Small parts, like this Hummel Bird belly cowl, are so complex that they need every tool In the shop! (Riek- ert Aviation, Texas)

SHEET METAL HAS BEEN used for mil- to tell about his years at Rolls- lennia to make gold funeral The Wheel Royce and wheeling polished masks, copper artworks and ves- Royal Air Force aircraft panels dur- sels, and steel armor. However, A sheet metal shaping machine ing World War II. because local smiths hand-ham- mered the entire supply of it, the KENT WHITE Designs & Capacities application of sheet metal stock Many of the full-size English ma- was limited. chines, such as Edwards, Brown When the water wheel started and Boggs, etc., had cast-iron turning grinding mills, some frames on the full-size models smart fellow developed the trip (48-inch throat) and a 4-inch hammer for working metal and flame-cut steel plate in the the lathe for turning wood and smaller (28-inch throat) models. metal. From these conveniences Early models of the large cast-iron came "round" parts, which were English wheels had Babbitt bear- then used to make even rounder ings in them, and when set with parts, like metal bushings and high pressures, they could be a bearings. Once bearings and little difficult to push and pull! shafts were reliable, the machine- These heavy cast-iron frames produced sheet metal held rough are nice for hard and/or thick thickness tolerances, and a sub- materials, such as .090-inch 2024 stantial trade was gradually born. T3 aluminum. Over the years, A few hundred years ago a frames of flame-cut weldments jewelry smith in central Europe These men are using a lightweight 48-inch were offered for those who (perhaps Silesia) supposedly took wheel to form a heavyweight part, the .090- needed suitable stiffness, as even the idea of the small rolling mill inch 2024 T3 aluminum cargo door skin for a cast iron is somewhat flexible. used for making wire and created Boeing 747. i These machines employ frame a small frame with two rollers on designs similar to the large rivet- it for planishing sheet metal. The de- and auto panels in the 20th century, ers, punch presses, and nibbling ma- vice spread across Europe, and ulti- it was never as popular as it was in chines. mately found its largest audience in England, which is why some people Recently, however, the resurgence England, where it is called the "wheel- call it the "English" wheel. My own of short-run parts for the auto and ing machine" or just the "wheel." teacher, an Irishman named Harry aircraft markets have brought in a Though used in Germany, Italy, Morrow, laughingly called his an whole crop of lightweight steel tube- and America to create some aircraft "Irish" wheel, and he had lots of stories frame machines. They are reasonably

98 MARCH 2001 ... The"How-To" New Experimental Aircraft priced and available as plans or as a & Kit Plane kit, and they are effective on thinner w Magazine for or softer materials, such as .050-inch 3003 HI4. Light Planes One odd variation on the wheel is the "roll-a-ball" machine used to and Ultralights form panels into a depression or cav- ity. The device operates like a pendu- lum, with a pivot on the ceiling Subscribe to suspending a long (8- to 15-foot) arm with a large roller (18 inch) on the Experimenter PosiTech® International (#PC8R209J) manufactures and distributes new oil end, which is held in a forked trun- S TODAY! coolers for experimental aircraft, nion. The worker grasps a handle af- •M home builts and kit planes, for such applications as RV - 4, 6 & 8, Clastar, fixed above the ball that alternately Call 800/564-6322 Lancair and Europa. All experimental pushes and pulls the roller over the aircraft oil coolers are backed with a panel. Pressure is increased periodi- 2yr/2000hr warranty. tXPWWAWWi PosiTech® international products are cally by lengthening the threaded competitively priced, with savings up rornes are used tor adjuster in the arm. Parts up to 5 feet reference purpose! to 40% when compared to OEM and only. It Is not other alternate aftermarket sources. across have been made this way, but fWcTM* ntemarionafsireei: Rigorous quality control standards the machine seems to be limited to allow you to benefit from OEM quality spherical shapes. at aftermarket price levels. Toll Free-1-800-357-1374 Yacht builders are even using PoslTeclr International, Inc. ,„ ,..-..,.._-.. . ,*„ •>•,• wheeling machines with frames 170 North 17tti Street Wheeling, west Virginia 26003 rittD:/,'*ww.oikoolei made of massive welded steel I- Recognized Distributors beams (24 by 18 by 2 inches) in or- Vans Aircraft, Inc. wicks Aircraft supply der to form 1/2- to 1-inch thicknesses of steel and aluminum plate. Of course, the pressures necessary to form such parts necessitate enor- mous force to shove them back and forth through the machine, so they use motorized chain-driven trolleys to move the large plates. One cre- ative fellow in the Northwest chose remnants of a farm tractor, having the advantage of multiple transmis- sion speeds—including reverse—for the task, for this purpose! ...Get DUATS* Free! Function & Applications Receive FREE color weather graphics for offline viewing when connecting The operation of the wheel is analo- through Cirrus For DynCorp DUATS Windows software. gous to a "silent continuous ham- Features include: mer." To apply pressure from the Version 4.0 now available lower part of the frame, you turn a Web DUATS Satellite Infrared hand-wheel or kick-wheel that turns Internet Access via Cirrus a threaded jackscrew that thrusts Satellite Visual Cirrus gives pilots easy access to free up-to-date color weather graphics and against a bearing-mounted roller. graphics-based flight planning.

