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craig(at)craigandjean.com
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 Posted: Tue Nov 07, 2006 8:02 am Post subject: Bending fuselage bows |
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I need to scratch-form 6B21-2, one of the 3/4 inch tubes that supports the
top skin over the luggage area. All I know is that I order the tubing with
extra length, cut my form-block and wrap the tubing around it. Anyone have
more details steps or tips? It seems to me that if I just wrap the tube
around the form there will be substantial spring-back. Do I just take the
bow off the form, pull it tighter and check it on the form until it
conforms?
-- Craig
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N601RT
Joined: 25 Feb 2006
Posts: 31
Location: Hillsboro, Oregon
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| Posted: Tue Nov 07, 2006 8:59 am Post subject: Re: Bending fuselage bows |
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Craig,
I'd recommend filling the tubing with sand (or kitty litter) and closing the ends of the tube with tape before starting to bend it. This will minimize the tendency for the tubing to collapse when you bend it.
Regards,
Roy
N601RT: CH601HDS, nose gear, Rotax 912ULS, All electric, IFR quipped, 651hrs, 750 landings
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nfivesl(at)yahoo.com
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| Posted: Tue Nov 07, 2006 12:30 pm Post subject: Bending fuselage bows |
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Craig:
You are right on about the over bend. What I did was draw the hoop out on a big sheet of paper, lay it on my table, then bent the pipe to match. If you are real careful and go slow you can get it pretty close. I had four hoops to bend and got better results when I used a pipe bender from Harbor freight but it is really overkill. This thing:
http://www.cooknwithgas.com/6_13_06_Canopy_Hoop_Bending2.JPG
It did, however limit the amount of "crimping" caused by the form that I got on the first two I bent.
You are also right on about starting with a longer pipe. Take it slow and you will get good results.
Scott.
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craig(at)craigandjean.com
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larry(at)macsmachine.com
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| Posted: Tue Nov 07, 2006 1:14 pm Post subject: Bending fuselage bows |
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Hi Craig,
You'll probably want to bend the bows more than you're going to get from
a simple former because of the bend-back
that the aluminum has. As mentioned, fill the tube tight with blasting
sand or any fine sand. Plug the ends with wood
and use your form. The side radii are most crucial to getting the skins
to wrap around fully to match the vertical of the side skins.
Do pay attention to that. Also, I devised a bender arrangement with
casters on a table that will allow you to get the exact bend you want.
You have to ink the shape you need on the table and then use it or the
form to see where the bend is going. This can be very accurate. The
radius in the bottom 10-inches each side is very important as you can
see in the link provided because the longeron is curving as your bows
are coming down to meet the side skins. I've seen too many that seem to
just have a bend angle at the longeron for lack of enough bend radius to
match and curve at the same time. You can do it.
http://www.macsmachine.com/images/canopy/full/canopyframeup.gif
http://www.macsmachine.com/images/canopy/full/frontbowbend.gif
If you over-bend, the same clamps and casters arrangement can be used to
ease off the radius as well.
Good luck,
Larry McFarland - 601HDS at www.macsmachine.com
Craig Payne wrote:
| Quote: |
I need to scratch-form 6B21-2, one of the 3/4 inch tubes that supports the
top skin over the luggage area. All I know is that I order the tubing with
extra length, cut my form-block and wrap the tubing around it. Anyone have
more details steps or tips? It seems to me that if I just wrap the tube
around the form there will be substantial spring-back. Do I just take the
bow off the form, pull it tighter and check it on the form until it
conforms?
-- Craig
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nfivesl(at)yahoo.com
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| Posted: Tue Nov 07, 2006 7:37 pm Post subject: Bending fuselage bows |
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No problem Craig. I'll set it on the front porch and you can get it when you get here at 4:00AM if you leave now and drive fast. I owe you anyway so you are welcome to it.
Scott Laughlin
DO NOT ARCHIVE
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craig(at)craigandjean.com
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| Posted: Tue Nov 07, 2006 7:59 pm Post subject: Bending fuselage bows |
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Drive? I expect you to fly it over after you fly off your 40 hours.
But as usual Larry did it with a couple of rusty casters and a c-clamp. I
expect his paint job will be a work of art too. Some of us (like me) buy
tools and some of us build them.
-- Craig
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davids601xl(at)yahoo.com
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| Posted: Thu Nov 09, 2006 6:25 am Post subject: Bending fuselage bows |
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For all those too averse people out there, I didn't
use anything fancy. After watching a video on making
tube and fabric planes and bending the chromoly over a
garbage can, I plotted the hoop on the worktable and
then (leaving the tube overly long so you have lots of
leverage) I simply bent it around a 45 gallon drum
covered with a blanket. The drum was vertical so I
just pulled on the areas of the tube that I was
bending at the time using my body to stop the barrel
from toppling over. You get the picture. Stop after
each iteration and compare to the drawing. Bend from
one end and work your way around or you may find you
have to unbend some sections. Guess you can figure out
how I learned about that! In the end you end up with
a nice hoop after cutting off the ends. Oh and
pulling this way keeps all the bends in the same plane
(yes I know they are all in the XL) but the hoop pays
flat on the able afterward. Have fun and experiment
with this.
David
PS
I never did get a single kink. Use something to bend
around with only a slightly smaller radius than your
finished piece and you can't miss.
--- Craig Payne <craig(at)craigandjean.com> wrote:
| Quote: |
<craig(at)craigandjean.com>
I need to scratch-form 6B21-2, one of the 3/4 inch
tubes that supports the
top skin over the luggage area. All I know is that I
order the tubing with
extra length, cut my form-block and wrap the tubing
around it. Anyone have
more details steps or tips? It seems to me that if I
just wrap the tube
around the form there will be substantial
spring-back. Do I just take the
bow off the form, pull it tighter and check it on
the form until it
conforms?
-- Craig
Click on
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David Barth
601 XL Plansbuilder 15% done?
Working on Wings
www.ch601.org
Want to start your own business?
http://smallbusiness.yahoo.com/r-index
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