I bought Jon Croke's excellent DVD on scratch building, which gave me heaps of ideas and methods that I probably wouldn't have thought of myself.
Made a bending brake just out of a hinged piece of Tas Oak on the side of the workbench (with another piece on the top which has an aluminium strip screwed to the edge with a 3mm routed edge for bending). At the moment I just screw this to the workbench when bending something, but have just bought a very stiff length of square section extrusion which will allow me to clamp the bending edge down instead.
I cut out all the parts for the rudder, bent, drilled and clecoed them together. As per the DVD I made forms out of solid timber (good old Tas Oak again - 20mm flooring) but as I haven't got a vice yet, clamped them to the workbench and bashed downwards with the rubber mallet. This seemed to work pretty well, even with the tight radius on the tip rib.
While I was making forms, I made the forms for the rear wing ribs. Because of the width I couldn't use the boards I'd used for the rudder ribs, so I faced them with Eco Ply which I glued and screwed to scrap particle board.
I've started work on the elevator ribs forms now. Before I finish the rudder skeleton I want to corrosion-proof each part. A fellow builder here in Tas told me about a Savannah he bought for parts - 2 years old and heaps of corrosion in it.
One thing I have realised on this build - you don't need a whole lot of expensive tools to get started, in a lot of cases brute force & ignorance is enough...

Views: 131

Comment

You need to be a member of Zenith Aircraft Builders and Flyers to add comments!

Join Zenith Aircraft Builders and Flyers

New from Zenith:

Zenith Planes For Sale 
 

Classified listing for buying or selling your Zenith building or flying related stuff...


Custom Instrument Panels
for your Zenith
:

Custom instrument panels are now available directly from Zenith Aircraft Company exclusively for Zenith builders and owners. Pre-cut panel, Dynon and Garmin avionics, and more.


Zenith Homecoming Tee:


Zenair Floats


Flying On Your Own Wings:
A Complete Guide to Understanding Light Airplane Design, by Chris Heintz


Builder & Pilot Supplies:

Aircraft Insurance:

 
 

West Coast USA:

 
Pro Builder Assistance:

 

Transition training:

Lavion Aero

K&S Aviation Services

Aircraft Spruce & Specialty for all your building and pilot supplies!

How to videos from HomebuiltHELP.com

Developed specifically for Zenith builders (by a builder) these videos on DVD are a great help in building your own kit plane by providing practical hands-on construction information. Visit HomebuiltHelp.com for the latest DVD titles.

© 2024   Created by Zenith.Aero.   Powered by

Badges  |  Report an Issue  |  Terms of Service