Bulkhead templates prepared

Build hours: 4

So it has been a few days since the last post. No, we haven't given up already! The bulkhead templates have been copied, cut and pasted to poster board to create a firm template. It was a real treat to create individual bulkheads out of the plans which have all the bulkhead outlines intertwined on 2 pages. In the hopes to document each step I will attach some pictures.

Also, after debating to buy or build some type of bending brake with shop space at a premium and budget to consider, I took a shot at building one. The 48" brake was built from red oak 1x4s, a piano hinge and a piece of steel angle from Lowes for approx. 40$. The brake bent a 45" piece of 2024-T3 .016 with no problem. The brake appears to be suited for the task.

Coming soon - bulkhead forming...

Tools Used

Tool List Updated 8/29/2007

Hand Tools:

14" Andy Snips (Malco MC14N - this size is really needed on the .040 matl)

10" Tin Snips (Wiss)

10" Fine File

Countersink - small hole deburring and rivet countersinking

(100 degree required for AN countersunk rivets)

( 120 degree for Cherry-Lok countersunk blind rivets)

Deburring Tool - large hole deburring

Homemade 48" Leaf Brake

http://cwsnyder2001.blogspot.com/2007_06_01_archive.html

Homemade 17" Heavy Duty Leaf Brake

http://cwsnyder2001.blogspot.com/2008_08_01_archive.html

Dead Blow Hammers (Harbor Freight)

Cleco Pliers

Power Tools:

Drill Press

Dewalt 12V Drill

Band Saw - cut out bulkhead forms, could have used jigsaw

JigSaw - cut out bulkhead forms

Belt Sander - cleanup bulkhead forms

Air Tools:

Air Nibbler - rough cut inside bulkhead patterns

Air Riveter for blind rivets - Harbor Freight

Air Drill - good for tight spaces

Air Angle Drill - good for tighter spaces

Air Hammer - can be used for riveting on the cheap

(A model with 3000 bpm or less should be used)

Rivet Gun - ATS 2x from Aircraft Spruce

(because I want to be a REAL airplane builder:))

Misc:

1/8", 3/16", 1/4" drill bits

Unibit/Step Drill

1 1/4" hole saw

1 1/2" hole saw
6" Vise

2" C Clamps - 16+

4" C Clamps - 4+

Batting gloves

Compass

Sharpie Ultra Fine Pens

(Red shows up the best, also, it doesn't look like a shadow when viewed through a hole)

6" Machinist Rule

Bucking bar from A&P school days

3/32" Clecoes - 300 (Aircraft Spruce)

1/8" Clecoes - 200 (Aircraft Spruce)

The blog begins...

Build hours: 0

A friend and I have decided to build two Hummel Ultracruiser ultralights. The plans have been purchased and reviewed. The shop is being updated and cleaned and materials for the bulkheads has been purchased. Hopefully, pictures of the build progress will follow shortly! In the meantime, I have posted a few pics of the Ultracruiser (UC) and prior projects.

Hummel UltraCruiser Prototype

Kolb Firestar I (current ride)

Titan Tornado I (prior project)

Pegasus Quantum 503 (last trike)