10/24/18
What a beautiful day it was here in the Northland,
sun shining (setting), mid 50's, light breezes.
Still, we kept the big door closed, haha! We had a light turnout of Youth Participants,
Parker and Ethan. It was nice though as without
them we couldn't work on the plane, and a
eager pair of workers too! Mentors were Tom,
Mike, Milt and me. You notice that Milt was
on the "Mentor" crew last evening.
Milt is in a special situation with us, sometimes Mentor, sometimes Youth
Participant (even though he is as old as any of us). Milt came to us years ago to learn about TIG welding
while we were repairing the fuselage and stayed on learning about all the other
aspects of aircraft restoration that we get into. When the time comes, he is all in passing on his
experience and knowledge to other Youth Participants. Thanks Milt!
So, Parker and Milt got after wiring the stringers
(which Milt is pretty good at). Parker had
not to this point done any safety wiring, so he got some good practice under Milt's
guidance. By the time the evening ended they
had finished up all the remaining stringers except for the ones attached to the
window frames (which I'll get to in a just a shake). It was at the very end of the evening that we
discovered that the 3 stringers on the top came away from the forward upper cabin
bow. This is all on me as they asked if the
top stringers were ready to wire and I gave them the go ahead. I hadn't noticed they weren't attached to the
cabin bow, which should come first. Darn it!
No worries though, next time we'll release the wires and secure the stringers
in the bow and continue. When one is learning
(and we're all learning) mistakes happen.
That's one way we learn. We'll back
up and then move forward!
Meanwhile, Ethan and Tom got setup to finish the varnishing
of the window frames and stringer assemblies.
The stage was set in the meeting room and parts were removed. Tom mixed up a batch of epoxy varnish and during
the induction period (about 30 minutes) Ethan and Mike installed the elevator bell
crank into the fuselage. That was just about
enough time for the varnish to sit, so Ethan and Tom went to work with the brushes.
When that task was finished there was just enough time for Ethan and Mike to set
the elevator push-pull tube in place on the control column and elevator bell crank. They didn't permanently install it as its length
will need to be adjusted to aid in the elevator's full range of movement. We have moving parts in our airplane, yay!
In between times, Mike took some measurements of the
control wheel shaft bushings, so we can replace the old ones. They looked good a first but, they allow too much
lateral movement in the control wheels for our liking. Mike will prepare some materials for another work
session to renew that bearing. Thanks Mike!
Thanks to all who turned out last evening. Now notice, next Work Session in on Halloween. Costumes are optional! I
for one am going to dress up as a "Spirit of Katrina" Sedan Work Session
worker guy! (see if you can recognize me!)
How 'bout you?
10/17/18
Last evening greeted us with light winds and a cool
clear sky. We had the heat on in the hangar
and kept the door closed, cozy! Autumn, Chris
and Milt were there to get busy. Tom, Mike,
Frank, Bill, Barry and I were there to help.
Rear window frames were on the menu again this time,
so Autumn and Chris got to it with Tom's and my guidance. They cleaned up the glue joints from last time
and shaped the stringer coming into the window frame. Mike dug out some pulleys and cable, so we could
stage the aileron cable that goes past the window sills, giving us a reference to
precisely locate the sills. Their task got
to be a little crowded, so Chris and Mike moved to tie wire the stringers, an ongoing
process. There are a few spots left, but
we're making progress. The stringers attached
to the window frames are left loose so that we can remove the window/stringer assemblies
for a final varnish touch-up on a bench.
We flipped the fuselage right side up to continue our work, my but this thing
is starting to look like an airplane!
Tom and Autumn continued with the window project and
located the rear headliner former into the window stringer. This former is an 1/8" wire that is anchored
into the stringer, giving the head liner something to hang from. There are five such stations where the headliner
hangs from, the rear one being the biggest.
It also should be nice and straight, I mean all on the same geometric plane,
so the headliner seam has a nice straight line.
After considerable attention, I think they got it!
Thanks to all who came out to work on the Sedan last
evening. With the continued participation
of our Youth, little by little, we continue to make progress. See you all next week!
10/10/18
Is Summer over or what?? I hope this weather is not a harbinger of things
to come! Nevertheless, we had a great turnout
last evening. Eager to get to work were Jacob
along with his Dad Brian, Ethan with his Dad Jordan and Chris with his Mentor Barry. The Chapter crew ready to lead the charge were
Tom, Mike, Al and me.
Jacob was especially excited to do some more riveting,
anxious to see what he remembered from his lesson last time. Al was happy to guide him, and together they reviewed
the basics and riveted two pieces together.
Jacob has big plans about finishing his project, he wants to add to it for
another project he has going at home.
Ethan was not to be still, so he and Tom got busy
with a drill stop and countersink to fit flat head fasteners in the window frames
and upper outboard cabin bows. That task
complete, Ethan installed AN3-6 bolts and nuts in the upper forward cabin bow. With time to spare he and Tom, along with Al,
glued the reinforcing strip on the left side window stringer splice.
Chris, in the meantime got busy cleaning up the glue
joint on the right-side window frame/stringer he and Barry clamped up last time
we met. That turned out real nice. After that the two of them joined Mike to put
the final torque on the right-side Control Column pivot bolt. Last time you may remember we were unable to finish
that job for lack of a thin washer to help clock the slot in the castellated nut
for installation of a cotter pin at the proper torque. (Whew!) With the additional washer, the nut drew up within
the proper torque range and the cotter pin slipped in. Setting the pin went smoothly
and on to the next task they went. Wiring
the stringers to the wooden bulkheads was the job, a continuation from last time
too.
It's fun, from one Work Session to another, to witness
what these kids retain and perfect with practice. I think we're starting to help them develop some
skills that will serve them well in the future!
9/26/18
I can't believe September is winding down already,
at this rate it will be spring before we know it! No? Well it was worth a shot! Last evening's Work Session was over before we
knew it, a busy couple of hours complete with visitors curious about our progress. Mike Busch stopped by as did Tom Setter and Ethan's
Dad Jordan. Youth Participants ready to work
and learn were Ethan, Autumn, John, Chris and Milt. Milt is kind of a floater, sometimes one of our
Y.P. and sometimes Mentor, pitching in when able. Thanks Milt!
Mentors were some of our usual crew, Tom, Al, Barry and me. Mike and Frank were off fulfilling other obligations.
The evening got started with Chris and Barry picking
up where they left off on the right-side window frame/stringer junction. Their glue joint cured, it needed to be cleaned
up which they took care of. Sanding flush the stringer to the frame. Next, they prepped the area for the reinforcement
strip and glued it into place.
Autumn, John and Tom prepped the left side window
frame for the same operation, drilling the additional fastener hole through the
frame to the fuselage at the top aft corner and gluing the stringer extension to
the bottom of the frame.
Ethan and I began the process of fastening the stringers
to the wooden bulkheads with .032 diameter safety wire from Tom's supply cabinet. Thanks Tom!
I gave Ethan a demonstration of the procedure with Milt looking on. Ethan did the next one with both Milt and me looking
on, and then Ethan and Milt were off to the races. I left them to their task, checking in occasionally. They were doing great work and completed a good
third of the connections.
With me on the loose and Autumn and John finished
with their window/stringer job, we went after the control column again, tightening
the pivot bolts and installing cotter pins to safety the nut to bolt. Neither Autumn or John had had any previous experience
with a torque wrench, so we went over some basics, reviewing the torque table in
the 43.13 manual, why we control the tension on bolt and nut fasteners, and so on. Then the actual tightening of the nut. With a range of torque acceptable we started on
the low end and checked the position of the slot in the castellated nuts to the
cotter pin hole to see how it matched up.
If the hole was clear and the cotter pin would slip in place, we stopped
there. If not, we set the wrench to mid-range,
loosened the nut some and torqued again, and again, until the cotter pin would go
in. Autumn and John then got a lesson on
installing cotter pins to safety the nut and bolt combination. On the right-hand side, we got up to the maximum
setting and the cotter pin hole was still covered. The next step is to place a thin washer under
the nut and torque again, provided there is room at the base of the slot to receive
the pin. Well, we didn't have a thin washer
on hand, so we'll have to wait until next time.
No worries, I'll bring one from home and we'll try again, all part of the
learning experience!
Meanwhile, John tried his hand at wiring up stringers,
and with Al's help really got into it. You
got to love this kind of enthusiasm!
Autumn had to leave early to catch up on homework
(there's a reason she gets so many A's), and Chris had worked himself out of a job,
so he and I installed the lower aileron cable pulleys onto the control column. Chris also had no previous experience with a torque
wrench, so we went through an intro and away we went. Tightening, checking, shimming with another washer,
tightening and checking again and then installing the cotter pin. Chris watched me do one, then he did one. Good job Chris. It's fun to watch the expression on his face when
he's concentrating, can you say Focused?
Thanks to all who came out last evening, including
our visitors. It's still so great to be in
the hustle and bustle of activity during one of these Sessions, the excitement is
contagious!
Next Wednesday will be October and time for our monthly
meeting so no Work Session then. We'll see
you back here on the 10th for another round, can't wait!
9/19/18
With yet another Work Session in the books, our Sedan
is really taking shape. Work continues on the controls and wooden work. Youth present to join the fun were John, Autumn,
Chris and Milt. Mentors were Mike, Tom, Barry,
Bill and me.
John and Mike got busy right away with their production
of the brace wire lugs. One to go and it
was completed in short order. It's too bad
that there aren't more to do because they've got it down now. System perfected, Good job!
Chris and Milt with Tom and Barry, got back to work
on the rear cabin window frames, getting the right side one ready to glue to its
stringer. Once the surface was prepared,
they set the frame in place and drilled the additional mounting hole for a #6 flat
head screw to the vertical fuselage tube.
Now with the frame in place, we turned the fuselage upside down to provide
better access to the glue joint. With everything
in position, they glued, and clamped the joint with teeny tiny (AN specific grade!)
nails and allowed to cure. Next week we can
finish the joint by gluing on the reinforcement piece, and then doing the same thing
to the left side.
Meanwhile, Autumn and I went to work on the control
column some more. Our focus was on the control
yoke shaft bushings. These are a brass piece
1/8" thick that fastens to the fuselage behind the instrument panel. We are using the old bushings but rotating them
to the sides without wear. About half way
through John, who had finished his work on the brace wire lugs, joined us. We studied the bushings, identifying the area
worn from years of flight control. We rotated
the bushings putting the unworn area to the bottom and bolted them on. We then shifted our focus to the lower main pivot
bolts. Last week we discovered and interference
between this bolt and the aileron cable pulley mounted next to it. Reversing the pivot bolt would correct this interference,
but what about future serviceability? We
tested the solution by a trial fitting of the lower boot cowling. We realized that in the future, the bolt can be
accessed from the outside by removing this cowling. Good to go.
We reversed the bolt and checked interference with the pulley. Just fine!
Just as we were going to torque and safety the bolts, John and Autumn had
to leave to do homework. No worries, we'll
complete this task next time and move on.
Thanks to all who came out last evening. Inch by inch, bolt by bolt, we are learning, and
restoring our Sedan!
9/12/18
Last evening was as warm as any this summer so we
enjoyed the big door wide open, that was until after dark when the mosquitoes found
warm bodies hard to resist! Still, the warm
air was welcome.
Youth here to participate were our old friends Samantha
and her brother Brett, Milt, John, and a couple of new fellows, brothers Parker
and Ethan who brought their Dad, Jordan Deters.
Welcome to the team guys! Mentors
were the usual suspects, Tom, Frank, Mike, Al, Bill and me.
Samantha and Brett got busy with Tom and Frank on
the rear window and stringer connection.
The outside edges of the stringers were smoothed and rounded to make a nice
line in the fabric. At our Pancake Breakfast
we were informed by Chester Nelson (who flew his beautifully restored Aeronca Sedan to the event) that there is another attach point
for the window frames we had not considered.
In the upper aft area of the frame as it crosses a vertical tube there is
an #8 screw hole that is used to hold the frame to the fuselage at that point. Our holes were stripped, so we elected to move
the hole up on the tube and make it a through and through, so we can put a flat
headed screw there with a nut on the backside of the tube. So, I welded up the old holes and we will tool
up for the new attachment.
John and Mike got back on their production of brace
wire lugs. They got three of the four done
before John had to go.
Parker and Ethan joined me in the final installation
of the Control Column. We checked the bolt
and washer arrangement of the main pivot and torqued and installed cotter pins. We then tried to install the lower aileron pulley
when we discovered an interference between the pulley and the pivot bolt. The parts book shows the bolt going from the inside
out presumably to allow for servicing the joint after the airplane is finished,
but the nut sticks out too far holding the pulley away. Further research is required. Mike joined the task after John left and he and
the guys test fit the elevator bell crank.
Everything went OK except we decided to find a shorter bolt. This one uses too many washers. I think I have one.
Thanks to all who came out last evening and a hearty
Welcome! to Parker and Ethan. It's always
great to see new faces and aspiring Aeronauts!
8/29/18
Yesterday presented yet another beautiful evening
to work on our Sedan. We did that and more. On board were Youth Participants Autumn, John,
Chris and Milt. Mentors were Tom, Mike, Frank,
Al, Barry and me.
First, Mike had his beautiful Stinson 108 over and
he and Autumn went flying. After they got
back, John went up with him for a little lesson in basic pilotage.
Back here on the ground we got busy. The crew of John (before he went flying), Chris,
Frank, Milt and I began to fit the rear window frames to their stringers in earnest. The splice member was cut and fit, now nearly
ready for the glue.
When Autumn got back, she and Tom got after the control
column, greased the pivots and set it in the fuselage along with the control yokes,
ready to torque and safety.
The evening flew by, literally for a few of us, and
suddenly it was time to wrap things up. August
is ending and next week is our meeting time, so no Work Session next week. Meanwhile, don't forget our Annual Chapter Pancake
Breakfast September 8th. Good food, lots
of folks visiting, Young Eagle rides and (fingers crossed) great weather. Come if you can, it'll be fun!
8/22/18
What a pleasant late summer evening it was yesterday. Big door wide open, nice breeze, perfect for varnishing! We had a good crew of Youth Participants on board
to work and learn. Micah and Noah were there
along with our old friend Chris. Along to
help was our regular Mentor bunch, Tom, Mike G., Frank, Al, Barry, Bill, Mike S.,
and me.
The first order of business was to scuff up the first
coat of varnish on the stringers. A week
has gone by and the stringers needed the shine knocked off to accept the second
coat. This was a team effort. All three of our youth grabbed a pad of Scotch
Brite, along with Tom, Frank and Mike S.
Our concern was that we'd run out of time before the job was completed so
we jumped all over it! Once the scuffing
was done, a wipe with solvent to get rid of the dust, the varnishing began. I mixed a batch and they went to town, even Al
got into the act! As they say, many hands
make light work, and the task was completed in plenty of time, in fact, time to
take on other tasks.
Meanwhile, Bill came around with his trusty C172 and
offered Chris a Young Eagle ride. Chris finished
scuffing the stringer he was working on and took Bill up on his offer. Barry went along, just because he could! They all came back with smiles on their faces,
and Chris got his Log Book signed. Now he's
ready to start his Private Pilot Ground School thru Sporty's
online course!
Micah and Mike G. got to work on the Control Column. We wanted to remove it to install drill a grease
hole in the main pivot sleeves to provide some lubrication to the joint. In the past these have rusted up and transferred
the movement to the attaching bolt and support brackets, not good. At the same time, we will replace the old bolts,
better than new!
Chris and Noah got busy touching up some places on
the fuselage missing varnish, the notches cut in the bulkheads for the stringer
tang. That complete and with Barry's help,
began installing new bolts to hold the bulkheads into place. Barry would hand each an AN
bolt of the right length, a couple of washers and a nut to replace the stove bolt
we used to temporarily fasten the bulkheads in place. With all the fasteners in place, Chris and Noah
tightened the nuts to the correct torque.
Now, normally the bulkheads are held in place with a special hollow rivet,
but with these not available to us we improvised using 1/4" AN bolts, thin washers and nyloc shear
nuts. With no torque specification, it was
"tighten to just the right how much” With the bolts in a shear load, we wanted
them to hold the parts securely but not to crush the wood. I tightened the first one to what I judged enough,
and the guys took it from there. The bolt
would turn with a wrench, but with resistance that they compared with the rest of
the fasteners. Chris and Noah got serious
about this task and did a very good job.
Thanks guys!
Just like that the Work Session ended. I'm excited to get the stringers back on the fuselage,
permanently! With the Control Column in place,
the next step will be control cables and pulleys and stuff. Our Sedan is taking shape, good reward for hard
work. Let's see what we can get accomplished
next week!
8/15/18
Last evening was a busy one and another Work Session in the book! We welcomed two new Youth Participants into the
Project, brothers Micah and Noah Stevens along with their Dad Mike. Welcome guys, it's great to have you aboard! Also, in attendance on the Youth Participant side
were our good friends Samantha and Brett LaGraves whom
we haven't seen for a while (summer activities), and our steady team mates Autumn
and Chris. We had our core group of Mentors
on the job, Tom, Frank, Mike, Barry, Al and me.
We had a full house, just in time too as varnishing was on the menu.
Autumn and Tom got updated on her Privet Pilot studies
and they were joined by Samantha as Tom went over the pre-flight checklist on his
Glasair II. Meanwhile,
Micah and Noah got introduced in the fine art of mixing Poly Fiber Epoxy Varnish. I poured out the 2-1 ratio of Varnish to Catalyst
and then after mixing we added another part of reducer for the first coat on the
stringers, nice and thin so it would soak in.
Once completed, they removed the bottom three stringer an set them up on plastic covered tables in the Classroom. By this time Autumn and Samantha were finished
with Tom's instruction and joined the varnishing crew. With Frank's help they set up another station
in the Classroom, removed three more stringers and begun applying varnish. About halfway through, all four of our Youth Varnishers signed their names to one or two of the stringers,
permanently recording their participation in the restoration. Fun! By the time the evening was done, they had the
first coat on all the stringers. Good job!
Meanwhile, Brett and Mike took on several tasks. First was fitting a washer for the control wheel
bearing that Mike made to replace one missing.
The shaft hole needed some refinement to fit so Brett and he got out the
file and went to work. They temporarily fit
it in place, perfect! Next, they trimmed
off the dowels glued into the misaligned holes in the left side rear window frame
and fit it into place aligned with the related stringer and drilled new holes. Finally,
they moved to making more the brace wire attach lugs. As you may recall, the top ones are finished and
on to the bottom ones. They got the tab bent
and drilled as the Work Session ended.
Chris and Barry continued their work refining the
bolt holes in the wooden stringers. With
that job completed, Chris grabbed a brush and touched up some placed missed on the
bulkheads. He next took the little touch
up brush we had and applied varnish to the tie wire holes drilled in the bulk heads. That completed, he finished up the same holes
in the stringer the other team had not finished.
