Metal Fittings

I spent a lot of down time thinking how I would produce the metal fittings. Sheets of 4130AQ are very costly and you generally need to buy a minimum quantity. I thought of using a sabre saw or a metal table saw but the finish using these tools would not be optimum. I met George Abernathy from Canberra here in Australia who is very handy with CAD and is working on drawing all the metal fittings and having them laser cut. George can cut many sets out of a sheet of 4130 and has these available to purchase.

George has posted some very good videos of dealing with some of the metal work.

Forming Pietenpol elevator horn part 1...

Forming Pietenpol elevator horn part 2...

0.32" fittings

 

Metal work is something I enjoy but unless you have the right tools, it can be a nightmare and dam dangerous as well! I was going to buy the metal parts ready made but with the cost of freight from the USA, I decided to have a go myself! Glad I did as it didnt take long and it felt good too! I was wondering how the best way to cut the 4130 tube would be. Then the penny dropped! Some time ago I picked up an older style Makita drop saw. It is all metal and weighs a ton! They dont build tools like that anymore! I took the wood cutting blade off and a trip to the local hardware store revealed a metal cut off wheel that bolted straight on. Worked an absolute treat!

 

I made the front rudder pedals...

 

...and the control system.

 

I was dreading having to cut all the sheet metal and was looking at buying the parts pre-made. I took the time to research how to use a hacksaw correctly and what blades for each metal and thickness of metal and surprise surprise, with a little cutting oil, it is not as hard as I thought! I made both sets of control stick hinge plates in about 30mins...

Learning to TIG weld is the next project!

 

Turnbuckles for rigging.

 

November 2013 I organised a TIG welding course in Canberra. We had 12 guys attend and at the end of two days we had a very good grasp of the process and the guys were producing some nice welds. Here are a couple of my practice pieces...

 

Made a jig as outlined in an article in the BPA newsletter from Chris I believe of WestCoastPiet fame to crush the ends of the 4130 tube as required in various metal parts...

 

TIG welding the front rudder pedals. Im not happy with the result so will remake them. Although it would probably hold, it looks like a dogs breakfast!...

 

After numerous attempts at these front rudder pedals I finally sorted what I was doing wrong and have them done and welded the stramlined section of the control crank to the tube!

 

Lower cabane fittings bolted to fuselage and bolt bearing TIG welded to cabane strut...

 

Lower control stick fittings TIG welded and holes drilled for mounting bolts...

 

Front rudder pedal mounting brackets fabricated and fitted...

 

Horizontal stabiliser wire brace fittings...

 

Rudder horn bent and Tig welded...

 

Elevator bell crank painted and fitted...

 

Elevator horns bent and TIG welded. Fitted to elevators and rope connected to check eventual control cable runs...

 

Aileron horn bent and TIG welded...

 

Elevator control cable support pulleys and brackets...

 

Rudder bar and post fabrication...

 

Crimping and folding the top section of the firewall with Fluting pliers...

 

Stainless fire wall secured to ply backing...

 

Connecting rods between rudder bar and front rudder pedals fabricated and fitted...