/IMG_20190511_090808_1.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="900" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBkMerM9uPISZ7LhTx93k4hsrcTmBBXCsHrDFRzBy3yGyiuYirLOxhJeZpm0A73Vr_m4Jdd6vclsY-jQauJgJz9JFtlR25JJVIVaR82Z25MGb9mdVCV4FJ3pKUUCvX0WmKqVKiX52XHovz/s320/IMG_20190511_090808_1.jpg" width="180" /></a></div>
Congratulations, Kayla!!! Woo-hoo!! She actually graduated in Dec '18, but the University does not have a mid-year commencement ceremony. So, this was her graduation ceremony. Here are all our daughters at Kayla's graduation:<br />
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Kayla has since been hired by the State of Montana Department of Agriculture as a poultry and meat inspector. She is off to a great start and she is loving her 1st job!<br />
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Then, in early June, our youngest daughter, Crysta, was honored as the valedictorian of her class:<br />
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And, a week later, here is a picture from her HS commencement ceremony:<br />
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Great job, kid!!! Soon, she will leave for 10 months on a Rotary International Exchange to Brazil. On the other end of academic spectrum, our middle daughter, Alexandra (on the right above), has accepted a 3-year partial scholarship to Jacobs University in Bremen, Germany. She'll be leaving in Aug this year. She previously completed a 10 month youth exchange to Germany during her junior year in high school. She has become very proficient and fluent in German, however the university teaches classes in English. So, she'll getting a lot of bi-lingual experience for the next several years. Congratulations on the scholarship, Alex! Excellent job!! </div>
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<u><b>FIRE!</b></u> - A few weeks ago, I was out in the shop and heard a helicopter come over very low. It was a CalFire helo and it was landing in the creek bottom behind our house. I ran up the steps to the shop office and saw a lot of smoke coming from that way!<br />
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I jumped in the truck and headed towards the fire. When I got to the to the other side of the creek, I saw this:<br />
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Within minutes, the helo had dipped in a nearby reservoir and made it's first pass:</div>
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Thankfully, CalFire got the fire contained and put out very quickly. Good thing, because the wind was blowing pretty strong out of the north that day, and my property was straight downwind!! After the devastating Carr and Camp Fires last year, this was a bit of a scare! Hopefully, this will be all for fires this summer!!<br />
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<u><b>Shop Painting </b></u>- It's been 10 years since I build my shop. It has needed a new paint job for a few years and this year it had to get done. I hired my nephew to help me get this done. In fact, Garrison did the majority of the painting work. Here's a picture of him reaching the high spots. As you might expect, my sister was not exactly all that excited with this picture:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgg9r3BWenhwVIqBcfvyY4TyrmJgkUqKIVHlGApeQTwAFvWiJU7HqLj8XqpnI_YTxikTbIg0NMY5uDVOe-qHSQEDqy0iY_j9BS_Telj2CVUcDQ1xK-05jgsQ8gv_Lyo_l1jmTuC46vsvgt9/s1600/IMG_20190607_104522%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="1512" height="270" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgg9r3BWenhwVIqBcfvyY4TyrmJgkUqKIVHlGApeQTwAFvWiJU7HqLj8XqpnI_YTxikTbIg0NMY5uDVOe-qHSQEDqy0iY_j9BS_Telj2CVUcDQ1xK-05jgsQ8gv_Lyo_l1jmTuC46vsvgt9/s320/IMG_20190607_104522%257E2.jpg" width="320" /></a></div>
Yeah, that's the ladder on top of the tractor canopy! In the end, Garrison did a great job. And, my steps to the office got painted for the first time, EVER!<br />
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There was one place that needed painting that Garrison couldn't get to since he had to head back home. And, this area needed some special attention. So, I handled it myself on some recent days off:<br />
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This wall needed special attention because it is a south facing wall. This wall gets the very worst of sun in the summer and driving rain in the winter. In fact, the first thing I had to do was find several leaks and patch them (I had rain water getting into the shop this past spring!).</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVvavxJnzqcSZLqoh8x-9DQqeLaQ4mCq0V59DpuO9AuQ3fbsuUfg_IcCW0NL05cpQiEjsbiDR3JrhmSWSt1w05cqU2uBLCAh3IszSuOzRR0J8ZP4PyhqusN0QxEuK9aOQvoAq5po3h0fT4/s1600/IMG950213.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVvavxJnzqcSZLqoh8x-9DQqeLaQ4mCq0V59DpuO9AuQ3fbsuUfg_IcCW0NL05cpQiEjsbiDR3JrhmSWSt1w05cqU2uBLCAh3IszSuOzRR0J8ZP4PyhqusN0QxEuK9aOQvoAq5po3h0fT4/s320/IMG950213.jpg" width="240" /></a></div>
It took about 3 days to get the leaks located and patched, then put 2 good thick coats of paint on everything. It's great to have the shop sealed back up and looking good again. Thanks for your help, Garrison!<br />
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<u><b>EAA Chapter 157 Father's Day Pancake Breakfast </b></u>- This spring, I was volunteering at the local EAA chapter's pancake breakfast (I was mixing the pancake batter - it was the only job I was qualified for since it involved a power tool!!). At one point, the girls came to wish me a happy Father's Day and handed me an envelop. It had a ticket in it for a ride in a T-6 Texan!! That's the plane in the background, and me with the girls together when I got back from the flight: </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcYAg84PALRSf_gK2dVI1dFS2qsbarqsImFaJPewZbrZDN8jHQBlYPTRPEVt_L30yGxNeuiU11ZOoszYyfRy4IuCaFrfJXZOQ2LNINw2O_VYaMMsUp3sghEJUUgcvs1Af0Kzh7lCML-2lP/s1600/IMG_20190616_103447.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1393" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcYAg84PALRSf_gK2dVI1dFS2qsbarqsImFaJPewZbrZDN8jHQBlYPTRPEVt_L30yGxNeuiU11ZOoszYyfRy4IuCaFrfJXZOQ2LNINw2O_VYaMMsUp3sghEJUUgcvs1Af0Kzh7lCML-2lP/s320/IMG_20190616_103447.jpg" width="278" /></a></div>
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As we walked out to the plane, I explained to the pilot that my daily driver was an Airbus A320. He said, "Well, that's no fun!" So, I assured him that he could have as much fun and he wanted on this ride. Needless to say, my flight included some "unusual attitude" flying. Ha! Thanks, Ladies!! That was a great Father's Day gift!</div>
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Well, since that day, I've been working the day job nearly non-stop so that I could get my hours in early in July for the company and then be off for all of the week of AirVenture. If you can make it to OSH this year, it's going to be a great year! It's the 50th anniversary of AirVenture at it's "new" home in OSH. I'll try to get another blog update in after AirVenture. I hope you all have a great summer!!</div>
Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-4561663675008429701.post-40247416109546901342019-07-03T14:22:00.000-07:002019-07-04T06:20:01.981-07:00Bud's Prowler is FOR SALE<div style="text-align: center;">
<span style="font-size: x-large;"><span style="font-family: "verdana" , sans-serif;">==================<br />FOR SALE</span></span></div>
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<span style="font-size: x-large;">Prowler N12BT</span></div>
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Bud has decided to sell his Prowler airplane. Here are a few recent photos:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3jpgMfd4Ev3X0LeSdSShtHc5j7CqcFq0E5MVmIw1eWprhsrj09XQTYPyKy979suam0Kl60tID5x_iDnaHHJfTsgtStO1vxgDy7I85vt94Pj2aPYh6zTjjw_zNcCIy9KTmLr1dnSebmcTi/s1600/IMG_20190629_112548394+%25282%2529.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3jpgMfd4Ev3X0LeSdSShtHc5j7CqcFq0E5MVmIw1eWprhsrj09XQTYPyKy979suam0Kl60tID5x_iDnaHHJfTsgtStO1vxgDy7I85vt94Pj2aPYh6zTjjw_zNcCIy9KTmLr1dnSebmcTi/s320/IMG_20190629_112548394+%25282%2529.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhh4cypvi0tHbPEOXi46RgTYnRsAQl4fM4a9bDZkLPnXHvpAA4HzWV_LPyQOm19mc6NmE67mhnc6MBOWI31ZiMoLvusXOR0iZuuV5klM2qLwffglptjJ6E4mqZq-Z5WaSzTpnDiybYBmem2/s1600/IMG_20190629_112509917_HDR+%25282%2529.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhh4cypvi0tHbPEOXi46RgTYnRsAQl4fM4a9bDZkLPnXHvpAA4HzWV_LPyQOm19mc6NmE67mhnc6MBOWI31ZiMoLvusXOR0iZuuV5klM2qLwffglptjJ6E4mqZq-Z5WaSzTpnDiybYBmem2/s320/IMG_20190629_112509917_HDR+%25282%2529.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWA7M2KtAadeibZiS12W3TGK5wAKeSxxR8hBJwXJ30jiMyQGQVLYhHpwqXxtj4BPhbAD34f4hqSe82t8hZr05FVVASmo-cz2u7d7NMqguhEA8AQMD64bLE5JRs6n106mSv82TjBvNAuWh-/s1600/IMG_20190629_112524380_HDR+%25282%2529.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWA7M2KtAadeibZiS12W3TGK5wAKeSxxR8hBJwXJ30jiMyQGQVLYhHpwqXxtj4BPhbAD34f4hqSe82t8hZr05FVVASmo-cz2u7d7NMqguhEA8AQMD64bLE5JRs6n106mSv82TjBvNAuWh-/s320/IMG_20190629_112524380_HDR+%25282%2529.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcqWe1HW2_O47VzykwqB4DqT77uOnuoQ3NcfVeKfUTitlHPqEUafinwTFNb68U2EJ9lcWYd1vi1-VTGGoNJAhqfcidPz7WguDH46DjQTNOc4mrpmn8rnnkEZ7_U5ObQPllEvEh2qEXhmrq/s1600/IMG_20190629_112446161+%25282%2529.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcqWe1HW2_O47VzykwqB4DqT77uOnuoQ3NcfVeKfUTitlHPqEUafinwTFNb68U2EJ9lcWYd1vi1-VTGGoNJAhqfcidPz7WguDH46DjQTNOc4mrpmn8rnnkEZ7_U5ObQPllEvEh2qEXhmrq/s320/IMG_20190629_112446161+%25282%2529.jpg" width="320" /></a></div>
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Here are a few more details:</div>
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=> The Airworthiness Certificate was issued in 2010<br />
=> The airplane is at the Apopka Airport, FL (X04)<br />
=> Currently 114 hrs on the airframe and engine <br />
=> Asking $80K USD
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Here are a few older pics I have of Bud's Prowler:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjavgxvkdukk2bqy8dZwz72hdArdjtRSGhyBY75O8gGyT-iFNiTvJXiWLj70BqpIgK0ybJ3-N88qKksWj8rZneFOTK22NL85U8e_KsoqJIAkwxPCSHvZSePURX9u3TcwDLpS2Glt7waPlfM/s1600/flight+1.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="484" data-original-width="644" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjavgxvkdukk2bqy8dZwz72hdArdjtRSGhyBY75O8gGyT-iFNiTvJXiWLj70BqpIgK0ybJ3-N88qKksWj8rZneFOTK22NL85U8e_KsoqJIAkwxPCSHvZSePURX9u3TcwDLpS2Glt7waPlfM/s320/flight+1.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEil6Y2GdvCknoWlODSzBTF4NLXYh6tG6ejV1Df3caLMJt_diUnMnk4YnWNWOQScGI3B-26TqznIbRBOw7ZtMt9MPeozk4Hh1M8KnyDO5v8oSXUQ3DDgYKFDd5jRPhhoXt_gsIyJjURrMi1f/s1600/flight+2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="484" data-original-width="644" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEil6Y2GdvCknoWlODSzBTF4NLXYh6tG6ejV1Df3caLMJt_diUnMnk4YnWNWOQScGI3B-26TqznIbRBOw7ZtMt9MPeozk4Hh1M8KnyDO5v8oSXUQ3DDgYKFDd5jRPhhoXt_gsIyJjURrMi1f/s320/flight+2.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbEjzYC3mm7Klp9SZphL9YtD__nOwswD7HEtf-rCsZ0JxduOBWsWiXR-QYmpnpgXq_ro2CVCr9nQ3Uxx3ckGDLA1iNLeB3-57P5LHQetxUHQcQgZizgiTrfaAo4lHBthyphenhyphenhxzywKEVVyrsd/s1600/Jaguar+16Jun%252713-red.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1091" data-original-width="1600" height="218" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbEjzYC3mm7Klp9SZphL9YtD__nOwswD7HEtf-rCsZ0JxduOBWsWiXR-QYmpnpgXq_ro2CVCr9nQ3Uxx3ckGDLA1iNLeB3-57P5LHQetxUHQcQgZizgiTrfaAo4lHBthyphenhyphenhxzywKEVVyrsd/s320/Jaguar+16Jun%252713-red.jpg" width="320" /></a></div>
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Here are a few videos that I have of Bud's airplane:<br />
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An engine start-up:<br />
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<iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dyG-2GYDiYzCn8O7TNWiC4W6oMxrFfh_enUyj1uAp8bXQs6q9058qkAJa7B1yVxLmiAnyeeJKPYMJTtq8ZqJQ' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div>
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A takeoff roll:<br />
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<iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dzcOyAruBnu_q3OTpxBzFrhPRpjhSGT5FZltscypxmRyumSrEAMXzZ44agI30C5_W2K8pq4LdYX7iQpocEjPg' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div>
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A couple of in flight videos:<br />
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<iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dwveFF9D3YaYGNuJoGdAWxi-botIyXQ4xCI-_Fl5pGh7pDUDTt9m-BXWsfB9r8GwMTAmIC4Mdjp6ci5eBT7FQ' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div>
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If you are interested in getting in contact with Bud, please send me an email to the feedback link located here: <a href="http://www.prowleraviation.com/contact/contact.html" target="_blank"> </a><a href="https://www.blogger.com/null" save_image_to_download="true">http://www.prowleraviation.com/contact/contact.html</a></div>
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Thanks!<br />
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<br />Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-4561663675008429701.post-17741323143430242862019-04-27T16:57:00.000-07:002019-04-27T16:57:06.685-07:00Another Prowler Shop Project - Rebuilding A Hardinge CHNC Lathe<div save_image_to_download="true">
As I mentioned in the last update, I've been working on another machine project on and off at the shop over the past year. I wanted to break this update out of the normal Prowler blog updates, since this update deals with my repair and alteration of a "new" machine that I hope to use in production Prowler parts - and does not contain much info related directly to the Prowler aircraft. So, if you're interest - Please have a look. If rebuilding old CNC machines is not your thing, feel free to pass on this one.<br />
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Last May, I had a buddy who wanted to sell his CNC lathe to raise some cash to buy another machine he liked better. He was tired of dealing with his Hardinge CHNC lathe with a Fagor 8025T control installed on it. It was his only production lathe that didn't have an OmniTurn control and and he wanted to purchase another Hardinge lathe he found that came with an OmniTurn control - so, that way, all of his machines would then be the same. I have actually worked on this machine for him many times over the years, so I knew pretty well what I was getting into. The lathe wasn't holding position well on the Z axis and there was a few other problems that would need to be addressed. The price was right, so I bought it from him. Here's a few pics from moving day:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDR6H0761uRO74-dK2InLC_ROSaPknkzLCzCo0GPSSIY7DC2C1S3PF-TbObHp-1A5AlgGPvms8q0Ibc2_cidra6qoLNG_Hkgqto1XdlKqSFH716wTixkPkhAonww6Lk4Q2dJwr-dH2HWAw/s1600/20180516_175154.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="808" data-original-width="1181" height="218" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDR6H0761uRO74-dK2InLC_ROSaPknkzLCzCo0GPSSIY7DC2C1S3PF-TbObHp-1A5AlgGPvms8q0Ibc2_cidra6qoLNG_Hkgqto1XdlKqSFH716wTixkPkhAonww6Lk4Q2dJwr-dH2HWAw/s320/20180516_175154.jpg" width="320" /></a></div>
I used the overhead gantry that I'd built for working on the 400 ton press to pick the machine up. Then, I backed the trailer under it:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigx-TgQ5_Kk849fwFzO9NZ3wEcT6JFHH8m5lpMq81XHYUuxZsCEE4EnZqxaLLRRZcFccJ0h4H90C06X0bvSV0VeumlwujZAkn6twYdYueu1i7fpPnswkKw5tYZc-eLmZiN-q-emMsriKNm/s1600/20180516_175218.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="810" data-original-width="973" height="266" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigx-TgQ5_Kk849fwFzO9NZ3wEcT6JFHH8m5lpMq81XHYUuxZsCEE4EnZqxaLLRRZcFccJ0h4H90C06X0bvSV0VeumlwujZAkn6twYdYueu1i7fpPnswkKw5tYZc-eLmZiN-q-emMsriKNm/s320/20180516_175218.jpg" width="320" /></a></div>
Here is the machine after I got it home to the shop and started to tear it down:<br />
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To start with, I did some research about this lathe. What I've found out is that this is the very 1st line of CNC lathes that Hardinge ever made. These machines were built in the late 1970's and this machine was #109 in that series of lathes. Unlike our current technology, anything built in the 1970's that had a computer attached to it was BIG! This lathe was no different. Here is pic from the cover of the maintenance manual that I found online:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvkBKu_1glLpvgOpZqyfZ6TxRtOKk0Fg8lpWHZzURgoXmhCYgN3bNezhkDBjHluJFMuzVxWk8s31rzn0LzW1jLxPHdJYwVB0MGxIq79erR2jGx3FCYcjWx8IujqHAjpMeTAbTTnUvJ5juC/s1600/20180511_082237-close.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1423" data-original-width="1473" height="309" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvkBKu_1glLpvgOpZqyfZ6TxRtOKk0Fg8lpWHZzURgoXmhCYgN3bNezhkDBjHluJFMuzVxWk8s31rzn0LzW1jLxPHdJYwVB0MGxIq79erR2jGx3FCYcjWx8IujqHAjpMeTAbTTnUvJ5juC/s320/20180511_082237-close.jpg" width="320" /></a></div>
Check out that control!! It's 1/2 the size of the lathe!! And, your smartphone today probably has 10,000 times the computing power than that old control did in 1979! If you follow that square tube that comes out of the top of the control and goes up and over the lathe you'll see it is attached to large electrical cabinet behind the lathe. That cabinet is about 5 feet tall, 3 feet wide and about 1 ft deep. It was designed to hold some huge, high current switches, breakers, relays and spindle control amplifiers that were the cutting edge technology of 1970's.<br />
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Now, sometime in the late 90's or early 2000's someone did a retro-fit to this machine and installed the Fagor 8025T control that is on the machine now. That got rid of that massive control in the foreground of the above picture (I wonder whatever happened to that??). However, when whoever did this retro-fit installed this new Fagor 8025T control, they left a lot of "stuff" in the machine that was no longer needed. There was a ton of "dead weight" that was hanging out in this machine that could be gutted out and gotten rid of. More on this later, but I figured, at the very least, the large electrical cabinet in back could be deleted and the machine streamlined significantly.<br />
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After some initial tear down and investigation, here is the punch list I've come up with for this lathe project:</div>
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1. Find out why the Z axis was not working well (loosing position and not repeating well - like during threading operations);</div>
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2. Remove the huge electronics cabinet off the back side and put the needed components into a smaller enclosure;</div>
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3. Overhaul the X axis servo, and belt drive system - it was kind of a hodge-podge mess;</div>
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4. Re-wire the machine with a single point power hook up and convenient switching to power up the control and the spindle systems; </div>
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5. Investigate the tool turret system and try to get it to be usable again; </div>
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6. Rehab the coolant system;<br />
7. Rehab the collet closer system and try to get it working again;<br />
8. Re-install new plexiglass into the enclosure doors.<br />
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<u><b>1. Z-Axis Issues</b></u> - So, one of the big problems with the machine was that the Z axis was not working well. It was loosing position often and the control was giving Z axis following errors. It was also not repeating its position well - like during threading operations. After the initial tear down, I started focusing in on the Z axis system. What I discovered is that the Z axis ballscrew was designed to be held in position along it's long axis by a bearing block system. There are basically two thrust bearings that are tightened towards each other by cylindrical bearing retainers with OD threads that are threaded into a big block of steel (from the each direction); and that block is rigidly bolted to the ways (main body of the lathe). Here is a pic of the Z ballscrew (under the covers) and the bearing block on the left end (the servo turns the ballscrew via a cogged pulley on the right end):</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEisWXUvoMhZi2J_XG0rTwnIw2X_xx2coZwyOkL_Nyjy_kplesfQyBtQpDd9PhrOZ1K8s39yjgLfU_bRMuH3S0it7-HWP_RRhCo8MYI0DfyIFyo_QPHkvioNafqI4FgruVkLmYaaQgrnHWJ3/s1600/20180524_204807.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="648" data-original-width="1600" height="129" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEisWXUvoMhZi2J_XG0rTwnIw2X_xx2coZwyOkL_Nyjy_kplesfQyBtQpDd9PhrOZ1K8s39yjgLfU_bRMuH3S0it7-HWP_RRhCo8MYI0DfyIFyo_QPHkvioNafqI4FgruVkLmYaaQgrnHWJ3/s320/20180524_204807.jpg" width="320" /></a></div>
Here is the pulley end of the Z axis ballscrew:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh60FmjNbHSE6Ps984VDLQNukpDGUbG55gc2LaZCmT9EEz6AmeobQjQeaEsSiBvmNTUiVhBAFLV3l-OtMX18nMy-wMyS8YwdT7cm6EhXrDrWuL0v9WfNMBMpWeum8ifl16F64-9SF2skaCC/s1600/IMG_20190426_071038.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="792" data-original-width="1147" height="220" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh60FmjNbHSE6Ps984VDLQNukpDGUbG55gc2LaZCmT9EEz6AmeobQjQeaEsSiBvmNTUiVhBAFLV3l-OtMX18nMy-wMyS8YwdT7cm6EhXrDrWuL0v9WfNMBMpWeum8ifl16F64-9SF2skaCC/s320/IMG_20190426_071038.jpg" width="320" /></a></div>
Turns out, those bearing retainer nuts had merely gotten loose and each time the Z axis changed directions,
the Z ballscrew would turn about 1/4 of a full turn and the cross-slide would not move (while the
bearings "slopped" inside the bearing block). So, just simply tightening up those retaining nuts took the backlash out of the Z axis ballscrew. After a few other small tweaks and putting it all back together, the Z axis is nice and tight and working well again.<br />
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<u><b>2. Huge Electronics Cabinet & Re-wiring</b></u> - As I previously mentioned, when the F8025T control retro-fit was accomplished on this machine, there was a lot of junk left on the machine that could have (should have) been removed. This was very true with the electrical cabinet. Before I moved this machine from my buddy's shop to mine, I decided that it would be easier if I removed that main electrical cabinet (also since I wasn't going to need it any longer, why leave it on). Here is a pic of the inside of that 5' x 3' x 1' electrical control panel just after I disconnected it and removed it from the main body of the lathe:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinCOLy3rsdhUzFcicbrhf-fqexy_I0NTn38slGoObBgNHBObgDlFAsJWUWDWQHxgPWuCswYv0DPyrAMzvTJdOft5dLaA8mTpPyMctFC_c3YbFLJ5zJRTjYfFqXldOJg_AfkaQ-_KhTvBkb/s1600/20180523_135358.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="900" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinCOLy3rsdhUzFcicbrhf-fqexy_I0NTn38slGoObBgNHBObgDlFAsJWUWDWQHxgPWuCswYv0DPyrAMzvTJdOft5dLaA8mTpPyMctFC_c3YbFLJ5zJRTjYfFqXldOJg_AfkaQ-_KhTvBkb/s320/20180523_135358.jpg" width="180" /></a></div>
Looking closely at this cabinet under the cover, you can see that the only component that is in use on the left side of this huge cabinet is the black box near the top. That is the spindle drive controller/amplifier. All the rest of the "stuff" on the left side of that box is not used and can get chucked! On the right side, the huge 60 amp switch on the upper right can be replaced with a 30 amp machine switch that is about 1/10th the size. The group of semi-conductor relays on the lower right can still be used, but about 1/2 of them are no longer needed. They have been replaced by relays in the F8025T control and can be deleted. The remaining "stuff" in the middle of the right side of the cabinet can be used as is, or replaced with a smaller updated component. Overall, I surmised that the items that are actually being used in this LARGE cabinet could be removed and installed into a much smaller cabinet. (I have an idea for another application for the large cabinet, but that'll be another project for a future update.)<br />
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Here is a picture of where and how this cabinet was attached to the machine. It was simply bolted to a sort-of "tunnel" that was welded to the back side of the lathe. <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcCsYlI_6zYgSP1MCg9pfJUrTmUlxe3qK0AOijdB3Rsn3bH10J5YbkIKgVVSpACLXJNM3ocCG-FKhmMS-b3zBwLo-wxxOWca1KLjFCLA1l3DWV3jzvMV7vAnJDQemLf_1x-bRykmLOHjUk/s1600/20180516_202206.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1389" data-original-width="918" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcCsYlI_6zYgSP1MCg9pfJUrTmUlxe3qK0AOijdB3Rsn3bH10J5YbkIKgVVSpACLXJNM3ocCG-FKhmMS-b3zBwLo-wxxOWca1KLjFCLA1l3DWV3jzvMV7vAnJDQemLf_1x-bRykmLOHjUk/s320/20180516_202206.jpg" width="211" /></a></div>
The various control and power wires were passed through this tunnel and then into the big cabinet. After looking this over for a long time and taking some measurements, I decided that all the electronic components that were needed to run this machine could be mounted into this tunnel. One big problem was going to be that divider plate welded down the middle of the tunnel. Also, you can't put a bunch of electronics into a small space and not ventilate it. Things will overheat. So, I was going to have to include some kind of ventilation fans and filters. Oh, and I'd have to fabricate a cover for it.<br />
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First things first - that divider had to go. A few minutes with the 4" angle grinder (with a thin cutting blade) and a lot of sparks later..... The divider was gone:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhftGOTwsUCbA7ZTG3DTSDqRagzIQq2EMs-_scElxXaiwPNnFoBhV0rQDUzcHGyBhx2vCvCu5DtmFVyjxREQdvZEfNto8S04Vty0dU4uRNZpOHOij4MtitrDyOi7EA9fneeXqfgJnTNLeJ1/s1600/20180815_161332.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="974" data-original-width="813" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhftGOTwsUCbA7ZTG3DTSDqRagzIQq2EMs-_scElxXaiwPNnFoBhV0rQDUzcHGyBhx2vCvCu5DtmFVyjxREQdvZEfNto8S04Vty0dU4uRNZpOHOij4MtitrDyOi7EA9fneeXqfgJnTNLeJ1/s320/20180815_161332.jpg" width="267" /></a></div>
With that gone, I could start moving the components over from the big cabinet to the small one. First, I traced out the circuit diagrams and took lots of pictures of the existing hook-ups, then that old divider plate became the new plate to mount the components on in the top portion of the tunnel. With that component plate in place, I started moving components over one-by-one. Here is the current result:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEguS0m64uWMYrGivdpyEUhpsjIx5SdOP4T8lN4mjFRg8-avXtZPANq7bl0HAtzXaDfnBe6GLwX_N7sW5FF28hKar-lLfMH87ixb0xpcoIcPfbwaTnekgdkJmC1KuUTusEelF4K0pB2F973x/s1600/20180816_212758.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1017" data-original-width="849" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEguS0m64uWMYrGivdpyEUhpsjIx5SdOP4T8lN4mjFRg8-avXtZPANq7bl0HAtzXaDfnBe6GLwX_N7sW5FF28hKar-lLfMH87ixb0xpcoIcPfbwaTnekgdkJmC1KuUTusEelF4K0pB2F973x/s320/20180816_212758.jpg" width="267" /></a></div>
At this point, everything in the new cabinet is moved over and hooked up except for the 115Vac items. The wires that are still hanging out of the tunnel all have to be somehow or other get hooked up to 115Vac power - which is still pending (I haven't done the main power hook-up wiring yet).<br />
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Next up, I started chasing down how to ventilate this tunnel. There were some large rectangular access plates that I had removed from the lower sides of the tunnel. Also, the big, old electrical cabinet had a large air filter set-up. I decided to use that and, somehow, attach it to one of those lower access plates. Here is what I came up with after I cut out a few chunks so that it would all fit together:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEid-vYRhukNyU2uQCfAB2_i-T5RCQhcE5ONrtplGOK4eaOUHZOQRGb2bHZS4WgXiCrzP_iBnSmDpczPAzVVuVwFR2z6WADxZlBTQd0UX28SK6Z0eonIE2b22jSKh5IMDZ6flgO01vCBSooa/s1600/IMG_20181107_100446.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="810" data-original-width="1415" height="183" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEid-vYRhukNyU2uQCfAB2_i-T5RCQhcE5ONrtplGOK4eaOUHZOQRGb2bHZS4WgXiCrzP_iBnSmDpczPAzVVuVwFR2z6WADxZlBTQd0UX28SK6Z0eonIE2b22jSKh5IMDZ6flgO01vCBSooa/s320/IMG_20181107_100446.jpg" width="320" /></a></div>
The lower access plate (on the left, above) got a square hole cut in it. The old filter assembly got a slice cut out of it. Here (below) is the new system after welding the cut pieces back together:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZSFZoioXnKHAbiuhJa3y9te3znYZl7GwOnHGbolGy6v9kwXt6EkztD8TY2CQMwMD8b6ezOm7UFrxv10hSwDxchn66zOL40_n7qDOOl4HPiBy6amgM6StzKfUZ14eP1MwvMAt-841M6EgX/s1600/IMG_20181107_112354.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1117" height="257" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZSFZoioXnKHAbiuhJa3y9te3znYZl7GwOnHGbolGy6v9kwXt6EkztD8TY2CQMwMD8b6ezOm7UFrxv10hSwDxchn66zOL40_n7qDOOl4HPiBy6amgM6StzKfUZ14eP1MwvMAt-841M6EgX/s320/IMG_20181107_112354.jpg" width="320" /></a></div>
There are stand offs at each corner that the cover bolts too. This provides and air gap all around the edges of the cover. Here is a test fitting of the new filter assembly on the tunnel:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhzmDS2kXkkt9tGeDK4l3pOjAKq-xfzYT9qB87XnPOavhG-fbqU5C3WiKKy6kZz-W0UACKck6oojKgKe2QDBR1NGTxHy7bmK-CI7YmzjB_XnW1LztLR1bresuWfHAowzkwF4_E7Sf7-pBae/s1600/IMG_20181107_113228.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1097" data-original-width="908" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhzmDS2kXkkt9tGeDK4l3pOjAKq-xfzYT9qB87XnPOavhG-fbqU5C3WiKKy6kZz-W0UACKck6oojKgKe2QDBR1NGTxHy7bmK-CI7YmzjB_XnW1LztLR1bresuWfHAowzkwF4_E7Sf7-pBae/s320/IMG_20181107_113228.jpg" width="264" /></a></div>
Next, add paint and some furnace filter material:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnC-Z6GyWkJ8N-zAV_J1WZ0PBmjB4AsgIBU51dvYt3Ho4xnu41Htcg5VbCQE6TK3nydHuhZO1ursxvwCOA65kZg4gGjY_P6jvRGgIxeE-X42C6cSKmPWWaeLLO4mFrEc7uXHzoLCdv8OH_/s1600/IMG_20181108_180544.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="823" data-original-width="1061" height="248" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnC-Z6GyWkJ8N-zAV_J1WZ0PBmjB4AsgIBU51dvYt3Ho4xnu41Htcg5VbCQE6TK3nydHuhZO1ursxvwCOA65kZg4gGjY_P6jvRGgIxeE-X42C6cSKmPWWaeLLO4mFrEc7uXHzoLCdv8OH_/s320/IMG_20181108_180544.jpg" width="320" /></a></div>
AND..... air filter assembly is completed:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhm3GMasc56iAW-bEHIe-xb9jZg2fmTzFEfICSrazq1n2AsGF3zJU4Q_eZ2brd4kuzg846u7Shn0tRmqGDdSGh-BMiDtYVj_5MMH0OoEZWNQy76pnrUucNA7H7GXlYsYcH3LND6ZxqGVpK2/s1600/IMG_20181108_180831.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="991" data-original-width="744" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhm3GMasc56iAW-bEHIe-xb9jZg2fmTzFEfICSrazq1n2AsGF3zJU4Q_eZ2brd4kuzg846u7Shn0tRmqGDdSGh-BMiDtYVj_5MMH0OoEZWNQy76pnrUucNA7H7GXlYsYcH3LND6ZxqGVpK2/s320/IMG_20181108_180831.jpg" width="240" /></a></div>
Now, I had to figure out a way to get air to move through the cabinet. A 115Vac cooling fan would work best. I found one locally sourced for $15, got it to the shop, took some measurements and cut a hole in the other lower access plate using a fly cutter in the mill:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKrwPMRjEiww2ZO34EZhXWC0TCOzSmdkNis-zjZhpXB-X404kdG7hFNzOLFUq5O5AMTeZnWO1UC2FHN8oJewEkTTY6sw5RSyaeZgRskIEo0ahAmXhTB_YSNJ4Vy7ikR9GvFbrpxgS6nBC6/s1600/IMG_20181107_182503.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="862" data-original-width="1104" height="249" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKrwPMRjEiww2ZO34EZhXWC0TCOzSmdkNis-zjZhpXB-X404kdG7hFNzOLFUq5O5AMTeZnWO1UC2FHN8oJewEkTTY6sw5RSyaeZgRskIEo0ahAmXhTB_YSNJ4Vy7ikR9GvFbrpxgS6nBC6/s320/IMG_20181107_182503.jpg" width="320" /></a></div>
Here's the access plate with the holes cut and the fan that will mount to it:<br />
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I decided that there was enough room on the access plate to also fit an electrical hook-up box to it that will be used for hooking power up to the machine:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhfs0z1RgB8-KYMGEhr2MPtpl5VQPpfiQKbNkTJOm3z6CafBw6UNp8_9agjG7hwgGJaPMnJKToZV1eO1toj2ZKcfx1cD4Kx_G-VW7T_FLr_FmdSOFiZqfiwqI6HBD6CsU5ycKeBGxobQbg1/s1600/IMG_20181107_193835.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1034" data-original-width="810" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhfs0z1RgB8-KYMGEhr2MPtpl5VQPpfiQKbNkTJOm3z6CafBw6UNp8_9agjG7hwgGJaPMnJKToZV1eO1toj2ZKcfx1cD4Kx_G-VW7T_FLr_FmdSOFiZqfiwqI6HBD6CsU5ycKeBGxobQbg1/s320/IMG_20181107_193835.jpg" width="250" /></a></div>
And:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_vekTv3pNxT_SzxQ2rRsJWh7LzTcu7C6IkD1DzHoAQz_SZ0MJPtzzRicFe-YGEmY61Z2-9jZMeMlbSSfEDatAvzX3MV9Xg57D7UwQLXyoliQAT06p5u6z0s4fQl3AXR8Gk8I1IlvbEwhE/s1600/IMG_20181107_193858.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="822" data-original-width="1211" height="217" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_vekTv3pNxT_SzxQ2rRsJWh7LzTcu7C6IkD1DzHoAQz_SZ0MJPtzzRicFe-YGEmY61Z2-9jZMeMlbSSfEDatAvzX3MV9Xg57D7UwQLXyoliQAT06p5u6z0s4fQl3AXR8Gk8I1IlvbEwhE/s320/IMG_20181107_193858.jpg" width="320" /></a></div>
Add paint and a little more furnace filter material:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2tb9Fd5RGjrm9hZseBDVLtkMQTyhkP1fOCRNshIWByIvwYLIBDp4O6fAY9C67X15ilWXcDCSK4uyJjoQx7qjQwLGNWTmbgfB17isQ2xfi8Q_u7JvWaSTRkHZoLANqzmdppRdd8IY_GqVh/s1600/IMG_20181108_175546.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="861" data-original-width="570" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2tb9Fd5RGjrm9hZseBDVLtkMQTyhkP1fOCRNshIWByIvwYLIBDp4O6fAY9C67X15ilWXcDCSK4uyJjoQx7qjQwLGNWTmbgfB17isQ2xfi8Q_u7JvWaSTRkHZoLANqzmdppRdd8IY_GqVh/s320/IMG_20181108_175546.jpg" width="211" /></a></div>
Here is the fan and power hook-up box mounted to the other side of the tunnel:<br />
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That all came out pretty nice. I'm happy with the results. Moving on to the X axis work:<br />
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<u><b>3. Overhaul Of The X-Axis Servo And Drive System</b></u> - Here is a picture of the X axis drive set up before I stripped it all down. You can see that it is a very "hodge-podge" set up with lots of plates, extensions, shims, etc.:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEir3SekhTztHGhNJUSNmD7k1_kiHCLGvQSSeLgHbHYqE9i5n8GrQXZU3-ALS0jiYOEYTS-9eKoig0_SnNP7dvEoETjm_lqh-rdPsRWyRqpOkLUFApsVYupzdMdCMOtsc-xZAFglrp7FW0Rw/s1600/20180521_165144.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="606" data-original-width="1548" height="125" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEir3SekhTztHGhNJUSNmD7k1_kiHCLGvQSSeLgHbHYqE9i5n8GrQXZU3-ALS0jiYOEYTS-9eKoig0_SnNP7dvEoETjm_lqh-rdPsRWyRqpOkLUFApsVYupzdMdCMOtsc-xZAFglrp7FW0Rw/s320/20180521_165144.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjyOrJ_r7vkYQhXyE72tD-LeELeYDZEOaZUuFXmKOQLd0iyOmaJST7uepG2gQeAUc35svnmBpkCVcyGtnWKSx8vW82TGdpX8CDRUiDpXCHp7B4I7s09SyQIYVuui5JXcvBbDd0KBf1Fyymq/s1600/20180521_165150.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="849" data-original-width="1516" height="179" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjyOrJ_r7vkYQhXyE72tD-LeELeYDZEOaZUuFXmKOQLd0iyOmaJST7uepG2gQeAUc35svnmBpkCVcyGtnWKSx8vW82TGdpX8CDRUiDpXCHp7B4I7s09SyQIYVuui5JXcvBbDd0KBf1Fyymq/s320/20180521_165150.jpg" width="320" /></a></div>
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From these pictures, it may not be immediately evident, but it was not an optimal and there is much room for improvement here. The servo that was installed on the X axis is quite oversized (servo power capability and physical size). A properly sized servo will negate the need for that big aluminum block spacer between the servo and the mounting plate. Also, the cogged pulley on the right in the top picture is very worn and needs replaced. After removing the servo and the aluminum cover plate here is the cogged pulley that drives the X axis:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIREV4Rs7Kn7ALoGjShp2zL883bxkr_RApsRzI68J-BjiJZeZoA_98tyTn9l8oStP7sQs_nt0GWqSFuRAgRB4ZYxm_pLOcJUBHueQR79_utnBK3OWNgzhiX7zYpdoMyxXf-t5LJ-kR6co9/s1600/IMG_20190426_070858.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="889" data-original-width="818" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIREV4Rs7Kn7ALoGjShp2zL883bxkr_RApsRzI68J-BjiJZeZoA_98tyTn9l8oStP7sQs_nt0GWqSFuRAgRB4ZYxm_pLOcJUBHueQR79_utnBK3OWNgzhiX7zYpdoMyxXf-t5LJ-kR6co9/s320/IMG_20190426_070858.jpg" width="294" /></a></div>
The pulley is pretty badly worn where the belt runs on the outer edge of it. It looks corroded too, like whatever someone was using as a coolant wasted away the aluminum where the belt ran. Here is the hub that the pulley attaches to on the end of the X axis ballscrew:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8W9JvXnIPbYiAmnGgkONa_IT3MXUzyyLUG0jTNHzdSewigBkatrae693KPA7yVOq-AoZbIUBCGjlycsPQOAxlLgi8GaYumI_j23a3zfNDWsOpQ8edpu28XcSN3BS-gV0AkJ2vknmv2du6/s1600/IMG_20190426_070844.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="787" data-original-width="914" height="275" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8W9JvXnIPbYiAmnGgkONa_IT3MXUzyyLUG0jTNHzdSewigBkatrae693KPA7yVOq-AoZbIUBCGjlycsPQOAxlLgi8GaYumI_j23a3zfNDWsOpQ8edpu28XcSN3BS-gV0AkJ2vknmv2du6/s320/IMG_20190426_070844.jpg" width="320" /></a></div>
I tried finding a 1" slab of that cogged pulley material that I could machine to make a new one identical to the existing, but I have been unable to locate any at a reasonable cost (most places wanted me to buy a 10' bar of the stuff!!). I beat up eBay an Amazon and found one new cogged pulley that might work. It is the one on the left here (old pulley on the right and ballscrew hub is below):</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMh6-o-IH_2y4MsJaomdzEaUfKsFiPhfD2Q4kzAo9vyGMDFkoomtkvpVNjsyXwdNc4s78oHVtP3cPdSmYuSXNb3caUNkMTUgGb2dAldNvdDoNKKjo1FGHiz5aTGV5qj49SpNW3zhVm8QpG/s1600/IMG_20190426_070949.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="846" data-original-width="1176" height="230" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMh6-o-IH_2y4MsJaomdzEaUfKsFiPhfD2Q4kzAo9vyGMDFkoomtkvpVNjsyXwdNc4s78oHVtP3cPdSmYuSXNb3caUNkMTUgGb2dAldNvdDoNKKjo1FGHiz5aTGV5qj49SpNW3zhVm8QpG/s320/IMG_20190426_070949.jpg" width="320" /></a></div>
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The new one I found has the correct specs with regard to the diameter and number of cogs, but it is much thinner than what is currently on the machine. That may not be a big issue as long as the small pulley on the servo can be made to align properly. Also, the center boss on the new pulley is too small to adapt it directly to the existing hub. Here's what that looks like: <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpkoEcJI5xkHHqyniMd2yS4zpqihpstekuxMTADCNCrpzQ-2oawpSRSznsab2G3Bx5klhle2E53qnCirnfWFGAIbGx_gL3SpD-7RviMqFPCwhSVRxmnF7YSFmfVz3YvF5Gs7owMEtM3KW0/s1600/IMG_20190426_070933.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="704" data-original-width="772" height="291" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpkoEcJI5xkHHqyniMd2yS4zpqihpstekuxMTADCNCrpzQ-2oawpSRSznsab2G3Bx5klhle2E53qnCirnfWFGAIbGx_gL3SpD-7RviMqFPCwhSVRxmnF7YSFmfVz3YvF5Gs7owMEtM3KW0/s320/IMG_20190426_070933.jpg" width="320" /></a></div>
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So, I'm going to have to find another way to adapt it. (Or, I might put a big piece of round aluminum bar in the super spacer on the mill some day and experiment with making my own replacement cogged pulley from scratch). More to be done here.<br />
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As for the servo itself, it is not the correct shaft size, not the correct physical size and the max speed is rated too low for the machine (F8025T control). The original servo went out on my buddy, so he bought a replacement off eBay. But, unfortunately, he got one that didn't have a high enough max speed. I installed it for him anyway, temporarily so that he could keep making parts - but, I had to limit the max speed on the control. Now, I'm keeping an eye on Ebay for a cost effective option to replace this servo with one that is more properly sized and will allow the control to run the machine at normal max speed. More to follow.</div>
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<u><b>4. Power Hook-ups & Machine Switching</b></u> - Previously, the machine was powered from 2 different sources. One source of 115Vac was fed into the large old electrical cabinet that powered the spindle and various relay controlled components (like coolant and collet closer, etc.). Then, the Fagor 8025T control (which includes the power to the servos and servo amplifiers) was fed from another 115Vac source (literally fed from a cord plugged into a wall outlet). Also, this machine originally used a cutting oil only coolant system with a huge tank under the lathe bed and was powered with a large 230Vac/3 phase pump. Somewhere along the way, the 230/240Vac system was removed, the tank emptied and the coolant system was converted to a Little Giant 115V coolant system.</div>
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I'm going to continue to use all 115Vac systems, but I'll create a single point power hook-up for the 115Vac power. Then, I'll install a remote switch on the front of the machine near the F8025T control that will turn on the spindle and power the coolant and various auxiliary systems. I'll hard-wire the F8025T control to the same 115Vac system and continue to used the power switch that is already installed on the control to turn it on and off. This way, I can turn on just the control if I want to jog the machine around and move the servos, etc. and not have to turn the spindle on. That could also be used to make "dry runs" to test part programs. Then, when ready to make chips, just hit the other switch to power up the rest of the machine.</div>
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<u><b>5. Tool turret system</b></u> - This will potentially be the most difficult part of this machine restoration. The lathe was built with a 8 position tool turret. The tool turret was computer controlled and moved automatically when tool changes were called for. This was accomplished using a complex system of pneumatic pistons, air motors, hydraulic actuators and an encoder type electrical position feedback system. However, when the machine was modified and the F8025T control installed, the tool turret was simply bolted down and a gang-bar tool system was mounted to the top of the turret. Here is the tool turret with the gang-bar removed:
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbblW5zvWGcVlgg9CwrNlI7ScOb6v8MG8BEFQfZIi9SQkQvPz2XiBffY_IeKe8jJjMBev0XRCkL6Z37-wSD_71l7XxU4DQpVFhkDmlmn3L1gawa_7oxGQDubzVOlKvVdE4X8deZ_9ceZ7N/s1600/20180525_091327.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1245" data-original-width="800" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbblW5zvWGcVlgg9CwrNlI7ScOb6v8MG8BEFQfZIi9SQkQvPz2XiBffY_IeKe8jJjMBev0XRCkL6Z37-wSD_71l7XxU4DQpVFhkDmlmn3L1gawa_7oxGQDubzVOlKvVdE4X8deZ_9ceZ7N/s320/20180525_091327.jpg" width="205" /></a></div>
Removing the top plate of the turret (the plate that the tools are actually mounted to) reveals a sturdy ring below that is rigidly mounted to the X axis and has two alignment dogs (black raised areas on the left and right sides of the picture below) and you see the top of the turret piston (area inside the bronze ring):<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioKLxOQLIvNdUSoOtqaDKFQL2X7lXN0wuxlSvxD59kNQ7v1FOsAO1Ny4VADWlpU1suvjj5c9iq8ieh1oAzjM7MxgpM_0wD_kW0CELGnJL_7p16FK8Uf2FpTAadJz-2cOVU3_5OQlp7oaFe/s1600/20180525_090655.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1448" data-original-width="724" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioKLxOQLIvNdUSoOtqaDKFQL2X7lXN0wuxlSvxD59kNQ7v1FOsAO1Ny4VADWlpU1suvjj5c9iq8ieh1oAzjM7MxgpM_0wD_kW0CELGnJL_7p16FK8Uf2FpTAadJz-2cOVU3_5OQlp7oaFe/s320/20180525_090655.jpg" width="160" /></a></div>
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The way that the tool changer selected a new tool was to apply compressed air under the tool turret piston and lift the piston and the tool mounting plate upward. Then, a rotary air screw turned the turret until the new tool was close to alignment with the tool position closest to the spindle "cutting position". Then the compressed air was removed from the bottom of the piston and ported to the top side of the turret piston. This forced the tool turret mount plate down onto the set of tapered dogs in the outer ring shown above. Those male dogs you see in the picture above are matched with female slots in the bottom of the tool holder plate. When the turret piston has compressed air on top of it, the air pressure holds the tool plate firmly down on those alignment dogs and keeps the tools perfectly aligned for cutting the part in the spindle. Here is the alignment ring with the alignment dogs removed to expose just the top of the tool turret piston:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhdsr_sdgAqTNCdjle_qG7GGmWWJGoUlVbpK3kf4-TwWAtqN96C3GxdzoPBOOyI2qM0u17IdXImmdl0JdKuR0T9AQ-OoqsxjWUn8H1jeC-EpyLEoiVBk6xSaBeidouzWtRTaNyRZnudA4ZS/s1600/20180525_085050.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1488" data-original-width="704" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhdsr_sdgAqTNCdjle_qG7GGmWWJGoUlVbpK3kf4-TwWAtqN96C3GxdzoPBOOyI2qM0u17IdXImmdl0JdKuR0T9AQ-OoqsxjWUn8H1jeC-EpyLEoiVBk6xSaBeidouzWtRTaNyRZnudA4ZS/s320/20180525_085050.jpg" width="151" /></a></div>
Here is the piston removed from the machine. You can see the aluminum piston and the o-ring around the outer edge that seals the piston inside the turret pocket:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTJUzLXvqOerw-z9GXWGZBT0vnLiZwHO6wp-VIccS-qXpWpg2qnbSjfSJiBZWKu3X5EbSPHF4qBkfE70d5MrQbWJRGI74ldi9nrVUGPqDUICiMqP2LRTrdISR4WSNTPDSyvgaPLgaLud1g/s1600/20180525_084520.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1023" data-original-width="741" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTJUzLXvqOerw-z9GXWGZBT0vnLiZwHO6wp-VIccS-qXpWpg2qnbSjfSJiBZWKu3X5EbSPHF4qBkfE70d5MrQbWJRGI74ldi9nrVUGPqDUICiMqP2LRTrdISR4WSNTPDSyvgaPLgaLud1g/s320/20180525_084520.jpg" width="231" /></a></div>
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The thick piece of steel you see to the left of the piston (between the piston and the gear on the far left) was an alignment stop device. When the turret was close to the desired position, a hydraulic arm would pop out from the side of the turret pocket and stop the turret in the desired position (the air servo would simply spin the turret until the old control made that hydraulic arm pop out and stop it in the desired position. Here's a shot of that arm that stops the turret in the desired position: <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcjtzeO-RCca-i8JwvX_VGRXOiSy0pttdpSU4WIxd7U3vnLPkjyTDuiAhis8avoQLS2VWQMdBmCNnip46HMNdCDvZVqIgcRGxPG3DWAnmqi2I43zWNBcjALjioXgXC11TFREFnYZ0p8i60/s1600/IMG_20190426_071221.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="644" data-original-width="1190" height="173" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcjtzeO-RCca-i8JwvX_VGRXOiSy0pttdpSU4WIxd7U3vnLPkjyTDuiAhis8avoQLS2VWQMdBmCNnip46HMNdCDvZVqIgcRGxPG3DWAnmqi2I43zWNBcjALjioXgXC11TFREFnYZ0p8i60/s320/IMG_20190426_071221.jpg" width="320" /></a></div>
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The finer pitch gear that is attached to the tool turret piston (photo 2 above) engages the idler gear that you see in top of the hole in this picture:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-F-IkyqG1KKPEY7KwTMksF5Wql1F8YhyFydcyRCJ7RlfXP6URylgv8zpoUVF7ZlUm3sM82eRs2B169ngTNAiQ__8eM5NZuJyQNnseW5n7_dv6znApxcCpfyxZvMoI0uEqSy1f1OrGh1Rx/s1600/20180525_084247.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1559" data-original-width="773" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-F-IkyqG1KKPEY7KwTMksF5Wql1F8YhyFydcyRCJ7RlfXP6URylgv8zpoUVF7ZlUm3sM82eRs2B169ngTNAiQ__8eM5NZuJyQNnseW5n7_dv6znApxcCpfyxZvMoI0uEqSy1f1OrGh1Rx/s320/20180525_084247.jpg" width="158" /></a></div>
That idler gear turns an electrical feedback encoder that is located under the rectangular cover just above the piston pocket in the picture above. The control would know where the desired position was by using those gears and the electrical feedback
encoder and and when the control saw the tool coming close to the "cutting" position, it would fire the hydraulic arm to stop the turret in that spot. You can see the top of the feedback encoder in the foreground of this picture (my fingers are holding the feedback shaft):</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi9YCpIvuRNrpT75CCd0zRk7WvNdkCxsrz8Mu6NGiDOVY6l6an2FkAmKhzY-6xKVcVi3V4zsTLu7GlpiGqg8YnynAgEH-xfEv81-ubblg60KsX7a2CiJbK2yhDtekryZ7QyYw4C5kXhk4cH/s1600/20180813_132209.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="918" data-original-width="1099" height="267" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi9YCpIvuRNrpT75CCd0zRk7WvNdkCxsrz8Mu6NGiDOVY6l6an2FkAmKhzY-6xKVcVi3V4zsTLu7GlpiGqg8YnynAgEH-xfEv81-ubblg60KsX7a2CiJbK2yhDtekryZ7QyYw4C5kXhk4cH/s320/20180813_132209.jpg" width="320" /></a></div>
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Anyway, the point of all this is that (I THINK!) I might be able to use the turret again by installing a 2-way pneumatic valve system that normally ports air to the top side of the turret piston to hold it in the normal cutting position, then have a spring loaded "Tool Change" position which will put compressed air under the piston when a tool change is desired. So, when you want to do a tool change the Gcode will have the control go into a pause routine for a tool change. Then, the operator will flip the 2-way pneumatic valve to the (non-normal) "Tool Change" position which will put compressed air under the turret piston and allow the turret to be turned by hand. With the new tool in the cutting position, the operator releases the 2-way valve and the compressed air will once again push the turret down onto the alignment dogs and hold the new tool in cutting position. At least, that is the theory. The application might be a little more "fun." More to follow......</div>
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<u><b>6. Rehab the coolant system</b></u> - As I mentioned above in the power system modifications, this lathe originally had a cutting oil "coolant" system. Heavy, petroleum based cutting oil was used as a coolant and it was stored in a large tank under the lathe. The cutting oil was pumped by a fairly large 230Vac/3-phase pump which was turned on/off by a large 3 phase switch in the electrical cabinet that was actuated by a 115Vac solenoid. The 115Vac solenoid was controlled by the old controller using Crydom solid state relays. Here is a pic of the accessible end of the coolant tank (and pump):</div>
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Using cutting oil like this is really not practical anymore and most coolants today are water based solutions that are much less toxic and much less expensive (imagine the cost of 30 gals of cutting oil today!!). I don't have a definite plan yet, but I hope to install a medium sized coolant tank with a 115Vac pump that can easily be controlled by the F8025T control using the Crydom relays. I have more research to do on as I design this new system and will follow-up on this when I get a firm plan together.</div>
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<u><b>7. Collet closer system</b></u> - The lathe has a pneumatic collet closer system installed. It has been semi-deleted and is not currently operating in automatic mode. Here is a pic:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNht-jBVGGAkZn98-TzQLK2asPXuHj3Jjmx8PUp7-eAhlbyFLfgIiXQTRjvymfNsB-iKzV86_oqdNEhTrb2Cmm53wz4pv8EtspYQ4dI93sQYf3IBrpvFWaT-rHecUZh0vYEb8zv8MV0BUj/s1600/IMG_20190426_071124.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1136" data-original-width="1134" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNht-jBVGGAkZn98-TzQLK2asPXuHj3Jjmx8PUp7-eAhlbyFLfgIiXQTRjvymfNsB-iKzV86_oqdNEhTrb2Cmm53wz4pv8EtspYQ4dI93sQYf3IBrpvFWaT-rHecUZh0vYEb8zv8MV0BUj/s320/IMG_20190426_071124.jpg" width="319" /></a></div>
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It does work manually by turning the whole body of the closer, the threaded rod will close the collet holder. I'm hoping to trace the electrical and pneumatic circuits in this system and figure out how the system is supposed to work.. Then, I will come up with a plan to repair, re-vamp, re-do, or otherwise re-install an operating collet closer system. Even if it is just ends up being a manually controlled collet closer (.vs. controlled by the F8025T controller) - that would be an improvement over the current manually threading mode. </div>
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<u><b>8. Re-install New Plexiglass Into Enclosure Doors</b></u> - I removed the enclosure bows so that I could work on the lathe more easily, but didn't have anywhere to store them out of the rain, so I turned them upside down on top of the machine, for now. Here is a pic as the machine currently exists.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVf28ivEHFrA9Mu3mRu4s-yOKkWfFkwGQs8CZXcPE2NXB91sY9ezIdsY4BHCV4KtdFh_hgK-wpDVf_adi6tVH2dln24ikZNK1AI5q2A25xsFIMMpbM4p2VfezoVHAqGdlOikg2QUr8HL1q/s1600/IMG_20190327_194459.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="893" data-original-width="704" height="320" save_image_to_download="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVf28ivEHFrA9Mu3mRu4s-yOKkWfFkwGQs8CZXcPE2NXB91sY9ezIdsY4BHCV4KtdFh_hgK-wpDVf_adi6tVH2dln24ikZNK1AI5q2A25xsFIMMpbM4p2VfezoVHAqGdlOikg2QUr8HL1q/s320/IMG_20190327_194459.jpg" width="252" /></a></div>
Once I have all the mechanical type repairs done to the lathe, then I will endeavor to source some plexiglass and install new panels into the doors so that there will be good visibility inside the machine while it is running, but keep the coolant from splashing and flying about.<br />
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Well, that the current state of "dis"-repair of this machine. I'll be pecking away at the hit list areas and will update on this machine again later. Hopefully, you might have found some of this useful information for a similar project or prospective project. Thanks for checking out the Hardinge CHNC Lathe project. Now, back to the normal Prowler Blog updates.Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-4561663675008429701.post-39664047322255439252019-04-12T10:02:00.000-07:002019-04-12T10:54:17.768-07:00Making Prowler Parts, Cutting Wing Rib Dies, Project X and Builder UpdatesI can't believe that it's been over 5 months since my last update! Life's been coming at me at warp speed lately. I usually try to get an end of year blog update - but, that one slipped past. Anyway, on to a new year! I hope everyone had a great holiday season and that 2019 is off to a good start for you. <br />
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I've had a couple months lately where I didn't have much support work to do for any of my current Prowler builders. This has afforded me some time to tackle some of the projects that have been sitting around on my various work benches for far too long. One good example is nose rib dies. It's crazy to think that it's been over 4 years since I cut 4 nose rib dies so that I could replace 4 nose ribs for Francis! Para 1. here: <a href="http://prowleraviation.blogspot.com/2014/12/more-rib-fabrication-and-santa-brought.html" target="_blank"> <span style="color: orange;">(http://prowleraviation.blogspot.com/2014/12/more-rib-fabrication-and-santa-brought.html)</span></a></div>
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Since then, I've had 3 more nose rib dies cut out (rough cut with the band saw) sitting on a bench waiting for a chance to put them in the CNC mill and get them done. Well, that time finally came this past couple months! More later.<br />
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Also, I spent some "down time" in a hotel recently and used it to set up a <span style="background-color: #fce5cd;"><span style="color: orange;"><a href="https://www.youtube.com/channel/UCvCZN-7jUt6ZKqn_KOFKV-Q" target="_blank"><b>Prowler Aviation YouTube channel</b></a></span></span>. You can find several videos of Prowler content here:<br />
<span style="background-color: #fce5cd;"><span style="color: orange;"><a href="https://www.youtube.com/channel/UCvCZN-7jUt6ZKqn_KOFKV-Q">https://www.youtube.com/channel/UCvCZN-7jUt6ZKqn_KOFKV-Q</a></span></span><br />
Head on over and check it out. If you're interested, please subscribe.<br />
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In this update:<br />
A. Completing 2 Sets of MLG Torque Tubes<br />
B. Making Parts of a Tailwheel Hydraulic Actuator for Ray
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C. Hydraulic Repairs to 400 Ton Press
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D. "Project X" - Making Test Parts For New Owners of Another <br />
Kit Aircraft Company<br />
E. Finally Completed Dies For All the Outboard Nose Ribs
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F. Ray's Work on MLG Torque Tube Pivots<br />
G. An Update From Francis<br />
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Before I start with the Prowler update items, I've got a cool feedback type report to share. For those of you that have followed my blog for a while, you may recall that I reported various times about working on and completing the installation of a backup diesel powered electric generator for my property. (Item #4 here:<span style="color: orange;"> <span style="background-color: #fce5cd;"><span style="color: orange;"><a href="http://prowleraviation.blogspot.com/2016/02/kit-15-has-new-owner-rays-tailwheel_17.html">http://prowleraviation.blogspot.com/2016/02/kit-15-has-new-owner-rays-tailwheel_17.html</a></span></span></span>).
