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Old 03-21-2011, 08:49 PM   #393
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Thanks for all the suggestions. I forgot the six pack and explitives!! If I had to wreck the plywood out is it imperitve to replace it with the 1"-8 ply treated plywood that appears to hold the tank in? Or will the 3/4" variety treated work with some shims?

Thanks,

Guiseppe
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Old 03-22-2011, 06:25 AM   #394
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I would laminate to the removed thickness.
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Old 03-22-2011, 12:16 PM   #395
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My thought was to use 2 1/2" pieces and glue them together for the 1" thickness. I will send you some more photos when I get to that point.

Thanks,

G
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Old 03-28-2011, 10:45 PM   #396
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Fixing dents and scrapes

Could you elaborate on this a little better and how to make the tool please. Thanks
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Originally Posted by Aerowood View Post
I'm hesitant to bring up this procedure due to the beating I'll probably get by some members stating it's not possible, but here it goes anyway. Most people think that the end caps are made of 2024-T3. I've been working aircraft sheet metal for so long that I can identify alloys and heat treatment just by how the metal works. When I first started working on the skin replacement on my Globetrotter I noticed that the end cap aluminum was quite abit softer then the flat sheets. They are 2024 but I know they are not T3. The skins are most likely stretch formed 2024-0 and any hardening was by cold working as the sheet formed over the die, so the temper is most likely some where in the neighborhood of T1. Knowing this I fabricated the tool below to try and roll out some gouges and dents. On the larger ones I (here comes the naysayers) I heated up the area to semi anneal the aluminum. I then rolled out the dents and gouges with my "new" tool with some areas backed up with a lead shot bag. The aluminum was stretched in some areas and I proceded to shrink the aluminum back using heat and cold water. It worked better then I expected. The End

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Old 03-29-2011, 01:39 AM   #397
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SO... I too have been doing some "homework" regarding the alloys of the end caps and have determined that the end caps are not 2024-T3, And further research has brought out even more questions! The end cap aluminum in 58-63 (seven panel) and my guess but still researching 64-69 (Five panel) are not Alclad at all! I have through further research found that 58-63 (seven panel) it is a aluminum alloy that is no longer used. It was used in the aero space industry in the 50's and early 60's. The 2024 Alclad even with no temper was not used in the "stretch forming" process. Based on common aircraft production of the time. If you look at any 58 to 63 trailer with the interior completely out you will even see a visual difference in luster of the un-weathered aluminum color. It appears to be a tad duller. After even more research I believe that the Aluminum seven panel end caps are made with 5005 aluminum very uncommonly used in todays market place or in forming of today! So... this raises the real question if you can not or should not use 2024-T3, 3003, 5052, or 6061 then what should you use and what can you use? I have discovered 6013! it is 10-13% higher yield than alclad and it the choice of Boeing in all stretch forming! It also has the highest amount of Magnesium than non Alclad aluminum making it shine or polish up just as good as Alclad...

As per the mill spec!!!

"6013 Aluminum Sheet

6013 is a new medium strength aerospace alloy that provides improved corrosion resistance and formability for use in aerospace applications including primary aircraft structures. Alloy 6013 is an aluminum-magnesium-silicon-copper alloy that has yield strengths 12% higher than alclad 2024-T3 and is virtually immune to exfoliation and stress corrosion cracking. Industry use has demonstrated that 6013 in the T4 condition has better stretch forming characteristics than other aerospace aluminum alloys. Parts can be formed in the T4 condition and aged to the T6 condition without costly heat-treating or annealing operations. Heat treatable.

Applications
Uses for 6013 include primary structural applications including fuselage panels, leading and trailing edges and engine cowlings. Lockheed has chosen 6013-T6 for the fuselage of the Navy's P-7A aircraft. Canadair has specified 6013-T6 for the leading edges of the Regional Jet.

Questair has been producing the Questair kit aircraft since 1986 entirely from 6013. Major jet aircraft builders are considering 6013 for applications on large commercial aircraft.

Alloy 6013 is receiving consideration in most new programs taking advantage of the improved formability, lower density and corrosion resistance."



Todd
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Old 03-29-2011, 06:50 AM   #398
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Could you elaborate on this a little better and how to make the tool please. Thanks
I just did it by eyeball. I drilled a 1/4" hole through the middle of some 1.5" Al. bar stock and then turned a slight radius on the it. I did this all by eye no dimensions. I bent the "'U" bracket up out of .125 6061-T6 aluminum. I used a piece of 1/4" all thread for the shaft. The handle is also 6061-T6 .75 Dia with a Keensert threaded into one end to bolt the bracket to.
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Old 04-23-2011, 05:33 PM   #399
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Lap seams

I don't quit understand Airstream engineers, why in the world would one cut a huge hole in the upper lap seam to install a waste vent. Being I am changing the location and style of vents I had one to patch. I decided to do a flush type lap seam repair only because I can. I also decided to install stringers on the upper lap seams. I also removed the fridge vent to roll out some dents and install a screen over the opening. I ran into another can of worms. The fridge vent was only riveted on with a few randomly spaced rivets. It also had a 1/8" cork gasket that was rotted out. I couldn't let this go so I removed the whole nine yards cleaned up the corrosion and the rest of the mess, and reinstalled with a few extra rivets. I still need to install nutplates for the vent cover. The lap seam itself was shot together dry and there was minor corrosion there as well. I cleaned this up also and shot the whole mess together with sealant. I am slowly working myself to the top.
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Old 04-23-2011, 06:21 PM   #400
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Hi Kip I've got a question for you. What are the cleco's with the wing nuts on them? If you don't mind can you explain their function and uses.
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Old 04-23-2011, 06:27 PM   #401
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Those are known in the aviation industry as "draw clecos". they can be tightened up tighter to draw two pieces of metal together. The can also clamp up a thicker stack up of material. I have the 1/4" size that will grip over 2" of stack up. They are basically a step up from the standard spring clecos. They are available in all the standard diameters
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Old 04-23-2011, 06:32 PM   #402
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Thanks Kip I had a feeling from looking at them that was what they did. Very interesting. Who sells them?
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Old 04-23-2011, 08:51 PM   #403
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They are available where ever fine avaition tools are sold, however they are not cheap.

Draw Clecos

Wing Nut Draw Clecos Used

Wing Nut Draw Clecos New
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Old 04-23-2011, 08:55 PM   #404
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I also removed the fridge vent to roll out some dents and install a screen over the opening.
As usual Kip, you do work I can only dream of being able to do. How sweet it is!

I have a question: your roller for the fridge vent looks a like like something that would be the leg of a bed frame; the round wheel, nicely curved to the sides.

Did you fabricate that, or what it something off the shelf?
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Old 04-23-2011, 10:06 PM   #405
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Nice flush patch Kip. Wonderful work as usual. It never ceases to amaze me as to what Airstream engineers conceive and what the assemblers do. There are probably 15 rivets I've found on Abby that were not bucked at all when she was made. Sometimes i think she was made on a Monday after the Superbowl or a Friday afternoon before a Jethro Tull concert. Someday, she'll be perfect!
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Old 04-24-2011, 09:28 AM   #406
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Did you fabricate that, or what it something off the shelf?
I made it from scratch. I plan on making another and donating it to the FCU Restoration Rally Raffle.
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