DR-1 (Sands): Builders Group - Page 9

Jim Bruton · 25 August 2004, 03:25 PM

Tail Skid complete- just need a Dreidecker to stick it in.

Jim Bruton · 25 August 2004, 03:26 PM

Landing Gear Rib Jig, Full Scale Rudder Jig- for bending the tubing, and the full scale drawing of an original rudder of a DR-1.

Jim Bruton · 25 August 2004, 03:27 PM

Little better shot of the rudder template and drawing....

Jim Bruton · 25 August 2004, 03:29 PM

My 2 wing rib jigs that you all made me make so i can catch up!

Rex · 25 August 2004, 06:53 PM

Pipe Bending

Seeing Jim's rudder jig jogged my memory to share my experiences with bending 4140N tubing. I have tried several methods but the one that worked for me is both simple and inexpensive.

The tubes around the cockpit area especially the four corner braces around the pilot opening are a little tricky to get the tight radius bends that look good (since they are out in the open and visible).

I made a template of wood much like Jim has done. I welded one end of the tubing closed, filled the tube with sand (silica sand works best because it packs the best but any sand will work- you can even borrow some from your kids sandbox and then return it when you are done) and welded the other end shut. Place the tube in your jig and pull it into shape by hand. This method worked great for the small tubing around the cockpit opening which had compound bends.

Sorry I don't have pictures of this process but it is simple and it works.

Fokker210 · 25 August 2004, 07:08 PM

Great shots Jim !
Out of cuiosity, where did you get the large triplane print ?
Just the thing for motivation !

Jim Bruton · 26 August 2004, 03:38 AM

Rex, love the idea of filling the tube to be bent with sand to prevent crimping! Another reason to make a trip to the beach while it is still warm! How is your Ferrules project coming? If it is just as easy to make 300 as it is 100, then let Fokker210 and me know.

Fokker210, glad you liked the shots. The large rudder print: i believe it is an original DR-1 technical drawing.... this was taken from page 121 of "Fokker Dr.1 Triplane- a World War One Legend" by Paul Leaman. First, I scanned the image into a 1 Gig (yes, HUGE) file, then opened it up in PhotoShop to correctly scale it. Then I printed it out on a 42" plotter.... that's how I made the large color print of the DR-1 in my shop too... I have since modified the size of the rudder file to make it easier to open on other computers. I found it nearly spot-on to Sands' rudder.

Rex · 26 August 2004, 06:33 AM

The hardest part of making the ferrules is the finish grinding on each end and filing the holes smooth. Winding the springs might take an hour for a full set. Cutting them to length might take another hour. I probably spent another hour to hour and a half grinding and filing.

If you want to see a sample email me your address and I will mail one to each of you.

Jim Bruton · 28 August 2004, 02:39 AM

I am heading out to Chicago today and will be gine until next Thursday night, so if i seem absent, it won't be for long! i did receive my wood for making ribs from Wicks- they generously add in some extra.... and now i have all the capstrips grooved and i am working on the front rib webs... and i have 8 capstrips in 2 bending jigs. hate to leave the project for a few days but look forward to getting stuck back into it upon my return. have a great weekend!

worldcrusier · 29 August 2004, 12:42 PM

I know that there are many ways to accomplish the scarf joints necessary for the spar construction. Here is how I am doing the scarfs. I built two jigs, one for the spars and one for the ply. I used a power plane, Black and Decker. I ground off about 1/4" off the ends of each blade to prevent the plane from damaging the jig. The first pic is the jig for the spar.