Drawings now online
I uploaded scans of all the Sopwith Pup drawings, SL fittings, etc to Mediafire... over 400 files in total!
Here's a link to all the files.
Bits & Pieces
Still not finding a huge amount of workshop time, but have at least been making a progress recently on the sourcing of various bits & pieces, with help from Jim McTaggart (laser-cut metal fittings, streamlined trailing edge tube) and Tim Rayner (fuel tank cap). Acquired a CD with the original plans scanned into it, which will be a useful resource. My big acquisition has been a Type 5/17 compass in really nice condition. It set me back quite a tidy little sum but Janet agreed to the purchase on the basis of it being an investment. Which is true, it definitely won't decline in value. It has been delivered to my parents' house in England and I'm excited to pick it up when I'm over in London next weekend.
Catching Up...
Oh dear... it has been a looooooong time since I updated the blog!
My main excuse is work - - I got quite seriously diverted by the big organizational "push" that we put into AirVenture this summer and never quite picked things up again afterwards.
It's not all bad news, there has been some progress. Over the summer I picked up a few bits & pieces from eBay. Here's a photo of my stash:
Which includes the Zenith altimeter restored and fully functional; a MkV pilot's stopwatch restored and fully functional, plus a replica housing that will attach it the dash; and two never-used Air Ministry brass magneto switches!
Visited Jack Kearbey not once but twice (will report on that in more detail at some future point). Placed a bid on an original 80hp Le Rhone in full working order with all accessories, but didn't get it (again, intend to post pictures & report later).
But progress on the actual project has been pretty slow. Jack kindly gave me a really nice piece of ash from which I can create a tailskid. Right now it's roughed-out and I am sanding it to a finish. I've also acquired the basswood for the instrument panel and all the material for the wing leading edges. Have been working out how to make those, and think that will be my starting point in the new year. My intent then is to do much better than over the past 6 months!
My main excuse is work - - I got quite seriously diverted by the big organizational "push" that we put into AirVenture this summer and never quite picked things up again afterwards.
It's not all bad news, there has been some progress. Over the summer I picked up a few bits & pieces from eBay. Here's a photo of my stash:
Which includes the Zenith altimeter restored and fully functional; a MkV pilot's stopwatch restored and fully functional, plus a replica housing that will attach it the dash; and two never-used Air Ministry brass magneto switches!
Visited Jack Kearbey not once but twice (will report on that in more detail at some future point). Placed a bid on an original 80hp Le Rhone in full working order with all accessories, but didn't get it (again, intend to post pictures & report later).
But progress on the actual project has been pretty slow. Jack kindly gave me a really nice piece of ash from which I can create a tailskid. Right now it's roughed-out and I am sanding it to a finish. I've also acquired the basswood for the instrument panel and all the material for the wing leading edges. Have been working out how to make those, and think that will be my starting point in the new year. My intent then is to do much better than over the past 6 months!
05/22/08 8:00
Have been extremely busy at work so not a very productive week in terms of project work... glued up a rib, but broke it being too heavy-handed pulling it out of the jig. Glued up another but got very frustrated with it.
The Zenith altimeter came back from the watchmaker, he has built a lovely little gear for it, think it will work perfectly now. Delighted... will reassemble and post photos.
Despite frustrations in the workshop had an excellent experience on Saturday, flew down to visit Joe Hauk's Pup project in New Berlin. Joe was a very generous host and my mind is still spinning with all the information he gave me, and the amazing tour he gave me of his basement.
Captioned slide show follows:
Have been extremely busy at work so not a very productive week in terms of project work... glued up a rib, but broke it being too heavy-handed pulling it out of the jig. Glued up another but got very frustrated with it.
The Zenith altimeter came back from the watchmaker, he has built a lovely little gear for it, think it will work perfectly now. Delighted... will reassemble and post photos.
Despite frustrations in the workshop had an excellent experience on Saturday, flew down to visit Joe Hauk's Pup project in New Berlin. Joe was a very generous host and my mind is still spinning with all the information he gave me, and the amazing tour he gave me of his basement.
