2/19/2007
Tonight was the beginning of longeron fun! Well, it was sorta fun. The instructions say that this part takes an artist touch, and a bit of finesse. I think it's just the opposite in taking a dead blow hammer, and whacking the crap out of some angle to get it to move. Maybe it's just me...both longerons turned out just fine. There will be some tweaking to do once the other bends are made, and there is some twist yet to put in.
I started with the 15' 3" piece of angle that was sent way back in the wing kit. These have been stored up near the ceiling of the garage for a year, and had plenty of dust on them.
First I marked the length to be cut. 173 7/16" to be exact. The only way to measure this is with a tape measure. I HATE tape measures because the little metal tab on the end is always loose, as it's supposed to be. In order to get an accurate measurement, I taped the tape at one end starting at 1".
This, of course, must be compensated for on the other end, so I adjusted the cut mark to 174 7/16".
I checked it three times, and went for it.
After that was done, I marked the aft ends of these to be trimmed, and trimmed them per instructions.
Next I needed to lay out the template that I had cut from drawing 17 that depicts the curve of the shallow bend. The only thing I had on hand long enough was some polystyrene left over from the wingtip ribs. Whatever works...
The time has come. I wasn't dreading this at all for two reasons. One, it's metal, and it bends. If it's off a little, just bend it back. Of course, you can't do this too many times, or the metal will start to work harden. And two, I checked with one of the metal shops here in town, and this angle can be purchased locally in the exact same quality and temper as Van's sells. So, if I boogered it up too badly, I'd just head there and get some.
In to the vise it went, and I started hammering away! (That Tool Shop clamp was just there to fit. I used a big C clamp to hold it vertically in the vise while I hammered.)
My method was per plans. I was going to use an alternative method, but decided against it at the last moment. The location of my vise and other tables contributed to me choosing the plans way. It worked out great (Why wouldn't it? They ARE plans!). The first one (right) is well within 1/16" all the way around. I used the C-frame to hold the end down because I didn't have anything supporting the end off the table.
Fours hours, and I have two longerons with shallow bends complete!
This really is not bad AT ALL. Patience is the word of the day when doing this.
4.0 hours