As you can imagine, there was a lot of activity in
the Hangar last night! It was fun, and time
flew by. Thanks to all who came out last
evening, I still get a thrill out of seeing all the activity and concentration,
everyone trying to do their best work. See
you all next week!
8/8/18
It's Been a while since we've been at the Hangar to
work on our bird, what with AirVenture and the monthly
meeting, but we're back in full force! Youth
present to participate were Autumn W., Chris S., Dave G., and Milt. Mentors were the core group, Frank, Tom, Mike,
Barry and me.
Autumn got together with Tom right away to clear up
some questions she had regarding her Private Pilot studies, including but not limited
to, the phonetic alphabet. This bugger can
be confusing to the newcomer, but she's getting it! Alpha, Bravo, Charlie and so
on. Next they moved
their attention to the stringers. Varnishing
to be specific. We rolled the fuselage on
it's side to present the bottom
three and they checked them over good before cutting the zip ties holding them in
place. They wanted to be sure all the fastening
holes had been made in them and the bulkheads, and that the bolt holes will receive
the final fasteners. The safety wire holes
are all in, but the 1/4" holes thru fuselage clips needed to be cleaned up
a little with a file to make a better fit.
With that done, they set up a varnishing station in the Hangar Classroom
on the long tables, covered with protective plastic to do the varnishing. At this stage, they realized time was short. Given that the pot life of mixed epoxy varnish
can be measured in hours at best, that mixing a small batch of the two-part finish
plus reducer for the first coat is not an exact science, and in the interest of
conserving materials they decided to wait until next week to mix and apply the first
coat of the epoxy varnish. We want to maximize
the generous donation of another kit of varnish from member Mark Marino of Hangar
10 Aero, we know this stuff doesn't grow on trees! We should be able to get most of the stringers
coated then.
Dave and Mike set their focus on the Control Column. It was discovered that the Control Wheel Shaft
Stop was installed on the right-hand side instead of where it belongs, on the left
side. They corrected that. They were going to install new hardware in the
Column pivot when we remembered that we want to drill a grease hole in the Column
pivot sleeves. We didn't have the correct
tools for the job, specifically a countersink to cut a bevel in the hole to match
our needle zirk, so they set that project aside for now. Next was fitting the rear window frames to the
stringer they mate up with. At first it seemed
that neither of them lined up once the stringers were set into place, but closer
examination showed the right-hand side was OK.
The left side however needed to be moved slightly and the frame itself required
trimming to optimize the fit. So, they trimmed
the frame and glued short pieces of 1/4 dowel into the existing holes, so they can
be re-drilled.
Milt and Frank got busy gluing up the scarf joint
in the broken stringer. Remember the broken stringer? Frank took it and a remnant section home to his
work shop to cut the tapered joint required to make the repair, brought it back
to finish, and demonstrate the correct way to make the repair. They then directed their attention to the elevator
bell crank we received from Mike Hoag. As
you may remember, our bell crank had pitted bearings which we were unable to find
a replacement for. Mike reached out to us
with the offer of a surplus bell crank he had with good bearings, which I received
from him while visiting AirVenture. Thanks Mike, again showing your friendship for
our Project! The part was fit into place,
but we need a thin 5/16" washer we'll bring for next time to complete the installation. I picked up a rod end ball joint at Oshkosh too,
to replace the rusted one we had in the elevator push pull tube, they installed
it. With that stuff out of the way and little
time left in the Session they did a little house cleaning. Putting away the steamer setup for one. General
organizing of tools and table tops is a necessary job in a busy work shop. With attention primarily on the job at hand, an
occasional "roll up" is required to clear the space for more efficient
activity. Thanks guys!
Not to be left out, Chris and Barry inventoried/received
a shipment of hardware ordered from Wag Aero for the wooden bulk heads and control
column. Chris got a good lesson in identifying
and measuring AN bolts and washers and nuts.
A couple of discrepancies were discovered. We received washers in pace of nuts and one bolt
was undrilled while we ordered a drilled one.
No worries, human mistakes. I called
the supplier this morning and they will be sending out the correct items right away
free of charge, with no loss of production in the shop! With the receiving complete they turned their
attention to the 1/4" holes in the wooden bulk heads. We want to be sure the fasteners have a clean
fit that we can varnish before they're finally installed. So
Chris, with file in hand and with Barry's help, went around to each of the holes
and made sure the bolts fit.
7/18/18
What a nice evening it was at the airport yesterday,
upper 70's and just a whisper of wind. Perfect
for Young Eagle rides, and that's just what happened. Bill I. took Chris S. and Barry up for a spin.
Smooth, barely a ripple I was told. Autumn
and Tom were in the air again too, continuing from where they left off from last
week. Autumn went through the pre-flight
inspection of Tom's Little Deuce Coupe with Tom guiding and observing. Then they went flying, more checklists, GPS programming
and navigating. They spent the whole time
in the air and on the ground. Autumn is very
serious about this flying business!
Meanwhile, back at the hangar, there was work to be done. Aaron
was there with his two beautiful kids to do some riveting on our practice materials. Tyler gets right in there, and so does Abby, until
I come over to see how they're doing, then she gets a little shy. They both do good work though, with the guiding
hands of their Dad!
Milt and Frank and I went over the stringers and decided
that the next order of business would be to drill tie wire holes in them and the
bulkheads. No better time, before we cut
them loose for varnish.
Once Chris got back from his Young Eagle ride and
had his feet firmly on the ground, he and Barry commenced a hardware inventory. With the lack of Waterbury eyelets, we will use
AN4 bolts to hold the bulkheads in place.
We now have a list. We also got a
list of new bolts needed for the Control Column.
Chris received a good lesson in measuring bolts and AN specifications.
The workforce was a little light
last evening in both the Youth Participant and Mentor areas, but understandable. Summer is a busy time around here with lots going
on and such a sweet short time to get it all done! No worries, it's all good!
Speaking of stuff going on, EAA's
AirVenture is on for next week in Oshkosh. The annual gathering will deplete our Mentor staff
to the point that we have decided to not hold the Work Session next Wednesday, and
the following Wednesday is our monthly meetings, so our next Work Session will be
held on August 8th. I hope you can hold your
enthusiasm until then, when we will resume with renewed vigor!
7/11/18
It was a busy evening at the Chapter Hangar yesterday. Youth Participants Autumn W, John T, and Chris
S were on hand along with Milt H. Mentors
were the usual bunch; Tom, Mike, Frank, Al, Barry and me.
Autumn and Tom got busy right away, pursuing Autumn's
Senior Project which includes Flight Training, with which Tom is happy to oblige. They got started with outlining procedures for
flight; preflight, engine start, takeoff check lists, and went flying. Among other things, Autumn executed a 360-degree
shallow turn, maintaining altitude and speed. Then the landing check list and post
flight debriefing. Tom complimented her on
her skill and natural talent handling his speedy little Glasair. Well done Autumn!
John and Mike continued their work manufacturing the
brace wire lugs. Mike had made a fixture
to help maintain accuracy in the parts which made the process go a little smoother,
but not without its challenges to which John offered solutions that were adopted
and included in the process. The education continues! Upper brace wire lugs finished, lower ones up
next.
The rest of us got after the remaining stringers and
placed them into the steam tube to soak for an hour and a half. With the steam pouring out from the tube we decided
to spend our time placing the control column into the fuselage, determine what hardware
needs to be replaced and see if anything else presents itself as needing attention. One thing we discovered is the bearings in the
elevator bell crank should be replaced. Frank
had removed them earlier and cleaned them up in hopes they would be serviceable
but no such luck. We'll search for new ones.
With time drawing to 8:00, we returned our focus to
the stringers. We turned the fuselage right
side up and pulled the stringers from the steam one at a time and zip tied them
in place, starting with the bottom ones on the sides and working our way up. Those sticks bent like cooked spaghetti! Well almost, but they all bent right into place
except for the ones that tie into the bottom of the rear windows. We put a ratchet strap on the forward end that
we thought should bend to the inside about a half of an inch, and the end of the
right-hand side one cracked, just as we thought we had it. Darn! We
examined the situation and determined that the piece can be spliced with minimal
to-do (a technical term), so not the end of the world.
What a difference those stringers make in defining
the shape of our Girl, with all the curves that show off sleek shape of the Sedan. We can just picture it with fabric, but only in
our mind's eye for now. We have lots of work
ahead of us!
Thanks to all who came out last evening. Many hands working in the same direction accomplish
great things!
I want to make note here about our upcoming Work Sessions. Our Session next week will go on as scheduled. During upcoming AirVenture
at Oshkosh however, our Session for the 25th will be cancelled, all us Mentors will
be at the Show. We'll meet again afterwards
on Aug 8, the first Work Session of that month. So, see you next week for more fun!
6/27/18
We had a light turnout in the Youth Participant category
last evening, John T was there along with Milt H. Milt rotates between” Youth Participant"
and Mentor, depending on conditions! (kind
of an artistic license) Milt is always looking for a chance to learn something new,
just like our Youth!
The usual crew of Mentors were there, Tom, Frank,
Mike, Al and me.
John and Mike continued their work on the brace wire
lugs, trying to perfect the operation. It
hasn't been to their satisfaction regarding hole placement, so Mike decided he's
going to make a fixture to hold the lug blank.
It seems like a lot of work to produce 4 pieces of each type, but when they're
barely an inch long, it's the only way to make them identical. Mike will make this fixture at his own hangar
and bring it to our next Work Session. This
is yet another way to teach the fabrication method, also John is getting good on
the bench grinder!
I came up with a modified steam tube. It's essentially the same as before, a length
of gutter downspout, but shorter and insulated with 2" green foam, with a little
bench made of 1/2" hardware cloth an inch or so high to hold the stringers
off the bottom and allow the steam hose to be under the stack to be treated. Our tube is now about 5 1/2 ft long, just long
enough to treat the forward end of our stringers, the end which bends the most. I got there early to get the water heating. Our experience last week suggested we need more
time to steam the pieces. I also put a water
pot on the kitchen stove to boil some back-up water. Like I mentioned earlier, John and Milt were our
Youth for the day, so Milt was our student for the task. Along with Frank and Al, we got the steamer set
up and loaded with a remnant and the three bottom stringers. This thing was delivering some real heat to the
tube! We tested the remnant after an hour
and it seemed flexible. We put it back in
and let it soak some more. We decided to
let them all go until 8:15. Frank brought a pocket full of zip ties to temporally
fasten the stringers in place, and the whole gang of us were on the job. They bent like cooked spaghetti, well almost! It took a total of about 6 minutes to place the
stringers one at a time on the fuselage.
I think we have a winner in the steamer department. We'll get the rest of them bent in place and dry,
then remove and varnish them before installing permanently.
While monitoring the steamer, Milt and Tom cut the
last slot in the forward upper cabin bow for anchoring the three upper stringers. We are now ready to set the rest of them in place. Nine more left to bend, can we get them all in
the steam tube at once? We'll see next time!
Thanks to all who turned out on a beautiful summer
evening. To our amusement and entertainment,
runway 4/22 Right, our grass runway, was full of powered parachutes, cruising around
the pattern. Wind was light from the west,
temps in the upper 70's, delightful!
Next Wednesday is the 4th of July so we're taking
the night off. See you all back here the
week after to see how the steaming goes.
Stay tuned!
6/20/18
With another Work Session under our belts, we are
making progress. Present to drive the project
were several of our Youth Participants; Autumn W, Chris S, John T, and Dave G. Present to guide and assist were Tom, Mike, Frank,
Al, Barry, and me.
Stringers were again on the menu. Dave and Autumn along with Tom, finished shaping
and fitting the two which are just outboard of the top center one. They then located and cut slots thru the upper
forward cabin bow to anchor the forward end of the top three stringers. Meanwhile Chris and Frank added a spacer to the
very bottom center one. This necessity presented
itself upon a trial fit. Once accomplished,
they set up our steamer apparatus to begin that process. They started with a four-foot piece of stringer
material left over as practice. By the end
of the session the piece was soft enough to bend. We tied it into place to dry. It's going to take longer than we thought. We also need a little refinement to the procedure,
but we have ideas like; insulating the steam tube, making a support to hold the
stringer off the bottom of the tube, and preheating water on the stove. It's all a learning process, but hey, isn't that
what we're up to? It's not just the Youth
that are getting educated here!
Not to be left out, John and Mike continued their
work on the brace wire lugs. Mike acquired
some 1/8" strips of 4130 steel 5/8" wide to begin making the real parts. As you may recall, last week they were experimenting
with mild steel, just to prove their process.
After some more experimenting they have developed a procedure that works
and are now in production. They also discovered
just how much stronger 4130 is than mild steel, it takes quite a bit more effort
to bend! They
will likely make good progress on the next go. I also noticed how John is
becoming more comfortable with the tools required for this job, it's great to see!
Thanks to all who turned out last evening, I never
tire of being in a room full of activity, all pulling for a common goal!
6/13/18
Yesterday greeted us with clear sunny sky, light winds
and upper 70s. What's not to like? A great evening to have the big door open and
air the hangar out! We were also greeted
by three eager Youth; Autumn, Chris and John.
Autumn now has the official "go ahead' to use our Project among other
things for her Senior Project at Superior High School. Yay! Her
Project centers around (let's see if I get this right) learning how to rebuild an
airplane and learning to fly. Best wishes
to you Autumn, we'll do all we can to help you complete your Project!
Mentors present to assist were Mike, Frank, Al, Barry,
me and Milt. As you may recall, Milt has
previously been regarded as a "Youth Participant" as he wanted to learn
all he could about welding 4130 tubing. He
assisted me quite a bit while we were repairing the fuselage. That phase nearly complete in our project (I say
nearly because you never know), he can use his varied experience and skills
to help guide the young minds that grace our Work Sessions every week!
With all that said, Autumn and Milt continued the
work on their stringers, as did Chris, Frank and Barry. Much work has been done on this phase, and what's
left is the aft end of two upper stringers that Chris and company are working on. What's next is to start the steaming process to
bend and tie the stringers into place. Once
that is done on all of them and they have dried, we can remove them, apply a couple
of coats of clear epoxy varnish, then fasten them in pertinently.
Meanwhile, John and Mike began to experiment making
some new tail feather brace wire support tabs, or simply "Lugs" as called
out in the parts book. They began with some
mild steel 5/8" wide and bent them in a mini press brake that Mike made up
for use in the bench vice. Quite the little piece of equipment. With just a minor tweek
or two, John and Mike will be in the Support Tab (Lug) Business!
As the Work Session was ending, a major clean-up got
underway. From miscellaneous scraps of wood
to trash to tools lying about, to dust and cottonwood fluff blowing around on the
floor, our crew got to work. The result is
a little cleaner hangar and work space. We
get a little lax in the clean-up department, with our focus on the task at hand,
it's hard to break off for housekeeping.
It's nice to start off with a clean and organized work space, which just
seems to allow the work to proceed that much better.
5/30/18
Last evening, we finished off May's Work Sessions
in great style with Chris and Autumn representing our Youth Participants, and Tom,
Mike, Frank, Al, Barry and me rounding out the Mentor side of the deal.
Stringers again were on the menu with Chris and Frank
teaming up and Autumn and Tom doing the same.
We are making steady progress on this wood work, working our way up from
the bottom of the fuselage to the sides and eventually the top.
Mike did some independent research in the attic, retrieving
the aileron control system to evaluate its condition. He found a couple of bearings in the aileron bellcrank less than perfect, so he's going to see if he can
find new ones to replace them. Mike also
found the elevator trim control and brought it down from the attic. Between Mike and Al and myself, we rediscovered
exactly where in the fuselage it is located.
As you may recall, Mike and Youth reconditioned the trim control mechanism
in past Work Sessions, so it's ready to be installed. These systems will be focused on as soon as we
complete the stringer phase of the project, so we want to be ready.
Big "Thanks!" go out to all who came out
last evening to work. It's fun to see the
progress on our bird, these stringers provide the fuselage all the graceful curves
the Sedan is known for. Exciting!
5/23/18
Another Sedan Work Session is in the log book, with
a good turnout of Youth and Mentors alike.
Youth Participants included Chris Schlies, John
Thro and Milt Huhta.
Mentors were Tom, Mike, Frank, Al, Barry and me. Stringers were the name of the game and we all
got into it.
First, John and Mike finished up their inventory and
evaluation of the Horizontal Stabilizer brace wires. They determined what parts we can use, and which
will need to be replaced. All eight of the
wires are looking rough but will be useful in staging the tail feathers and aiding
in running control cables.
So, on to the stringers. For those not familiar, the stringers are narrow
strips of wood the run fore and aft along the fuselage, and wooden bulkheads in
the aft portion of the fuselage, that give the fabric support for the aerodynamic
shape it needs to reduce drag while in flight and make possible the incredible speed
for which the Sedan is known for (100 miles per hour, maybe!).
Chris teamed up with Frank and Barry, Milt with Tom
and John with Mike. Al and I oversaw the
operation, primarily trying to stay out of the way of progress, answering questions
as they came up and helping coordinate the three teams. I brought in a hand-held power planer that helped
speed up the tapering of the aft end of some of the stringers, while the rest of
the guys shaped the forward ends and adjusted the fit in the many standoff brackets
that hold the stringers in place. All the
bottom ones are fit, and now we're working our way up the sides of the fuselage.
Next week will be more of the same except for possibly
hanging the horizontals and elevator to start staging the pulleys and control cables. Of course, we don't want to impede the progress
on the stringers, we'll see how it goes.
Last evening was the first time we had the big door
open during the session, it was nice to have fresh air in the place for a change. Boy, I like summer!
Thanks to all who turned out, you all work like a
well-oiled machine, busy in the airplane factory!
5/16/18
Last evening, we had a crew of eager workers; Chris
Schlies, John Thro and Autumn Wolters. Mentors were about the same bunch as always, Tom
Betts, Mike Gardonio, Frank Kolo,
and me. Bill Irving made himself available
and of course, Barry was there for Chris.
For the most part, Stringers were on the menu. Chris
and Frank continued their work on the center bottom one. Besides shaping the forward end to fit into its
socket, they sanded down the tang of the stringer just a bit to fit the slot of
the support brackets. Mission accomplished,
all except for tapering off the aft end of it, which we will tool up for next time.
A bench hand plane should do the job nicely.
I have a couple I can bring in. They then moved to another pair of stringers,
moving up the sides of the fuselage.
Autumn talked to Tom about using our project, among other aspects of aviation (including
flying of course), as part of her Senior Project at Superior High School. Tom agreed to be her official Mentor for her Project. As I understand it, all Seniors are to complete
an in-depth effort of independent study in an area of their choosing as a requirement
for their graduation. Autumn is the second
Youth we have had use our Sedan for their Project, glad to help! With that discussion complete, they continued
work on the two stringers Dave and Tom started a couple of sessions ago, fitting
them to the support brackets like Chris and Frank were doing.