Captioned slide show follows:
05/11/08 2:30
Best weekend in ages, feel like I've accomplished a lot in terms of "getting organised". Emailed with John Brecher who is running the student project to build a Sopwith Pup in Dallas. He is putting me in touch with a person in Texas who has already put all the Sopwith fittings into CAD and can get them cut out with water jet. John says the quality is very high. He also recommends Western Aircraft Spruce in BC as supplier for the main structural wood. I must admit I am not thrilled with the quality of what I've been receiving from Aircraft Spruce and Specialty. Some of the wood is excellent, tight grained, but some of it is a bit rough. But my biggest beef is (A) I ordered two lots of capstrip from them both ostensibly 3/8" thick; but there is a significant difference, probably 3/32" between the two orders. (B) I asked for a mixture of 5 ft and 6ft lengths in the second order and they sent all 5ft, which is not very helpful.
Update 5/12/08 : I spoke to Spruce today and they are waiving the shipping on a new order of 6ft lengths... so they are partially redeemed...
Best weekend in ages, feel like I've accomplished a lot in terms of "getting organised". Emailed with John Brecher who is running the student project to build a Sopwith Pup in Dallas. He is putting me in touch with a person in Texas who has already put all the Sopwith fittings into CAD and can get them cut out with water jet. John says the quality is very high. He also recommends Western Aircraft Spruce in BC as supplier for the main structural wood. I must admit I am not thrilled with the quality of what I've been receiving from Aircraft Spruce and Specialty. Some of the wood is excellent, tight grained, but some of it is a bit rough. But my biggest beef is (A) I ordered two lots of capstrip from them both ostensibly 3/8" thick; but there is a significant difference, probably 3/32" between the two orders. (B) I asked for a mixture of 5 ft and 6ft lengths in the second order and they sent all 5ft, which is not very helpful.
Update 5/12/08 : I spoke to Spruce today and they are waiving the shipping on a new order of 6ft lengths... so they are partially redeemed...
5/10/08 10:00
Best day’s work in a long time. Stopped in at the Weeks hangar first to look at the Bleriot project which is really coming together, the fuselage is taking shape and the whole thing is starting to look like a real aeroplane. Glued up another rib… just two more to go before I have completed the full set of “Type A” ribs! Cut out enough webs for another 6 ribs or so. Will do the 12 “Type C” ribs next, because I have run out of 6ft lengths of capstrip and will need to order more from Aircraft Spruce; the “Type C” ribs are shorter so I can use up the many 5ft lengths that I have. Cleaned up about a month’s worth of sawdust. Got the scrollsaw working again… found that a fuse had popped. Stripped the paint from the Zenith altimeter, tidied up the corrosion and repainted it with black enamel. Visited the clock repair shop to see if they can fix the broken gear on the altimeter. The repairer was not in, but the assistant said he’s fixed aircraft instruments before, so I will stop in later in the week. Studied the plans for the first time in quite a while… I think I’ll order the spar and nosing material next, and also make the instrument panel. Overall it’s been quite a productive week. Alan Westby was in San Diego and shot a whole bunch of detail photos of their Pup. I also talked to Jack Kearbey in Tulsa who is building a Pup – made arrangements to pay him a visit in early June. His work is legendary.
