Falconar F11A STAB

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May 2nd, 2006
5hrs - 42hrs total

The jig for the stab ribs is complete.  The wood was steamed and pre-bent into shape before being installed in the jig. Bending wood is scary before you try it but after the first piece is bent, you realize its easy.  Below is my high tech set-up.  

Yup, a simple electric kettle and a 2 inch ABS pipe.  The wood cap strips are placed in the ABS pipe and 15-30 minutes later, the wood is very pliable. The wood is clamped in a second jig that is bent about 15%-30%  more than required.  This accounts for the springback once the clamps are released

May 6th, 2006
5hrs - 47hrs total

Good progress on the stab ribs.  8 done, 2 to go.

May 7th, 2006
2hrs - 49hrs total

The last two stab ribs are glued and drying.  As can be seen at the top of the picture, the first two elevator ribs are also drying.  The tools seen at the bottom are the typical tools used.  The small key chain laser light is useful to check alignment.

June 19th, 2006
2hrs - 63hrs total

The aft Horizontal Stab Spar is started.  I was able to rip down a piece of spruce to the right size to replace a part I had previously forgot to order.  Once trimmed to size, the spar will be covered with 1.5mm plywood and 2mm gussets.  As can be seen above, my table has angle-irons attached to the sides.  I use these as built-in straight edges to ensure the parts are straight and level.  You may also notice pencil marks on the white table top in some pictures, for long pieces, I draw the shape on workbench.  I use the same technique as previously describes for the jigs.  A pattern to be built is drawn (in this case on the workbench surface) and small nails are nailed into the perimeter of the drawing.  The nail heads are cut off and the wood is placed in the "Jig".  This technique ensures accurate, and consistent parts.

July 5th, 2006
3hrs - 72hrs total

The fwd main Stab spar is done.

July 19, 2006

4hrs - 83hrs total.

The Falconar F11A Aft Stab spar is done and the assembly of the stab is started.  It is a little tricky as the individual ribs have some minor variations.  These variations are removed by fitting everything together temporarily with tape (scotch tape as can be seen in the picture), shooting a laser line (laser and tripod can be seen at the far right of the picture), marking some trim lines and disassembling for rework.  Repeat this half a dozen times - inserting a cursing pause between each cycle and your half done!  All that is left to do to add epoxy.  As can be seen at the bottom right of the image, the leading edge has been scarfed and will be glued at the same time.  The laser is a bit of a PITA (pain in the arse).  Before having the laser, I could not tell if an item was 1 or 2mm out of alignment, over a length of 8 ft so it was not an issue.  Now 0.5 mm has me debating if I should rework the item.  PITA but the results are great!  The feed-through's in the stab ribs were made with a dremel saw.  The plans call for two pieces of plywood to cover the ribs with a gap to allow the fwd spar but with an accurate cut-out, the fit is tighter and stronger, INHO.

July 28, 2006

9hrs - 92hrs total.

The Horizontal Stab is glued!  I decided to include myself in this picture to provide a size perspective.  In the background, the rudder can be seen.  Remaining to do:

- Fuselage Attachment blocks (after the fuse is completed)
- hinge assemblies (after the elevator is completed)
- corner reinforcements
- plywood skins (one side at a later date, the other side after the Transport Canada inspection)