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In mid Feb this spring, we had a freak snow storm in the Northern CA valley area and we got 6-11 inches of wet, heavy snow (depending on the exact location). At the shop, we got about 6 inches. To the north of us, they got more like 10-11 inches. Check this out:
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Now, I grew up in east central WI and snow like this isn't impressive to me. But, for our area of Northern CA, this is not at all normal. Typically, once each winter it snows just enough to make the ground white and it usually melts off the same day. Well, because it never snows this much here AND because it was so wet and heavy, it stuck to all the trees and pulled them down by the 1000's!!! Of course, falling trees play hell with power lines and (you know where this is going), we lost normal PG&E power. In fact, our power at home was out for 8 hours short of a full week!! Thankfully, we had the backup diesel generator, and it proved it's worth in spades!! Here's a picture of it as it currently looks installed in the gen shack:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVVT5HmSn1xSDwqjX7_5oZvYhdc4bl__Z4FP6vdgcUXzor5URJp0Gt-Q9jz3d16W90W0XXxAWUJ1nKRmluJB9JC1J9m5QGy3Qjs-_8b0P5tXGeVDgztAwJfNGc6yYBcAbVww0DYPahC0A9/s1600/IMG_20190327_191102%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="898" data-original-width="745" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVVT5HmSn1xSDwqjX7_5oZvYhdc4bl__Z4FP6vdgcUXzor5URJp0Gt-Q9jz3d16W90W0XXxAWUJ1nKRmluJB9JC1J9m5QGy3Qjs-_8b0P5tXGeVDgztAwJfNGc6yYBcAbVww0DYPahC0A9/s320/IMG_20190327_191102%257E2.jpg" width="265" /></a></div>
We ran the gen from 5:30am to 10:00pm every day for a week and it never missed a beat!! If it had been summer time, we would have run the generator 24/7, but since it was cool enough outside to snow and it didn't get too cold in the house overnight, we saved the 1/2 gal of diesel that it burns per hour for the 7-8 overnight hours. On average, over the 7 days, it burned about 6-7 gals of diesel per day. At the current rate of $3.09/gal of red dye diesel, it was costing about $20/day to run it. That's fairly expensive for power by the KWhr, but way better than the alternative (no water, no lights, no internet, etc., etc.). The beauty part of this rig is that you can run anything and everything on the property (well pump, furnace, dryer, etc.). I created a checklist for the ladies to use to run the system when I'm not home. And, with the 15KW capacity, I don't (didn't) have to worry about the girls overloading it accidentally.</div>
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This one power outage event made all the work, cost and time invested into building and installing this system very, very well worth it! If you live in a rural area and you have the ability to build or buy something similar, it is definitely a worthwhile investment!</div>
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On with the Prowler update. <br />
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<u><b>A. Completing 2 Sets of MLG Torque Tubes</b></u> - Another project that had been sitting on the bench for a while was completing a few sets of MLG torque tubes that I started last year. In a previous update, I covered the fabrication of the main portion of the torque tubes. The only thing remaining was to cut a bearing retaining sleeve for each torque tube, drill and tap some holes in the correct locations and install some temporary screws to hold them in place for shipping, etc.</div>
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To start this part of the project, I had to put each torque tube in a super spacer mounted in the mill. Then, the flat part of the end flange had to be aligned 90 degrees to the mill table like this:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh7BvLd3z6z2Bh47oNnd2GCvOWkdx5pF8UJ3v6db9ZxnuJVlpGXuMcwP2Vx-RrUmslpYH3e4sGomEfE05Xas0brvXWg59OH_dBH5GXcd2Oa-Yh8-ctaguk4oheAPapmcrVRJtoUr6JQiRMq/s1600/IMG_20181102_153628.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1078" data-original-width="654" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh7BvLd3z6z2Bh47oNnd2GCvOWkdx5pF8UJ3v6db9ZxnuJVlpGXuMcwP2Vx-RrUmslpYH3e4sGomEfE05Xas0brvXWg59OH_dBH5GXcd2Oa-Yh8-ctaguk4oheAPapmcrVRJtoUr6JQiRMq/s320/IMG_20181102_153628.jpg" width="194" /></a></div>
Also, notice the 1/2" ground shaft mounted in the spindle that is bumped up against the stationary sleeve welded to the torque tube. This was used to touch off each side of the torque tube to get the mill Y axis centered on the OD of the tube, and it was to get the spindle set to X=0 at the aft facing edge of the stationary sleeve. This way, the X axis can be moved to place holes in the correct location for the removable sleeve that will be installed. The torque tube for the other MLG had to be placed in the setup the opposite way, like this:<br />
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With the mill centered on the long axis of the tube and the set to X=0 at the aft edge of the stationary sleeve, I cranked the X axis to get the correct hole position for the removable sleeve and marked the hole with a center drill:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKlOhc88voBUu0begUbJLBmV0Rb9f8TFVnjOOrRgr-5KlAqvac8FdCF1jyJpFa37wAum2JaqVdtAamN7U7BxoYAR4xxic7d4DsPh1vl4fsAXQHUdIvyPDy6X0Ame6qysnZF8ncFtf9SsEw/s1600/IMG_20181102_154415.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="987" data-original-width="619" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKlOhc88voBUu0begUbJLBmV0Rb9f8TFVnjOOrRgr-5KlAqvac8FdCF1jyJpFa37wAum2JaqVdtAamN7U7BxoYAR4xxic7d4DsPh1vl4fsAXQHUdIvyPDy6X0Ame6qysnZF8ncFtf9SsEw/s320/IMG_20181102_154415.jpg" width="200" /></a></div>
After a quick tool change, I drilled the hole with a 1/8" pilot drill:<br />
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Then, the hole is opened up to a letter "I" drill (the correct drill for a 5/16" x 24NF tapped hole):<br />
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Next, I cut the removable bearing sleeves from the correct size tubing and put those into the 8" super spacer on the mill. Then, I marked and drilled these the same as described above for the torque tubes:<br />
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And;<br />
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With those complete, I placed the removable bearing sleeves onto the torque tubes and aligned the holes. Here is a set showing that:<br />
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Then, these holes are tapped with a 5/16" x 24NF tap all the way through the sleeve and the torque tubes (so that the threads of a machine screw will engage on all them. Here are both sets with the holes tapped and temporary machine screws installed to hold the sleeves in place:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiho9qDxAEY7oeKjrnv5vtZrbMuHWiqmXNcLsGth5vKP-nlv6dnx5xLYaxLTGVw_xUQiY3FhhYfD6EFtg_8JjiKotaxv_r-44nbcB9eMnn3HmYmjKZnbTon-iJAlBQxT7fFWCe6RPZY3KEf/s1600/IMG_20181102_164337.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="857" data-original-width="987" height="277" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiho9qDxAEY7oeKjrnv5vtZrbMuHWiqmXNcLsGth5vKP-nlv6dnx5xLYaxLTGVw_xUQiY3FhhYfD6EFtg_8JjiKotaxv_r-44nbcB9eMnn3HmYmjKZnbTon-iJAlBQxT7fFWCe6RPZY3KEf/s320/IMG_20181102_164337.jpg" width="320" /></a></div>
They are ready to put with a kit and this is another project moved off of the to-do list!<br />
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<u><b>B. Making Parts Of A Tailwheel Hydraulic Actuator for Ray</b></u> - This fall, I was headed down to see Ray before a work trip. He'd been having problems with is tailwheel strut hydraulic actuator leaking (leaking by the piston). I had the materials readily at hand, since I was planning to make a few of these for Kit #18 and a few to have in inventory. I decided to make up a new cylinder, piston and piston rod for Ray and bring it along. The first step was to cut the cylinders to length. That's a pretty easy task, just measure, cut with a band saw and trim in the disk sander: Here are three of them finished:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8fRCqnUs7u2ILxDn6Ifs5yI1NUO9ZWBX1olEzm8ZXLj8jfOrTeMcwFAc-NHfU1rd8EbKSGTKN_-DbNMqYusLQivY27Yf_Xjp_VfBNw6_ha4AQmSK8ey61bh5zgOLZR4IFVx9kV02zY977/s1600/IMG_20181113_120043.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="653" data-original-width="1281" height="163" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8fRCqnUs7u2ILxDn6Ifs5yI1NUO9ZWBX1olEzm8ZXLj8jfOrTeMcwFAc-NHfU1rd8EbKSGTKN_-DbNMqYusLQivY27Yf_Xjp_VfBNw6_ha4AQmSK8ey61bh5zgOLZR4IFVx9kV02zY977/s320/IMG_20181113_120043.jpg" width="320" /></a></div>
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Next step was to put each of them into the 8" super spacer (really handy tool for machining round stuff!!) and put the correct sized holes in the correct places:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgo63ldLmL9HhGO0EJ2PANVIvGCD7tG7L_9KWOuuDHsUzhyY4vohnCIXBQqay15mjQBVPMyA8i9ldpBWaIquUyWMEE6QCFbaMJBlxDGlKARrqhfsnCx_P62V5yuMSt1veFusjDL_RAx5JlU/s1600/IMG_20181113_115558.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="704" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgo63ldLmL9HhGO0EJ2PANVIvGCD7tG7L_9KWOuuDHsUzhyY4vohnCIXBQqay15mjQBVPMyA8i9ldpBWaIquUyWMEE6QCFbaMJBlxDGlKARrqhfsnCx_P62V5yuMSt1veFusjDL_RAx5JlU/s320/IMG_20181113_115558.jpg" width="297" /></a></div>
And:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_WbP3tCF49K0LhxPNxoyckR56yhhyrKMTq6NJs2so4TsrdPLmnErkgJVm4A42-3O2J9WECgZNiVFVBWGSwM_QO0FJSZhunoVkayQf8kgtYkqljDC0vJUr2TiSYQWea9RAlnr3NMlsyNih/s1600/IMG_20181113_120107.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="973" data-original-width="801" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_WbP3tCF49K0LhxPNxoyckR56yhhyrKMTq6NJs2so4TsrdPLmnErkgJVm4A42-3O2J9WECgZNiVFVBWGSwM_QO0FJSZhunoVkayQf8kgtYkqljDC0vJUr2TiSYQWea9RAlnr3NMlsyNih/s320/IMG_20181113_120107.jpg" width="263" /></a></div>
After machining the holes, I deburred them and ran a cylinder hone through them to clean them up and get a smooth finish for the piston O rings to slide against. With the cylinders completed I prepped several pieces of piston rod and placed them in the lathe. The first operation was to center drill and pilot drill the rod for a tie rod connector on one end:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQOE5MO1Ho0EKxKvsz8t5NPUkDUglvorbxUiihUoJqJE80W8EJktZQj5JrspTMDgVTXsV7M0tcxbjrC176pGPLy0CdBz9MwxoK7zZSdnwzufnHrWQ5TtWe8aQKvpunwu3EBZWtpdEMpWzL/s1600/IMG_20181113_134502.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="838" data-original-width="1132" height="236" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQOE5MO1Ho0EKxKvsz8t5NPUkDUglvorbxUiihUoJqJE80W8EJktZQj5JrspTMDgVTXsV7M0tcxbjrC176pGPLy0CdBz9MwxoK7zZSdnwzufnHrWQ5TtWe8aQKvpunwu3EBZWtpdEMpWzL/s320/IMG_20181113_134502.jpg" width="320" /></a></div>
And:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXB0ZO5TWdqPwBirTMAe1m79sqt6TQmbu7y4R9FUPqnogkynomhV7ovuWDZWnjPSBI3zMPAG1PpGIWHGUzrOYybWCqXl_JNKZZo_SA7zniJN1uKG0YHnvMpj-TuKLbEfKLc6NjyU2q8tH7/s1600/IMG_20181113_135025.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1157" height="209" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXB0ZO5TWdqPwBirTMAe1m79sqt6TQmbu7y4R9FUPqnogkynomhV7ovuWDZWnjPSBI3zMPAG1PpGIWHGUzrOYybWCqXl_JNKZZo_SA7zniJN1uKG0YHnvMpj-TuKLbEfKLc6NjyU2q8tH7/s320/IMG_20181113_135025.jpg" width="320" /></a></div>
Then, that hole was tapped to eventually thread a tie rod end into it. Then, I turned the piston rods around and ran the correct sized die onto the shaft to thread it for the piston. The OD of the rod and the ID of the piston are threaded to match and then turned onto one another. Here is the rod getting threaded:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjnddUtuvRyxgxwWOZGRKHvj6I7hC42saVpvk07GeOUvhMCPXNEMN3BTAh9VC2Nxz3ZKoblGOMaVkYAcVMc1owYm2jYXCnXxb1AOJsu_77Fk78zztXaujEw9Zt5TWhVGCs4KRqurYHXEbe6/s1600/IMG_20181113_142947.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="700" data-original-width="1184" height="189" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjnddUtuvRyxgxwWOZGRKHvj6I7hC42saVpvk07GeOUvhMCPXNEMN3BTAh9VC2Nxz3ZKoblGOMaVkYAcVMc1owYm2jYXCnXxb1AOJsu_77Fk78zztXaujEw9Zt5TWhVGCs4KRqurYHXEbe6/s320/IMG_20181113_142947.jpg" width="320" /></a></div>
Next, the piston stock was cut off of a round bar of 7/8" steel 4130 rod. Then, one side is faced and a hole marked, drilled and tapped to accept the piston rod:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6sZN1gi6yGe5CdvImPFwSkrEJ8yWj1kpNNb716u0rTg7g7r96W-AkVRIVzu9XCfOvThXsXTs86DVhkPiW0QtrY3ZMsOtw5P3jfVIZPI0Gd0D4zps8Q5jNqNjQavJ4pLW0Ng6KtYbGlg-i/s1600/IMG_20181113_145233.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="716" data-original-width="1001" height="228" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6sZN1gi6yGe5CdvImPFwSkrEJ8yWj1kpNNb716u0rTg7g7r96W-AkVRIVzu9XCfOvThXsXTs86DVhkPiW0QtrY3ZMsOtw5P3jfVIZPI0Gd0D4zps8Q5jNqNjQavJ4pLW0Ng6KtYbGlg-i/s320/IMG_20181113_145233.jpg" width="320" /></a></div>
And:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimjkHHP-a2gaz2tccmb3-Jqwo7T1bTXghXl4OEnu40KLiS5aNIMWt5Uk9a-VFOounOt_poSORLjfBXP3Qga6mpEgnUBlSSWA7RZmtsId8At4TDJdCqWc53TIzwscsmNvsb57TLx-_Oku6y/s1600/IMG_20181113_145507.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="701" data-original-width="862" height="260" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimjkHHP-a2gaz2tccmb3-Jqwo7T1bTXghXl4OEnu40KLiS5aNIMWt5Uk9a-VFOounOt_poSORLjfBXP3Qga6mpEgnUBlSSWA7RZmtsId8At4TDJdCqWc53TIzwscsmNvsb57TLx-_Oku6y/s320/IMG_20181113_145507.jpg" width="320" /></a></div>
And:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNsknJdxzC-cOB2SjExJ5YZ2bVM1y0qjtCY_cPWidDEE9kSMUzYB0lAsI-31liPiVfUCBxR5D0bfZntwtJ317h98cIRoIf0jH04oP4OSyfYVD-mpmsVRcx3tYXm8UrM_bEXUc5oVL0lGa9/s1600/IMG_20181113_145850.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="679" data-original-width="1024" height="212" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNsknJdxzC-cOB2SjExJ5YZ2bVM1y0qjtCY_cPWidDEE9kSMUzYB0lAsI-31liPiVfUCBxR5D0bfZntwtJ317h98cIRoIf0jH04oP4OSyfYVD-mpmsVRcx3tYXm8UrM_bEXUc5oVL0lGa9/s320/IMG_20181113_145850.jpg" width="320" /></a></div>
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With that done, I threaded the rod onto the piston and placed it in the headstock. Then, I machined the other face of the piston and cut the OD of the piston true to the center of the piston rod (the correct diameter and concentric). With that done, I cut the O ring grooves and polished the whole assembly. Unfortunately, I forgot to get some pics of that, but I have more of these actuators to make (for Kit #18 and for inventory), so I'll have more pics then. </div>
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<u><b>C. Hydraulic Repairs to 400 Ton Press</b></u> - Not long after I assembled the hydraulic unit for the big press, and ran it a few times, I noticed several small hydraulic oil leaks. I hate oil leaks but, I walked around this problem and ignored it for months (easy to do when you're already so busy you also neglect to do timely blog updates).<br />
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The first leak I discovered (too late), was the pump shaft seal. On the back side of the tank, where the large belt pulley powers the pump input shaft, the shaft passes through a flange that is bolted to the pump. The pump is inserted into the back side of the tank and the flange, in turn, is bolted to the tank. Here is a side view of the pump: </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhM9aTJso7aPs_9uY5bDe20gLZ8yrmhyphenhyphenSa0ZY-Cz7v-cJqMS5IZnRTl3olJ0LvEJvoR03dfuh8i9V9qQT00txwp9bBTTPSi28bPCIHxVNTLfTTU4XzZ5g5Fu5yeb7pmd5UZgIfcavMaUnbP/s1600/20161122_203915.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="466" data-original-width="924" height="161" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhM9aTJso7aPs_9uY5bDe20gLZ8yrmhyphenhyphenSa0ZY-Cz7v-cJqMS5IZnRTl3olJ0LvEJvoR03dfuh8i9V9qQT00txwp9bBTTPSi28bPCIHxVNTLfTTU4XzZ5g5Fu5yeb7pmd5UZgIfcavMaUnbP/s320/20161122_203915.jpg" width="320" /></a></div>
Here is a front view of the pump (the face of the pump you see that is not inside the oil reservoir/tank): <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdX3jpuCQhJg7WK_zz8CEdBRLKzTUMlUKlVP0y8OQNZOFkFMv1tQ1pwIM7gaQjTBfPG7EdWB7_B0uew6d-A0q_c8XOkDJVSuNILpAtd7ClKeO_4QRjjm_lSQPmR6EhVTT6r9d4Clj86KQe/s1600/20161122_203931.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="476" data-original-width="734" height="207" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdX3jpuCQhJg7WK_zz8CEdBRLKzTUMlUKlVP0y8OQNZOFkFMv1tQ1pwIM7gaQjTBfPG7EdWB7_B0uew6d-A0q_c8XOkDJVSuNILpAtd7ClKeO_4QRjjm_lSQPmR6EhVTT6r9d4Clj86KQe/s320/20161122_203931.jpg" width="320" /></a></div>
Around the input shaft and inside that flange is an oil seal that is leaking. It must be old, dry and/or cracked, because the oil from the reservoir slowly leaks out through the pump and past that seal. Earlier, I said I discovered this "too late." What I
meant by that is, I could have easily changed that seal when I had the
pump on the bench and took the pics above. To change that seal now, I've got to empty the entire tank, move the motor (to remove the belt) and then remove the pump again. Bummer! Once I discovered this leak, I was able to find a plastic pan to wedge below the leak and catch the drips - it has now been that way for over a year.<br />
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The next leaks I discovered were the bolts holding the flanges onto the front and back of the tank (the return line flange and the pump flange). You can see the leaks here around the front (return oil line) flange:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaW-3VadyJkad8jZGeDK97A6Xtw2Y5LO4C-i_3XgBETt2j-V7SJO_zJ2pxUzUacrtwhuSha8DvgblPTmcrmN3Zwaz1ljSVU-cfywHWb5jsxWv1lnjyyI2U_Hrr-BaDHPiCNQw7ybJqE7p5/s1600/IMG_20190327_194221.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="647" data-original-width="1003" height="206" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaW-3VadyJkad8jZGeDK97A6Xtw2Y5LO4C-i_3XgBETt2j-V7SJO_zJ2pxUzUacrtwhuSha8DvgblPTmcrmN3Zwaz1ljSVU-cfywHWb5jsxWv1lnjyyI2U_Hrr-BaDHPiCNQw7ybJqE7p5/s320/IMG_20190327_194221.jpg" width="320" /></a></div>
The leak streaks you see at the bottom of the tank (below the flange) are actually originating around each of the bolt heads through the flange. What's happening there is that the bolts that are holding this flange to the tank pass through clearance holes in the flange, the flange gasket and the tank wall. There are threaded nuts welded to the inside of the tank centered on each bolt hole. However, the threads on a standard bolt are not self tightening. So, there is room between the nut and bolt for oil to slowly make its way past the nut threads, past the flange and leak past the bolt heads. Ugh!!<br />
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The third leaks I discovered took a while to show up. When I remodeled this hydraulic unit, I had to expand the reservoir (tank) to get more volume of oil. It takes about 9 gals of oil to raise the press ram the distance needed to press the airplane parts. In order to get the extra volume I needed, I literally cut the tank in half horizontally and added 8" of height to the tank by adding 4 steel plates on each wall of the tank. Then, I had it welded up. Well, in 3 places in the welds, there are pin hole leaks and a very small rivulet of oil is leaking out. Here is one:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMQfbi_Mmrnwgpv4tXx09gavhz-BQ5hbj-ZeMMsW8y3EDx6iFyAWCsezUdT1ThwHWegU_nzWHhC14FhZzexbXaGAMzLiONBoyZiYI5GiWfFcjr6M3VlD8e-0UxzdZIjrF0g6ouY8YdePU9/s1600/IMG_20190211_120130.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="712" data-original-width="1038" height="219" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMQfbi_Mmrnwgpv4tXx09gavhz-BQ5hbj-ZeMMsW8y3EDx6iFyAWCsezUdT1ThwHWegU_nzWHhC14FhZzexbXaGAMzLiONBoyZiYI5GiWfFcjr6M3VlD8e-0UxzdZIjrF0g6ouY8YdePU9/s320/IMG_20190211_120130.jpg" width="320" /></a></div>
And another:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHemn2ceGCbeXfOfODSefsvArl1-Br5KZBYMtzRZGocaaNxes4tAPiNRZOcgxtjpARQjVN57pN4LcjE1C0Uxn4yNmUktuzKszDxHT45KxOj7XqzuDdhk4Gs-o8of9ewL_96uCG8lxUkPCG/s1600/IMG_20190211_120138.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="640" data-original-width="840" height="243" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHemn2ceGCbeXfOfODSefsvArl1-Br5KZBYMtzRZGocaaNxes4tAPiNRZOcgxtjpARQjVN57pN4LcjE1C0Uxn4yNmUktuzKszDxHT45KxOj7XqzuDdhk4Gs-o8of9ewL_96uCG8lxUkPCG/s320/IMG_20190211_120138.jpg" width="320" /></a></div>
There is one other leak that was on a corner of the tank that I couldn't get a good picture of. However, that one (being on a corner) had enough rigidity that I was able to use a ball peen hammer and peen the area and seal up the leak. The other two I can't peen without emptying the tank and bucking the back side of the tank wall. Bummer!<br />
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Well, I decided that it was time to start pressing some airplane parts soon and that it was time to tackle these issues and try to fix them - somehow. The
purist in me wanted to take this whole thing back apart and tighten the
be-jeezus out of everything. But, in order to take it all apart I'd
have to empty the entire reservoir and the hoses and, without a doubt,
I'd have more oil on the machine and the floor than into the storage
jugs and pans. I really did not want to have to empty the tank and pull the pump.<br />
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So, instead, I climbed up and looked at the plastic catch pan that I had wedged under the leaky pump shaft seal. There was a fair amount of oil in the pan, but it had taken over a year to get that much oil in the pan. I figured, at that rate, it wouldn't be too big of a deal to just get on a ladder once every couple months and empty the catch pan back into the reservoir. And, who knows, when I start using the pump more, with heat from motion and use, maybe the seal will expand and seal more tightly again (hey - it's possible!). First leak - SOLVED!!<br />
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As for the flange bolt heads leaking oil, I decided to back each bolt out (one at a time) and wrap a large wad of Teflon tape around the shank of the bolt just under the bolt head. Then, I tightened them back down snugly. By doing this, I was able to significantly slow (and in some cases stop) the leak rate from these flange bolts. Second leak(s) - SOLVED!!</div>
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The tiny leaks from the tank welds I decided were not worth dealing with for the time being. Third leak(s) - SOLVED!! </div>
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In addition to the leaks I mentioned above - as I was climbing around the hydraulic unit, I noticed that there were also leaks coming from several of the threaded piping connections that I had put together to make this whole thing work. I tightened several of them as soon as I discovered them. Then, I went back and tied folded paper towels around each plumbing joint to use as a tell-tale. It looks kinda funny with all these white "band aids" all over the hydraulic unit. Look here:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbDAv0RAv_b_8C3FLP_syqGeUwhYWUG-CUyxjcGqGl1g6oNE1naogQ0GmYl7GvP5Ujo0abcw0Ncqo8eYMkwHfJf4dn4l_UZT6vPZw-Y1OpU2fY36R7E3YWUPXe35Uq6-PX0wT_YG90AEDa/s1600/IMG_20190327_194233.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="992" data-original-width="684" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbDAv0RAv_b_8C3FLP_syqGeUwhYWUG-CUyxjcGqGl1g6oNE1naogQ0GmYl7GvP5Ujo0abcw0Ncqo8eYMkwHfJf4dn4l_UZT6vPZw-Y1OpU2fY36R7E3YWUPXe35Uq6-PX0wT_YG90AEDa/s320/IMG_20190327_194233.jpg" width="220" /></a></div>
But, it works! If you look closely at the one towel that is second down from the top left - the towel is
yellow and saturated with oil. That just so happens to be the main
pressure line from the pump to the piston. I've tightened that line 3 times. It's still leaking. I'm afraid to crank on it any harder for fear that I'll damage the threads on the thing, or break it off altogether. For now, I'm just monitoring it.<br />
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So, I do realize that I really didn't do the correct fixes to these oil leaks. Essentially, I just did some temporary "bush fixes." I really want to use this press over the next several months, but if I tear it all apart to do the correct fixes it might be a very long time before I can get it all back together (my work sked and other time commitments being what they are). For now, at least, I'll be able to use the press and make some parts - particularly for the guys I'll discuss next in Para. D.</div>
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<u><b>D. "Project X" - Making Test Parts For New Owners of Another Kit Aircraft Company</b></u> - I was recently contacted by a couple gents who have purchased another, established kit aircraft company. They were wondering if I'd be interested in helping them form some parts for their project. I figured that this might be a great opportunity to collaborate with other folks who were trying to accomplish a lot of the same things that I am. We might be able to help each other out with problems we're having. So, I'm calling this "Project X" and I agreed to do whatever I can to help them with their project. The biggest challenge they are undertaking with their project is working to change the wing from a straight wing ("Hershey Bar") to a tapered wing design, like the Prowler. That is a sizeable undertaking - and will be very interesting to be a part of!</div>
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To kick things off, I decided to cut out a couple of sets of blanks for one of the nose rib dies that I made for helping Francis several years ago. For the Prowler, these would be made from 2024-T3 in 0.040" thickness. But, for their project, their ribs are formed from 0.032" material. Here is one of the blanks after cutting it out with the MotionMaster CNC router:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGR1s_GZwTSLE8h8kr8NECvZjg6IdQ7wdcvpQXK0TS78aMXnxCPrIalP1PzGBnhiZD5WrGuspX4Cm7iJD8IEYH7hr1NJ2jwAXrsgGuOS6ktYpXEYn3OMJ3fMaGraDoj5t5fwVLLCU_3MBa/s1600/IMG_20190220_142504.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="709" data-original-width="1426" height="158" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGR1s_GZwTSLE8h8kr8NECvZjg6IdQ7wdcvpQXK0TS78aMXnxCPrIalP1PzGBnhiZD5WrGuspX4Cm7iJD8IEYH7hr1NJ2jwAXrsgGuOS6ktYpXEYn3OMJ3fMaGraDoj5t5fwVLLCU_3MBa/s320/IMG_20190220_142504.jpg" width="320" /></a></div>
Here's also a link to a video of the CNC router cutting that blank out:<br />
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<span style="background-color: #fce5cd;"><a href="https://www.youtube.com/watch?v=mW0BVK83MrU">https://www.youtube.com/watch?v=mW0BVK83MrU</a></span></div>
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Once I had the blank cut out, I hit the die (form block) and the blank with some Pledge furniture polish. The Pledge has some lubricity to it and helps the parts and the rubber move without galling, ripping or tearing (I learned that from, and credit to Brian Carpenter):</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivTia1JKh9x0rmDmgE4ZwkXE2OX_C7euMjT0W2nD5Lif8hPL9D6_1iMemvn41MwPFxnhTg9uLsk0ZlYa44mBNfe0TZP0XWaqEk7e9xpTgZ3a1aIKBeQtpLM2MUTeIVcKZGAtFAAemVo9di/s1600/IMG_20190220_145222.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="648" data-original-width="986" height="210" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivTia1JKh9x0rmDmgE4ZwkXE2OX_C7euMjT0W2nD5Lif8hPL9D6_1iMemvn41MwPFxnhTg9uLsk0ZlYa44mBNfe0TZP0XWaqEk7e9xpTgZ3a1aIKBeQtpLM2MUTeIVcKZGAtFAAemVo9di/s320/IMG_20190220_145222.jpg" width="320" /></a></div>
Then, I placed the blank onto the die with tooling hole pins and spray a little more Pledge on the top of the blank to let it slip on the wear pad more easily:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhI4lvgL3aPG8Jmvf4HU-Uo2oKnfceuF_ZKIaAziyPCoPFTG2GIplBADhVjyy1CO72PN40FwapozOds3ezkVdpK59gGzYQP579RktV-qXWIHBRLR0dzHv4I8kJDrGxbZF1hAqmAK886IEOy/s1600/IMG_20190220_145301.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="618" data-original-width="1098" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhI4lvgL3aPG8Jmvf4HU-Uo2oKnfceuF_ZKIaAziyPCoPFTG2GIplBADhVjyy1CO72PN40FwapozOds3ezkVdpK59gGzYQP579RktV-qXWIHBRLR0dzHv4I8kJDrGxbZF1hAqmAK886IEOy/s320/IMG_20190220_145301.jpg" width="320" /></a></div>
Then, the whole thing went into the press:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi15yuRvFU3DUTh8BCJwWKj1OJ8L4q2wPukCPGV6ufV2mzcVUOSvg14Gyt73n0KKHxZqx1bxTJGif-u94aQphofssz8_Wi_CRCytnvqa63F_9FPFx0OLulJW19xXwR8jfPHRoaX6BUnQvZl/s1600/IMG_20190220_145419.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="681" data-original-width="1210" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi15yuRvFU3DUTh8BCJwWKj1OJ8L4q2wPukCPGV6ufV2mzcVUOSvg14Gyt73n0KKHxZqx1bxTJGif-u94aQphofssz8_Wi_CRCytnvqa63F_9FPFx0OLulJW19xXwR8jfPHRoaX6BUnQvZl/s320/IMG_20190220_145419.jpg" width="320" /></a></div>
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Here is the wear pad with some Pledge sprayed onto it: </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkL-5eVyekPm6koSWgeuXo_f-zd65QkmTsNlfu939T11qE2xNfxE5ijLXxsjrHdwjQWOOGqJ_DzrKb4iIpk1DjU2yGyKZ6EnwmC6YKOZUzpwCKdXlrBTR9XEAg6XdcX_d4ZMcaBcSTs-rI/s1600/IMG_20190220_145340.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="907" data-original-width="666" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkL-5eVyekPm6koSWgeuXo_f-zd65QkmTsNlfu939T11qE2xNfxE5ijLXxsjrHdwjQWOOGqJ_DzrKb4iIpk1DjU2yGyKZ6EnwmC6YKOZUzpwCKdXlrBTR9XEAg6XdcX_d4ZMcaBcSTs-rI/s320/IMG_20190220_145340.jpg" width="234" /></a></div>
Then, the wear pad goes on top of the blank and die:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXOpThwSewKw0SO9LH2iWxaivEF1bysMlRj-LeDhyphenhyphenHLvfhADx9KINBB5vdr6k-WOMvHskNFRsHtWOxdTv3r4_tqm5DSpBbd8XKq0yVfzJAqxsupGcaA0w26n-ET1GTVI1egdjZ1poIbH-P/s1600/IMG_20190220_145500.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="681" data-original-width="1210" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXOpThwSewKw0SO9LH2iWxaivEF1bysMlRj-LeDhyphenhyphenHLvfhADx9KINBB5vdr6k-WOMvHskNFRsHtWOxdTv3r4_tqm5DSpBbd8XKq0yVfzJAqxsupGcaA0w26n-ET1GTVI1egdjZ1poIbH-P/s320/IMG_20190220_145500.jpg" width="320" /></a></div>
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Finally, I turn on the hydraulic pump motor and run the red platen (called the bolster) up into the rubber box (black box above the blue wear pad). The force of the press (400 tons) is converted into pressure (per square inch) of the blue wear pad onto the flat blank and forces it down over the die (form block). When the ram is run back down and the pressure is released on the rubber, I take out the form block with the newly formed part on it. (The first video link below shows this process as I actually do it in the press, check it out!). Here is what two of them looked like after forming and some hand work:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-A15fzq2WDed9zv2t3ildLMr9HSbniUXw9lXfscWmif5QWPKBJyh7gaOkh67gxtJL5_UK_c9AZQwkCZTo7lwI9jqJG4vXiMBJu2VbcZqpz2i1BIW1BhmEVbio6UUmiazWlJRzf37sNgha/s1600/IMG_20190327_191504.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="611" data-original-width="1206" height="162" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-A15fzq2WDed9zv2t3ildLMr9HSbniUXw9lXfscWmif5QWPKBJyh7gaOkh67gxtJL5_UK_c9AZQwkCZTo7lwI9jqJG4vXiMBJu2VbcZqpz2i1BIW1BhmEVbio6UUmiazWlJRzf37sNgha/s320/IMG_20190327_191504.jpg" width="320" /></a></div>
Here's all four of the practice pieces I made for them:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjyxbtXppVGQ7e3RhvHU_-aY6kal6XLN_Vq0-Ulnf9akItKhQdRpPANU2MUESvb13jyUhYbLq7n02G1BnY577J66Ccpu6dgD4HAhVr7f4krB3AUv9odu-gyWN_Q_0GrFt826_rgxuaVUd8o/s1600/IMG_20190327_191546.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="945" data-original-width="1170" height="258" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjyxbtXppVGQ7e3RhvHU_-aY6kal6XLN_Vq0-Ulnf9akItKhQdRpPANU2MUESvb13jyUhYbLq7n02G1BnY577J66Ccpu6dgD4HAhVr7f4krB3AUv9odu-gyWN_Q_0GrFt826_rgxuaVUd8o/s320/IMG_20190327_191546.jpg" width="320" /></a></div>
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I trimmed the tip of the nose rib on the bottom right - just an example as to how some manufacturers avoid having to deal with the significant forming issues that occur in that area.</div>
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The guys liked my process and have asked me to make some mid-ribs for them next. They emailed me the CAD files for cutting the rib blanks and I should have the form blocks that they made up in a few days. The next time I get home from a trip I will cut the blanks and press them out. More to follow.</div>
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BTW - I made a couple videos for the guys to see what I was able to do for them. You can see them here:<br />
Part 1 - <span style="background-color: #fce5cd;"><a href="https://www.youtube.com/watch?v=yDCJAnK-jeo">https://www.youtube.com/watch?v=yDCJAnK-jeo</a></span><br />
Part 2 - <span style="background-color: #fce5cd;"><a href="https://www.youtube.com/watch?v=mfN2ATu_saQ">https://www.youtube.com/watch?v=mfN2ATu_saQ</a></span><br />
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(These videos are also posted to they Prowler YouTube Channel I mentioned earlier.)<br />
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<u><b>E. Finally Completed Dies For All the Outboard Nose Ribs</b></u> - Working with the fellas above got me motivated to get more of my dies fabricated so that I can press out some Prowler wing ribs. Until now, I had made the two tip rib dies, and 4 nose rib dies for Francis (total of 6 dies). I had the chunks of 1" thick aluminum laying out (for the past 4+ years) ready to make 4 of the remaining nose rib dies for the outboard wings. If I could make those 4 dies and then the last two remaining large dies, I have all the outboard nose rib dies done. The goal was set! I had a couple of nice stretches of days off in Feb, so I tackled those dies. Here you can see 4 of the 6 remaining dies that I needed to finish - they are the ones that are raised up and sitting on the wooden patterns:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxSqdJbirp_pLKks9AQ2MFVqaqeX4D_jMtDLEcwkRWqEFYNX3ws7ABban4VCemPwjvADR7FNLweJYCVR5jGXTe0MyqemCyfguHUa3ONAcvFsFL66T5_UxcDjnEjvje7EgkiFOX3ctk-pVa/s1600/IMG_20190225_093012%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="521" data-original-width="1207" height="138" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxSqdJbirp_pLKks9AQ2MFVqaqeX4D_jMtDLEcwkRWqEFYNX3ws7ABban4VCemPwjvADR7FNLweJYCVR5jGXTe0MyqemCyfguHUa3ONAcvFsFL66T5_UxcDjnEjvje7EgkiFOX3ctk-pVa/s320/IMG_20190225_093012%257E2.jpg" width="320" /></a></div>
The upper left die, and the lower three on the right were the ones that I recently finished:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5t67CSjAPyxMe9UdFYpQSTA_WubxT4jRovTraxbseE4RdhNFElt_WDSkjnpg5yWa7nGpeDnfxSu10NnR1Gqa3M5qKpUh4HZtstK9LaBFu0qrWGRnxHuuXIsGvLRYh0tORGpsPo4OgbJOI/s1600/IMG_20190225_093021%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="582" data-original-width="856" height="217" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5t67CSjAPyxMe9UdFYpQSTA_WubxT4jRovTraxbseE4RdhNFElt_WDSkjnpg5yWa7nGpeDnfxSu10NnR1Gqa3M5qKpUh4HZtstK9LaBFu0qrWGRnxHuuXIsGvLRYh0tORGpsPo4OgbJOI/s320/IMG_20190225_093021%257E2.jpg" width="320" /></a></div>
After I got those 4 dies finished, there were just the two larger dies left to complete. These two remaining dies are the ones that will be used to make the ribs at the wing joint on the Prowler (where the outboard wing meets the center wing section on each side). The size of these two dies begins to get fairly large (approx 6" x 18"). I found some material to make them from and got them mounted in the mill. Here is the first one completed:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_bkY4sKfqY8WJhv1NOjCK3tSUXXlDiWNT28HDj8esPB1KHaZ_vglzy1ZSlTWvEbvI7UcihxLEw0wXkGcVKpjnI76gfmH6EiTNIJvi3WScu5JhkrZqFn1j1gEujVOV7dBkU5yNkjUwGJvn/s1600/IMG_20190313_290137.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="599" data-original-width="1120" height="171" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_bkY4sKfqY8WJhv1NOjCK3tSUXXlDiWNT28HDj8esPB1KHaZ_vglzy1ZSlTWvEbvI7UcihxLEw0wXkGcVKpjnI76gfmH6EiTNIJvi3WScu5JhkrZqFn1j1gEujVOV7dBkU5yNkjUwGJvn/s320/IMG_20190313_290137.jpg" width="320" /></a></div>
Notice the pocket for the lightening hole. When the hole in the blank (smaller diameter) is pressed into the rubber, it bends the blank down into the pocket and forms a flange on the lightening hole:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJJXaIjq776dCGgO4LhKeNTNh-qWOBUdRi2ob_eEqzNHTW1KzLwmihyphenhypheni2twDLFEZrw-UuvgcxMCRv8do73c7f8JDQ63aY5wL8WAR3ii8DlKkTZCMZkvvutBOcXf0ekg3zhyE9TAbGeUkYl/s1600/IMG_20190313_382546.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJJXaIjq776dCGgO4LhKeNTNh-qWOBUdRi2ob_eEqzNHTW1KzLwmihyphenhypheni2twDLFEZrw-UuvgcxMCRv8do73c7f8JDQ63aY5wL8WAR3ii8DlKkTZCMZkvvutBOcXf0ekg3zhyE9TAbGeUkYl/s320/IMG_20190313_382546.jpg" width="320" /></a></div>
However, a new problem appeared. These dies, being at the wing junction, are going to be used to form two nose ribs for each kit. The LH die will form the nose rib that goes on the outboard side of the left wing junction AND the inboard nose rib and the right wing junction. The RH die will form the other two. The problem is, the inboard ribs at both junctions have lightening holes and the outboard ones do not.<br />
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So, if I'm going to use the same die to press BOTH ribs - what to do with the rib blank that does not have the lightening hole cut in it??? Without some how covering that pocket in the die, the rib without the lightening hole would have a big dimple pressed into it when the rubber pad presses down on it. The answer is, I need to fill the pocket. So, I machined a disc that will just drop into the pocket and fill it, but come back out easily. Here is the result:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMfo11aSklIu1nBnjyQyHo_XTYMmjOC4ulaU2z9AWrB49tVZzPSnOxCiZxzpAe5jzjIM3rFdEohGk1bhxe3-M8enHzrx-SGE1oLK9-jf25nwQEZjBY4we0kbRg7SFqLQ5zPcyLLN51a5J4/s1600/IMG_20190315_182559.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMfo11aSklIu1nBnjyQyHo_XTYMmjOC4ulaU2z9AWrB49tVZzPSnOxCiZxzpAe5jzjIM3rFdEohGk1bhxe3-M8enHzrx-SGE1oLK9-jf25nwQEZjBY4we0kbRg7SFqLQ5zPcyLLN51a5J4/s320/IMG_20190315_182559.jpg" width="320" /></a></div>
It fits perfectly in the pocket and if you flip the die over, it falls right out. Here it is in the LH nose rib die:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0inY-SK1-23ys7fCpvDcOFBTREGdt99syaBZqXpCVyEtTIat6Ak94HeaED_mEqYVP57p0iqiVsSmTI7AYCwnGQlE5rKksteo9oys9qFOrovkkMsSFdutuwR8sn9s0rwI4vyosmgafX_SI/s1600/IMG_20190315_182605.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0inY-SK1-23ys7fCpvDcOFBTREGdt99syaBZqXpCVyEtTIat6Ak94HeaED_mEqYVP57p0iqiVsSmTI7AYCwnGQlE5rKksteo9oys9qFOrovkkMsSFdutuwR8sn9s0rwI4vyosmgafX_SI/s320/IMG_20190315_182605.jpg" width="320" /></a></div>
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I machined out the other wing junction nose rib die and decided to just use the same disc for both dies (it was a little bit of a challenge to make that disc without any holes or other features to hold it rigidly while machining it - how do you think I did it??). With that die complete, I had finished making all of the nose rib dies for the outboard wing sections. Here they are all together:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcGdRKAhUtFQGelIrJLt-RLr40TaOZmwGIql_npvU7Rz7VjcJ41r1OBK1uKk7uUgsxuJLK8Fn2zc39HCxJRpgepxuWOKSo1D_QZyxyrgnoRy8TNmkwqpZXUmlKUazrSIbBZIvkZqlCbXHT/s1600/IMG_20190316_164007%257E2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="702" data-original-width="872" height="257" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcGdRKAhUtFQGelIrJLt-RLr40TaOZmwGIql_npvU7Rz7VjcJ41r1OBK1uKk7uUgsxuJLK8Fn2zc39HCxJRpgepxuWOKSo1D_QZyxyrgnoRy8TNmkwqpZXUmlKUazrSIbBZIvkZqlCbXHT/s320/IMG_20190316_164007%257E2.jpg" width="320" /></a></div>
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With those completed, I was trying to decide which way to go next. Should I start on the outboard mid-rib dies, or the wing center section nose rib dies? Then, it occurred to me that I have to make a set of the dies to form the cockpit floor stringers (from the main spar back to the aft bulkhead that attaches to the aft spar). Kit #18 in my office needs a set of those to help make the kit complete. But, that brought up a new problem - material to make those from. Those parts are 9+ inches at the widest point and are nearly 30" long!</div>
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I have been buying 1" thick aluminum plates/bar from a local surplus house - when I find them in sizes that I need. They charge me $3/lbs for these pieces but, finding a piece that wide and that long was hit-n-miss at the surplus place. I was chatting with my machinist buddy about this and he offered to check what his metal supplier charges for aluminum bar. Turns out, he could buy me a new 12 ft stick of 1" x 10" aluminum bar for $2.20/lbs!! Holy cow - the size I need and less expensive too!! Score! Well, less expensive is a relative thing, I guess - cuz, there are a lot of those "lbs" in a stick of aluminum that size. To be exact, $320 worth of "lbs". But, I wouldn't get it cheaper anywhere else, so he ordered one for me and two days later it was in my shop:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjuFVlDofe5CNCAPR7bhWZE3-BtLHWELt5oUQD5dO_5gQyOP-QucG7roeGUh_Ib6RCNQ_ssGEVqFqxWfcLlE8RdyTR33d2hZjMrDCGPZqTr5ixkZaN31aClhvKcoOUVBYU-MHBmIX71ScoU/s1600/IMG_20190305_163536.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="798" data-original-width="708" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjuFVlDofe5CNCAPR7bhWZE3-BtLHWELt5oUQD5dO_5gQyOP-QucG7roeGUh_Ib6RCNQ_ssGEVqFqxWfcLlE8RdyTR33d2hZjMrDCGPZqTr5ixkZaN31aClhvKcoOUVBYU-MHBmIX71ScoU/s320/IMG_20190305_163536.jpg" width="283" /></a></div>
The good news is that this one stick of 10" wide bar will be enough to make all of the dies for the largest parts of the Prowler. From here on out I will be need to get the 8" wide bars to make dies from. Anyway, I pulled out the patterns for all of the Prowler parts that will need the 10" wide bars to make the dies from. Here are the pieces that will make the dies for the floor stringers:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj46zNFN-YQHaSm81wh-iXmR-ibZfKk6u8VFrwEHc0dySLQ54xULJz4zBq0cPVgWdcOz8r_ije7uHkkKn53wEFH7Hn9p41qfqbzh5Cyk5nph-kFj6QGGrUV-NAkcYEYm3HTed0LN3Bz03gD/s1600/IMG_20190327_192137.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="641" data-original-width="990" height="207" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj46zNFN-YQHaSm81wh-iXmR-ibZfKk6u8VFrwEHc0dySLQ54xULJz4zBq0cPVgWdcOz8r_ije7uHkkKn53wEFH7Hn9p41qfqbzh5Cyk5nph-kFj6QGGrUV-NAkcYEYm3HTed0LN3Bz03gD/s320/IMG_20190327_192137.jpg" width="320" /></a></div>