Best day’s work in a long time. Stopped in at the Weeks hangar first to look at the Bleriot project which is really coming together, the fuselage is taking shape and the whole thing is starting to look like a real aeroplane. Glued up another rib… just two more to go before I have completed the full set of “Type A” ribs! Cut out enough webs for another 6 ribs or so. Will do the 12 “Type C” ribs next, because I have run out of 6ft lengths of capstrip and will need to order more from Aircraft Spruce; the “Type C” ribs are shorter so I can use up the many 5ft lengths that I have. Cleaned up about a month’s worth of sawdust. Got the scrollsaw working again… found that a fuse had popped. Stripped the paint from the Zenith altimeter, tidied up the corrosion and repainted it with black enamel. Visited the clock repair shop to see if they can fix the broken gear on the altimeter. The repairer was not in, but the assistant said he’s fixed aircraft instruments before, so I will stop in later in the week. Studied the plans for the first time in quite a while… I think I’ll order the spar and nosing material next, and also make the instrument panel. Overall it’s been quite a productive week. Alan Westby was in San Diego and shot a whole bunch of detail photos of their Pup. I also talked to Jack Kearbey in Tulsa who is building a Pup – made arrangements to pay him a visit in early June. His work is legendary.
4/30/08 5:00
Hasn't been a great couple of weeks... have managed to get to the hangar for 3 brief visits, on each occasion I glued up a rib. Am now up to 9 of them. Had been hoping to do four per week but the reality has been more like two. However, the pile is slowly growing. Obtained a Zenith Height Gauge from eBay for $300. It's not in great condition and is broken (would pay two or three times that for a good one) but is exactly the right type for a Sopwith Pup. Having received it, I am pretty happy with my buy. The main altimeter mechanism (internal) seems to be in perfect condition and working order. What I need to fix is the external paintwork (very do-able) and one small gear part internally (will be harder, but is not a particularly complicated thing and am sure I can track one down). Talked some more to Kermit Weeks during the EAA Board meetings and he is convinced I should shoot for a 80hp Le Rhone.
Found an interesting website, a technical college in Dallas is building a Pup replica. Some useful info here. http://www.aimschool.com/?cat=5 This comment on their blog resonates: "Students are getting tired of ribs. 104 nose/false ribs, 48 main ribs, 20 trailing ribs, and 28 unique ribs!!"
Hasn't been a great couple of weeks... have managed to get to the hangar for 3 brief visits, on each occasion I glued up a rib. Am now up to 9 of them. Had been hoping to do four per week but the reality has been more like two. However, the pile is slowly growing. Obtained a Zenith Height Gauge from eBay for $300. It's not in great condition and is broken (would pay two or three times that for a good one) but is exactly the right type for a Sopwith Pup. Having received it, I am pretty happy with my buy. The main altimeter mechanism (internal) seems to be in perfect condition and working order. What I need to fix is the external paintwork (very do-able) and one small gear part internally (will be harder, but is not a particularly complicated thing and am sure I can track one down). Talked some more to Kermit Weeks during the EAA Board meetings and he is convinced I should shoot for a 80hp Le Rhone.
Found an interesting website, a technical college in Dallas is building a Pup replica. Some useful info here. http://www.aimschool.com/?cat=5 This comment on their blog resonates: "Students are getting tired of ribs. 104 nose/false ribs, 48 main ribs, 20 trailing ribs, and 28 unique ribs!!"
Here's another excellent video from the EAA Hints for Homebuilders series. This is one of the first videos we made and I saw this about 2 months ago. Have been using exactly this techniquie to bend the capstrips on my ribs, with one minor exception - - rather than soaking the wood for 24 hours, I have been boiling up the kettle and soaking the wood in hot water for about an hour.
General update...
Talked to Joe Hauk in New Berlin, will go and visit his project some time soon after the EAA Board meetings. Acquired my first original part from eBay, a stopwatch that will go on the instrument panel. Will try and get some photos up soon. It's the "real deal" exactly the correct type for a Sopwith Pup with the Air Ministry stamp on the back. Looks to be in great condition but doesn't run, so maybe I will get it repaired. I have also picked up a Zenith altimeter from eBay, again of the correct type, although I know this one isn't in good condition. Am starting to think what my next task will be (beyond wing ribs). It will take me ages to chew through all the different ribs, and I feel the need for some variety in my work (also, I can only really do one rib per day).