We're going to get good at this stringer business,
before you know it they'll all be fit, and we'll be ready to fire up the steamer
again!
Meanwhile, John and Mike finished up the riveting
on the Forward Rudder Cable Cover. It is
now ready for final fitting and adjustments that may have to be made once it's fit
onto the floor of the cabin. With time left,
they gathered up the Horizontal Stabilizer Brace Wires to assess their airworthiness. They found all the parts that go with them, labeled
them, and initial impressions are that they need replacing. Further inspection may confirm that, we'll see
next time.
It was discovered that our fuselage had fallen victim
to hangar rash! One of the stringer support
brackets got bent to the point where the weld cracked, so I welded it back on. These brackets are delicate without the stringer
in place and have enough sharp corners on them to jump out and grab anyone walking
by. We must be careful with our baby as work
progresses so that we can keep moving forward!
Thanks to all who turned out on what became a very
cool and blustery evening. Crazy, from record
high temps during the day to upper 40's by Work Session end. That is the magic of Lake Superior. The wind switched from SW to NE, the temps dropped
20 degrees in 20 minutes! It's amazing we
don't all catch pneumonia! Haha!!
5/9/18
Yesterday was a little dampish, but we had a good
turnout just the same. Chris Schlies, Brett LaGraves, Jacob Koczur and Milt Huhta were there with
open minds and eager to work. Mentors were
Frank, Mike, Tom, Bill, Barry, Jacobs Dad Brian and m.
Stringers were a point of focus and Chris and Frank
dove right in. They finished the scarf joint
and reinforcement glued up last time, sanding off excess glue and shaping sharp
corners. This stringer is the one intended
for the center of the belly, sixteen feet long requiring a team effort to even move
around the hangar! With a preliminary fit,
they rough cut it to length and prepared the forward end to fit into the socket
that keeps it in place. It was a matter of
shape and fit, shape and fit for a nice engagement but they got it. Now to taper the end to eliminate any stress risers
and then shape the aft end.
Meanwhile, Tom and Jim went through the remaining
stringer materials to make sure we had them organized and sufficient to complete
the job. As you recall, we previously thought
we discovered a shortage of material. Upon
closer examination and including a rectangular shape (that Ken Peters had provided
us) for the lower side stringers (which were original to the aircraft), we now have
all stringers ready for fitting. We will
dry fit all of them, get the steamer going and set them in place to dry. I can just imagine them filling out the fuselage,
giving our Sedan it's beautiful aerodynamic shape!
Not to be lost in the shuffle, Brett and Jacob worked
with Mike with the intention of finishing the riveting on the forward rudder cable
cover. Some practice was in order, so they
got their strips and angles. Mike guided
them on the finer points of squeezing rivets, both universal and flush head. They started with the smaller diameter 3/32"
size before moving to the larger 1/8" diameter ones. As it happens, time ran out before they got to
the big ones so that will have to wait till next time. The extra bonus of working on their strips and
angles is that they can take their work home with them and show off what they've
been doing. All in all, very nice work!
Milt got busy and replaced a couple of window frames
and formers removed from the fuselage when the paint was touched up. Last Monday, Mike, Frank, Tom and I came in and
painted the fuselage satin black in the places that won't be covered when the project
is finished. Places like the "V"
brace below the windshield, wing and landing gear fittings, and other tabs and handles
that will be left exposed. We did this job
without any Youth present simply because of the hazardous nature of the oil-based
enamel, keep it safe!
Don't forget to check out our project on our Sedan
page at sedanproject.com
that our web guru Bill Irving keeps up to date.
It has all kinds of fun info about us!
Thanks to all who came out last evening, it sure is
exciting to see the old bird take shape!
See you all next time.
4/25/18
What a lovely evening it was yesterday, lots of sunshine
and light winds. So nice that Bill Irving
showed up with his trusty C-172 and gave rides to all takers. Chris went for the first time, didn't say much
I heard, but came back with a giant grin on his face and a big thumb up! John, Abby, Barry and Aaron went along too. Just a nice chance for a ride.
As you may have gathered, Youth Participants ready
for work were Chris, John and Abby. Mentors
were Tom, Frank, Al, Bill, Aaron, Jim and Barry.
John and Frank glued up a scarf joint that Frank had
prepared earlier in the week at home on his radial arm saw. This was on a stringer, number 4-38, the long
one on the bottom of the fuselage. Later,
Chris joined the project while John went for his airplane ride. They glued on a 4" long piece of 1/16 aircraft plywood, a reinforcement
at a nail hole, mixing up a batch of glue/sawdust to fill a low spot.
Chris then joined Tom at the fuselage to install the
upper forward cabin bow. They drilled holes
to attach the stiffeners and glued on the block splices.
Al suggested we choose a paint color to paint the
fuselage tubing that doesn't get covered up.
Oops! I guess we had better before
it's too late. Now, which part of the fuselage
is that.......?
When John got back from his ride, he and I gathered
up the forward rudder cable cover with the intention of finishing up the riveting
on it. Well, first we though a little practice
was in order as John had never driven rivets before. We started with 1/8" rivets on a piece of
scrap which didn't go so well, so we moved to our practice pieces with 3/32"
rivets. Much easier, and better to perfect
our technique before moving up to the larger rivets. We finished up with our practice just about the
time to quit for the night, so we'll have to wait ‘til next time.
I can't tell you what a difference nice weather makes
('cause you already know 😀). It won't
be long, and we can keep the big door open for our work, smell the fresh air and
feel the gentle breeze. Can you tell I love
summer? Next week is our meeting time, so
we'll see you all in a couple.
4/18/18
Spring is in the air and I just love it! I heard last week that we've had over 180 days
with snow on the ground. 6 months? Enough
already! This week we'll be saying "So
long snow!" Exciting, isn't it?
We had a good turnout last night, Chris Schlies, Dave Gramstrup and Milt were
our Youth Participants. Tom, Mike, Frank,
Bill, Al, Aaron and myself were the Guides, along with Barry, Chris' Mentor.
Milt, with Frank and Bill got busy gluing tie strips
onto the bulkheads installed last week. Those
things are in place for keeps now! When they
were done with that Milt worked with Aaron to practice squeezing flush and universal
head rivets on our practice materials. New
skills to be had all around!
Dave and Tom continued sorting out the stringers,
combining an inventory and quality inspection at the same time. They discovered that we could use two more pieces
about 8 feet long to round out our requirement.
I'll be contacting our friend Ken Peters to see if he is able to help us
out. We then rolled the fuselage over to
make the bottom easier to get at and fit the two that go along the outside edges
of the bottom. Dave got them cut to length
and began to trim the ends just like the old ones. This thing is really starting
to take shape!
Chris and Mike continued their work on the forward
rudder cable cover. Chris, as you recall
had some practice squeezing rivets on our practice pieces last month and helped
fit the new piece on the cover a couple of weeks ago. So, he was all set to move
up to the next level, driving rivets with the pneumatic rivet gun and bucking bar. With some practice on other material Mike was
confident Chris was up to the task, and away they went. Just a few rivets left, and the piece will be
ready for paint.
Thanks to all who came out last evening. I wouldn't be surprised to see an airplane ride
happening in the next Session or two!
4/11/18
Yesterday was a momentous occasion. We welcomed the fuselage back from paint with
a brand-new coating of epoxy primer, thanks to Chris Penny and his Precision Powder
Coating team for sandblasting and painting, and to our own Mark Marino and his Hangar
10 Aero for the primer materials. Thank you
both for bringing to close a two year long repair of the fuselage, the foundation
of our Sedan.
To witness this grand occasion were Youth Milt Huhta, John Thro, Dave Gramstrup and
Chris Schlies.
Chapter Members present were Tom, Frank, Al and me with Barry Beyer, Chris'
mentor.
Now we get to add stuff to it! Things like wooden bulkheads and formers. That is just what we did. After John and Frank reattached the aft pivot
block, we all set it on the floor and got busy.
John with Tom and Frank set about to sort out the
stringers, making sure we had them all, matching them up with the old ones to better
understand how the ends will be shaped, and giving them a close inspection for defects
and determining how they'll be affected.
As you all well understand, Airworthy Standards are quite particular, so
we must be careful. Thing are looking pretty
good so far.
Chris, Dave and Milt went about setting the wooden
bulkheads and formers in place on the fuselage.
Boy, does that change the look of our project, starting to get some character!
Thanks to all who came out last evening, our Sedan
sure looks different than it has for a long time!
3/28/18
Boy, yesterday felt like spring! Snow melting, water
running, blue sky and sunshine. I can feel
it!
We had a good turnout last evening, with Dave Granstrup, Chris Schlies, Abby Breitkreutz and a fellow new to our project Jacob Koczur along with his Dad Brian. Along to help steer the evening were Mike, Tom,
Frank, Bill and me.
Dave, along with Tom, Frank and Bill got busy with
the wooden stringers. They brought them all
down from the attic and began to re-acquaint themselves with what we have and where
they go, so they might find an extra one to experiment with in the steamer. Easier said than done. There was some sorting going on, with deciphering
inventory notes taken two years ago, but I think we have it. They found a likely candidate for the steamer,
treated it and placed it on the fuselage.
I think it's going to work!
Chris and Mike went to work on the rudder cable cover,
removing rivets and installing the new part.
Chris seems to be a natural, picking up on guidance from Mike well. They got the new part aligned and drilled, ready
for new rivets.
Abby and Jacob joined me at the rivet station where
they were introduced to the rivet squeezing process on materials from KidVenture. Abby is so
cute! Young as she is she pays attention
and follows direction happily. Her little
fingers are just the right size for inserting the rivets into their places, and
squeezes with all her might (I help) to set the rivet. Jacob also is a bright young man, eager to do
and learn, welcome to the crew Jacob. They
each got about halfway done with their pieces and took them home to show off. They'll bring them back next time and finish them
up.
Thanks to all who came out last evening, all pulling
together to show these young people a little of what it takes to make an airplane!
Next week is time for our Committee meeting, so no
Work Session. See you April 11!
3/21/18
Last evening went off without a hitch with the help
of our Youth Participants Chris Schlies, Dave Gramstrup, Abby Breitkreutz and Milt
Huhta. Mentors
present were Tom, Mike, Frank, Al, Bill and me.
The first item of business was to load the fuselage
onto a trailer I brought to get it ready for the move to the paint shop. Chris Penny's shop is busy right now with customer
work and doesn't have room for us, so we'll wait 'till he has space and time to
take care of us. The good thing is, when
he says OK, we can respond. We're ready when
you are Chris!
Dave and Mike were working on the forward rudder cable
cover, riveting on the new section. Mike
doesn't like the result. The rivets were
set correctly but the part was not well aligned. He will now take this opportunity to deliver a
lesson in rivet removal, and reassembly of the cover with a new part he will make
up in his own hangar. Sometimes things must
go a little backwards in order to move forward, it's just
another lesson in life, and after all we're here for the education, right?
Bill and Frank were busy setting up a steamer to eventually
steam the stringers we have that, as you may recall, were produced by our good friend
Ken Peters two springs ago. This process
may take a couple of sessions to perfect but seems to be progressing nicely. Bill brought in a wall paper steamer, which when
warmed up, produces a surprising amount of steam. They directed the steam into a section of gutter
down spout holding the experimental wood.
Looks promising!
I decided to introduce Chris into the world of riveting. We took a couple of pieces Al brought from KidVenture and went to work. After a brief tutorial on the finer
points of setting solid rivets, Chris got hands on experience with the squeezer,
setting AN470AD3-3 rivets like a pro. He
picked up on the requirement that the tool must be perpendicular to the material
throughout the process, among other points.
Good job Chris!
Thanks to all who came out last evening and pitched
in. The work goes quick and easy, before
we know it, it's time to go home!
3/14/18
What a Spring like day it was today, gives one hope that 'ol man Winter is on the ropes and again will not survive our
Planet's march around the Sun. Yay!
Last evening, we were greeted with a crew of Youth Participants,
John Thro, Autumn Wolters, Chris Schiles, and Milt Huhta. Along to help
guide these young minds were Tom, Mike, Frank, Barry, Bill and me.
We set about getting the fuselage ready to be moved to the paint
shop. John and Chris helped me to replace
the right-side Fuselage Wrap Around Support, which had mostly gone missing. In fact, if you recall from a previous post, we
nearly missed it altogether had it not been for the sharp eyes of our inspection
crew. Anyway, Mike had formed up some .025
4130 sheets into the angle we needed. John
cut it to length and prepared it to fit into place, then Chris and I welded it onto
the fuselage. The part requires holes in
it to attach the Wrap Around, so we cleaned up and set the part onto the fuselage,
clamped it into place, and discovered one possible reason our Support was mostly
missing. The line of holes in the Wrap Around
was not straight, in fact some nearly ran off the support to the point that they
would compromise the strength of the little part. So, we decided to hold off drilling
holes until we make a new Wrap Around, which after 69 years of service is showing
a good bit a wear. We then gave the fuselage another inspection and called it "good
to go"!
Meanwhile, Autumn and Mike continued work on the Lower Rudder
Control Cover, kind of like a center console between the rudder cables. Mike had previously reproduced the aft end of
it which was pretty bent up. Autumn got a
very nice lesson in riveting, both with a squeezer and the gun with bucking bar. Some practice proceeded riveting the actual part,
demonstrating what not to do and what works!
Under Mike's guidance Autumn is picking up the skill nicely.
Everyone else were "floaters" throughout the evening,
helping out where needed, helping make the whole Session
a success.
Next time we will begin the process of preparing a steamer for
bending the stringers, exciting stuff!
2/21/18
Boy I love the longer days this time of year, I think the winter
days are numbered again for this season!
Last evening, we had a nice turnout. Three smiling faces that we haven't seen in a
while, Samantha and Brett LaGraves, and Tyler Breitkreutz were able to join us. It's always good to have them aboard. To round off our Youth Participant crew was Christopher
Schlies, our new member last week. Chapter mentors here to guide our young minds
were Frank, Mike, Aaron, Tom, Bill I, and me.
To start off with Frank and Tyler focused on the rubber bumpers
for the tail wheel upper and lower limit stops, both in the tail wheel auxiliary
assembly and in the fuselage. This involved
sanding off the inside corners of our bumper material made from a hockey puck. Next was to drill a hole in the bumper as a keeper. Talk about some rubber with a high durometer,
nice and stiff! Rubber is also a difficult
material to drill, kind of gummy, but they did a great job. Some might say "perfect"!
Samantha and Chris joined Tom in a class of Hand Tool 101. Tom explains the function and safe use of the
hand tools we use in our program, giving the Youth a foundation of safety and proper
use of basic hand tools. "A screw driver
is not necessarily a pry bar!" ;-), and more!
Brett and Mike inspected the tail feathers; rudder, horizontal
stabilizers and elevators, for fit and general condition prior to re priming them. Aside from needing a little cleanup in the hinge
areas, (we can clean those areas up easily after priming), they are deemed good to go.
Chris and Aaron began by giving the fuselage a thorough going
over, looking for incomplete or cracked welds, missing and bent parts (tabs and
such), or anything else we want to complete before we move it to the paint shop. Well, they found several places that needed attention. Aaron's sharp eye picked up on several items,
instructing Chris and later Samantha and Brett on what to look for, marking the
places with blue tape along the way. I got
busy welding on a few missing nut tabs and clips, some needing straightening before
re-welding, and small cracked welds. One
significant part was found completely missing!
In the book they call it a Fuselage Wrap Around Support. It's a small angle shaped piece that's about 16"
long with bolt holes in it, up front in the boot cowl area on the right side. We will be making a new support,
and weld it on before the big move.
Thanks to everyone who made it out last evening. It's a learning experience for all of us, and
surprising what comes to light in these Work Sessions!
2/14/18
What a beautiful day it was yesterday. Warm and sunny, just makes you want to get out
and do stuff! And we did, a whole bunch of
us, at the Chapter Hangar. Tim Friendsuhu was there to see what we were up to, moved his RV8A
out and it didn't even cool the place off a bit, opening that giant door. Can't wait till spring!
We met a fine young fellow last night. 13 yr old Christopher Schlies along with
his Mentor Barry Beyer. Chris and Barry met
through Mentor Duluth. Chris is interested
in anything aviation. He has joined the Duluth
CAP and wants to get his pilots license as soon as he
can! After the work session Chris said he
definitely wants to come back and get some more of what
we have going on here. Good deal, welcome
Chris!
Along with Chris, we were delighted with the arrival of Autumn
Wolters, John Thro, Dave Gramstrup and Milt Huhta, eager to work and learn something new. There to help with that were Mike Gardonio, Tom Betts, Frank Kolo, Bill
Irving and me.
Autumn and Mike finished up the picture frames for the Sedan
Apparel Cabinet, installing a couple of dandy shots of Youth in Action to be displayed
on the cabinet in the Airport Terminal. After
that they, along with Dave, got busy with the new brake calipers, installing brake
pads, installing new hardware
and
transferring serviceable parts from the old calipers. The brakes are now ready to
be installed on the airplane when we're ready.
With that out of the way, they decided to tackle riveting practice on some
aluminum materials, .025" aluminum, punched with matching 3/32" holes. Some of the pieces were bent 90 degrees to form
an angle , so when riveted together, 3 pieces would make
a channel shape, or a mini spar if you can imagine. Good riveting skills are mandatory for nearly
any airplane construction.
All the while that was going on Chris, along with his Mentor
Barry and Frank set about to clean up the bores of the new hinges welded to the
rudder and fuselage rudder post. The hinge
parts shrink due to welding and need to be resized. This crew expertly took care of the task and then
set the rudder in place to check fit. A little
attention was needed to provide clearance around the new parts, with a file that
Chris handled with precision! Another file
helped remove any sharp weld edges on the rudder so that the covering will go on
nice and smooth. Tom looked on, offering
suggestions about the work to be done and helping to straighten some interior bows
and channels. With his first experience working
on an actual airplane, Chris showed great interest and attention to detail. I think we may have a budding Aircraft Mechanic
on our hands!
John and Milt joined me with the last welding (I think) on the fuselage. Last evening's work was to replace two damaged
stringer clips on the bottom along with replacing a missing tinnerman
nut plate tab. We then set to remove any
welding scabs left over from the major repair work that was done mostly on the aft
portion. Next Wednesday will be "Fuselage
Inspection Wednesday"
where we will go over it with a thorough inspection, looking for anything
missed, in preparation for the move to the paint shop.
As usual, Bill was our roving photographer and log book recorder.
Thanks Bill, and everyone else who turned out last evening. It's always good to see activity and progress!
