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Making custom CroMoly wintips & light holders for a Fleet 80 Canuck.

submitted by Rotteuxx to Welding 2.7 yearsAug 16, 2021 20:44:04 ago (+24/-0)     (files.catbox.moe)

https://files.catbox.moe/78it7k.jpg

This is an ongoing project I've been working on since October 2019, things got slowed down by the jewdemic, the owner & his engineer living in 2 different provinces 40 mins away from eachother was a nightmare for a while.

I had to make new teardrop wingtips out of 3/4" o.d. cromoly tube, going from 3/4" thick to 1/4" towards the back of the wing. Here's one of the fusted out originals (Not my messy workshop!).

https://files.catbox.moe/c5ogci.jpg

Made a pattern to follow

https://files.catbox.moe/w07222.jpg

Then I shaped the teardrop using a pipe bender die welded onto a worktable, didn't take many pics of that because I had reverse nigger hands. This is what the taper looked like once pressed.

https://files.catbox.moe/j13q8x.jpg

Matched up on the pattern it looked decent.

https://files.catbox.moe/ls7loa.jpg

Successful fitting (Yes, there is a shameful bump, shhhh).

https://files.catbox.moe/gbhyip.jpg

https://files.catbox.moe/h6o0bf.jpg

Then came the light holders for these 500$ LEDs.

https://files.catbox.moe/7te62n.jpg

I started out with .050" chromoly sheet metal.

https://files.catbox.moe/rn3pv2.jpg

Roughly shaped the teardrop form & hammered the edge round.

https://files.catbox.moe/od3bwy.jpg

Then I started tacking on the top plate.

https://files.catbox.moe/756ifs.jpg

https://files.catbox.moe/fgszqv.jpg

Quickly welded before a rough finish.

https://files.catbox.moe/v10tx6.jpg

https://files.catbox.moe/80ht7r.jpg

After that I had to fit those onto the wingtips.

https://files.catbox.moe/5l0ohi.jpg

https://files.catbox.moe/t9qso5.jpg

Then I installed riveted threaded thingies & prepped it for welding.

https://files.catbox.moe/ijqpng.jpg

Freshly welded on

https://files.catbox.moe/1tgs3n.jpg

https://files.catbox.moe/tgib1y.jpg

https://files.catbox.moe/e71pi2.jpg

Top view

https://files.catbox.moe/x5qfjo.jpg

Side view

https://files.catbox.moe/78it7k.jpg


8 comments block

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[ - ] Jiggggg 1 point 2.7 yearsAug 17, 2021 06:06:15 ago (+1/-0)

Beautiful work

[ - ] 061916 1 point 2.7 yearsAug 17, 2021 04:06:04 ago (+1/-0)

Awesome work, I have always wanted to build my own airplane. I have drooled over a kitfox with radial engine and floats for years. It's amazing to see people who build everything from scratch though and not just a kit. Can't imagine the hours that go into it. I've got a classic car restoration going that I've been neglecting because I'm not sure if throwing money at it in this time is wise but I sure feel great when I'm working on it.

[ - ] Rotteuxx [op] 0 points 2.7 yearsAug 17, 2021 09:28:32 ago (+0/-0)

Restauration is a work of passion, it can rarely be profitable. Just for my part on this project, we're close to 10k$ and that was just restoring the airframe, wings, rudders & elevators. New doors, engine cowlings & cabin roof are still on the to-do list. Getting a port & polish + tuneup on that engine is another 12k$, fabric and paint were upwards of 25k$ (AAA job though).

The thing is, it's a piece of aviation history that'll be restored in better conditions than comparable airplanes at the Ottawa aviation museum (those look nice, don't poke around though) & will be fully certified.

So yeah, passion passion passion.

[ - ] SaneGoatiSwear 1 point 2.7 yearsAug 17, 2021 03:48:42 ago (+1/-0)

Excellent post fren. It’s great to have good original content on Voat. Keep up the good work!

[ - ] aleleopathic 1 point 2.7 yearsAug 17, 2021 03:29:26 ago (+1/-0)

Gorgeous work.

Roughly shaped the teardrop form & hammered the edge round.
Question - how did you hammer a rounded edge into the sheet metal? Do you need a divoted anvil or something?

And how many hours does it take to do a fab job like this?

[ - ] Rotteuxx [op] 1 point 2.7 yearsAug 17, 2021 09:34:28 ago (+1/-0)

I just stuck a piece of round stock bar in the vise, extended the sheet metal over the edge about 1/16th & hammered it, 3 or 4 passes extending it a bit more every time. Cromoly is extremely hard, it's not like hammering soft steel...

Including jig fabrication, about 15 hours for the wingtips, another 11 or 12 for the light holders to be made & fitted on. It took as long to fabricate the pressing jig than it did to shape & press the tips into the tapered form.

[ - ] inaminit 1 point 2.7 yearsAug 16, 2021 22:12:10 ago (+1/-0)

Looking good Rotty...

[ - ] Rotteuxx [op] 1 point 2.7 yearsAug 16, 2021 23:36:37 ago (+1/-0)

Thx fren!