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Head in the clouds

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Head in the clouds last won the day on August 23

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About Head in the clouds

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  • Birthday 10/09/1957

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    Gold Coast, Qld
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    Australia

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  1. Head in the clouds

    Marty d's CH-701 build log

    IBob - in thin sheet metal you don't cut the countersink, you use a dimpling tool to form dimple recesses in both (or all) sheets. If you cut the countersink or oversize the holes you will massively weaken the joint. When you press dimples into the sheet metal you need to start with undersize holes so that when the metal stretches to form the dimple, the holes end up the right size (start with about 2.8-3mm for 1/8 rivets). If you only have a few holes to do you can make a dimpling tool using a pair of dies (male and female) turned up in a lathe and drawn together with a 2.5mm SHCS and nut. If you have a lot of them to do then you make a similar pair of dies and draw them together with a hardened and headed mandrel in a standard riveter - naturally you don't break the mandrel each time, so that you can use it time and again, and it's hardened so that it doesn't get chewed up by the jaws of your riveter and so that it then releases easily when you take the pressure off the riveter handles. Note - don't pull the mandrel any harder than needed to form the dimple (which isn't very hard at all) with the riveter or, if the mandrel is properly hard, you will flatten the teeth of your riveter's jaws. Alternatively, and perhaps more easily for most folks, you can use a rivnut tool and screw the mandrel into a nut (instead of a rivnut) on the other side of the dies for each hole you want to dimple, takes a few seconds longer per hole but it's no big deal in the scheme of things.
  2. Head in the clouds

    Guess This Aircraft ?

    J3 Pup ...? I'm getting older mate. My memory is fine, it's just all the other baskets around me can't remember a thing ... or hear anything ... what? I heard that ... 😂
  3. Head in the clouds

    Guess This Aircraft ?

    Just to show there are plenty of others of us following ... but T88 is just too good for words! Is it a Karaone? Or maybe ... I think they were called N3 Pup? Nice looking little plane, whatever it is, well done for finding all these red750, you're a champion!
  4. Head in the clouds

    DooMaw - building a STOL

    Many thanks apm and rgmwa! I'd seen Oleg's thing before and completely forgotten about it, and QwikEFIS is new to me, so I'll have a good look at both and see where we go from there. Are there any more like this out there that I should be considering?
  5. Head in the clouds

    DooMaw - building a STOL

    Another crappy weather day, 7am and gusting 20kts already, so regardless that it's Saturday and the club Christmas BBQ is at lunchtime, the Kestrel will be staying in its trailer yet again. It does handle the strong winds quite well, my flight before last was in 25kts, gusting 35kts and it was all quite controllable, which is pretty good for a 150kg ultralight, but at 55kts cruise it's a long time getting anywhere, or back, depending whether 'anywhere' is into wind or downwind ... It's not even that, so much, but with the light wing-loading it can be quite a rough ride and that takes a lot of the fun out of it. Anyway, it's probably a good thing, if the weather was always nice I'd be flying a lot more, but there would be even less progress on DooMaw. So - having had the big tidy-up and all the various half-done parts of the project have their own project box on its own shelf in the relevant steel cabinet among the line of steel cabinets (oh, joy, I can find everything in an instant now), so it's time to get back to productive work. Here is what I think of as rather an historic photo of the work-bench - taken yesterday, and historic because it's ancient times since the bench was last completely clear - Right now there is just one thing on the whole work-bench, so even I can't confuse myself and start wondering what I was working on last! Here is a photo - That is how far I got with building the instrument panel about two months ago. The instrument positioning looks a bit unconventional because they have to be located where they won't clash with the truss which resolves the landing gear loads, which is directly behind the panel. There's only about 3mm clearance around each instrument, so they have to be placed quite accurately, especially since the panel is rubber mounted, though it doesn't move more than about 1-2mm each way. Down the track I will invest in a pair of MGL digital instruments and do away with most of the steam gauges but for the moment, due to their $6-7k price, they will have to stay on the wish-list. The angled flat portion of the panel is for a nav tablet and the pieces sticking up will be folded over and trimmed, to hold the tablet in place. Next stage is to make up the parts to complete the flanges at the corners and weld them in - I suppose I can still remember how to weld ...
  6. Head in the clouds

    DooMaw - building a STOL

    No, actually wiring of a test rig I had set up, and they chewed a lot of the exposed 240V wiring under the house as well ...
  7. Head in the clouds

