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Hat Stiffener Press + Pic of the day

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sky_ranger161

Joined: 07 Jun 2006
Posts: 91

Posted: Fri Jul 28, 2006 4:53 am Post subject: Hat Stiffener Press + Pic of the day

After a few failed attempts at making hat stiffeners for the main spar, I decided to try making a press die for them in much the same way I made my flanging dies. Here's what I came up with. I used the same timbertech composite material as I used for the flanging dies, and was able to fabricate the whole set using a table saw and some 5-minute epoxy from ACE hardware. I rounded all of the corners to the proper radius, and epoxied the male 45-degree press flange to the top die. To use them, I put a piece of .025 between the dies and put them under pressure with the shop press until the bend is formed, then trim the flanges to the proper size. Out comes perfectly shaped, high-quality, repeatable hat stiffeners lookin' like the factory made 'em. 

   

  Debo Cox

  Nags Head, NC

  XL/Corvair

  Moving slow, but still moving (which is good)

hat_stiffener_press.JPG

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TxDave

Joined: 22 Jul 2006
Posts: 168
Location: Temple, TX

Posted: Fri Jul 28, 2006 7:07 am Post subject: Re: Hat Stiffener Press + Pic of the day

Debo, I've said it before, you're a genius. What a creative use of plastic lumber.



do not archive



Dave

Temple, TX

601XL

Kevin Bonds

Joined: 09 Jan 2006
Posts: 171
Location: Nashville, Tn

Posted: Fri Jul 28, 2006 10:58 am Post subject: Hat Stiffener Press + Pic of the day

Messages like this one are why I stay on this list. This one is a gem. Bravo. I would never have thought of that.  

     

Kevin Bonds  

Nashville TN  

601XL Corvair powered; Plans building.  

Empennage done; working on wings and engine.  

http://home.comcast.net/~kevinbonds  

   

do not archive DO NOT ARCHIVE   

     

   

    

   

  

        

  

From: owner-zenith-list-server(at)matronics.com [mailto:owner-zenith-list-server(at)matronics.com] On Behalf Of Debo Cox

 Sent: Friday, July 28, 2006 7:52 AM

 To: zenith-list(at)matronics.com

 Subject: Hat Stiffener Press + Pic of the day  

  

     

After a few failed attempts at making hat stiffeners for the main spar, I decided to try making a press die for them in much the same way I made my flanging dies. Here's what I came up with. I used the same timbertech composite material as I used for the flanging dies, and was able to fabricate the whole set using a   

    

Debo Cox  

    

Nags Head, NC  

    

XL/Corvair  

    

Moving slow, but still moving (which is good)

_________________
KevinBonds
Nashville, TN
Plans-building Zenith CH601XL w/Corvair Power
http://home.comcast.net/~kevinbonds

Kevin Bonds

Joined: 09 Jan 2006
Posts: 171
Location: Nashville, Tn

Posted: Fri Jul 28, 2006 11:21 am Post subject: Hat Stiffener Press + Pic of the day

Did you engineer this to take into account spring-back (i.e. did you add more angle to the bends)?  

     

Kevin Bonds  

Nashville TN  

601XL Corvair powered; Plans building.  

Empennage done; working on wings and engine.  

http://home.comcast.net/~kevinbonds  

   

do not archive DO NOT ARCHIVE   

     

   

  

        

  

From: owner-zenith-list-server(at)matronics.com [mailto:owner-zenith-list-server(at)matronics.com] On Behalf Of Debo Cox

 Sent: Friday, July 28, 2006 7:52 AM

 To: zenith-list(at)matronics.com

 Subject: Hat Stiffener Press + Pic of the day  

  

     

After a few failed attempts at making hat stiffeners for the main spar, I decided to try making a press die for them in much the same way I made my flanging dies. Here's what I came up with. I used the same timbertech composite material as I used for the flanging dies, and was able to fabricate the whole set using a table saw and some 5-minute epoxy from ACE hardware. I rounded all of the corners to the proper radius, and epoxied the male 45-degree press flange to the top die. To use them, I put a piece of .025 between the dies and put them under pressure with the shop press until the bend is formed, then trim the flanges to the proper size. Out comes perfectly shaped, high-quality, repeatable hat stiffeners lookin' like the factory made 'em.   

    

   

    

Debo Cox  

    

Nags Head, NC  

    

XL/Corvair  

    

Moving slow, but still moving (which is good)

_________________
KevinBonds
Nashville, TN
Plans-building Zenith CH601XL w/Corvair Power
http://home.comcast.net/~kevinbonds

sky_ranger161

Joined: 07 Jun 2006
Posts: 91

Posted: Fri Jul 28, 2006 1:45 pm Post subject: Hat Stiffener Press + Pic of the day

Hi Kevin,

   

  Thanks for the kind words. I've used your web site for inspiration and ideas a lot - so right back atcha. 

   

  I didn't add any angle for springback, and haven't found any to really be necessary. I suppose it's because the part is being pressed out under pressure, but it doesn't seem to be a factor - at least with mine. I'm not sure if it was just dumb luck, or my, uh, "engineering", but I suspect the first one.

   

  The whole setup was really easy to make - took less than an hour, and I even screwed up a couple pieces of material trying to get the dimensions right. The first ones I tried to make on my brake were a disaster, so this seemed like a workable alternative. I've made a complete set for the right wing so far, and it's so far, so good.