BTW - That's a 24" scale laying on the one die piece. Here are the two largest mid ribs in the center wing section that needed to be make from the 10" wide aluminum bar, again with the 24" scale laying on the upper die piece:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgatEdI-Rn4WfXPgf-q0Vzirk7tE5qj6Ws-zgAsOLnKx2ryuBw6GFORyJH5akzJznBZPmrGQ6SBZEDDtlbX-1F2FngxfivMb-KHnovxFhqyx4ttPk1U_iR8Mbvsb2W5Sc_VlxBIOI-YOZl/s1600/IMG_20190327_192943.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="599" data-original-width="874" height="219" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgatEdI-Rn4WfXPgf-q0Vzirk7tE5qj6Ws-zgAsOLnKx2ryuBw6GFORyJH5akzJznBZPmrGQ6SBZEDDtlbX-1F2FngxfivMb-KHnovxFhqyx4ttPk1U_iR8Mbvsb2W5Sc_VlxBIOI-YOZl/s320/IMG_20190327_192943.jpg" width="320" /></a></div>
While searching for material to make the nose rib dies above, I found enough material to cut these two smaller outboard wing mid ribs die pieces:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3sQfN3rQbQynzvW9JpCtJJna8hjw5EK2YR5_Rk83LCZW6h3Hxzl2bVAkvM4WXpcgirYk6ZXoNploZ2ESyQz3Ye83wvnA0JjrvoWp2qrSh-hL0AZ23yh_kSoWtPkYMgTbitwG8n7iEom6Q/s1600/IMG_20190327_191725.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="628" data-original-width="1096" height="183" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3sQfN3rQbQynzvW9JpCtJJna8hjw5EK2YR5_Rk83LCZW6h3Hxzl2bVAkvM4WXpcgirYk6ZXoNploZ2ESyQz3Ye83wvnA0JjrvoWp2qrSh-hL0AZ23yh_kSoWtPkYMgTbitwG8n7iEom6Q/s320/IMG_20190327_191725.jpg" width="320" /></a></div>
I'll cover the making of these dies in a future update.<br />
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<u><b>F. Ray's Work on MLG Torque Tube Pivots</b></u> - In previous updates I reported on an issue that Ray was having with his MLG torque tube pivots. He had discovered the bearings that were pressed into the pivot links were not properly staked into the link and eventually wiggled their way out of the pivot link. His fix was to cut access panels in the tops of the wings and gain access to the pivot links via the access plates that he'd also built into the tops of the torque boxes. Here's what that looks like:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7ZDzHpeIEuMnIzrfH_IqgiuNwVx-6ZTI8gRTcTN1AyAYZs8eL9A30147jYtt10bYehWEmdnJNvVlWOoAF2ChmUbSKY3R005XkSrJ6vqtlET5TG7BBdDgC0M7_dgpmZMxqg_qPKXsJJ6ma/s1600/IMG_20181114_144419.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="933" data-original-width="756" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7ZDzHpeIEuMnIzrfH_IqgiuNwVx-6ZTI8gRTcTN1AyAYZs8eL9A30147jYtt10bYehWEmdnJNvVlWOoAF2ChmUbSKY3R005XkSrJ6vqtlET5TG7BBdDgC0M7_dgpmZMxqg_qPKXsJJ6ma/s320/IMG_20181114_144419.jpg" width="259" /></a></div>
This access panel in the top of the torque box was not something that was incorporated into the original design. This was something that Ray added on his own, and was a very insightful design change! In fact, I am going to add this to the basic Prowler design for future kits. Here is another view:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgh1bN2gSQeK7No6xu0OsEHnBcFHdp3GFep3p5CLk9_DOA0lgzO1HxClr_fl2vSUQMIDVSjRkE2QaDfC1R4FjH5YiOqXKjrY-XBySQ1-BI1ok5VUAdT-fxmKzjf-b3bdr_iHPAPxoLT52iH/s1600/IMG_20181114_144429.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="940" data-original-width="756" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgh1bN2gSQeK7No6xu0OsEHnBcFHdp3GFep3p5CLk9_DOA0lgzO1HxClr_fl2vSUQMIDVSjRkE2QaDfC1R4FjH5YiOqXKjrY-XBySQ1-BI1ok5VUAdT-fxmKzjf-b3bdr_iHPAPxoLT52iH/s320/IMG_20181114_144429.jpg" width="257" /></a></div>
Here is a close up view of the problem area on the pivot link. It's not easy to tell from this picture, but the black looking shaft that is on either side of the pivot link is actually a sleeve that slides over the pivot bolt (that bolt runs through the U channel and the bottom of the pivot link). The sleeve ensures that the bearing in the pivot link cannot slide out of it's pocket - in this case upward towards the nut on the pivot bolt:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEisz3GxbMkuJvV9m9tvBaqOkOehIUtClHTbON2XV2DHfbVvl5a0qMu_2Whl2Nvvmrn8XZYCwzwhznynoLqB7S4mT4YFsqpEt3_PoWclwKxXVQ09PkfiW0FrPSdunNEhviFXCnLZHzPHfGws/s1600/IMG_20181114_144438.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="846" data-original-width="718" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEisz3GxbMkuJvV9m9tvBaqOkOehIUtClHTbON2XV2DHfbVvl5a0qMu_2Whl2Nvvmrn8XZYCwzwhznynoLqB7S4mT4YFsqpEt3_PoWclwKxXVQ09PkfiW0FrPSdunNEhviFXCnLZHzPHfGws/s320/IMG_20181114_144438.jpg" width="271" /></a></div>
Once Ray had the bearings back in position and this repair completed, here is a picture of the access panel back on the top of the torque box and the work he is doing to complete the access panel for the top wing skin:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhH95r0J525roo8cHfaHIerwmDFWXyWYCfwNpyxXAiMxGY4SlC_M6SlMYFObWh8s3_m9_v9tJ5JRgwauV8vFcyadmeDIr0JZiDtu9fnMEbze6fey45L4ih-m6QrHgB2aGGWmh_QmhByTHwL/s1600/IMG_20181114_144923.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="697" data-original-width="714" height="312" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhH95r0J525roo8cHfaHIerwmDFWXyWYCfwNpyxXAiMxGY4SlC_M6SlMYFObWh8s3_m9_v9tJ5JRgwauV8vFcyadmeDIr0JZiDtu9fnMEbze6fey45L4ih-m6QrHgB2aGGWmh_QmhByTHwL/s320/IMG_20181114_144923.jpg" width="320" /></a></div>
Nice work, Ray! That was a great idea to put the access panels in the top of the torque boxes! Glad you got the gear cycling well again.<br />
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I think I've mentioned in previous updates that Ray is in the process of moving out of his home & hangar in Thousand Oaks area of Southern CA and into their new home in near Bend, OR. I got George's old Prowler Trailer back when I moved N611GM back from EZ last fall. In Nov last year, I drove the trailer down to Ray so that he could use it to pull his Prowler up to Bend. Over the winter, Ray has done many modifications to the Prowler trailer to make it easier to load and unload an aircraft. I have not seen these yet, but I hope to meet Ray near my place on his drive up to his new place. <br />
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<u><b>G. An Update From Francis </b></u>- Francis the "FrogProwler" keeps jumping right along on his Prowler project. In a recent update he emailed to me, he says:<br />
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<span style="background-color: #b45f06;"><span style="font-size: small;"><span style="font-family: "trebuchet ms" , sans-serif;">Hello Todd,<br />After some hours deburing holes😅, And ,some dimples😅, After ....$#&%@}{! PR!🤭😱🤢 [I think he's referring to "ProSeal or something similar - he included these pics]</span></span></span></div>
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<span style="font-size: small;"><span style="font-family: "trebuchet ms" , sans-serif;"><span style="background-color: #f9cb9c;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPpTtMUBlupyAd6B6ApCuJyG9LyIFW1x5ShYHI74gbS8JwkYO6jCa5dgwSl-DfOgey5PpgHdOE3wZxsUFF6xOwMzZb0nUmw5Ll5GKEWBvQx1NMJ4nd0DWeb9RTnr7xFApNgrWDpLKyI_bs/s1600/20181215_181541.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="778" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPpTtMUBlupyAd6B6ApCuJyG9LyIFW1x5ShYHI74gbS8JwkYO6jCa5dgwSl-DfOgey5PpgHdOE3wZxsUFF6xOwMzZb0nUmw5Ll5GKEWBvQx1NMJ4nd0DWeb9RTnr7xFApNgrWDpLKyI_bs/s320/20181215_181541.jpg" width="155" /></a></span></span></span></div>
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[<span style="background-color: #b45f06;">Francis, really, really likes the ProSeal or whatever material he is using to seal his fuel tanks!! You can tell from his colorful wording... HA!!] </span><br />
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<span style="font-size: small;"><span style="font-family: "trebuchet ms" , sans-serif;"><span style="background-color: #f9cb9c;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhtDzLjS-reYYMrg84er8rJRkK2CZWq1UHrZopArUBsLytg3PIydWoVNipah1L2-AI4rHtOwBGgZuj7wNw4Gg1pTvdU9NgS2FyAh5-RJb9YNJ7zJNhnCn_lVvSRfcXmjrcj36-puLS1SJw/s1600/20181215_181707.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="778" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhtDzLjS-reYYMrg84er8rJRkK2CZWq1UHrZopArUBsLytg3PIydWoVNipah1L2-AI4rHtOwBGgZuj7wNw4Gg1pTvdU9NgS2FyAh5-RJb9YNJ7zJNhnCn_lVvSRfcXmjrcj36-puLS1SJw/s320/20181215_181707.jpg" width="155" /></a></span></span></span></div>
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<span style="background-color: #b45f06;">After have some inquir[ies] with some guy [who] was a choumack [French word for metal-smith], the best way is the small foam paint roller! [I think he means using foam roller to apply the ProSeal](for riveting the nose ribs).</span></span></span></span></div>
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<span style="background-color: #b45f06;"><span style="font-size: small;"><span style="font-family: "trebuchet ms" , sans-serif;"><br />TIP : Put on about 5 layers of nitrile gloves [on before you start working with the ProSeal], like that you can [have] clean [hands] in 10seconds (because the humidity of hands for putting on [new] gloves makes it difficult..)🤬😡 But leave [to remove] a layer is easy!😉✌👌<br /> </span></span></span></div>
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<span style="background-color: #b45f06;"><span style="font-size: small;"><span style="font-family: "trebuchet ms" , sans-serif;">I learn too, how to fill up an empty plastic tube cleanly and with out "bulle d'air" [air bubble] for applying this fu..ng PR with the pneumatic gun. [See, he really likes it!!] <br />When i do that [again] ,I'll try to film it to explain!!</span></span></span></div>
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<span style="background-color: #b45f06;"><span style="font-size: small;"><span style="font-family: "trebuchet ms" , sans-serif;"><br />And, I [am also] working on the landing gear over center links axles [pivot links].<br />Thanks very much to RAY for his clever [idea] to open trap doors [access panels in the] landing gear box lid!😘<br />I hope everybody is ok with you and the Prowler guys!</span></span></span></div>
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Here is a pic of the access panels that Francis made using Ray's idea:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNBOcvm5wP8E__Pny33nJEGx8k9ao2CKmIOUshG1MmewmxUaATWeDdE3w9zyU_dUl4pVEtNbqgWLhk6L5ElN7WAqS6tlVdhyF0g1FKgstNfrs9VcXo4_5rkVoijWZ4W-vzupwxHFSn4v7B/s1600/20181103_152538.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="778" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNBOcvm5wP8E__Pny33nJEGx8k9ao2CKmIOUshG1MmewmxUaATWeDdE3w9zyU_dUl4pVEtNbqgWLhk6L5ElN7WAqS6tlVdhyF0g1FKgstNfrs9VcXo4_5rkVoijWZ4W-vzupwxHFSn4v7B/s320/20181103_152538.jpg" width="155" /></a></div>
I believe the following pic shows Francis' work straightening his forward wing skins aft edge to match up to the aft wing skins at the forward spar. I really like how he mounted the file to the wooden block. It gives you much more of something to hang onto when using it. BTW - those files are the real deal on straightening skin edges and long, skinny spar components! They are designed for filing large journal bearings, but they work great on aluminum in the situations described above: <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbLZoD8JnWfgN_NGmZcyXJZz5bt9dtH_REnT8UnQLgdtDUcSKqLpJDTPRf_S5uejbas9FxeOjXrSrafoEVsuQSn78loF-iqvb6GQQhzMFpIIzEw65YfwQPsWM_J165vRfBfCn5tlR-W2Ak/s1600/20190302_163022.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="778" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbLZoD8JnWfgN_NGmZcyXJZz5bt9dtH_REnT8UnQLgdtDUcSKqLpJDTPRf_S5uejbas9FxeOjXrSrafoEVsuQSn78loF-iqvb6GQQhzMFpIIzEw65YfwQPsWM_J165vRfBfCn5tlR-W2Ak/s320/20190302_163022.jpg" width="155" /></a></div>
Thank you, Francis for the updates on the progress of your project. It is looking excellent! I really appreciate the feedback and it is great to share your progress with the rest of the Prowler group. Keep up the great work!<br />
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OK, that's all for this update. I have a kind of big project to report on that I started almost a year ago. I'll probably post that update next (soon). Then, shortly after that I'll follow with another blog update that will have more Prowler related items. Thanks for keeping up with the Prowler blog. I hope everyone is off to a great 2019 and hope everyone is ready for a great summer. AirVenture is only 17 weeks away!!!Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-4561663675008429701.post-28532893909990680772018-11-02T06:59:00.000-07:002018-11-02T06:59:32.443-07:00Prowler Aviation Summer 2018 Wrap-upHello Again Everyone,<br />
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Thanks for stopping by to check in on Prowler Aviation. To say that this summer was a tough one would be an understatement. In June EZ had his engine failure and forced landing. Then, I came home from AirVenture to find the Carr Fire burning out of control in northern CA. A few days later I discovered that George had passed away. So, that is why it's taken me until now to get back to updating on some of the Prowler happenings over the summer.</div>
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I've recently written a blog post that is a tribute to George (see it <a href="http://prowleraviation.blogspot.com/2018/09/george-morse-jr-gone-west-farewell-to.html" target="_blank">here</a>). And, I've also written up a blog update recently that re-caps EZ's harrowing experience and info on N611GM (see it <a href="http://prowleraviation.blogspot.com/2018/10/ernest-n611gm-survive-engine-failure.html" target="_blank">here</a>). So, the intent with this update is to go back and cover all the other things that were going on this summer while I was mostly dealing with these big items.</div>
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So, in this update I have:
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1. Finishing More Parts for Kit #18
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2. Builder Update
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Francis - Excellent Progress Continues
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Francis - Visit With Eric In Montreal
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Ray - Update On MLG Torque Tube Problem
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3. Work on the New FWF with Larry at AutoPSRU's
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4. Update on Progress with N611GM Static Display<br />
5. AirVenture 2018<br />
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Before I move into the Prowler stuff, I wanted to share something that I witnessed recently that was pretty amazing. One night recently on a flight from JFK to LAX we suddenly saw this bright, funny looking light grow out of the horizon and climb in the western sky ahead of us. My First Officer saw it first:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLg7XDrRvVV7363noe1roDm7YmyNIIDvoCkSs21uvwBrXBcuIiIiov8DU_7KRQoZYZdbvEpo7DdQs211uOEipKO2RtHtkbfl9d3ZlFF3hpgd-VNT59ZvgMvy8KNEbRiFhsyJNRFWMq_frx/s1600/IMG_20181007_222618.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="831" data-original-width="1363" height="195" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLg7XDrRvVV7363noe1roDm7YmyNIIDvoCkSs21uvwBrXBcuIiIiov8DU_7KRQoZYZdbvEpo7DdQs211uOEipKO2RtHtkbfl9d3ZlFF3hpgd-VNT59ZvgMvy8KNEbRiFhsyJNRFWMq_frx/s320/IMG_20181007_222618.jpg" width="320" /></a></div>
It's not a great picture, but you get the idea. Looks kind-of like a comet, huh!?!? It was definitely nothing that either one of us had ever seen before. It was lit up very uniquely (can't really tell this from the photo) but, the sun was well down below the horizon ahead of us and it was a fairly dark night where we were. Yet, the sun was illuminating the cone of material that was sort-of pointed towards us.<br />
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Well, this "thing" was different enough that the center frequencies started perking up with calls from other aircraft that also saw this. Turns out it was a SpaceX rocket launch from somewhere near LA (maybe in the Mojave or over in Vandenberg - I'm not sure). But, it was really amazing to see from FL360. What was more amazing is that we were still over DEN!! Really!! We were headed west and just approaching the Rockies! To see something that large in the sky and still be 1/2 the continent away was really something different. Go SpaceX!! I have a kid who really wants to go to Mars someday! (More on that a little later).</div>
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Anyway, on with the Prowler update.<br />
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<b>1. <u>Finishing More Parts for Kit #18</u> -</b> In previous blog updates I posted on fabricating the parts to make various sets of steel parts. Some of these included TW linkages, MLG torque tubes, sets of MLG hydraulic actuators and others. Most of these are some of the steel parts that I needed to make for Kit #18. While setting up to make these parts for Kit #18 I have also made 1-2 additional sets to have some spare parts in inventory and also have a set for one more additional kit that I might possibly assemble (sometime down the road).<br />
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Anyway, here are a few of those assemblies now that they are all welded, completed and ready to add to the boxes of parts for Kit #18. Here are two sets of stress mounts that fit into the 4 main fuselage longerons and face the aft side of the firewall at the motor mount positions. These transfer the propulsion forces (stresses) from the motor mounts into the fuselage skins via the 4 main longerons. They turned out really nice:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMGMfygw3PEPi9DvLUDv__ZmcTdEqoApq4dVxH8Cqm7Z9eSWO9y9A2H7VYfPN2NvugFZQcvM5IZbwogd_3RjiBihzr5PzLkfYOJ7w4-ulUImGmIQ2TpVz84DmekCY0ng-c-9mOOcL0GL5z/s1600/IMG_20181031_081342.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="730" data-original-width="1224" height="190" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMGMfygw3PEPi9DvLUDv__ZmcTdEqoApq4dVxH8Cqm7Z9eSWO9y9A2H7VYfPN2NvugFZQcvM5IZbwogd_3RjiBihzr5PzLkfYOJ7w4-ulUImGmIQ2TpVz84DmekCY0ng-c-9mOOcL0GL5z/s320/IMG_20181031_081342.jpg" width="320" /></a></div>
Here's 2 sets of flap actuators. These mount to the forward side of the rear spar and transfer the flap motor linear motion into movement of the wing flaps:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMTih4xeI3sWpvJ7_XVVpoR768YMbjQrIYFG_Ci-EgvvViZXKUhK2d10WaGd_NSm0GRoxWWUPf65fpa5nNZclDIANfOHPy8T-Ufqby4Sz6oq5zZ31kkCQwfGAWlU5eU4ppq9iFLLnPUfgk/s1600/IMG_20181031_083459.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="653" data-original-width="1328" height="157" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMTih4xeI3sWpvJ7_XVVpoR768YMbjQrIYFG_Ci-EgvvViZXKUhK2d10WaGd_NSm0GRoxWWUPf65fpa5nNZclDIANfOHPy8T-Ufqby4Sz6oq5zZ31kkCQwfGAWlU5eU4ppq9iFLLnPUfgk/s320/IMG_20181031_083459.jpg" width="320" /></a></div>
Here's 2 sets of MLG torque tubes. These mount inside the torque boxes, pass through large spherical bearings mounted in the main wing spars and provide a place for the tops of the MLG struts to mount to (clamp to):<br />
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Here's a couple sets of the new style mounting brackets for the dead ends of the MLG hydraulic actuators. Bryan designed these to provide better angular matching to the motion of the hydraulic actuators and also incorporate the mounting brackets for the lower portions of the negative G mounts:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXxJdULg2Cx7cRUhWbw8QNpW4X9abtpdqOlq05KBhc851X4w06176AOujlhUmjrUCKw5cpynvJqDMLa2scb0XjTepmiLuWIdziC2utpNWxS9p2iEXkN6b4065FRdgkWEUUZ52lNInMKjEY/s1600/IMG_20181031_083918.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="724" data-original-width="743" height="311" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXxJdULg2Cx7cRUhWbw8QNpW4X9abtpdqOlq05KBhc851X4w06176AOujlhUmjrUCKw5cpynvJqDMLa2scb0XjTepmiLuWIdziC2utpNWxS9p2iEXkN6b4065FRdgkWEUUZ52lNInMKjEY/s320/IMG_20181031_083918.jpg" width="320" /></a></div>
Here are 3 sets of the negative G brackets (upper portion) that mount to the cockpit fuselage bulkhead side formers. A 5/16" bolt passes from the upper bracket to the lower bracket and holds the fuselage to the wing spar in high negative G loads.<br />
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And, finally, 2 sets of TW actuating linkages:</div>
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I still have more parts to make for the TW systems, but I've gotten the more difficult ones knocked out for now. I'll update on the remaining parts in the next update.<br />
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<b>2. <u>Builder Updates</u> -</b> Of course, the builder update that has dominated my world for the past several months has been EZ and his story (mentioned above and link above). Beyond this, the Prowler world continued to move on and I have some of their updates to share with you.<br />
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<b>2.A. <u>Francis - Excellent Progress Continues</u> -</b> Currently, Francis continues to be my most active builder (but, Eric might be a close second - see below). He has shared many pictures and notes with me as he goes about each successive part of the airplane that he is working on. Here, Francis has hinges laid out on the table to make his ailerons and flaps (He claims that the pink glasses are NOT his.....well, I don't know!?!? It looks like they might fit. Just sayin'!?!?):</div>
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Actually, he sent me this picture because he was having some misalignment between the trailing edges of the outboard flaps and the aileron. I checked with Ray and he had the same issue. So, by using a hinge with a slightly wider flange on each side, the hinge on the outboard flap and the hinge on the aileron could be aligned more closely (and still have enough room to rivet the forward hinge flange to the aft wing spar flange. If this doesn't make a lot of sense to you now - when you build the wing and you get to this point, then it will become clear!</div>
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Here, Francis has the left wing aileron (on the left) and the inboard flap section (on the right) laid end-to-end with the trailing edges resting against and aluminum angle (closest to front of picture). He has a single piece of hinge stock temporarily in place along the front edges (toward back of pic). If you look closely, you can see the junction between the two parts and the slight misalignment just behind the two clecos:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhD7vO33DXylldM_7Z9iOSKPVBX4UDftS8fbbmXYtmQKDcydWikZuk1I1EfnoC79UeJ66axeFEksT0XfVLyI2wkTCslZSPW2zDnwFxc2H-SO2sLvieEouVnBHdMKgmhnc7b462WD648pjDO/s1600/20180422_151715.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1059" data-original-width="1412" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhD7vO33DXylldM_7Z9iOSKPVBX4UDftS8fbbmXYtmQKDcydWikZuk1I1EfnoC79UeJ66axeFEksT0XfVLyI2wkTCslZSPW2zDnwFxc2H-SO2sLvieEouVnBHdMKgmhnc7b462WD648pjDO/s320/20180422_151715.jpg" width="320" /></a></div>
Another view from the other side:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHfO0gaMiEWYu7LQOPqw-vHvfJ0N5stIYW7csDaTNpe_doIOGxDW-ElkociBb1iVas4uXQVfRO6pZKew9JjxBX1TEAzOxodyl7dktn9HP4hI6OEguryf1Fvdb3GfCn9WPjbZWLw6T9Shsw/s1600/20180422_150832-.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1412" data-original-width="1059" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHfO0gaMiEWYu7LQOPqw-vHvfJ0N5stIYW7csDaTNpe_doIOGxDW-ElkociBb1iVas4uXQVfRO6pZKew9JjxBX1TEAzOxodyl7dktn9HP4hI6OEguryf1Fvdb3GfCn9WPjbZWLw6T9Shsw/s320/20180422_150832-.jpg" width="240" /></a></div>
Here is his aileron assembly getting fitted for the stiffeners:<br />
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And, a top view looking down:<br />
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There have been almost as many ways devised to roll the leading edge of the flap and aileron skins as there have been Prowler builders (over the years). Here is how Francis rolled his. It looks like he found a good, hardwood, 1/2 round rod. Then, he screwed one flange of an aluminum channel to the flat side of the 1/2 round rod. I can't see in these pictures, but he must have somehow (maybe tape? or, maybe there is a small 90 deg flange bend on the skin?) affixed the leading edge of the aileron skin and/or flap skins to the joint between the aluminum angle flange and the 1/2 round rod. Then, he just rolled the aluminum channel and forced the skin to curl around the 1/2 round rod:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2M0dOz4ICGV4_LeF5hpZuWX3qaFg1cCT_s3-l4M9K95G7PbCPI0oXXQuBKHe8tkROY5OVtdFuJXkeZWpp8b79bmMzOd15Kgl95UaExq-w7D9F-ECrxHorgYq1bEWQDQuGol-jH_M1x53p/s1600/20180704_142715.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="908" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2M0dOz4ICGV4_LeF5hpZuWX3qaFg1cCT_s3-l4M9K95G7PbCPI0oXXQuBKHe8tkROY5OVtdFuJXkeZWpp8b79bmMzOd15Kgl95UaExq-w7D9F-ECrxHorgYq1bEWQDQuGol-jH_M1x53p/s320/20180704_142715.jpg" width="240" /></a></div>
I'm not sure I ever asked George how he did this. But, I seem to think/remember that he just taped the leading edge of the skin to a piece of tubing about 1" in diamter and then just turned the tubing to curl the leading edge. Here is another view of the set up that Francis used:<br />
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Here are some fuel tank access panels that he is fabricating:<br />
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Very, very nice craftsmanship! I think that these are the access panels that will eventually hold the fuel level sensors on the inside of the forward wing fuel tanks:<br />
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More excellent work on the access panels, but it looks like something he was fabricating broke:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcoR5scTbsdVQBIACn8PJ3f9KJynmDliuFmghyYVizQ4n4C-nfTtoALtkI8tK6plSxR-_F7KlHl_sMp51dyuKaPdP5RM53yIRHKpawSoV-CP_5o4GPVntOT97gWAZNtfozXl8c_j5mfHfC/s1600/20180911_184149.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="684" data-original-width="1180" height="185" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcoR5scTbsdVQBIACn8PJ3f9KJynmDliuFmghyYVizQ4n4C-nfTtoALtkI8tK6plSxR-_F7KlHl_sMp51dyuKaPdP5RM53yIRHKpawSoV-CP_5o4GPVntOT97gWAZNtfozXl8c_j5mfHfC/s320/20180911_184149.jpg" width="320" /></a></div>
Here is one of those panels installed on the inboard wing rib:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBrFfKyLef0gZQw9pKqyk3xfC-zwkvSbVwXHdbjqixZ_1rKlYqzWJ2UOBrbTqTL_QA-shNPyVg7EapKqYntP4KaLFOBK2S-qTNSxm7ah8aRoikeShpzLEtSkemauJODekJGNRGCILoVPsZ/s1600/20180913_030050.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="588" data-original-width="1210" height="155" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBrFfKyLef0gZQw9pKqyk3xfC-zwkvSbVwXHdbjqixZ_1rKlYqzWJ2UOBrbTqTL_QA-shNPyVg7EapKqYntP4KaLFOBK2S-qTNSxm7ah8aRoikeShpzLEtSkemauJODekJGNRGCILoVPsZ/s320/20180913_030050.jpg" width="320" /></a></div>
Another view from the inside (note the steel clips that link the inboard and outboard flap segments together in the background):<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg6XNEf_9F5IPHMjvegDFEW-V0GW25Cdj0d2fDo5uCOeb46oUuNFBa064JcBfZ1RkLPDuzCf80UaO9xS7hs-5T_RSf2nFEfGu6utIBb8jrzgY1QB5fdysCHsxQE8dTCh5436T0SOPna7IHZ/s1600/20180913_030256.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="778" data-original-width="1600" height="155" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg6XNEf_9F5IPHMjvegDFEW-V0GW25Cdj0d2fDo5uCOeb46oUuNFBa064JcBfZ1RkLPDuzCf80UaO9xS7hs-5T_RSf2nFEfGu6utIBb8jrzgY1QB5fdysCHsxQE8dTCh5436T0SOPna7IHZ/s320/20180913_030256.jpg" width="320" /></a></div>
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Here are some of his nose ribs that make the boundaries of the fuel tanks in the leading edges of the outboard wings:</div>
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Notice the fuel tank sealant. In the email he sent me with these pictures, Francis wrote:</div>
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<span style="color: #4c1130;"><span style="background-color: #fce5cd;"><i><b><span style="font-family: "trebuchet ms" , sans-serif;">Hello Todd,<br />That's official, I hate the sealant!!</span></b></i></span></span><span style="background-color: #fce5cd;">😒</span><br />
<span style="color: #4c1130;"><span style="background-color: #fce5cd;"><i><b><span style="font-family: "trebuchet ms" , sans-serif;">That stinks of the death</span></b></i></span></span><span style="background-color: #fce5cd;">🤢🤮</span><span style="color: #4c1130;"><span style="background-color: #fce5cd;"><i><b><span save_image_to_download="true" style="font-family: "trebuchet ms" , sans-serif;">!! After 2 days thats[it] still smell[s]!<br />In 5 minutes all the tools are sticky, and used 1 box of nitrile gloves</span></b></i></span></span><span style="background-color: #fce5cd;">😅</span></div>
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I have not had the pleasure of attempting this yet, myself. Now, I guess I'm not looking forward to this either!</div>
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As always, Francis, thank you very much for sending me all of your progress updates and pictures so that I can share them with the other Prowler builders!! I know the time it takes to do this and I really appreciate it (and I'm sure the other Prowler guys do as well). You are doing outstanding work and making excellent progress! We look forward to more, soon!</div>
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<b>2.B. <u>Francis - Visit With Eric In Montreal</u> -</b> Somehow, while doing all of his own Prowler work, Francis emailed me and told me that he was on vacation in the USA and wanted to try to go visit Eric in Montreal. I sent him the info to contact Eric and they did get an opportunity to meet. Here are some of the humorous email exchanges I had with Francis: </div>
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<span style="color: #4c1130;"><span style="background-color: #fce5cd;"><i><b><span style="font-family: "trebuchet ms" , sans-serif;">Hi Todd, </span></b></i></span></span><br />
<span style="color: #4c1130;"><span style="background-color: #fce5cd;"><i><b><span style="font-family: "trebuchet ms" , sans-serif;">I work hard for[to] convince my girlfriend for[to] visit Montreal and meet Eric !!</span></b></i></span></span><br />
<span style="color: #4c1130;"><span style="background-color: #fce5cd;"><i><b><span style="font-family: "trebuchet ms" , sans-serif;">Still 406 miles separates us! [But,] I am on good [the]way!!</span></b></i></span></span><span style="background-color: #fce5cd;">😁🤣🙂</span><br />
<span style="color: #4c1130;"><span style="background-color: #fce5cd;"><i><b><span style="font-family: "trebuchet ms" , sans-serif;">[That is] If the wheel bearing of [this] Korean rental car permits it!</span></b></i></span></span><br />
<span style="color: #4c1130;"><span style="background-color: #fce5cd;"><i><b><span style="font-family: "trebuchet ms" , sans-serif;">Our head and ears can [might] explode before [we get there]!<span style="background-color: #fce5cd;">!</span></span></b></i></span></span><span style="background-color: #fce5cd;">😎</span><br />
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And;<br />
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<span style="color: #4c1130;"><span style="background-color: #fce5cd;"><i><b><span style="font-family: "trebuchet ms" , sans-serif;">Hello Todd,</span></b></i></span></span><br />
<span style="color: #4c1130;"><span style="background-color: #fce5cd;"><i><b><span style="font-family: "trebuchet ms" , sans-serif;">I am at the motel at[about] 1000 feet to[from] Eric's house!</span></b></i></span></span><br />
<span style="color: #4c1130;"><span style="background-color: #fce5cd;"><i><b><span style="font-family: "trebuchet ms" , sans-serif;">(A very nice house and cars [out] front!) </span></b></i></span></span><br />
<span style="color: #4c1130;"><span style="background-color: #fce5cd;"><i><b><span style="font-family: "trebuchet ms" , sans-serif;">I think I have to[should] shave and put [on] my better clothes!</span></b></i></span></span><span style="background-color: #fce5cd;">😁</span><br />
<span style="color: #4c1130;"><span style="background-color: #fce5cd;"><i><b><span style="font-family: "trebuchet ms" , sans-serif;">He was not here [today?] but he reserved his Sunday for me!</span></b></i></span></span><br />
<span style="color: #4c1130;"><span style="background-color: #fce5cd;"><i><b><span style="font-family: "trebuchet ms" , sans-serif;">Of course, I take a lot of pictures of his plane [for you].</span></b></i></span></span><br />
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later:<br />
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<span style="color: #4c1130;"><span style="background-color: #fce5cd;"><i><b><span save_image_to_download="true" style="font-family: "trebuchet ms" , sans-serif;">Before I meet Eric tomorrow he do[did] a low pass vertical [over] the motel with an RV with [the] smoke on </span></b></i></span></span><span style="background-color: #fce5cd;">😎🤩😁👌👍</span><br />
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(I think I just figured out that Francis is a pretty funny & witty guy, but sometimes I miss a lot of it because it gets lost in the French-to-English translation!) <br />
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Anyway, Francis did meet with Eric! And, he did take several pictures that he sent me. Here are a few of them. Great craftsmanship here with the wing skin stiffeners in the radiator holes:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhfgECMovLfkpydPntMPzll0IlhUpRhDXgUYozNBDQKoCflPWmROX4XifG8XlKyLa7BguLzkDeXRr_AIYMQr77qGBTpILBkoM85roTYyaPX5V4kA-iDsGvjdaKVZQ_AkstmVeH4T2-NUI5f/s1600/20180819_105622-red.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="908" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhfgECMovLfkpydPntMPzll0IlhUpRhDXgUYozNBDQKoCflPWmROX4XifG8XlKyLa7BguLzkDeXRr_AIYMQr77qGBTpILBkoM85roTYyaPX5V4kA-iDsGvjdaKVZQ_AkstmVeH4T2-NUI5f/s320/20180819_105622-red.jpg" width="240" /></a></div>
The wing joint area of the left wing. Those are the access plates and mounting plates for the fuel level sensors in the aft wing tanks:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjF8M3goT9bIBv4UyHLVSuu1EwNw0_f2ZbobxZeYQ6Vlu4I101SQQNwuQFQfVuDFOa30ApqUJE8wbBAljk88HVBIpm0ByobMy8vIWx-bWowHnElFaykebjO8z4VeG0KSiWA8Oeqi2SZc1G5/s1600/20180819_105746-red.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="908" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjF8M3goT9bIBv4UyHLVSuu1EwNw0_f2ZbobxZeYQ6Vlu4I101SQQNwuQFQfVuDFOa30ApqUJE8wbBAljk88HVBIpm0ByobMy8vIWx-bWowHnElFaykebjO8z4VeG0KSiWA8Oeqi2SZc1G5/s320/20180819_105746-red.jpg" width="240" /></a></div>
First, what a beautiful job on the wing jig construction here. (Eric, after you are done with your wing building hold onto the wing jig. You will probably be able to sell it to another future Prowler builder. Nice job!) Also, excellent wing construction! <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEglEY6LfEFdjVR1BS953MRwTMBYg_fkbop_9IAqXPvh7JrMEjD5ZoaLzjYooXJCJKxb2U9u_RCczjQQfTDrCblraz4AbcKzsVnDAmVgwfCtrvqf_fSu9GkWOiZWPhdOVSUcsVfXlA-Wxob_/s1600/20180819_151729-red.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="1210" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEglEY6LfEFdjVR1BS953MRwTMBYg_fkbop_9IAqXPvh7JrMEjD5ZoaLzjYooXJCJKxb2U9u_RCczjQQfTDrCblraz4AbcKzsVnDAmVgwfCtrvqf_fSu9GkWOiZWPhdOVSUcsVfXlA-Wxob_/s320/20180819_151729-red.jpg" width="320" /></a></div>
Very, very nice assembly of the main wing:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhjBXNSiuTNIVyb1w4S867Zm6AnNYqC5w3TdnKDoH5QHCCnezfX7r3xrUplh3GgFWWmNNyYWuVI0RAbDz2kTR3tz_p4OnMxRbn0kgN1gnwmMtBY1D7pEes33oFs6ewux99PWMfgsxFjv1S/s1600/20180819_151919-red.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="1210" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhjBXNSiuTNIVyb1w4S867Zm6AnNYqC5w3TdnKDoH5QHCCnezfX7r3xrUplh3GgFWWmNNyYWuVI0RAbDz2kTR3tz_p4OnMxRbn0kgN1gnwmMtBY1D7pEes33oFs6ewux99PWMfgsxFjv1S/s320/20180819_151919-red.jpg" width="320" /></a></div>
Those two long "ribs" on the top of the wing assembly are supports for the aft cockpit floor. They are flat along the top flange and curved to fit the bottom of the fuselage along the left hand flanges (as you look at them in this picture) [BTW - I need to make a set of those for my Kit #18 and that is one of the reasons I need to get my big "Orange Crush" press going.....soon.]<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSxG7Oxw6PmqtD4Tl_XDosU1pZFP0-3w7y5j-zMLPc9v_ulFn7D8jhs75MB_7Z7ML8aKw4dmV2SXWSCB0V6873mUuecfpEhV3K9ZhK-u8n45NnQYBAUsX02evIKypPw9_4vCgzOCbro_bB/s1600/20180819_152406-red.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1210" data-original-width="908" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSxG7Oxw6PmqtD4Tl_XDosU1pZFP0-3w7y5j-zMLPc9v_ulFn7D8jhs75MB_7Z7ML8aKw4dmV2SXWSCB0V6873mUuecfpEhV3K9ZhK-u8n45NnQYBAUsX02evIKypPw9_4vCgzOCbro_bB/s320/20180819_152406-red.jpg" width="240" /></a></div>
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Excellent work, Eric! <br />
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After his meeting with Eric, Francis emailed me a few more times and sent me the pictures above. Here are some of his observations:</div>
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<span style="color: #4c1130;"><span style="background-color: #fce5cd;"><i><span style="font-family: "trebuchet ms" , sans-serif;"><b>We had a very, very, very good time with Eric!</b></span></i></span></span><br />
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<span style="color: #4c1130;"><span style="background-color: #fce5cd;"><i><span style="font-family: "trebuchet ms" , sans-serif;"><b save_image_to_download="true">He has a very good prowler kit (nice aluminum manufactured parts, straight and rigid (I am jealous)!</b></span></i></span></span></div>
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<span style="color: #4c1130;"><span style="background-color: #fce5cd;"><i><span style="font-family: "trebuchet ms" , sans-serif;"><b>His work on his Prowler look good, he make the wing in is garage [at] home so he can work when[ever] he have some time. So he [is] progress[ing] rapidly!</b></span></i></span></span></div>
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<span style="color: #4c1130;"><span style="background-color: #fce5cd;"><i><span style="font-family: "trebuchet ms" , sans-serif;"><b>He think[s] [he will] finish the plane in 3 years!</b></span></i></span></span></div>
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And, in a later email<br />
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<i><b><span style="font-family: "trebuchet ms" , sans-serif;"><span style="color: #4c1130;"><span style="background-color: #fce5cd;">Eric is a veritable work addict! He built his beautiful home. The furniture in his house [is] all home built (with out sofa), [also] 3/4 of his hangar, [and] a nice tricycle RV...<br />He offered to us a very good meal in his restaurant😋😃 (if you visit him try the "gibelotte" and "tarte au sucre"!) homemade by his very charming girlfriend.<br />I think HE is the faster Prowler builder (with out sacrificing build quality).</span></span></span></b></i><br />
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[Sidebar comment: I think the "without sofa" comment is Francis being witty again - meaning that he doesn't think that Eric ever sits around long enough to enjoy a sofa!]</div>
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It appears that Francis admits, in his own words, that he thinks that Eric is doing a better job, and building his Prowler faster! In any event, my complements to you both! You are BOTH doing an awesome job building your Prowlers. It is awesome to see Prowler builders getting together to share some information, a meal, and some fun! </div>
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Francis - Thank you very, very much for providing me with this information for the Prowler blog!</div>
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Eric - Outstanding job on your Prowler building! I agree with Francis - you are doing an excellent job! From the pictures he sent, you are a master aircraft builder!! Well done.</div>
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<b>2.C. <u>Ray - Update On MLG Torque Tube Problem</u> -</b> You may recall from a previous blog update that Ray and I were trying to cycle the MLG on his plane. We discovered a problem with the right MLG and deduced that there was something wrong inside the torque box where the pivot link attaches the end of the torque tube to the heavy steel channel built into it. Well, when he had time, Ray cut open access panels in the tops of his wings and was able to access the torque boxes through access panels that he had built into them during his wing construction. Here is his explanation of what he found: <br />
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<span style="color: #4c1130;"><span style="background-color: #fce5cd;"><i><b><span style="font-family: "trebuchet ms" , sans-serif;">The problem I had with the landing gear shaft looks like it could be a problem for all the aircraft unless the bearing was located on the tube sleeve that the mounting bolt passes through. The right gear bearing had moved forward out of the aft part of the gear shaft, it worked it’s way out each time the gear moved in the up direction, but didn’t reverse when the gear was lowered and move back into position. I found that both the right and left bearings were a loose press fit in the location on the gear shaft, the right had moved, the left one was still in place, but was easy to push in and out of the part.</span></b></i></span></span><br />
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<span style="color: #4c1130;"><span style="background-color: #fce5cd;"><i><b><span style="font-family: "trebuchet ms" , sans-serif;">The problem looks like it is caused by the rotation of the bearing as the gear retracts. When the gear is down the end of the shaft is with the bearing having very little rotation between the inner and outer races, almost flat. When the gear goes up the shaft rotates on the bearing enough that almost all of the angular movement of the bearing is used and the inner and outer race centerlines are about 20 deg apart, and the bearing is far enough out of a flat position that the part the bearing is pressed into can bind on the sleeve the mounting bolt goes through. This binding causes the bearing to move each time it goes up and can be seen by a zig zag line on the bearings outer race as it made it’s movement.
