Tree top pilot

This is what the plane looks like...........nice

Me and the missus like to enjoy the .22 rifles....but have a real hard time getting .22LR. This has been going on for 3 years now. Nothing wrong with some target shooting competition....but cant even enjoy that. Last gun show in town sold out most all ammo by Saturday....anything in bulk was gone. Have heard that Wallyworld had .22 but you had to be there when the truck came in.....limit 3 boxes...of anything.

It would seem that we are screwed. Question is..... what can be done to rectify the situation....?? Guess I am banned already with this line through my text.......

I am really liking that set of spars. There's a lot of nice things with that design. I bet the die for that was slightly high priced.... Nice looking wings ! Still wanting to form a set of ribs out of aluminum.....I know they can be made lighter. Lots of ideas and not enough time... I should have started earlier in life with all the airplane stuff....
 
I had spoken with another engineer in my area about making the ribs from 6061 T-0 and then having them heat treated. After we looked at some CAD models and there would be a need for compression struts...but allowed the use of cables for sail/anti sail bracing and tube trailing edge. Could CNC the rib die and form ribs with rubber block in press ready to phosphate and rivet in place.... We estimated that would come out to a completed wing near 25 lds ready for fabric. The flaperon hinges would also be T-6....flaperons made up of aly ribs and .018" 2024 sheeting. Round tube wingtip of T-6. Basic profile and lighter weight....unless parts were all carbon composite.....
 
Ed... that water that looked milky was the abrasive that is suspended in the water to aid in the cutting action. I know a guy out west that has one in his shop...said he needed that machine 20 years ago for the time it saves his shop. No slag to clean up or hardened edge to grind beyond....and doesn't warp the metals from heat of CNC torch - laser - plasma cutting. Says it takes just enough pressure to keep the parts from wiggling around to hold them in place when cutting.

Take heart...I have been at a kit that was supposed to be ready to assemble. Got taken and now have 2 airplanes....one for scrap{the original} and one that is going to be safe and airworthy. Helps me sleep a little better. Over the "I hate this" thing and want to see it finished now.

OK I decided to start all over from square one with the wings. Making enough stuff for 4 wings is easier than just 2 helping another. So we got up an order for AS and went router bit shopping. A Local Klingspor wood shop had a nice selection of bits- we picked up the solid carbide downward chip ejection with roller bearings. Ply wood came in- 5 ply for capstrips and 10 ply for ribs. Dust flew....and piled up outside.....reminded me of snow. Now we are set. I have a full set of new ribs and falsies for the aileron and flaps. All new steel parts are also in the works....everything new. Now that I have been getting a little better health wise....I now have to find another place of employment. Guess I was "downsized" or just plain phased out. Never the less I will tinker with this as I can and share results. I made all the master templates and metal fixtures for the parts being made. At this rate I may want to start building airplanes....It's not like I don't have the equipment to. That's just fine . Something else to cloud my thoughts.

Thanks for all the info on plywood ! 

Still would like to know what thickness have been used out there....my reasoning below....partially
 
OK for the math.....4130 N steel has a yield of near 63100 psi. The cross sectional area of the narrow portion that bears most of the load is .040" thick x 4" long = .16 sq. in. per side of the fitting. Both sides combined = .32 sq. in.  So then take sectional area  x  area of the part......63100psi  x .32 = 20192 psi. Divide by a safety factor of 2 =10096psi. That is a lot of force to just get this to start to tear open. That is for pure tension only...no bending moments. The math gets a little scary for the real stresses that are present in these little pieces so I won't take you on that trip. There is a small component of compression...but those loads are transferred directly to the spar tube and the wing moves up. Not enough to be an issue....but the force is there at times. You have to look at everything a part can encounter alone and in the place it will work with other parts as a whole. Time and math is the only way to be certain provided the materials have no flaws to skew your calculation. That is why I like to use a safety factor of 2 instead of 1.5. Errors on the strong side only adds a tiny bit of weight.....but a ton of confidence. So for my little bird that would mean about =7 G's before the fitting would start to fail with correct FEA load testing. The spar would probably give up the ghost first. But this is not taking into consideration the two sides are tied together as a unit of three pieces....that's when the game starts getting more complicated. The stainless rivets are good for over 400 psi in shear....
 As for the original fittings....my attorney said to keep them. The reason being is that I am going to make a full disclosure of my experience. We both have photo documentation and the original parts as delivered on the following day to cover any issue of a slander suit in any form by the manufacturer. I just want the truth to be known. It may keep someone from being hurt. I would be willing to loan out my fixtures if you want to make a set.
 