1/31/18
Last evening was a quiet one, with Milt Huhta
our lone Youth Participant. :-) That didn't
stop us (Mike G., Tom B., Frank K., Bill I., and me) from working with Milt on the
tail wheel assembly.
Last week John Thro worked on, among other things, cutting out
a pair of shims to take up the slack between the tail wheel saddle and tail wheel
assembly. At first
we thought the material was too thin to bridge the gap, but I later thought that
to wedge the shims out against the saddle and weld them in place was the correct
procedure. That's just what we did. As the walls of the saddle are somewhat sloped,
the shims fit perfectly and we ended up with a very snug
fit. Good work John!
Since welding was the task last evening, and the bottle of argon
ran out just as we finished the tail wheel, we decided to call it quits around 8:15. I'll refill it and get on with finishing up the
remaining welding on the fuselage and getting it to the paint shop. Once repainted, we can move on to more exciting
tasks in the rebuild. I can't wait!
Just a reminder, next week is our night for the Committee meeting
so the Work Session will not be held. Set
your sights on Wednesday, Feb 14 for the first Work Session in February. I realize
that it's Valentines Day so I
understand if you want to be with your Love instead, or, you can celebrate
you're love for each other by working on a classic old airplane! (haha, just a thought!)
With Ground Hogs Day tomorrow and the sun moving higher in the
sky, I can almost see spring on the distant horizon, almost. Enjoy winter while it lasts, it will warm
up eventually!
1/17/18
Last evening was a pleasant one even though a bit breezy, the
hangar was warm enough to work in for a change!
Youth Participants attending were John Thro and Milt Huhta. Mentors there were Frank, Tom, Bill I and me.
We concentrated on the rudder mostly. We finished fitting and tack welding the lower
hinge group to the rudder, and fit the outer bow to the
bottom of the rudder post. After that we
were able to remove the rudder and tail wheel assembly from the fuselage to the
bench to weld out.
Bill was our roving photographer, recording the event. Just who is that old man in the fancy hat!?!
Now, everything on the fuselage is replaced that needed replacing,
fit that needed to be fit, I think, save a couple of stringer clips that will be
replaced next time we have the fuselage up-side down. I can just see it, with all the new work in fresh
primer, ready to receive everything that will make it an airplane again. That will be a big day!
Thanks to all who turned out last evening, we're making progress,
one step at a time.
1/10/18
Last evening felt like a nice October evening, mid 30's and light
winds. Not like today after the cold front got here, snow and wind and falling temps. Good 'ol January is
back!
Autumn Wolters, Dave Gramstrup, and
Milt Huhta were in attendance, ready to work and learn. Mike, Tom, Frank, Bill I., Al and I were here
to help.
Autumn and Mike set to work on making up some picture frames. These frames will be used to display pictures
of "Youth at Work" on the Sedan, and placed on
the apparel cabinet we have in the main terminal of the airport. Mike has them configured so we can easily change
the picture, to keep up with the progress of our project and to better tell our
story, encouraging sales of our shirts and hats.
Dave, Milt and I continued our work on the fuselage, tack welding
in the parts fabricated last time including the braces and bumper mount for the
tail wheel lower limit stop, and replacing the lower hinge
group on the rudder post. Proper care must
be taken to control all the grinding sparks, we don't want to start any fires or
damage any equipment! The fuselage continues
taking shape, inching ever closer to the next phase of restoration. Stay tuned for further developments!
Thanks to all who came out last evening. It has been a couple of weeks since our last Work
Session, but we all fell into the groove without missing a beat, build on!
12/13/17
Last
evening was preceded by a snowy, slippery day but we carried on. Brave souls who turned out to enjoy the Christmas
Party were John Thro and his Mom Catherine, Bret LaGraves
and his Dad Chris, and Milt Huhta. Mentor members also on board were Al White, Frank
Kolo, with three huge pizzas under his arm, Tom Betts,
and me.
The
first thing we did was to dig into the pizza and pop and start telling Christmas
stories. The conversation rolled around to a picture of the Duluth Airport, taken
back in 1987, with the Concord airliner on the runway, and another pic of it taking
off. What an awesome aircraft it was. It was here for an airshow put on by the Chapter
and our own Tom Betts went for a ride. Just
a short hop to Green Bay by way of Oshkosh and back. He'll never forget it! There was more conversation about Christmas, and
then the big drawing for the model airplane, Franks Vought FU4 Corsair. Brett and John were in the hat, and John came
out the lucky one! My great regret is that
in all the excitement, I neglected to get a picture of the lad and his new airplane!
:-( Sorry folks, you'll just have to imagine
John's grin from ear to ear in your mind's eye!
Things
were winding down, everybody was full of pizza, so John, Milt and I decided to work
on the Sedan for the rest of the evening.
They were able to finish fitting the brace tubes they were working on last
time, so all the parts for the tail wheel lower limit stop are ready to weld. Good job guys, we just might finish this thing
yet!
I
want to wish each and every one of you a very Merry Christmas
and a Happy New Year! We won't meet again
until January 10, so I hope the Holidays are all you hope them to be, full of love
and blessings and friends, and Thanks for the Pizza Frank, it was delicious!!
11/22/17
Last
evening started out to be a quiet one as I met Al White at the Chapter Hangar,
just in from deer hunting on the airport.
He had just bagged one, but was waiting to see
if I was going to be joined by others before he went back to skin his
quarry. Then Dave Gramstrup
and Milt Huhta showed up. Followed by Mike Gardonio and Aaron Breitkreutz
who rounded out our crew and we were in business.
We
decided to combine our efforts and focus on the rudder. Specifically, the lower hinge knuckle which
needs to be welded on. So, we hung the
rudder on the fuselage and discovered a misalignment. We examined the rudder and fuselage and Al
suggested we heat the rudder post to bring it into alignment, so without a
torch we turned our attention to the tail wheel lower limit stop.
By
the time our session ended, we had all the parts roughed in and nearly ready to
weld. This part went well, so we'll have
to look at it again next time to see what we might have done wrong and fix it
before it's too late!
Happy
Thanksgiving to all! I hope your past
year has been bountiful and full of joy, all good things to be thankful for,
and a hope that the coming year is even better!
11/15/17
Last
evening, we were greeted by Autumn Wolters, John Thro, Brett Lagraves and Milt Huhta, ready to
dig in. There to assist were Mike Gardonio, Tom Betts, Frank Kolo,
Bill Irving and me.
Autumn
and John, along with Frank and Tom went after the rudder, fitting the lower
channel rib, tack welding it into place, and making an extension to the outer
bow as it attaches to the lower rudder post at the tail wheel steering fork
(can you picture it?). All this is in
preparation for hanging the rudder in place on the fuselage to 1. Locate the
lower hinge knuckle and 2. Check for the tail wheel travel so we know where to
put the added tail wheel lower limit stop.
Brett
and Mike were busy cleaning brake parts, getting ready for matching up
serviceable old parts with new replacement ones. A little solvent cleaning (with protective
apparel of course!), a little buffing, a little drilling out rivets on old
brake lining, and a little elbow grease is all it takes!
Meanwhile,
Milt and I were busy welding up the lower aft bow assembly, the one that holds
the forward end of the belly stringers in place. Once that was done, we removed the rotation
stand on the aft end of the fuselage and set the fuselage on a temporary stand,
getting ready to hang the rudder in preparation for work mentioned earlier.
All
this time, Bill was circulating, documenting the event with camera and log
book.
Thanks,
as always, to all who turned out last evening.
It's fun to add things to the fuselage (if only temporary), makes it
look like and airplane!
For
those wondering about the Work Session next week, the day before Thanksgiving,
we will be there, at least I'll be there, for whoever is able to come to
work.
11/8/17
Man,
it was loud in the hangar last evening.
We had the air compressor going along with die grinder, angle grinder,
belt sander and bench grinder Whew! But
we got some work done!
Present
to join the fun were John Thro, Autumn Wolters, Eva Hobbs, Dave Gramstrup and Milt Huhta. Also present to drive the activity were Tom,
Mike G, Frank, Bill I, and me.
Eva
and Mike went right to work sawing some tubing for the rudder hinge, but then
shifted gears over to the main brakes.
They concentrated on removing hardware from the old worn out calipers to
be cleaned and made ready for the new parts.
They will continue their efforts next time.
Frank
and John went to work on the rudder, removing the lower rib (with an odd repair
we don't like) to be replaced with a new one that Mike G made for us some weeks
ago. They got everything all cleaned up
and the rib trimmed to fit just right.
Autumn
trimmed the lower aft stringer bow that Eva and Jim formed up last time to fit
the fuselage. Meanwhile, Milt went at
the old bow with a hack saw then an angle grinder to remove all traces of it
from the fuselage. Once the stringer
sockets that the bow holds were cut free, Autumn cleaned them up by trimming
close with a hack saw and then the bench grinder with the assistance of Tom, so
we can put them back in place on the new bow.
Follow that? With the parts all
prepared, Milt and I tack welded the new bow in place. Then the fun began. With an old stringer that Mike found
upstairs, Autumn, Dave G, Mike and I located the stringer sockets onto the new
bow and tack welded them in place. It
was kind of a juggling act, but we got them positioned in line with the other
stringer brackets.
Dave
G got busy with the control column, disassembling it for temporary storage and
evaluating the fasteners again to determine which bolts need to be replaced and
which ones are fit to be used again.
Only four fit the latter category, so we'll put the rest on our Hardware
Want List.
Through
the din of activity was Bill, taking pictures and recording the event in the
log. Thanks Bill!
As
I mentioned earlier, it was a fun but noisy couple of hours, but we are moving the
project along with great participation from students and mentors alike. Many
thanks to all attending, including the parents of our youth attending,
occasionally stepping in to see just what their kids are up to. See you next week!
10/25/17
With
October winding down, we got in one more work session before the meeting in
November. Eva Hobbs, Brett LaGraves, and Dave Gramstrup were
our Youth Participants, with Mike Gardonio, Tom
Betts, Bill Irving and me acting as Mentors.
We
got right to work with Brett and Mike assembling the last of the Elevator Trim
Control, including the handle!
Dave
and Tom went after the control column, aligning and drilling out the last of
the bolt holes in the new universal joints, taking care to keep the control
yokes parallel. The control column
should now be about ready to fit back into the fuselage when the time comes.
Eva
and I concentrated on bending some 3/8" 4130 tubing to replace the damaged
lower aft fuselage bow assembly. This
bow holds fittings for the forward end of the wooden stringers that give the
bottom of the fuselage shape. We had a
template to follow that Mike made up some weeks ago, and a tubing bender that
was made available to us by Mark Marino.
Thanks Mark, your bender worked just fine. Eva and I were able to follow the contour of
the template quite well and produced a nice replacement bow.
Bill
again was our PR guy, photographing key elements of the operation, as well as
recording the activity in our Restoration Log.
Thanks
to all participating last evening, we're gaining on 'er!
Remember,
next Wednesday is our meeting time, so no Work Session. Our next one will be November 8th, see you
then.
I
encourage all to check out our Sedan Web Page at sedanproject.com for updates to
our page. On it we have a link to
"Spirit of Katrina" apparel which we have on sale to help support our
project, and much more. Check it out!
Thanks!!
10/18/17
Last
evening we met, we worked, we learned! John Thro was here with his brother Thomas,
and Milt Huhta.
Mentors were Tom Betts, Frank Kolo, Bill
Irving and myself. Al White was here for
a bit but then had to leave.
The
Thro crew along with Tom and Frank attended to the rudder, checking alignment
in preparation for welding. All
measurements were taken and adjusted, all looks good. I then put the TIG torch to work and welded
up the splice and rosette joints. Thomas
was very curious about this welding business, so he watched the process. Success!
All seems straight and aligned, so on to the next bit, replacing the
damaged rib and reconnecting the aft perimeter tube to the post.
Meanwhile,
Milt and I fit the cabin door top hinge that we welded up last time. With a little adjustment it fits just fine,
so on to the lower hinge, rebuilding the area around the worn pivot point.
Bill
was our official recorder, taking pictures of the action and logging the
session in the book. A critical
function!
Thanks
to all who came out on a lovely fall evening, it's a pleasure to see smiling
faces working and learning!
10/11/17
Yesterday
was a quiet evening with Eva Hobbs, the lone Youth attending, along with her
parents, of course! Also present for the
session were Bill I., Tom, Mike, Frank, and me.
Eva
continues to show interest and enthusiasm for the work, and
began with getting an introduction on the rudder repair. It soon became apparent that this was not the
task for her, so Mike got her working on the elevator trim control that they
were working on last time. Much better!
Cleaning and painting and lubricating, all critical aspects of aircraft
restoration. Eva has a sharp mind, is
attentive with focus, and a very welcome Youth Participant!
Meanwhile,
Tom and Frank took to further the fit-up of the rudder parts, they're nearly
ready to weld together.
I
took the opportunity to tack weld the upper door hinge together and get the
door to swing open. Moving parts! I will finish welding up the hinge, then we
can concentrate on the lower one. That
one involves drilling and riveting.
Bill,
as it turns out is becoming our Work Session Recorder, recording the evenings
events in the Log Book, a very necessary part of our
rebuild. Thanks Bill! Bill also prepared a cash box for the sales
our "Spirit of Katrina" Sedan apparel over in the Main Terminal. If you get a chance, get over to the terminal
and check out our display, it fits in very nice there.
Thanks
again to everyone who turned out last evening, we're making progress!
9/27/17
The
rain finally stopped and the sky became partly cloudy for
our work session last evening. We were greeted
by yet another Youth Participant, Eva Hobbs.
No, she isn't an heir to the "Hobbs" meter legacy, but she is an
energetic and eager girl curious about airplanes. Welcome Eva!
Also, present and eager to learn about airplanes was Dave Kostuch, Dave Grambush, John Thro,
Isabella Easterday and Milt Huhta. Mentors on board were Tom Betts, Frank Kolo, Mike Gardonio, Al White, Aaron
Breitkreutz, myself and Mike Philips. Mike is new to our Chapter. He hails from St. Cloud, Mn and EAA Chapter 551. Mike has moved to Superior and has joined our
Chapter. Mike holds an Airframe and Powerplant
Certification, working on his Inspection Authority, and is excited to join our Aeronca Sedan group.
Welcome Mike!
Work
continued on the Control Column assembly, with Dave G.,
Milt, Al, Frank, Mark, and Aaron combining their wisdom around installing the new
universal joints. Holes need to be drilled
in the u joints to match ones in the assembly.
The Control Yokes also need to be clocked the same using their existing bolt
holes, so much discussion was had around achieving that result. They decided to use the existing holes as drill
guides and move on. So far, so good.
John
Thro and Dave K. worked with Tom on the rudder, continuing to fit up the scarf joint
and locate rosette welds required to reinforce the joint.
Eva
and Isabella were on team Mike with their focus on the new parts we received a couple
of weeks ago. They distributed them to the
bins of parts they are going to replace.
We are trying to stay organized as possible, we don't want to lose anything! Next, they turned their attention to the elevator
trim control. They continued to fabricate
a new bracket for the trim indicator.
Dave
K. and Milt came over to help me with fitting the cabin door. With the door clamped in place, using shims to
hold it as central as we could get it, we continued to fit the modified upper hinge,
getting ready to weld it up. We're getting
close!
Thanks
to everyone who turned out last evening.
I can't say it often enough what a great group we have, all pulling in the
same direction. t's a wonderful thing and I am proud to be a part of it!
Next
week is our meeting Wednesday, so the next Work Session will be in October, the
11th.
9/20/17
We
were greeted last evening by beautiful, clear and warm weather (it's all about the
weather, isn't it?), and a hangar full of activity. New to our group was Dave Gramstrup's
Dad, Dave Gramstrup. It took us a while to get over the
name confusion and come to the realization that our Dave is a Jr. We can be so dense sometimes! Also new to the project is Isabella Easterday, an energetic youngster eager to learn about airplanes. She is a little young for our program, but her
Dad Don stayed for the session, and she remained engaged and attentive throughout
the evening, under the guidance of Mike Gardonio. She is a budding aeronautical engineer if I ever
saw one! The remainder of our participants
were Brett LaGraves, Milt Huhta,
and Jared Harger.
Dave Jr. and Jared are in the same class at LSC A&P school. Adult Mentors on the scene were Tom Betts, Mike
Gardonio, Bill Irving, Dave Gramstrup
Sr., Don Easterday and me.
Dave
and Dave, Jared and myself focused on the control column. Frank Kolo with a previous
commitment couldn’t be here, so after a brief study of the assembly to understand
what need to be done we got to work. The
aileron control sprockets seemed to be out of time with each other, so the chain
was adjusted. The remaining pulleys were
mounted and old hardware evaluated. Dave Jr. discovered that the bolts holding the
lower pulleys are bent, so we'll order new ones. Nice catch Dave! We discussed the procedure for installing the
new universal joints which needed the bolt holes drilled. We determined that the new holes should be drilled
90 degrees to the existing ones to maintain perfect alignment of match drilled holes,
and discussed the procedure to accomplish the task, keeping in mind the the holes in the control yoke shaft must be aligned to keep
the yokes in the correct position with the ailerons neutral. Whew, all this thinking
can make your head spin! We'll drill and
ream holes next time.
Tom
and Mike, along with Isabella, Brett and Milt worked on setting up the rudder for
welding on the replacement lower section.
They built a fixture to hold everything in alignment. Later, Mike took Brett and Isabella aside and
paid some attention to the elevator trim control, cleaning parts and preparing material
to make a new bracket for the assembly.
With
yet another successful work session under our belts, I want to thank everyone who
came out, especially our new comers. You
make it all worthwhile!
9/13/17
Last
evening ended up unseasonably warm and pleasant, so we left the big door open. Boy, did the mosquitoes come out, or in. They sure kept us hopping!
We
had a good turnout. For students we had Tyler
Brietkreutz, Brett and Samantha LaGraves
with Brett's friend Delten. Also, along were John Thro and, new to our group,
Jared and his Dad Jim Harger, and Milt Huhta. Mentors included
Frank Kolo, MIke Gardonio, Tom Betts, Aaron Breitkreutz
and me.
Mike
and Brett went to work on the elevator control mechanism along with Deegan Hoffbauer
and Tyler looking on. They were able to complete
the placard that goes under the crank. Deegan
is an enthusiastic young fella, much like his pal Brett. It was also good to see Tyler again, he hasn't
been here in a while.
Autumn
and Tom along with Milt went after the rudder, researching the particulars of the scarf joint and rosette welds, and how to
best fixture the assembly to keep everything square, straight and the right length. Some classroom work was done using the AC 43.13-1B
manual of Acceptable Methods and Practices to determine how the joint should be
configured. They could come up with a list
of materials to construct the fixture for next time.
