Construction Log
STOL King Experimental Airplane
This site is dedicated to the construction of a plans-built airplane
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2/1/05 - 1.0 hours - Total Time 114.0 hours.
Continued to work on tubing layout.  Made some more jig blocks.
2/2/05 - 1.0 hours - Total Time 115.0 hours.
Continued to work on tubing layout.  Cut and fit vertical at lower longeron and Station 0.  Used joint jigger to cut horizontal at Sta. 84.  Made a few more jig blocks.  Checked the table for accuracy one more time.
2/4/05 - 1.5 hours - Total Time 116.5 hours.
Continued to work on tubing layout.  Cut and fit vertical at upper longeron and Station 0.  Fit horizontal to top longeron at Sta. 84.  I used 45 degree cuts on these to keep them sealed.  I was just eye balling it until I made a 45 degree line on the table with a compass.  These first few have taken some time, but I think I will get faster as I go.  Still learning this part.  You can't put the metal back on once it's ground or cut off.  The moving table with the belt sander and grinder is already coming in handy!  Keeps it close.
2/5/05 - 1.5 hours - Total Time 118.0 hours.
Continued to work on tubing layout.  Cut and fit vertical between longerons at Sta. 28 1/2 and at Sta. 42 3/4.  Continued to use the tubing notcher.  So far, I haven't broken any hole saw teeth.  I had broken quite a few when practicing.  I think I was just going too fast.  I have slowed down the cuts, and turned-up the mist cooler. 

The first cut is easy.  Measuring out the second cut is a little more difficult, especially if you have to figure in an angle.  I have been using the T-bevel to transfer the angle.  Then, using a short piece of tube in the already cut end, I line the fish mouth up with the axis of the drill arbor.  Just like a golfer lining up a put.

With just a little trimming on the grinder and disk sander, each tube fits perfectly.  I have also been spraying down the finished ends with Rust Lick, since they are wet from the coolant.
2/7/05 - 2.5 hours - Total Time 120.5 hours.
Continued to work on tubing layout.  Cut and fit vertical between longerons at Sta. 54 1/2 and at Sta. 66 3/4.  Also fit diagonal at Sta. 28 1/2 and forward.  This was a new experience because of the acute angle of cut required.

For this I turned the tubing clamp upside down, (a trick I learned from Darin Bishop) and used a couple of small clamps to hold it in place.  I may just continue to use the notcher this way, as it keeps the coolant from running inside the tubing.

It took me quite a while to fit this piece.  Partly because I'm learning the nuances of the task, but I also cut one of the verticals too short this morning.  So, I'm trying to not end up with a bunch of expensive wind chimes.
2/9/05 - 1.0 hours - Total Time 121.5 hours.
Continued to work on tubing layout.  Cut and fit two diagonals forward of Sta. 28.5.
2/10/05 - 1.5 hours - Total Time 123.0 hours.
Cut and fit 1/2" horizontals at Sta. 108 and 138.  Made some .0625 shims to keep 1/2" tubing at correct height off table.  Practiced welding a 5/8" .035 joint.  Compared to the odd sized tubing I had been practicing on, this was very easy.  I still plan to practice quite a bit more  before I start to final weld, but that is some time away.