    DooMaw - building a STOL

    So - ten weeks ago I said I was back on the case, then I found that I simply couldn't do another thing at all because every square inch of the workbench was piled high with 'stuff', mostly bits and pieces left over and not sorted and put away from previously completed or partially completed parts of the project. I started to make the instrument panel and drove myself mad because every time I put anything down I lost it among the other detritus on the bench, or I didn't have room to set up a jig or a hand-rest. Consequently I embarked on a 'quick' clean-up, but I have this problem, with me it's all or nothing, so I ended up searching the net and travelling far and wide to get hold of as many steel 'Brownbuilt' style cabinets as I could ... oh, I forgot to mention we had a minor rodent plague here as well and they crapped all over the work I'd been doing and chewed some wiring and other bits I had to re-do so I also spent long hours buying and testing the whole gamut of rodent annihilation devices. For anyone who's curious - they all work but though some are better than others, you need all of them if you want to win. We don't use poisons here because we have 4-500 birds that gather daily to amuse my good wife, and some of them would eat a dead or sick mouse and die as a result, and because of the birds and the occasional mouse we also have a number of friendly pythons and they might suffer a similar fate, and neither would I wish a nasty end on the two large eastern browns hanging here looking for a free feed, even the one which took a swipe at me a couple of weeks ago ... so it's all about trying to trap the wily (rodent) baskets - the ones the pythons and browns and kookaburras don't get, that is. Best result so far has been with the 9000V rodent zapper, though any roach will also trigger it and it's therefore harmless until reset in the morning - the magpies love the zapped roaches. The Nooski seems like a lovely and easy trap concept but with two of them and three months has only produced one casualty so far. Snap traps are a waste of time here, the rodents' great grandparents have told millennium mouse all about how to raid them unscathed, and the self resetting box trap that will catch 'up to ten mice at a time' for release or drowning, hasn't caught anything except a very apologetic cane toad who had an irresistible urge to sample cat biscuits and dried baitfish. The winner? The walk the plank and fall in a bucket thing. In the meantime I've been itching for much more flying the lovely little Kestrel. I've done lots of maintenance and replacing worn out things on it and it gets better and better, a few flights back I came home each time trailing long lengthens of gap strip (the fabric strips that close the gap between the wing trailing edge and the ailerons). It looked like a fair bit of hassle to replace them but I couldn't ignore the itch so ordered new fabric and the adhesive tapes and stitched them up and cleaned off the old adhesive and finally got it done - and wow, well I'd almost convinced myself it wasn't worth worrying about because the ailerons were so sluggish anyway ... but now the roll rate rivals anything I've flown, so I'm delighted. BUT - since then the weather has been totally crappy for weeks. Okay, next post I'll tell something about the progress on DooMaw.
  8. Head in the clouds

    Affirm? Or Roger...

    I've just got to say, Nobody, that I just love your forum name, modesty it may have been intended to be, and it's a classic! Gets me every time I see "Nobody said this and Nobody said that ..." love it.
  9. Head in the clouds

    A short story, then a long journey

    I didn't take any offence - maybe you missed the 'wink' at the end of my comment? I was just somewhat bemused at your regular egg-sucking tutorials - I guess you might have been a school teacher in a previous life. Yes, of course you will have far better results with thick walled tubing, which is why I suggested it to DP in the first place. And, no, I didn't use a good quality mandrel bender with tight fitting formers, the part I posted pictures of was simply bent around my bullbar as I described earlier. Having had to 'make do' in the bush a lot of my life I have a passable understanding of what will work and what won't, since I've tried most things at one time or another.
  10. Head in the clouds

    8 minute Video Montage of my Flight journey thus far...

    Ah, I see, I thought an instructor was demonstrating a power on stall to you. My concern was that the instructor seemed to be doing/teaching the wrong thing ...
  11. Head in the clouds

    8 minute Video Montage of my Flight journey thus far...

    Yes, that didn't look at all good to me either, a recipe for instant spin entry in many aircraft. Also - watch his feet during the aileron input, the first correction with left aileron is accompanied by right rudder - you can see his left knee bend to accommodate the left pedal moving back.
  12. Head in the clouds

    What Now - please advise

    I really like the way the site is coming on - very nice! I have noticed that the individual posts used to be numbered which was useful for saying, for example, "See post #1234 for photos of XYZ" - could that numbering be re-instated? Also - just a very small point but a nicety - a long while ago the Notifications icon used to open and drop-down if you hovered over it which was better than having to click it.
  13. Head in the clouds

    A short story, then a long journey

    Then your estimate would be wrong, I just measured it, the pictures I posted show a 90° bend with a C/L radius of 71mm. BUT - you need to re-read DP's request (it's near the bottom of page 3) - he didn't ask for a 75mm radius, he asked for a 75mm offset with 'best radius possible' bends. It'll crack if you try and bend it too tight, but I bent it quite happily to a 71mm radius with no indication of cracking, or more to the point being an aluminium alloy, no failure in compression on the inside of the bend. No, actually 'that grade' (6061T6) isn't difficult to bend, it's easier and far more predictable than lower tensile grades if you know what you're doing, though it does take more force, naturally. Of course it resists deformation, so does a banana, it's all a matter of scale isn't it? Fortunately I did remember about the stretching and compressing and distortion and stresses, and gladly I did choose a material with satisfactory properties, which could handle the distortion and stresses ... but thanks for the reminder anyway, I am getting older so I might have complete brain fade one day I expect 😉
  14. Head in the clouds

    A short story, then a long journey

    Ah well, if it can't be done, it can't be done - If you get tired of mucking about with sand you could try one of these -
  15. Head in the clouds

    A short story, then a long journey

    For the small amount of extra weight in a joystick, I wouldn't worry about using thin walled tube, I'd rather it was strong anyway. In which case Capral sell 22.23 (7/8") tube with a 5.99mm wall, it's a 6061T6 grade (marine structural) and comes in 6m lengths which would cost you about $40 (Capral Material No. 851607). If you let them know you only need a metre and speak to them nicely they might let you know who they last sold (or regularly sell) that size to, and you might be able to get an offcut from them instead. With that size and wall thickness you wouldn't need a bender to shape it, you could just bend it cold in the crook of a tree or round a mate's bullbar - don't use your own bullbar it might leave marks and scratches on it 😉 . Seriously though, add a bit of padding and a car towball also makes a handy bender for that sort of job. Half a metre of that size and wall thickness tube only weighs 400gm, so it's not a big weight penalty for quite a lot of improved simplicity and strength.
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