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<span style="color: #4c1130;"><span style="background-color: #fce5cd;"><i><b><span style="font-family: "trebuchet ms" , sans-serif;">The fix was to put a sleeve over the mounting bolt sleeve to keep the bearing from sliding along the sleeve. I used a tube with a .634” ID to slide over the .625” bolt sleeve. The short part was cut to about .375, and the longer one was about .730”. I did have to belt sand a notch across both parts on one end about half way across and .090” deep to allow the spacer to not bind on the gear shaft when the gear was fully in the up position. After putting it all together, I cycled the shaft by hand several times and did find that the bearing moved to a neutral position where it didn’t bind and was happy.
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<span style="background-color: #4c1130;"><i><b><span style="font-family: "trebuchet ms" , sans-serif;"><span style="color: #4c1130;"><span style="background-color: #fce5cd;">Getting to the part is a pain since the wing skin has to be cut for an access panel, and if there was never a cutout in the landing gear torque box top that is an even larger problem.</span></span>
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OK, here's a few pictures to go with all that textual description. In the drawing below, I have highlighted the bearing that is the problem and the bolt that the assembly pivots on:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiGMwq7BLB51asGkUbGiDFNXeuz_wv1WNKFpj6eNdJoo_myFyouMtVXpcPdiNxPKZtXg6EBayriN5NQrU5hNLkbPcFlxWpajne25yGArkBGuKscBiETA7q7Tfkx56mgmhnBuMC6dTMeTrgh/s1600/Torque+Tube+%2526+Pivot+Bracket+-+Rays+Problem+1.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="684" data-original-width="884" height="247" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiGMwq7BLB51asGkUbGiDFNXeuz_wv1WNKFpj6eNdJoo_myFyouMtVXpcPdiNxPKZtXg6EBayriN5NQrU5hNLkbPcFlxWpajne25yGArkBGuKscBiETA7q7Tfkx56mgmhnBuMC6dTMeTrgh/s320/Torque+Tube+%2526+Pivot+Bracket+-+Rays+Problem+1.JPG" width="320" /></a></div>
Here is a good picture of the assembly inside Ray's completed torque box on the left wing:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQTMLTKrTZMNkVltKWlc0Ih2k5TPEh2SppxocacZ1LoaD4GSMXIZgtpiWhH5pKMasDDvwWBWXe53jTA0003x9vCnnOEnkIHAasZOqzROsW3cVm0ZgjZyJ5Q4t18h6xofo7w-3_oPt2zUHV/s1600/Ray+Tbox+-+%252818%2529.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="885" data-original-width="589" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQTMLTKrTZMNkVltKWlc0Ih2k5TPEh2SppxocacZ1LoaD4GSMXIZgtpiWhH5pKMasDDvwWBWXe53jTA0003x9vCnnOEnkIHAasZOqzROsW3cVm0ZgjZyJ5Q4t18h6xofo7w-3_oPt2zUHV/s320/Ray+Tbox+-+%252818%2529.JPG" width="212" /></a></div>
Here is the torque tube turned to the position it is in when the gear is down:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNDtByYSpoK-XVi-MU36t5OybUgcTfv_rEK-l4XmEvl4zp-xZzwkA2-gsapVm1elRohNwlGoEOHRWmA_Fzl9n1uvf9D5dk6P4sLuavkhQurOPysuE80CbJq5V2L-k-lvj0SjP6xccbdY72/s1600/Ray+Tbox+-+%252819%2529+Gear+Down.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="885" data-original-width="589" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNDtByYSpoK-XVi-MU36t5OybUgcTfv_rEK-l4XmEvl4zp-xZzwkA2-gsapVm1elRohNwlGoEOHRWmA_Fzl9n1uvf9D5dk6P4sLuavkhQurOPysuE80CbJq5V2L-k-lvj0SjP6xccbdY72/s320/Ray+Tbox+-+%252819%2529+Gear+Down.JPG" width="212" /></a></div>
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And, here it is turned to the position when the gear is up:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjI87dxUunxxcDyCTULN61y3IdvMGO68KxiG2X3zK_q_aycSlhc2EgQgvyZqN1tr-4gFtBZCtJV111UYPIN8iCswby1Vx5q2M8jwBgwQryOxmZOql6HJYxlw4ddfBy4FWVZ1CZvhyphenhyphenWiYjtE/s1600/Ray+Tbox+-+%252819%2529+Gear+UP.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="885" data-original-width="589" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjI87dxUunxxcDyCTULN61y3IdvMGO68KxiG2X3zK_q_aycSlhc2EgQgvyZqN1tr-4gFtBZCtJV111UYPIN8iCswby1Vx5q2M8jwBgwQryOxmZOql6HJYxlw4ddfBy4FWVZ1CZvhyphenhyphenWiYjtE/s320/Ray+Tbox+-+%252819%2529+Gear+UP.JPG" width="212" /></a></div>
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Now, as the gear cycles thru the 90 deg travel each time, that spherical bearing is going from where it's at the full limit of travel one way to the where the bearing nearly flat (sphere not rotated inside of the outer bearing race). When it was doing this, it (the bearing outer race) was constantly being wedged in its bore (in the pivot link) one way, then the "released' on the other way. What this did was allow the outer bearing race to "walk" out of the bore. This "walking" happened because the bearing wasn't pressed in tightly enough (the bore was slightly too large) and the pivot link was not staked well enough to prevent this from happening (staking a bearing is deforming the metal around the bore to prevent the bearing race from moving back out of the bore). </div>
<br />
Ray's fix, for now (because it would be a lot of work to get the pivot links back out of the plane) was to simply put an appropriate sized spacer on each side of the bolt (and the wear sleeve) so that the bearing race could not move out of the bore in the pivot link. The last we talked, he had the airplane all back together with the
exception of making the new access covers that he had to cut into the
wing skins above the torque boxes. He's going to get to that soon.<br />
<br />
Also, note the access panel that Ray had the foresight to build into the tops of his torque boxes. This was a great idea and saved him a lot of frustration in fixing this current issue. He (and I) recommends that everyone currently building their plane incorporate this mod into your builds. I will be making this standard on the kits that will be made in the future.<br />
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Thank you for the update on this issue! I'm glad you got it resolved without too much adversity. Also, Ray has decided to move out of Southern California. He has purchased a new home in Redmond, Oregon and is planning to start the moving process late this year and into next year. Congratulations Ray!<br />
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<b>3. <u>Work on the new Prowler FWF with Larry at AutoPSRU's</u> -</b> I stopped by to see Stuart and Larry again this year at their AutoPSRU's booth during AirVenture. Larry is making progress with the new Mustang style motor mount for the Prowler. Here is the latest picture I have from Larry of the new motor mount (that's a steel mock-up of a Prowler firewall on the left):<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOzV-jHlz2w3Kqj-9rON6-9mlhiYqaRSQ1e7mmmK_EUgwGFnK3J-xTs23-yDXe602_mWpC7IbZDil9K7l5UEu2Nm2o1e5GdXMJoau4oG5XgnY-aMaya0V-b1ispUOlIJMG3sv8corR2N_C/s1600/20180306_102035-red.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="800" data-original-width="1088" height="235" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOzV-jHlz2w3Kqj-9rON6-9mlhiYqaRSQ1e7mmmK_EUgwGFnK3J-xTs23-yDXe602_mWpC7IbZDil9K7l5UEu2Nm2o1e5GdXMJoau4oG5XgnY-aMaya0V-b1ispUOlIJMG3sv8corR2N_C/s320/20180306_102035-red.jpg" width="320" /></a></div>
He was up to the point where I needed to send the AutoPSRU gearbox back that they let me borrow to check my FWF mock-up. He also needed to have a forward engine compartment bulkhead so that he could find a way to create a mounting point for it.<br />
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So, one day in Aug when I had some time I went down to the shed and took several measurements off of my mock-up with the AutoPSRU gearbox installed. [That way, I have some baseline measurements to work from.] Here are a few examples. The distance from the block to the final prop hub mounting flange:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJKFeyu647huEebGo-AWlZXecabmuUelm6v-guxbH_TCNo5KzHvTdiSYi-Kr5WWyCQ6WMJxUlS7FIMYeJZASailaX5D-OXYQbXO9fLYE74SIgWnhIsVYc9QxVoiWcrMzHYtoNwEKuDSptK/s1600/20180830_114741.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="959" data-original-width="1317" height="233" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJKFeyu647huEebGo-AWlZXecabmuUelm6v-guxbH_TCNo5KzHvTdiSYi-Kr5WWyCQ6WMJxUlS7FIMYeJZASailaX5D-OXYQbXO9fLYE74SIgWnhIsVYc9QxVoiWcrMzHYtoNwEKuDSptK/s320/20180830_114741.jpg" width="320" /></a></div>
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This was a measurement to show Larry where the top of the forward engine compartment bulkhead should end up in relationship to a level off of the top, center of the firewall:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgE3GbpMEn10-Q5C0rv3qthedfCF4pGA67yEGKSI8Ms8mf__PHHuM78cIzjyUV18Xzybc_kF8dytyBNF1MYqfcZKvpWLchHVWpNgW2IA6pUlo5JwJlCts5OkRovO-o1PU-89CsyQ1wOFkbQ/s1600/20180902_092438.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1234" data-original-width="881" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgE3GbpMEn10-Q5C0rv3qthedfCF4pGA67yEGKSI8Ms8mf__PHHuM78cIzjyUV18Xzybc_kF8dytyBNF1MYqfcZKvpWLchHVWpNgW2IA6pUlo5JwJlCts5OkRovO-o1PU-89CsyQ1wOFkbQ/s320/20180902_092438.jpg" width="228" /></a></div>
Then, I also clamped up a very ruff guess (using a slightly bent thin strip of wood) at where the engine compartment longerons will run so that Larry can get an idea of how much room there will be on each side of the engine at the front, middle and aft of the exhaust flange mounting surface. Here is the measure from the front/left corner of the exhaust manifold mounting surface to the left side engine compartment longeron outer surface (where the skins will be): <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbDHuOKotTWt5l0sXca8tv5ZkuH25QRZaGWdgrcI3U_UsK4vwkSQoNdBak45qqCFZOWxU8FyOCAi7RsuvB4cG3vQNPnF1x56WSueQ0btIDXso9DnkPsN-VjNof0JXuLRnSvnpVsZdnJvO-/s1600/Space+at+forward+exh+port.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="668" data-original-width="1023" height="208" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbDHuOKotTWt5l0sXca8tv5ZkuH25QRZaGWdgrcI3U_UsK4vwkSQoNdBak45qqCFZOWxU8FyOCAi7RsuvB4cG3vQNPnF1x56WSueQ0btIDXso9DnkPsN-VjNof0JXuLRnSvnpVsZdnJvO-/s320/Space+at+forward+exh+port.jpg" width="320" /></a></div>
Then, I removed the AutoPSRU gearbox from my FWF mock-up and set it up on the workbench with my somewhat crude (yellow) mock-up that I built several years ago. This allowed me to see how good of a job I did fabricating my gearbox mock-up. It's actually pretty good! Here's a side view:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPKBB6VwFHCUxRjHuN4YXyJ_jzXJPYf9ote0tW_L5SJ02tns7x82G5UL40SawcLCwoFXHewNi9fhb2ncnWaxzSvs9Hr1pEsoUfNlHCYnztGY7q3duSY4SGR9hqqCp-CHyPBYx3U4V5vzkA/s1600/20180830_121209.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="896" data-original-width="1358" height="211" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPKBB6VwFHCUxRjHuN4YXyJ_jzXJPYf9ote0tW_L5SJ02tns7x82G5UL40SawcLCwoFXHewNi9fhb2ncnWaxzSvs9Hr1pEsoUfNlHCYnztGY7q3duSY4SGR9hqqCp-CHyPBYx3U4V5vzkA/s320/20180830_121209.jpg" width="320" /></a></div>
Here's a back-to-back comparison:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEje7vBUtzrYXpg4c32lvmwdwgaudo2Rfr4V7vKtGI9PWNa9tW9UsX1qFQgIbLHXXHeenuOGowfRcupqhT4AG4Njl7VVtBR5XmoiErTlUZfKg4p9VpfwPcv5HvOwdHcKWWdGCYyQbwLoSX0X/s1600/20180830_122419.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1092" data-original-width="926" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEje7vBUtzrYXpg4c32lvmwdwgaudo2Rfr4V7vKtGI9PWNa9tW9UsX1qFQgIbLHXXHeenuOGowfRcupqhT4AG4Njl7VVtBR5XmoiErTlUZfKg4p9VpfwPcv5HvOwdHcKWWdGCYyQbwLoSX0X/s320/20180830_122419.jpg" width="271" /></a></div>
I made several notes from these comparisons so that I could make a more accurate mock-up later on.<br />
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Later, I cooked up a "pseudo" forward engine compartment bulkhead (most of us refer to this part as the "horse collar" - for obvious reasons). I shipped this to Larry to use to design a
mounting point for it. I made it from pieces of flat aluminum sheet that I riveted
together. This mock-up horse collar only has 90 flanges, but it will work
well enough for now so that he can design a mounting system. [In production, this horse collar will be formed from a single piece of sheet and pressed in the big press I made. But, I don't have the press fully working yet - and I didn't want to hold Larry up. So, I just made one by hand that is a close approximation.] Here is a view of the aft side of the horse collar:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRMiV7Sf9SAAVOEzrQNfgSrx-u0j6mr6pEceJyyZ86SAu9RET1EMc8mpkfTF3MT7ziXFleL7zs3x3HipJUzw_kIxLvP5xcw58M7HfMsRqYdiaYkpkRhyhyphenhyphenuYOMx-ddioySg_fYmrEp6KUZ/s1600/20180901_112729.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="861" data-original-width="849" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRMiV7Sf9SAAVOEzrQNfgSrx-u0j6mr6pEceJyyZ86SAu9RET1EMc8mpkfTF3MT7ziXFleL7zs3x3HipJUzw_kIxLvP5xcw58M7HfMsRqYdiaYkpkRhyhyphenhyphenuYOMx-ddioySg_fYmrEp6KUZ/s320/20180901_112729.jpg" width="315" /></a></div>
You can also see the steel brackets that I made up for mounting the horse collar. Larry will build up some hard-points off the the motor mount to meet up with this bracket that I supplied. Here is a view of the front side of the horse collar:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzhskVYbptI8uMw3oVbExh8I6G_Br2umoxsl4ksIekR6By9YRXdsaBHeNi4W1OBdssb2KQKqOGMPy3x1sXL6KmD4N4TlGcAY2YcDE0kifSdlXc2cg8nWIy7ujFOGI3-mEgQTo8AefuyAiI/s1600/20180901_112754.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="821" data-original-width="850" height="309" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzhskVYbptI8uMw3oVbExh8I6G_Br2umoxsl4ksIekR6By9YRXdsaBHeNi4W1OBdssb2KQKqOGMPy3x1sXL6KmD4N4TlGcAY2YcDE0kifSdlXc2cg8nWIy7ujFOGI3-mEgQTo8AefuyAiI/s320/20180901_112754.jpg" width="320" /></a></div>
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So, now Larry has the AutoPSRUs gearbox back and he received my horse collar. He's currently working on building this up on his Prowler FWF mock-up. Once he has this done, I will form some engine compartment longerons for him and he will be able to clamp them onto his mock-up. This will help ensure that the whole FWF will fit inside an engine compartment and (hopefully) will be as close as possible to the silhouette of the original production Prowler. More on this as it develops.</div>
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<b>4. <u>Update on Progress with N611GM Static Display</u> -</b> Since the last blog update I have made a little progress on making a static display from N611GM. After removing the engine in the last update, I needed to clean up the firewall and get everything off of it. This would allow me to mount a cage to the firewall to take the place of the engine. Here is a picture of the airplane as it sat after I got it off the trailer and set up next to my pumphouse:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZVgYrBrQw1aM3oBP4Lpzquwmeucz3lBUWwrMX2eDUpiOpJXw9kYFU93dyB5bfEm4YhF9pvTgql9vAhqmfcRtxn_2O9nrGGyMcQq7mzv5lKTjEJwronq6uek3z4N98vmdS8r4XmNJejE8h/s1600/20180906_143947-.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="556" data-original-width="861" height="206" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZVgYrBrQw1aM3oBP4Lpzquwmeucz3lBUWwrMX2eDUpiOpJXw9kYFU93dyB5bfEm4YhF9pvTgql9vAhqmfcRtxn_2O9nrGGyMcQq7mzv5lKTjEJwronq6uek3z4N98vmdS8r4XmNJejE8h/s320/20180906_143947-.jpg" width="320" /></a></div>
In order to get the engine control cables off of the firewall, I had to get into the cockpit and disconnect all of the cables so that I could pull them through. Here is a picture of the cockpit as I began the process of digging into it and getting things cleaned up and disconnected [BTW - that's dried up sea weed in the foot wells!]:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3ImLjzEwezwp6DL4Ul-IPApqdKJjsfmZ8AHi26y-i9hqVi9MfEyjq2aSOUcECaG2fu2A_D4VXaCk5nfKwbSMaJGmzG9y9kk5Byg0h2jVrMYgdek-TEszOSQ2XtNIuGe0P4xcAccNuJ6er/s1600/IMG_20181010_103809.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1344" data-original-width="756" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3ImLjzEwezwp6DL4Ul-IPApqdKJjsfmZ8AHi26y-i9hqVi9MfEyjq2aSOUcECaG2fu2A_D4VXaCk5nfKwbSMaJGmzG9y9kk5Byg0h2jVrMYgdek-TEszOSQ2XtNIuGe0P4xcAccNuJ6er/s320/IMG_20181010_103809.jpg" width="180" /></a></div>
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Once I had the firewall cleaned off, I could start to make the cage that would replace the engine and gearbox and provide me something sturdy to mount the propeller blades to. To get started, I measured the original distance that the forward engine compartment bulkhead mounting brackets were located from the firewall (got these off the old engine mount). From that, I could begin rebuilding the engine compartment off the firewall. With enough of the engine compartment built back up, I could locate the forward bulkhead mounting brackets and then build up the "cage" to meet those brackets. Here is a pic of that in progress:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxDo2CTcYXIwDp8MhyCJqmCnIkZhkxpPtlLBm2rWKx558mn7TqZQgo_GumfoDTwSbhhou_K4B7hYOA-YMYje_JDW8ApNDIGlnxZh2lYBOpKDl_N_dGOH-PvERdCY_ZeE8zjTP12-GgXU6P/s1600/IMG_20181015_172048.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="727" data-original-width="1291" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxDo2CTcYXIwDp8MhyCJqmCnIkZhkxpPtlLBm2rWKx558mn7TqZQgo_GumfoDTwSbhhou_K4B7hYOA-YMYje_JDW8ApNDIGlnxZh2lYBOpKDl_N_dGOH-PvERdCY_ZeE8zjTP12-GgXU6P/s320/IMG_20181015_172048.jpg" width="320" /></a></div>
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Eventually, I got all the individual pieces cut to size and tack welded together. Then, I took it all back apart and did a permanent weld to the cage. (I have a pile of this uni-strut material laying around that I got from an estate sale for super cheap, so I decided to use some of it up on this project) After getting the cage welded up, I mounted it back onto the firewall:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgc6OXKdcpQSJ5_aFkd53RCGJGuU0X5I_5viuQvmSr8k3qs2SRfHUnrOLwynRNqYb__oP0d-R0cKFzZEmX1cAkzC5LkD6MVonjsbzPpb6FctBu33k0vMal42JxtrwpMlIEhlUxCSKtldkcq/s1600/IMG_20181015_183805.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="681" data-original-width="1210" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgc6OXKdcpQSJ5_aFkd53RCGJGuU0X5I_5viuQvmSr8k3qs2SRfHUnrOLwynRNqYb__oP0d-R0cKFzZEmX1cAkzC5LkD6MVonjsbzPpb6FctBu33k0vMal42JxtrwpMlIEhlUxCSKtldkcq/s320/IMG_20181015_183805.jpg" width="320" /></a></div>
Then, I could begin to build the engine compartment back around the cage, like this:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjweHwa8QPODlxaQg42_9Ci0gid7NlSkFUeD7D5ODO-axybevvEEFPku7kRpT1QdxqtK7Jum-uIj1QkNSn1Bkd_wFRqSKaG6gWbPiHBrb1sK0ClKxkkGaDMEVpOOY2Bw02H6ZlwWAjRshYE/s1600/IMG_20181015_172115.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="681" data-original-width="1210" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjweHwa8QPODlxaQg42_9Ci0gid7NlSkFUeD7D5ODO-axybevvEEFPku7kRpT1QdxqtK7Jum-uIj1QkNSn1Bkd_wFRqSKaG6gWbPiHBrb1sK0ClKxkkGaDMEVpOOY2Bw02H6ZlwWAjRshYE/s320/IMG_20181015_172115.jpg" width="320" /></a></div>
And, from the other side:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEFKGRjKQ0Njvl9eV3XzXfkOGtZhkC6dJR9w-ov2sprhtVnKZE3Ie69DqbPikMn_m4N5EozO6alDW-t7QJK98goc4Od1h08rQrQocyERHYhVfYqU2llrSpbzeAG7Kww0zXrV3yrbBlcQOS/s1600/IMG_20181015_174633.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="681" data-original-width="1210" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEFKGRjKQ0Njvl9eV3XzXfkOGtZhkC6dJR9w-ov2sprhtVnKZE3Ie69DqbPikMn_m4N5EozO6alDW-t7QJK98goc4Od1h08rQrQocyERHYhVfYqU2llrSpbzeAG7Kww0zXrV3yrbBlcQOS/s320/IMG_20181015_174633.jpg" width="320" /></a></div>
Eventually, I got the engine compartment rebuilt around the cage. With that done, I mounted the spinner backer directly off of the forward engine compartment bulkhead using some appropriately sized spacers. This allowed me to, finally, mount the spinner. Now, it was looking much better and getting closer. When it was all back together, it looked like this: <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEix85dNi9SvhJgSaGCFMzKczXIFN5pofC18iMhAt8V2mSQY0ufMuwG0HXLDRrIgPyF3JP7SRQaNreCgAh0gV4i7ZHI4t36x9-T4FFX_NTHoZ_9Vz5sV-M921AN5ldaIEeEskYyu_EncTmUm/s1600/IMG_20181017_092022.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="681" data-original-width="1210" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEix85dNi9SvhJgSaGCFMzKczXIFN5pofC18iMhAt8V2mSQY0ufMuwG0HXLDRrIgPyF3JP7SRQaNreCgAh0gV4i7ZHI4t36x9-T4FFX_NTHoZ_9Vz5sV-M921AN5ldaIEeEskYyu_EncTmUm/s320/IMG_20181017_092022.jpg" width="320" /></a></div>
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Now, it was time to turn to the prop blades. The first order of business was to get the blades off of the hub, so that I could straighten them. I had never taken anything like this apart before. It wasn't easy, but I managed to figure it out, eventually. Here is the hub and props before I started:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEib5SrlO4wUj0a-zcnvvO9SdixE959dW1tjV0eAvSr0DLZY5EqXJmUwLFrAw85RUWmv5thAr7shJgWArAiOiU7u_F5Xo_6cKUVzjhXPBAcChawbqwywDweFD58K5e1KEB_QJl6dc836JXEr/s1600/IMG_20181008_142233.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="959" data-original-width="1398" height="219" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEib5SrlO4wUj0a-zcnvvO9SdixE959dW1tjV0eAvSr0DLZY5EqXJmUwLFrAw85RUWmv5thAr7shJgWArAiOiU7u_F5Xo_6cKUVzjhXPBAcChawbqwywDweFD58K5e1KEB_QJl6dc836JXEr/s320/IMG_20181008_142233.jpg" width="320" /></a></div>
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The first step was to remove the piston cylinder. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqHp5V1oHiagihkj3-EiV6nJwBIJZa-5KTM_OWIQaxhrHW-GLQsJwDXSSkpi4utdA9N2jcggBm07vE4We2A9TUrsSjhlxlsS8X_AEqrUU2NCJYe4v55pTEfzD1BeW5OcHD7FZjGqwMQyM2/s1600/IMG_20181008_143829.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="882" data-original-width="1076" height="262" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqHp5V1oHiagihkj3-EiV6nJwBIJZa-5KTM_OWIQaxhrHW-GLQsJwDXSSkpi4utdA9N2jcggBm07vE4We2A9TUrsSjhlxlsS8X_AEqrUU2NCJYe4v55pTEfzD1BeW5OcHD7FZjGqwMQyM2/s320/IMG_20181008_143829.jpg" width="320" /></a></div>
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Here is the hub with the piston still mounted to the blades. The part in my hand is some kind of floating piston dampener (or travel limiter), I'm not sure: </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgO00miZ1AHIVMbNTdzPXsxnNpv_wBkiB-3HNznO797rstVttcMwuxb301-dWDiuVMxytiLsP7jm8BsdRaH4_TGtF7DORFgNeGiarR3dw7U_SpbK0IPMW7Y6XpLPcJDuxaKybU99LsIKQt9/s1600/IMG_20181008_143841.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="890" data-original-width="1172" height="243" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgO00miZ1AHIVMbNTdzPXsxnNpv_wBkiB-3HNznO797rstVttcMwuxb301-dWDiuVMxytiLsP7jm8BsdRaH4_TGtF7DORFgNeGiarR3dw7U_SpbK0IPMW7Y6XpLPcJDuxaKybU99LsIKQt9/s320/IMG_20181008_143841.jpg" width="320" /></a></div>
I now know much more about how a controllable pitch prop works and how all the parts are connected, at least in a McCaulley prop design (Hartzell is much different. I saw the insides of one of those from a youTube vid).<br />
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With the blades removed, I then set up some blocks of wood in the 20 ton press and used them to straighten the prop blades. Here is one of them with pressure being applied to straighten it:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiki0xIKX21DgQ8cd4tSu0oH0Of0e8A8cSOw_GvXHs8BNZZDF7r98fYOJ1PaCkXLOFN5AHtAoRcJUSbqV561OQVZY62d8Gg_g98PWeQvTTDHYB4r-9xKAj1Hwh40f4wx8I1MDoiTT4Dit3c/s1600/IMG_20181008_173730.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="672" data-original-width="1283" height="167" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiki0xIKX21DgQ8cd4tSu0oH0Of0e8A8cSOw_GvXHs8BNZZDF7r98fYOJ1PaCkXLOFN5AHtAoRcJUSbqV561OQVZY62d8Gg_g98PWeQvTTDHYB4r-9xKAj1Hwh40f4wx8I1MDoiTT4Dit3c/s320/IMG_20181008_173730.jpg" width="320" /></a></div>
This was just a trial-and-error process where I would put pressure on a
spot (over bend it slightly) and then take the blade back out of the press and put a straight
edge on the back side of the blade. I would note where it needed a
little more pressure to straighten it a little more. Eventually, I got all 3 blades mostly straight again - at least good enough for a static display. Here they are all leaning on the work bench: <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJlH6Odw7kiswLlOObwnhX_kQUaQE9DrBsT0S4lYi4B5VvHAj48vOdDocRpideu1jbXUVsGeULA0LuSTkxAu6vqXW80JX0GOF-TZQLM94idmDEUwQAqAwrpVb7WzaAEffu37TJa6M3IXYg/s1600/IMG_20181008_174141.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1462" data-original-width="666" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJlH6Odw7kiswLlOObwnhX_kQUaQE9DrBsT0S4lYi4B5VvHAj48vOdDocRpideu1jbXUVsGeULA0LuSTkxAu6vqXW80JX0GOF-TZQLM94idmDEUwQAqAwrpVb7WzaAEffu37TJa6M3IXYg/s320/IMG_20181008_174141.jpg" width="145" /></a></div>
At some point, they will need to be cleaned up and re-painted. But, for now, the focus was to get them mounted back on the static display.<br />
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With the blades straightened, it was now time to figure out how to mount them. I probably could have used the original hub, somehow. But, it was fairly heavy and only had mounting holes that would mount to the prop shaft - which is still attached to the engine and in the gearbox. I did not want to break apart the gearbox, so I looked for a different way. I went searching in the shop and I found a good heavy wall piece of tubing about 18 inches long. I figured that this would probably work OK. I would just need to adapt the blades to it. To do this, I put the tubing in the super spacer on the mill and cut 3 flat spots onto the end of the tubing at the proper angles:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEicO5K4KHYFov8YAN8qs9yHL0RegK5-NxK0AB0KmiCEDAkjN84ouDLlxm0tYddSo8qKv8s0IvJtO_7zKpoGf6us1HnPFQXWJo3W6ef5XjrVhVnL_CH8BJf-zw8n_lWfHmumYSu4qYSA-LXw/s1600/IMG_20181017_141219.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="1037" height="280" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEicO5K4KHYFov8YAN8qs9yHL0RegK5-NxK0AB0KmiCEDAkjN84ouDLlxm0tYddSo8qKv8s0IvJtO_7zKpoGf6us1HnPFQXWJo3W6ef5XjrVhVnL_CH8BJf-zw8n_lWfHmumYSu4qYSA-LXw/s320/IMG_20181017_141219.jpg" width="320" /></a></div>
With that done, I found some shaft that had a 1" diameter and cut it into 3 pieces. Then, I welded one of these pieces onto each flat spot on the tubing wall near the end. Here is what it looked like after I also welded a heavy washer to the end of the tube:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfMRx21hI3ywU1RXdBJk9gLZrwbCKZr3SbFwrR9o7BRPa2hvt4KYus70OuvlErhSQHCwHByAYuiY0ejCIzksKiaouV-DdrYQBsawZS01RpQlh0fvErV7AG1zFMnFltrsrMiJ0J3jBBUQgZ/s1600/IMG_20181017_143718.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="763" data-original-width="1190" height="205" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfMRx21hI3ywU1RXdBJk9gLZrwbCKZr3SbFwrR9o7BRPa2hvt4KYus70OuvlErhSQHCwHByAYuiY0ejCIzksKiaouV-DdrYQBsawZS01RpQlh0fvErV7AG1zFMnFltrsrMiJ0J3jBBUQgZ/s320/IMG_20181017_143718.jpg" width="320" /></a></div>
Next, I was going to have to find a way to adapt the new prop shaft style piece of tubing so that it would hold each prop blade securely. The ends of the props each had a 2.5" diameter hole/pocket in them like this:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyV7a8fMn0kfFbd0dh4H3gO0w9BbBgh0NhtVHxcUoWyL-kvIHjQ4GSw6BCo8JM1Q9NbhgTQMWJT6BnIapY0i9H6ug9rRk8wb4f8BUkUwIkmd12tUMcaaq4Q7EBTpZwU3i7-mfNZ7L6C8HY/s1600/IMG_20181017_154717.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="888" data-original-width="1089" height="260" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyV7a8fMn0kfFbd0dh4H3gO0w9BbBgh0NhtVHxcUoWyL-kvIHjQ4GSw6BCo8JM1Q9NbhgTQMWJT6BnIapY0i9H6ug9rRk8wb4f8BUkUwIkmd12tUMcaaq4Q7EBTpZwU3i7-mfNZ7L6C8HY/s320/IMG_20181017_154717.jpg" width="320" /></a></div>
But, the my new "prop shaft" has 1" diameter rods to hold the blades. So, a big bushing of some kind was in order. I jumped on the golf cart and headed down to the shed where I had stashed a bunch of steel and aluminum that I'd bought at an auction a few years back. Luckily, I found a piece of 6160 aluminum rod that would work perfect for this - and, it was already 2.5" on the O.D., so I didn't even need to turn them down to size! All I would need to do was clean up the outer surfaces and sand them down a bit to get them to fit. Here are the 3 pieces of bushing after I cut them each from the piece of stock I had:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7B-_J0I7xl9sbyUEBIpxiSjI1VGtEPl55wPi9MUNTTtczCV7Hw5Wgm-gaadXIq9rsL690S6v9BPVoZVn4X_1G89CWqIiEYuhu8JTExiPgjCnL4H01CrSFoe4F5eFrT74WOeomnCbtq1Cm/s1600/IMG_20181017_154657.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="733" data-original-width="1231" height="190" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7B-_J0I7xl9sbyUEBIpxiSjI1VGtEPl55wPi9MUNTTtczCV7Hw5Wgm-gaadXIq9rsL690S6v9BPVoZVn4X_1G89CWqIiEYuhu8JTExiPgjCnL4H01CrSFoe4F5eFrT74WOeomnCbtq1Cm/s320/IMG_20181017_154657.jpg" width="320" /></a></div>
After a little lathe work, I had the 3 bushings fitted into the prop blade roots and had some pilot holes drilled into them:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjyR-_gY2L2xd-g2Q9LHsqI9LMYSaueJIwaguMCz91FBT9Ku3D_5hNU7iDUzUnnscWOGZG86tGQ7GyTtXBkXg9ABDFTMeZiN4tGJ92LAKB2dbggkEot4QHPRpCZFU63WJVRprOxxhEC84Nn/s1600/IMG_20181017_180114.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="846" data-original-width="1045" height="259" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjyR-_gY2L2xd-g2Q9LHsqI9LMYSaueJIwaguMCz91FBT9Ku3D_5hNU7iDUzUnnscWOGZG86tGQ7GyTtXBkXg9ABDFTMeZiN4tGJ92LAKB2dbggkEot4QHPRpCZFU63WJVRprOxxhEC84Nn/s320/IMG_20181017_180114.jpg" width="320" /></a></div>
After a little more lathe work, I had each bushing fitting fully into the ends of the prop blades and got them fitted onto my new "prop shaft." Here is the assembly with 1 blade ready to mark the position of where I wanted to put a single hole and a counter sink to mount the blade:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJejbM7ldEnw1yEgN69T3oM1t4Y72w95xWdSMrconBAma0ab7jXDKrOLE54garlIqW_gzpKDKzI66sAR4Y3k0hwnkCmMJ1echh5rev_D79idz2mPT4UEkDZpNa8Jo6ssS98442cjxnWVBe/s1600/IMG_20181017_230655.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="935" data-original-width="689" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJejbM7ldEnw1yEgN69T3oM1t4Y72w95xWdSMrconBAma0ab7jXDKrOLE54garlIqW_gzpKDKzI66sAR4Y3k0hwnkCmMJ1echh5rev_D79idz2mPT4UEkDZpNa8Jo6ssS98442cjxnWVBe/s320/IMG_20181017_230655.jpg" width="235" /></a></div>
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At this point, I started to look the other direction from this new makeshift prop shaft that I was making. I had previously mounted the prop spinner backing plate to the forward engine compartment bulkhead. However, the prop spinner backer has a 5" diameter hole it it. But, my new makeshift prop shaft was only 1.5" in diameter. Time to make another bushing. I found a piece of round aluminum plate in my "misc aluminum drawer". After a little lathe work, here is the bushing test fitted into the prop spinner backing plate: </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMCn3NLZAvNQDvtVHZfuYK1onbmng8jdw-V5q6JJN2LRESMz5xO5c2wHi9yO3ZvyksAuXygRPR3s2Ptf-lK_RgogGQlAjwVNzgiXVrhJLe7veeiqCa_0kcKh0uBCngbS7LEt4E8STJJ1Kl/s1600/IMG_20181017_180904.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="720" data-original-width="1074" height="214" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMCn3NLZAvNQDvtVHZfuYK1onbmng8jdw-V5q6JJN2LRESMz5xO5c2wHi9yO3ZvyksAuXygRPR3s2Ptf-lK_RgogGQlAjwVNzgiXVrhJLe7veeiqCa_0kcKh0uBCngbS7LEt4E8STJJ1Kl/s320/IMG_20181017_180904.jpg" width="320" /></a></div>
With that bushing in place, I was able to square the new prop shaft tubing to the airframe so that the prop blades would be correctly oriented to the static display. With that done, I went back into the shop and machined a correctly placed hole and counter bore into each prop blade root that would hold the blade to the new prop shaft. Here is one of the blades in the mill getting the hole and counter bore done:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjlO7cSuVJEigFnmt9n0gEKUta5guMr_3z9WMtbhSYrmzV_qihxFLbXI3Dbh2vNiuDGQAPFUW8afDCX5blCnKtV_dIbcDLxpmULr_NSUCXNsY7hVpSoOJEkNcpuJQoOE6zX036I1_4aXwCX/s1600/IMG_20181018_101124.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="762" data-original-width="1417" height="172" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjlO7cSuVJEigFnmt9n0gEKUta5guMr_3z9WMtbhSYrmzV_qihxFLbXI3Dbh2vNiuDGQAPFUW8afDCX5blCnKtV_dIbcDLxpmULr_NSUCXNsY7hVpSoOJEkNcpuJQoOE6zX036I1_4aXwCX/s320/IMG_20181018_101124.jpg" width="320" /></a></div>
And, a close up of the hole and counter bore:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjToTRTrwdWpH4lA2LCo674QHGOwmP4gIocG4kk_IQ726gdql3CCIDyupStcv1TKdVSTxy3A0EyvOQlt5XcXzEQXB1iYcCQbH3O08xmuvv6FMyPJ3FV3GgdAae9w0wWdmxIl5kDYnmPsxW_/s1600/IMG_20181018_101422.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="801" data-original-width="1297" height="197" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjToTRTrwdWpH4lA2LCo674QHGOwmP4gIocG4kk_IQ726gdql3CCIDyupStcv1TKdVSTxy3A0EyvOQlt5XcXzEQXB1iYcCQbH3O08xmuvv6FMyPJ3FV3GgdAae9w0wWdmxIl5kDYnmPsxW_/s320/IMG_20181018_101422.jpg" width="320" /></a></div>
With these holes in the prop blade roots, I was able to position each blade onto the new prop shaft and mark the position where I needed to drill and tap a hole into the new prop shaft rods. Here is a pic where I am drilling the last of these holes (note the other 2 have already been tapped and have a 3/8" socket head cap screw in them):<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3rDdZyRs_bEGJ5mKBOUJkXYAnbY3Gb3zM09TuzUksLVA8yKux6h_Xqimam78uRirKrOHt0HUuy5rpKgLDMozwJKH6zaR9kANeASuELr3uoHulHYeIASpuGMbXl_OClrlC5tPUSKzlmN-b/s1600/IMG_20181018_110851.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="862" data-original-width="1065" height="259" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3rDdZyRs_bEGJ5mKBOUJkXYAnbY3Gb3zM09TuzUksLVA8yKux6h_Xqimam78uRirKrOHt0HUuy5rpKgLDMozwJKH6zaR9kANeASuELr3uoHulHYeIASpuGMbXl_OClrlC5tPUSKzlmN-b/s320/IMG_20181018_110851.jpg" width="320" /></a></div>
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With these holes all drilled and tapped in the correct places. The final step was to re-mount the new prop shaft tube into the static display and then weld it permanently onto the cage built inside of the engine compartment. Once the prop shaft was welded firmly into place, then I placed each blade onto it's prop shaft position and put the 3/8" socket head cap screw into the prop blade root and tightened them down snugly. With all 3 blades mounted, I put the prop spinner back on. Here is the net result:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKLGKJsrSjSec0I8NF7DBIjymIsWu4eYosvHHA1dor6hR68rXQ3DQMlBm3qZSg2i6C2SU41XGy59wKVRDj-SxrIx-XJKfHOrKOi-zzh26zu3ts7RKbYU-pMhB_T1eUrXsYArgi-1WVWcfo/s1600/IMG_20181019_074952.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="884" data-original-width="1413" height="200" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKLGKJsrSjSec0I8NF7DBIjymIsWu4eYosvHHA1dor6hR68rXQ3DQMlBm3qZSg2i6C2SU41XGy59wKVRDj-SxrIx-XJKfHOrKOi-zzh26zu3ts7RKbYU-pMhB_T1eUrXsYArgi-1WVWcfo/s320/IMG_20181019_074952.jpg" width="320" /></a></div>
The FWF on the static display looks very good. I purposely placed the prop blades at an angle that was not flat pitch. I wanted to have them look more like they would actually be with the plane in flight and the blades loaded up slightly. Here's a head on view:<br />
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Overall, I think it looks really good. So, now the static display is pretty much complete from the fire wall
forward - except that the prop blades need to be re-painted. From here,
I will continue to work from firewall and make my way aft as I fix things up. <br />
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My "yard art" definitely makes a much bigger "statement" with the FWF finished! Next, I'm going to work on the inner gear doors and begin to work on the inner and outer flap segments that got bent in the recovery. I'll keep you posted on the progress.<br />
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<b>5. <u>AirVenture 2018</u> -</b> This year, AirVenture was a little different experience for me. After many years of staying off site and driving into AirVenture each day - I finally purchased a 5th wheel RV that I could use to stay on the grounds at Camp Scholler with the rest of the "gang" that I normally meet up with during the week. I actually have been looking for a rig for the past few years, but this past spring I finally found a rig that I really liked that was in my $$ range. Here is a pic of it and of the spots that I staked out for 3 of us this year (I got there on the Sat prior to the show and was the 1st one there): <br />
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The next day, Bryan showed up with his rig (on the right):<br />
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And, early Mon morning Dave & Laura joined us with their brand spankin' new rig (on the left):<br />
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We were all set up along a drainage ditch behind our rigs. It worked out very well - no neighbors directly behind us.<br />
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This was an interesting newcomer to AirVenture this year that I'd never seen before. I initially saw it flying from Camp Scholler (it was down over the N/S runway in "the box") and couldn't tell from that distance exactly what it was. It looked like I small P-38 from that vantage point. It wasn't until I took my first walk down the flight line that I figured it out! It's and interesting design. It's like a twin Extra with a jet engine mounted on the center-line. Isn't AirVenture cool!</div>
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Because I had extra room for people to stay with me this year, I invited a couple folks to join us (my 2 youngest daughters and I) this year. Here is Jen and Jordan checking out the HondaJet:</div>
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I met Jordan through my local EAA chapter. He went to school with my/our girls, he was heavily involved with our local CAP program and is pursuing a career in aviation. He won an EAA Air Academy scholarship in 2017 and really enjoyed it. This year, in 2018, he really wanted to go to AirVenture again, but didn't have a place to stay. I invited him to stay with us, and he (and his folks) accepted.</div>
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I met Jen on one of my flights in May. She is one of our Inflight crew members and told me that she was working as a flight attendant to fund her flight training to become a pilot. One day over breakfast I was talking about EAA and AirVenture. She'd never heard of it and was interested. So, I offered for her to also join us this year as well. After a bit of a frustrating experience (non-rev and space available) getting to OSH, she did join us and really enjoyed the AirVenture experience. Here are the 3 of us at the Brown Arch:</div>
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It was a pleasure having both of them with us this year. I enjoyed showing them the "ropes" of AirVenture and how to get around and see & do whatever appeals to them. They both really enjoyed the intense "everything aviation" experience that is AirVenture. It is awesome to see the interest and the enthusiasm that each of them has for aviation. My girls and I were really happy that we could help share the AirVenture experience with them. Jen emailed me recently and said she has already arranged vacation time for AirVenture 2019 and was working on arranging more "positive space" travel to and from the show next year. I think Jordan is going to try to make it back next year too, but he is in is first year of college and involved with the AFROTC program. So, he's not sure if his summer sked will allow it. I hope so - and you are both welcome join us again in 2019! </div>
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While I was walking the grounds showing Jen and Jordan around, we ran into a new Corsair that I'd not seen before. If you've been following my blog for any length of time, you know that I am an F-4U fan. It's my all-time favorite aircraft. Here is a pic of the "new guy":</div>
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Here is some history about this beautiful aircraft:<br />
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The airshows were awesome again - as always. Here is a pic of some of the "bomb drops" during the Wednesday Warbirds airshow:</div>
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On the last day for Jen and Jordan this year, we only had a few hours in the morning before they had to start their treks back to "real life." So, I figured that a couple of hours in the EAA museum might be a good fit. Plus, it'd been a while since I'd gone through it myself. The collection has grown a lot since my last time. Here's a shot of the main floor when you walk in:<br />
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This picture really doesn't need description - suffice it to say, to have your own 50'x100' wall covered with your airplanes and awards in a museum would probably indicate that you've done some amazing things in your life! Burt Rutan's contribution to experimental aviation cannot (IMHO) ever be overstated! If you just (only) considered the Voyager project - that, in and of itself, was an almost unbelievable feat and an incredible story! This is a well-deserved tribute to both Burt & Dick Rutan:<br />
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Once again, the Wed night airshow got rained out. Actually, this year they cancelled it before
everyone headed down to the flight line (due to an advancing storm front). The night airshow got rescheduled for Thurs night, and it was impressive, as always. The closing fireworks is always amazing: </div>
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I think the fireworks that EAA puts on after the night airshow is consistently the best fireworks show that I've ever seen. It is loud, long,
and intense all the way until...... you know..... what happens at the end: </div>
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Here are our two youngest daughters in front of another one of my favorite airplanes:</div>
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And, the girls near Boeing Plaza with the C17 in the background:<br />
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Our middle daughter is really interested in NASA and travel to Mars. So, guess who spent a lot of time in this tent!?!?!<br />
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The girls participated again this year in the EAA program called Women Soar, You Soar (WSYS). It is such a great program!! If you have a high school aged girl that is interested in anything related to aviation, please check it out. This year, the youngest daughter got a Grumman Goose ride at the Seaplane Base:<br />
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As you can see, this year's AirVenture was less about me and Prowler Aviation and more about offering and sharing the experience with others. It was a great show, and we are all counting down the days until AirVenture 2019!<br />
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That's a wrap for this update. I hope to have some time in the shop this fall and get some more parts made for Kit #18. I would also like to get the big hydraulic press plumbing tweaked and leaks fixed up and then get some parts made with it. Have a great fall season, everyone! </div>
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Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-4561663675008429701.post-19406281171810917702018-10-02T07:59:00.000-07:002018-10-02T07:59:49.292-07:00Ernest & N611GM Survive Engine Failure and Forced Landing in Carr Inlet, WA* * * * * * * * * * * * * * * * * * * * * * * * * * * *<br />
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On Saturday, June 16th, 2018 Ernest ("EZ") went out about noon from the Tacoma, WA airport (KTIW) to do his "Second 1st flight" in his Prowler. (This aircraft was kit #5, the silver and black airplane and the 3rd Prowler that George built). The flight went great for about 7-8 minutes, right up until the engine
suffered a failure that caused a loss of engine oil pressure. With little to no
oil pressure, the props hit the low-pitch stops which caused the prop to over-speed and the engine began to come apart. The flight terminated in a forced, off-field landing on a beach at the north end of the McNeil Island - southwest of Tacoma Narrows. Here are some pics of where airplane came to rest:</div>
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Thankfully, EZ walked away uninjured, but the plane is a total loss (due to sea water intrusion). He landed on a narrow strip of beach created at low tide and the plane was completely submerged in salt water at each high tide for about 4 days. EZ did an amazing job getting his airplane on the ground! He essentially had 3 options for landing - into 200 ft trees on McNeil Island, in the water (Carr Inlet), or the beach that he ended up landing on. Incredible job, EZ!! We are all so very, very thankful that you were not injured during this forced landing!<br />
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I am ultimately frustrated, sickened and dismayed for EZ - because I worked closely with him to help him and support him while he got the airplane put back together after a previous forced landing in the airplane. I know first-hand the effort, energy and expense that he put into rebuilding the airplane. I went to see him and the plane a couple of times and we talked on the phone frequently solving issues and working out solutions. He and his mechanic, Dave, did a great job! He did 20+ hours of engine runs including high speed taxi runs to prepare for this flight. They did all the right things, as near as I can tell. He was so excited about getting the airplane back into the air. It's so sad!! As I stated earlier, though, I'm just so happy that he did such a great job getting the airplane down and was not injured!! The airplane can be replaced, but he cannot!! [In fact, the airplane has already been replaced with a Van's RV-8.]</div>
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Ultimately, the incident did not meet the requirements of NTSB 830.2 definition of "substantial damage." That means the NTSB did not have to do an investigation and the FAA asked a few questions and filled out a few reports. No other actions were taken.</div>
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The insurance company hired a salvage company and arranged to have the aircraft extracted from the beach so that a causal inspection could be completed: </div>
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The causal inspection revealed that the engine (somehow) shed two crankshaft main journal bearings. When these bearings came out the engine oil gallery was uncovered and resulted in significant loss of oil pressure. Based on this, the insurance company paid EZ for his loss. </div>
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<span style="font-family: "times" , "times new roman" , serif;"><b><i>[<span style="font-family: "georgia" , "times new roman" , serif;">Sidebar
note: This is, at least, the 2nd event that I am aware of where the
loss of engine oil pressure has caused the loss of prop control and a
prop over-speed. Based on this, I will be coming out with a
recommendation that anyone using George's Autoaviation engine setup add a
separate, dedicated oil supply system to provide backup oil pressure to
the prop governor pump. This will require a separate oil line off of
the oil sump and require adding a separate dedicated electric oil boost
pump with a regulator/pressure relief to supply pressure directly to the
prop governor in case the engine oil system pressure drops. I will be
reaching out directly to each of the owners of George's Autoaviation
engines in the near future to get ideas for this system and I will share
it with everyone when we determine the most simple, safe and reliable
backup system. By doing this, in theory, a loss of engine oil pressure