Frank
had a big crew to work with around the Control Column. At one time he had Tom and Milt and Jared and
Jim and Aaron looking on, but mostly Jim and Jared. We finally got our hands on a pair of universal
joints we were waiting for so work on this part can proceed. The first order of business was figuring out where
we left off! Once accomplished, work progressed.
installing the aileron chain assembly and new cable pulleys, and
assessing hardware.
John
and I were back on the fuselage, but in the forward end this time. We straightened the lower forward fairing bow
assembly, then moved to the fitting of the cabin door. The upper hinge needs some rework, so that was
studied and a possible remodel was determined. We'll have materials for next time.
All
in all it was a busy, productive time last night with stuff
going on in every corner. Thanks to all who
came out yesterday, it's good to see new faces, and the old familiar ones too, our
group just keeps getting bigger and better!
8/30/17
School
is starting soon, as evidenced by the absence of most of our Youth Participants. Orientation, kids growing up, moving to new schools. Autumn was able to come however, along with Milt,
so we had work to do. Along to balance out
the other side were Frank and me with Bill I. and Al looking in.
First of all, Autumn and I inventoried a shipment
of parts received from Aircraft Spruce and Specialtiy
Co. In the box were parts for the control column, control cables, brake parts and
pulleys. We have work to do now! Everything was shipped as expected, beautiful
parts. Now we can make up control cables
for the rudder, elevator and trim tab, and aileron cables within the fuselage (there
are still a set of cables in the wings to address). We can complete the control column and brakes
too, lots to do!
Once
complete Autumn, Milt and I focused on the rudder. At the last work sesion
the scarf joint for the splice was laid out on the rudder and replacement section. We double checked both parts to see how they compared. Identical.
We also check with the guide book, AC 3.13-1B Acceptable Methods and Practices,
to determine the length and size of the reinforcement sleeve. We cut a piece of 7/8" x .035 wall 4130 tube
5" long, Frank cleaned up some minor surface corrosion, making it ready for
welding. Next, we set up to make the cuts
with a hand held 5" angle grinder. Once
made we de-burred and inspected the joint.
The alignment is very nice, just a little refinement, some plug weld holes
to drill and it should be ready to weld.
It
was a quiet evening (mostly, except for the grinder!) with only one task at hand
but progress no less. Thanks to everyone
who turned out. Next work session will be
in September, where did the summer go?
8/23/17
Last
night we were greeted by Autumn Wolters who we haven't seen in a while. She has been busy with other activities this summer,
most importantly, having fun! Also, along
for the ride were our old friends Dave Gramstrup and Milt
Huhta. Present
to lead the Session were Tom Betts, Al White, Frank Kolo,
Bill Irving and me.
Autumn
and Dave jumped right in with Tom on the rudder. Their task was to mark the scarf joint on the
rudder and the new section to replace the damage. Their set-up was somewhat elaborate in order to repeat the cut line in the same place on both pieces,
but I think they got it right on. Next time
we'll double check the marks and make the cuts.
Milt
and I finished up welding of the sleeves at the aft end of the fuselage (I thought
it would never get there!). Next, we welded
on a stringer stand-off to replace a bent up one that was removed previously. Our man Mike Gardonio
had made up the new one some time ago, I'm glad we didn't lose it in the interim! Next, we'll focus on the lower aft fuselage fairing
bow. This and the forward one have been subject to rough handling in a previous life and need
some attention.
Al
and Bill and Frank did some remodeling on the tall coffee maker table so that we
can park our new welding machine under it, out of harm’s way. All they had to do was to notch the front rail
a little to provide clearance for the argon cylinder and flow meter. Short work, nice job. The machine is now parked safely away under the
bench. Thanks guys!
It's
always surprising how early the days end this time of year. We had the big door open for the session, it was
a very nice evening, we really noticed when the sun went down, Dark! Thanks to everyone who came out last evening,
we're making progress!
8/16/17
We met again last evening, with John Thro back from
his baseball tournament in Indiana where they won one of four, very well by all
accounts! Also attending for enlightenment
was Milt Huhta.
Mentors on board were Tom B., Al, Bill I.,Mike G., and me
We got busy without delay, John and Tom focusing on
the rudder, fitting the control horn to the replacement tube. That involved laying out and cutting the relief
for the lower hinge bushing and locating it aligned with the steering fork. We tacked it in place, ready to cut the splice
joint on the rudder.
Mike and Al made a cardboard template to replicate a
bow assembly on the bottom of the fuselage that got bent up pretty
bad at some point along the line.
We have some 3/8" x .035 tube to bend for its replacement. The template will help us make a form to aid in
the bending.
Milt and I continued our work on welding up the fuselage. The sleeves fit on those two aft tubs are nearly
all welded. Some tight places there, where
the tubes come together on the rudder post, but we got it! Inching ever closer to completion!
Thanks to everyone who turned out last night, what a
great bunch!
8/9/17
Last
evening was our first Work Session in 3 weeks, what with AirVenture
and meetings, it seemed like forever! We
fell back into the swing of it though like we never missed a day, Sweeet! Youth attending
were Samantha and Brett LaGraves along with Milt Huhta. Mentors present
to teach and learn were Mike Gardonio, Tom Betts, Bill
Irving, Frank Kolo and me.
Brett
and Mike went after the elevator trim control to clean and to measure the turnbuckles
so that we can replace them with the correct ones.
Samantha
and Tom were back on the rudder, fitting a new control horn that Mike made back
in his own hangar. Thanks Mike! There was
some confusion and discussion regarding locations and procedures. It seems that time does funny things with memory,
that's why we always try to write dimensions down and don't dismantle the old part
before the new one is ready to replace it.
We're all set now though, so next time it's full steam ahead!
Milt
and I continued fitting and welding the reinforcement sleeves at the aft end of
the fuselage with our new Lincoln welding machine we just brought home from EAA
Sport Air Workshops. Nice machine, it will
serve the Chapter well. Thanks to EAA and
Charlie Becker for making the donation possible and our life easier and more enriched!
Frank
and Bill finished up the "Spirit of Katrina" apparel cabinet, applying
the signage to the front. Pretty spiffy guys! It's now ready to load with shirts and hats and
move to the Superior Airport Terminal, officially putting our stuff on sale. So, if you can, check it out and buy a hat or
shirt!
Thanks
to everyone for coming out last evening, everyone pulling in the same direction
is just a joy!
7/19/17
Last
evening was a very pleasant one with just a breeze off the big lake to cool things
off from the day's heat (we're not used to heat up here). We had a good turnout with Dave Kostuch and Dave Gramstrup, and Milt
Huhta filling out the group of students. Tom Betts, Bill Irving, Frank Kolo, Todd Gremmels and myself were there to help out.
First,
Bill took Dave K. and his mom Krista up for a ride in his C172 to look around. It was Krista's first ride ever in a small airplane
and she was a little nervous. No worries,
she and Dave came back with smiles on their faces, and Krisa
with a new faith and perspective in the ability of small aircraft.
Dave
G. joined Tom and Todd working on a Quickie which has appeared in our hangar since
last time. This aircraft has been a weather
vane perched on a rotating column in front of our hangar for a few years and was
taken down last Saturday for repairs. The
poor old bird has experienced some weathering damage and trauma from kids climbing
on it. Todd, who has fiberglass experience,
has agreed to lead the repair for a speedy return to it's
post in good condition (for a weather vane!).
When Dave and Krista returned from their ride, Dave joined the crew, learning
about yet another type of airplane.
Frank
was then joined by Bill, lining the display shelf of the apparel cabinet. One step closer!
Milt
and I went over the control cables that Mike and crew measured last time. We wanted some confirming information on the size
of the turnbuckles and number of other parts that make up the cables that live in
the fuselage. Everything checks out. We then continued fitting the sleeves on the fuselage
aft tubing. Almost ready for welding, one
more section to go.
Thanks
everyone for coming out on such a beautiful (rare) evening to work on our birds. As you may have heard, our meeting next Wednesday
is cancelled due to most every one of our mentor's attendance at Airventure next week. With our board meetings the following
week, we'll see you all on August 9th.
7/12/17
Last
evening was a cool wind right off the big lake, foggy and damp. That did not deter us though, we had a full evening
of activity, inside!
The
LaGraves crew was here, Brett, Samantha and Emily, and
John Thro. John was recently back from Air
Academy where he was immersed in hands on activities like sheet metal work, composites,
chart reading and navigation to mention a few subjects. John said he thoroughly enjoyed the experience, but was disappointed when they were unable to climb
the rock wall outside because recent rain making it too slippery! Overall, he loved
it!
Adults
here to assist were Tom Betts, Mike Gardonio, Frank Kolo, Bill Irving, Al White, Milt Huhta
and me.
Brett
and Mike finished assembling the tail wheel, fitting the tire, assembling the wheel
halves and a final lube. Tail wheel ready
to install. Whew, that was a long hard pull!
Tom
showed Emily and Samantha all about testing the Emergency Locator Transmitter on
his Glasair. Tom
had a recent lightening activating event with his ELT so
he wanted to test it and thought the young Ladies might be interested in learning
all about it, they were. One more aspect
of aviation to add to the list.
Afterward,
the LaGraves crew helped Mike gather control cables, measure
their length, and record how the ends were built. It's time we replaced them, so we need to know
what they are.
John
and Milt and I worked on the tubing sleeves at the aft of the fuselage, tacking
them in place to reinforce the corroded areas.
Tight spot but we'er getting it!
Frank
and Bill continued work on the apparel cabinet, touching up the paint job and checking
out the signage stencil that Mark Marino made up for us. Thanks Mark! The Cabinet will be looking pretty slick by the time we get done with it.
Thanks
to all who came out to participate. This
session, as always, we learned a few things as we inch further along on our Sedan
project.
6/28/17
Well,
last evening was a little unusual in that we had no youth attending. My guess is the gloomy weather, raining cats and
dogs all day and cool temps. Also, John Thro
and Dave Kostuch are at Air Academy in Oshkosh so they were predisposed. No worries, we will resume in July on Wednesday
the 12th right in stride.
We
did have a contingent of Adults/Mentors though, with Tom Betts, Mike Gardonio, Al White, Frank Kolo an
myself ready for action. We get a few minor
things done in the hangar, and helped member Tim Friendshuh modify the front seat back in his RV8A. Riveting is new to Tim
so we were able to help him out a little and move his project along.
Thanks
again to all who came out on a gloomy, wet evening. Even though we had no youth this evening, it's
all good. We'll pick it up next time.
06/21/17
Last
Wednesday evening was witness to yet another successful session of work on our Sedan. John Thro and Dave Gramstrup
were on board to assist and learn. There
to pitch in were Tom Betts, Mike Gardonio, Al White, Milt
Huhta, Bill Irving and me.
Dave
and Tom and Milt went to work fitting the cabin door into the fuselage opening in order to finish the lower hinge arm. It was determined that when the door is properly
centered in the opening, upper hinge does not match the hinge tabs. It was determined that the hinge must be moved,
therefore the three began the surgical removal of the rivets holding the hinge in
place. This is an exacting process to remove
the rivets, preserving the holes, so that the corrected hinge can be reinstalled.
Once the steel hinge is removed, the door can again be fit into place, the lower
hinge arm located and the upper hinge remodeled to fit.
John
and I went about to fit the sleeves that were made to reinforce the two tubes that
meet the rudder post. As it turns out, my
suggestion to use 5/8 dia x .035 wall tube split down
the center was a poor one as the gap left between the sections is too great. On to plan "B". Al suggested we fashion a doubler
from flat sheet, forming it to fit the tubes.
Al demonstrated the process by getting some thin sheet to use as a pattern
and began to trim and fit. In the mean time John and I made final preparations to the horizontal
stabilizer brace wire tabs and tacked them into the lower longerons at the 20 degree angle that the original ones were set at.
Bill
and Mike busied themselves putting a first coat of green paint on the apparel display
case.
Just
about the time we were all finishing up for the evening, the clouds opened, the
thunder boomed and the rain came down. In buckets!
Wow, we are going to get soaked on our way to the cars, I was thinking. Just about the time we were going to make our
move, the rain quit, with nothing more than a nice clean smell in the air! No worries!
Thanks
everyone who came out to help. It never ceases
to give me a thrill to see such activity toward a common goal, engaging youth and
adults alike, everybody learning something new, and making our lives richer for
it. Keep up the good work!
06/14/17
Last
Wednesday evening was witness to yet another successful session of work on our Sedan. John Thro and Dave Gramstrup
were on board to assist and learn. There
to pitch in were Tom Betts, Mike Gardonio, Al White, Milt
Huhta, Bill Irving and me.
Dave
and Tom and Milt went to work fitting the cabin door into the fuselage opening in order to finish the lower hinge arm. It was determined that when the door is properly
centered in the opening, upper hinge does not match the hinge tabs. It was determined that the hinge must be moved,
therefore the three began the surgical removal of the rivets holding the hinge in
place. This is an exacting process to remove
the rivets, preserving the holes, so that the corrected hinge can be reinstalled.
Once the steel hinge is removed, the door can again be fit into place, the lower
hinge arm located and the upper hinge remodeled to fit.
John
and I went about to fit the sleeves that were made to reinforce the two tubes that
meet the rudder post. As it turns out, my
suggestion to use 5/8 dia x .035 wall tube split down
the center was a poor one as the gap left between the sections is too great. On to plan "B". Al suggested we fashion a doubler
from flat sheet, forming it to fit the tubes.
Al demonstrated the process by getting some thin sheet to use as a pattern
and began to trim and fit. In the mean time John and I made final preparations to the horizontal
stabilizer brace wire tabs and tacked them into the lower longerons at the 20 degree angle that the original ones were set at.
Bill
and Mike busied themselves putting a first coat of green paint on the apparel display
case.
Just
about the time we were all finishing up for the evening, the clouds opened up, the
thunder boomed and the rain came down. In buckets!
Wow, we are going to get soaked on our way to the cars, I was thinking. Just about the time we were going to make our
move, the rain quit, with nothing more than a nice clean smell in the air! No worries!
Thanks
everyone who came out to help. It never ceases
to give me a thrill to see such activity toward a common goal, engaging youth and
adults alike, everybody learning something new, and making our lives richer for
it. Keep up the good work!
05/24/17
Students: Dave Granstrup,
Brett and Samantha LaGrave, David Kostuch
Adults: Tom Betts, Frank Kolo, Mike Gardonio, Milt Huhta, Tim Friendshuh
Tom, Dave Granstrup,
Frank and Milt continued the effort to remove the insert from the Rudder, without
much luck though. The combination of weld,
rust and tight fit are making it impossible to move the insert without destroying
the outer tube.
Mike Dave Kostuch,
and Brett LaGrave enlarged the slots in the lower fuselage
tubing to accept the Horizontal Stabilizer flying wire tabs. After the tabs were fit, the tabs were dressed
a little bit and set aside for welding. They
then finished cutting out the lower rear longeron patches that were started last
week.
Mike and Samantha LaGrave
removed the bearing cones from the tail wheel.
They will be replaced with a different type of bearing that will better fit
the tail gear axel. Tim Freindshuh came in to go for a ride in his RV-8 and was gracious
enough to give Dave Kostuch and Brett and Samantha LaGrave all a ride around town too. Thanks Jim!
05/17/17
It
was a wet one last evening, but that didn't dampen our spirits or turn-out for another
round of work on the "Spirit of Katrina". Dave Gramstrup and John
Thro came eager to help and learn. Mike Gardonio, Tom Betts, Frank Kolo, Al
White, Aaron Breitkreutz and I were along for the ride!
Tom
and Dave went after the rudder, assisted by Mike, repairing the section below the
rudder horn. They ran into a snag however
as the reinforcing tube was also fused to the rudder main tube right at the horn. This was due to another previous repair to the
horn, as the weld penetrated thru the rudder tube into the reinforcing inner tube. We may have to carry the repair higher up and
replace the horn too. We'll see...
John
and I continued our work on the fuselage.
John worked to further the repair sleeve preparation for the corroded tube
section at the base of the rudder post. John
is getting to be quite the metal worker, showing a good understanding of what needs
to be done. In the meantime
I made slots in the longerons to accept the horizontal stabilizer brace wire anchor
tabs.
Thanks
to all who pitched in last night. Team work
is what makes this project the joy that it is!
05/10/17
Youth
Participats in attendance were Dave Kostuch, Samantha LaGraves, Dave Gramstrup and Milt Huhta, our most
senior Participant (and still eager to learn!).
Mentors aboard were Tom Betts, Mike Gardonio, Frank
Kolo, Bill Irving and me.
Here
we are in May with our first work session of the month in the log book. It was a lovely evening, warm, with scattered
sprinkles now and then, and rainbows! Not
too many sprinkles though for Bill to steal away Dave K and Samantha for a ride
around the harbor in is trusty C172. The kids came back with grins on their faces!
Dave
G. and Tom went to work on the rudder, actually removing
the damage on the lower hinge post that holds the tail wheel steering arm. Cutting the tubing at a 30 degree
miter so close to the rudder control arm with our primitive equipment is proving
to be a challenge, but not one they cannot meet. The cut has to
be close to the arm as there is an old butt joint (from a previous repair) within
2 inches that needs to be removed. Just a
little more work and they'll have it. Oh for a vertical metal cutting band saw!
Samantha
and Mike got out the landing gear structure and inspected it for any potential problems
(interrupted briefly by an airplane ride).
They performed a visual inspection followed by spot sand blasting to better
expose suspect areas. They found a few that
need attention. They mostly look like weld
defects from manufacturing which shouldn't develop into any problems, but we have
the technology to correct them!
Dave
and Milt worked with me on the fuselage.
Milt worked to prepare sleeves to reinforce two tubes at the base of the
ruder post that have some corrosion. Dave
K. (again, when he got back from his airplane ride) helped to position the ground
handling handles and tack them into place.
Next we located and marked the tabs that hold the
wires for the horizontal stabilizer.
Thanks
to everyone who turned out to work on our bird.
I just love to work with the big door open to enjoy the warm breezes!
04/19/17
Chilly! We had a couple of eager fellows none the less,
ready to work and learn. Dave Kostuch and John Thro, who incidentally, will be attending Air
Academy at Oshkosh this summer for the first time. Congratulations guys! Ready to guide were Mike Gardonio,
Aaron Breitkreutz, Bill Irving and me. We had a couple of guests, formally from Oshkosh,
Jim Kersting and his friend Jody. Jim, as you may recall, was instrumental in our
acquiring the Sedan in the beginning! Thanks
for coming by Jim!
Dave
and Mike began the evening packing grease in the bearings for the tail wheel before
reassembling. I was discovered the job couldn't be completed due to lack of bearing
seals and the axle being too short. It turns
out that we have the correct axle but we need seals so
the job was put aside. Dave then moved to
work with Aaron on the Cabin Door, lower hinge.
