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Our Cub Project

Wings...We are going to build some square tip wings. We got our spars from D&E aircraft. Scott and Steve met us at Sun N Fun for delivery. We are using some salvaged brackets and rebuilding a few broken (destroyed) ribs from a Pawnee and a Cub.

Rats Nest? It felt a little heavy :)

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Swept tip cub!? Speed mod.
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This is a Chicago Pneumatics Drill, not to be confused with Harbor Freight "Central Pneumatics". I bought it on amazon.com and it is great. The trigger is easy to feather, it is reversible and it is strong for its size. The guys on the VAN's site like them and so do we.

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The Beginning of Rib repairs, everyone of the ribs we have needed a repair. We used the "T" Extrusion from Carleson to insert into the piper folded "T" and rivet to reinforce. It works very well and seems to be plenty strong. Dad made various shaped tapping tools to coax the ribs back into the Modified USA 35B shape.

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The Rib Jig

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Insert for the 3/4 ribs

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Pliers to form repairs

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Riveting the ribs proved a challenge at first. The solution, make a manual rivet machine on the table. It makes both ends round like a brad with a few blows from the hammer.

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After the ribs were repaired, we stripped the old paint/primer, dipped them in coil cleaner, flushed them with water, dried them in the sun and painted them with etch primer.

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A table was build to accommodate the wing build.

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We used the plans to verify the old spars from the junk wings were correct and then used them for templates. Drill bushings helped pilot the holes for the unibit. We got the Dakota Butt hinges front and rear to replace the factory ones that were suspect. The rear is beefier than the piper part.

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Things are starting to take shape and soon we will start making the false spars on our "new to us" 8 foot break. 8)

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I can measure the time by my outfits, when we started I was in a Jacket and Jeans, now It is T-shirt and shorts with the air condition on. Time flys.
 
The Left wing is nearing completion and we are hoping to start on the Right wing in the coming month. The Right wing has ribs on spars and N struts and compression members. The Left wing has been a learning experience (read PITA) with a lot of lessons learned paving the way for success. We made the false spar material on our brake and after a steep learning curve got the trailing edges to come out all looking the same. We have a new to us 8.5 ft WYSONG brake that makes the nicest bends. Craigslist find! Also Pictured are our Carbon Fiber wing tips and Leading edges. I will have a write up on them soon. The tips weigh 17 oz and fit great.

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We ended up scrounging 8 ailerons and 4 flaps. Great for making extended surfaces.

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80" Flaps in-boarded to the fuselage.

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We had a special visitor to our little field, an osprey came and shot some touch and goes. That thing makes a strange thumping sound. It made a low pass and it moves out.
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Thank You!

Thanks so much for those pictures. I am struggling with machining of smaller wing parts and your wing pictures are right up there in detail. Could you comment on how you trimmed the D&E spars at the inboard end? I guess you just used the old spars for patterns. I wish someone would put together a box of old part examples with maybe 1' of the end of each spar to loan around to us "clonners". Working from the drawings is fine but it would be nice to make double damn sure before drilling and cutting. I managed to make some expensive scrap out of some 302 stainless yesterday (drag pull straps). Ughhhhh!:evil:
 
Where did you get your Carbon fiber wing tips? would love a set for mine..........Pricey I bet ! Your project is looking awesome! very nice craftsmenship...........:)
 
qsmx440 said:
Could you comment on how you trimmed the D&E spars at the inboard end? I guess you just used the old spars for patterns. I wish someone would put together a box of old part examples with maybe 1' of the end of each spar to loan around to us "clonners".
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Here are some pics of the inboard end. PM me and I will send you a 1' section or the front and rear from the old ones. <br>

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<br>
We trimmed the ends with a cut off wheel and a 90 sander. We used a scrap of Steel to guard the web from nicks. Get some bushing stock for pilot drilling the holes and finish them off with a unibit.<br
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edit: moved to own thread
http://www.supercub.org/forum/showthread.php?38506-Left-Door-Throttles


mike mcs repair said:
this is a quick sketch of it...

one problem with this is no throttle when door open.. might want something up in front of door like you have in throttle cable..
blue part is on inside of door, and red is on inside of fuselage, both share the pivot location(but not one bolt)(stolen from 1929 fairchild aileron linkage for the folding wings)

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Here is a picture from today. We are almost finished with the wings, waiting on carbon fiber leading edges from Randy Apling (and a little surprise part). We are going to work on the fuel system over thanksgiving and who knows, maybe one day we will get to fly this thing. The flaps and ailerons are also complete.
 

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We got our carbon fiber leading edges from 8856Charlie (Randy Apling) and they are sweet. They are 2lbs per 6' vs. .020 2024 T3 that is 4 lbs per 6'. However, we could not get it working right because our nose ribs and full ribs are not uniform enough to make the carbon work. They are very well made and for someone that is using stamped or just a new set of ribs, they will offer significant savings and improve the overall cool factor! Randy worked with us and offered advice, but in the end we could not get it to work. So made some metal leading edges out of .020 2024 T3. I do not have a pic of the roller, but I will get it posted soon. Also, Randy's wingtips are in and man, those things are light! 16 ounces and they fit like a glove.

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Waiting on Steve P's clamps to arrive.
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Shipped on Tue. And arrives on Monday. Get stuff from Spruce in two days. Maybe you should go back to work and straighten them out Lou. ;)
 
Steve Pierce said:
Shipped on Tue. And arrives on Monday. Get stuff from Spruce in two days. Maybe you should go back to work and straighten them out Lou. ;)
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Maybe you shipped it UPS Ground by mistake....:lol:8)

No way, I have been replaced by a younger model...MUCH younger!:sad:
 
I am trying to put the electric trim on my 2+2 and was wondering if you could send me a little bit more detail as to how you made the coupler between the motor and the end of the jack screw. Also how did you handle the relay switching to revers the motor. If you can help please PM me and I will get back in touch with you. Thanks.
 
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