I killed my air compressor!

Hey Gang, 

After 14 years of use and abuse, my little 8-gallon Harbor Freight air compressor gave up the ghost. They don't offer the same model anymore (mine was a 3.0 HP model), but this one is similar. It's been a great little machine. I paid less than $100 for it 14 years ago! However, building an all-metal airplane requires a lot more air than my old one could muster. About an hour and a half into match-drilling the horizontal stabilizer skin to the skeleton, I noticed a burning smell. Thinking I was simply approaching the thermal overload limit, which trips an internal breaker on the compressor, I kept going. I'd done this a few times before, so I wasn't concerned. However, this time around, it tripped the GFI circuit in the garage instead. After that, any attempt to turn on the compressor just trips the GFI. No activity from the compressor at all! I think I blew the start capacitor, but we'll see.

Anyway, since I need a compressor for other things (like winterizing my travel trailer and my sprinkler system within the next week or so), I couldn't really wait and try to fix the little one. Besides, it's too small for the plane project anyway. So, I ended up selecting a new Husky C302H 30-gallon portable compressor from Home Depot.

Check out my video on how and why I selected this particular model:

I did the 20-minute break-in on the new compressor and changed the oil to a synthetic blend. The factory oil was really dirty after the break-in, so an oil change was necessary. I also re-plumbed the condensate drain because the original one is all but inaccessible without tipping the compressor. It should give many years of service now, and last well beyond the length of the project. I hope so, since I plan to scratch-build a Zenith CH 640 someday!

As for the little compressor, I will try to fix it if the repair can be done inexpensively. I may try to sell it after that, give it away or keep it as a spare. No idea at this point...for now, it's just going to sit in a corner. Stay tuned for more progress! I have upcoming updates on the horizontal stabilizer, the elevator and the flaperons. Maybe, just maybe, I'll be able to start the wings this winter!

Cheers!

Slow Progress On The Tail

Hey Gang,

One step forward, two steps back...that's been my whole summer. After recovering from my back injury in time for AirVenture 2016 and having a great time, I was eager to return home to get back to work on the project. I had a really hard time with fatigue and sleepless nights due to my allergies. Most of August and September were unproductive months...I then found out I actually had Mono, of all things! I made some slow progress on the tail section during that time, but managed to get some footage and work toward some new videos. Here are a few photos of my progress, and I will hopefully have some more videos coming soon.

Horizontal Stabilizer Skin:

 

The skin itself is just over 8.5' long. I clamped a straight edge along one side, and clamped it to the bench along the other side. I then took a piece of wood, and very gently started bending the center line in. This took 2 people, and I had to keep the measured center line in the center of the curve as I bent, but it worked quite well. Not as consistent of a bend as a brake performs, but since it's a sweeping curve (27mm radius), you can do it manually.

 Horizontal Stabilizer Skin Clecoed to Bottom Surface:

I actually screwed up doing the skin...started on the wrong side! It is much easier and makes more sense to start on the top side of the stabilizer, which is flat. Then you only have to draw the skin down around the bottom end. Now, I'll have to get creative when I draw the skin down, because it has to bend up around the rib, and then down around the top surface. Funny, I looked over the construction manual several times before starting it, and still did it wrong...this is what you get when you're fatigued: stupid mistakes. On top of that, I put 5-6 smileys in the skin because I got a little too eager to form it all the way around the radius without a second set of hands. It is extremely easy to put smileys in .020...even easier in .016! Fortunately, I can work the smileys out somewhat, and they'll be in inconspicuous spots anyway. Very aggravating though! This thing isn't supposed to get wear and tear until AFTER I start flying it in the bush!

Elevator Skeleton Parts Laid Out:

Above, I've laid out the elevator skeleton parts, including the trim motor and wiring. It's amazing how simple some of these structures really are.

Elevator Center Section Drilled and Clecoed:

 

Elevator Skeleton Match-drilled & Assembled (sans control horns):

 

Well, that's it for now. I need to finish skinning the horizontal stabilizer and finish up the videos for that. Then I'll cut and bend the skins for the elevator, match drill them and then work on installing the trim system. Lots to do, but once these are done I can start the wings! I'm hoping the warm weather holds out long enough so I can get these parts primed and riveted in time to also get my wing spars assembled. They require full corrosion protection on all of the mating surfaces and exposed surfaces, and are completely solid-riveted as an assembly before you start attaching ribs and other structures. I have to completely finish the wing spar assemblies before starting wing construction. Hoping I can get that all done before the cold weather rolls in and prevents me from doing the corrosion protection, otherwise I'll have to wait until roughly May 2017 to do assembly of the spars. There's other stuff I can do during the winter, but I may actually run out of major assemblies to work on if I can't start the wings by then. Off to the shop...

Cheers!