They were repairing the hinge pivot area to renew and reinforce a worn bolt
hole.
John
and I were back on the fuselage, John got to studying the AC43.13-1B manual of Acceptable
Methods and Techniques and Practices, to design a tube sleeve that will reinforce
a pair of corroded tubes that join the rudder post, while I welded up tubing joints. We conferred, and John went ahead and prepared
some parts for the task. Afterward with just
a few minutes remaining, John took a file to clean off weld tacks from the lower
longerons left from the truss we used to stabilize the fuselage during longeron
replacement.
Thanks
to everyone who came out on a chilly and blustery spring evening, the work continues!
04/12/17
Well
here we are in the middle of April. I know
it's spring now because the frogs have started croaking. What a beautiful sound after months of cold and
snow!
Last
evening was another beautiful mild one, perfect for a few Young Eagle rides. Three of our four students went up for a tour
of the Twin Ports and came back ready to work.
They were Autumn Wolter, Samantha LaGraves, John
Thro, and Dave Gramstrup didn't get ride, just came to work. Mentors and pilots were Tom Betts, Bill Irving,
Al White, Mike Gardonio, Frank Kolo,
Bill Bergland and me.
John
and I got started back on the fuselage, completing the welding of joints in the
new tubing untill he went for his ride with Al. When he got back we continued with Samantha looking
on occasionally.
Dave
and Frank pressed the bearings out of the elevator control bell crank so they could clean it up for painting and service the
bearings. Autumn used the sand blast cabinet,
guided by Frank to do the actual cleaning.
Dave
and Mike mounted the tail wheel tire and finished building the tail wheel with grease
and safety wiring the appropriate fasteners.
Samantha joined in later to see what it was all about.
Autumn
and Tom worked on the rudder, deciding how to make the cut to section in the new
material.
Dave
and Mike, along with Al, brought out the main gear legs for inspection. Basically they are in
good repair except for some pin holes in existing welds which will be repaired. The main pivot bushings will also receive further
analysis before making a go-no go decision on their airworthiness.
All
in all it was a bustling evening with activity going on
in all corners of the hangar. Try to make
available next Wednesday to join in the experience that is the "Spirit of Katrina"
Sedan Work Session!
03/29/17
Last
evening greeted us with more typical March weather, low ceilings and a brisk wind
off of Gitche Gumee. That didn't stop
us from working though (although it did prevent any airplane rides). Folks showed up and we got to work. In attendance were the LaGraves,
Brett and Samantha, and visiting for the first time was Emily, their sister who
lives in Madison, Wi. She will likely be
back this summer. Welcome Emily! Also here to learn about
fuselage repair was Milt Huhta. Supervisors along were Tom Betts, Mike Gardonio, Aaron Breitkuetz, Al White,
Frank Kolo, Bill Bergland, Bill
Irving and me.
Samantha
and Emily joined up with Aaron to work on the cabin door, specifically the lower
hinge. The pivot pin area had broken and
been repaired, but not to our standards.
Aaron coached the ladies on a better repair which included removing the previous
reinforcement to replace it with one more robust. They were able to disassemble it and are designing
a new reinforcement.
Brett
and Mike went to work on a new addition to our hangar. New style chair racks, built by Mike and Tom and
Jim last weekend, and powder coated by our friend Chris Penny at Precision Powder
Coating in Superior. Thanks Chris! Brett and Mike drove plastic plugs into the ends
of the tubing and bolted on the casters.
Just about everybody pitched in to transfer the chairs from the old racks
to the new ones. Tom and Mike tried them
out pushing them through the door into our furnace room, perfect fit! Next will be a new cart for folding tables so
that all can be stored in the furnace room, making more room in the hangar proper. Good job fellas! Once that big job was completed, Brett and Mike
drilled a hole in a tail wheel bumper bracket they made for the new tail wheel stop. Brett is a hole driller, and a good one too!
Milt
and I continued work on the fuselage, tacking in the last of the cross members we
replaced and welding some of the joints.
We next started the planning of a tail wheel stop to prevent it contacting
the rudder in the event of a bunge and safety cable failure. This is a modification adapted after our Sedan
was manufactured.
Thanks
to all who participated last evening, our last for March. Next week is our scheduled committee and board
meetings so there will be no work session.
April 12 is the next one, I hope to see you all then. Happy Spring!
03/22/17
Yesterday
provided us with another bright sunny evening.
It was just right for a couple of airplane rides, provided by Tom for Autumn
and Tyler. I am told that Autumn even made
the position calls upon back taxi to the ramp.
Do we have a future pilot in our crew?
In
addition to Autumn and Tyler, Dave Kostuch and John Thro
rounded out the Youth Participant contingent, with Milt Huhta
along to observe the fuselage repair. Member Mentors were Tom Betts, Mike Gardonio, Aaron Breitkruetz, Frank
Kolo and me.
Tyler
and Aaron continued the work on the cabin door.
I brought a piece of .032" thick 2024 aluminum alloy formed at 90 deg. to
reinforce the door latch and handle. Tyler
and Aaron proceeded to fit it, assisted by Autumn after her ride with Tom. They got a good start on the task!
Dave
and Mike got to work finishing up the tail wheel assembly including final lubrication,
ready for the tire and wheel. They then turned
their attention to the rudder to continue the work from last week, removing an array
of rosette welds holding an inner sleeve from a previous repair. This will allow us to replace the damaged lower
section.
After
Tyler got back from his ride, he helped Frank fit some spacers to the lower control
column. This is where the control column
pivots back and forth in the fuselage with the Control Yokes. Our spacers were stuck, so Al pressed them out
last weekend. Mike Hoag sent us a set he
had (Thanks Mike) which are in better condition than ours, so that's what Tyler
and Frank were fitting. Almost done!
John
and Milt helped me fit the last diagonal brace just ahead of where the tail wheel
mounts. We made a pattern piece, then John
and Milt fabricated the replacement tube.
We got to fit, ready to tack into place.
We also removed the reinforcing truss that was temporarily welded to the
longeron while the fuselage was repaired.
We are beginning to see the light at the end of the tunnel on this task!
Thank
you to all who attended last evening. Little
by little we're all getting smarter, as the "Spirit of Katrina" inches
closer to overcoming gravity!
03/15/17
Yesterday
felt like spring. With daylight savings time
it might be darker in the morning, but the afternoon daylight sure is nice. So nice that Tom took the opportunity to give
the first youth participant to arrive a Young Eagle ride. Dave Kostuch was the
lucky one, so up they went! Also on board to work and learn was Dave Gramstrup,
Brett and Samantha Lagraves, and Milt Huhta who is one of our own Chapter members, here to pick up
some tips on fuselage repair and TIG welding.
Welcome Milt! To round out the other side of the equation were Tom Betts,
Aaron Breitkreutz, Al White, Bill Irving and me.
Dave
G. and Milt worked with me on the fuselage, fitting the last couple of cross and
diagonal members just ahead of the tail wheel mount. Dave got a taste of cutting and fitting the pattern
piece of the diagonal, discovering some fitting considerations along the way. A great teaching moment!
Aaron
and Samantha worked on the cabin door latch area, straightening out the latch mount
and with Al's help, plan a reinforcement for a little crack in the door skin there
to give the latch more support. They then
went on to remove the lower hinge and plan a repair for it. The hinge pin hole had been broken off and a hasty
repair made. We want to refine it and perhaps
make it stronger to boot.
Brett
and Bill went to work on the control column.
Seems that the main pivot bushings are stuck and won't rotate. To help press them out of the control arm, they
had to fasten a vice to a work bench. Brett
loves to drill holes! They got the vice fastened
down just fine, but no joy was found removing the bushings. More investigation is required.
When
Tom and Dave K. returned from their flight, (and once Dave was able to keep his
feet firmly on the ground) they turned their focus on the rudder.
Specifically where the tail wheel steering arm attaches. The arm was corroded into the steel tube of the
rudder, the attach holes are too big, so the lower section must be replaced. Along with Al and I we determined a course of
action and Dave and Tom went to work removing an array of rosette welds holding
an inner sleeve from a previous repair.
It's
so nice to be on this side of winter with the promise of spring in the air, not
to mention Young Eagles! Thanks to all who
participated last evening, I believe we're making progress!
03/08/17
Last
evening it was nice to finally walk around outside without having to chase your
hat across the yard! Boy this wind has been
something! Never the less, we had a good
turnout for the Work Session, with Autumn Wolters and John Thro eager to get to
work. To help with their desire was Mike
Gardonio, Frank Kolo, Bill Irving
and me. We even had two Chapter visitors,
Dave Kauppi and Milt Huhta. Milt was especially interested in the fuselage
repair and the welding process it involved.
Autumn
and Mike went to work preparing a section of tubing to replace the lower section
of the rudder where the tail wheel steering fork attaches. Our rudder is compromised in this area so we will replace it.
Autumn and Mike drilled holes in the tube to match the steering arm, not
a small task to do it precisely, and make it ready to section into the rudder. They also drilled out the steering arm where the
steering cables attach. This area had previously
been welded closed to repair the original holes which showed excessive ware. These holes will be fitted with AN42 eye bolts
to receive the spring as suggested by our friend Burl Rodgers in Alaska.
John
and Milt were paying very close attention while we continued to fit and replace
corroded tubing in the aft end of the fuselage.
I think we are getting closer to the end of this process, just a few more
sessions!
Thanks
to everyone who came out last night in spite of the Gales
of March, another in a long string of successful work sessions!
2/22/17
Despite
the rain and then snow, we had a god turnout for the work session. In fact, we had a new fellow come to see what
we're up to. Matthew Ierino,
at the invitation of long time friend of John Thro. Matt says he hasn't built any airplanes yet, but is eager to learn how! He is interested in Industrial Arts and showed
good aptitude last night. Welcome to the
Project Matt! Also
eager to work were Samantha and Brett Lagraves. Helping to direct our crew were Frank Kolo, Aaron Breitkreutz and me.
The
evening started with Samantha and Aaron inspecting the rear window task. They cleaned up any drips in the varnish, put
the woodwork away for the time-being and cleaned up the work station. They then moved over to the display cabinet and
hung the doors which were painted last time.
That complete, they shifted their focus to the Sedan door. The latch area needs a little attention. With a little clamping fixture that I had made
up last week they pulled a little dent out on the inside skin and studied how to
correct some minor deformation around the latch mount area. We will tool up for that job for next time.
Brett
and Frank were back on the control column, cleaning the aileron control chain assembly
and the rod ends in the elevator push-pull tube assembly. Once we get our replacement parts, this control
column will be good as new!
John
and Matt were in there with me on the fuselage.
We fabricated another jack post to hold the longeron spacing and made up
a couple of cross members just ahead of the tail wheel frame assembly pivot.
Thanks
to all who turned out last night, a new Youth Participant and good work done, progress
indeed!
2/15/17
Last
evening we had a little smaller group than usual, but it
was fun and educational as ever! Dave Gramstrup, Brett and Samantha LaGraves
were here ready to dig in. Here it assist and advise were Mike Gardonio,
Aaron Breitkreutz, Bill Irving and me.
I
worked on the fuselage along with Samantha and Brett at times, Samantha worked with
Bill too, putting the last finishing touches on the rear window frames (which I
really think are done now!)
Mike
got Dave going on preparing a piece of tubing ready to replace the lower section
of the rudder post where the tail wheel steering fork bolts on. Once this piece is prepared we will weld it onto
the rudder.
Mike
and Brett drilled some holes in a piece of 4130 steel sheet to shear into Tinnerman nut tabs to weld onto the fuselage where necessary,
and then they reassembled and lubricated the old Maul tail wheel gear.
Aaron,
Brett and Samantha worked on the display case, painting and installing trim. This thing is looking pretty
nice! Soon we will be able to display
our "Spirit of Katrina" apparel in the Superior Airport Terminal to help
raise funds and spread the word for our Project.
2/8/17
Last
night was a chilly one. Here to work and
learn was Dave Gramstrup. Present to guide were Tom Betts, Frank Kolo, Al White, Bill Irving, Mike Gardonio
and me.
Mike
showed up last evening with a spread sheet list he put together with all the fasteners,
bushings and clamps identified in the Parts Catalog. This will be used to determine what new hardware
is needed for the complete rebuild. I counted
159 individual part numbers all together.
Good job Mike, thanks!
Dave
and I got right to work fitting and tacking in the last section of longeron, just
forward of the tail wheel pivot on the left side. Dave did all the cutting and fitting of the piece
and I tacked it in. Good job Dave!
Frank
continued cleaning some bearings on the Control Column while Mike and Al pressed
the bearing cups into the tail wheel hubs.
The rest of the crew did some cleaning and sorting out of stuff in the hangar.
Thanks
to everyone who came out last night, in spite of the cold. I mean, winter can't last forever, can it?
1/25/17
Last
evening was another typical Sedan work session, solid activity for two hours. Youth
attending eager to pitch in were Dave Gramstrup. Samantha
and Brett LaGraves, John Thro and Dave Kostuch. Rounding out
the grown-up side of this were Tom Betts, Mike Gardonio,
Frank Kolo, Al White, Aaron Breitkrutz,
our friend from EAA Chapter 1221 John Welna, and me.
Dave
K. and Frank worked on the control column, cleaning and packing bearings and reassembling. The column was powder coated last week by our
friend Chris Penny at Precision Powder Coating, a local Superior, WI business. Thank you, Chris!
Samantha
and Tom put another coat of varnish on the rear window woodwork. Once finished with that, Sam moved over and helped
Aaron paint the display case. That display
case is really shaping up, casters and everything!
Brett
and Mike shifted to work on the tail wheel.
Al had earlier pressed our new king pin bushing into the housing that we
got from Jon Meserer last week. As it turns out, the tail
wheel arm king pin from Jon fits the bushing just fine, so our search for tail wheel
parts is over for now. Brett and Mike drilled and tapped a grease fitting hole in
the bushing and reassembled the tail wheel locking mechanism. More progress!
Dave
G. and I continued our work on the fuselage.
We cleaned up the cluster where our new longeron passes through and adjusted
the trial piece. We tack welded the bushing
that holds the left side of the tail wheel in place and then made a pattern from
our trial piece and transferred it to a new piece of material. Time ran out before we could cut the new piece
out, so we left it until next time.
Meanwhile,
Al floated around, giving advise where needed.
He even signed off some paperwork Mike submitted on the main wheel rebuild. Permanent records, I love it!
John Thro and John Welna
trial fit the cabin door to see how we might repair the lower hinge leaf. They also wanted to find out what sort of reinforcement
we could fit onto the door latch area to repair a little bitty crack in the area. There is room, and They made a pattern for a reinforcement. We'll concentrate on that area next time.
1/18/17
Boy!
I like this weather way better than below zero.
January thaws are my favorite!
Dave
Gramstrup, Tyler Breitkreutz,
Samantha and Brett LaGraves were here, eager to work.
Tom, Mike, Al, Bill I., Aaron and I provided guidance and direction.
Tyler
and Aaron were busy preparing the new "Spirit of Katrina" apparel display
case for paint, sanding and scraping away.
I wonder what color they will paint it?
My guess is whatever color we have the most of on hand. Anyone have a fabulous color paint lying around?
Samantha
and Tom put another coat of varnish on the rear window frames after checking, "which
edge is it now that gets glued?" They
are going to be beautiful!
Brett
and Mike and Al adjusted the air pressure in the main tires for storage and went
after the tail wheel. Last week we received
a used tail wheel assembly from Jon Messerer, of Jonathan
Aero. As it turns out, the arm on that one,
along with our new king pin bushing, will be just fine. Thanks Jon!
The outer bearing races will be pressed into the tail wheel next time and
then should be complete. Progress!!
Dave
and I continued our pursuit of an airworthy fuselage frame. We removed the last corroded longeron section
and stabilized the structure in preparation for fitting the new tubing. The work is coming along well and should progress
quickly once this piece is in place. Just
a few more cross and diagonal members to deal with; fabricating a revision, an additional
tail wheel assembly stop (this is to prevent the rudder hitting the ground in the
event of a bungee and restraining cable failure), a few miscellaneous repairs and
ta da!
Mark
Marino helped us out with some stenciling for the header on our "Spirit of
Katrina" youth participant board. This
is a place where we put the names of all the youth who have helped with the project. So far we have 22 names
on that board with plenty of room for more!
If you know of a eager young mind looking to develop
an interest in aviation, steer them over here and we'll show them a way!
Thanks
to everyone who came out last night, it feels so good to see the activity and progress
in our Chapter hangar. Build on!
1/11/17
Last
evening, we met again, for the first time this year. The air was chilly, and the roads were slick,
but Dave Gramstrup and John Thro came to work. There to assist were Al White, Tom Betts, Mike
Gardonio, Frank Kolo, Bill Berglund
and me.
Dave
and crew, Mike and Al, set to assembling the main gear with brakes and tubes and
tires. The project is complete except for
setting a storage tire air pressure next time.
John
and I continued work on the fuselage, fitting the truss removed from the left side
to the right side. With a little grinding
and checking, we got it close enough to weld in place. John discovered the welding observation hoods
wouldn't turn on, so while I welded the truss in place, he went to work with Frank
and Bill examining and cleaning the control column parts. When I was finished welding, John came back and we rotated the fuselage 180 degrees to set the stage
for replacement of the last of the corroded tubes. We discussed what we needed to do next, and measured the angle of the lifting handle to be 30 degrees
up from horizontal, as it too must be replaced.
I
regret to say that through the focused work and excitement, I failed to get any
pictures of the activity last evening. Sorry,
but you all know what we look like, and I'll get a picture of the beautiful mounted
tires next time!
12/28/16
Last night was still a little icy but a few
brave souls made it over to the work session anyway. Ready, willing and able were Dave Gramstrup, Samantha and Brett LaGraves
along with their grandparents, Dawn and Bob DeSoto, in from N Dakota. I was the only one representing our chapter, but
with Grandma and Grandpa on board it was full steam ahead.
After a short tour of the project for
Grandma and Grandpa, Samantha and Brett went right to work on the window frames
that they worked on with Sam taking the lead.
I was pleasantly surprised with her presence and knowledge from previous
work sessions. "Shouldn't we sand the
work from last time before we varnish?" she asked. Yes, we should, both the previous coat (we'll
be needing two) and the run over on the bare side. She and Brett got busy with sand paper with Grandpa
Bob pitching in too.
In the meantime, Dave and I got to work
on the fuselage. The first order of business
was to remove the truss we had welded onto the left side to hold the fuselage in
shape while we worked on the lower longeron on the right side. After a little coaching, Dave got busy with the
grinder and removed the truss, beautiful.