will not necessarily lead directly to a loss of prop control. As long
as there is still oil in the sump, the prop will still be controllable.</span><span style="font-family: "georgia" , "times new roman" , serif;"> More to follow on this. </span>]</i></b></span></div>
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The secondary damage to the airplane (damage during the forced landing) included mostly just the main landing gear, the flaps and the left wing tip. During the hard landing, the right main landing gear was forced up so much that it bent the MLG torque tube and punched the forward end of the RH saddle/clamp up through the wing skin:<br />
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Also, the landing on the soft silt on beach tore the left main gear strut out of the strut saddle/clamp:</div>
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The left wing tip was also damaged from the weight of the plane on the left wing after the left MLG was torn off. This also caused some damage to the inboard and outboard flap segments.<br />
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The tertiary damage to the aircraft includes damaged wing fairings and flaps from the slings used to recover the plane:
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However, believe it, or not, were it not for the sea water damage to the aircraft, the plane could have (fairly easily) been rebuilt! The main spar had no damage. The airframe was not bent at all. I took measurements several ways to the tail from reference points on the main spar - and everything was symmetric. So, while it is true that the propulsion system suffered a serious failure, the airframe is solid. Granted, the hard landing took its toll on the MLG systems, but the spar was not damaged and the airframe is still straight as an arrow! This is good testament to the fact that George created a very robust design for the airframe of the Prowler.<br />
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During his dealings with his insurance adjuster, EZ was also instrumental in helping to arrange for me to make an offer to the insurance company to buy the hull. Since the insurance company was simply going to scrap the aircraft, I just couldn't let George's 3rd Prowler get melted down! Thankfully, the insurance company accepted my offer and I drove up to Tacoma in early Sep to get the airplane. Here is the airplane on a trailer that was used to get it from the salvage company and to the hangar it was in to perform the causal inspection:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEoFTGVvdUjh-iBdQ3ukL0dqQCZ04Bv6olsNltE5ovIytX0dnEcGw1WXwKGDo8F3lRbo9B23Z_-TAxF_hTLw-AdYJy1nZNaWFdfOtk96Dh-xj1EpUCxCLvH5oKshCgFmVP-PdOV2SyrGHD/s1600/20180903_145221.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEoFTGVvdUjh-iBdQ3ukL0dqQCZ04Bv6olsNltE5ovIytX0dnEcGw1WXwKGDo8F3lRbo9B23Z_-TAxF_hTLw-AdYJy1nZNaWFdfOtk96Dh-xj1EpUCxCLvH5oKshCgFmVP-PdOV2SyrGHD/s400/20180903_145221.jpg" width="400" /></a></div>
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Here is the plane after we got it lifted off of the other trailer and set onto George's old trailer (EZ was letting me use George's trailer to get it back to my shop):</div>
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Here is the airplane on George's trailer all tied down and ready to head back down to my shop:</div>
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And, here is the truck and airplane the next morning at 730am when I pulled back into my driveway:</div>
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The plane and the trailer pulled great the entire way! The next day, I took the engine off the plane to make it lighter and easier for me to get off of the trailer by myself. Here is the plane just prior to removing the engine:</div>
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The day after removing the engine, I was able to get the airplane off of the trailer and placed on stands in my front yard. First, I got it off the trailer using an engine hoist on one wing and my tractor on the other:<br />
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Then, I got it set down onto two aircraft jacks and one tail stand:<br />
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So, for now, N611GM will be "yard art" in my front yard between the pump house and a tree. Eventually, I plan to remove as many panels as possible and rinse the airplane out as best as I can to get the sea salt and sea weed out of it. Then, I'm going to hammer out the dents and fix the plane up so that it looks good from a distance. My goal (for now) is to make it a static display that looks good from 20-30 feet. Maybe, someday, it will be my Prowler Aviation billboard!?!?Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-4561663675008429701.post-22674220208085326762018-09-28T08:42:00.000-07:002018-09-29T07:31:54.444-07:00George Morse Jr. Gone West - Farewell To The Designer Of The Prowler Aircraft And A Prolific Experimental Builder<br />
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<span style="font-size: large;"><b>George Morse Jr.<br />Gone West </b></span></div>
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<span style="font-size: large;"><b>- </b></span></div>
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<span style="font-size: large;"><b>Farewell To</b></span></div>
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<span style="font-size: large;"><b>The Designer Of The Prowler Aircraft</b></span></div>
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<span style="font-size: large;"><b>And A</b></span></div>
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<span style="font-size: large;"><b>Prolific Experimental Aircraft Builder</b></span></div>
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<span save_image_to_download="true" style="font-size: small;">It is with great sadness and a heavy heart that I announce to the Prowler Aviation community, and the experimental aviation community, that the designer of the Prowler Aircraft (and founder of the original Prowler Aviation) has passed away on June 27th, 2018. He was 90 years old. George had not been feeling well and ultimately passed from sepsis associated with his illness.</span><span save_image_to_download="true" style="font-size: small;"><br /><br />Here is the program from his funeral service on Sep 14th: </span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhu1PPyRChkukPS6_yy-PFN1NikqaHyyrM2Wi7r2c84nHacum-P2Fy1jBhia_8ck4WLVbGOVsf0jNNG-e2OcfDMCENlSk-qiiMu0XKa2yHeWkc7qn5ApZU6GevV4LydVnhB4-KfGs9fRocU/s1600/George+Funeral+Program-1_red55.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1234" data-original-width="1600" height="246" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhu1PPyRChkukPS6_yy-PFN1NikqaHyyrM2Wi7r2c84nHacum-P2Fy1jBhia_8ck4WLVbGOVsf0jNNG-e2OcfDMCENlSk-qiiMu0XKa2yHeWkc7qn5ApZU6GevV4LydVnhB4-KfGs9fRocU/s320/George+Funeral+Program-1_red55.jpg" width="320" /></a></div>
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George Morse Jr. 9/2/1927 to 6/27/2018</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqXdL4k0Q3yWaapR80O8vAAoLPG8f0Q-N-TiNIONQvjAznIE_LHdGUpgX9ehGsx0W3VNaESEJtDXQdHi6yVcY9BL3X6bSXpOrSw4o3FHJOp69RVs35LfR3aD4RFVgYmQA4qpziq32ANNAg/s1600/George+Funeral+Program-2_red55.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1234" data-original-width="1600" height="246" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqXdL4k0Q3yWaapR80O8vAAoLPG8f0Q-N-TiNIONQvjAznIE_LHdGUpgX9ehGsx0W3VNaESEJtDXQdHi6yVcY9BL3X6bSXpOrSw4o3FHJOp69RVs35LfR3aD4RFVgYmQA4qpziq32ANNAg/s320/George+Funeral+Program-2_red55.jpg" width="320" /></a></div>
<span save_image_to_download="true" style="font-size: small;">(The reason for the nearly 3 month delay in his funeral service was due the the 2018 Carr Fire in northern CA. George wanted to be buried in the Northern CA Veteran's Cemetery with his wife of 65 years, Kathleen. The fire burned literally up to the perimeter of the cemetery. The associated mandatory evacuations forced all the services scheduled at the cemetery to get delayed and re-scheduled.)</span><br />
<span save_image_to_download="true" style="font-size: small;"><br />The last time I saw George was when we had lunch together sometime in very late May. He seemed fine then and we talked about Prowlers and such the way we always did. I updated him on the status of all the current builders and owners. He was always interested to know what was happening with all the Prowler airplanes and their builders and owners. To me, he never really seemed to age. He pretty much always looked like he did on the very first day that I met him almost 13 years ago. Here is a picture of him and Kathleen in Oct 2005 on the day we rolled into Redding with a Penske truck full of everything we owned:</span><br />
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George and Kathleen are survived by their 5 children and many grandchildren (outlined in the funeral program above). The family has been awesome to me and has entrusted me with numerous Prowler related items that belonged to Kathleen and George. They have given me hundreds of Prowler photos, several magazines with articles featuring the Prowler, dozens of newspaper clippings, several framed photos of Prowlers and the "Holy Grail" - George's bronze Lindy Award that he won at EAA in 1986 when he took his original Prowler to Oshkosh. Check this out!:
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEig-JJ1JDMP9uPkwN1BHIj-nkHMGwIbaAjmp4STmUNoXdQJRo9uhj3da8Zi8qiqvhQj4kF4OYqmsKZmsgueQXljhdz4cppth14CzfzmO6ubxA5edv3k_fc4kU_PTt88qVVVfCgcLeblII7L/s1600/1+IMG_20180920_135530.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1476" data-original-width="643" height="320" save_image_to_download="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEig-JJ1JDMP9uPkwN1BHIj-nkHMGwIbaAjmp4STmUNoXdQJRo9uhj3da8Zi8qiqvhQj4kF4OYqmsKZmsgueQXljhdz4cppth14CzfzmO6ubxA5edv3k_fc4kU_PTt88qVVVfCgcLeblII7L/s320/1+IMG_20180920_135530.jpg" width="139" /></a></div>
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So cool! I am so flattered and appreciative that the family has entrusted me to keep this award with the new Prowler Aviation! This is an incredible part of the history of Prowler Aviation and I am so happy to be able to keep it with all the other Prowler history that I've collected over the years. Thank you all, so much!</div>
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I never really comprehended the depth of George's experimental aircraft work. It wasn't until I was going through the 100's of pictures from the family that I saw how many different experimental aircraft that he either built or worked on in some way. George either built, or re-built, several airplanes in his life. Here is an RV that he worked on in the driveway:</div>
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And, there was a BD-4:<br />
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Of course, there was the Steen Skybolt:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNoosKTI8XVWNLlLFydM23gtDWgfarfqlOFoOFKTmRaHL6TibML599vGkhqoBRHn91KfkqPMVN6pgO58NkGAzwkiPlVzDBcEG89O72HhNZll-SpaKsKFuzOL8wSAco755Gz6mGjjcqX6Py/s1600/Skybolt+1.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1099" data-original-width="1600" height="273" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNoosKTI8XVWNLlLFydM23gtDWgfarfqlOFoOFKTmRaHL6TibML599vGkhqoBRHn91KfkqPMVN6pgO58NkGAzwkiPlVzDBcEG89O72HhNZll-SpaKsKFuzOL8wSAco755Gz6mGjjcqX6Py/s400/Skybolt+1.jpg" width="400" /></a></div>
And, there may have been more that I'm not yet aware of. However, the Skybolt was the airplane that led him to develop an alternative engine to power his airplane. Being very practical, George was just put off by the extreme cost of certified engines. So, he set out to convert an auto engine that could power his Skybolt. The result was the Olds F-85 aluminum block engine with a gearbox that he designed to fit on the front of the engine and the back side of the engine adapted to turn various accessories (distributors, pumps, etc.). Here is what it looked like installed on N85GM:<br />
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This turned out to be quite a successful design and he ended up starting a company called AutoAviation and building approximately 30 of these system that he sold to Skybolt builders and others.<br />
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In fact, George's Skybolt was built in 1979 and was still flying in this 1997 article. Check it out here:<span save_image_to_download="true" style="font-size: small;"><a href="http://www.steenaero.com/articles_detail.cfm?ArticleID=35" save_image_to_download="true">http://www.steenaero.com/articles_detail.cfm?ArticleID=35</a>
<br /><br />Here is a later version of the same engine design, except that this used a Rodeck block engine that would eventually power the 1st Prowler:</span>
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<span save_image_to_download="true" style="font-size: small;">All the time while he was working on the AutoAviation project, George was planning and designing a new airplane to put his AutoAviation V8 engine into. He explains in a promotional video how he came to conceive the looks of the Prowler and how he incorporated some of the looks of the P51 Mustang, Spitfire, P-40 Warhawk and the Me109 into an airplane that looked like a WWII fighter, but wasn't trying to look like any one specific WWII fighter; a very clever design philosophy! </span><span save_image_to_download="true" style="font-size: small;">See it here:</span></div>
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<span save_image_to_download="true" style="font-size: small;">With a plan in mind, George set out to construct his 1st Prowler. Here some pictures of this initial construction at his shop in Watsonville:</span></div>
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Notice the wire he used to silhouette what the final shape of the Prowler would be (below):</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-2Yi8d5ERCrilxTo_ANMCP9q0mg-XRw02o3qhexT5f7p_hzbi0pe5UrkNDWSYMPEBf4Wf9fpMhMu10ti7EPnDPfxRl0p6W6iPslC5Pj5zcfCG-qs04jTpBkvWIMgFSzLs8_PEpVytaKUt/s1600/Original+Prowler+Early+%25286%2529.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1144" data-original-width="1600" height="228" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-2Yi8d5ERCrilxTo_ANMCP9q0mg-XRw02o3qhexT5f7p_hzbi0pe5UrkNDWSYMPEBf4Wf9fpMhMu10ti7EPnDPfxRl0p6W6iPslC5Pj5zcfCG-qs04jTpBkvWIMgFSzLs8_PEpVytaKUt/s320/Original+Prowler+Early+%25286%2529.jpg" width="320" /></a></div>
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Interestingly, I think he built this airplane right side up so that he could take his vision of what he wanted the Prowler to look like and accurately cast it into the real thing. (Later, production Prowlers were built in a jig with the wing oriented leading edge down and trailing edge up. Also, with adequate overhead space, the firewall and cockpit floor could be attached to the wing before removal from the jig). But, for this 1st Prowler, he could envision things more easily with the plane sitting on the tables he built:</div>
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<span save_image_to_download="true" style="font-size: small;">Ultimately, this beautiful aircraft was the result of years of George's creativity, craftiness, vision, determination, dedication and hard work:</span></div>
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<span save_image_to_download="true" style="font-size: small;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfPSFi5nLKg1KouUaYTxf99f1OuNo6VNPWoRJC6aE1XA5DDrWteC7FDiIAC1izwp7tUNLZcJYe_B8yQSqZe_EcZNrrFY4sEEY8q_3nfoJ5hCrkwdeo7NJYtn65c0zNiX1erJwOyTh_6APW/s1600/IMG_0044.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1059" data-original-width="1600" height="263" save_image_to_download="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfPSFi5nLKg1KouUaYTxf99f1OuNo6VNPWoRJC6aE1XA5DDrWteC7FDiIAC1izwp7tUNLZcJYe_B8yQSqZe_EcZNrrFY4sEEY8q_3nfoJ5hCrkwdeo7NJYtn65c0zNiX1erJwOyTh_6APW/s400/IMG_0044.jpg" width="400" /></a></span></div>
<span save_image_to_download="true" style="font-size: small;">What a awesome aircraft! It was a real head turner! It's easy to see why he won the Lindy award that I mentioned earlier! After winning that award at EAA '86 and with the huge amount of positive feedback received from 1000's of letters requesting information about the Prowler, George decided to try to make and sell the Prowler as a kit aircraft. Prowler Aviation was born!<br /><br />After deciding to produce Prowler kits, George started searching for a place to set up shop and look for people to help him start Prowler Aviation. He was not happy with the cost of renting shop space in Santa Cruz/Watsonville/Salinas area. But, he found that he could get shop space for 1/2 the cost up in Redding CA. They decided that George would move there to start Prowler Aviation and Kathleen would stay behind and keep working at her current job. </span><span save_image_to_download="true" style="font-size: small;"><span save_image_to_download="true" style="font-size: small;">George ended up renting 6,000 sq ft of shop space right next to the Redding Airport. On 3/1/89 he moved Prowler Aviation into 3707 Meadow View Dr. in Redding. Here are a few pics of the shop at various times
during the production of the original 15 kits:</span></span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8xYK6IN1ymHstOkgIH56edY2nEILFGFALmU_KCVUX9355tA8fJTjRbzzREX1u5DOlkyzr6t5tWPd-7Bl7KvVzOGTbcYhsndrf_KpZkj7UITEOJl8wexnwBWZdwd-nmY7iJXlWKR3iinq9/s1600/307956-R1-45-45_046_+%25281%2529.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1081" data-original-width="1600" height="216" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8xYK6IN1ymHstOkgIH56edY2nEILFGFALmU_KCVUX9355tA8fJTjRbzzREX1u5DOlkyzr6t5tWPd-7Bl7KvVzOGTbcYhsndrf_KpZkj7UITEOJl8wexnwBWZdwd-nmY7iJXlWKR3iinq9/s320/307956-R1-45-45_046_+%25281%2529.jpg" width="320" /></a></div>
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<span save_image_to_download="true" style="font-size: small;">Eventually, George and Kathleen bought a home in Redding and she moved up to join George there when she finished working. The company went on to produce 15 Prowler kits. Of those 15 kits, 4 of those kits have been assembled and have flown. </span><span save_image_to_download="true" style="font-size: small;">One kit is now close to it's 1st flight. </span><span save_image_to_download="true" style="font-size: small;">One kit is mostly assembled, but not actively being worked on to complete it. Currently, there are 3 kits that are actively being built. There are 3 kits are currently owned, but not being worked on. (The remaining 3 kits I have lost track of and not yet located).<br /><br />Eventually, George had to retire from the experimental aircraft business and he closed down Prowler Aviation. But, retirement could not slow him down. He decided to take a partial kit he had (Kit #5) and build one more Prowler using the left over inventory that he had from Prowler Aviation. George built N611GM and it got it's experimental certificate in 2001. This was George's 3rd Prowler that he built and it was the one that he was most fond of: </span></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFHDGit1hBHCAOOgfn0j-5LtOXQJOMZn5MrsfQc6dg2IH1DWZKZHJpodHxv_SvXm6r1yWW3TixCtWP16vuBGxLdnnIehcLA-bbk5xQrw179f65T-hu7e8pFY1fDnDiVM19kglUo1EZBbIA/s1600/Prowler+010.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFHDGit1hBHCAOOgfn0j-5LtOXQJOMZn5MrsfQc6dg2IH1DWZKZHJpodHxv_SvXm6r1yWW3TixCtWP16vuBGxLdnnIehcLA-bbk5xQrw179f65T-hu7e8pFY1fDnDiVM19kglUo1EZBbIA/s320/Prowler+010.jpg" width="320" /></a></div>
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<span save_image_to_download="true" style="font-size: small;">After
buying Prowler Aviation from George, he still did not slow down! He
then turned his attention to rebuilding a car that he found that he
always had a passion for - a 1961 Oldsmobile Starfire convertible. He
started working on this car shortly after I moved to Redding. He
completed the restoration in late 2007 but continued to work on the car
and fix things on the car up until very recently. Here are a few pics of George, Kathleen and his Starfire:</span></div>
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<span save_image_to_download="true" style="font-size: small;">I learned something from George around this time. Several times I found him at his hangar laying on the
cold, wet concrete floor under his Olds Starfire when he was 80+ years
old!! If I suggested in any way that I could help him - he'd say "I can
do it!" And, often it was followed with him saying; "I gotta have something
to do. If I sit on the couch and watch TV, I'll die!" </span><span save_image_to_download="true" style="font-size: small;">I believe
he was right! </span><span save_image_to_download="true" style="font-size: small;">The lesson I
took from this is that everyone has to have a reason to get up each
morning and put their boots on and get out and do something. His activity kept him going and kept him feeling alive - especially after Kathleen's
passing 3-1/2 years ago (which left such a large gap in his life).</span></div>
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<span save_image_to_download="true" style="font-size: small;"><br />George was a complex guy. I discovered at his funeral (from a story told by his son, Ray) that George really
only had an 8th grade education. He could be stubborn to a fault, and
this is principally why he only completed school through 8th grade - when
he had every opportunity to compete high school (there is a longer,
interesting back story). Despite this, he went on to accomplish many
amazing feats in his lifetime, ultimately designing and flying his own aircraft powered
by his own auto-engine conversion design!! He obviously could learn.
But, it had to be done George's way!<br /><br />The world of experimental aviation has lost a staunch supporter and a real "can do" individual who did just that - he got out and did it. He did what he wanted and accomplished myriad things that most of us just dream about. No doubt, to be sure, George was also a dreamer! But, his dreams were not a boundary - they were merely a starting line! He took his dreams and make them real! The world of experimental aviation would not be where it is today were it not, at least in part, for the accomplishments of Mr. George Morse Jr.!<br /><br /><span style="font-size: large;"><i><b>Farewell, my friend. Your legacy will live on through your family, friends and Prowler Aviation! </b></i></span><br /><br />Here, in no particular order, are several more pictures that I have found of George and his airplanes: </span></div>
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Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-4561663675008429701.post-13381097841629191952018-04-15T22:20:00.000-07:002018-04-15T22:20:29.885-07:00Making A Set Of MLG Hydraulic Actuators And A Fix To The MotionMasterHello Everyone,<br />
<br />
Welcome back. Since we are 3+ months into 2018, it's time for a quick Prowler update. Most of the past two months has found my time consumed with getting qualified to go back to work, and then actually getting back to work. With a whole afternoon off in a hotel room, there's no better time to post an update. So, here's what I have for you this time:<br />
<br />
1. Making My 1st Set of MLG Hydraulic Actuators <br />
2. Another Fix To The MotionMaster<br />
3. Fabricating Long Aluminum Channels <br />
4. Builder Updates:<br />
A. Bud Is Flying Again!!!<br />
B. EZ Is Ready To Go - 2nd First Flight<br />
C. Ray's Having MLG Problems<br />
D. Francis Keeps Marching Along<br /> E. Eric Is Working On Ailerons<br />
<br />
Most of the work that is the content of this update post was completed in late Dec 2017 and Jan 2018 before I went back to work. Admittedly, since the end of January, I've not had much time to get in the shop. I'm hoping to reverse this trend and get in the shop enough to complete Kit #18 before AirVenture this year. That's because it's looking pretty certain that EZ will be flying his Prowler to KOSH this year for AirVenture 2018. And, Bryan has committed that if EZ flies his Prowler to the show, then he will try to trailer his Prowler up to display as a "work in progress". So, we could have 2 Prowlers at AirVenture this year! The Prowler brand is quite likely going to get a fair amount of attention if this happens. So, I'm hoping to have at least one kit to sell when I get the inevitable question(s)....<br />
<br />
Anyway, more to follow on the AirVenture 2018 Prowler presence. For now, on with the update.<br />
<br />
<u><b>1. Making My 1st Set of MLG Hydraulic Actuators -</b></u> One of the big outstanding assemblies left on the "To Do List" for Kit #18 is the hydraulic actuators that move the MLG up and down. Since I had a few weeks of uninterrupted time left in the shop towards the end of my medical LOA time - I wanted to tackle getting these components made. In general, they are not incredibly complex parts to fabricate. However, I found that engineering that goes into sizing and fabricating of parts associated with O rings is pretty complex.<br />
<br />
The MLG Hyd Actuators are essentially made up from 5 parts (not including the vendor items - O rings, locknut and spherical bearing). Here is an exploded CAD drawing I made several years ago:<br />
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I refer to these 5 parts as the:<br />
A. Piston Rod;<br />
B. Piston;<br />
C. Cylinder;<br />
D. Live End Plug (cylinder plug that piston rod passes through);<br />
E. Dead End Plug (cylinder plug that facilitates attachment to wing spar);<br />
I will go through the fabrication of these parts in this order.<br />
<br />
<u>A. Piston Rod -</u> George made these from 4130 steel rod. I originally purchased enough 4130 rod to make 1 set of these. After I made them I looked at them closely and discovered that the mill finish on these was very rough. The surfaces were covered with pits, waves and other deformities that I was certain would tear up any O ring after a few uses - even if I tried to smooth and polish the surfaces of them. I was also concerned about the oxidation of the surfaces of these rods when the gear were extended and they were exposed to air for long periods of time.<br />
<br />
After a discussion with Ray, I decided to pitch that set of piston rods and start over with piston rods made from 303 stainless steel. So, I sourced some correctly sized stainless rod and cut them into the necessary lengths. Here is what one looks like when I started:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgd6_X8egPFT9Uh-8xhTx9n_HYUp0-RRRnIzBAcgfWRIE2BlabaLZKhDP0kQ72si8uQgwLSQpFKI-swq8BEFvABT84YrYshOSWQTByZ8t73ijgPM3ohG4jYezrEo68E4dnGb8xaiqevRzQx/s1600/20180114_105210.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="280" data-original-width="1220" height="73" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgd6_X8egPFT9Uh-8xhTx9n_HYUp0-RRRnIzBAcgfWRIE2BlabaLZKhDP0kQ72si8uQgwLSQpFKI-swq8BEFvABT84YrYshOSWQTByZ8t73ijgPM3ohG4jYezrEo68E4dnGb8xaiqevRzQx/s320/20180114_105210.jpg" width="320" /></a></div>
The first thing to do was to put it in the lathe and reduce one end to 3/8":<br />
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Here is one completed and ready to cut threads to 3/8" fine pitch:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWiNupnZts9r3CP78e0yZrXDM0Vr4Nc4kKZkPKtTPMh6G2ItRk3VnX9wI1P5llFJP6vJvJd5YBddl8TTjtmgOEgjvwcHELlfxGdaO7J5A04hMWV0H6fuW_AZ1aEmKejSjCl2svFyCGww-c/s1600/20180113_194444.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="818" data-original-width="589" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWiNupnZts9r3CP78e0yZrXDM0Vr4Nc4kKZkPKtTPMh6G2ItRk3VnX9wI1P5llFJP6vJvJd5YBddl8TTjtmgOEgjvwcHELlfxGdaO7J5A04hMWV0H6fuW_AZ1aEmKejSjCl2svFyCGww-c/s320/20180113_194444.jpg" width="230" /></a></div>
Instead of trying to cut the threads with the lathe, I decided to use a thread cutting die and use the lathe to align it and begin the thread cutting:<br />
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Once I had 2-3 threads cut on the end, then I took the rod out and put them into my 8" super spacers that was mounted on my mill table. Using this to hold the rod, I continued cutting the threads using a hand threading handle holding the 3/8" fine thread die:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXYk6NK4kFSN9-koJlWLR5Eu2Sm_aZWMl3Wcn1p7ZKqBJZlmDLbqkuCs78bIYez6YImhTFY0p7APb_SWsVzKhK28ax78hqDhdgF9haE30WyCefpK6gnz6VZiWj6ijJI18AwjJYn-uykeek/s1600/20180113_215558.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1006" data-original-width="881" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXYk6NK4kFSN9-koJlWLR5Eu2Sm_aZWMl3Wcn1p7ZKqBJZlmDLbqkuCs78bIYez6YImhTFY0p7APb_SWsVzKhK28ax78hqDhdgF9haE30WyCefpK6gnz6VZiWj6ijJI18AwjJYn-uykeek/s320/20180113_215558.jpg" width="280" /></a></div>
Here is one that is done:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiw3a_iiZJtU6LGU7tiwnKupLlZWFwncPAqFWuc1b0Ax3wUS0rjSJr9ZFwwtu0OALTYBGRvWoAVaglCjRGkpOCu2CUOlY8T2i0IBgf_FwqrZop45xPpuyRBlvGS3NGQzY7r0SgDAC2_ej-v/s1600/20180113_215840.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1194" data-original-width="816" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiw3a_iiZJtU6LGU7tiwnKupLlZWFwncPAqFWuc1b0Ax3wUS0rjSJr9ZFwwtu0OALTYBGRvWoAVaglCjRGkpOCu2CUOlY8T2i0IBgf_FwqrZop45xPpuyRBlvGS3NGQzY7r0SgDAC2_ej-v/s320/20180113_215840.jpg" width="218" /></a></div>
Next step is to drill and tap the other end of the piston rod. This is drilled and tapped to 5/16" fine threads to hold a tie rod end that will be used to attach to the MLG brace attach point. Here is the pilot hole getting drilled in the lathe:<br />
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Drilling the correct sized hole for the 5/16" fine tap:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8hS4Lb1IgeldCsmOb2vojn2UJvaIB_tD_1Rx3jTwk1EKRkz2dc0YXrxnOge642WokkkDbDvm5TCzJX3tBTYFgEyW0OWFZ8t_O0E7zJ0rHcPQ5qM_Z_6dtW17c9-cazvDz2xvvYs1EzF0B/s1600/20180114_105125.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="811" data-original-width="643" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8hS4Lb1IgeldCsmOb2vojn2UJvaIB_tD_1Rx3jTwk1EKRkz2dc0YXrxnOge642WokkkDbDvm5TCzJX3tBTYFgEyW0OWFZ8t_O0E7zJ0rHcPQ5qM_Z_6dtW17c9-cazvDz2xvvYs1EzF0B/s320/20180114_105125.jpg" width="253" /></a></div>
And, here is the setup I used to start the tap in the hole of the piston rod. I placed the tap in the drill chuck mounted in the tail stock and then turned the headstock by hand to get the tap started straight and aligned: <br />
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Once I had a few threads tapped in the lathe, I put the rod back in the super spacer and continued hand tapping the holes all the way:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOnR7xxvSTUZ4SVfedEJdPmZ7ORyxuRYLpJiUJmrL2WlGFsRdqovoUS7qRyBWc3TyjZNx-h-_d52Y4iUe-kQdXy22ZAnmhN_nY3om2fW_0TN99rCJovUSmyiRAKXHBwbHIFfeSGSNBtoKt/s1600/20180113_214003.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="938" data-original-width="639" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOnR7xxvSTUZ4SVfedEJdPmZ7ORyxuRYLpJiUJmrL2WlGFsRdqovoUS7qRyBWc3TyjZNx-h-_d52Y4iUe-kQdXy22ZAnmhN_nY3om2fW_0TN99rCJovUSmyiRAKXHBwbHIFfeSGSNBtoKt/s320/20180113_214003.jpg" width="217" /></a></div>
The last thing to do was to put flat sides on the end with the threaded hole to provide a means to "hold the roll" when threading the 5/16" tie rod end into the end of the rod. I did this using a 5C collet and a square collet block I pinched in a vise. Then, it's just a simple short cut on each side with a 1/2 end mill:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGUVtLeQhIsEBk7zZiOK5EXBFmhba5gC5aIo0NiV2FinYh5nZEB0IfCd0OIYJbVnzDY6ao-EpaglT_k6MV8vG8bjQ6X8nB0jeE0nZHVne0LYts05m4f6KasmhEM0lLt2Ab_jAidz-jsocG/s1600/20180114_105041.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="660" data-original-width="643" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGUVtLeQhIsEBk7zZiOK5EXBFmhba5gC5aIo0NiV2FinYh5nZEB0IfCd0OIYJbVnzDY6ao-EpaglT_k6MV8vG8bjQ6X8nB0jeE0nZHVne0LYts05m4f6KasmhEM0lLt2Ab_jAidz-jsocG/s320/20180114_105041.jpg" width="311" /></a></div>
With that done, it was time to put the rods back into the lathe and clean them up. I used the lathe with a fine pitch file to knock off any large "goobers." Then, I used 220 grit emery cloth, 440 emery cloth and finally 600 emery cloth to polish the rods to a pretty clean, smooth finish:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMKI_D1KRZOkPM_7jjAyVN9xbB4gungg73caPVQFB5eHJiRbke_c0iBgVluA-nF9L-RyiHRWr650wi0CW1OUyZ1cuoy4jJ8_R7BeyDKtXDBsMnKlAL4Uk6HLKdlad8eEBUbEM3jqpY1kqB/s1600/20180114_105022.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="470" data-original-width="1290" height="116" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMKI_D1KRZOkPM_7jjAyVN9xbB4gungg73caPVQFB5eHJiRbke_c0iBgVluA-nF9L-RyiHRWr650wi0CW1OUyZ1cuoy4jJ8_R7BeyDKtXDBsMnKlAL4Uk6HLKdlad8eEBUbEM3jqpY1kqB/s320/20180114_105022.jpg" width="320" /></a></div>
<br />
Here are 2 finished sets of my piston rods:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhr_9j5yS7p4GS7e1xuL7osHPYV_EoK-mqCysoTQNwxD9UIP1cz5IOlRx7dLK2NFzjkrlarWSAJIaI8xJAjUHqSi-etaEj0N5Nf2EGg9tUvV6wBkOgajxtNb2hsBO5PPQv6LB75RumQuctw/s1600/20180114_105005.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="499" data-original-width="1256" height="126" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhr_9j5yS7p4GS7e1xuL7osHPYV_EoK-mqCysoTQNwxD9UIP1cz5IOlRx7dLK2NFzjkrlarWSAJIaI8xJAjUHqSi-etaEj0N5Nf2EGg9tUvV6wBkOgajxtNb2hsBO5PPQv6LB75RumQuctw/s320/20180114_105005.jpg" width="320" /></a></div>
<br />
<u>B. Piston -</u> The pistons are fabricated from 7075 Al rod. Here is a piston "puck" in the lathe getting the hole drilled that will get tapped to 3/8" fine thread:<br />
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Here is the 3/8" fine tap getting started in the correct sized hole:<br />
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Again, once the treads were started straight, I put them in the vise and completed the tapping by hand:<br />
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With this done, I put the pistons back into the lathe and cut a counter bore on one side with a 5/8" end mill. This is for the locking nut to sit into to lock the piston to the piston rod. I don't have a pic of that, but here is the piston mounted to the piston rod and chucked in lathe. This set up was used to cut the grooves for the O rings that will seal the piston in the cylinder:<br />
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Here is one of the pistons after the O ring grooves are completed:<br />
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Here are 3 sets of pistons and rods that I made:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBnHL7UEQW4vSC_wIWx5W7FgL9ZrtmM87ttqeaNdxiZEprlFoICDKxkbXdNJD5nf0t2EtZN8oIoFRnUcnnK-t_Z2fB2skfOnL5frBMgeNDco9DSd6R1rUYE-BOLrmR7JsTkHXxtjNviKkX/s1600/20180117_143259.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="785" data-original-width="1003" height="250" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBnHL7UEQW4vSC_wIWx5W7FgL9ZrtmM87ttqeaNdxiZEprlFoICDKxkbXdNJD5nf0t2EtZN8oIoFRnUcnnK-t_Z2fB2skfOnL5frBMgeNDco9DSd6R1rUYE-BOLrmR7JsTkHXxtjNviKkX/s320/20180117_143259.jpg" width="320" /></a></div>
On a recommendation from Ray, I decided to make a couple sets of these
with dual O ring seals. Ray experience some pressure bypassing around
the piston. It turns out that the bypassing was caused by worn out O
rings - but, I thought I'd try a few sets of these anyway, just to see how they work
out.<br />
<br />
<u>C. Cylinders -</u> The cylinders were probably the easiest of these parts to make. I simply had to lop off a length of 4130 steel tube and cut 3 holes in each end. I did that in the 8" super spacer again and used the mill to cut the holes. Here is the set up:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhsqvCUIcH80f68nkmrza4vFVnNRW0ZoRYl1jMghM2Cv0e-GdugUcT8CHAk6khPohyYsiSs3bNYqGf4lIwO58VWQX9Es5vWmdHR9KAvlQR8k6Yim08HOcZ-tsI75necIhUJRVgvKdJd-iOl/s1600/20180115_164810.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1143" data-original-width="643" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhsqvCUIcH80f68nkmrza4vFVnNRW0ZoRYl1jMghM2Cv0e-GdugUcT8CHAk6khPohyYsiSs3bNYqGf4lIwO58VWQX9Es5vWmdHR9KAvlQR8k6Yim08HOcZ-tsI75necIhUJRVgvKdJd-iOl/s320/20180115_164810.jpg" width="180" /></a></div>
Initially, I just spot drilled the holes, then went back and cut the hole the correct size with an end mill:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBCoEb0P4w46YwarvAT95OEVeRihuDC-SYkyU7_QAOpVzTmBFIYFjr2l9d7wjHmHbzV8hB0HSNPX24i5S5koDZKiqYFVLDC5L-r3MGsg6FypRsK5aZ6RC-XpBAgwL7DJ8FvtbIy2nkRUX1/s1600/20180115_164823.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1143" data-original-width="643" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBCoEb0P4w46YwarvAT95OEVeRihuDC-SYkyU7_QAOpVzTmBFIYFjr2l9d7wjHmHbzV8hB0HSNPX24i5S5koDZKiqYFVLDC5L-r3MGsg6FypRsK5aZ6RC-XpBAgwL7DJ8FvtbIy2nkRUX1/s320/20180115_164823.jpg" width="180" /></a></div>
The only other thing I had to do with the cylinders was to thoroughly deburr the holes on the inside and then run a 320 grit ball cylinder hone in the cylinder to give them an initial polishing. This will prolong the life of the sealing O rings on the pistons. <br />
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<u>D. Live End Plug -</u> One end of the cylinders must be "plugged" with some thing that will allow the piston rod to pass through it. I refer to this as the "live end". The other end of the cylinder has a plug that allows for the whole assembly to be mounted to the wing spar. I refer to this as the "dead end" of the actuator. End plug also provides for a threaded hole to act as port for the hydraulic oil to flow in and out of the actuator.<br />
Both ends are made from a 7075 Al rod. The live end is bored out to the correct diameter and has O ring grooves cut on the ID for sealing to the piston rod and O ring grooves cut on the outside to seal to the cylinder. Here is one of the plugs being squared up and cut to length in the lathe:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7gVmXnoHnMPDhMjSWhXqrSKGu-Q3tOw9_zzrVU_r4gnTOBhsjJyJtXF0cXQBsmZ7WswDlSXh5f5QT2V_5JnIgjloH5fLw71jVahlCENI8lQkmGz7GhmOjFPb9xmoZVkfcm0A8XdZnFUQl/s1600/20180117_192814.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="762" data-original-width="1303" height="187" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7gVmXnoHnMPDhMjSWhXqrSKGu-Q3tOw9_zzrVU_r4gnTOBhsjJyJtXF0cXQBsmZ7WswDlSXh5f5QT2V_5JnIgjloH5fLw71jVahlCENI8lQkmGz7GhmOjFPb9xmoZVkfcm0A8XdZnFUQl/s320/20180117_192814.jpg" width="320" /></a></div>
Here are two sets of both live end and dead end plugs after initial forming (live end plugs in front and dead end ones in back:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3swdSdhkvEHcpB8ayKzyidNMO4S3-7F8_a3n5l2k8JJcaAF6-bilZzPVuTNmmYfdkV2L4ZhYtzY8VSXT3rfy1Ht07zN9S5GHahi51oQux2VGP4sDz05-ciWsBAz05Fu17A4f_NNuoNL6t/s1600/20180117_193710.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="719" data-original-width="892" height="257" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3swdSdhkvEHcpB8ayKzyidNMO4S3-7F8_a3n5l2k8JJcaAF6-bilZzPVuTNmmYfdkV2L4ZhYtzY8VSXT3rfy1Ht07zN9S5GHahi51oQux2VGP4sDz05-ciWsBAz05Fu17A4f_NNuoNL6t/s320/20180117_193710.jpg" width="320" /></a></div>
Here is drilling the pilot hole through a live end plug:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgt823VFRsdoluWRJPG2Sdnx8VchbycD8cgJnvPMzEB2utS09SpqWht5lra77BGJ4n532K_Rg0tAExLi5UX3x_u1et7Mkka4660eeygUW0XWncg8dni79CFG_Ke49jyzgasVEK3DLvMUQEp/s1600/20180117_195227.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="619" data-original-width="1173" height="168" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgt823VFRsdoluWRJPG2Sdnx8VchbycD8cgJnvPMzEB2utS09SpqWht5lra77BGJ4n532K_Rg0tAExLi5UX3x_u1et7Mkka4660eeygUW0XWncg8dni79CFG_Ke49jyzgasVEK3DLvMUQEp/s320/20180117_195227.jpg" width="320" /></a></div>
Next, I drilled the hole to slightly under the piston rod size. After that, I ran a reamer through the hole to get a uniform bore:<br />
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Next, I turned the live end around in the chuck and used an end mill to drill a counter-bore part way into the live end. This provides a passage for the oil to flow around the piston rod and the inside of this counter bore:<br />
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Here are all three sets of pistons, piston rods and live ends pseudo-assembled (no O ring grooves on the live ends yet - but there are grooves on the pistons):<br />
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Here is a live end chucked in the lathe and cutting the outside O ring groove (Note: I'm using an ID grooving tool to cut an OD groove - so, I had to move the tool all the way back, turn the lathe the opposite direction and cut while moving the tool in -X direction). Cutting the 1st O ring groove:<br />
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And, cutting the 2nd O ring groove:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjG0smonYS8132RidI35B9X4aSZNZp4Mv3V3IHW0KVI-0NMlVrSGW48UEQuz_MWbyXLC4nZ2u_I1hGveJqW7B1QC778J3JiOVdDcIhiCopS-cvnLIzjlZVeZyPllMXvLhwyLZOZlerBiwIQ/s1600/20180119_230805.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="643" data-original-width="1143" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjG0smonYS8132RidI35B9X4aSZNZp4Mv3V3IHW0KVI-0NMlVrSGW48UEQuz_MWbyXLC4nZ2u_I1hGveJqW7B1QC778J3JiOVdDcIhiCopS-cvnLIzjlZVeZyPllMXvLhwyLZOZlerBiwIQ/s320/20180119_230805.jpg" width="320" /></a></div>
Here is the live end with both OD grooves cut for the O rings. Ray recommended trying to use double O ring grooves on these parts to make the part more stable inside the cylinder and to cut down on any leakage. We will see how this design works out, over time:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjnROqbF4Uik6y2DsanDbqF2JO0eimZr1gIPe4ckbkSwZUBJ9gGCPNWGJusnHLodXCELjr2wtCalydAS-FPwyqoz-XnbGRnQbqW9PRyP6OsNfiqVMTkCV1W4Splfp1LlrUuv8QaRCXGhaN/s1600/20180119_234525.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="653" data-original-width="827" height="252" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjnROqbF4Uik6y2DsanDbqF2JO0eimZr1gIPe4ckbkSwZUBJ9gGCPNWGJusnHLodXCELjr2wtCalydAS-FPwyqoz-XnbGRnQbqW9PRyP6OsNfiqVMTkCV1W4Splfp1LlrUuv8QaRCXGhaN/s320/20180119_234525.jpg" width="320" /></a></div>
Here is a close up shot of the double O ring grooves on the ID of the live end. This might be overkill, but again I thought I'd try a double O ring seal on the piston rod, just to prevent leakage. (If one is good, two must be better - right!?!?)If it turns out to add too much drag to the piston rod, I reasoned that I can always just remove one O ring. <br />
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Here is the set of three pistons, rods and live ends, again (with O rings on one piston on the left):<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNuObIuMp5AI69NfVLVoutVIFGPUBGr_8Ud8ct-vlxgCnouHDEOrr-HVVxZdUZYm3q_N91ieGQNwHnGrhyKcsErV-UD49kiH0rj2i0Lkrqm6vqSYFDO8qadWJVtYlBhg-7OBvay0fio-Vy/s1600/20180119_234507.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="841" data-original-width="918" height="292" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNuObIuMp5AI69NfVLVoutVIFGPUBGr_8Ud8ct-vlxgCnouHDEOrr-HVVxZdUZYm3q_N91ieGQNwHnGrhyKcsErV-UD49kiH0rj2i0Lkrqm6vqSYFDO8qadWJVtYlBhg-7OBvay0fio-Vy/s320/20180119_234507.jpg" width="320" /></a></div>
Remember the hydraulic ports that I mentioned earlier, well here is the setup in the mill to drill the holes for the live ends. Each live end gets 3 holes drill and tapped that are 120 deg apart. In one port goes the hydraulic 90 deg elbow to attach the hose, and the other 2 holes get pipe plugs. The three of these fittings are what holds the plug inside the cylinder. Here is the setup:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYbGKmZVp2YdgCDTAmsTIc3qkB0aYIqXov0FHrRvqb8nLQH415Gi1lQSH50jz5V5jNmClzQJWALcmenZGBZav-qbSV6Q3A6V83A3MVCRiYAcqeJcuB5otJ5ykNlvYGW68Vkj6Gy9tWiBvr/s1600/20180120_174314.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1194" data-original-width="714" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYbGKmZVp2YdgCDTAmsTIc3qkB0aYIqXov0FHrRvqb8nLQH415Gi1lQSH50jz5V5jNmClzQJWALcmenZGBZav-qbSV6Q3A6V83A3MVCRiYAcqeJcuB5otJ5ykNlvYGW68Vkj6Gy9tWiBvr/s320/20180120_174314.jpg" width="191" /></a></div>
Later, these will get tapped to a 1/8" NPT thread.<br />
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<u>E. Dead End Plug</u> - Here is one of the dead end plugs getting the hydraulic oil port cut into the inside end. Later, there will be 3 radial holes drilled into the dead end plug - one of them will connect to this drilled hole to make the oil passage:<br />
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Here are the 3 sets of dead end plugs after the O ring grooves were cut and before beginning the machining of rounded tabs:<br />
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Also, before beginning the machining to form the rounded tabs on these parts, I drilled the 3 radial holes that are 120 deg apart. Here's that setup:<br />
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Here are all the parts of one set of actuators with the parts placed in their relative positions:<br />
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In the picture above you can see a sample of what this dead end will eventually be on the right side there in between the two dead ends that are still not complete. These were actually the most difficult of all the actuator parts to fabricate.<br />
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This rounded tab is formed by removing a fair amount of material from each side of the round rod to make a flat, square tab. Then, the tab gets rounded off and a bore (with a counter bore) gets put into the tab. This bore is to make a pocket to press the spherical bearing into that makes the attachment point for the actuators. Here is a partially finished live end next to the inventory sample I had on hand:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizwfpHtJdZaRojXRvqgg7qjkT43vzXgkle7ZfYcpS5-5TBdVFpfFizkzqzibHdQys0OQ0bRAl1Ap9-Jrrwvf8WR6dKpjptY9Ha_hEQPd_lw8wu03DRNaooCTSA6RwKQrKdr56bvolO1h-W/s1600/20180212_181716.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="676" data-original-width="853" height="253" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizwfpHtJdZaRojXRvqgg7qjkT43vzXgkle7ZfYcpS5-5TBdVFpfFizkzqzibHdQys0OQ0bRAl1Ap9-Jrrwvf8WR6dKpjptY9Ha_hEQPd_lw8wu03DRNaooCTSA6RwKQrKdr56bvolO1h-W/s320/20180212_181716.jpg" width="320" /></a></div>
To make this rounded tab, the first thing I had to do was figure out how to hold the parts during machining. I decided to use a section of the same tube that the actuator cylinders are made from. Next, I found a piece of square tubing that I was able to just press the round tube inside of. Then, I welded it in place and cut a slot 1/2 way thru the assembly (lengthwise). I welded a 3/8" nuts on top of the slot one each side and welded 5/16" nuts under the slots. With a 5/16" bolt thru this, it forms a clamp to hold the part. Additionally, the square tubing on the outside provides for a quick, convenient way to turn the assembly 90 deg to do the 2nd and 3rd operations to form the rounded tab. Here is the assembly during fabrication:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg2RWz660CCKK6uvig1CyyKmuHmY20J3Qdv_h-EEtpLhAU_2J2DVWJHLyqR16B2uVL8u2SJAGmCvFarx71Yxkmuo26RKJu4UWVK0Rz0k2YuReXSYH9EHydlhrrkGsaONxPKsMOMc5-Lm8_B/s1600/20180214_144859.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="643" data-original-width="988" height="208" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg2RWz660CCKK6uvig1CyyKmuHmY20J3Qdv_h-EEtpLhAU_2J2DVWJHLyqR16B2uVL8u2SJAGmCvFarx71Yxkmuo26RKJu4UWVK0Rz0k2YuReXSYH9EHydlhrrkGsaONxPKsMOMc5-Lm8_B/s320/20180214_144859.jpg" width="320" /></a></div>