This "lower roll" in turn presses the To receive your free copy of Cirrus electronically or on CD-Rom, send an e-mail to sheet metal against the upper wheel [email protected]. To download Cirrus DUATS from the World Wide Web, that is mounted with a bearing to visit us at http://www.duats.com. For DUATS help, contact the Technical Support and Order Line at 1 -800-345- the upper part of the frame. With 3828, or by e-mail at [email protected]. For DUATS access, call 1-800-767- compression applied to the sheet 9989, Internet Telenet at direct.duats.com, or Internet Web site at metal between the rolling parts, you www.duats.com. move the sheet back and forth, and DynCorp DUATS was previously known as GTE DUATS the subsequent rolling makes tracks on the metal, raising it by stretching. For more information, visit SPORT AVIATION on the Web at www.eaa.org Sport Aviation 99 Craft & Technique

A homemade 24-inch wheel of "muf- fler-moly" exhaust tubing, using a caster and skateboard wheel. It's a very flexible frame, but It will do .032-inch 3003 H14 aluminum.

By applying different pressures A real American 6-inch wheel, circa and tracking patterns, parts of many 1922. Ford Motor Company made differing contours may be raised and some of these and sold them in fit entirely on the wheel or simply sets of 6-, 9-, and 12-inch sizes for This 31-inch wheel is a flame-cut planished after being roughed on ei- smoothing auto body work. Some weldment of 3/8-Inch steel plate, ther the bag or the air hammer. The designs had a flat-faced shoe In the and it is just one of many designs wheel requires no electric or pneu- upper position instead of a roll. offered these days in plan form. matic power, so when the California blackouts roll through our neighbor- do, and I can also say there are times 36-inch throats, and then they made hood, we simply fire up the Coleman when I wish I had anything else! the parts rapidly for years thereafter. lantern and start wheeling sheet There is an old story out of the Another story concerns an ideal metal parts. (though difficult) application for Because you set the pressure man- the wheel: A damaged Spartan Ex- ually and because the sheet metal ecutive needed a fresh fuselage changes thickness during the wheel- top skin: 8 feet long by 35 inches ing process (remember from prior ar- wide, made of .032-inch 2024 T3 ticles, stretching equals a larger but aluminum, in polished condition. thinner panel), the pressure The craftsman on the job went "loosens" as the metal stretches and looking for the "right" way to must then be reset at some point. If make it and asked several differ- you must go back and rework a sec- ent sources for information. tion to get a better fit, you should re- Here craftsmen use the heavy- One resource replied that the fac- set the pressure correctly for that weight 52-inch wheel to make a tory originally made them on the area. If you miss setting the pressure lightweight part, the .050-inch power hammer. (Research has shown correctly, you can waste time by 2024 "0" condition fuselage belly they were pressed with dies.) A skilled working the metal insufficiently with skin for a Twin Commander. power hammer guy said, "too thin slack pressure or by overworking the and floppy," and a third, who used metal and marking it from excessive Grumman plant in New York during both the wheel and power hammer, pressure. The wheel is therefore a World War II. It seems they had a lot unexpectedly said, "Heck, that thing "thickness-based" device, like the of small and very thin (.025 inch) looks very hard.... I'd hire you!" The Pullmax-type machine. panels to form. And the big Yoder craftsman ended up making the panel People often wonder how the wheel and Pettingell power hammers were on the wheel because it was so big is best used or if it is "better" than an way overkill, and the wheels were too and floppy; if it was held right and air hammer, power hammer, or Pull- slow. They did a little research in the figured right, it would turn out right. max-type machine. I dare say that tool industry and ordered a bunch of The ideal applications are for plan- there are times when nothing else will air planishing hammers with 18- and ishing (smoothing by light pres-