Your mileage may vary...I am on medication.
Have a happy and safe 4th....and thank you to all who have served to keep freedom of all we have to enjoy. I lost a good friend in Iraq.

Just to make sure we're both on the same page......made from .040 molly sheet. Rusty ones were the poorly made parts as delivered. No pride in the workmanship......not to mention no concern for safety. I powder coat most all small parts that will fit in the shop's oven. Girly pic is my nose art I am working on / editing as time gets closer to finish.

The old ones were made from .040". Just wanted to see what else was out there. There is a lot of stresses where these make the bend coming off the tube. As for the inserts.....a suggestion was made here to make them from 1/4" plywood. So I drilled and "V" shaped the ends and sealed with epoxy clear-coat. That should do the job of keeping the tube in shape and from collapsing under all those + G forces. I mean if .040" will safely handle a 1350 MTOW on an Avid I would like to know that it has been proven to be safe. There was a pair of washers welded on the bolt hole side to spread the load on the bolt. It was to be finished reamed to .250" before bonding to the spar.
Thanks for looking into this.....

It was done by a helper with a propane torch...while I was absent. I would hate to scrap what I have....but it is critical. I am at a loss here. He told me it was heated from the inside enough to wiggle the rib off. So who knows...it was more than a year ago. As for replacing the spar...you know how much work that would be. Better off to start all new again. I am trying to figure a way out of doing just that. I agree with a fish-mouth to prevent a stress point. I am just trying to rationalize this as some other aircraft have a welded headrack tube made from T-6....and they are not falling out of the sky. My MTOW will be under 650lds. But .........I will be in touch with a person at Alcoa soon. Hopefully they will help in some capacity. Thanks for the suggestions......a lot to swallow at this point. Just now being able to get back to work on it a bit before the next round of health issues retards my activities.

US state constitutions state....a right of revol.......couldn't get it to copy and paste...
 

One thing I have learned is that mistakes/ accidents happen. If you need to un-bond a junction using Hysol 9460.... here is what I have found. The glass transition temperature of 9460 is near 160 deg. F......so with careful monitoring of temps....you should be able to un-bond a glue joint on most parts. Seeing as T-6061 has a problem with losing some temper near or above 320 deg. F for more than a few minutes.....one should be able to take a wing apart with no problems. Reason being is that I am helping with a spar replacement on a Kitfox . Jason was worried about the drag tubes getting heat through the attach bracket....and then the metallurgical books and Alcoa documents reading began. Man what a job. Just thought I would pass along the info we have gathered in a nutshell.

I have made my own tailspring from 1.24" X 6mm titanium. Formed over a 6 " radius - limit of radii for that thickness cold bending. Single leaf as my MTOW will be less than 600lds. If you bend one....make sure there are no sanding marks or anything else on the edges of both sides before hand...sand and polish mirror finish. This is where the cracks will begin as it does it's job over cycling a lot. Made the wheel on the CNC with a urethane convoluted tire. Machined the arm and block from 7075 ally...with a bronze bushing. I have not done the math for anything over 600lds service duty....I am sure a 4mm top leaf would bolster it more than enough. Just food for thought on saving weight....cut off more than 2 lds. with my setup.

Like I told my father at the gun show last weekend....Every time I hear something about gun control on the radio I go and buy more ammo...and sometimes a new toy. Heres the deal with a personal issue/habbit. I smoked for over 30 years. Now I have been cigarette free for over 2 years. I quit cigarettes using an electronic vaporizer. Now the govt wants to ban them with fda legislation in April. So many people have quit using these products....
They changed things on April 12,1861.....this thug is trying to bend and dissolve every aspect of our Constitution.
They are proven fun haters....and don't have rspect for us at all. An ad for a BB gun had a warning of not to brandish the gun in public as it may scare someone or be illeagal to do so. Go figure....sheeple. I am sick of it.

An independent investigation into the deadly Sept. 11 attack on the U.S. diplomatic mission in Benghazi, Libya, is complete, and Congress will be briefed on its findings this week, the State Department said Monday. The…

I guess that true Americans can get killed for trying to do what's right...or am I missing something here? The media is constantly feeding crap over the airwaves.
There are some nice places in Brazil with similar climates as the States....and no BS down there.
I just don't understand why Osama bin ladin has not been impeached....after all there have been so many items that are clearly breaking the laws of the land. But that too is probably just a technicality now for them to ALSO sweep under the rug.
I personally think we are all screwed....unless something changes....and soon.

Like Rush said....it's damn hard to beat Santa...