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Debo Cox - Zodiac 601 XL
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Date:  5-4-2008
Number of Hours:  6.00
Manual Reference:  6B
Brief Description:  Seat Belt Attachments, .063 Part Blanks

Even though I haven't made an entry in a few days, I've been busy after work, on breaks, and a little when I get home at night. I finished up my seat belt attachments, then went on to the brake cylinder brackets. Since I don't have my master cylinders yet, I decided to wait until they're in hand so I can get the dimensions exactly right. I spent the remainder of the last few days cutting out .063 part blanks. That's pretty thick stuff, and I was able to use the table saw with some success, but I got scared I was going to impale myself with flying shrapnel, so I finished up the bulk of the cutting on my band saw. I used the rip fence that came with the band saw and was able to get very straight, nice cuts. They'll require a little filing, but it's better than a trip to the emergency room. To understand my fear, you need to know that I got hit with a piece of flying wood kicked back from my saw once and it made a bruise on my belly that looked like I'd been hit with a baseball bat (felt like it too.) I REALLY didn't want to take any chances with thick, sharp metal and that kind of kinetic energy. If you're scratchbuilding, get yourself a decent band saw. You'll use it over and over. I've been able to make due with my little cheapo $99 Ryobi and a metal-cutting blade, but only because there's a big Delta I can use at work when the going gets tough (rib form blocks, etc.) After bending these parts, it's on to the .090 stuff. I'm getting dangerously close to beginning construction on the fuselage. Probably another week.
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Seat belt attachments

Seat belt attachments

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Brake cylinder brackets (raw form)

Brake cylinder brackets (raw form)

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.063 part blanks

.063 part blanks

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