Well, after monkeying around for quite some time we finally resolved some issues we were having with plotting the vertical skin out on paper (1:1 scale) and actually glued it (with 3M 77 spray adhesive) to a piece of 0.025 aluminum, cut, filed and drilled it. We used a 1″step drill bitto create the inside corners and tin snips to cut the sheet out. Leaving a bit of material to be filed down to the line with a vixen file on the generally straight edges and a half moon round file on the inside corners was the way to go and made it easy to get right up to the edge of the lines the paer layout provided.
Of course the main advantage in plotting the skin out in paper first is to more easliy mark the numerous drill holes and then (as we had done in the fall) wrap the paper around the frame to verify the pilot holes were something close to the center of the ribs. This along with obtaining a very good layout of the many irregular dimensions as well as getting the layout somewhat symetrical.
The original sheet we plotted and wrapped around the frame was a bit smaller than the design dimensions and so we went through numerous attempts to generate an accurate 1:1 scale plot. As it turns out, the problem we were having was partly due to the inaccuracy of the plotter but there was a much larger issue to deal with. Hygroscopic expansion (and contraction) of the paper.
Hygro-what you say? A large sheet of paper will change by a significant amount in it’s dimensions when moved from high to low humidity environments. What’s more, it will change with a very short time constant. Short as in minutes, not hours or days. We found this by measuring a plot that appeared to be nearly perfect when first generated in an office environment and then after sitting it in a cool garage in a Minnesota winter over night, found that it had shrunk by 3/16″ over a 36″ length. We then moved the sheet back to the warm and relatively humid office environment and watched it regain nearly all of it’s lost dimension over a 20 minute period.
We verified this dimensional change with one of the guys in our research lab that happened to have ran an experiment over the last few years to identify this precise phenomenon. What we were observing agreed very closely with the experimental information that was previously done.
So, we dug out one of the original plots that was pretty close to the correct dimensions when left in the garage overnight and just glued it to the aluminum skin. Once glued to the aluminim the paper was constrained to the dimension of the aluminum.
Before gluing the paper to the skin, we checked the alignment of the rib frame with the paper and found it to be close in overall dimensions but some of the ribs were slightly off from their design locations. We marked which side of the line to drill the pilot holes to accommodate the slight misalignment and then verified these adjustments before drilling the skin.
We had previously drilled out an aluminum ruler to be used for drilling hinges and used this as a guide for edge drilling the trailing edge of the skin first. We verified the location of the holes for the hinge and used the ruler to drill out the trailing edge that would have the hinge attached. We then match drilled the other trailing edge of the skin with the first trailing edge as a pattern.
The gluing of the paper to the aluminum and adjustment of the holes were done on February 7th, 2011 with Tim and I. It was Superbowel Sunday and we both had places to be so we had to stop work. I (Dan) did the remainder of the drilling and skin forming shown below the following night…..
At this point the two trailing edges are clecoed together and the skin can be carefully pressed down on the table with a 2×4 (I used a 1×6 instead) to form the leading edge. With the trailing edges clecoed together it insures that the leading edge is formed in the center of the sheet.
I clamped the sheet to each side and used a sharpie to marke through the skin to the ribs to see how well the holes lined up with the rib centers.
I examined all the ribs and found that the match drill alignment was as good as I could have hoped on all ribs and on both sides.
There still is some work to do; Clamp and match drill the ribs, dimple the skin and ribs for flush rivets, prime and assemble the frame, rivet the skin to the frame. But to a large degree these steps are “busy work” and don’t carry the concern we had prior to bending the skin.
Even though we have the horizontal stabilizer almost to the same point as well as the rudder and elevator almost ready to rivet together, this will be the first completed frame and skin assembly and it is kind of a mile stone from the fact that it represents (when assembled with the rudder) the completion of many of the procedures for scratch building. There are still many things to do for the first time but having completed this portion is a confidence builder.