Canadian Flag Blowing In The Wind Ron Leclerc Zenith CH701 Construction Log


Zenair CH701 STOL Aircraft...
CH701 STOL

Winnipeg

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CH701 Float Design:   Previous...   1 | 2 | 3 | 4 |
 

 
Basic Bulkhead Design & Construction; Continued
 
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July 3, 2011
F15 Bulkhead Forming Block... made out of MDF board, very easy to work with. Stands up well and is only required to be used to form 2 parts!

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July 3, 2011
F1-F15 Bulkheads Forming Blocks... used scrap 3/4" chipboard as backup!

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July 3, 2011
F15 Bulkhead Parts blank... 2 required.

 
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July 3, 2011
F15 Bulkhead Ready to be bent into a part shape...

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July 3, 2011
F15 Bulkhead Formed into Part... 2 required! Started out as a pattern, now it's looks like a 0.032 part, special for the aft Rudder Bulkhead. So there you have it... it's really that simple!

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July 9, 2011
F15 Bulkhead with Rudder Hinge assembly...

 
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July 9, 2011
F15 Bulkhead with Rudder Hinge assembly...

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July 9, 2011
F15 Bulkheads Formed into 2 Parts!

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July 9, 2011
F15 Bulkheads Formed into 2 Parts!

 
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July 9, 2011
F15 Bulkheads with Rudder Hinge assembly...

 
Making all of the individual bulkhead forming blocks is a tough task! Having said that... you need them, even though you only have to make 2 parts per forming block. Well here is a simple way... make only one forming block and use it to form all the bulkhead parts! Take and make your largest forming block first... that would be F9(at the step). Make both parts and make sure that they are done just right, because after the next step you won't be able to make the parts again with this block.

So there...the next step is very simple, take the pattern for your next larger size bulkhead... that would be either F6 or F10 and trace it out on the F9 forming block that you are finished making parts for(you hope). Then cut the forming block down to either the F6 or F10 pattern size traced out on the F9 block! It's just that simple... and there it is, go on to the next larger size bulkhead and do the same!

You did make all of the needed bulkhead patterns... didn't you??? That is a whole lot easier then making all of those danged old forming blocks!
 

 
Float Rudder Design & Construction
When I started to design the Float Rudder Assembly... I had a problem, I do not weld and I wanted to keep the build as simple as possible so... this design became a bolt together unit only... no welding involved, anyone can do it... just good old AN Stainless Steel Bolt, Nuts & Washers... and common sense. The bolt sizes are AN3 & AN4!

 
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May 27, 2010
Patterns for the Float Rudder Assembly...

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May 27, 2010
Basic Float Rudder Pattern...

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May 27, 2010
Float Rudder Hinge Part Pattern... 2 required.

 
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June 1, 2010
Float Rudder Control Horn Pattern...

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June 1, 2010
Float Rudder Hinge Mount Pattern...

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June 1, 2010
Plywood Float Rudder Mockup...

 

 
Float Rudder Parts Fabrication!

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June 1, 2010
Float Rudder Hinge Mount - 1/8" 6061-T6 Aluminum...

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June 1, 2010
Float Rudder Control Horn - 1/8" 6061 - T6 Aluminum...

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June 1, 2010
Float Rudder Nylon Bumper Stop - with 0.050 6061-T6 mounting side plates...

 
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June 3, 2010
Rudder Hinge Parts Blank - 1/8" 6061 - T6 Aluminum... Ready for bending...

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June 3, 2010
Rudder Hinge Parts all formed with side reinforcing plates - ready for final assembly - 1/8" 6061 - T6 Aluminum...

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June 5, 2010
Rudder Hinge Mounting Plate - 0.060 6061 - T6 Aluminum...

 
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June 7, 2010
Rudder Hinge Post - 1" x 1" - 0.063 - 6061 - T6 Aluminum. Includes Rudder Nylon Bumper Stop and Control Horn 1/8" mounting angles...

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June 7, 2010
Rudder Hinge Post Mounting Angles - 1/8" 6061-T6 Aluminum...

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June 7, 2010
Float Rudder Hinge Assembly - 6061-T6 Aluminum...

 
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June 5, 2010
Float Rudder Hinge Assembly - 6061-T6 Aluminum...

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June 7, 2010
Plywood Rudder Mockup - showing location for the hinge assembly installation...

 

 
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CH701 Float Design:   Previous...   1 | 2 | 3 | 4 |
 
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