100 MARCH 2001 jisjjii, Ji I—Tools, Videos, Trainings - Aircraft Aluminum Gas Welding System Rated as the finest system ever available—Video, Booklet, Torch, Special Eyewear, Flux and Methods. Items sold seperately or as a kit. ($285) sures), shaping low crowns, and 4130 Chromemoly Airframe Construction Video shaping large and/or thin panels. 4+ hours. Shows you how to build complete from plans. Table-jig construct- Or for doing polished work. Ulti- ion, bending, fishmouthing, welding and stress relief. See rudder pedals and rudder built from scratch. 11 most-asked questions at Oshkosh welding mately, it is the particular "bent" of workshops. 2-tape set $85 the craftsman as to which forming New! Vintage Film Series: 1) Factory Construction of the Piper Cub:$20 method suits his way of under- 2) Repairing Structural Tubing: $20 standing. The wheel does require 3) Repairs to the P38: $20 ig-g5 organization, patience, and deduc- 4) Metal Aircraft T? ^ Technologies t White Construction: $20 tive reasoning, i.e., go slowly and ob- _-:/* mL <««ji»- . Tools and Methods for Better Metalwork serve carefully. For our 60- paj>c ( 5.50) 292-350(1 www.tinmnntech.com The wheel's limitations are that it is slow to shape panels with lots of crown, and therefore some as- HIGH PERFORMANCE^™ FELT BETTER! sistance may be needed by other methods of generating shape, such In this fully aeragltic kit build aircraft! as in the shrinking or heavy Begin your acrobatic journey with stretching departments. The wheel the DR-109, a world class aircraft will shrink, as I have demonstrated capable of unlimited to students many times, but this is aerobatics. It is available to purchase in seven limited to soft metals. separate kit packages. It will shape small or intricate panels, but only those panels hav- ing crowns or radii larger than Web site: www.users.aol.com/danrihn what the lower roll has. Other- Phone 562-761-1630 • Email [email protected] wise, the panel winds so tightly around the roll that the worker cannot move it. This concludes the first article in the series on the wheel. Next month we'll cover adjustments, settings, accuracy, and methods for use. The previous series on fair- ings has been compiled into a video for better views and more detailed instruction of the process. Keep practicing and watch care- fully! «&

EAA Technical Counselor Kent White achieved master technician's status in The leaders in: 1976 at Harrah's Auto Collection, where he restored metal components for "IP T-Hangars IP Clear Span Hangars aircraft and autos. He started his own 1 metal restoration company in 1977 and "u Bi-Fold Doors IP Bottom Rolling Doors now teaches, writes, and develops tools for metalworking while he still pounds Since 1963 out parts. He encourages any welder or metalworker, man or woman, to contact him in regard to preserving the tradi- tions of aircraft metalworking. To con- EREC UBE c. tact him, call 530/292-3506, e-mail 800-624-9219 www,eiect-a-tube,com kentda'tinmantech.com, or send snail mail to 17167 Salmon Mine Road, "If it's not manufactured by Erect-A-Tube, Nevada City, CA 95959. its just an imitation."

