New Cordless Hacksaw

[Brian Jackson]

In an earlier thread (http://www.rotaryforum.com/forum/showthread.php?t=2502) a gentleman asked about "building spaces" and constrictions we've cleverly overcome in pursuit of our aircraft projects. I'm happy to report yet another, and surprisingly, the addition of a hack saw of all things. Until yesterday I would NEVER have mentioned Gyroplane and Hacksaw in the same sentence... We're post-Wright Brothers builders after all; we know better. But here's where it gets strange...

This afternoon I bought a precision hack saw, a great blade and a Cheap-O mitre box just to see what I could do on intelligent muscle power alone. I fully expected a cross-cut resembling some Neanderthal bone-pounding art. I was wrong.

Tonight I practiced with a 1/8" long scrap trimming if 2" X 2" X 1/8" 6061-T6. a mirror-like perfect surface resulted. Damn, if you use your head about it, you can build anything. Literally. Keep in mind how many World Voyages were made in the 1700s before powertools were even a pipe-dream. Where there was a will there was a way.

Well I did something crazy and actually tried to polish a part and square it up with a flat-blade file. It was a perfect mirror.

Can a GyroBee be built, technically, with no power tools other than a drill, and be considered a "safe" gyro"? I believe it can. Prove me wrong.

[Ron Marlett]

There is an old saying "It is not what you have but how you use it" If you are skillfull enough and have the time, you could build one with NO power tools.

Ron

[Brian Jackson]

There is an old saying "It is not what you have but how you use it"...
Funny, my wife tells me that :D. Seriously though, I won't skimp on the drill press though. However if I'm getting consistently great results with the hand tooling, I don't mind putting in the elbow grease. I could stand to lose a few pounds anyway!

Cheers,
Brian Jackson

[KDOG]

Considerably cheaper too. Brian did you get your 1.5" angle yet? Got mine today. My days off are tomorrow and thursday. Guess what I'm doing tommorrow? I have 2 more orders from wicks coming - some more angle (1") and another order that contains alot of nuts and bolts, another keel and the alodine.

I'll be working on the engine mount tomorrow. The plans call for a weird measurement on the horizontal pieces. They are measured at 18.938 inches!!! Well, I found that .9375 is 15/16ths so I figure I'll make it an even 19" and by the time I file and sand I will have taken at least a 16th off. I am redoing my keel, cluster plates and maybe the seat braces, I may not have to. Wish me luck!!! Muhahahaha!!<evil laugh>

[banaari]

...However if I'm getting consistently great results with the hand tooling, I don't mind putting in the elbow grease. I could stand to lose a few pounds anyway!...

My sentiments entirely - this is something I've been contemplating, what to do about the cutting. Frankly, (speaking from utter inexperience here!) there doesn't seem to be THAT much of it... I simply assumed from the outset that with a project of this magnitude there'd be a lot of hard work involved.

John

[Vance]

It sounds like you fellas are starting to understand fabrication. Using a manuel hack saw is even more fun. There is great pleasure in sneaking up on a dimension with a file. Using a center punch is a hard earned skill. You may find that you need a better scale if you have to fudge that far on your measurements, or even a dial caliper. It helps to scribe a V next to the mark on your scale instead of a single mark. A square is also a very usefull lay out tool. Good luck, Vance

[Brian Jackson]

Hi Vance.
Yes, there is a certain satisfaction in "muscling in" a perfect edge... I can kick back with my feet up listening to classical music while I'm filing the cut edge down to a square mirror-fine surface with the skillful touch of a flat file. It's almost therapeutic in a way. With care and attention to detail, I'll have a CNC-accurate airframe that I can trulely say is literally hand-made. Center-punching is being done using blue layout dye and a .0005" accurate caliper micrometer to mark the crosshairs. All holes will be .007" undersized, then final reamed to exact (smooth bore) diameters. I'm truly going about this like a craftsman approaches a new work of art. My only hope is that the quality is evident when she's ready to flex her blades...

[Vance]

Yes Brian, I believe you've got it except for the use of the term "muscling in". Part of what makes it cathartic is how little muscel it takes to make art. Thank You Vance

[KDOG]

Good grief, Brian. You are really going crazy with this aren't you? In a good way I meant. I can only cut my engine mount pieces today I have to wait for the new Keel piece to get here before I do anything else. :(

In a bit I will order the gear tubes, getting it up on the gear is the milestone that I'm looking forward to, but I want to get the parts painted first.

[gyroman]

KDOG,

I would test fit the entire airframe together before you start painting. You may need to file/sand something and if you have already painted then you have to redo...

[KDOG]

Not a bad idea. I may wait till spring to paint it, cuz its starting to get cold and its not good to paint outside in the cold... I have the alodine coming so I'm good as far as the prep goes. Can I etch and alodine and then leave it till spring? I am tempted even to leave it unpainted till a get a few dozen hours of flight in it so I can check for cracks and the what not. Opinions?

[Ralph]

KDOG,

In your situation, I would assemble the major airframe components for fit using hardware-store hardware. Once you know everything goes together properly, take it apart, paint/finish everything, and then put it back together with aircraft hardware.

Personally, if you might not paint it until Spring, I would wait until the disassembly (above), alodine and finish it, and then go for final assembly.

If you fly it first, you will have to disassemble absolutely everything and you will waste a LOT or aircraft nuts!. You will not be putting yourself at any significant additional risk by painting/finishing the machine prior to flying it for the first time.

Ralph

[scottessex]

The only problem with flying it unpainted, is once you are flying, are you going to want to take it "out of service" and paint? :confused:
NO!
Not being able to fly will be killin' ya, I know! I was going to take mine apart and paint it "later" :eek:

My rebuild, everything will be cut and fitted, then it will be dissassembled and painted, THEN I will do the wiring. Otherwise it will never be painted if i fly it first.

I have built and painted motorcycles for years, yes customs, Unlike what you see on TV, it is put together many times until everything fits, then once complete, it is taken apart and painted, then assembled for the final time.


You will be much happier.

[KDOG]

I think you all are right. I just have to wait for my next order from Wicks - Oh the agony of waiting!!! Its like waiting for Christmas as a kid. Thanks for the tips guys...