The 3rd bolt mounted on the top of the fixture is to provide for a means to position the part correctly in the fixture. The 3/8" bolt has the threads on the end turned down to the precise correct side so that it just slips into one of the (as yet) unthreaded holes. This holds the part in the same orientation if taken out and put back in, and it also help to prevent the part from slipping inside the round tube. Here is the fixture mounted in the vise on the mill table:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-sc5I2_kjKBkYZP7HfVVfpLTtsaaXayagVG0piIQHWmomhNYzsiLyWSHq9IqkKqYvkg1FK8L5DCwXp3XQBCsTINio2sXTejyeQtWNPbPNnmkF07sjqU2NOVlOnH7tedS-l9ImkhUJEtzI/s1600/20180214_150110.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="647" data-original-width="1214" height="170" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-sc5I2_kjKBkYZP7HfVVfpLTtsaaXayagVG0piIQHWmomhNYzsiLyWSHq9IqkKqYvkg1FK8L5DCwXp3XQBCsTINio2sXTejyeQtWNPbPNnmkF07sjqU2NOVlOnH7tedS-l9ImkhUJEtzI/s320/20180214_150110.jpg" width="320" /></a></div>
And, tightening down the bolts to clamp the part in place:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiu7_mXUhW0LS7_iUZ3nUQ9ySb2hfAfHLrVBtcS1ex_LQTTjX5uJK7jDmzqPYatV2oJevpngINe8B7DwUyOZBudUjRyuh70ZzLRJi60p0lZp76AeJrnatAGhCAtZoIhVeDvllWjKlQUoB83/s1600/20180214_150147.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="662" data-original-width="1036" height="204" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiu7_mXUhW0LS7_iUZ3nUQ9ySb2hfAfHLrVBtcS1ex_LQTTjX5uJK7jDmzqPYatV2oJevpngINe8B7DwUyOZBudUjRyuh70ZzLRJi60p0lZp76AeJrnatAGhCAtZoIhVeDvllWjKlQUoB83/s320/20180214_150147.jpg" width="320" /></a></div>
Here, one of the dead ends has just had the flat, square tab formed on the end of the part: <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1Ay6UMBcNTYE9TTBnDi9n2VFUeSd6d1qm15W33ChlYTOxc9fu8LNVuNvPc7VXxalXUZVuv61OgU-RRN8Nyqye3yplhETdD8RKB8ilILMGsBcLog4WCtKVDDtxMJuGjS5Jt5ZSwL7ILiPf/s1600/20180215_152958.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="585" data-original-width="1062" height="176" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1Ay6UMBcNTYE9TTBnDi9n2VFUeSd6d1qm15W33ChlYTOxc9fu8LNVuNvPc7VXxalXUZVuv61OgU-RRN8Nyqye3yplhETdD8RKB8ilILMGsBcLog4WCtKVDDtxMJuGjS5Jt5ZSwL7ILiPf/s320/20180215_152958.jpg" width="320" /></a></div>
Here is the dead end after the flat, square tab has been formed:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgU9t-7DLDh29Y6bNOY00pj5o9xWxJp_K9ZRqBde_TLMRPEeAm_sBTDKz8uZx0c_hhw2nG-XHtfQEZKHjMI8WvAc9mVjYAK9KHXqoICU2FgfHfojHfellV8xkTxRZiTpNt54lXnzPET-bV3/s1600/20180215_155742.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="753" data-original-width="449" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgU9t-7DLDh29Y6bNOY00pj5o9xWxJp_K9ZRqBde_TLMRPEeAm_sBTDKz8uZx0c_hhw2nG-XHtfQEZKHjMI8WvAc9mVjYAK9KHXqoICU2FgfHfojHfellV8xkTxRZiTpNt54lXnzPET-bV3/s320/20180215_155742.jpg" width="190" /></a></div>
Here is the dead end after the tab has been rounded off, and the bearing pocket is being formed (notice the fixture has been turned 90 deg and the bolt heads are now facing the front of the mill):<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEip1l1YwpbGkwsFvK5inbTYMTqp7tzc6GMjssEvj2LpaXEP58GB9j5-8_7AWYoTfSxXmS5M1j_jEAtOhsGRrMR9Q4OUEenwmIDq18KEjHViRiBeXLCyl4_92eVX3SVzwe9OiAZ46LMYEOKl/s1600/20180224_081025.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1143" data-original-width="643" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEip1l1YwpbGkwsFvK5inbTYMTqp7tzc6GMjssEvj2LpaXEP58GB9j5-8_7AWYoTfSxXmS5M1j_jEAtOhsGRrMR9Q4OUEenwmIDq18KEjHViRiBeXLCyl4_92eVX3SVzwe9OiAZ46LMYEOKl/s320/20180224_081025.jpg" width="180" /></a></div>
Here is a dead end plug after fabrication and getting de-burred:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhh3vCMxuV0YsuTFlzevxM-AplqhiNu_OC-jNTHypPztsHfkOJ-3aQPjjNtQMa5GE5vBkTM8mWllBKWoDGficyEpoG9y8nqhc1H3tYhDoRphFnka2s8AMHYqkmqs-X__ZjqZMfCFyDDzfeD/s1600/20180224_084344.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="837" data-original-width="508" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhh3vCMxuV0YsuTFlzevxM-AplqhiNu_OC-jNTHypPztsHfkOJ-3aQPjjNtQMa5GE5vBkTM8mWllBKWoDGficyEpoG9y8nqhc1H3tYhDoRphFnka2s8AMHYqkmqs-X__ZjqZMfCFyDDzfeD/s320/20180224_084344.jpg" width="193" /></a></div>
Here is one of the bearing that gets pressed into the bearing pocket on the dead end tab:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEguoPbJvpTnpTOfWYlzzlfgdEfIK1KidAZHqwqw6ZLwucFDkLA22j-jmgOHAUm330Kf09U32xXgQSjM_r8JvT59kb68Xofi7VIbhBwJIOj_0PyhODJSkDYa8zHCPZY6PhqctqWLH2wg2xdp/s1600/20180224_084609.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="609" data-original-width="676" height="288" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEguoPbJvpTnpTOfWYlzzlfgdEfIK1KidAZHqwqw6ZLwucFDkLA22j-jmgOHAUm330Kf09U32xXgQSjM_r8JvT59kb68Xofi7VIbhBwJIOj_0PyhODJSkDYa8zHCPZY6PhqctqWLH2wg2xdp/s320/20180224_084609.jpg" width="320" /></a></div>
Here is one set of the dead ends with the bearings pressed into place:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj69hNm0AHJms4UIVpl7_rcuvSV8l01Z1tCE1uvays21Mtf8iiZRFBgP7GN1KRYhnFsQMl_3qWiJoOv1pC96Dy2MsDG0MglfV0XbeQK5zLs54qFoOzzkONlgKe2EFQA1nT-qfv99YqyOf9j/s1600/20180223_202617.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="626" data-original-width="681" height="294" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj69hNm0AHJms4UIVpl7_rcuvSV8l01Z1tCE1uvays21Mtf8iiZRFBgP7GN1KRYhnFsQMl_3qWiJoOv1pC96Dy2MsDG0MglfV0XbeQK5zLs54qFoOzzkONlgKe2EFQA1nT-qfv99YqyOf9j/s320/20180223_202617.jpg" width="320" /></a></div>
At this point, the only thing that needs to be done is to figure out a way to keep the bearings from backing out of the pockets. There is a formal process for this, known as "staking" a bearing. There are many ways to stake a bearing - the simplest is to just use a punch and pound divots around the edge of the pocket. While this will work, it can come out looking a little non-uniform and inconsistent.<br />
<br />
I thought about it a while and decided to make a tool to use bearing balls to press divots into the material around the bearing pocket. I envisioned a pin that would go down through the bearing and have that position 4 bearing balls in the correct place. Then, I could put it in the arbor press and stake the bearing. Here is the tool I made:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFTNk-paXTkQekOUhlEsFsk-Pp7Nn9GOnsGLgKHeHEFNOVtoBLeLcppCYCC-glx_QJ8biLkaFCfZLIx4FbOxEvf2gM97odeSGCGRpcTRIg9nSqyK4uBn00O1vRcFPqHIHxBiqbpi4o03XI/s1600/20180222_172908.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="546" data-original-width="924" height="189" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFTNk-paXTkQekOUhlEsFsk-Pp7Nn9GOnsGLgKHeHEFNOVtoBLeLcppCYCC-glx_QJ8biLkaFCfZLIx4FbOxEvf2gM97odeSGCGRpcTRIg9nSqyK4uBn00O1vRcFPqHIHxBiqbpi4o03XI/s320/20180222_172908.jpg" width="320" /></a></div>
This is how it works:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKwQiBj4zi46LIY-FndPD7bgCZILGExomATtF6_TnYP8UEKTtcSB5rwpSTvKxumkOJxB5ZOrZhaHteCYWip1e3HgDrp2OmHUBBCKDgckS7RnCH1yhcDrdr426HPhwSSnZZR3llesM6b9w5/s1600/20180222_173140.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="541" data-original-width="785" height="220" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKwQiBj4zi46LIY-FndPD7bgCZILGExomATtF6_TnYP8UEKTtcSB5rwpSTvKxumkOJxB5ZOrZhaHteCYWip1e3HgDrp2OmHUBBCKDgckS7RnCH1yhcDrdr426HPhwSSnZZR3llesM6b9w5/s320/20180222_173140.jpg" width="320" /></a></div>
After pressing in the hydraulic press, this is how the dead ends looks after the bearings are staked:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitPF_jQ8lMBaqOfXUqxH5S3a4TfwgnrOCSPTHU9y3vFSQdj15wOUs08qDYoaUY7x_XMmHSkOCf65uvuIvegqK8pExL2l9OrRFJ8ugZQBnTplCaCuI1FtweLnYiP83ScFJy6BPbJTL7adbM/s1600/20180224_111325.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="734" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitPF_jQ8lMBaqOfXUqxH5S3a4TfwgnrOCSPTHU9y3vFSQdj15wOUs08qDYoaUY7x_XMmHSkOCf65uvuIvegqK8pExL2l9OrRFJ8ugZQBnTplCaCuI1FtweLnYiP83ScFJy6BPbJTL7adbM/s320/20180224_111325.jpg" width="310" /></a></div>
Overall, the appearance is good and the bearing is secure. By using only 4 stake points, I reasoned that "if" the bearing ever needed to be removed, or replaced, you could press the old bearing out, re-bore the hole and put a new bearing in. Then, the bearing could be re-staked with the bearing balls turned 45 deg to fall in between the existing staking divots.<br />
The last remaining task was to tap all the plug holes to 1/8" NPT. Here is a live end in the drill press getting the tap started. I used a "<a href="http://www.eagleamerica.com/product/448-5990/woodboring_-_brad_point_sets" target="_blank">Center-It</a>" to place the part under the drill press chuck. <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEib5LW71q0z2x_kLJmjBcLRLN3uyoU8rOBno_iMk8gtVggvaBPIYbajSL891mN6pFG-nSz8STC4YZHW7e5EWUgYJ5zY1DWEa87x_s58jgpgfMnuXSR7zv1KlsrfkPU7JkStXBbDdZEHzrgc/s1600/20180224_153620.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1107" data-original-width="643" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEib5LW71q0z2x_kLJmjBcLRLN3uyoU8rOBno_iMk8gtVggvaBPIYbajSL891mN6pFG-nSz8STC4YZHW7e5EWUgYJ5zY1DWEa87x_s58jgpgfMnuXSR7zv1KlsrfkPU7JkStXBbDdZEHzrgc/s320/20180224_153620.jpg" width="185" /></a></div>
Then, I hold pressure down on the drill press spindle while turning the
spindle by hand. This gets the tap started in the hole straight and square:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjoje2O0l1bR_Fs7gSnOGNeBJQdiRY_TrZcAl5v9XXJ8zrUneyPtFE-RfKCoT1VK3NT3kPXf68dZyl3fQOvewdP7K1wOt61uQhH45ABTIb17IEeS0m3-mRUZSxp8HVYwI5BQAx2mPimFJqz/s1600/20180224_153702.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1010" data-original-width="643" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjoje2O0l1bR_Fs7gSnOGNeBJQdiRY_TrZcAl5v9XXJ8zrUneyPtFE-RfKCoT1VK3NT3kPXf68dZyl3fQOvewdP7K1wOt61uQhH45ABTIb17IEeS0m3-mRUZSxp8HVYwI5BQAx2mPimFJqz/s320/20180224_153702.jpg" width="203" /></a></div>
Once I have 3-4 threads started, I take the part to the workbench vise and finish tapping the hole by hand:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhBAWInPbsQxHVhWFcD3M1kwQGHJXVLSNG_NK91tQPx1RWo6mA80Eq1Vv-WPXRGUGeTiHvYMJcZMWjNNAZAFu3mmdYMxN7t_lWt9Dkrv7SJS_NIvU8Wn-bnBZNI_BTeWI7bjeY8EMUR6ghf/s1600/20180224_155526.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="715" data-original-width="856" height="267" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhBAWInPbsQxHVhWFcD3M1kwQGHJXVLSNG_NK91tQPx1RWo6mA80Eq1Vv-WPXRGUGeTiHvYMJcZMWjNNAZAFu3mmdYMxN7t_lWt9Dkrv7SJS_NIvU8Wn-bnBZNI_BTeWI7bjeY8EMUR6ghf/s320/20180224_155526.jpg" width="320" /></a></div>
Finally, here is one set of actuators cleaned up, painted and assembled (except for the 1/8" NPT pipe plugs and hydraulic line fitting) :<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5x7X6cienrP8eTV2fFSAHXQKiVrt2QLmn7ihnT8nXwhArB_2IIvLK5RGZTS6LuRKfOvCz6y6_8QcgY7tJv7z5wzZ_ZGr5bRZBPR4gjx_cvfRrzyfcNKAXQdapPOC9PCSTgfkMtogludht/s1600/20180224_184219.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="464" data-original-width="1600" height="92" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5x7X6cienrP8eTV2fFSAHXQKiVrt2QLmn7ihnT8nXwhArB_2IIvLK5RGZTS6LuRKfOvCz6y6_8QcgY7tJv7z5wzZ_ZGr5bRZBPR4gjx_cvfRrzyfcNKAXQdapPOC9PCSTgfkMtogludht/s320/20180224_184219.jpg" width="320" /></a></div>
That is one more set of parts to take off the "To-Do" list for kit #18. For a good view of where and how these actuators work, see Ray's Builder Update in Section 4, below.<br />
<br />
<br />
<u><b>2. Another Fix To The MotionMaster -</b></u> After all the lathe work to make the hydraulic actuators, I decided to mix it up and get some router work done with the MotionMaster to fabricate some long channel parts for kit #18. The day came to put some aluminum on the table and fire up the machine - and when I went to push the button......there was no "fire." What-the-heck, now!?!? I pulled the cover off the rotary phase converter and found this:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfREi9-0UbceYWj8_ef1QoNPMNo3tFUFBNvHX-gmtZF12gPP3CsUKY2B6acdqHFSSoOaqKiXS6F-Dm09wn8WKjJhMvXTUh4iBs4IJznMMLU78UIYnj6sb8o7MFa4oURlfapI_GGldJVBsC/s1600/20171229_141544.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1115" data-original-width="681" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfREi9-0UbceYWj8_ef1QoNPMNo3tFUFBNvHX-gmtZF12gPP3CsUKY2B6acdqHFSSoOaqKiXS6F-Dm09wn8WKjJhMvXTUh4iBs4IJznMMLU78UIYnj6sb8o7MFa4oURlfapI_GGldJVBsC/s320/20171229_141544.jpg" width="195" /></a></div>
It might not be easy to see in the above pic, but the main power relay on the upper left is hanging by the wires. Here (below) is the place where the relay is supposed to be - the main mounting plate and the 4 "legs" are still mounted there, but the relay body is broken off:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1D8h2nZYcem9_sXoNy9yYLZeNmixnCrpjYsg2BzpusYh0Rh37q2JIHjRppumsFlursMYnuDrbu9WeLJ_gluFk0UjNFSCB7h5jtrCYFpeqil6zbavCoBDrPApKVJsvIckM2Ulwzm4mLqdS/s1600/20171229_142426.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1051" data-original-width="661" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1D8h2nZYcem9_sXoNy9yYLZeNmixnCrpjYsg2BzpusYh0Rh37q2JIHjRppumsFlursMYnuDrbu9WeLJ_gluFk0UjNFSCB7h5jtrCYFpeqil6zbavCoBDrPApKVJsvIckM2Ulwzm4mLqdS/s320/20171229_142426.jpg" width="201" /></a></div>
Here is the back of the main relay. You can see the 3 of the 4 points where the "legs" broke off.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGisu_JyaY10JbkOKrnRwa2K0k1U57TAB4D_oL_fd01Hr9fw7rQV3stzt_vfF-azJtPjAVK_CvaRVYBqfEbKSGYqCkKUNADH9Qs_XtQ7Ii-NHl9Oewj0i_-J_0j2rw2FaCqNfhkvhX2quv/s1600/20171229_142428.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1175" data-original-width="685" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGisu_JyaY10JbkOKrnRwa2K0k1U57TAB4D_oL_fd01Hr9fw7rQV3stzt_vfF-azJtPjAVK_CvaRVYBqfEbKSGYqCkKUNADH9Qs_XtQ7Ii-NHl9Oewj0i_-J_0j2rw2FaCqNfhkvhX2quv/s320/20171229_142428.jpg" width="186" /></a></div>
After I got it all apart, I remembered that this part was originally damaged when it was shipped to me when I was building the 25HP rotary phase converter. During shipping, the jarring knocked a couple capacitors loose inside the box. Then, those rattled around a broke more components - like the main power relay. At that time, I just wanted to get the rotary phase converter built and running - so, instead of taking the time to send the part back for a replacement I just "Krazy Glued" the legs back onto the relay. Well, the Krazy Glue held for quite a while, but let go sometime during the 3 years that I hadn't used the machine.<br />
A little more thorough repair was in order now. I "Krazy Glued" the legs back on again, but this time I ruffed up the plastic with a Dremel tool all around the breaks:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEij7rSmyQQfjCCw5lrCJ6LO0I29C2cCFfLcy9hqI-m_lRdr3xcETq9K0mCnhnbFSpIBk6pXKpnmDL6yKyCOkGA0ELuLHrs-ZdSOIovJDmzsbAKMi-qStLiqNvmrkJmU61V_jie_x4asNUEH/s1600/20171229_145013.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="928" data-original-width="710" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEij7rSmyQQfjCCw5lrCJ6LO0I29C2cCFfLcy9hqI-m_lRdr3xcETq9K0mCnhnbFSpIBk6pXKpnmDL6yKyCOkGA0ELuLHrs-ZdSOIovJDmzsbAKMi-qStLiqNvmrkJmU61V_jie_x4asNUEH/s320/20171229_145013.jpg" width="244" /></a></div>
With the legs all ruffed up, it looked like this:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIkkTCQsY0aRyWraxcODB69uCfzdSvIqQdHKp8fr3vxsZqjQNyq7Ql4UK1dPXs0mb4_xTrlq-bVBcwNvyJonD7wMkE3SjMQJS_f91iKbTpsPzwohdKGdYJ5In9ZGYQO2lthxMH1z7i2d1E/s1600/20171229_145212.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="767" data-original-width="725" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIkkTCQsY0aRyWraxcODB69uCfzdSvIqQdHKp8fr3vxsZqjQNyq7Ql4UK1dPXs0mb4_xTrlq-bVBcwNvyJonD7wMkE3SjMQJS_f91iKbTpsPzwohdKGdYJ5In9ZGYQO2lthxMH1z7i2d1E/s320/20171229_145212.jpg" width="302" /></a></div>
Then, I slathered on a layer of JB Weld onto the ruffed up areas to help reinforce the Krazy Glue repairs. This should help the joint stay stable and not break again:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzOIXZ9qW65HZVWX2VXHxfMuWglORVvw4uBtHXG7AR6WpdktTwnpyBMOp204o7KlsfiWgrD8kbgCo1hRFAIZFgerWQZBs3e1DAsgjrck9ebc5xIHK6FJNeE7GbE3qisqO7ikI48QEAX5l9/s1600/20171229_151813.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="711" data-original-width="709" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzOIXZ9qW65HZVWX2VXHxfMuWglORVvw4uBtHXG7AR6WpdktTwnpyBMOp204o7KlsfiWgrD8kbgCo1hRFAIZFgerWQZBs3e1DAsgjrck9ebc5xIHK6FJNeE7GbE3qisqO7ikI48QEAX5l9/s320/20171229_151813.jpg" width="319" /></a></div>
After the repair cured, I put it all back together and got the machine running. Here is the machine trimming a sheet of aluminum:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYo8I1HRneEZfD1Ej1WJU9XnNQMDfR0qsTrKdJZhxqs5KekpldJX-xhtSD_TDOuqRV6YdtJWJzm5RQF9z9Q_Q4lgNtbBSgeQDkCsX5qhuoHht59ea7Wh6IP3lLEKJKjibLuqavo3lxtXui/s1600/20171231_145524.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="854" data-original-width="1570" height="174" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYo8I1HRneEZfD1Ej1WJU9XnNQMDfR0qsTrKdJZhxqs5KekpldJX-xhtSD_TDOuqRV6YdtJWJzm5RQF9z9Q_Q4lgNtbBSgeQDkCsX5qhuoHht59ea7Wh6IP3lLEKJKjibLuqavo3lxtXui/s320/20171231_145524.jpg" width="320" /></a></div>
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<u><b>3. Fabricating Long Aluminum Channels</b></u> - Kit #18 needs several long aluminum channels fabricated for it. I needed to make some 2024-T3 (.032" thick) to make the longeron covers for the cockpit. I also needed to fabricate the (0.040") outboard wing trailing edge hinge support channels for the kit. And, lastly, the kit needed a set of five 2" channels (0.040") that make up the upper and lower mid-framing longerons.<br />
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To start this project, I cut up part of a sheet of 0.032" Al for the cockpit longeron covers, and an entire 4' x 8' sheet of 0.040" aluminum into strips the correct width to make the various 2" channels. Here's the MotionMonster cutting the 0.040" strips:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjoJ6UK01dxI9LfD8oa4FpzEsARghTUHiJt7Z1Olk5Ndt7FCSC4Cvhwme5wDQdk1C3LPtRBHd4_km6gEmK4KqIc7DE6IDiwAw5XRtiNDDYsXYBVWAgXiUpfUR7zaEUDQs6yUVOpqg91bYeq/s1600/20171231_182612.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="735" data-original-width="1306" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjoJ6UK01dxI9LfD8oa4FpzEsARghTUHiJt7Z1Olk5Ndt7FCSC4Cvhwme5wDQdk1C3LPtRBHd4_km6gEmK4KqIc7DE6IDiwAw5XRtiNDDYsXYBVWAgXiUpfUR7zaEUDQs6yUVOpqg91bYeq/s320/20171231_182612.jpg" width="320" /></a></div>
Once I got the strips cut and deburred the edges, I hauled out the 8' press brake and got re-acquainted with it. It's probably been 3-4 years since I used it to bend any long channels. I think the last time I used the press brake was when I formed the outer wing spar channels and the main center spar skin flanges. That was years ago, already!<br />
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Anyway, here is one of the outer wing trailing edge hinge support angles being formed in the press brake. It's hard to see because the camera didn't focus on the close end of the part (look just up from the bolt head in the middle left side of the picture and you'll see the fuzzy looking end of the part being formed): <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhicCklkspVj7xrATiYco3mFXCTHP_eo5iW4HHP0L06f12VkL8I0aNR_qY_1EPBiFeHvqWOwroXHMJ8ArN8ZWmdFZWa2nn62GAX2eMfdXpirDZj_OQDMVG6VLbvJfrhhHDLb-Q0U1iai1bC/s1600/20180102_115252.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="911" data-original-width="706" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhicCklkspVj7xrATiYco3mFXCTHP_eo5iW4HHP0L06f12VkL8I0aNR_qY_1EPBiFeHvqWOwroXHMJ8ArN8ZWmdFZWa2nn62GAX2eMfdXpirDZj_OQDMVG6VLbvJfrhhHDLb-Q0U1iai1bC/s320/20180102_115252.jpg" width="247" /></a></div>
This part is nearly 8' long and has a 48 deg flange formed on each side - and at the same time the part is tapered in width along the entire length (this picture below has the narrow end in the foreground):<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKqFlTwOLELbmIbpSyL3LqScNiQZpLnLmjdbLHsbiuHjgRP5UMXvMbKSWpnhi428Xd545WUNkisrCwHFMPgrGM1RkGXOiXF7QuBBF6Jbm4nRX2KjNyEOcXTJrfjm_5FA_gMY5EiR8FPvgU/s1600/20180102_100716.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="982" data-original-width="570" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKqFlTwOLELbmIbpSyL3LqScNiQZpLnLmjdbLHsbiuHjgRP5UMXvMbKSWpnhi428Xd545WUNkisrCwHFMPgrGM1RkGXOiXF7QuBBF6Jbm4nRX2KjNyEOcXTJrfjm_5FA_gMY5EiR8FPvgU/s320/20180102_100716.jpg" width="185" /></a></div>
Here are the same completed parts with the wide end closest to the camera:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMKk_KLw7khg7jUHtpdyXUHE8Q9AfkBIL9DIXGIC_wObjwrG1Dp-Bh2xeepe9xPvgsPT7YI4s5ZdGWgOgzTtATauKpAtniUbdNFgR94JLsoBzdEyYHNZ6RHUgTsDazpQOAwrB5bc-7D861/s1600/20180102_100742.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="819" data-original-width="723" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMKk_KLw7khg7jUHtpdyXUHE8Q9AfkBIL9DIXGIC_wObjwrG1Dp-Bh2xeepe9xPvgsPT7YI4s5ZdGWgOgzTtATauKpAtniUbdNFgR94JLsoBzdEyYHNZ6RHUgTsDazpQOAwrB5bc-7D861/s320/20180102_100742.jpg" width="282" /></a></div>
These hinge supports were a little tricky to make accurately in the press. I figured out the best way to form them and wrote it all down in my book of secret tricks for next time!<br />
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After forming the hinge supports, I went on and formed the 2" channels for the longerons and the longeron covers. I've made a few sets of these in the past, but it still took a few practice runs to get them right. Once again, I (re)figured out the best way to form them in the press brake and wrote my notes in my book Prowler building secrets for next time. Here are all five of the longerons for Kit #18 on the left, and the cockpit longeron covers on the right side:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7jiGFy7WHd6gVBWT6_ub_RYJgdg8IBIIAIrCfjQZH8iJ5rUNlMHLfaXzEjZhpvatPAnv3SiuZtslibXIC4C0D2hw_HVy79yvVLjuw2r_3OO4Iy668NK4DuiOYw7izOTyWmC1wxzOl1SOX/s1600/20180414_182605.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1390" data-original-width="476" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7jiGFy7WHd6gVBWT6_ub_RYJgdg8IBIIAIrCfjQZH8iJ5rUNlMHLfaXzEjZhpvatPAnv3SiuZtslibXIC4C0D2hw_HVy79yvVLjuw2r_3OO4Iy668NK4DuiOYw7izOTyWmC1wxzOl1SOX/s320/20180414_182605.jpg" width="109" /></a></div>
Here is a closer pic of the ends of the 5 longeron channels. The press brake that I build with Dad all those years ago is a little tricky to use sometimes, but it is still the best tool for the job. It makes these long 2" channels nice and straight with a uniform bend angle:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvbtxKhV2dZuYaChomhBnRyusOIWoZRwLxRO8V9Xi0dAM2coN-h5qG4vuZIwTh5fo8ZDrF-19g_Ndo7wvLTqmiDGPbnCcYMT8NfcrG3ZhLwEUBF6FLELrcrXEXYCnnmCL1EVSfO07mevxg/s1600/20180414_182646.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="712" data-original-width="1190" height="191" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvbtxKhV2dZuYaChomhBnRyusOIWoZRwLxRO8V9Xi0dAM2coN-h5qG4vuZIwTh5fo8ZDrF-19g_Ndo7wvLTqmiDGPbnCcYMT8NfcrG3ZhLwEUBF6FLELrcrXEXYCnnmCL1EVSfO07mevxg/s320/20180414_182646.jpg" width="320" /></a></div>
In the interest of full disclosure, I cut up several (OK, many) strips of the 0.040" that were too narrow (I did a mental math error entering numbers into the CNC control - UGH!). So I had to look through my parts lists and find out how many parts there were that could be made from narrow strips of 0.040" 2024-T3. I ended up making lots of parts to put in inventory to used up that material. Here is one example:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4h3VRcq-yjfZfL8ITOj8cpZwStDmRAwkcpEEE6Nhyphenhyphenl15zB2lG_K_b3i2Tf5kydlTc9VvkWbCJ4L3idBerEVBSpik1XAqdNzoUsu8nNg2IEx_vpgsqf5zlieUPfYiz-yPwWNaC_MwUY3TM/s1600/20180107_085832.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="352" data-original-width="1552" height="72" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4h3VRcq-yjfZfL8ITOj8cpZwStDmRAwkcpEEE6Nhyphenhyphenl15zB2lG_K_b3i2Tf5kydlTc9VvkWbCJ4L3idBerEVBSpik1XAqdNzoUsu8nNg2IEx_vpgsqf5zlieUPfYiz-yPwWNaC_MwUY3TM/s320/20180107_085832.jpg" width="320" /></a></div>
They are the inboard and outboard flap angle clips that form the leading edge corners of those flap segments. These go in the corners where the flap spars meet the end ribs. So, in the end, I was able to recover gracefully from this goof - but, I hate it when I do stuff like that! <br />
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<u><b>4. Builder Updates: </b></u> <br />
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<u>A. Bud Is Flying Again! Yay!</u> - Ray & I got a quick email from Bud on March 9th to let us know that he got his Prowler flying again. In his own words:<br />
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<span style="color: #20124d;"><span style="background-color: #f4cccc;"><span style="font-family: "verdana" , sans-serif;">After a year and a half of frustration and expense, and with a lot of help from the Prowler-ites, Jaguar 12BT took to the air today. With a couple of small issues, the flight went well and I am ecstatic to have her flying again.</span></span></span><br />
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<span style="color: #20124d;"><span style="background-color: #f4cccc;"><span style="font-family: "verdana" , sans-serif;">Today’s flight was, primarily, to seat the piston rings. During ground run, the EGTs were all over the board with #6 being 200 deg less the next higher EGT. A compression check revealed air blowing by the rings and out the breather. Ground running at 2400 RPM overheated the coolant temperature within :05. The only answer was to fly.</span></span></span></div>
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<span style="color: #20124d;"><span style="background-color: #f4cccc;"><span style="font-family: "verdana" , sans-serif;">During TO, the airplane accelerated a bit faster than I remembered and required more aggressive right rudder than before. Within :10, the engine ran smoother and all the EGTs were within +/- 30 deg of each other.</span></span></span><br />
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<span style="color: #20124d;"><span style="background-color: #f4cccc;"><span style="font-family: "verdana" , sans-serif;">Bud</span></span></span></div>
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Here's a little more background info on this. Bud's Prowler suffered a PSRU failure nearly two years ago that took the airplane out of service. The pinion gear that George employed was a 2 piece design. This design was susceptible to a fatigue mode failure that fractured off a part of the gear inner bore shoulder and sent it bouncing around inside the PSRU. After analyzing this failure, Ray & I (with input from all the Prowler owners & builders that have George's gearbox) set out to design and procure new one-piece pinion gears for all the current owner/builders. It took a while, but we eventually got the new gears. <br />
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This failure also badly damaged Bud's crankshaft (splines). Bud did a huge amount of research and thorough search for a machine shop that could repair his crankshaft and simultaneously mate the new PSRU pinion gear to it. To date, Bud, Ray and Ernest have installed the new gear into their PSRUs. However, Bud was the 1st to fly with the new pinion gear. Congratulations, Bud!! Very impressive work! Thanks for sharing your great news.</div>
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<u> B. Ernest Is Ready To Go (2nd First Flight) </u>- I got a call from EZ last week. He's all ready to get his Prowler in the air again - just waiting on the paperwork. This will be his first flight in his Prowler since doing extensive work on the airplane, including changing out his PSRU pinion gear (mentioned above). Here is a recent pic he sent me on Apr 9th with the associated text message => "Snarlin'! Aaahhh.....paperwork! The bain!":<br />
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It looks awesome, EZ! Looking forward to seeing the airplane take off again, soon. We are trying to coordinate time off of work so that I can jumpseat up to SEA and join him when he does this flight. I hope that I can be there to photo and video document the flight.<br />
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On a separate note, one of the mods that EZ did to the plane was to add the same oil spray line to the PSRU that shoots a small stream of engine oil down onto the bull gear. It's a system that Ray designed and installed on his plane that incorporates a NOX "pill" that nitrous guys use in race cars . After the install, EZ was seeing oil pressures drop to less than 20PSI when the oil was warm. He basically had the option to try a higher viscosity oil or replace the NOX pill with a pill that has a smaller orifice. He decided to try to oil first. Here's his report:<br />
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<span style="color: #20124d;"><span style="background-color: #f4cccc;"><span style="font-family: "verdana" , sans-serif;">Put the 10-50 with Moly oil in and the oil pressure problem is.........wait for it.....GONE!!! @ 190F oil temp and 1200 RPM, oil pressure is 32psi instead of 18! NICE!! Of course we have to wait until the 1st oil analysis results to know for sure that there is sufficient lubrication. But she’s all buttoned up and just waiting for the paperwork to go fly. Talk to ya soon. EZ</span></span></span></div>
</div>
<br />
So, for anyone that wants to install this oil spray system on their PSRU, this is good info. If you want more details on how Ray & EZ did this, let me know. I'll send you some info.<br />
<br />
Outstanding work, EZ! Hopefully, we can do this in the next few weeks. See ya soon!<br />
<br />
<br />
<u>C. Ray's Having MLG Problems</u> - The last time I was down to see Ray, we tried to cycle his gear. For some reason, the right MLG was catching on something and not going all the way into the gear well. Here's a video: <br />
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<iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dxKAcKC5-x2SOdPmgmW8jx_fwA4A4gKs60iIOvKyoVnTJb5SsJTxhRBYKdFGHnzLJz2eCSAi57Nj4I4wMz7Ow' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div>
After a little troubleshooting, we determined that the post on the end of the gear yoke that normally rides up and into the gear uplock was not hitting the mark. Instead, the post was hitting the wrong place on the uplock preventing the gear from going all the way into the well. This caused the sequence valve for the gear door to not get activated which kept the door open. The door remaining open prevents the pump from turning off.<br />
So, we figured out that all out. But, what we couldn't figure out was, why? Why was the gear post not lining up the same as before? Well, Ray did more investigation and has determined that something has happened in the torque box in the area of the pivot link. Somehow, something has worked loose or has otherwise failed and it has moved the gear strut out of its normal arc of travel. This drawing shows the area where Ray thinks the problem is:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFEyZnCdePTxOuLZS9djRgzX2U-Fibz7YQ6_78DAnNyR0zPG0v_9-2MGVWuljO463E76aegxlHpJcC7tQ8EJu1sZylb8r-R-8Ikfm0pL288vKVgrfzLEufbrFeVw7H_xC1Ty-ubqECG-iC/s1600/Torque+Box+Shaft+%2526+Pivot+Bracket+Assy_circle.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="693" data-original-width="999" height="221" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFEyZnCdePTxOuLZS9djRgzX2U-Fibz7YQ6_78DAnNyR0zPG0v_9-2MGVWuljO463E76aegxlHpJcC7tQ8EJu1sZylb8r-R-8Ikfm0pL288vKVgrfzLEufbrFeVw7H_xC1Ty-ubqECG-iC/s320/Torque+Box+Shaft+%2526+Pivot+Bracket+Assy_circle.jpg" width="320" /></a></div>
Fortunately, Ray put access panels in the torque boxes. But, unfortunately, he will have to cut access panels in the wing skins in order to gain access to this area and investigate further. Right now, he has other projects he is working on and needs to finish. Then, he'll get on this. I'll let you know what he finds. Stay tuned.<br />
<br />
BTW - here is a pic of Ray's right MLG well. This pic shows the shows the location and orientation of the MLG Hydraulic actuators that I discussed earlier in this update:
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwX0J19VTELAY19o0P0l4P1FyXy99Im4eQho2xQhsS4Iu7sydG7B95odBVn0NYDvJueDB1xeg6cMW_PNaHxpRYfzsdB1YqKSiMhTGcqTUhbyX7wThGDrxaDnCEZCFSwKp_jhqUUnbQJBI6/s1600/20180228_124629.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="827" data-original-width="1469" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwX0J19VTELAY19o0P0l4P1FyXy99Im4eQho2xQhsS4Iu7sydG7B95odBVn0NYDvJueDB1xeg6cMW_PNaHxpRYfzsdB1YqKSiMhTGcqTUhbyX7wThGDrxaDnCEZCFSwKp_jhqUUnbQJBI6/s320/20180228_124629.jpg" width="320" /></a></div>
While is was visiting Ray last, we dragged the airplane out of the hangar and Ray let me jump in and fire it up to run the engine for a while. Here's a pic from that day:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmFd5-QxxaQSHCYIYBKHkZNs8LOlKVhHdT9GydO8Q6l_TabGr7cCbIMqZwfs3d_4TGENKqV5ropNq5QzTQHQUS2JUQwMmojL623lPKPJptp0HfQ6PKQ9-ofAU3-SBZYnVyl98GljmmTj4i/s1600/20180228_142815.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="735" data-original-width="1306" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmFd5-QxxaQSHCYIYBKHkZNs8LOlKVhHdT9GydO8Q6l_TabGr7cCbIMqZwfs3d_4TGENKqV5ropNq5QzTQHQUS2JUQwMmojL623lPKPJptp0HfQ6PKQ9-ofAU3-SBZYnVyl98GljmmTj4i/s320/20180228_142815.jpg" width="320" /></a></div>
What a great looking airplane, and I really appreciate the engine run time, Ray! It sure sounds awesome! Can't wait for your 1st flight too!!<br />
<br />
<u>D. Francis Keeps Marching Along</u> - Francis is still chugging along on his project. He's sent me several pictures over the past 3 months. It looks like most of his work lately has been on the ailerons. This looks like a tool that he as made to set the stiffener rivets on the ailerons (and flaps, too):<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4SrSjwC0njudqwGodDNHa5cOGbA26Xyz9pkSBGDJj50BlBvOAsphdvhITFvZrUL5hrevYQslLAsh4PKPQjCSVhQdxpSFE4rvpk0ej2GTk24zL2YuwTsJ0sv9OocMUtnilcHwTzdkI-3Ji/s1600/20180203_175807.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="1210" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4SrSjwC0njudqwGodDNHa5cOGbA26Xyz9pkSBGDJj50BlBvOAsphdvhITFvZrUL5hrevYQslLAsh4PKPQjCSVhQdxpSFE4rvpk0ej2GTk24zL2YuwTsJ0sv9OocMUtnilcHwTzdkI-3Ji/s320/20180203_175807.jpg" width="320" /></a></div>
Here is some of his work on the aileron stiffeners:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihogVOPD04t6ND9H0YdvkEzzf4_YwC-vZUCnfkuI14MQL6bsnA7MubOrlhpFC2gzbWh8bvL9rlPZ8BrvUUb4eFFlChuZmgIUs0bLbUu4zVJGfyWWq1ATgE5hoLbyU768iv8O6CbrBIQ879/s1600/20180203_175839.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="1210" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihogVOPD04t6ND9H0YdvkEzzf4_YwC-vZUCnfkuI14MQL6bsnA7MubOrlhpFC2gzbWh8bvL9rlPZ8BrvUUb4eFFlChuZmgIUs0bLbUu4zVJGfyWWq1ATgE5hoLbyU768iv8O6CbrBIQ879/s320/20180203_175839.jpg" width="320" /></a></div>
The rivet set tool, at work:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIw9j3hIRI5u83GWKc6IKE_rKlXAYKAHf4KcJNFgyZyrViNGm5jGYQ44cHI7G1rKzoAAXhshbeRnuuixngRl-9ZcdJe1fmloVSaImY8bMZ-Cw7FIJ7m_VoquDj8e-QWzcCMWwIadvmqsr6/s1600/20180210_172758.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="1210" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIw9j3hIRI5u83GWKc6IKE_rKlXAYKAHf4KcJNFgyZyrViNGm5jGYQ44cHI7G1rKzoAAXhshbeRnuuixngRl-9ZcdJe1fmloVSaImY8bMZ-Cw7FIJ7m_VoquDj8e-QWzcCMWwIadvmqsr6/s320/20180210_172758.jpg" width="320" /></a></div>
More aileron work:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirWT6Pi_bqY3sQugz34ZjcDY-KYBERontltwhNB7uzhrceQpvAP1E7ccFHxfAdVSCf_AxM3Eotp1gU6wlYgLtBxVI2PSdRa4eYL4s2wiWCVxcH0y41AWXgctznrL9-mMtp4y_ifItt3Ozp/s1600/20180210_181047.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="1210" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirWT6Pi_bqY3sQugz34ZjcDY-KYBERontltwhNB7uzhrceQpvAP1E7ccFHxfAdVSCf_AxM3Eotp1gU6wlYgLtBxVI2PSdRa4eYL4s2wiWCVxcH0y41AWXgctznrL9-mMtp4y_ifItt3Ozp/s320/20180210_181047.jpg" width="320" /></a></div>
Installing the doubler around the aileron servo pocket:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEidD9EqD1ZzTntwhb4lmxejKkTf8YNVmIOlO4SBrASu_O3JDt0oAoVKxhWQO8ceDcQ7ZhoVaT3hw7tFfF5qoJt3GeV5_rYkzrlfW3seUz1Ryp8B5AeIH9BrOPS7m0FDwg7l-9Es4Pt0gTUL/s1600/20180225_181227.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="908" data-original-width="1210" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEidD9EqD1ZzTntwhb4lmxejKkTf8YNVmIOlO4SBrASu_O3JDt0oAoVKxhWQO8ceDcQ7ZhoVaT3hw7tFfF5qoJt3GeV5_rYkzrlfW3seUz1Ryp8B5AeIH9BrOPS7m0FDwg7l-9Es4Pt0gTUL/s320/20180225_181227.jpg" width="320" /></a></div>
One of the aileron spars with the actuator attach plate getting installed:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrBepd8xRk0oazygugV0cOKJRTYu1Dd5983tZOvSBaOOATTeVgrDYQ0VXHTBwpuOycyTjDvqf-CBzDoHn_OnRlUEF3_sKqE1XE-mKQxlyQcPA2qCcohpdcMBIHHisUe65JyKDobhZ7PBjg/s1600/20180225_181933.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="800" data-original-width="1152" height="222" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrBepd8xRk0oazygugV0cOKJRTYu1Dd5983tZOvSBaOOATTeVgrDYQ0VXHTBwpuOycyTjDvqf-CBzDoHn_OnRlUEF3_sKqE1XE-mKQxlyQcPA2qCcohpdcMBIHHisUe65JyKDobhZ7PBjg/s320/20180225_181933.jpg" width="320" /></a></div>
More overall aileron pics:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjofunJ7Wh3pGfb9ofEm1OQHQuJAyLn1cjgt57fJN4QXPsbOzSxgxnRxdfo1yvunWzC0zqKs9IErgyx5Yqd_1ZgYzHBhIwXn7wPCT4EFYlxv_agqAgZSf35-gRkZtlZZReJNWkjNqqdDQT_/s1600/20180303_190723.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="741" data-original-width="1204" height="196" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjofunJ7Wh3pGfb9ofEm1OQHQuJAyLn1cjgt57fJN4QXPsbOzSxgxnRxdfo1yvunWzC0zqKs9IErgyx5Yqd_1ZgYzHBhIwXn7wPCT4EFYlxv_agqAgZSf35-gRkZtlZZReJNWkjNqqdDQT_/s320/20180303_190723.jpg" width="320" /></a></div>
Note the rolled leading edge that closes the gap at the top, trailing edge of the wing skin:<br />
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Top skin of the aileron - notice the Prowler pics on the back wall - love it!!!<br />
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Keep up the excellent work, Francis! You are doing an excellent job. And, thank you for sharing your work with us. It is great to see your Frog Prowler accomplishments over there in Euro-land!<br />
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<u>E. Eric Is Working On Ailerons</u> - The only other builder update I have is that Eric emailed me asking for typical aileron deflection (angle) measurements for the airplane. With the help of Ray and Bryan, I got him some of those measurements for him. Later, he replied with this:<br />
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<span style="color: #20124d;"><span style="background-color: #f4cccc;">Thank you so much for this information everybody. (It) is same degree (angle measurements) on mine. I suppose I built correctly. Eric</span></span></div>
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Excellent! I'm happy to hear that your project is going well, Eric. Thank you. Please send a pic when you have time.<br />
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Well, that is all for this update. I started this update over a week ago! Finally, just now, getting it spell checked, grammar checked and published. I'll post at least one more blog update prior to AirVenture with details about the possible Prowler presence there this year! I hope everyone has a great spring. <br />
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<br />Unknownnoreply@blogger.com0tag:blogger.com,1999:blog-4561663675008429701.post-41903997030916575432017-12-29T13:58:00.000-08:002017-12-29T13:58:04.924-08:00Merry Christmas 2017 - Year End Wrap-up Merry Christmas Everyone!<br />
<br />
Wow - another year has blasted past us! Since my last update was just last month, I only have a few items/projects to report for Prowler Aviation on this update. Here's the list for this update:<br />
<br />
1. Prowler Motionmaster Fix<br />
2. Several Steel assemblies for Kit 18<br />
2.A. Neg G Stress Mount<br />
2.B. Engine Stress Mounts<br />
2.C. Tailwheel Upper Retract Yoke<br />
2.D. Tailwheel Aft Retract Arm<br />
2.E. Tailwheel Forward Shock Yoke<br />
2.F. Instrument Panel Center Flange<br />
3. New Prowler Engine Mount <br />
4. Builder Updates:<br />
4.A. Ray Solved The Gear Hydraulic Problem<br />
4.B. Ernest Is Getting Closer to His Second 1st Flight<br />
5. New Tool For Making Prowler Parts<br />
6. Golf Cart Makeover <br />
<br />
Since the last update, my knee blew up on me again just before Thanksgiving. In fact, I spent Wed - Sat of T-day holiday with my leg up and my knee on ice. No one is sure what happened, and a new MRI did not indicate any problems - so, now I'm back at PT after a mandatory two week "give your knee a rest" from the doc. If all goes well I'll be released to go back to work in mid Jan. In the meantime, I'm quite a lot more mobile now and I've been able to get out to the shop and get some parts made for Kit #18, among other things.<br />
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Thanks for checking in! On with the update:<br />
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<b><u>1. Prowler Motionmaster Fix</u></b> - You might recall, several years ago I purchased, refurb'ed, modified and installed an industrial CNC router in the shop that I found online. When I do finally make it into some kind of limited Prowler production, this machine will be running a lot! Here is what it currently looks like sitting in the shop:<br />
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So, about 6 weeks ago (after I got off crutches) one of my buddies who also has a CNC machine with a Fagor 8025 controller called to ask me if I had a spare backup battery module for the control. I did and that reminded me that I'd never changed the battery in my control. I went out to check it and it was 20+ years old - I was living on borrowed time. If this battery goes dead, you will lose all the parameter settings in the control and the next time you start it you'll see a bunch of Spanish come up on the control screen (default parameters). (If you have saved copies of your parameters, it's not too difficult to recover from this - but, if you don't have the parameters.....it will not be very much fun at all.) Well, I happened to be headed into town that day anyway and went to the battery store and got us each a new battery (AA sized 3.6 Li cell).<br />
<br />
I got home and decided to fire up the machine and change the battery (you change batteries when the machine is running so that removing the battery doesn't affect the memory - it's being powered by the computer while running). I haven't run this machine for over 2 years. In fact, the last thing I cut with it was the blanks to make the nose ribs for Francis (OMG!!!...looking back in my pics, that was in Nov 2014....3 years ago!! Ugh!!) Anyway, after I changed the battery I decided to home the machine and then jog it around a bit. When I did - the X axis worked normally. But, when I went to home the Y axis, the table shot off at max feedrate for about 6 inches and then failed on a "following error." Well, that was not good. I reset the control and then tried to jog the table in the Y axis and it worked, but was not controllable after the initial push of the jog button. Each time, I had to hit the E-stop to get the machine to stop moving. Huh! That definitely was a problem.<br />
<br />
A few days later, I got to troubleshooting the problem and eventually tracked the problem down to the Y axis servo motor. My machine has some crazy expensive Baldor servos on it (like $3.2K new, $1.7K used). All three axis servos are actually the same. They look like this:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhsi-XA2LBzFwHp9I_43V5b4HRf33y5l1H74tEkhFgJKvXqYP05WFlrUNShZjPvqI1eLzlBXTnYTyn5uMhwU9pkUipxmFwNDc51ctlL5GM37HxKXW0c9qR4hvzfLzQn8C76dKaBogxnnj5f/s1600/Baldor+MTE-4090-BLBCE+Img.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="647" data-original-width="992" height="208" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhsi-XA2LBzFwHp9I_43V5b4HRf33y5l1H74tEkhFgJKvXqYP05WFlrUNShZjPvqI1eLzlBXTnYTyn5uMhwU9pkUipxmFwNDc51ctlL5GM37HxKXW0c9qR4hvzfLzQn8C76dKaBogxnnj5f/s320/Baldor+MTE-4090-BLBCE+Img.png" width="320" /></a></div>
There are really only a few things that can go wrong with a servo: 1.) the brushes wear out; 2.) the bearings go out or other mechanical failure; 3.) the motor windings burn out; 4.) the tachometer fails; or 5.) the encoder goes bad. My failure was not the motor windings (it was moving) and it seemed to be related to the servo's feedback to the CNC control (so it was an electrical problem). So, I could rule out problems 1, 2, & 3. That left 4 & 5 as the possible culprits. I yarded the servo out of the machine and got it on the bench.<br />
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I pulled the end cap off the servo that is opposite the shaft end to expose the encoder. I decided to start with that, since it was the easiest to get to (rotary encoders are mounted on the end of the armature shaft that is opposite of the output shaft) and because the problem seemed to be related to the servo feedback to the CNC (which is what the encoder is part of). I pulled the encoder off the servo and cut the cable between the cannon plug and the encoder. Here's what mine looked like under the end cap:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4JTcYl7NOinNxDvngZSz8ENtJ8czv5wTHWJArFxlViYhOy_MxPiJdXs2ho1BdiqOezS84AoPJvwaefLFUzipNdNxfitdGf-QK7gHBYbvhzo9ea-EmVhWKmX0lsGQPBvZUy87l5R8HA9Se/s1600/20171114_222942.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="906" data-original-width="569" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4JTcYl7NOinNxDvngZSz8ENtJ8czv5wTHWJArFxlViYhOy_MxPiJdXs2ho1BdiqOezS84AoPJvwaefLFUzipNdNxfitdGf-QK7gHBYbvhzo9ea-EmVhWKmX0lsGQPBvZUy87l5R8HA9Se/s320/20171114_222942.jpg" width="200" /></a></div>
All that an encoder really is, is a pulse generator that has a marker in it that sends a reference pulse at the same position every shaft rotation - then sends out a stream of square wave pulses for each number of degrees of rotation. The number of degrees depends on how the machine is designed and the required pulse count of the encoder. They can be made with almost any number of pulse counts per revolution.<br />
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The encoder on this servo happened to be a 400 CPR (counts per rev). But, for demonstration sake, lets use a clock face as an analogy and pretend that we have a 60 CPR encoder. You can then think of an encoder sending a reference pulse (marker pulse) at the 12 o'clock position on each rotation. And then additionally, the encoder will send another square wave pulse at each minute mark all the way around the clock face. In this way, the CNC (computer) counts the pulse stream coming from the axis servo and can interpret from this where the machine is at - all the time. Here is my (failed) 400 CPR encoder:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0nAiQ64e9u_fVWyDj_jE3NcgpwSKi5aII-zhI9Pyhep6VwDCJky7W9gI7OE3dcKqxSmndaDUIIZDoG-HSS3IpbXtEAZQtbZgOgFEZqjEbAd3YRWd2VBagkBa4MAcw_EpSyf9TvWaJaZxs/s1600/20171114_235250.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="941" data-original-width="950" height="316" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0nAiQ64e9u_fVWyDj_jE3NcgpwSKi5aII-zhI9Pyhep6VwDCJky7W9gI7OE3dcKqxSmndaDUIIZDoG-HSS3IpbXtEAZQtbZgOgFEZqjEbAd3YRWd2VBagkBa4MAcw_EpSyf9TvWaJaZxs/s320/20171114_235250.jpg" width="320" /></a></div>
I got online and figured out that by applying +5Vdc power to the encoder and using a DC voltmeter, you can do some rudimentary troubleshooting of an encoder. Of course, you have to know the pin-out of the device and hook everything up correctly. I found this and it helped me with the wiring info:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDnZeiURH1jGqXnWqqcqwdN6QgudxeiUUkCHwV1j3P0RlXe2VZnGEvX2TUMQPkpI_qEmedyundIA4IPTpMLbR6jYDUfA5Cv6La2JUPqFz36In9dhYECcdJIrkGgziEX-c0p2NYz7bmQxRK/s1600/Encoder+pinout.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="720" data-original-width="779" height="295" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDnZeiURH1jGqXnWqqcqwdN6QgudxeiUUkCHwV1j3P0RlXe2VZnGEvX2TUMQPkpI_qEmedyundIA4IPTpMLbR6jYDUfA5Cv6La2JUPqFz36In9dhYECcdJIrkGgziEX-c0p2NYz7bmQxRK/s320/Encoder+pinout.png" width="320" /></a></div>
