Progress Update

A forum about all aspects of the construction and maintenance of the Billy Dawson inspired modified Hatz Classic biplane. Here is the place to ask your questions and get the answers from the real experts.

Re: Progress Update

Postby orchardair » Wed May 10, 2017 2:26 pm

Just to show that I am not 100% lazy or anything, here is the next step - welded (although not very pretty):
1494379763623 (1).jpg
welded the tubes
1494379763623 (1).jpg (19.36 KiB) Viewed 369 times

Next will be cutting the excess metal, and shortening the tubes to required length.
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Re: Progress Update

Postby orchardair » Thu May 11, 2017 11:51 am

Much lighter now...
metal removed.jpg
Still needs tubes trimmed to final length
metal removed.jpg (37.94 KiB) Viewed 362 times

The one edge of the (rectangular tube) pieces which is laying on the bench is sometimes shown as being metal. In my case it is air. I did not weld anything on that edge - just removed a bunch of metal.
Since the longer of the two 3/8" tubes goes all the way through the rectangular tube, I figured it is sturdy enough for this non-structural part.
In other words - I added lightness.
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Re: Progress Update

Postby Bitshifter » Tue May 23, 2017 3:32 pm

20170520_165508.jpg
20170520_165508.jpg (123.11 KiB) Viewed 347 times
I needed to throw in a progress update since I finally got it pushed out of the garage.
Ed White
HC 154

"In life 10% wrong is failure, in school it's an A"
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Re: Progress Update

Postby 1964m20e » Tue May 23, 2017 8:41 pm

looking good
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Re: Progress Update

Postby HC85 » Thu May 25, 2017 10:44 am

NICE!!!

I love it!

Looking forward to the day when my ship is at that level of completion!
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Re: Progress Update

Postby orchardair » Wed Jul 12, 2017 5:29 pm

What a beauty!
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Re: Progress Update

Postby orchardair » Tue Jul 18, 2017 1:01 pm

One of my "How did you ..." pictorial essays.
This time, perpendicular tube-in tube with doublers. This is used several times in the Hatz Classic. Specifically in this case I am working on the landing gear parts.

Step 1:
I drill the hole for the bushing tube before I cut the long tube to length. This gives me freedom to drill wherever the drill bit hits the tube. Also leave enough length (1/2" ?) at the short side of the tube beyond the hole, to make things easier.
Drill pre-cut.jpg
Drill pre-cut.jpg (76.88 KiB) Viewed 237 times


Step 2:
Cut the bushing tubes over-sized, ream the hole, cut the long tube to size (measure twice!).
Cut to length.jpg
Cut to length.jpg (70.55 KiB) Viewed 237 times


Step 3:
Tack-weld the bushing, but only on the part that won't be cut off (see later).
Tack weld.jpg
Tack weld.jpg (86.17 KiB) Viewed 237 times


Step 4:
Using a combination of angle-grinder, bench grinder, jedi-force and any other trick you have, cut the long tube to shape.
Shape.jpg
Shape.jpg (56.23 KiB) Viewed 237 times


Step 5:
Prepare the doublers. In this case I don't think these are on the files you can download for your waterjet cutter. I just used my angle grinder to cut them from 0.050 sheet, finished on the sander.
Doublers.jpg
Doublers.jpg (80.55 KiB) Viewed 237 times


The next few steps will be in a separate post. I guess there's a limit to how many pictures or size a single post can have.
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Re: Progress Update

Postby orchardair » Tue Jul 18, 2017 1:03 pm

...(continued)

Step 6:
Position and tack-weld the doublers.
Tack Doubler.jpg
Tack Doubler.jpg (58.16 KiB) Viewed 237 times


Step 7:
Heat and bend the doublers.
Heat bend.jpg
Heat bend.jpg (84.8 KiB) Viewed 237 times


Step 8:
Ready to weld around the doubler.
Ready to weld.jpg
Ready to weld.jpg (74.57 KiB) Viewed 237 times
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Re: Progress Update

Postby mmarien » Tue Jul 18, 2017 9:03 pm

Nice. I haven't started on the metal other than the compression tubes but there is nothing better for building confidence than someone else making it look easy.
Murray Marien - HC 0180
Saskatoon Canada
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Re: Progress Update

Postby orchardair » Wed Jul 19, 2017 10:22 pm

Here ya go, welded all around:

DSC_1868.jpg
DSC_1868.jpg (90.56 KiB) Viewed 226 times


Need to ream the small tubes to 5/16", shorten them to the correct length and drill the holes in the longer tubes.
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