1 Feb 2008 Started Pietenpol building process!! 11 Feb 2008 The plans for my Pietenpol arrived 14 Feb 2008 I starting building the wing rib jigs this weekend. I bought a 4' x 8' sheet of 3/4" MDF and had it cut it down to (2) 2' x 6' pieces. I used a light coat of cloth glue to secure the full size rib plans to the board. I then took an exacto knife and cut along the outline of the rib plan, removing the extra paper, leaving the paper outline of the rib (to be removed later). I then spray painted the board (purple was my daughter's favorite color), however I could still use the paper to position the jig blocks. I then cut out numerous disks and blocks and bolted them to the jig, and then removed the paper out line. This left the unpainted outline of the rib (kinda of a negative). 20 Feb 2008 Finished the jigs with the pieces to hold the gussets which I made out of 1/8" x 1" aluminum. Hours: 2.0 28 Feb 2008 I built a separate jig for the lower cap strip bending Hours: 1.0 1 March 2008 I cut two 2"x8"s for the capstrip bending jig and formed them using a copy of the full size rib plans. Hours: 1.0 3 march 2008 Using a large kettle and some 2" PVC I tested a steaming system. Seemed to work fine, but am still looking for some CPVC or series 80 PVC so it doesn't soften as much under the steam.
4 March 2008 The weighing scale I bought off ebay arrived today, works great. 5 March 2008 Tested the steamer tonight. After several attempts with PVC and CPVC, resorted to using 2" aluminum pipe. I simply laid one open end over the opening of a large dutch kettle and will leave the other end open. ~~There is beauty in Simplicity~~ It puts out a large amount of steam, approx. 212'F at the entrance, and 185'F at the exit of the tube. This should be good, because I am only concerned with the first 1/3 of the capstrip. 12 March 2008 I picked up my delivery of wood from Aircraft Spruce today at the UPS outlet. It arrived in pretty good shape, one hole punched thru a box, but no damage. They did a great job packing. 13 March 2008 Steamed my first two capstrips today, will see tomorrow how they came out. Everything was straight forward. I need to make one small addition to the jig, I need to add a "stop" in the front so when I slide in the capstrip quickly it stops at the right depth in the jig, otherwise I was adjusting a few times trying to get the capstrip in. But otherwise it seemed to go real smooth. I will check the springback tomorrow. 20 March 2008 Cut out rib gussets. Hours: 8.0 27 March 2008 Finished making aluminum templates for the wood rib pieces. I cut out the wood for the first rib and tried them in the jig. I had to due some slight modifications to the jig. I also cut some pieces of oak to act as wing spars jigs. They fit real well, but I had to even them up. The plans do not indicate angles etc, so I just ensure they were parallel, 27 3/4" from bottom to bottom and top to top. I then cut out wedges for the top of the spars and where the rear capstrips come together, and these also fit pretty well. I then test fit all the gussets, spars, and pieces, everything seemed go together nicely. To late to epoxy tonight, hopefully will get to epoxy the first rib this weekend. Hours: 3.0
30 March 2008 Removed first rib (Rib #1) from jig 1 to jig 2 and epoxied in place. Lessons Learned from first rib: 1.There is plenty of time to work the epoxy, don't rush. Approx .8oz for jig 1, and .7 for jig 2. 2. Epoxy does not stick to the plastic (page protectors) placed under gussets to prevent excess epoxy sticking. Excellent idea! 3. I mixed way too much epoxy for jig 1, and Waaaaaay too much for jig two (1 oz each). Only need about .8oz on first jig and less for second jig (first jig has the extra wedges etc). 4. Jig clamps tend to twist when tightening, which twists the gusset, need to add more washers to prevent this, otherwise it worked great. 5. An extra 2-3 inch piece of capstrip makes a great scraper for excess epoxy which ozzes out. Will need to router the gusset over hangs so wheeled router will need to ride smoothly along outside of cap strips. Hours: 1.0 Also cleaned and spray painted some engine parts this weekend, and bought a heavy duty parts cleaner and put in an order for a sandblasting box. Hours: 1.0 30 March 2008 Pulled rib #1 out of jig 2....First rib built!!! Will still need to router gussets. 1 April 2008 Glued rib # 2 in jig 2, and started rib #3. Hours: 1.0 3 April 2008 Pulled rib #2 out of jig 2, glued rib #3, steamed caps for rib #4. Hours: 1.0 5 April 2008 Pulled rib #3 out of jig 2, glued rib #4, steamed caps for rib #5. Hours: 1.0 8 April 2008 Pulled rib #4 out of jig 2, glued rib #5, steamed caps for rib #6. Hours: 1.0 10 April 2008 Pulled rib #5 out of jig 2, glued rib #6, steamed caps for rib #7. Put together new sand blasting cabinet. Hours: 1.0 14 April 2008 Pulled rib #6 out of jig 2, glued rib #7. Hours: 1.0 21 April 2008 Pulled rib #7 out of jig 2, glued rib #8, steamed caps for rib #9. Hours: 1.0 Took a break from posting daily: 10 June 2008-15 ribs completed, started cutting rib #16. Hours: 6.0 30 June 2008-19 ribs completed, started cutting rib #20. Missed a couple of days due to leg surgery. Hours: 4.0 1 Jan 2009-Up to rib number 25. Took a break to work at Tracy's Sports warehouse. Hours: 10.0
13 Feb 2009 After a break away, I have started working on the ribs again. Rib #26 completed. Have stoped to retool for the final 6 ribs which will have the additional braces added. I purchased enough hardware to make 14 more clamps, 7 for each side of the rib jig. Hours: 2.0 17 Feb 2009-End rib #1 completed Hours: 3.0 20 Feb 2009-End rib #2 completed Hours: 3.0 24 Feb 2009-End rib #3 completed Hours: 3.0 28 Feb 2009-End rib #4 completed Hours: 3.0 3 March 2009-End rib #5 completed, # 6 steamed Hours: 3.0 5 March 2009-End rib #6 completed Hours: 3.0
10-14 March 2009 - Completed the router table, and using a formica bit, started trimming the rib gussets. Because of the extra epoxy between the gussets, the router bit did not always ride smooth, so I made one pass over the entire rib, then sanded each gusset, then routed them again. Hours: 6.0 14-15 March 2009 - Made a jib to hold the ribs to trim the leading edge. Screwed and glued two small pieces of 3/4 inch oak, simulating the spar onto a piece of plywood. The next day, I placed each rib in the jig which I had clamped to the mitre saw. Trimmed each leading edge exactly the same, and did this in less then an hour, very simple and with very good results. Hours: 2.0