I looked in on the sanding job. Those
guys really know what they're doing! After
the work session, the Grandparents were taking Sam and Brett to their Great Grandma's
house several miles south of town, so they had to cut their evening with us short. The window pieces were left, all sanded, ready
for the next coat of varnish next time. Thanks
Dawn and Bob for the visit, I hope you can come back for another visit real soon.
Dave had removed the temporary tail wheel
frame assembly pivot bolt, cleaned it up and reversed it in the assembly. We then punched a pair of witness points and strung
a string to check alignment. So far, so good! With the work session coming
to a close, we began to fit the truss on the right side for operation on
the remaining corroded longeron.
Thanks to all for another successful work
session. I am always surprised how all thoughts
of the rest of the world step aside while in the work session, and how fast the
time goes. You know what they say about time
and fun!
Remember, for more information about our
project, go to sedanproject.com
for our web page.
12/21/16
The Sedan work party again went off very
well with a turn out and some projects to do. The adults on hand were; Aaron, Mike,
Frank, Bill Berglund, Al, and Tom. Jim was away for the holidays. The students were;
Brett LaGraves, Samantha LaGraves,
John Thro and Autumn Walter.
Tom, Autumn and Samantha worked rear window
frame parts, first removing them from the fuselage and setting them up for varnishing.
They learned that set-up and prep of the parts for varnishing is more involved than
the actual varnishing of the parts. Part way into the project Brett joined the varnishing
team and we made short work of it.
Mike, Brett and John greased the bearings
for the main wheel halves and temporarily assembled the halves. We need new nuts
and another type of felt seal for back halves.
Aaron and John cleaned up the display
cabinet and a real in the appearance.
Everyone wound
up the work at about 8:10, we cleaned up and headed home. It was fun and productive
evening for all.
11/30/16
The
turkey has settled and we were filled with energy, enough
to build an airplane. Well, at least enough
for a couple of hours work! Eager to get
to it were Dave Gramstrup, Brett LaGraves and his sister Samantha. Samantha is a 5th grader who "knows a little
bit about airplanes but hasn't built one yet", so we're going to try to fix
that last one. Welcome to the crew Samantha!
Big
kids present to guide their young minds were Tom, Mike, Al, Frank, Aaron, Bill Bergland, and me.
Brett
and Mike dove into their landing gear project with some new parts generously donated
by Aircraft Spruce and Specialty Co. Thank
you, Desiree, Chenelle and Janette! Wheel bearings on the main wheels were first on
their minds. Mike brought some dry ice to
freeze and shrink the outer races and placed the wheels in the kitchen oven to warm
up and expand. The races dropped in place
like magic, the temperatures equalized and the races are
there for keeps. Brett got a good lesson
in what happens to things with temperature, they move quite a bit, don't they? They next focused on the tail wheel kingpin bushing,
removing the worn out one to make ready for pressing in the new one.
Samantha
and her crew of Aaron, Frank, Al and Bill continued work on the door. Removal of the extra skin was first. The only thing holding it on after work from last
time was the door lock, which took some delicate fingers to remove, that Samantha
provided. With the lock removed, the spot
welds and a few remaining rivets holding the original door parts together were in
their sights. Rivets were drilled out and
spot weld removed with a carbide burr on a die grinder. The outer door skin must be replaced once the
rest of the door is repaired. We are still
on the fence about replacing the entire door if we can find one in serviceable condition
at the right price or repairing this one.
Anyone know of one available?
Dave
and I concentrated on the fuselage longeron that was fit and tacked into place last
time. I brought Dave up to date on the task
and explained why we were doing what we were doing. We checked that the fuselage was still straight
and true as we could with a string line and our witness marks. We welded, rolled the fuselage, welded, checked
alignment, welded, rolled the fuselage, welded and checked again. We did this pretty much all evening and went as
far as we could. Next is removing the truss
and the last section of longeron.
Thanks
again to all who participated last night, slow but steady, progress marches on.
11/16/16
Last
night was our last work session before Thanksgiving, and progress was made. Dave Gramstrup Brett
LaGraves, Autumn Wolter and John Thro came to make sure
of that! Here to assist were Tom Betts, Mike
Gardonio, Aaron Breitkreutz,
Al White and me. New to our group of mentors
last night was John Welna. John is an Aeronca flyer
and builder who hails from EAA Chapter 1221 that operates from KCOQ, Cloquet, MN. John came to see what we were up to and if he
could lend a hand. Thanks John!
Autumn
and Tom continued their work on the rear window frames, positioning the frames and
drilling mounting holes. The frames are about
ready for varnish and Lexan. Progress indeed.
Brett
and Mike continued cleaning wheels in preparation for new parts that are on their
way. When they took that task as far as they
could they moved to the tail wheel steering fork mount on the rudder. The steering fork was frozen into the rudder and
when removed and corrosion cleaned up, the rudder tube wall is too thin. We will replace the lower section of the ruder
where the steering fork mounts. Brett and
Mike began preparing a section of tubing by drilling the bolt holes that secure
the steering arm. Once they are satisfied
the bolt holes are correct we will cut the tube to length and replace the damaged
section with it.
Dave
Gramstrup was assisted by quite a crew as consensus was
achieved on the direction to go with the door.
As mention before, the door has a fair amount of damage so further disassembly
is in order. With the outside door skin riveted
in place, rivet removal was the task. After
the lower section of door skin was removed, it was discovered that at some point,
the door had been repaired with an additional sheet of aluminum on top of the original.
Hmmm! In the beginning, John Welna said that his Champ
door had been spot welded together where ours was riveted. Now we know why because beneath the riveted skin,
the original was still there, spot welded.
We will continue to disassemble the door, and at the same time search for
a replacement possibility. John thinks the
Champ door may be the same.
John
Thro and I continued with the fuselage repair.
The longeron section was prepared and trial fitted last time so we carried on.
First, alignment of the fuselage was checked with a string line down the
center, our witness punch marks were measured and the tail
wheel assembly fit verified. All seems good. The replacement tube fit was refined and tack welded into place. Next time we'll weld it in a little more before
moving to the other side.
11/09/16
With this unusually
warm weather, it's hard to believe it's November! At least it gets dark early
so we don't have to feel bad about working inside on the Sedan. That's exactly what we did last evening. Dave Kostuch, Dave Granstrup, Brett Lagraves and Autumn
Wolter pitched in along with Brett's Dad Chris.
Chapter members there to help shine the light were Tom Betts, Mike Gardonio, Bill Irving and me.
Autumn and
Tom got busy on the rear window frames, Tom showing a method for plugging holes
drilled in the wrong place, with a dowel epoxied into place, then fitting them into
the fuselage. Tabs on the fuselage will be
used to locate the new holes in the correct position.
Brett, and
his Dad, helped Mike examine the brake calipers and hydraulic lines that feed brake
fluid to the calipers. They were disappointed
to find massive corrosion on inside of the calipers. There is a good chance that they are damaged beyond
salvage but we'll look closer before we make that determination.
Dave G. and
Bill focused on the cabin door. There were
a couple of patches in the upper hinge area, pull riveted in place that covered
some damage. Rivets were drilled out and
patches removed. This did not reveal much. Further study is needed to make a proper repair. Their attention turned to the door latch. The handle is loose and the latch sticky. There is a plastic bushing for the door handle
all worn out that will have to be replaced.
They were able to remove the latch box, take it apart and found it full of
dirt and corrosion. They think it can be
cleaned up and put back into service. We'll
know more next time.
Dave K. and
I worked on producing a replacement tube section for the longeron removed earlier. Dave got a chance to read about accepted methods
of repair to steel tubing in aircraft in the FAA Circular "AC 41.13-1B, Acceptable
Methods, Techniques and Principles" This is the recognized authority that describes
all sorts of repair and construction procedures in all aircraft. We then made a paper pattern from our trial tube
and transferred it to a new piece of tubing, to cut, grind and fit it into place. Once that was done Dave cut another piece of tube
to act as an internal reinforcement for our scarf joint of the appropriate diameter
and length determined from what he learned from studying in the AC 41.13-1B. Next we will refine our
fit, check the fuselage for alignment and tack our new pieces in place.
10/26/16
On a dark and
gloomy Halloween like evening we were met by three eager fellows, Brett LaGraves, John Thro and Dave Granstrup. Present to assist were Mike G, Aaron B, Bill I,
Frank K, and me. We had them outnumbered!
First of all, Aaron and Bill went upstairs and found the left
side, pilot's window and the door. Dave worked
with them to inspect and assess their condition. The left side sliding panels simply need to be
replaced salvaging the steel frames. The rivets holding them on were drilled out
on the drill press and removed. The window
was then used as a pattern to trace out the shape on our new lexan sheet provided by Aircraft Spruce. The door will be more
of an issue as it was damaged around the upper hinge area, and the handle needs
to be re-bushed.
Brett and Mike
paid attention to the main wheel halves, removing the bearing outer races. The wheels were one at a time placed in the chapter's
kitchen oven at 215 degrees for 20 minutes, and the races were then tapped out using
a block of hard wood as a drift. Out they came, clean as a whistle! The wheels were then scuffed up for repainting.
John and I
continued our work on the fuselage, successfully removing the corroded longeron
section we have been working on and then fitting a pattern to make the replacement
tube. This section involves the boss for
the tail wheel pivot on one end and a splice joint on the other. Next time we'll prepare the new tube and splice,
hoping to have them tacked together.
All together
it was another successful session, even though the hangar was cold! Someone didn't turn up the heat, I think we were
thinking it's still summertime. With our
floor heat there is quite a lag in raising the temperature out there. Next time we'll try to be more on the ball, I
don't think it's going to be warmer out any time soon!
10/19/16
They came,
they worked, they learned, they grinned!
Dave Kostuch, John Thro, Autumn Wolter and Brett
LaGraves were at it again bringing the Spirit of Katrina
ever closer to her former glory. Present
to assist were Tom Betts, Mike Gardonio, Bill Irving,
Al White and me.
Autumn and
Dave teamed up with Tom to further the instillation of the right rear window. This task is proving itself way more challenging
than it appeared at first. However, steady
progress is being made. Next week they should be able to bolt it into place. The left one will be a piece of cake, with all
the questions and issues solved by the right one. Go Team!
Brett and Mike
got after cleaning and inspecting the wheels of the landing gear. The tail wheel needs some machine work as the
king pin on the arm is bent. The rims of the wheels need new bearings too, that's
next time.
John and I
focused on the fuselage. We extended the
truss we built earlier to the next cross member, much stronger, and placed a screw
jack under it to "add suspenders to the belt" to help keep everything
in place. Our string line shows we are on
the right track, as well as the two witness points we established before the surgery
began. John continued, removing the corroded
tubes in this section. Next week we'll remove
everything that isn't the lower longeron in this section and hopefully begin to
fit the new tube.
Al floated
around making suggestions and helped us make sure the work being done is in accordance
with approved practices.
10/12/16
Last evening's
work session was a bustle of activity. Eager
to help and learn were Dave Granstrup, Autumn Wolter,
John Thro and Dave Kosutch. Chapter members ready to lend a hand and show
the way were Tom, Mike G., Frank, Bill I., Al and Jim.
Work started
with arranging the furniture in the hangar, making room for some benches and a dandy
media blast cabinet donated to the Chapter by Gene Amorde. Thanks, Gene!
Next we divided to conquer, Autumn and Tom teamed
up to fit the right rear window to the fuselage with help from Frank and Bill and
Al. I think they got it figured out. Dave K. and Mike got together to disassemble the
tail wheel post assembly for inspection and evaluation, and Dave G. and John threw
in with Jim on the fuselage. We strung a
string line down the center of the fuselage to gauge symmetry, which showed the
fuselage pretty straight. We then made the bevel cut on the lower right
longeron in the third bay forward of the rudder post. This point is the end of corrosion damage needing
attention in the lower right longeron. We
noticed the truss we built was shorter than it should be as the fuselage sagged
a little once the tube was cut. No worries,
we put a jack post under the forward end of the truss to bring everything back into
alignment and started making parts to extend the truss to the next cross member.
Bill presented
the crew with a work sheet to help us be better organized in our documentation of
work accomplished. The two-sided form allows
room to specify the date, the task, people involved, steps taken, note conditions
and on the back, room to identify specific parts required to complete the task. Good job Bill. This form will become a permanent part of the
restoration record, stored in a dedicated binder.
These work
sessions are kind of exciting in that we don't know exactly who is going to show
up and thus what we are going to do for any given evening. However once the crew
is all together, we coalesce into a finely tuned machine dedicated to restoring
this classic aircraft. It is a joy to pause
and take it all in. You folks are amazing!
9/28/16
We had a good turnout last evening. Eager to work and learn were Autumn Wolter, John
Thro, Brett LaGraves and Tyler Breitkreutz. Rounding out the grown-up side of things were
Tom Betts, Bill Irving, Frank Kolo, Aaron Breitkreutz, Brett's Dad, and me.
Right off the bat, Bill had his C-172
on hand for a young eagle flight, a young fellow independent of our group. As soon as Bill got back, all the kids except
John disappeared. They were off flying with
Bill! I understand that Autumn executed an
excellent take-off and flew most of the flight, you go girl!!
John and I got back into building a truss
to hold the fuselage in place while we remove and replace a corroded section of
the lower right longeron. We have it nearly
finished, just a couple of small welds left to make, then the surgery begins. John is showing himself as a darn good metal man!
Autumn and Tom continued work on the rear
window arm rests and frames. Autumn showed
us her skill with wood work, doing a great job on her assignment.
Tyler and Brett followed Frank and Aaron
up into the upper parts storage and came down with the control column assembly to
inspect and disassemble. First apparent were
the dried and cracked u-joint boots. The
rest of the parts seem serviceable with only cleaning and repainting required. We'll know for sure when the inspection is complete.
Thanks to all who participated last evening. The time flies by, but we get work done. Fun!
9/24/16
I was a dark and stormy night, lightning
flashed, thunder boomed and the rain was pouring down (I
always wanted to open with a line like that!) but we had a great turnout just the
same. Young people ready to work were Dave Kostuch, Dave
Granstrup, John Thro, Brett LaGraves,
Tyler Breitkreutz, and our newest, Autumn Wolter, our
first young lady to grace our crew. We are
excited to have you on board Autumn, a fine addition to our crew! Present to guide and assist were Bill I, Mike
G., Tom B., Aaron B., Frank K., and myself.
Dave, Dave and Mike continued their disassembly
and inspection of the main wheels and found corroded bearings which will be replaced,
but the wheels were otherwise in good condition.
Tom took Brett and Autumn aside for shop
safety and hand tool instruction as is protocol for new participants. Brett missed
his opportunity last time, so he got his chance last evening.
Tyler and Aaron were busy inspecting and
assessing the condition of the seat frames and cushions. They found the rear seat in very good shape, nothing
wrong that a little cleaning won't fix, but the front ones are a little more worn
and will need repair. The front seat frames
appear to be serviceable but a little closer assessment
is in order.
John and I focused on the fuselage and
longeron repair. Earlier in the week I had
a conversation with a friend of the Chapter, Roger Sundin. Roger is very experienced in all kinds of aircraft
repair so I leaned on him for some advice before we moved
to the next phase of our repair. His suggestion
was to build a structure, more or less a fixture onto the
fuselage to hold it in shape while corroded members are removed and replaced. This makes total sense; I would have done the
very thing back in my welding shop on any other complex framework that needed surgery. Thanks Roger!
Well, John and I set out to do just that. I brought in some square tubing I had at home so we designed and began to build our truss. John was the man behind the saw guided by Bill,
and I assembled the pieces. Dave and Dave stopped over to help take critical measurements
of pieces to be removed, and to observe the process. We still have a little more fabricating to do
before we cut out the corroded section, but we're well on our way.
Thanks to all who came out in the foul
weather last evening. A very dedicated crew
I am proud to be associated with!
9/14/16
Hi Folks,
Last night was anything but normal for
our work session. First of all we were met by a photo journalist from KQDS FOX 21 TV News
to do a story on our little project! You
will find a link below to their piece, only about a minute long, that pretty well captures what were up to, including a link to our
Sedan web site at the end of the text. Check
it out!
Now, back to the work session. We had a full house last evening with Dave Granstrup, Jon Thro, Dave Kostuch,
Tyler Brietkreutz and a new fellow, Brett Lagraves, here to learn.
Chapter members were Mike, Bill I, Frank, Aaron and me. Tom was home sick
with pneumonia, get well fast Tom, we missed you!
First of all
it was my distinct pleasure to present to the crew our first shipment of parts donated
from Aircraft Spruce & Specialty Co.
We received main and tail wheel tires and tubes, shock rings for suspension
and enough acrylic sheets to make all the side windows. Thanks you so much Desiree
Czaplinski, Marketing Manager for ACS for such wonderful
support! You are an inspiration to us all!
After the bright lights of the media were
gone we settled down to work. Dave and Dave
along with Mike got into disassembling, cleaning and inspecting the tail and main
wheels. They discovered the bearings on the
tail wheel were rough, with the verdict still out on the main wheel bearings and
tail wheel arm oilite bushing and locking mechanism. Tyler, Brett and Frank continued work on the rear
window frame and arm rest. Jon and Bill brought down and started inspection of the
front seat frames, finding no glaring discrepancies. Further inspection will be required. Jon and I moved to the fuselage, preparing to
remove the next section of longeron from the tail wheel assembly pivot forward. This will be a rather complex procedure as there
are multiple clusters involved. No worries
though, it's all good!
It was great to be a part of all the activity
last evening. Thanks to all who participated.
If you haven't been to a work session, I encourage you come out and experience
for yourself what we have going on. It's
a lot of fun too!
8/31/16
There was a gathering at the hangar last evening. In attendance was our old friend Dave Granstrup. You remember Dave, he used our Sedan as his Senior
Project last winter. Dave graduated from
Superior Senior High last spring and is now attending Lake Superior College in their
Aircraft Maintenance course. He said that
his experience with us gives him a leg up with his studies at LSU. Way to go Dave! Also in attendance was
Jon Thro, and Brandon Cegelske's two sons, Owen and Mason.
Chapter members helping out to show these young fellows the way were Brandon, Tom B, Mike G, Frank K, Bill I, Al W, and me.
Dave
and Mike set out to press some new oilite bushings into
the tail wheel assembly. Jon helped out until my wife came by with some welding equipment
I forgot to bring with in the first place.
