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Mark's Web Site
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Date: 12-31-2015
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Number of Hours: 6.00
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Manual Reference: 23-02
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Brief Description: Longeron shaping (23-02)
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Initially I cut out a piece of card stock to what I though was 95.4 deg, but it turned out that it was a little shy of that so I had to go back and increase the spread. I've determined that anytime you touch the longerons, they change shape, so I felt like I was starting over. Flare a little, twist it back, which takes out most of the flare, and then start again. After a while I was able to get it to meet, but ended up with a couple gouges from the crescent wrench, which I had to blend out. I also noticed the surfaces where a little bent, so I used a file to flatten them out. This whole process is quite time consuming and requires a lot of patience.
Once I got the ends flared I started back on the bend. The bend dies arrived in about 2 days so it worked out well. The dies worked great and it doesn’t take too much effort to get them to bend just right. I moved it every ½” and applied a little pressure each time. I protected the vertical edges with some electric tape and lubed it up with some boelube to let it slide easier. The dies kept it from twisting as much, but it would droop. So I had to iterate back and forth to add more bend (checking against the F-1234), then work the longeron over a 2X4 to remove the droop. I just did that by hand pushing down and straddling the 2X4 block to just bend it back a little and working my way along the length. Bottom line is that it takes a lot of back and forth from one technique to the next to bend, and then adjust for the bend by fixing the droop and twist. There isn’t an exact formula for success, except to try for yourself and keep working at it a little at a time. Be patient with the metal and yourself….plus the bending die was a huge help…good luck.
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Spreading apart to 5.4 degrees (95.4 deg)
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Set angle and kept spreading and twinsting until it met
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Used bending dies to help ben without so much twisting
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