I discovered that the B/B* and Z/Z* channels were giving an output signal, but the A/A* channel was not. The A channel was stuck at +5 Vdc and the A* channel was stuck at 0 Vdc. So, this encoder was apparently shot. I used the page of info below that I found online for my encoder and called the company to order a new one. <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIAdc6X9LqUOmOZpHYn-uBcse4szCTD95N1lGB1U91CqsbQF0dROM46k_KI7Pgz7pDaurcAmlJmFXRflzo51WBbjNJKXWGU6ykqCS9-5q-l8WkfrYd8pfNEViUw2B6jCW70P3447IO81GQ/s1600/Encoder+Order+Info.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1207" data-original-width="1002" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIAdc6X9LqUOmOZpHYn-uBcse4szCTD95N1lGB1U91CqsbQF0dROM46k_KI7Pgz7pDaurcAmlJmFXRflzo51WBbjNJKXWGU6ykqCS9-5q-l8WkfrYd8pfNEViUw2B6jCW70P3447IO81GQ/s320/Encoder+Order+Info.png" width="265" /></a></div>
Mine was not exactly a very standard pulse count encoder and they were going to have to build me one - so it would take a few weeks to get it.<br />
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In the meantime, I noticed when I took the servo out of the machine, that the shaft seemed to be pretty sloppy in the end of the servo and set out to also fix that. I pulled that end of the servo apart and I found that the bearing was loose on the shaft and the shaft had been spinning inside the bearing. It had worn the shaft down in the area of the bearing ID and it was now about .015" smaller in diameter where the bearing is supposed to sit. Well, this is also not good. Here is the old bearing:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjs5jRm_M6KiW9PKpS2vJdnQ9tk5gcY7hUm6jmaZvxYOpjMk4ImFDe0XQMn9c4kkckBBgC_nU5v53uiOz5HI6uKp24inOvkYNJBV-Z46mqJp2sqWx7gXtrCo9Wz8lmI3B1jk5oPKzZvO8SV/s1600/20171119_163328.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="837" data-original-width="918" height="291" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjs5jRm_M6KiW9PKpS2vJdnQ9tk5gcY7hUm6jmaZvxYOpjMk4ImFDe0XQMn9c4kkckBBgC_nU5v53uiOz5HI6uKp24inOvkYNJBV-Z46mqJp2sqWx7gXtrCo9Wz8lmI3B1jk5oPKzZvO8SV/s320/20171119_163328.jpg" width="320" /></a></div>
This is a close up picture of the armature. You can definitely see that the shaft is worn down in the area where the bearing is supposed to seat:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJ2EDfgCSf8aq4nQEt80SN5tFX5EDTe-WuGXtpWCRDZ5fD7uogtOhHc1rDJR2EW_QvlEesowe36FyqT9RtJ7wHEEYODyTeJQgqbBF9xGYt0SAKzl-rpGtShHXAas0YDQK67M0H3XRDOqOE/s1600/20171119_145613.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1143" data-original-width="643" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJ2EDfgCSf8aq4nQEt80SN5tFX5EDTe-WuGXtpWCRDZ5fD7uogtOhHc1rDJR2EW_QvlEesowe36FyqT9RtJ7wHEEYODyTeJQgqbBF9xGYt0SAKzl-rpGtShHXAas0YDQK67M0H3XRDOqOE/s320/20171119_145613.jpg" width="180" /></a></div>
My 1st thought to fix this was to have my master welder build this area up with weld and then turn it back down to the proper diameter in a lathe. But, the other end of the shaft is still connected to the section of the servo that has the brushes and tachometer in it. I really didn't want to take all that off, if I didn't really need to. You can see it here:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkLWvY8MQnNYeGv27i12GIkqqmDLkBfd96OGR4GliweHqO78i43Ig9UyBNNZ_aVOlNOAezV1z17FleQR4VOV1GVPYiLzuBSrb0abSsABhyphenhyphenAYlZvrZM0poq4QgEq1YTpd6kyU0BytJpfk5R/s1600/20171119_145603.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1231" data-original-width="679" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkLWvY8MQnNYeGv27i12GIkqqmDLkBfd96OGR4GliweHqO78i43Ig9UyBNNZ_aVOlNOAezV1z17FleQR4VOV1GVPYiLzuBSrb0abSsABhyphenhyphenAYlZvrZM0poq4QgEq1YTpd6kyU0BytJpfk5R/s320/20171119_145603.jpg" width="176" /></a></div>
Huh!?!? What to do? Well, when I'm stumped, I go to the ultimate resource - Dad! I filled him in on what I had and he told me to prick the shaft. What!?!? Well, the idea is to put the shaft on a good stable surface and then use a sharpened prick punch to put small, symmetrical divots around the shaft in the "low" area where the bearing ID is supposed to sit. You basically deform the metal causing craters and sending some of the material out to and slightly beyond the desired diameter. This will give the ID of the inner bearing race something to contact and, if done properly, will keep the bearing re-centered on the shaft. Then, you position the shaft and put Loctite Bearing Set down into gaps and let it setup.<br />
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So, that's what I did with this servo armature shaft. I found a good piece of steel just the right height and cut a saddle in it with the same diameter as the armature shaft. Then, I positioned it on the welding table and punched the divots into the shaft. When I got done it looked like this:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgM93FlX6DE7Z_hy3eIJNu53pzJMxOW2r_gLUCE7T_XkNgktSmfA99wQyyUVGaACmnqhyphenhyphend1FSTkLahusx75VLAwYvmiCP7Gj-XIFNLDUOJdzwlH_rbcN_KAzlPj7GDnDp4NNji6D2zofIlb/s1600/20171119_161510.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="643" data-original-width="1143" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgM93FlX6DE7Z_hy3eIJNu53pzJMxOW2r_gLUCE7T_XkNgktSmfA99wQyyUVGaACmnqhyphenhyphend1FSTkLahusx75VLAwYvmiCP7Gj-XIFNLDUOJdzwlH_rbcN_KAzlPj7GDnDp4NNji6D2zofIlb/s320/20171119_161510.jpg" width="320" /></a></div>
I ordered a new bearing for the shaft and a few days later it showed up. I pressed the new bearing into place over the divots in the shaft:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaVxsWTGRU7cqT8BdN7lBK5x6INp0X2kxz3PWZkgN3nIackPFotG7mGiUrgKoypER3LxhaR3s0mt8_Gfw4sFy5sVb0XT_bW9ay_3ArUb6zSnWzcCE5FjMmH3-5n-LeiNRkqMjeQl87ksKZ/s1600/20171119_161637.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="810" data-original-width="643" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaVxsWTGRU7cqT8BdN7lBK5x6INp0X2kxz3PWZkgN3nIackPFotG7mGiUrgKoypER3LxhaR3s0mt8_Gfw4sFy5sVb0XT_bW9ay_3ArUb6zSnWzcCE5FjMmH3-5n-LeiNRkqMjeQl87ksKZ/s320/20171119_161637.jpg" width="254" /></a></div>
Then, I stood the servo on end and soaked the area with Loctite bearing set overnite so that it would seep down into the gaps between the shaft and the bearing ID:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5x-x_5ijwVOP85INmZKSUuBpu76g4DAk0dfqBMav0xq0EJXr92Y3B45MvqH6DLzTwRQT54ilfJs1BqcNELX0XYlXFcqmMDgyBPVLzVXkwX5vfq-ttgqZR6-AvHg3fHBYQsyaBnomF4MSC/s1600/20171127_121401.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="696" data-original-width="700" height="318" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5x-x_5ijwVOP85INmZKSUuBpu76g4DAk0dfqBMav0xq0EJXr92Y3B45MvqH6DLzTwRQT54ilfJs1BqcNELX0XYlXFcqmMDgyBPVLzVXkwX5vfq-ttgqZR6-AvHg3fHBYQsyaBnomF4MSC/s320/20171127_121401.jpg" width="320" /></a></div>
The next day, I put the servo back together (minus the encoder) and tested the new armature bearing. It rolled over smoothly and didn't make any noise. So far, so good. The next week, the new encoder showed up. Here is what $326 of new rotary encoder looks like (sorry, the pic is not in focus):<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpBZlagBxqobL-ER3lNBsc2_BDHc7brCXsh_i8_pwuFB90UWXMZ-x0reW5dCj5t9masAM3zhFsQwgCLSnt9mLu3n5ftMObaPv7yzqPtucomxvCajQqqfFvc-v-0Vdhk7i5rrGN2vUuC0zM/s1600/20171222_203242.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="777" data-original-width="773" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpBZlagBxqobL-ER3lNBsc2_BDHc7brCXsh_i8_pwuFB90UWXMZ-x0reW5dCj5t9masAM3zhFsQwgCLSnt9mLu3n5ftMObaPv7yzqPtucomxvCajQqqfFvc-v-0Vdhk7i5rrGN2vUuC0zM/s320/20171222_203242.jpg" width="318" /></a></div>
You might notice that I ordered the new encoder with 800 pulses per rev. While doing all of this troubleshooting, I discovered that the machine was originally built with 0.0005" resolution on the X axis, but only 0.001" resolution on the Y axis. Not sure why that was done, but by ordering an encoder with 800 CPR and changing one parameter in the CNC, I was able to make both X & Y axis have 0.0005" table resolution.<br />
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In the end, it took about an hour to solder in the new encoder, put the servo back together and install it in the router. I fired up the machine, changed the necessary parameters and gave it a test. All is well and machine is working fine again. I'm not sure what made this encoder go bad. It worked 3 years ago and then I turned it on last month and it was no-worky. But, I'm happy that I was able to repair it for a reasonable cost (approx $360) .vs. having to purchase a replacement (prices mentioned earlier)!! Time to put this machine back to work.<br />
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<u><b>2. Several Steel assemblies for Kit 18</b></u> - I am getting down to very last parts/assemblies that I need to complete
Kit #18 that I have up in the office (yup - it's still for sale). I'm trying to get this kit ready for next summer. If Ernest does take his Prowler to Airventure, I am expecting lots of inquiries about the Prowler and I'd like to have this kit ready to sell in case someone really wants a kit to build. So, here are the parts I made for the kit recently:<br />
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<b><u>2.A. Neg G Stress Mount</u></b> - This is the part that attaches to the bottom of the bulkhead former in the cockpit area just over the wing spar. These attach to the former with several rivets and transfer any negative G loads to the main spar via a bolt that goes down from this stress mount thru the cockpit floor and into another clip attached to the top cap of the main spar. Here are all the parts (3 sets) laid out on a sheet of .050" steel:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHICXye2LxXs6YtDgRRblj0NletGNY1vfFVzet8ciP1lnLY4ZKgHxeniW6fWmj7SmSK1bapVBkIkzvRjEdfJvtWlixDeLnLPFsb9optq5FgdBSkij4_ST5PYl-NYMWTC8B0rWwWx9fCtlF/s1600/20171207_121439.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="643" data-original-width="868" height="237" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHICXye2LxXs6YtDgRRblj0NletGNY1vfFVzet8ciP1lnLY4ZKgHxeniW6fWmj7SmSK1bapVBkIkzvRjEdfJvtWlixDeLnLPFsb9optq5FgdBSkij4_ST5PYl-NYMWTC8B0rWwWx9fCtlF/s320/20171207_121439.jpg" width="320" /></a></div>
Once the main plates are cut out, there are two tooling holes drilled into them and then they get mounted in the CNC mill, like this:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4T1ArU06P3Nhl_9Ay6bMidYsxqeHV2N7ILspMM4xndvn-UA0iWcFyFeN_L6_b3wLmsYCyPLk8G4dm_dBsxHke2KOB2c6mgNJYZC2XKMo2NQo8i026veXrB3UIW9Hlv7DWa72H7Op1DOwa/s1600/20171208_061144.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="578" data-original-width="1009" height="183" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4T1ArU06P3Nhl_9Ay6bMidYsxqeHV2N7ILspMM4xndvn-UA0iWcFyFeN_L6_b3wLmsYCyPLk8G4dm_dBsxHke2KOB2c6mgNJYZC2XKMo2NQo8i026veXrB3UIW9Hlv7DWa72H7Op1DOwa/s320/20171208_061144.jpg" width="320" /></a></div>
Here are the same parts after the profile milling of the edges and drilling rivet holes for attaching to the fuselage former:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4bQKY3_It5NexHHHb60PBjtk2Ol-e7FSTZVzn-k8d7XvodMZ5usQgw7KUu4SVpvvHVfI2Fa63bbkGpAGrjvkQ0XvYgZyN0YPYphtedm14Hg_CSDqXdjWBcTOII4XXQAXfRoT61MbQ0Hxc/s1600/20171208_133028.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="612" data-original-width="865" height="226" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4bQKY3_It5NexHHHb60PBjtk2Ol-e7FSTZVzn-k8d7XvodMZ5usQgw7KUu4SVpvvHVfI2Fa63bbkGpAGrjvkQ0XvYgZyN0YPYphtedm14Hg_CSDqXdjWBcTOII4XXQAXfRoT61MbQ0Hxc/s320/20171208_133028.jpg" width="320" /></a></div>
And, here are the 3 sets of parts ready for welding:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjlcRvS4vkMu1bBYV1IbdthkCV4Ia4B7D0kfNQQ9fMUkSyolJ0-4IsIu2YvdxV00uvjRJM-R9gCyrhqLTJPUHTf4j3d6tNZC5XVdtIyNzwfqV_7P50aksWH6HWRcjK2cyDoNWsGaZ0AsEhJ/s1600/20171208_172041.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="716" data-original-width="795" height="288" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjlcRvS4vkMu1bBYV1IbdthkCV4Ia4B7D0kfNQQ9fMUkSyolJ0-4IsIu2YvdxV00uvjRJM-R9gCyrhqLTJPUHTf4j3d6tNZC5XVdtIyNzwfqV_7P50aksWH6HWRcjK2cyDoNWsGaZ0AsEhJ/s320/20171208_172041.jpg" width="320" /></a></div>
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<b><u>2.B. Engine Stress Mounts</u></b> -These are the steel pieces that mount into forward ends of the main fuselage longerons. The engine mount bolts go through these assemblies and transfer all of the engine flight loads into the fuselage. Needless to say, they are pretty important assemblies. They are made from 3 pieces of flat steel. The main body is cut from flat steel and is formed into a U shape. Then, there is another U shaped piece that fits inside the main body and gets welded to the flanges. Finally, there is a flat piece of thick steel that gets welded bottom of the smaller U shaped part to reinforce the area where the engine bolt passes through. Here is a sample assembly (left over inventory) and a sheet of steel cut to make the main body:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLl-3rRsccOsdP5ZBJ-1FaLsfgTM4dWdnCJdOJCdVWl6HyMio4ZCsa1Tiakx1i1ygl-HVBH-YwlMOl3aEFXzWUN7ND76eql-HlE2uwxaqDxwOL_D9ATofaCOaPV5_T_iJrs7rlwA_y3qlS/s1600/20171209_191618.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="648" data-original-width="1039" height="199" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLl-3rRsccOsdP5ZBJ-1FaLsfgTM4dWdnCJdOJCdVWl6HyMio4ZCsa1Tiakx1i1ygl-HVBH-YwlMOl3aEFXzWUN7ND76eql-HlE2uwxaqDxwOL_D9ATofaCOaPV5_T_iJrs7rlwA_y3qlS/s320/20171209_191618.jpg" width="320" /></a></div>
I don't have a sheet metal brake large enough to bend a piece of steel this thick and this long. And, besides, bending a part like this in sheet metal brake is prone to error. If you don't get your bend lines perfectly parallel, the part will come out wracked and not be useable. I needed to find a more accurate way to make this piece of the assembly. I decided to make a bending fixture (tool) for it. Here was my idea of how to form these parts from 4 pieces of steel that I had laying in the steel pile:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWvMVm6uKNUupdzE-g0QaLNA8iq5H-Gnd60GVGPIL7bduefM3wdN8HF2S6l_gCiVl_gNvQWW8S_tgscEG7APHWNiSX34dzirGHEGifboXn7gMlRiwzfQ8ioVr5-s8lMGyNo57r2WazpePJ/s1600/20171209_191629.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="680" data-original-width="677" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWvMVm6uKNUupdzE-g0QaLNA8iq5H-Gnd60GVGPIL7bduefM3wdN8HF2S6l_gCiVl_gNvQWW8S_tgscEG7APHWNiSX34dzirGHEGifboXn7gMlRiwzfQ8ioVr5-s8lMGyNo57r2WazpePJ/s320/20171209_191629.jpg" width="318" /></a></div>
Next, I had to find a good, large piece of steel to use as a base to mount the other pieces to. Then, I had to position the lower dies and space them with shims the same thickness as the material to be fomed....plus a few sheets of paper for a small relief - and clamp it all together:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh24G8EtPG28HBlGUUIYg8zEshR9mZyw-_L5aJe15QxO_cbBAuzRfdE83PNpCRCS_Hlcp81dFXHBI0dM0ydWta10pO_9_SVC3V3Wc6AIY3nUJ4GABKVg0yZ2fKr93sBQLUK3zi2JatSlT2z/s1600/20171209_191729.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="605" data-original-width="935" height="207" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh24G8EtPG28HBlGUUIYg8zEshR9mZyw-_L5aJe15QxO_cbBAuzRfdE83PNpCRCS_Hlcp81dFXHBI0dM0ydWta10pO_9_SVC3V3Wc6AIY3nUJ4GABKVg0yZ2fKr93sBQLUK3zi2JatSlT2z/s320/20171209_191729.jpg" width="320" /></a></div>
That got welded up. Then, I turned my attention to the punch die. Here it is upside down in the vise (after welding) so that I can file a radius onto the lower edges. You don't want these to be too sharp as it will deform the metal too much. It also doesn't have to be too big of a radius. I made it about 1/16" radius and checked it with a radius gauge frequently:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgH3bTtAlt3vsWWfF7ep1i7UZ-x9t6DhFxYieLr7B73heoCopSWqAg8oYv_ZdPQ3_SnsO1AnKk4jAEYlxlSGNS8Lt9yleQKv5mH-tHD6kjmzrc8TrxEpHpi_jzGfWCtwoV-Tul9JZdaoS-u/s1600/20171209_191735.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="785" data-original-width="579" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgH3bTtAlt3vsWWfF7ep1i7UZ-x9t6DhFxYieLr7B73heoCopSWqAg8oYv_ZdPQ3_SnsO1AnKk4jAEYlxlSGNS8Lt9yleQKv5mH-tHD6kjmzrc8TrxEpHpi_jzGfWCtwoV-Tul9JZdaoS-u/s320/20171209_191735.jpg" width="236" /></a></div>
I could have put this in the mill and used a roundover bit to shape the
radius - but, it doesn't take too long with a good sharp file to do the
same thing by hand. Plus, it's good to practice this kind of work by
hand every once-in-a-while - to keep your handworking skills up.<br />
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Here is the forming tool all put together. I had to add some guides in the ends to keep the punch die properly aligned with the blanks and also to keep the punch die from going too far toward one end or the other. <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjanSKpnVvcv0hbd3_mqoSRJTAjYaeHQdJwIOac_e9MTxPIOZtjWc-D3I5TjKenXaY_6esUikfTD4BOCE9i0zaQFeJfxXNPhfQ7X1Bdptk1wyl-1lnWeCz87K73_YFATy2UWoJakInEer_M/s1600/20171209_191739.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="573" data-original-width="1087" height="168" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjanSKpnVvcv0hbd3_mqoSRJTAjYaeHQdJwIOac_e9MTxPIOZtjWc-D3I5TjKenXaY_6esUikfTD4BOCE9i0zaQFeJfxXNPhfQ7X1Bdptk1wyl-1lnWeCz87K73_YFATy2UWoJakInEer_M/s320/20171209_191739.jpg" width="320" /></a></div>
Here it is in the 20 ton press forming the first part. Turns out, the punch die tended to roll one way or the other. I suspected that I did not have enough "bearing" area where the press contacted the punch die. More "flat" area up there would keep the punch die aligned vertically (the large round steel piece is just a spacer):<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNvzYEuOgdQFhyqDtpTI2CH7XaGNj8LGFLa_wHOXrGTTvJXt4rQpMVuvR82fUChJjBxtPWMPyv3wg-9jCi1wg0gM0U9ZCPAPsgihvo0Gu-grMdF_4TZBY9vbNMwAY98CQotuqgT2LMv5ti/s1600/20171209_191855.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="755" data-original-width="661" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNvzYEuOgdQFhyqDtpTI2CH7XaGNj8LGFLa_wHOXrGTTvJXt4rQpMVuvR82fUChJjBxtPWMPyv3wg-9jCi1wg0gM0U9ZCPAPsgihvo0Gu-grMdF_4TZBY9vbNMwAY98CQotuqgT2LMv5ti/s320/20171209_191855.jpg" width="280" /></a></div>
After a little wrangling, it did work for the 1st part and formed it adequately:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEifYTxnebETdjxCPU21H5NuewPVwQoWIBXg-IvhWK5FkJeZCRlxv1Nfo6Iqrj0ejN_zSoT5u9pnK4Fajp8ML6h58v3xJd6UkM1kBj5TI_YxdOjFMnog1ZZPRtBiVqBV3Qzgxv6Zrh-5zLJH/s1600/20171209_191976.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="573" data-original-width="1020" height="179" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEifYTxnebETdjxCPU21H5NuewPVwQoWIBXg-IvhWK5FkJeZCRlxv1Nfo6Iqrj0ejN_zSoT5u9pnK4Fajp8ML6h58v3xJd6UkM1kBj5TI_YxdOjFMnog1ZZPRtBiVqBV3Qzgxv6Zrh-5zLJH/s320/20171209_191976.jpg" width="320" /></a></div>
After forming that 1st piece, I stopped to weld a piece of 1/2" steel to the top of the punch die (nice and square to the vertical bar). Here is the tool pressing the 2nd part:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKvk7MY1BwUeZsRAckshkSAd1CRiqeimhof3hABJRhOpY2HvBxPMqLmiN53bX-LfcxwRJdEQlj0XqwzHTYM6n2oKADlNxPqmeR8OBwUDZV7lPdOJRpeDpOyc0t5FmGcaP8AwBYxtVv2rq9/s1600/20171209_191978.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="564" data-original-width="1025" height="176" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKvk7MY1BwUeZsRAckshkSAd1CRiqeimhof3hABJRhOpY2HvBxPMqLmiN53bX-LfcxwRJdEQlj0XqwzHTYM6n2oKADlNxPqmeR8OBwUDZV7lPdOJRpeDpOyc0t5FmGcaP8AwBYxtVv2rq9/s320/20171209_191978.jpg" width="320" /></a></div>
That final mod worked great and kept the punch die from wanting to roll over like it was previously. I went on to use it to form all 8 parts (I decided to make 2 sets of 4 of these assemblies):<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcxN25hYtPwzKyJgNmGObzWkSyuvAh9_pcjBp5Ye2-nEY4s5LzKyxrblD2wR9YCoZIFZ-BZEmjQi8DMKlp3gVWmjxirfgtxd6n42_PBR9sBSsBJ1Tfexufmt_rDxY3TJzhjz_4QE64o4jY/s1600/20171209_191985.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="393" data-original-width="1206" height="104" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcxN25hYtPwzKyJgNmGObzWkSyuvAh9_pcjBp5Ye2-nEY4s5LzKyxrblD2wR9YCoZIFZ-BZEmjQi8DMKlp3gVWmjxirfgtxd6n42_PBR9sBSsBJ1Tfexufmt_rDxY3TJzhjz_4QE64o4jY/s320/20171209_191985.jpg" width="320" /></a></div>
Now, to make the smaller U shaped part that goes in the end of the main body and gets welded to the flanges. This part is thicker steel and definitely needs a bending tool. For this part, I did get a bending tool from George that he had made. Here it is, ready to form the first part:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjU3xuscxO1vBEiZlyUXDJFKidN1bOBA8jtDUz9YJE7uPdtoHAsJTn-HvI_UZch2_sIzQoH33SF4JqgR8QlXcbRP52ptESei7z2f07T-7y9pMvZ6AFA_WEG0C7fCbSzA8obP_M0lvarbzcm/s1600/20171209_194608.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="753" data-original-width="938" height="256" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjU3xuscxO1vBEiZlyUXDJFKidN1bOBA8jtDUz9YJE7uPdtoHAsJTn-HvI_UZch2_sIzQoH33SF4JqgR8QlXcbRP52ptESei7z2f07T-7y9pMvZ6AFA_WEG0C7fCbSzA8obP_M0lvarbzcm/s320/20171209_194608.jpg" width="320" /></a></div>
Here it is in action:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgs4Rn2aaO-WHbigI72csRoA6lfGnJy7g2a5gRsx82HahDzXWQ_KwNdm9BRdj2tcM_zciPxh127GFwNBhhkrbgK-CuDOetlfxIgbXKnByrngzDqmhMfW1DEry2lzvhjIM4YlB514DjN5alo/s1600/20171209_194611.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="716" data-original-width="956" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgs4Rn2aaO-WHbigI72csRoA6lfGnJy7g2a5gRsx82HahDzXWQ_KwNdm9BRdj2tcM_zciPxh127GFwNBhhkrbgK-CuDOetlfxIgbXKnByrngzDqmhMfW1DEry2lzvhjIM4YlB514DjN5alo/s320/20171209_194611.jpg" width="320" /></a></div>
When the part comes out of the forming tool, it is still not completely formed. There is still too much curvature to the bottom of the U. You can see it here:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMV-L1WPVTqg2HUcxLrNCIS886YnqNQV7MdSPQ4KbqGtPYi80py8CQ2Ep6TUIMghtZ2UGyJwc5BNbHaw63GGn7jg_bH_LFnO3RBXbXaAti8-knRirpzm3mwPwCz4kMTNhMOVIBC1xXD7PJ/s1600/20171209_201345.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="831" data-original-width="680" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMV-L1WPVTqg2HUcxLrNCIS886YnqNQV7MdSPQ4KbqGtPYi80py8CQ2Ep6TUIMghtZ2UGyJwc5BNbHaw63GGn7jg_bH_LFnO3RBXbXaAti8-knRirpzm3mwPwCz4kMTNhMOVIBC1xXD7PJ/s320/20171209_201345.jpg" width="261" /></a></div>
I found that by pressing the parts again without the use of the bending tool makes the bottom of the U much flatter, but that also causes the flanges to spread back open. To fold the flanges back into a 90 deg bend, I found that a few whacks with 3 lbs hammer (via a piece of flat steel to take the hammer blow deformation) worked great. This made the pieces have nice square bends and formed them to fit nicely into the main body pieces:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5eY_dr8yolDnGeVu4G5J51CiY-ioBOrpbx5p6mHL1zXolHcj9wECZ_r0ECQHivHVSfrtU1CiZlD-y23M7aswHh2NoolOxCnUeUU52ViJjFiyFBdSxCovQD5FXI71ojrCjhblmUQZH4QPM/s1600/20171209_201418.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="703" data-original-width="1062" height="211" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5eY_dr8yolDnGeVu4G5J51CiY-ioBOrpbx5p6mHL1zXolHcj9wECZ_r0ECQHivHVSfrtU1CiZlD-y23M7aswHh2NoolOxCnUeUU52ViJjFiyFBdSxCovQD5FXI71ojrCjhblmUQZH4QPM/s320/20171209_201418.jpg" width="320" /></a></div>
Here is how these first two pieces fit together:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQHwBUMLN1F5llyzn_7Ek_2RuGeoOcP6BWsFjVlCKYDx_Ga-SG-5YX8oBMB0r-yH55o7RGnc0E0tsjMrkMH_G4kQR6S1mzMmxTRQnMbwa2HxdwIY5u5b77XjcWTot_R9MgOD5zhUjT32nU/s1600/20171209_202218.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="617" data-original-width="1237" height="159" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQHwBUMLN1F5llyzn_7Ek_2RuGeoOcP6BWsFjVlCKYDx_Ga-SG-5YX8oBMB0r-yH55o7RGnc0E0tsjMrkMH_G4kQR6S1mzMmxTRQnMbwa2HxdwIY5u5b77XjcWTot_R9MgOD5zhUjT32nU/s320/20171209_202218.jpg" width="320" /></a></div>
I completed making all the U shaped parts and then cut 8 pieces of flat steel and put a good radius on the edges of one side. Here are all the parts ready for welding:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEje83EG5p5AzeJqF3-v-w7Tr3yPTB7DqDucgxyo7C41CTS5YNpjMs4YmUkLCaDYZhZNE_Wwt77V_idzZJPus0Bw9S6uaYg8ghKa-_FlV6ax6DZSmtcVTBU2DZFKR5Z3ty7UVn0BOykPWZGa/s1600/20171212_210305.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="390" data-original-width="1285" height="97" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEje83EG5p5AzeJqF3-v-w7Tr3yPTB7DqDucgxyo7C41CTS5YNpjMs4YmUkLCaDYZhZNE_Wwt77V_idzZJPus0Bw9S6uaYg8ghKa-_FlV6ax6DZSmtcVTBU2DZFKR5Z3ty7UVn0BOykPWZGa/s320/20171212_210305.jpg" width="320" /></a></div>
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<b><u>2.C. Tailwheel Upper Retract Yoke</u></b> - This assembly mounts between the mid-point of the tailwheel strut and the lower side of the upper aft tailwheel compartment. It guides the strut through the tailwheel extension and retraction cycles. This is what it looks like when finished:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDPCKiq59vFZsKxn9RbC169BdlGtkNaHhgtz0SLz0oePGIMgmwvvJOyt6jazWCJMcaYY0-INPRT41X_8zEfYxJXCS_VXHIKPCQRzUdvi5Vmz66IBEM_jh7YgdeBy_x2zcQHl7xvQKW9rus/s1600/FTW54_RP5.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="822" data-original-width="1251" height="210" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDPCKiq59vFZsKxn9RbC169BdlGtkNaHhgtz0SLz0oePGIMgmwvvJOyt6jazWCJMcaYY0-INPRT41X_8zEfYxJXCS_VXHIKPCQRzUdvi5Vmz66IBEM_jh7YgdeBy_x2zcQHl7xvQKW9rus/s320/FTW54_RP5.JPG" width="320" /></a></div>
The tough part of making this assembly is cutting the two long tubes that make up each side of the V shape. On the right hand side, the tube is essentially cut with taper that fits to the outside of the U shaped lower yoke. Cutting the tube to length is the first step. Then, I put it in the mill using a 5C collet and holder in the vise. Then, run an end mill of the same diameter as the tube to notch the upper end.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjnXQJVLgkVAGfuP_WpbluqJ21CpRupXWyzr01wz1PJoMCB1szjHYQGzmOZxHoEi5QaDUcDZ9392h9A2Nrtw0csDQLawaUV1hUNB4DEZYmAv6d9OiIFG3siJs_V1v914rfuvWcR7_1PZmqu/s1600/20171218_172456.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="754" data-original-width="735" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjnXQJVLgkVAGfuP_WpbluqJ21CpRupXWyzr01wz1PJoMCB1szjHYQGzmOZxHoEi5QaDUcDZ9392h9A2Nrtw0csDQLawaUV1hUNB4DEZYmAv6d9OiIFG3siJs_V1v914rfuvWcR7_1PZmqu/s320/20171218_172456.jpg" width="311" /></a></div>
Then, after marking it in the welding jig, I took them to the band saw and used a clamp to help me make sure that I kept the tube from rolling while I was cutting it (keep it vertically aligned to the saw blade):<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiV7kVCdYs5BXpGgF724wpvehvG-HYwa_yMjZJrUwER-5Pf5aAOrauc-SC2I7y0gGLuGRlc60iCUyxUgSMpyKa4HgBEw-KYwfMVeCK96VPUU34itaSjMMBU-ghpkyFvfYzpE4hM_ex_9srw/s1600/20171218_205659.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="885" data-original-width="428" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiV7kVCdYs5BXpGgF724wpvehvG-HYwa_yMjZJrUwER-5Pf5aAOrauc-SC2I7y0gGLuGRlc60iCUyxUgSMpyKa4HgBEw-KYwfMVeCK96VPUU34itaSjMMBU-ghpkyFvfYzpE4hM_ex_9srw/s320/20171218_205659.jpg" width="154" /></a></div>
Then, I put all the parts in the welding jig and clamped them into position. This jig makes sure that the lower bushings are in perfect alignment and parallel to the top pivot bar (on the right in the picture below):<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBU62VLDyHz6Eg1RnFXwwLPgeW1KGrxSehVTpbGbRn74rW6uwTlILepl3PvVd96dPEM3EYopRv742iW1m5ySZMe-9skE1QHrzcHBx_kd8YRrtFMIlhCUKvPD5p8tiE5kIvBzZitOPWPtMP/s1600/20171218_184221.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="577" data-original-width="850" height="217" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBU62VLDyHz6Eg1RnFXwwLPgeW1KGrxSehVTpbGbRn74rW6uwTlILepl3PvVd96dPEM3EYopRv742iW1m5ySZMe-9skE1QHrzcHBx_kd8YRrtFMIlhCUKvPD5p8tiE5kIvBzZitOPWPtMP/s320/20171218_184221.jpg" width="320" /></a></div>
After this portion of the welding is done, the assembly gets transferred to a different welding jig that holds and aligns the side plates that you see on the finished part in the first picture above. That's all there is to that assembly.<br />
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<b><u>2,D. Tailwheel Aft Retract Arm</u></b> - This is the assembly that the TW hydraulic actuator gets attached to on the "live" end. The finished part looks like this:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4VdzgzvU5Z5o0Wtz3atx4UBjuFMpuBylRkEJ6wxNCUMwnAJrVr33HIRzNIm5IVop5OJmlxNdgkNod7eIfqchqtRSIvVddatTml6p31MT0bwg-yDToENySKTzwehAO5O6gNfRFzPog7Vgk/s1600/FTW52_RP3.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1152" data-original-width="1536" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4VdzgzvU5Z5o0Wtz3atx4UBjuFMpuBylRkEJ6wxNCUMwnAJrVr33HIRzNIm5IVop5OJmlxNdgkNod7eIfqchqtRSIvVddatTml6p31MT0bwg-yDToENySKTzwehAO5O6gNfRFzPog7Vgk/s320/FTW52_RP3.JPG" width="320" /></a></div>
I started this part my making the side straps. There is one strap of steel that runs along each side and has a flattened "Z" bend. Here are the pieces before bending (sample from inventory is on the right):<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMMdiTzVSCGwPcmEfcoRJNZxsGpmoyMsOZoKzS5V8bCVkqbKDhKKSe2CKcUv1tZIG2OccNnbcrdVCw1TUkwt5Q1dEIFYg2T4FgIpfID72B6S0D27mhrlJLlipMJc9215XH5eOSc9rKhtEW/s1600/20171214_094913.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="952" data-original-width="575" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMMdiTzVSCGwPcmEfcoRJNZxsGpmoyMsOZoKzS5V8bCVkqbKDhKKSe2CKcUv1tZIG2OccNnbcrdVCw1TUkwt5Q1dEIFYg2T4FgIpfID72B6S0D27mhrlJLlipMJc9215XH5eOSc9rKhtEW/s320/20171214_094913.jpg" width="193" /></a></div>
Here is the 1st bend in the sheet metal brake, using the protractor to check the angle (make them parallel):<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0R_5_gJhc11ea7FEtusJKUz48ZhK9X-Xsg815BWaDUS6rxZ6BJg7TSLAf_5GGSa3JWIMxEmXYsskDlR9IqSnnDIzyeDkDTwmxIIBPsbg767z4zNnN2HjGoOZwYJ2Q7wCCjJOQYSy2ICtv/s1600/20171214_094320.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="643" data-original-width="1143" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0R_5_gJhc11ea7FEtusJKUz48ZhK9X-Xsg815BWaDUS6rxZ6BJg7TSLAf_5GGSa3JWIMxEmXYsskDlR9IqSnnDIzyeDkDTwmxIIBPsbg767z4zNnN2HjGoOZwYJ2Q7wCCjJOQYSy2ICtv/s320/20171214_094320.jpg" width="320" /></a></div>
There are several more pieces to make this assembly, but they are all simply cutting out parts from flat steel and drilling some holes. When the parts are all stacked up in the welding jig....it looks like this:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhx1TP9gbrnm863DmXkJXzaeRABdIBR23HzbUO7UyC_RPnhamcaZBFHRJHW6dqKwA5f_n9KuYGgeSxk_6kYWAmT8IMNwkvpCdYsuyXqu23I8W82BF9V0clEXrvogWlDx1DJYDhCOajB3xId/s1600/20171214_184644.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="735" data-original-width="774" height="303" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhx1TP9gbrnm863DmXkJXzaeRABdIBR23HzbUO7UyC_RPnhamcaZBFHRJHW6dqKwA5f_n9KuYGgeSxk_6kYWAmT8IMNwkvpCdYsuyXqu23I8W82BF9V0clEXrvogWlDx1DJYDhCOajB3xId/s320/20171214_184644.jpg" width="320" /></a></div>
I also made 2 sets of parts for this assembly. Once you have everything set up to make one part, it only takes a little time and a little more material to make another one. Here are my 2 sets of parts ready for welding:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKXD0uUzTocjOFSJfOe47FmWL2S7TRDSPKMfN1Sv99XKc5yLM0SKbDabwROjNAlyJtqdyVkIxwRwBUPF439HN2ufAtlvVtcFtdzd-HjzjS_H4lDSYOWhd4qfCCad0QzdvUzVXuPQ0BgxR-/s1600/20171214_184710.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="665" data-original-width="1094" height="194" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKXD0uUzTocjOFSJfOe47FmWL2S7TRDSPKMfN1Sv99XKc5yLM0SKbDabwROjNAlyJtqdyVkIxwRwBUPF439HN2ufAtlvVtcFtdzd-HjzjS_H4lDSYOWhd4qfCCad0QzdvUzVXuPQ0BgxR-/s320/20171214_184710.jpg" width="320" /></a></div>
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<b><u>2.E. Tailwheel Forward Shock Yoke</u></b> -This is the assembly that mounts between the top attachment point of the tailwheel strut and the forward bulkhead of the TW compartment. When finished the whole assembly looks like this:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjkHZMaHj3tsly_Ei2JupnY8n_mRXBU3UcW-fYG0MjBS1SMHhPWchrdyuFlTuWqjcXYmam34lV_xXdEf6stSsEpl3-b1UYl-KaSWPYTImFL1Y2SczYmSvWIRyXOH2eyqgXZd047XJ5LvYEh/s1600/FTW58+Composite.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="670" data-original-width="932" height="230" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjkHZMaHj3tsly_Ei2JupnY8n_mRXBU3UcW-fYG0MjBS1SMHhPWchrdyuFlTuWqjcXYmam34lV_xXdEf6stSsEpl3-b1UYl-KaSWPYTImFL1Y2SczYmSvWIRyXOH2eyqgXZd047XJ5LvYEh/s320/FTW58+Composite.png" width="320" /></a></div>
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The blue part slides in/out of the green part. The green part pivots on the gray posts. This assembly helps guide the top of the TW strut through the extension and retraction cycles. The idea of the the "shock" mount is that rubber is stuffed into the square tube. The blue part compresses against the rubber when a force pushes aft on the bottom of the TW strut (which pushes forward on the top of the TW strut) - thereby adsorbing the "shock".<br />
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Here is one set of the parts cut out and ready for welding. Most of the parts of this assembly are simply cutting off pieces of tubing or flat parts and drilling holes. There are 2 parts that need to be formed in some way. The first formed parts are the 45 degree flanges that go between the square tubing and the round tubing in the pic below. These flanges are cut from flat 0.050" steel sheet and then formed in a sheet metal brake. Here are all the parts that make up the forward half of this assembly: <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg08AajQXvBdNajr_2GQOPOv3DgZwtthU3Db2M2QSq9JC1TklEIzj5KjndWy6LkQFYSPH4l1gHb_XhWm-gpZVz3iMve03I7nsKosWENV52JlAb6nNg7bqS-AuWFgyYSk6WJEaF4KXCbM_Mc/s1600/20171227_131431.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="674" data-original-width="677" height="318" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg08AajQXvBdNajr_2GQOPOv3DgZwtthU3Db2M2QSq9JC1TklEIzj5KjndWy6LkQFYSPH4l1gHb_XhWm-gpZVz3iMve03I7nsKosWENV52JlAb6nNg7bqS-AuWFgyYSk6WJEaF4KXCbM_Mc/s320/20171227_131431.jpg" width="320" /></a></div>
Here is the solid square bar piece getting the holes drilled that will become a slotted hole in the "shock mount": <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgy2IfTyjBE2ODRLNpy-PXOplnI_XlZ_v4OrHxQ6At3l7S1wRS1rR93RMMaJGrXG6RB_G4WIeOSw5DZBtasjn0s642ZsYthsxhyphenhyphenpj_m85baxLUd-foB6wkpNaAIBimsoKLgw_VBqr56ipNY/s1600/20171214_184714.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1261" data-original-width="1600" height="252" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgy2IfTyjBE2ODRLNpy-PXOplnI_XlZ_v4OrHxQ6At3l7S1wRS1rR93RMMaJGrXG6RB_G4WIeOSw5DZBtasjn0s642ZsYthsxhyphenhyphenpj_m85baxLUd-foB6wkpNaAIBimsoKLgw_VBqr56ipNY/s320/20171214_184714.jpg" width="320" /></a></div>
This is the other formed part in this assembly. It is made from pretty thick steel and required me to make a new tool for forming it (and other airplane parts like this). [See para. 5 below for the making of the new purpose built forming tool for this.] Here is the formed yoke part:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCSh9PhrOgDL7Stky8t68OqmM-eQpzGxmDg-OdW69eH6ZIASnRyB3Ndx8V0_gPvxhZyaqtmpkiHXP9M2j0ioHmOAE9cL37LrfRjJD8l9w1EYq1dEdS6MVZ9Mc60nqZQkxFLpfdLzU-C1NJ/s1600/20171214_184914.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="595" data-original-width="658" height="289" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCSh9PhrOgDL7Stky8t68OqmM-eQpzGxmDg-OdW69eH6ZIASnRyB3Ndx8V0_gPvxhZyaqtmpkiHXP9M2j0ioHmOAE9cL37LrfRjJD8l9w1EYq1dEdS6MVZ9Mc60nqZQkxFLpfdLzU-C1NJ/s320/20171214_184914.jpg" width="320" /></a></div>
Here are the two parts from above clamped together and ready to be welded:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivtBLiqm2bA4KkAb7nMqABB1C-3gMYwZXydO0zL_b1WPgxGWw80JFTvZbK1Z0_AzOcKuu1IFeCe_JG0-VMqauIu50svj6np1CIfSptrwmOxDBa86HN3v9PfLY8F5DfDwQ-DBGPOsQXN3_m/s1600/20171227_130948.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="467" data-original-width="1045" height="143" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivtBLiqm2bA4KkAb7nMqABB1C-3gMYwZXydO0zL_b1WPgxGWw80JFTvZbK1Z0_AzOcKuu1IFeCe_JG0-VMqauIu50svj6np1CIfSptrwmOxDBa86HN3v9PfLY8F5DfDwQ-DBGPOsQXN3_m/s320/20171227_130948.jpg" width="320" /></a></div>
And, finally, here are all the parts of this assembly placed in their approximate positions and ready to be welded:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7Gsu2jeySsjU-A6LVDMVc-UPpcWx1ficHd_XlQ2v4cETBgB2CXi5KU-Hj8JRLO65p7w9Hpuzxku1xHV_BJBsZiyc0XfYEJ8PfMCDCEI2HVFQW4r-VTMf7HCNlSJvCuGSrxyFhlz3vBfNO/s1600/20171227_131559.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="614" data-original-width="884" height="222" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7Gsu2jeySsjU-A6LVDMVc-UPpcWx1ficHd_XlQ2v4cETBgB2CXi5KU-Hj8JRLO65p7w9Hpuzxku1xHV_BJBsZiyc0XfYEJ8PfMCDCEI2HVFQW4r-VTMf7HCNlSJvCuGSrxyFhlz3vBfNO/s320/20171227_131559.jpg" width="320" /></a></div>
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<u><b>2.F. Instrument Panel Center Flange</b></u> - This part is not fabricated from steel, but I still needed a set for the kit. It turned out to be a bit challenging to make. It is essentially a curved angle piece that is used to secure the top edge of the instrument panel to the upper skin of the fuselage under the windscreen. Cutting the strip of aluminum and bending it into a 90 deg angle is pretty easy - the trouble comes when you try shrinking the 3/4" flange to make the thing curve to match the radius of the top of the instrument panel. And, that is not a constant radius - it changes as you move along the edge from the top down towards the sides.<br />
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Let's just say that making this set of parts really expanded my metal working skills - at the cost of fairly elevated levels of blood pressure and frustration (for a while). Turns out, there is a method to the madness - you just have to figure it out (or be shown how). I ended up figuring it out on my own - but it wasn't until AFTER I broke one part and had to start it all over again. Here is the left side part laying above the radius guide/template:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEggLsJoCxTDOU-KCCzeiCP1dlFXK955MduoBDtZ-bf4r0jF3H9rf2ehJAa1Jcic-sud9w90xFyvGG7v4szE8Nv-iWtbesS_qb2QyqOq41_3k-QYScpTCg4gSNWfRfCKHMzpfUntIqPV1bnG/s1600/20171226_184944.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="643" data-original-width="1011" height="203" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEggLsJoCxTDOU-KCCzeiCP1dlFXK955MduoBDtZ-bf4r0jF3H9rf2ehJAa1Jcic-sud9w90xFyvGG7v4szE8Nv-iWtbesS_qb2QyqOq41_3k-QYScpTCg4gSNWfRfCKHMzpfUntIqPV1bnG/s320/20171226_184944.jpg" width="320" /></a></div>
The part on top is the part that I broke when trying to stretch it out (a little) in an area that had been shrunk quite a bit. Note: when you do a significant amount of shrinking to a piece of tempered aluminum in one area - don't go back and try to stretch it again! I won't stretch much, if any, before it just snaps. So, the real challenge is to continually take small amount of shrinking and compare it to the template and NOT over shrink it in the first place! Armed with that knowledge, I went on to finish the left side and even did a better job at making the right side angle flange. Here they both are placed on top of the radius template:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_liykEDukGwTbqvUQ8Mvkqd7126ZRBhMrUS-ln5Wcv_xaoUqX2vdSIV8NHQSAxYEGeBhaIXH4CbfnMW7vxSFtbwp3DPox8Clsba1skt4M8B7KAUN238T036t0nRiWnBeuyN3WJ-PuDPeF/s1600/20171226_185809.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="328" data-original-width="1127" height="93" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_liykEDukGwTbqvUQ8Mvkqd7126ZRBhMrUS-ln5Wcv_xaoUqX2vdSIV8NHQSAxYEGeBhaIXH4CbfnMW7vxSFtbwp3DPox8Clsba1skt4M8B7KAUN238T036t0nRiWnBeuyN3WJ-PuDPeF/s320/20171226_185809.jpg" width="320" /></a></div>
In the future, I am going to think of a way to form these with the 400 ton press and try to forego all this shrinking work.<br />
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<u><b>3. New Prowler Engine Mount</b></u> - I have been working with Stuart and Larry at AutoPSRU's for a couple of years now, preparing to have them create a FWF product for the Prowler. My plan is to sell Prowler airframes and then leave the Prowler builders with 2 options for an engine package. Option 1 will be to purchase the Prowler FWF package from AutoPSRU's; and option 2 will be to develop his/her own FWF solution (like what Bryan is doing with the Deltahawk diesel engine). I got an email recently from Larry at AutoPSRU's and he's gotten started on fabricating the 1st new Prowler motor mount. Here it is:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZ0OeML6IzZiFqQjdlHobOsvlxcZrtXxlISNeorBs01qGPPZnmSG0J7VXdYFWmRnjj7EjTSrr9z9FdVaq0360lfXi02elMQtx4btj5MfQUjNtdpHxJWqcVWk42-B7fvVyo0ihoAEZztCdN/s1600/20171129_100836%2528red%2529.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="756" data-original-width="1008" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZ0OeML6IzZiFqQjdlHobOsvlxcZrtXxlISNeorBs01qGPPZnmSG0J7VXdYFWmRnjj7EjTSrr9z9FdVaq0360lfXi02elMQtx4btj5MfQUjNtdpHxJWqcVWk42-B7fvVyo0ihoAEZztCdN/s320/20171129_100836%2528red%2529.jpg" width="320" /></a></div>
It's going to be a P-51 style engine mount and will hold the AutoPSRU FWF package to the existing firewall mounting holes on the Prowler. In fact, that's a Prowler firewall in the picture above. Larry made if from drawings and tracings that I sent to him earlier. Larry is building this mount to incorporate a 2 deg down and 2 deg right thrust line (fairly common for high-power, high performance designs).<br />
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I noticed, however, that the top of the engine in the picture of Larry's mock-up above seems to be much higher than the top of the engine in my mock-up. I started to research this and discovered that I had never included the 2 deg down and 2 deg right thrust line pitch. So, I went down to the shed one day and tweaked the mock-up to give the 2 deg down thrustline. Here is what the setup looked like:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgnoFNnfvz34c2Hlx0shP7Csbqo1Zbi5BXovc2M7YhZkvh2qZcDqHZIAiV3HJEWUzjXOMkNxg6uM3YskdKqoMiixKljyuNHT6Yh8Zp2gppX299cFlXBM-uZT1YW9HfPAOlRVmv2ywXhkMA/s1600/20171129_143334.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="735" data-original-width="1306" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgnoFNnfvz34c2Hlx0shP7Csbqo1Zbi5BXovc2M7YhZkvh2qZcDqHZIAiV3HJEWUzjXOMkNxg6uM3YskdKqoMiixKljyuNHT6Yh8Zp2gppX299cFlXBM-uZT1YW9HfPAOlRVmv2ywXhkMA/s320/20171129_143334.jpg" width="320" /></a></div>
I've got the firewall perfectly plumb, then using the 4 ft level I'm coming off the top of the firewall. At the front of the engine, the center of the prop hub should be 11.5 inches down from the level line off the top of the firewall. I double checked it, and it is right (read the right side of the scale): <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgc6gBeTuN8N9obOOv2sOT3B4uFephMScJmrpTvhYZeQSdAIimtBGh5rMxgt73qY_uj8QLWu_FgdSzlWpdJ0A32aSGsOgsYxahTnHNN2B15zATgeY0mP1ejJU3SoqRb_Mw9FHntqehs5Lkn/s1600/20171129_143350.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="758" data-original-width="692" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgc6gBeTuN8N9obOOv2sOT3B4uFephMScJmrpTvhYZeQSdAIimtBGh5rMxgt73qY_uj8QLWu_FgdSzlWpdJ0A32aSGsOgsYxahTnHNN2B15zATgeY0mP1ejJU3SoqRb_Mw9FHntqehs5Lkn/s320/20171129_143350.jpg" width="292" /></a></div>
With that, I'm getting about 2 inches from the top of the intake manifold between the top of the forward "hump" in the intake manifold to the level line off the top of the firewall. Larry seems to have quite a bit less than this. So, we are currently trying to figure out where the difference is.<br />
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While I was down there, I took advantage of the opportunity to see what I would also have for clearance between the engine and the side of the engine compartment. Turns out to be just about 2.5 inches without any 2 deg right thrust line adjustments. Here is the right side:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjO0PmP49rDypLl_Sl5CsM1DBY96jLumlnXI_KNr5xzltYItElCn6EF7P3CGviOf-ZhriNmIIXslpLHLIMDBQLvQjKgDmKcdEV0T-CcOIPxI7DsWEZse_Q7pFrUP0dIwqI-tLN1KvMEkDvt/s1600/20171129_144402.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="657" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjO0PmP49rDypLl_Sl5CsM1DBY96jLumlnXI_KNr5xzltYItElCn6EF7P3CGviOf-ZhriNmIIXslpLHLIMDBQLvQjKgDmKcdEV0T-CcOIPxI7DsWEZse_Q7pFrUP0dIwqI-tLN1KvMEkDvt/s320/20171129_144402.jpg" width="131" /></a></div>
And the left side:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTj25yYZ2e_e9FA4NsIFSkEP92WFVWn-LFgig4GEG7Wf2UK3HQ4XJSlvD1reA_FSFec3Xx0UUDryinoq4lOymoU5C5HiIft8NNAAy5Wd2ty61VUq7mnbD_UGVu1naWXrMwQ2450BahESFB/s1600/20171129_144803.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="689" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTj25yYZ2e_e9FA4NsIFSkEP92WFVWn-LFgig4GEG7Wf2UK3HQ4XJSlvD1reA_FSFec3Xx0UUDryinoq4lOymoU5C5HiIft8NNAAy5Wd2ty61VUq7mnbD_UGVu1naWXrMwQ2450BahESFB/s320/20171129_144803.jpg" width="137" /></a></div>
This might also turn out to be a problem. When I get a chance to move the engine in the mock-up to have the 2 deg right thrustline - it will change these clearances. We have to find room in there for an exhaust manifold to hold the O2 sensor for the LS series engine computers. Might be a bit of a challenge. More to follow.....<br />
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<u><b>4. Builder Updates:</b></u><br />
Since it has only been a month or so since my last update, I haven't gotten too much for updates from many of the builders. I did get a great report from Ray - he's finally solved his hydraulic pump chatter and gear cycling problem. And; I got a quick update from Ernest.<br />
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<u><b>4.A. Ray Solved The Gear Hydraulic Problem</b></u> - I'll make this easy and just include the text from the email that I got from Ray. He explains the fix very well:<br /><br />
<span style="font-size: small;"><span style="color: #e69138;"><span style="font-family: "verdana" , sans-serif;"> Finally have the gear working right. Turns out the problem
was internal leakage that was growing worse. Originally, when I had the leakage
in the tail wheel cylinder, I re-cut the O ring groove and polished the cylinder
with a brush hone and also polished the piston rod. That seems to be working
good and almost totally leak free. The pressure gauge seems to have a damper in
the system so I couldn’t really see the small rapid fluctuations in the pressure
that the pressure switch was reacting to.<br /> What finally happened was the leakage was dropping the
pressure very rapidly and there was no point going after the pressure switch
thing. I had put new seals in the main gear (hydraulic actuating) cylinders before but not the gear
door cylinders. I figured that it was the door cylinders at first, but I began
to have a problem of the system not retracting the main gear at all, I had to push
the struts up to lock them, that was the final clue. (The MLG Hydraulic Actuators were internally leaking by.)<br /> None of those cylinders had ever been honed by me nor anyone. The main gear replacement seals were very well worn and some of the
original door seals were hard from age. I bought a hone for the main cylinders
and used the one I got for the tail wheel, and polished the piston rods. The new
seals in the polished cylinders were so smooth that I was afraid they wouldn’t
seal at all. Today I ran the system with only a few external leaks that were
easy to stop. The gear operates much smoother and the switch only required very
small adjustment work correctly.<br /> If anybody is having problems with them (gear hydraulics or actuators), first
thing to do should be to hone them (main gear and door cylinders) and polish the piston rods and use new O rings - before
trying to figure out the rest of what is going on. Also the double seals that we have
talked about on the cylinder ends would be extra protection against leakage.