Talked to Joe Hauk in New Berlin, will go and visit his project some time soon after the EAA Board meetings. Acquired my first original part from eBay, a stopwatch that will go on the instrument panel. Will try and get some photos up soon. It's the "real deal" exactly the correct type for a Sopwith Pup with the Air Ministry stamp on the back. Looks to be in great condition but doesn't run, so maybe I will get it repaired. I have also picked up a Zenith altimeter from eBay, again of the correct type, although I know this one isn't in good condition. Am starting to think what my next task will be (beyond wing ribs). It will take me ages to chew through all the different ribs, and I feel the need for some variety in my work (also, I can only really do one rib per day).
04/14/08 2:00
Missed a couple of weeks there due to flying down to Sun n Fun and back in the Cub... it was a long haul - - 2,800 miles and 32 flying hours! In my absence a new supply of wood has arrived from Aircraft Spruce, so I should be set for quite a while. Also Janet got some new shelving and laid out the hangar and tools in a much better way. 5 wing ribs completed to date, also I have made the pattern for the centre web of the "Type B" rib, of which there are 6. Tonight I prepared another 2 ribs worth of materials, will try and get them glued up later in the week. I received a CD of photos of the Pup in the San Diego Air & Space Museum, kindly sent to me by Peter Barker of Virginia, who kindly responded to my request via The Aerodrome forum (which is my main hang-out for building information). Slide show below - -
Missed a couple of weeks there due to flying down to Sun n Fun and back in the Cub... it was a long haul - - 2,800 miles and 32 flying hours! In my absence a new supply of wood has arrived from Aircraft Spruce, so I should be set for quite a while. Also Janet got some new shelving and laid out the hangar and tools in a much better way. 5 wing ribs completed to date, also I have made the pattern for the centre web of the "Type B" rib, of which there are 6. Tonight I prepared another 2 ribs worth of materials, will try and get them glued up later in the week. I received a CD of photos of the Pup in the San Diego Air & Space Museum, kindly sent to me by Peter Barker of Virginia, who kindly responded to my request via The Aerodrome forum (which is my main hang-out for building information). Slide show below - -
04/01/08 7:30
90th anniversary of the Royal Air Force today. Have completed a grand total of 4 ribs now, seems to be taking a couple of hours to complete each one, plus they each need at least a night clamped in the jig for the glue to set. Janet helped me make one on Sunday evening that turned out particularly well. T-88 glue is excellent for strength but pretty gloopy stuff to work with... I've learned that a syringe comes in very useful for dispensing it into the channel in the capstrip, sort of like icing a cake.
Visited the Weeks Hangar on Saturday to look at the Bleriot project. Got some good ideas and advice from Gary Buettner.
90th anniversary of the Royal Air Force today. Have completed a grand total of 4 ribs now, seems to be taking a couple of hours to complete each one, plus they each need at least a night clamped in the jig for the glue to set. Janet helped me make one on Sunday evening that turned out particularly well. T-88 glue is excellent for strength but pretty gloopy stuff to work with... I've learned that a syringe comes in very useful for dispensing it into the channel in the capstrip, sort of like icing a cake.
Visited the Weeks Hangar on Saturday to look at the Bleriot project. Got some good ideas and advice from Gary Buettner.
3/26/08 2:30
Hooray, finished my first wing rib! I showed my practice pieces to Timm who gave me some good advice on gluing. On Monday evening I glued up my first full rib. Found myself using about a dozen clamps as well as the jig, to get everything in nice and tight. Was away for a couple of days and came back this evening to pull it out. Had been worrying about having glued the rib to my jig but it came out without too much fuss. The tip of putting greaseproof paper down really worked well. Am pleased with the result... it looks & feels "right". Will have the experts look at it before declaring it usable, though. Now I need to get the production line running... only 45 more to go! I think they will take me a couple of hours each.
