Landing Gear

 

DCP_6088

Turning the neck features on the fuselage socket side of the landing gear

DCP_6090

Lathe dog is attached to the Ankle / wheel side of the gear leg to give the torque to turn between centers

DCP_6091

Tail Stock is off set with live center attached to create the landing gear taper.

DCP_6092

overview showing the full setup

DCP_6094

taper cut with the X axis in Auto Feed mode

DCP_6095

Making a ton of chips, passes are run until taper meets the small end diameter and the black sharpie line on the fuselage / socket side.

DCP_6096

Approaching the final cuts

DCP_6107

Final gear profile, geometry is similar to an RV leg but thicker due to the legs being made from 2024-T3 rod stock

DCP_6260

Ankle leg to axle adapter over all rough cut

DCP_6261

corners knocked off to aid in the turning operation.

DCP_6264

Ankle setup also turned between centers but with no tail stock off set.

DCP_6267

Custom made steady rest with ball bearing guides set up to start the boring process of the part.

DCP_6412

early boring bar setup bringing the ID to the finished 1.25″

DCP_6277

landing gear sockets also processed on the lathe providing thickness reduction in the low stress / no leg contact areas along with a tooth pastern for the bonding operation. cross bolt bushings are also produced.

DCP_6415

Showing the full axle > ankle bracket > Leg > socket setup.

DCP_6417

Another view of the leg setup.

DCP_6420

Detail view of the ankle bracket

DCP_6425

pair of ankle brackets with 4x AN4’s dry fitted

DCP_6934

centering, drilling and reaming setup for cross bolt, bushings are bonded to the tube, final step this whole area gets burred in a ton of layups and G10

DCP_6962

sockets cleaned and primed with Aeropoxy ES 6228 metal bond epoxy

DCP_7808

outside layout on the fire wall, gear come in from the corner at 45º

DCP_7809

Preliminary dry fit of the socket.

 

 

DCP_7908

alignment of the sockets via attaching the legs and brackets, once good to go the inside is tacked in with flox fillets, you can see the folding chair under the plane to help get in the right position.

DCP_7918

Flox / Metal bond epoxy fillet added and surface prepped for lamination.

DCP_7920

initial 7715 plies

DCP_7921

Kevlar 49 energy adsorbing ply

DCP_7927

7725 cover ply and peel ply edge treatment

DCP_7933

free end of the socket was cut to a bevel angle that intersects with the fire wall, the part is also bonded to the fire wall

DCP_7945

initial socket to fuselage connection laminates

DCP_7955

cardboard templates and final Carbon diagonal gussets

DCP_7960

diagonal gussets aligned

DCP_7964

tacking in the diagonal gussets with a Micro / Flox mix

DCP_7981

rotary razor cutting some 7715 for cloth kits

DCP_7982

diagonal gusset to fuselage layups w/ peel ply edge treatment

DCP_7984

inverted setup with some bungee cords for connection safety.

DCP_7996

Large surface area Cross bolt G10 plates

DCP_8012

thick “fillet G10 plate processing progression

DCP_8013

outside bevel and ID processed on the lathe, G10 Machines very well and chips are fairly easy to clean up.

DCP_8015

 

DCP_8017

G10 beef up structure for cross bolt

DCP_8019

compression bar gusset being fitted, tan masking tape to scribe in the fit with a Sharpie

DCP_8033

connection layup

DCP_8173

gear drag compression gusset processed

DCP_8198

ankle bracket alignment, setup for cross drill

DCP_8220

final wheel end of the landing gear assembly

DCP_8070

preliminary marks for the tail wheel socket pass thru

DCP_8095

Laser left to right alignment of the tail wheel spring & socket

DCP_8099

Angle alignment of the tail wheel socket & spring

DCP_8209

inside in process view of the backup gusset structures for the tail wheel spring along with much of the H stab pass thru returns & gussets

DCP_7871

Milling the tail wheel fork bracket

DCP_7879

turning the tail wheel spring to fork adapter.

DCP_7913

Near Finished tail wheel assembly

Advertisements

Leave a Reply

Please log in using one of these methods to post your comment:

WordPress.com Logo

You are commenting using your WordPress.com account. Log Out /  Change )

Google+ photo

You are commenting using your Google+ account. Log Out /  Change )

Twitter picture

You are commenting using your Twitter account. Log Out /  Change )

Facebook photo

You are commenting using your Facebook account. Log Out /  Change )

Connecting to %s