Shop Activity, Jan. '10

Making the Wing Bows

Posted Feb. ’11

A stew pot, an angelfood cake pan (my wife is still wondering where it went) and some 2″ PVC and you have a nice little steamer for small stock. We steamed one end of the bow at a time, and put it in the form overnight. We started with some ash that didn’t work out so well as you can see in the third photo.
            
Well if at first you don’t succeed, ……… start over with some better air dried ash. A friend cut this lumber out of a tree he had taken down a couple of years ago.
            
A few passes through the 40″ band saw, the joiner and planer and we had the stock we needed.
            
This time we chose to do the shaping after we kurf sawed the ends to be bent and then steam bent them with the inter-leaf strips in place. After forming and attaching a backing board to the already formed and glued bow, we were ready to shape it on the router with the tool shown.
            
Fitting the finished product to the lower wing. We are quite proud of the way it came out. Nice work Roger!
            

Leading Edge Fitted

November 2009

More Leading Edge Work

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Cutting the inside of the leading edge.












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After final cut.
















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Cutting the relief for the 1/16th in. plywood over-
lap.











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Leading edge in place.
















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Leading Edge takes shape

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Setup on the Bridgeport.  You will notice there are two pieces of stock glued to a set of sacrificial blocks in the center. The purpose of this was to conserve on the Sitka Spruce and to get the proper orientation of the grain.  You will also notice the leading edge stock is rough cut to limit the amount of material the cutter will have to remove.

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Don hand feeds the stock.















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The tool














The Lead Man (Jud) rips off the sacrificial blocks to leave the two pieces ready to be routed inside.

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Dry Fitting

P1030633_edited-1Buckey Dew is dry fitting ribs and cap strips.   We are just about ready to open the glue pot.
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First parts are glued into place. P1030685_edited-1
Roger Pellerin sets rib caps into bending jig after steaming.
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‘Leading edge is next.’ says Roger.
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Don readies the stock for the leading edge cap for the next operation which is the milling machine. If you look real close you can see we separated the two pieces of Sitka spruce stock with sacrificial blocks of scrap wood to save the good stuff. We are nearing the end of our stock pile so conserving is important.

Close Relatives: Curtiss ‘America’ and Thomas-Morse S4-C Scout

How are they related?  It just so happens that the 1914 Curtiss ‘America’ and the 1917 Thomas-Morse Scout had the same Chief Designer; B. Douglas Thomas.  Mr Thomas came to Ithaca after designing the America to work for the Thomas Brothers (no relation) and subsequently the Thomas-Morse Airplane Co.  There he was assigned the task of designing the Thomas-Morse S4-C Scout, a pursuit trainer for the US Army.

The videos that follow were taken Saturday, Sept. 19, 2009.  The flight of the ‘America’ was part of the Seaplane Homecoming at Hammondsport, sponsored by the Glenn H. Curtiss Museum on this weekend every year.

The following videos were taken in the sequence shown.

Engine starts and taxi

Lift off

Fly-by (sparkling propellers)

Another pass

Smooooooth landing

A fire hose welcome……

Mission accomplished!

If you haven’t visited the Glenn H. Curtiss Museum lately, do it soon.  You will be amazed.

Shop activity August 7, 2009

Volunteer Buckey Dew puts finishing touches on ribs

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Wing is taking shape.  Note the vintage clamp being used.  We believe these clamps found in the shop date back to the “Tommy’ era.

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Shop activity July 22, 2009

Volunteer Bob Gosse routing wing rib (trailing edge)

Volunteer Buckey Dew rough cuts wing rib, ready for routing

Shop Activity (June 10, 2009)

Roger Pellerin routs the rounded edges of cap strips

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Don Funke marks up material for roughing out a rib

Bucky Dew roughs out a rib, readying it for routing.


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Roger and Bucky can’t wait for things to take shape

Routing the Spars

Jud, milling out a spar

Jud,with his magic touch

The finished product

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