Hooray, finished my first wing rib! I showed my practice pieces to Timm who gave me some good advice on gluing. On Monday evening I glued up my first full rib. Found myself using about a dozen clamps as well as the jig, to get everything in nice and tight. Was away for a couple of days and came back this evening to pull it out. Had been worrying about having glued the rib to my jig but it came out without too much fuss. The tip of putting greaseproof paper down really worked well. Am pleased with the result... it looks & feels "right". Will have the experts look at it before declaring it usable, though. Now I need to get the production line running... only 45 more to go! I think they will take me a couple of hours each.
3/23/08 17:00
Two steps forward, one step back...
After feeling that I'd made a lot of progress, last weekend ended in disappointment as I realised that I'd been working to incorrect information. The "full size wing rib" diagram on the plans was not in fact full size. It meaured 58 inches, when the chord is supposed to be 61.5 inches. There must have been some shrinkage in the plans copying process. It was (in hindsight) a stupid error not to have measured it before launching into my work...but, lesson learned. Apart from the capstrip, everything else I've made went into the scrap bin.
I was a bit depressed at first about throwing away so much work, but after a while it was a relief to think that I found the error as early as I did. Also, a lot of my work wasn't wasted - a lot of it is "thinking & working things out", that won't need to be repeated.
Played with the large plans copier at Kinkos and after some trial and error discovered that increasing the size to 102.2% got all the dimensions right. Spent most of Saturday making patterns for the front, middle & rear plywood sections. Shaping and sanding the lightening holes is no less laborious the second time around. But everything seemed to go a lot faster, and was helped by having a second copy of the full size wing rib that I could cut out and use.
Started making my wing rib jig today, and made quite a lot of progress with it. Next step will be to glue up my first rib. One of the EAA "Hints for Homebuilders" videos was really helpful in giving me an idea to use locking cams in the jig. These will work perfectly (I think).
Experimented with soaking and pre-bending my capstrip, also I have glued up a couple of sample pieces to start getting a feel for gluing (those discarded pieces in the scrap bin coming in useful...) Ordered a load more wood from Aircraft Spruce.
Paul Poberezny and Chuck Parnall stopped by this afternoon. Paul seemed satisfied with the quality of my work, which was comforting to hear. This week Paul put me in touch with a guy called Joe Hauk here in Wisconsin who is about 5 years into a Pup project. He sent me some photos and has done great work. Look forward to catching up with him at some point.
Two steps forward, one step back...
After feeling that I'd made a lot of progress, last weekend ended in disappointment as I realised that I'd been working to incorrect information. The "full size wing rib" diagram on the plans was not in fact full size. It meaured 58 inches, when the chord is supposed to be 61.5 inches. There must have been some shrinkage in the plans copying process. It was (in hindsight) a stupid error not to have measured it before launching into my work...but, lesson learned. Apart from the capstrip, everything else I've made went into the scrap bin.
I was a bit depressed at first about throwing away so much work, but after a while it was a relief to think that I found the error as early as I did. Also, a lot of my work wasn't wasted - a lot of it is "thinking & working things out", that won't need to be repeated.
Played with the large plans copier at Kinkos and after some trial and error discovered that increasing the size to 102.2% got all the dimensions right. Spent most of Saturday making patterns for the front, middle & rear plywood sections. Shaping and sanding the lightening holes is no less laborious the second time around. But everything seemed to go a lot faster, and was helped by having a second copy of the full size wing rib that I could cut out and use.
Started making my wing rib jig today, and made quite a lot of progress with it. Next step will be to glue up my first rib. One of the EAA "Hints for Homebuilders" videos was really helpful in giving me an idea to use locking cams in the jig. These will work perfectly (I think).
Experimented with soaking and pre-bending my capstrip, also I have glued up a couple of sample pieces to start getting a feel for gluing (those discarded pieces in the scrap bin coming in useful...) Ordered a load more wood from Aircraft Spruce.
Paul Poberezny and Chuck Parnall stopped by this afternoon. Paul seemed satisfied with the quality of my work, which was comforting to hear. This week Paul put me in touch with a guy called Joe Hauk here in Wisconsin who is about 5 years into a Pup project. He sent me some photos and has done great work. Look forward to catching up with him at some point.
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