blocks, shroud blocks, small frames and fairing blocks. These have ... ing ply covered thus forming the two walls of the aileron slot. ... wood pieces which can then be band-sawed or cut with a fretsaw. Each wood piece is drilled with the tooling.
Production Techniques For The Homebuilder By Arthur W. J. G. Ord-Hume, EAA 8579 "Mirador", Rose Mead, Lake, Sandown, Isle of Wight, England (Chorles Everest Photos)
REPETITION WOODWORK TO CLOSE LIMITS
T IS OFTEN necessary to produce a number of small Idimensional wooden components of the same design to uniform accuracy. Such items would include rib noseblocks, shroud blocks, small frames and fairing blocks. These have to be uniformly accurate — i.e. accurate not only to drawing limits, but to each other — especially where the parts form supports for ply covering when any variation could result in distortion of the finished skin. Fig. 1 shows a typical instance. The wing trailing edge at the aileron gap has a shroud block at each rib to support a curved plywood skin. The aileron itself has a shaped nose block at each rib, the whole nose section being ply covered thus forming the two walls of the aileron slot.
Any variation in block dimensions will result in
distortion of the slot and, in extreme cases, the physical fouling of the aileron with the main rib shroud during operation. A simple way out is to make up two templates for the parts in mild sheet steel. Ideally for the production of large numbers of parts (quantities of more than two dozen), these should be case-hardened. The two templates are drilled with tooling holes and bolted up together before filing and finishing off to the drawing limits so that these two pieces are absolutely identical. The templates are now used to mark out roughly the wood pieces which can then be band-sawed or cut with a fretsaw. Each wood piece is drilled with the tooling holes through the template. These holes may be either Vs in. diameter or 3/16 in. to suit the job and they should be placed as far apart as possible. The stack of wood pieces is now bolted up tightly between the two templates. Adjust these carefully since the long bolts through the wood can easily permit unintentional "fanning" of the pieces. A visual check at two opposite ends of the pile with a tri-square will insure on this point.
Fig. 2. The stack of pieces, bolted between steel templates, is clamped in the vise and planed to shape. Note how the plane is being held at an angle of about 30 deg.
to the direction of the cut to eliminate judder at the start of the cut and subsequent digging in.
Now work on the pile to conform to the templates using a block plane, spoke-shave, chisel or rasp as the shape dictates. Finish off with a medium file (a half-round if the work is concavely curved) and check that the pile is dead level cross-wise all around. This can be done using a rule or square held on edge and checking for rocking or low-spots (Fig. 3). The pieces are then unbolted and any raggedness is taken off with smooth grit paper. On assembly, when the blocks are trued up in the normal manner using a straightedge held spanwise at intervals across three ribs or more at a time, little if any extra shaving will be needed to present a perfectly true plane for skinning. (Continued on bottom of page 13)
Fig. 1.
A typical case where a num-
ber of parts are required to the same dimensional accuracy. This extract from a working drawing shows part of the wing section at the aileron slot. The portion of the rib immediately aft of the rear spar comprises a shaped plywood block which supports the shroud ply skin. The forward part of the aileron is again built up on shaped ply blocks which carry ply covering. These parts must be very accurately
A simple way out is to make up two templates for the parts in mild ... are drilled with tooling holes and bolted up together be- ... (Continued on bottom of page 13).
Mack suffered some burns also, but none too seri- ous, we are happy to say. The only apparent reason for this was the fact that the heat of the iron was too much.
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