Thanks Cathy, you saved the day! As
soon as my equipment arrived, Jon and I resumed our job of welding the replacement
tubes in the fuselage. Dave also stopped
over to observe and pick up some pointers on TIG welding. Owen and Mason, with Tom and Brandon, started
to make a replacement arm rest for the right side rear window. It was in there someplace that Tom gave Mason,
a young fella just starting the 4th grade, a lesson in hand tool safety. Mason passed the quiz at the end with 100% correct. Congratulations Mason! When Dave and Mike finished with the tail wheel
assembly they gathered up the tail and main wheels and prepared for their disassembly
and inspection. Frank continued working on
name tags and Al, our A&P/IA floated around observing and telling us what we
were doing right, and wrong! For example,
I had asked Cragin Machine to make an axle for the tail
wheel assembly which required cutting threads on a grade 8 bolt. Turns out that this is not allowed in aircraft
construction. The threads must be rolled
to minimize stress risers and grade 8 is too brittle, AN bolts
(closer to a grade 5) must be used. Thanks
for your help anyway Bob. We'll be in touch
with any machine work we run across. So the search begins for an extra-long AN bolt. Stay tuned!
Thanks
to everyone who participated last night.
Progress, that's what they call it!
8/24/16
Yesterday turned out to be a very nice evening, a little breezy
but no rain! Two fellows eventually came
to join in the project, 13 year old Dave Kostuch, new to our group came with his Mom Krista. It was just the three of us for a while as all
other comers from Duluth were stuck in traffic. Road construction! We three started going over some basic tool orientation
when the crew started to arrive. Among them
was our old friend, Jon Thro and his Mom Catherine. We decided to move into the
hangar and get to work.
Present
to assist Dave and John were Tom, Aaron, Frank, Mike, Bill I., Al and me. Mike Busch, president of EAA 1128 stopped by to
be a familiar face for Dave and Krista. He
referred them to us after they visited him in Two Harbors a couple of weeks ago. John and I got back on the fuselage, fitting
the tube we removed last time while Al arranged a Young Eagle ride for Dave. After Al and Dave returned, with the usual Young
Eagle grin on his face. Dave set in to join
Frank and Tom cutting out name tag blanks from the old fabric. These name tags will have the names of all our
participants written and then posted on a cork board hung on the wall. That way we can see at a glance all the youth
we have introduced to our project!
The
evening came to a close way too quickly, and we all went
our separate ways. It was great to see a
new face at the hangar. Dave, we look forward
to seeing you again, thanks Krista for bringing him by, there is much more work
to be done!
Thanks
to all who participated, it's good to be back in the swing of things.
7/20/16
It
was cool in town last evening, the lake breeze felt good for a change. Jon Thro and Tyler Breitkrentz
came to work and Tom, Mike, Aaron, Bill Irving and I were there to assist.
Repairing
the fuselage was the task at hand. First of all, we fabricated a jack post, to be used along with
a bar clamp, to hold the structure in place while welding. Tyler and Aaron were busy cutting some 5/8 threaded
rod while Jon prepared the tubing. We put
the fixture in place before tack welding the tube we fit last time. Next we rolled the fuselage
over and removed the opposite tube. We were
all ready to cut and fit the new one when it was time to go. Time flies when you’re having fun! We're making progress, one tube at a time.
Meanwhile
Bill was flying a Young Eagle and her Mom, a gal that had contacted him thru our
Chapter web site. They all came back from
the flight with the usual ear to ear grin.
Tom was busy going thru his pre-flight inspection with Tyler and they too
went for a Young Eagle flight. Tyler came
back with the usual grin that lasted the rest of the evening. He showed me the selfie Tom took while he was
flying. There was one happy guy!
Thanks
to everyone who showed up to work, you make it all possible!
Due
to member participation at Airventure in Oshkosh next
week, there will be no work session on Wednesday the 27th. Then, with the Chapter meetings on August 3rd,
the next session will be on August 10th.
Wow, that seems like a long time from now, but enjoy the summer, August 10th
will be here before you know it!
7/13/16
Yesterday,
a day that earlier promised good flying weather did not deliver, so much. Even so, there was a window thru which Tom was
able to give a Young Eagle ride to Jon Thro and get back just in time for a downpour! Both were thrilled to get an up close and personal
look at local rain clouds and yet stay dry.
Good job Tom, Thanks!
Otherwise,
it was Jon, Andrew Wcklund and Owen Cegelske that came to build an airplane. Chapter members on board to help guide the boys
were Tom, Mike, Frank, Bill Irving and me.
The order for the day was to begin replacement of corroded tubing from the
aft end of the fuselage. Thanks to Mark Marino
we now have all the tubing we need to accomplish this task. Thank you Mark! I started with the aft most tube on the right
side. It was removed and then a new piece
of 5/8 dia. X .035 wall tube was cut and fit into place. Time ran out before it could be tacked in place,
but that will be first thing to do next time.
Meanwhile Mike and Tom helped Jon and Andrew glue the rear window frames
together getting them ready to fit into the fuselage.
Thanks
to everyone who came and helped out yesterday, it's a joy
to work with you all!
6/30/16
Last evening found us again at the chapter hangar with
four eager lads wanting to build an airplane.
Jon Thro, Owen Cegelski, Chris Young and and a new fellow, Hans and his dad. I am sorry, in the excitement of the session,
I forgot their last names. Hans, please come
next time and straighten me out! Chapter
members were Brandon Cegelski, Tom Betts, Mike Gardonio, Rob Cotter, Bill Bergland,
Bill Irving, Frank Kolo, Al White and me.
Order for the day was to continue work on the rear window
frames, headed up by Tom and Mike with help from Bill I., Chris and Hans. Mike brought his router table to cut the rabbit
for the rear window and to fit the vertical bar to complete the frame. The frames are shaping up nicely with more work
to be done such as fastening the fore mention pieces together and fitting the arm
rest. Next the frames can be fitted to the
fuselage and varnished like the rest of the wood work.
Meanwhile, Jon and Owen were busy itemizing the tubing
needing replacement in the tail wheel area with help from Rob and me. We now have a list of tubing sizes and lengths
required. I then demonstrated the process
of inspecting the interior of some of the tubes by cutting a hole with a burr on
a die grinder and looking inside the tubes.
To our surprise and delight, the interior of the tubes were very clean and free of corrosion. This means that there is likely no corrosion from
the inside out, only the outside in, which makes repair pretty
straight forward. Next thing, we studied
the drawing for installing a left side "Seaplane" door provided to us
by Mike Hoag, (thanks again Mike!) to figure out what materials we will need to
make that change.
Next session we will continue on
with the rear window frames and begin to replace tubing in the tail wheel area of
the fuselage.
In a quiet moment, Hans's Dad gave some basic flight
theory to Hans and Chris in the chapter meeting room.
The weather last night was so beautiful we found ourselves
asking, why aren't we flying these kids on a day like today? Well, the short answer is that we failed to provide
them with Young Eagle release forms to make it all legal and insured! This has since been corrected. From now on, and I admit to falling behind the
curve on this one, our intention is to have the crew flight ready in the event that weather permits for Young Eagle Flights. To that end, I would like to extent an open invitation
to any and all Pilots wishing to give Young Eagle rides
to show up on all but the first Wed. of the month around 6:30 pm to share the joy
of flight to these deserving youngsters.
Thanks to all who helped last night, your excitement
and contribution gives this project life!
6/15/16
On
a rainy Wednesday evening, varnishing was the name of the game. On board to work were Jon Thro, Andrew Wicklund, Chris Young and new to our group, Ryan Miller from
Superior Senior along with his mentor Linda Harper. Welcome Ryan and Linda! It's exciting to see new faces come to our project.
Chapter members were Tom, Mike G., Frank, Bill I, Al, and me.
First
order of business was to mix up some varnish and get previously varnished pieces
ready for the second coat and a place to work on the floor boards. While Jon and Chris and Andrew were scuffing previously
varnished bulkheads, Ryan helped set up an additional table for the floor boards. When all was said and done, we got a second coat
on one side of all the bulkheads and formers, and a coat on both sides of the floorboards. Man that bare wood soaks
up the varnish! Sometimes it's hard to see
where you've been it soaks it up so much.
Nothing was done to the fuselage last night, I was afraid of getting iron
and grinding dust in the wet varnish, we'll get to that next time.
In
the meantime, off site, Tom has been making ready pieces for the rear window frames
from Douglas fir donated by Ken Peters. Tom
has them beautifully milled and spent some time last night shaping the inside of
the frames. I suspect that we'll be gluing
them up soon and making ready to receive the Plexiglas.
Thanks
to all who threw in last night. It's amazing
what can be accomplished in just a couple of hours. Again, welcome Ryan and Linda, you are a great
addition to our crew!
6/8/16
Yesterday
started out with warm sunny skies so we opened the hangar door to let some fresh
air in. After a while it got a little chilly so we closed the door. Go figure, I love Superior! We were also greeted by Andrew Wicklund, accompanied by his Dad Joe, and a new fellow, Chris
Young. Chris is a 6th grader from Cooper
Elementary School and a hard worker. Our
mentors who came to help were Tom, Mike G, Frank, Rob, Al and me.
Our
task last night was varnishing the other side of the wooden bulkheads and formers. We scuffed up the varnish which found itself on
the back side from last time and proceeded to varnish. We covered all of the
pieces we did last time plus the forward most section of the floorboards. Meanwhile,
we organized the work space by putting away the old bulkheads and stringers to the
attic along with the new stringers awaiting their time to be installed. Once the way was cleared we turned the fuselage
over and began to inspect the corroded tubing for candidates for replacement. We found some obvious ones and some not so obvious
ones. A more detailed exam will have to be performed to determine the scope of the
task.
5/25/16
Last
evening was a rainy but productive round of work on the Sedan. We were greeted by our 'ol
buddies Jon Thro and Tyler Breitkruetz, and a new comer
Andrew Wicklund, an 8th grader from Superior Middle School. Andrew was accompanied by his Mom Jenna and his
Mentor, Jean Walsh. Jean and Andrew have
been together for 6 years thru Mentor Superior.
Welcome to the project! Our project
mentors included Aaron Breitkreutz, Frank Kolo, Bill Bergland, Mike Gardonio, Tom Betts and me.
The
order for the evening was to begin varnishing the woodwork. Several of the fuselage fairing bulkheads had
been removed for the gluing on of stiffener strips, so they were ready to go. The rest of them were removed from the fuselage
except for the upper fwd cabin bow which Tyler, Aaron
and Frank were still working on. The pieces
were laid out on a plastic sheet covered table and the varnish mixed. Jon and Mike discovered a missing access hole
in one of the bulkheads so they cut that prior to varnishing. With safety glasses and nitrile gloves on the
varnishing began. Jon and Andrew learned
how much the thinned varnish soaks into fresh clean wood and darkens it, showing
all the places we missed! We did one side
of the pieces, leaving the other side for next time when the first coat is dry. Meanwhile, Tyler was doing double duty helping
Tom shape the rear window frames.
More
varnishing is on tap for next time as we begin to shift gears to working on the
fuselage, replacing corroded tubing, fabricating a left side door and possibly a
separate door for the baggage compartment.
Thanks
to all who turned out on rainy evening, this project gets funner
every time!!
5/11/16
Jim
Nelson here, back on the job. I have found that the project has progressed quite
well in my absence. Reinforcements were added
to the wooden bulkheads, notches we're cut to receive the stringers, cabin formers
at the wing root were made and installed, and the forward floorboards had shims
glued on in the appropriate places. Tom and
Frank have been experimenting with steaming the stringers so that they would more
easily bend into shape. More experimenting
is on tap for that.
Last
night Jon Thro was on board to work. He was
joined by Mike Gardonio, Frank Kolo,
Al White, Tom Bets, Bill Irving and me. Needless
to say Jon had plenty of mentoring going on! First of all he tried
the front floor boards back in place for fit.
It was decided all's good. We then
checked the aft floorboards and found one place on each that could use a shim. Floorboards were marked
and shims glued into place. While the glue
was drying, it was noted that the forward most floorboard was missing so we proceeded
to produce it. A template was first made
from cardboard, and when that fit properly, Jon traced it onto a piece of 1/4"
plywood and cut it out with the band saw and jig saw. After a little minor adjustments,
the piece fits just fine.
We
had a little time left so we checked out the rear window frames and came up with
a couple of questions to answer before next time.
After
the work was done last night, Jon was awarded a hot off the press "Aeronca Sedan Project" tee shirt for his continuous dedication
and perseverance with our project. It will
look good on him!
3/23/2016
Last
night there was another in a long string of successful work sessions on the Sedan. Jon Thro and Tyler Breitkreutz
were on board with enthusiasm! There to lend a helping hand were Tom Betts, Mike
Gardonio, Frank Kolo, Bill Bergland, Al White, Aaron Breitkreutz
and me.
Our
task was to finish fitting the floor boards and sort out the remaining formers above
the cabin. We were able to get the floorboards
to fit real nice thanks to the skill demonstrated by Jon and Tyler. Thanks guys, you make this all possible!
I
invite you to come by the Chapter hangar anytime and check out our progress, this
bird is starting to take shape!
3/9/2016
Last
night we had yet another successful round of work on the Sedan. Despite the nasty March wintry mix, two experienced
and eager young fellows came back for more, Owen Cegelski
and John Thro. The crew of advisers was also
strong, with Tom Betts, Frank Kolo, Rob Cotter, Mike Gardonio, Al White, Brandon Cegelske,
Bill Irving and me.
Sawdust
flew again with the sawing and saanding of the remaining
wooden bulk heads and formers, and the rear window frames. Floorboards were further fitted and trimmed, with
installation considerations discussed. Communication
was strained at times over the noise of the belt sander, but fun, as that is the
sound of progress!
I
was able to present to the crew our latest acquisition, beautifully milled stringers
and former strips, generously produced and donated by Ken Peters. Ken is a new friend of the Sedan Project and mine,
he lives in Cloquet and makes his living working with wood and timber framing. Thank you so much Ken for your generosity and
interest in our project. Your efforts will
be put to good use! We inventoried and inspected
the wood, which we found beautiful and plentiful.
Another
contribution to the project was presented, a kit of Poly Fiber Epoxy Varnish from
our own Mark Marino, thanks Mark! The kit
is enough to varnish all the wood in the plane.
The Sedan is going to be so pretty it will almost be a shame to cover it
all with fabric!
2/24/2016
With our Sedan Project Leader, Father Jim Nelson out of town, I went
out to the join our crew of adults and students in our first effort at installing
our new wood formers. The formers and stringers to follow, will give the fabric
its shape. We also set the floor boards in place and confirmed that they will need
to be cut a little closer. I had purchased a box of quarter inch bolts and nuts
to temporarily attach the parts and test the fit as Jim had suggested. We still
have to fit the stringers and then remove all those wood
parts for varnishing. With the temporary fasteners, they’ll come off quickly.
The folks involved were; Dave Granstrup,
Josh Canfield, John Thro, Frank Kolo, Bill Bergland,
Mike Gardonio, Aaron Breitkreutz
and Tom Betts.
These two hour evenings seem to go by very
fast. It’s pretty light, we’re having fun with it!
2/17/2016
Last night at
the Chapter Hanger we had another round of working on the Sedan. We were graced with a couple of new faces, brothers
Ryan and Kyle Granquist of Northwestern Middle School. They rode with Brandon Cegelski
who also brought his son Owen. To round off
our crew, we had Tyler Breitkreutz and John Thro. Chapter members advising last night were Tom Betts,
Aaron Breitkruetz, Mike Gardonio
and Jim Nelson.
To
start off the evening the young men were given a brief tour of the project and then
Tom set up a little classroom instruction session to orient the lads in the safe
use of some hand tools from pliers and hammers and drills to wrenches and screw
drivers. The instruction ended with a quiz
in which everyone got a perfect score. Good
job boys, and Tom! The lesson materials were
provided to us by Bret Steffen from EAA Headquarters. Thanks Bret! We plan on expanding the lesson part of the Sedan
experience to include many more tools and Safe Practices for Shop Work.
The
evening continued with a demonstration conducted by Mike and Jim in the proper use
of epoxy resin as an adhesive. We set up
to join laminates of the rear window frames.
The parts cut were made from 1/4" plywood which
we had been using for all the bulkheads, the finished parts are 1/2" thick
so we just put two together for each of two windows, follow? As we worked we talked about various aspects of
working with epoxy resin, safety and properties, and some places where this material
is used and its role in aviation.
At
the end of the evening, we turned the fuselage right side up in anticipation of
our next session, where we will be fitting wooden bulkheads and floorboards.
Thanks
to everyone who attended, we look forward to the next session.
1/31/16
Some sawdust flew but mostly we were tracing
out the last of the patterns, floor boards today. Devon and Tyler dove in on transferring
the patterns and did a fine job. We were
able to nest the parts in the remaining plywood on hand, and then they were made
into smaller pieces, ready for the band saw.
Tyler had an opportunity to try his hand with a jigsaw for the first time,
separating the patterns from the sheet. He
did very well, listens to instructions, and seemed to thoroughly enjoy himself. We hope he comes back for more!
Meanwhile, Al and Austyn, assisted by
various members operated on the right side horizontal stabilizer which had a hangar
rash type dent in the forward tube (the one which holds the hinge bushings). The dent was about 6" from the outboard end
of the tube. Al had turned an 8" length
of steel to a diameter to just fit inside, to drive into the tube and force the
dent out from inside. Once the drift was
in place, a little coaxing with a hammer on the outside of the tube removed the
dent. There was a slight learning curve to
the process when it came to removing the drift, but Austyn
got a firsthand look at what "figuring it out as you go" in the arena
of aviation is like, a valuable lesson!
1/28/16
Last night we had another round of making
sawdust in the Chapter hangar, cutting out bulkheads and window frames for the Sedan.
Dave Gramstrup,
John Thro were busy, with a new fellow, 6th grader Owen Cegelske
along with his Dad, our own Brandon Cegelske, who came
to check us out and to help. Owen is an eager
worker and seemed to enjoy himself. We look
forward to the next time he joins us. Dave
and John dove right in, working practically unsupervised making great progress. Guiding the young minds were Tom, Frank, Al and
Jim
We are finished roughing out the bulkheads
and window frames so it won't be long and we'll be fitting
them to the fuselage. This is a fun part
where we see our work taking shape!
Yesterday we had another work session
at the Chapter hangar, with a couple of Boy Scouts from Troop 16 this time, brothers
Austyn and Devon Smelley, and Aaron Breitkreutz's son Tyler.
Members of our crew were Al White, Frank Kolo,
Mike Gardonio, Aaron Breitlreutz,
and Jim Nelson. Tom Betts was there, in and
out, flying a Young Eagle on a beautiful winter's day.
1/21/2016
Last night we had another productive work
session on the Sedan. John Thro was our
man, demonstrating his skill on the band saw, cutting out parts for the rear window
frames and the upper forward cabin bow.
His assistants were Frank Kolo, Aaron Breikreutz, Mike Gardonio, Robt Edelstein,
and Jim Nelson.
Our next scheduled session is next Wednesday
the 27th at 6:30, come if you can and join the fun. We will be cutting out the interior of the window
frames and gluing the 1/4" plywood together to make 1/2" thick frames. Depending on the crew, we'll continue producing
wooden parts from the tissue patterns.