January 30, 2007



Started out today where I left off yesterday.  I decided to start with a different clip after drilling the wrong size holes yesterday.  This one is made from some of the angle stock.
 


Here's the angle marked before cutting.  This view is looking from the back of the angle.  The lines really are straight - the angle of the AL makes them look crooked.



First cut with the snips.  I cut it just a bit long so I can clean up the edge with a file & some sandpaper.  The snips leave a "textured" edge because the teeth aren't smooth.



Here's the angle after cutting.  There's plenty of extra material to clean up the edges and get the dimensions perfect.



After trimming and deburring.



Perfect length.  Yet again, the full size drawings are GREAT.



Another view showing the piece compared to the drawing.  This one is an easy dimension - some of this stuff is measured to the 64th.



I had to stare at this picture for a sec to realize what I was trying to document.  There is a mark at the top of the angle to cut he angles on each end of the bracket.  The ruler runs from this mark to the outside edge of the bottom flange.



Here's a fuzzy pic showing the bracket after cutting the end angles.  Hopefully this makes the last image a bit more clear.



Marking the bracket for the pilot holes called out on the drawing.



Before drilling the holes in the bracket I use a spring loaded punch to help keep the bit from walking.



All of the holes punched, just before drilling.  It took a while to get the laser sighted in on the drill press but it is handy for getting the bit aligned.



And through the magic of the internet, there are two.  The steps are the same for the second one (go figure).



Here the .060 is marked to make T06-05.  I also marked the other parts that get cut out of the .060.



After cutting it on the bandsaw.  I wax the blade for every cut so it lasts longer.



A New Yankee Workshop moment - "The most important safety tip is these - safety glasses."



The bracket after bending on the brake.  The location of the holes allows them to be drilled before or after bending.  I chose to do it after.



The pilot holes laid out and drilled.  The cross hairs on the drawing are almost invisible, but they're there.



Here I started cleaning up the front spar.  The part number sticker says "finish work required" - they're not kidding.  The machining process leaves a pretty rough surface.  Sorry the pic is so dark, I must have had the flash off.



Here's the spar after an hours worth of scotchbrite and sandpaper.  It still needs work, but its getting there.



Its hard to see in this photo, but the scotchbrite wheel is leaving very shallow gashes in the surface.  It works fast, but its just too aggressive.  I'll be polishing this out with sandpaper.



Here's another shot - the marks almost look like ripples.  They do come out with some polishing though.




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