Progress Update

[orchardair]

Just to show that I am not 100% lazy or anything, here is the next step - welded (although not very pretty):

welded the tubes

1494379763623 (1).jpg (19.36 KiB) Viewed 4416 times

Next will be cutting the excess metal, and shortening the tubes to required length.

[orchardair]

Much lighter now...

Still needs tubes trimmed to final length

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The one edge of the (rectangular tube) pieces which is laying on the bench is sometimes shown as being metal. In my case it is air. I did not weld anything on that edge - just removed a bunch of metal.
Since the longer of the two 3/8" tubes goes all the way through the rectangular tube, I figured it is sturdy enough for this non-structural part.
In other words - I added lightness.

[Bitshifter]

20170520_165508.jpg (123.11 KiB) Viewed 4394 times

I needed to throw in a progress update since I finally got it pushed out of the garage.

[1964m20e]

looking good

[HC85]

NICE!!!

I love it!

Looking forward to the day when my ship is at that level of completion!

[orchardair]

What a beauty!

[orchardair]

One of my "How did you ..." pictorial essays.
This time, perpendicular tube-in tube with doublers. This is used several times in the Hatz Classic. Specifically in this case I am working on the landing gear parts.

Step 1:
I drill the hole for the bushing tube before I cut the long tube to length. This gives me freedom to drill wherever the drill bit hits the tube. Also leave enough length (1/2" ?) at the short side of the tube beyond the hole, to make things easier.

Drill pre-cut.jpg (76.88 KiB) Viewed 4286 times

Step 2:
Cut the bushing tubes over-sized, ream the hole, cut the long tube to size (measure twice!).

Cut to length.jpg (70.55 KiB) Viewed 4286 times

Step 3:
Tack-weld the bushing, but only on the part that won't be cut off (see later).

Tack weld.jpg (86.17 KiB) Viewed 4286 times

Step 4:
Using a combination of angle-grinder, bench grinder, jedi-force and any other trick you have, cut the long tube to shape.

Shape.jpg (56.23 KiB) Viewed 4286 times

Step 5:
Prepare the doublers. In this case I don't think these are on the files you can download for your waterjet cutter. I just used my angle grinder to cut them from 0.050 sheet, finished on the sander.

Doublers.jpg (80.55 KiB) Viewed 4286 times

The next few steps will be in a separate post. I guess there's a limit to how many pictures or size a single post can have.

[orchardair]

...(continued)

Step 6:
Position and tack-weld the doublers.

Tack Doubler.jpg (58.16 KiB) Viewed 4286 times

Step 7:
Heat and bend the doublers.

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Step 8:
Ready to weld around the doubler.

Ready to weld.jpg (74.57 KiB) Viewed 4286 times

[mmarien]

Nice. I haven't started on the metal other than the compression tubes but there is nothing better for building confidence than someone else making it look easy.

[orchardair]

Here ya go, welded all around:

DSC_1868.jpg (90.56 KiB) Viewed 4275 times

Need to ream the small tubes to 5/16", shorten them to the correct length and drill the holes in the longer tubes.