Finally got the fuselage back into the shop. The first thing I did is fix a few mistakes. The U channel above the D window was attached to close toward the inside of fuselage. So I ground down the welds and moved it outward on both sides and welded it again. The issue was when I would put the D window and trim on I think it would have been interfering with the wing root fairings. The other thing was the U channel at the elevator attach was to close together at the tail post and was just touching the elevator tab at the top that connects to the spring on the cable. I ground out the welds and moved both of them outward about a 1/4 inch each and welded them again. Everything got epoxy primer after. I installed the last of the rivnuts on the U channel for the wing root fairings and attached all the tinnermans to the tabs for the interior panels.
Wagabond build
- Thread starter todd2391
- Start date
I riveted brake pads on the brake plates and new O-rings on the pistons. I drilled and mounted the brake backing plates to the gear legs on both sides, then made up the brake lines that sit inside the gear legs. Next I removed the gear and attached the fuselage to the rotisserie. I am starting to cover the gear legs, getting the back side fabric glued down and smoothed out. I am waiting on the fuselage fabric as the wrong fabric was shipped to me (light) instead of medium, should be here this coming week.
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They are pre made. The ones from the brake masters to the gear hard line are 18" with 90 degree ends and the ones from the gear hard line to the brake caliper are 6" ones. https://www.speedwaymotors.com/shop/speedway-motors-brake-lines~8207-10191-4295-3-476-30464 I got them here
I got the fabric I needed delivered earlier than expected. I glued the fabric to the outside of both gear legs and smoothed and cleaned up the glue seams, heat shrunk them both down to 350 degrees and brushed the first coat of poly brush down. On the fuselage I cut out fabric for the left and right sides, ironed the fold on the edge, pinned the left and right sides together and then sewed the center seam from the rear of the skylight to the top of the vertical fin. I glued the bottom fabric to the fuselage longerons, cleaned and smoothed out the glue seams. I put a small amount of glue on the top center stringer and clamped the sewn seam over it to keep it centered as I glued the left and right sides to the bottom longeron.
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I finished glueing the left and right side fabric to the lower longerons, cleaned up the glued areas and heat smoothed all the seams. On the gear I drew out the areas for the finishing tapes and applied poly brush, let it dry, and then applied the finishing tapes to both left and right gear legs. On the fuselage I glued the rest of the fabric around the doors, D windows, and the front areas by the boot cowl. I cleaned up these glued areas and then shrunk the fuselage fabric to 250, alternating from front to back, side to side, and bottom. Then I shrunk it down the same way to 350, cleaned all the fabric with MEK and then brushed on one coat of poly brush. Next I drew out all the finishing taped areas, inspection rings, and panels. I got the top of the vertical stab rib stitched and next I brushed a coat of poly brush on these areas and then started laying finishing tapes starting at the front bottom and working my way back. I made aluminum reinforcements to glue down for the inspection panels and also glued down the inspection rings on the bottom side before taping them over. Also its not very fun working with a hot iron in 90 degree temps.
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Thanks for the compliments. Yes you have to go under the bottom u-channel and over the top of the top u-channel to allow for screwing in of the wing root fairings. I did it by cutting the fabric on the side of the top u-channel and then going under the bottom u-channel. There is very little room for error here and you will have a decent size wrinkle at the very trailing edge. Then I glued the fabric under the bottom u-channel to the top longeron. That wrinkle will go away once you start gluing to the bottom longeron and pulling the fabric a little tighter in this area. I also seen people use 3 pieces of fabric here. Sides and top glues over the top longerons
I finished laying down the rest of the tapes and inspection panel reinforcements on the fuselage. I got the bigger wrinkles out of all the taped areas with the iron. Next I brushed on a coat of poly brush over all the taped areas on the fuselage and gear legs. Also I had a question, I am looking for a exhaust system for the build, O-235, anyone have leads on where to get exhaust and which type would be better the muffler in rear like colt 108, or under the front like cessna 152 with O-235, or location to buy a used exhaust. Any input would be greatly appreciated.
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Thanks, I did the sewn top instead of the 3 pieces method (2 sewn seems) because it was easier to sew one seam instead of two. I also did this with my other build, glue bottom on and then the two side pieces sewn together at top center and it worked out nice. Now I have to heat smooth all the tapes and then start spraying.
Graham, Texas, United States
I prefer the Sutton (Grumman style) exhaust. Less heat on the firewall and easier to work on the back of the engine.
We use the sewn center seam down the center stringer after covering the belly separate as well.
We use the sewn center seam down the center stringer after covering the belly separate as well.
Thanks for the info, the day I posted about the exhaust I actually came across a set of new straight pipes and got them at a decent price. I heat smoothed all the tapes and inspection panel gussets down, cleaned everything up and sprayed 2 coats of poly brush on the fuselage and gear legs. After letting this dry for a few days I sprayed one cross coat of poly spray silver on the fuselage and gear legs today.
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Got the 2nd cross coat of poly spray silver on the fuselage and gear legs. I let this dry for a few days and then wet sanded the fuselage and gear legs. I burned drain holes and holes for all the screws for inspection panels with a soldering iron and sprayed the final cross coat of poly spray silver. I let this sit for a couple of days and then sprayed 3 coats of poly tone Daytona white on the fuselage and gear legs. First was mist coat, 2nd was medium coat, and the final coat was a wet coat. All in all it looks pretty good. Stripe is next.