   

  Debo Cox

  Nags Head, NC

  XL/Corvair

   

  do  not archive



  		Yahoo! Music Unlimited - Access over 1 million songs. [url=http://pa.yahoo.com/*http://us.rd.yahoo.com/evt=36035/*http://music.yahoo.com/unlimited/  ]Try it free.[/url]

mgraves(at)usmo.com
Guest

Posted: Fri Jul 28, 2006 3:57 pm Post subject: Hat Stiffener Press + Pic of the day

These really are a nice set of dies Debo..  I hadn't thought of using the 

plastic deck material....  This type of die would also work for a lot of 

other things too.    Like the relief beads on the gas tanks.....  fair lead 

pieces for cables,   and might even work for the hat stiffeners on the 

floor pan of the 701.   I wish I had seen your dies,  before I purchased 

mine for the 701



Monty Graves



At 02:41 PM 7/28/2006 -0700, you wrote:

 	  Quote: 	
		  Hi Kevin,



Thanks for the kind words. I've used your web site for inspiration and 

ideas a lot - so right back atcha.



I didn't add any angle for springback, and haven't found any to really be 

necessary. I suppose it's because the part is being pressed out under 

pressure, but it doesn't seem to be a factor - at least with mine. I'm not 

sure if it was just dumb luck, or my, uh, "engineering", but I suspect the 

first one.



The whole setup was really easy to make - took less than an hour, and I 

even screwed up a couple pieces of material trying to get the dimensions 

right. The first ones I tried to make on my brake were a disaster, so this 

seemed like a workable alternative. I've made a complete set for the right 

wing so far, and it's so far, so good.



Debo Cox

Nags Head, NC

XL/Corvair

ihab.awad(at)gmail.com
Guest

Posted: Fri Jul 28, 2006 4:06 pm Post subject: Hat Stiffener Press + Pic of the day

On 7/28/06, Monty Graves <mgraves(at)usmo.com> wrote:

 	  Quote: 	
		   These really are a nice set of dies Debo..  I hadn't thought of using the

 plastic deck material....  This type of die would also work for a lot of

 other things too.


	


Yup ... purely speculating, I would say this general technique could

probably be used to make very clean joggles on longerons by making

male and female forms that cuddle the angle securely on all sides with

sheetmetal shims glued to the faces to do the joggling. -- Ihab



-- 

Ihab A.B. Awad, Palo Alto, CA

Ron Lendon

Joined: 10 Jan 2006
Posts: 685
Location: Clinton Twp., MI

Posted: Fri Jul 28, 2006 6:44 pm Post subject: Re: Hat Stiffener Press + Pic of the day

Debo,



You are the master.  I had someone offer to buy my flanging dies the other day, which I declined, and I refered him to your pics.



You might wanna take a look at how I solved bending the flaps.  The final 163 degree bend was done with the 200lb gravity actuated stomp press

_________________
Ron Lendon
WW Corvair with Roy's Garage 5th bearing
CH 601 XLB
N601LT - Flying
http://www.mykitlog.com/rlendon
Corvair Engine Prints:
https://sites.google.com/site/corvairenginedata/

sky_ranger161

Joined: 07 Jun 2006
Posts: 91

Posted: Sat Jul 29, 2006 5:20 am Post subject: Hat Stiffener Press + Pic of the day

Thanks guys. I'm glad the press idea sparked a little head-scratchin'. That's the really cool thing about this list. One guy finds a way to get himself out of a pickle - shares it, and gets a dozen good ideas back in the process. And you thought the internet was just good for lookin' at porn. 

   

  Ron, I laughed out loud like a moron when I read about the "200lb gravity actuated stomp press" - classic.



  Debo Cox

  Nags Head, NC

  XL/Corvair (working on wing parts)

   

  do not archive



  		Yahoo! Music Unlimited - Access over 1 million songs. [url=http://pa.yahoo.com/*http://us.rd.yahoo.com/evt=36035/*http://music.yahoo.com/unlimited/  ]Try it free.[/url]

ashontz

Joined: 27 Dec 2006
Posts: 723

Posted: Sun Feb 04, 2007 5:07 am Post subject: Re: Hat Stiffener Press + Pic of the day

 	  sky_ranger161 wrote: 	
		  After a few failed attempts at making hat stiffeners for the main spar, I decided to try making a press die for them in much the same way I made my flanging dies. Here's what I came up with. I used the same timbertech composite material as I used for the flanging dies, and was able to fabricate the whole set using a table saw and some 5-minute epoxy from ACE hardware. I rounded all of the corners to the proper radius, and epoxied the male 45-degree press flange to the top die. To use them, I put a piece of .025 between the dies and put them under pressure with the shop press until the bend is formed, then trim the flanges to the proper size. Out comes perfectly shaped, high-quality,?repeatable hat stiffeners lookin' like the factory made 'em. 

  ?

  Debo Cox

  Nags Head, NC

  XL/Corvair

  Moving slow, but still moving (which is good)



 	




I started to design the exact same thing last night. Good to see it works. My only question, do you have any spring back in the angles or contour the exact same as the part specified in the plans? I was thinking of making one with spring back built in but it may not be necessary. I'll try this frist because building in springback is a lot more work and if it doesn't need it that'd be great.

ashontz

Joined: 27 Dec 2006
Posts: 723

Posted: Sun Feb 04, 2007 5:15 am Post subject: Re: Hat Stiffener Press + Pic of the day

 	  Ron Lendon wrote: 	
		  Debo,



You are the master.  I had someone offer to buy my flanging dies the other day, which I declined, and I refered him to your pics.



You might wanna take a look at how I solved bending the flaps.  The final 163 degree bend was done with the 200lb gravity actuated stomp press 	




I used the same gravity actuated stomp press for my rudder skin and elevator skin. Can't beat the price.

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