Double rings on the main gear pistons couldn’t hurt the
operation.<br /> The El Camino is now finished, Toyota is down to painting the new
wheels and the Prowler is ready for flight after I get a bi-annual out of the
way and some recent tail wheel time.</span></span></span><br /><br />So, there you have it - it was the MLG hydraulic actuators that were the root problem. I am making a set of MLG hydraulic actuator right now for Kit #18 and I have already included a double O-ring design into the actuator pistons that I will make from now on. I've also incorporated a double O-ring design into the piston rod seal area as well. I plan to do initial honing of the cylinders and piston rods - but I think I will sell all the new kits with these actuators in pieces and allow the builders to complete the final honing to their own liking. Then, I can provide instructions for assembling the actuators (they are really, really easy to assemble).<br />
<br />
Thanks for the update, Ray. Glad you found the problem and the ultimate solution! Thank you also for sharing this with the rest of the group. Now, get your BFR done and some tailwheel time in the logbook so that you can get on to the 1st flight. We're all chomping at the bit....for you!!! <br />
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<u><b>4.B. Ernest Is Getting Closer to His Second 1st Flight</b></u> - I got just a quick update from EZ yesterday. He said, and I quote, "Main gear doors are back on and the gear has been swung about 15 times. So, I'm very, very close." Close to his second 1st flight, that is!!! He has promised to send pics and videos when that happens. I'll post them as soon as it all happens. Stay tuned!!!<br />
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<u><b>5. New Tool For Making Prowler Parts</b></u> - Recently, as I was making all these steel parts for the various sub-assemblies that are part of the aft empennage and the tailwheel system - I came to the conclusion that I needed a better way to form some of these smaller steel parts. I searched online for what some others have come up with for homebrew press brakes. I came across a couple of pictures similar to this:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQGKKX4kY_gdwQK4sThpzeQL49AGuJmgma-xW319fXf1gpbxHWapmHoLYBY8Z5kxBwDotsHSXHWwQU_QzrC8W4PJb3XcT-8OG1Hpv5eLU7t8pdyn9uNT-p85FuSCJsXd2K42MUsSMO3-3X/s1600/cfadcc033fbf913b45fd3f822fb00250--metal-bending-garage-tools.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="310" data-original-width="232" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQGKKX4kY_gdwQK4sThpzeQL49AGuJmgma-xW319fXf1gpbxHWapmHoLYBY8Z5kxBwDotsHSXHWwQU_QzrC8W4PJb3XcT-8OG1Hpv5eLU7t8pdyn9uNT-p85FuSCJsXd2K42MUsSMO3-3X/s1600/cfadcc033fbf913b45fd3f822fb00250--metal-bending-garage-tools.jpg" /></a></div>
Using this as my basic starting point idea - I started rummaging through all my piles of steel pieces to see what I could come up with. First off, my press only has to handle parts up to 6 inches wide and steel only up to 0.125" thick. So, I don' t need a 20 ton bottle jack. A 4 ton bottle jack will do. I picked up a brand new one at HFT for this project. I also found an old piece of 4 inch channel iron that would make a nice base to build this tool on. So, this was a good start:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgm0nbMSnPyymtl5y3RZ_nJZsZpPrnTxJQCadZQYcf5-XYtZN2Agu1Mfru1cfrqhbzj7-gZ9zXJfPXvgkDUf-hJDcpXE8WEjjLAdrv8C2iOYY_soNr-ivWJIfw3GL-Bazm2KYk5zwZPfKeK/s1600/20171220_145657.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="779" data-original-width="643" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgm0nbMSnPyymtl5y3RZ_nJZsZpPrnTxJQCadZQYcf5-XYtZN2Agu1Mfru1cfrqhbzj7-gZ9zXJfPXvgkDUf-hJDcpXE8WEjjLAdrv8C2iOYY_soNr-ivWJIfw3GL-Bazm2KYk5zwZPfKeK/s320/20171220_145657.jpg" width="264" /></a></div>
Next, I scrounged around and found an old piece of 3" channel iron that was all bent up in the web, but the flanges looked to be in decent shape. So, I loped off 6" of that and cut the flanges off. I figured that these would make good lower dies if separated by a 1/2" piece of flat bar steel:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCfiNhZXF8fKReTM7AmNx2yEce_Y_LA9w3EL1dFUvTRfPzAGCPKtXPpNs827CMZ2Go8TSqI1LoFYTxphM0rAEbURgTGQw2acEinjzryID5bgcXpxeLrb1YF29RiMugDstT2lMMphRZozfn/s1600/20171220_145753.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="625" data-original-width="643" height="311" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCfiNhZXF8fKReTM7AmNx2yEce_Y_LA9w3EL1dFUvTRfPzAGCPKtXPpNs827CMZ2Go8TSqI1LoFYTxphM0rAEbURgTGQw2acEinjzryID5bgcXpxeLrb1YF29RiMugDstT2lMMphRZozfn/s320/20171220_145753.jpg" width="320" /></a></div>
So, I found, and cut, another piece of 1/2" plate steel that was in the scrap pile (litterally, nearly all of this tool is made from stuff in my scrap pile!!) Here are the two lower dies clamped together with the 1/2" spacer between them:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJZvje8ZcfPfTK9wJbq4N6QphKvH4forfnW463E7LP5BA3ecBVKWsg5lbScZk80ra6nkmssXjzFLLDYNAAnJ1GwUv0oYW_gA2p5LZVzU8IvPhw0Ng8IBaiqyDJvR1Y8ILWPGPGQNCi1qDa/s1600/20171220_145927.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="966" data-original-width="589" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJZvje8ZcfPfTK9wJbq4N6QphKvH4forfnW463E7LP5BA3ecBVKWsg5lbScZk80ra6nkmssXjzFLLDYNAAnJ1GwUv0oYW_gA2p5LZVzU8IvPhw0Ng8IBaiqyDJvR1Y8ILWPGPGQNCi1qDa/s320/20171220_145927.jpg" width="195" /></a></div>
I welded those together, and then had to make some kind of "wings" or "ears" that would be rigidly mounted to the lower die and could slide up & down between two upright pieces of angle iron. Here's another piece from the scrap pile with the pattern for the wings drawn on it, ready to get cut in the band saw:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmBtsAfKAQO3-TH_Q41PV2kMfBESlLH7ikWYMCLvawT5omVfDWnjd4GreN8KPbj8OklRphprVfmM9WLYgoOPGWroS7Y9ElzoZ9rBbLffM4r2IaeLlVB3pP3hztgmQAzid6l7JsMb_cbwE_/s1600/20171220_145952.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="642" data-original-width="639" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmBtsAfKAQO3-TH_Q41PV2kMfBESlLH7ikWYMCLvawT5omVfDWnjd4GreN8KPbj8OklRphprVfmM9WLYgoOPGWroS7Y9ElzoZ9rBbLffM4r2IaeLlVB3pP3hztgmQAzid6l7JsMb_cbwE_/s320/20171220_145952.jpg" width="318" /></a></div>
Here is the lower die assembly with the wings welded in place:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhzUpDMPdnLzTbzeGJLkjQsgqbHMCcqWzcehAkWtDjSNPX_o-rAR4ilPzN7sw2aLLkY-W2pnkIcUMXNt2bcRYMJlHw4L8wBSxBRRJGuQyq9KXPgWM3MV4d5X4mjsPVqGlRq-9ZmSQewwlue/s1600/20171220_163716.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="453" data-original-width="918" height="157" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhzUpDMPdnLzTbzeGJLkjQsgqbHMCcqWzcehAkWtDjSNPX_o-rAR4ilPzN7sw2aLLkY-W2pnkIcUMXNt2bcRYMJlHw4L8wBSxBRRJGuQyq9KXPgWM3MV4d5X4mjsPVqGlRq-9ZmSQewwlue/s320/20171220_163716.jpg" width="320" /></a></div>
The last thing it needed was a good, stiff piece of plate steel to make a sturdy base for the bottle jack to press against. Here is the completed lower die assembly all welded up and ready to go:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZmK3twtTF7NJ6oqLvNKdEiEEKRn5cxs9tI91WrrvrvBroLxKVpUkY4l6QZoSvmnRc8rAGuVR2CgybJ59EA6QArrj31AgMzGyBluJfjTan-9mgnqgL_kdrtfY0ZOMvGoqPWJJW8U6wcWdc/s1600/20171220_165723.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="581" data-original-width="918" height="202" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZmK3twtTF7NJ6oqLvNKdEiEEKRn5cxs9tI91WrrvrvBroLxKVpUkY4l6QZoSvmnRc8rAGuVR2CgybJ59EA6QArrj31AgMzGyBluJfjTan-9mgnqgL_kdrtfY0ZOMvGoqPWJJW8U6wcWdc/s320/20171220_165723.jpg" width="320" /></a></div>
I dug out some angle iron I had laying around. These weren't exactly scrap, but they were left over pieces from another job (I think they came from building the EAA mobile simulator catwalk). Anyway, here is the lower die with the vertical angle iron guides clamped to it and set over the top of the bottle jack (to give me an idea of what it would look like and how it would function):<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqYMcuMk7wTqFUafq4xBymdJiy1F_BoW5sjNrT5pkSKj6wwOvRqsn32VP1Y65ErhTFF3y2qtm7DGo57gDrrazEkO904XBhgwDsijykqxYKYs88aaSWtDTnRD4cy2ij9OohEMtaKVyCGqrE/s1600/20171220_190014.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1049" data-original-width="658" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqYMcuMk7wTqFUafq4xBymdJiy1F_BoW5sjNrT5pkSKj6wwOvRqsn32VP1Y65ErhTFF3y2qtm7DGo57gDrrazEkO904XBhgwDsijykqxYKYs88aaSWtDTnRD4cy2ij9OohEMtaKVyCGqrE/s320/20171220_190014.jpg" width="200" /></a></div>
Also, in the picture above, I'd found a 1/4" piece of steel flat bar that was in the scrap pile and I fashioned it into a punch die for the press. You can see the edge with the radius facing the camera in the picture above. Now, I had to cut some pieces of 1/8" steel to weld to each end of the punch die that would provide a uniform spacing between the angle iron guides (from the main base up to the punch die). Here those spacers are clamped into position for welding:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnC-2MO_IC_NPwMw50Plv_84oxRpZanJKF_CIWvI0YfKXGRQcsnzqsXdYobGa1A-vfF8FOfReQLEVK3nbw82O-4iTJ-4D1YG_bT074sXZB2cJZZwMQB4Yrnp-OOuy1EAwKv78CEG4ant8J/s1600/20171220_190104.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="767" data-original-width="612" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnC-2MO_IC_NPwMw50Plv_84oxRpZanJKF_CIWvI0YfKXGRQcsnzqsXdYobGa1A-vfF8FOfReQLEVK3nbw82O-4iTJ-4D1YG_bT074sXZB2cJZZwMQB4Yrnp-OOuy1EAwKv78CEG4ant8J/s320/20171220_190104.jpg" width="255" /></a></div>
Here is the punch die with the spacers welded to each side:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRqr9B0xSJj87ej8OSYFbMNwqNrL1uJqkmqFUkg7_cmItfdvh83ZUhrgphbflPl5d2uni77umEPOanCIGjwZ6TiOkb-c-RTgmvc4qXEVLCLnkhE2PuD6V6sQOeHnU1e00dCK8y_cRZOwat/s1600/20171220_222843.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="407" data-original-width="1102" height="118" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRqr9B0xSJj87ej8OSYFbMNwqNrL1uJqkmqFUkg7_cmItfdvh83ZUhrgphbflPl5d2uni77umEPOanCIGjwZ6TiOkb-c-RTgmvc4qXEVLCLnkhE2PuD6V6sQOeHnU1e00dCK8y_cRZOwat/s320/20171220_222843.jpg" width="320" /></a></div>
Actually, the punch die and the spacers at the main base would need to have a
small shim placed on each side do that the lower die piece would slide
up and down easily and not bind on the guides. I used some thin pieces
of tin cut from a 6" round heating duct (they are about 0.008" thick and
make a perfect size gap). With all the pieces clamped together and the shims placed on the top and bottom of the angle irons, I welded the assembly together. I found some appropriate springs in my "junk box of springs" and then drilled and tapped holes into the lower die wings. Also, drilled holes for 1/4" eyebolts in the main base. When I put it all together, it looked like this:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEik0KWv9pJfUTCPUzpFC2Cl-aMnAeF4nAHIExLxd-NGA2qxomaRsOPW8hOMptbU2H_6z7sfcXu9BXD5U4N9GGUwnuvtjAPUw1LpwycpdrlfeFRsa_CocAG2LEuxwSY9go4ylTPRs61Ydrm0/s1600/20171220_232612.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="948" data-original-width="646" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEik0KWv9pJfUTCPUzpFC2Cl-aMnAeF4nAHIExLxd-NGA2qxomaRsOPW8hOMptbU2H_6z7sfcXu9BXD5U4N9GGUwnuvtjAPUw1LpwycpdrlfeFRsa_CocAG2LEuxwSY9go4ylTPRs61Ydrm0/s320/20171220_232612.jpg" width="218" /></a></div>
I did not weld the punch die into place. Instead, I wanted to bolt that in place - just in case I ever want/need to take the press back apart. By removing the bolts in the upper punch die, I can get the lower die out of the press. I added a few more improvements like a round knob on the release valve stem and some paint left over from the golf cart painting. This is the final product, ready to make some Prowler parts:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWW_QcPbeGUgpJ0fM-8n-wXpOTJ9a7Kbh2lXhnBtipsKxElEzh1ZtGg_UlBfFSsgnaMZqSINjAoZ7ecV6SNXk04Z43U8aMOoUiLdPk9xDMfsrROJoasR4GLQirjIk_2bWh3NV9yKSr_oOI/s1600/20171221_180306.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="918" data-original-width="618" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWW_QcPbeGUgpJ0fM-8n-wXpOTJ9a7Kbh2lXhnBtipsKxElEzh1ZtGg_UlBfFSsgnaMZqSINjAoZ7ecV6SNXk04Z43U8aMOoUiLdPk9xDMfsrROJoasR4GLQirjIk_2bWh3NV9yKSr_oOI/s320/20171221_180306.jpg" width="215" /></a></div>
Here it is, bending the first part - the yoke piece for the TW shock mount I described above:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhB2W03bkQqpvel5M1GGNcmuPBfiTgMTEJ-Gq0uviS4QSb7ysjt_NYbQls0kw4eWQIlAWHBvNlAGRaTbNFeqNtN0Fh9Z-_dSeOdXVmRRwNLZU3mhA96cBDKL8JwmrSmoIUHbTbvpAnj_TzA/s1600/20171221_205820.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1143" data-original-width="643" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhB2W03bkQqpvel5M1GGNcmuPBfiTgMTEJ-Gq0uviS4QSb7ysjt_NYbQls0kw4eWQIlAWHBvNlAGRaTbNFeqNtN0Fh9Z-_dSeOdXVmRRwNLZU3mhA96cBDKL8JwmrSmoIUHbTbvpAnj_TzA/s320/20171221_205820.jpg" width="180" /></a></div>
And, here is the completed, formed part. The press works great!<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpdpToNnHhKmhgiknJoIvgzTpr-1ndH8pEXxn8px9soPXT5Lk3G4zt7g2dZEfwOl0xfWk-kb5pz4int5OlSvMbYP5o9dhCbnvhpZD896QidnO1WIog26wq3wawKM0JAF3IJVgkt5b3pPri/s1600/20171221_211217.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="595" data-original-width="658" height="289" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpdpToNnHhKmhgiknJoIvgzTpr-1ndH8pEXxn8px9soPXT5Lk3G4zt7g2dZEfwOl0xfWk-kb5pz4int5OlSvMbYP5o9dhCbnvhpZD896QidnO1WIog26wq3wawKM0JAF3IJVgkt5b3pPri/s320/20171221_211217.jpg" width="320" /></a></div>
Did I just mention a golf cart!?!? What a coincidence, that's up next.<br />
<br />
<u><b>6. Golf Cart Makeover</b></u> - In a previous post about 2-1/2 years ago I posted about a golf cart project that I started on. In that update I reported that I got it running, but it was backfiring a lot and needed the correct air cleaner assembly installed. Here is what it looked like then:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBBuMtmImdthFbiObxw4XMBmw40aw9ui-CON17Zjt1WvoLpG7p1RBgIIkwsppxlT7Bg5ynIIXzFmCuvrrdyjYrihT0KTeqj7sWNCE9o4DyHjDJaiZy2Ee1BDKLzkyuc-igroFN1mlrNWsl/s1600/20151101_151128.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="721" data-original-width="1149" height="200" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBBuMtmImdthFbiObxw4XMBmw40aw9ui-CON17Zjt1WvoLpG7p1RBgIIkwsppxlT7Bg5ynIIXzFmCuvrrdyjYrihT0KTeqj7sWNCE9o4DyHjDJaiZy2Ee1BDKLzkyuc-igroFN1mlrNWsl/s320/20151101_151128.jpg" width="320" /></a></div>
I ended up getting that air cleaner installed and it started running a little better, but it just wasn't running right. I did a bunch more troubleshooting and was about to throw in the towel on this thing. There was one last thing to try to get it to run better, and that was invest another almost $200 into an ignition module for it. I really wasn't sure if I wanted to risk the cost of that electrical part on this thing or not (generally, you can't return electrical parts once they're installed). So, I started driving it as it was, never sure if it was going to crap out on me (notice the tow rope in the picture below). I never put any of the body pieces back on it, cuz if it needed more work I'd just have to remove them again. So, I drove it around naked, without it's clothes on for quite a while:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_gVmoSZMpZZytspuEkDmAIMsQZ9GFnGmi4WW__rSgwJwp0A7HnkI71v8o-v2GvvBDGj2XfI-88Dd2-o7sabzDvYQ0XhMiPpSKLbGWMy2efEDmmhbVQ14OToYUsQS2aECGdA25_-vLEZgb/s1600/20161116_164310.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="758" data-original-width="971" height="249" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_gVmoSZMpZZytspuEkDmAIMsQZ9GFnGmi4WW__rSgwJwp0A7HnkI71v8o-v2GvvBDGj2XfI-88Dd2-o7sabzDvYQ0XhMiPpSKLbGWMy2efEDmmhbVQ14OToYUsQS2aECGdA25_-vLEZgb/s320/20161116_164310.jpg" width="320" /></a></div>
Finally, one day I beat up the internet and found the best deal I could for the correct
ignition module and finally popped for it. Turns out, that was what was
wrong all along. The old module was working, but not very well. After snapping
in the new one, the thing ran like I champ! Well, over the course of
the past (nearly) 2 years, I've been making little improvements on the cart. Last spring I needed something to haul around my 25 gallon weed sprayer and kill the grass and weeds in my driveways and other areas. I decided to modify the back end of the golf cart to be able to do this. However, I didn't want to make it a permanent installation, cuz I also want the cart to haul junk around the property for me when I need to. I came up with a plan to make a frame on the back of the cart that could hold a "platform". I could make multiple platforms and install whatever I wanted on these different platforms and just drop whichever item I would need to onto the back of the cart. Here is the modification to the back of the cart and the frame used to hold these platforms:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjv9Se3cmlNUiJcDi5c0oPfvjQDxnUDgXxLPsSvkLNi5lO4W2v42Rw73FueRX0J9MFK_E_jT88wIj1QaGX2vzXxy8TVhtgw6IxeN5iZvx0BiVrtYpRJdIaJQYwU1MRSe9WR-WtosOS15PYL/s1600/20170216_192855.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="735" data-original-width="1306" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjv9Se3cmlNUiJcDi5c0oPfvjQDxnUDgXxLPsSvkLNi5lO4W2v42Rw73FueRX0J9MFK_E_jT88wIj1QaGX2vzXxy8TVhtgw6IxeN5iZvx0BiVrtYpRJdIaJQYwU1MRSe9WR-WtosOS15PYL/s320/20170216_192855.jpg" width="320" /></a></div>
Next, I literally made a wood platform by placing 2x4 pieces flat side down in a rectanglar shape that fits inside the angle iron frame you see above. Then, I cut a piece of OSB the same size as the rectangle and glued and screwed the OSB to the 2x4 frame. Then, I cut holes in the right places and mounted my weed sprayer to the platform. I dropped the assembly into the frame on the back of the cart, and, this is what I got:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSutQiyAwz6TcOWbAsGAcrFh13YmqGvSGImfFwac0grh863Baf2yjIcAB6dYjEqaEstK4lhjh-PXnhjHVUonc0pPLOqVDcfk3Iu5sEgGeUsEgAMuh93P5DnvJhSIo0jayAC4JxXOwegHwL/s1600/20170217_154319.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="735" data-original-width="1306" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSutQiyAwz6TcOWbAsGAcrFh13YmqGvSGImfFwac0grh863Baf2yjIcAB6dYjEqaEstK4lhjh-PXnhjHVUonc0pPLOqVDcfk3Iu5sEgGeUsEgAMuh93P5DnvJhSIo0jayAC4JxXOwegHwL/s320/20170217_154319.jpg" width="320" /></a></div>
It works awesome! Unfortunately, the first time I filled the weed sprayer, I discovered that the weight of the water was just a bit too heavy for the aft suspension on the cart. The lower portion of my modification (the gray area that I call the "trunk") was bumping down onto the top of the transmission. It wasn't hurting anything by doing that - but, I didn't like it. So, after a few minutes in the "thinking chair" I decided that the cart needed a lift kit. After scrounging around for some appropriate steel pieces.....my lift kit was welded into place:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjSz3kOKBQ4MHI4cHlbjEzyVF2wTuJ2c68jC8MSPz67rATPaD2OAq0PCRnPtpCvOwxh7B62ppulWFaenaNf_z-99qp5w9bIYdw5krlIN1aC0At4R6asUZCi0MppR12Zqzo2rAwFS9ohMiWl/s1600/20170308_152618.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="684" data-original-width="815" height="268" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjSz3kOKBQ4MHI4cHlbjEzyVF2wTuJ2c68jC8MSPz67rATPaD2OAq0PCRnPtpCvOwxh7B62ppulWFaenaNf_z-99qp5w9bIYdw5krlIN1aC0At4R6asUZCi0MppR12Zqzo2rAwFS9ohMiWl/s320/20170308_152618.jpg" width="320" /></a></div>
Problem solved! It even gave the cart a little more "racy" stance:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1jOdhcXobCZOwzr-1878ljG4MAAUhMTPQr3XunIB1cZeB3yp3U2j0_SczrrvatCkZz2l75BCYE44TV5Ex_JtKiJObUFFaZrSvNXdV65CnO3AnCDHd-u2M5wBBYMLp6ARyB1h7wm9autqf/s1600/20170308_154710.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="566" data-original-width="968" height="187" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1jOdhcXobCZOwzr-1878ljG4MAAUhMTPQr3XunIB1cZeB3yp3U2j0_SczrrvatCkZz2l75BCYE44TV5Ex_JtKiJObUFFaZrSvNXdV65CnO3AnCDHd-u2M5wBBYMLp6ARyB1h7wm9autqf/s320/20170308_154710.jpg" width="320" /></a></div>
After weed season was over, I wanted to be able to use the cart to haul some stuff around. So, I made another "platform" and built a wooden box onto it. I pulled the weed sprayer off and dropped the junk box onto the cart. Each platform is held to the cart with 2 lag bolts thru the side of the frame on each side. You can see the heads of the lag bolts in this pic:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDcewKiylPUyeyNoiwsCKS8ONaFezDVESqt4dfUd1jmZhtF6dIqlVXYm-HUJi2crBovk7VfqtiKx6YmMexEdSdOJe6u4jJ_54J1NjWQHydRr1JuXrtZIZzbA4UxNHvtiLjRwJzvEkLDP7r/s1600/20170427_100914.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="635" data-original-width="941" height="215" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDcewKiylPUyeyNoiwsCKS8ONaFezDVESqt4dfUd1jmZhtF6dIqlVXYm-HUJi2crBovk7VfqtiKx6YmMexEdSdOJe6u4jJ_54J1NjWQHydRr1JuXrtZIZzbA4UxNHvtiLjRwJzvEkLDP7r/s320/20170427_100914.jpg" width="320" /></a></div>
So, I've been driving the cart around and using it quite a bit for the past 2 years and recently decided that it was not going to blow up on me. Maybe, it was time to invest a little effort into fixing up its appearance. I started by making a new control panel for it. The original keyed ignition switch had been cut out and was never there. So, to cover up that hole and make a way to hold the switches I installed I made up this aluminum plate to mount on the dash:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhlFapNudxs2ElkSnJ2bUxZaObnE7GRqRbT2PnB8CXEMwNg5s3SUftI1Ny-bVrX7D-nsfuuxel0xihx3Fh4raB5WdPYhtCEQ6mc0ZDsyEKa6_gUdd1DrSPKTVUoLBRNtodS7eSDlrYVZMZp/s1600/20171202_155525.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="643" data-original-width="1224" height="168" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhlFapNudxs2ElkSnJ2bUxZaObnE7GRqRbT2PnB8CXEMwNg5s3SUftI1Ny-bVrX7D-nsfuuxel0xihx3Fh4raB5WdPYhtCEQ6mc0ZDsyEKa6_gUdd1DrSPKTVUoLBRNtodS7eSDlrYVZMZp/s320/20171202_155525.jpg" width="320" /></a></div>
Nothing is really labeled - but, that's my security system. I know what the switches do - but, no one else does. As my knee was slowly getting better, I was able to get out to the shop and do some things. I decided that this would be a good time to get on fixing up the body panels that came with the cart. I never really got any good pictures of how bad the body panels were that came with this cart. But, here is a small, distant shot of them laying out behind the shop last spirng:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVZtHUqT9UW7OOLUQav-e4tKd3aFHGN3U75U6T4AMx3qraoNC0OgIejt9H7nyMYuClxkT2DwKMoo_JpugjaRSuHDk5MSsa13I8mIcFqdLoWTBkw4OKqwQxN3BHEJ1n_qECzXjyX6FwCiWr/s1600/20170215_120145.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="241" data-original-width="359" height="214" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVZtHUqT9UW7OOLUQav-e4tKd3aFHGN3U75U6T4AMx3qraoNC0OgIejt9H7nyMYuClxkT2DwKMoo_JpugjaRSuHDk5MSsa13I8mIcFqdLoWTBkw4OKqwQxN3BHEJ1n_qECzXjyX6FwCiWr/s320/20170215_120145.jpg" width="320" /></a></div>
The guy that I bought this project from actually gave me 2 aft bodies - one was the correct, original boy and the other was not correct. The front body panel was really beat up - the right front corner had been busted off completely and what was there was cracked in about 3 places.<br />
<br />The first thing I did was to take the aft body panel and modify it to fit back onto the cart with my "modified" back end. That was really, simply a matter of doing a straight line cut across the entire back end of the body panel so that the body panel ended just forward of the angle iron frame for the platforms. Then, I noticed that the left back corner of the body that I cut off the back body panel looked pretty similar in shape to what was missing from the front right corner of the front body panel. So, I hacked out that corner and started to fit it into the space on the front body panel where it was missing.<br /><br />I did a little research online and it turns out that the material that these body panels were made from is called "<a href="https://en.wikipedia.org/wiki/Metton" target="_blank">metton</a>".
Metton can be repaired by applying fiberglass. So, I taught myself
how to do fiberglass work again and got started on repairing the body
parts. Here is some of the fiberglass work (on the inside of the front body panel) that I did to "fillet" in the new front right corner:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfTg5XtYi8HSF99ZS1GT1rL5QB3GP3iW9IYOpS3ZGTin3W6a6mVEs4TcWFujzoD050IrPXUZz_WGth4lGaAbBeNe8WYf75BPR2x5HWsNiUcue0__enMaMemi35Zncf4jdSU23j9f73YGE6/s1600/20171207_181714.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="564" data-original-width="1185" height="152" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfTg5XtYi8HSF99ZS1GT1rL5QB3GP3iW9IYOpS3ZGTin3W6a6mVEs4TcWFujzoD050IrPXUZz_WGth4lGaAbBeNe8WYf75BPR2x5HWsNiUcue0__enMaMemi35Zncf4jdSU23j9f73YGE6/s320/20171207_181714.jpg" width="320" /></a></div>
It took about 3 days of applying 2 fiberglass layups each day to get the new front right corner fixed up. Here is front body panel temporarily installed on the cart before body-filler and paint work:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFEVZE5KPZahY-SiSJqT_MC4ZlcTj51LdgJwxS9joyc8Ds50ipiFaHNaBtRST761Myuodn6WVbVXkQY7SBlfw6CVUCaP1Pj-EvwBtQXZk7YkILGjBmqsvtriUPFJhjVcqib-rvgjuVI7RO/s1600/20171209_153842.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="735" data-original-width="854" height="275" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFEVZE5KPZahY-SiSJqT_MC4ZlcTj51LdgJwxS9joyc8Ds50ipiFaHNaBtRST761Myuodn6WVbVXkQY7SBlfw6CVUCaP1Pj-EvwBtQXZk7YkILGjBmqsvtriUPFJhjVcqib-rvgjuVI7RO/s320/20171209_153842.jpg" width="320" /></a></div>
Notice in the above pic, the aft body has been painted and installed. You can see where the aft body has been cut off about the 1/2 point above the rear wheels. Here is a close up shot of the front right corner of the body after the fiberglass work on the inside, but before any body filler and work on the outside. The tan colored piece is the part that came off the back body. You can see how mangled this thing was when I got it:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjouG5VEQRlqKYc1K2ZkEoCvRchjBM2rYt99G9hGtRgm68H-Isu7BdkkcJdq2Bp8kxV8RWoAyumbmVg4e8VXVXACTPOgv8Cx650idGG1EnJOFVv0ORJ3YINVJ3fS2EZ7fyVJNQnG9Nt9V4H/s1600/20171209_154143.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="549" data-original-width="957" height="183" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjouG5VEQRlqKYc1K2ZkEoCvRchjBM2rYt99G9hGtRgm68H-Isu7BdkkcJdq2Bp8kxV8RWoAyumbmVg4e8VXVXACTPOgv8Cx650idGG1EnJOFVv0ORJ3YINVJ3fS2EZ7fyVJNQnG9Nt9V4H/s320/20171209_154143.jpg" width="320" /></a></div>
Here is the cart after about 2 days of body filler and block sanding:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioxQauWiJZLfxUUXP1iuRQhyFaSh3A8vmt8oE3xn-sVllyL3YYBQDiAxCHU4JVAC6GyTbzad2ypcFvsFoizwovfjDrZC0IVf9_XIjwmoqOG7tPuY3x1X7h6bZjHJXfYNQEySHWFf2hZnZP/s1600/20171212_211110.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="643" data-original-width="901" height="228" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioxQauWiJZLfxUUXP1iuRQhyFaSh3A8vmt8oE3xn-sVllyL3YYBQDiAxCHU4JVAC6GyTbzad2ypcFvsFoizwovfjDrZC0IVf9_XIjwmoqOG7tPuY3x1X7h6bZjHJXfYNQEySHWFf2hZnZP/s320/20171212_211110.jpg" width="320" /></a></div>
And, here is the cart with paint on the front body and new headlights installed. If you look closely you will see that I am definitely <u>NOT</u> a body repairman. In the sunlight the paint looks horrible. But, I just don't have the patience for doing good body work and I just couldn't invest more time in this project. In the end, this was several days of repairing and painting. Here it is, as it is: <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8A9CJ4PkCJ0pcZ8C7-YvFDUlovoQQLDCkzkRJSb1Cx_B8K2Th8ab-9iNcqMgTufjRFjcAGM3DWkaLVXQaWlQcwKT6TsQggbjnw6Us23Deyv-HrltTpcbwj6IJ5dWCIRQDXlpb_7R_GK9E/s1600/20171215_232526.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="735" data-original-width="801" height="293" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8A9CJ4PkCJ0pcZ8C7-YvFDUlovoQQLDCkzkRJSb1Cx_B8K2Th8ab-9iNcqMgTufjRFjcAGM3DWkaLVXQaWlQcwKT6TsQggbjnw6Us23Deyv-HrltTpcbwj6IJ5dWCIRQDXlpb_7R_GK9E/s320/20171215_232526.jpg" width="320" /></a></div>
Yeah, sure, the paint doesn't look great up close in the sunlight. But, from
10 feet away the whole thing looks a whole lot better than it did the
week before! And, all in, it's not too bad for 2 days of sanding and $8
worth of rattle can paint.<br />
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The only thing that was still missing was the front bumper. I actually had the bumper that came with the cart. It was a torn-up, ratty piece of plastic that was not useable. So, I went digging in the scrap steel pile again and came out with a curvy piece of something that was long enough to do the job. I wanted to add some curvature to the ends of the bumper to sort-of match the curve of the front body. So, I took the port-a-band and cut some slots in the material and then bent the ends down and stuck the end of a 1/8" welding rod into the gap - like this:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjf2vIsBj0gum3vcJqCjLYpS7IvPucMQVaTMZxYmGMcouLQGzLGQY_KQq9PVLnovB2ASbZSwW5tHtwJRKipMRRhg9U-4MGGbeXvJQ8bdtjsNcSPCligeNB4qQfITRnB3N9J2Wt88R_jsF0-/s1600/20171217_171436.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="554" data-original-width="583" height="304" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjf2vIsBj0gum3vcJqCjLYpS7IvPucMQVaTMZxYmGMcouLQGzLGQY_KQq9PVLnovB2ASbZSwW5tHtwJRKipMRRhg9U-4MGGbeXvJQ8bdtjsNcSPCligeNB4qQfITRnB3N9J2Wt88R_jsF0-/s320/20171217_171436.jpg" width="320" /></a></div>
By doing this several times to each end, it gave the new bumper some curvature the ends. Here's what it looked like with just a couple cuts in the ends:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0hU7UbdUm-kGvBrucuNhd0vTBi7Js2MS95kC2Ka8wsitsJfeCLQHT8eNwJ2FRGz809z-QJtHitA0RXuHp-mzMCswvpUqoiSSqVChZVdZ3ZnU765JnYrrh4yznGaZFcLgdN1ifSOGKVOYx/s1600/20171217_171437.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="210" data-original-width="1100" height="61" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0hU7UbdUm-kGvBrucuNhd0vTBi7Js2MS95kC2Ka8wsitsJfeCLQHT8eNwJ2FRGz809z-QJtHitA0RXuHp-mzMCswvpUqoiSSqVChZVdZ3ZnU765JnYrrh4yznGaZFcLgdN1ifSOGKVOYx/s320/20171217_171437.jpg" style="cursor: move;" width="320" /></a></div>
I kept up the same process until I got the right amount of curvature. Then, I spent about 2 hours grinding it all down and making the ends smooth. I added a short piece, edge-to-edge, along the bottom to give a flat area to mount the new bumper to the bracket on the front of the cart. This also raised the new bumper to the right height that looked good. I added a few coats of rattle can gloss black paint and, then, I put the bumper on the cart. The last touch was to put the "Yamaha" logo back on the front. Here is the new and improved Prowler Shop Cart:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEju5i4O3Uut4G-fYUJW_dm8rL7vmYTF8RdljwSLGsKv8ha3Sc7IIk_5lT_H8ud3TWYu25W_Jg4vathufmuEwg9MixoC1SgCzUA2bBUPFm4wTasLtRHQGp1SfykGnGw_MKPwkqZWGZoIAscF/s1600/20171227_095626.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="661" data-original-width="903" height="234" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEju5i4O3Uut4G-fYUJW_dm8rL7vmYTF8RdljwSLGsKv8ha3Sc7IIk_5lT_H8ud3TWYu25W_Jg4vathufmuEwg9MixoC1SgCzUA2bBUPFm4wTasLtRHQGp1SfykGnGw_MKPwkqZWGZoIAscF/s320/20171227_095626.jpg" width="320" /></a></div>
It still needs to have some body work done to the back sides/corners. I'll have to think about how to accomplish that for a while longer. It also needs some better wheels/tires, but I'll wear these out first. Overall, this has been a nice project - it's great to be able to take it from the near basket case condition that it came in back into a useful machine.<br />
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Well, that's all for this update. Thanks for stopping by. I'll post again early in the new year. Hope you all have a great end to 2017.Unknownnoreply@blogger.com0