Sport Aviation 101 For more information, visit SPORT AVIATION on the Web at www.eaa.org This big panel lsnTTOs"elage Wfrskin for Spartan Executive, and it is coming right on down to the buck, after more than of working It. It is 0.032-insMfl64 T3,.and ' It Is being worked to abolished condltl

THE WHEEL LOOKS so tungsten or "tungsten doggoned simple—it The Wheel, Part 2 spit" from an over- must be easy to use! heated electrode, be- How often have people Making your settings, adjustments, and contact cause even hardened come to me with their tooling is never hard wheeling problems KENT WHITE enough for this. and then, with great Stainless rolls may discouragement, re- help avoid corrosion lated tales of woe that in damp salty cli- were fundamental. I must say the withdrawing the panel under pres- mates, but the hardness will not be danged thing is deceptively simple. sure and when the roll (the lower sufficient for much other than soft roller) spanks the wheel. metals. Remember that if the tool- Settings & Adjustments ing's surface is compromised, then When I first bring a job to a wheel- all parts made from then on will ing machine I check for a number Think of making be also, unless the tooling is sent of conditions and adjustments. out for regrinding or turning. First, are the bearings in the upper a shape with the Last, I check the bearing in and wheel nice and tight and free to roll the surface finish of the lower roll, smoothly? Many times over the wheel as layering and then I establish a gap of a few years I've found the bearings to be thousandths between the upper trashed to the point oi suggesting a number of and lower rollers and spin the up- that the machine had been used to per while watching the gap for any crush rocks. If the bearings are old passes with heavy run-out. Then I spin check the or rumbly, replace them. Oiling or lower roll. Run-out of 0.010 inch greasing will not smooth them out. paint or fiberglass will make repeating lumps in the Rumbles will translate into the sur- panel. Ideally there should be no face of your work, leaving marks resin to make a run-out. Making the axles with cen- that resemble in no small way the ters allows for precision grinding of surface of a washboard road. solid blister shape. both the wheel and the rolls on the Next I check the surface of the bearings, making them run true. upper wheel for dings, scores, pits, Wheeling hard stainless steel or gouges. If the wheel is unhard- can gouge or score unhardened Contact Area ened, then it will be susceptible to tooling, as can wheeling butt welds Using a piece of scrap material surface deterioration from grit on mild steel. The worst offense identical to what needs work, I en- blowing around or adhering to the comes from wheeling TIG welds gage it with a guess at a starting panel. And it may get dinged when that hide either a snapped-off pressure. I make a few 30-inch passes

02 MAY 2001 Gapping the rollers allows for a run-out check. The black The horizontal tracking patterns show two 1-inch wide marks on the upper roller are picked off the panel by the ex- paths from a #2 roll, staggered for a 50-percent over- treme pressure of the wheel. At nearly two tons, everything, lap. Four vertical tracks show heavy shoulder contact no matter how tiny, leaves marks in the panel. Dandruff, on one side. Remedy: Shim the axle 0.016-inch for eyelashes, and even the oxide layer will lift off and bunch up. that pressure. and withdraw the panel, looking for the track is heavy on one side, then meaning they will do a middle-sized trueness of the tracking contact area. the axle must be shimmed in the panel well. The rolls are logically cut If the run-out is noticeable, it will saddle to bring the contact even all to sets of certain radii, from dead flat show up now as alternating heavy the way across. down to nearly spherical (a 2-inch and light spots in the track. If the Here's a non-trivial design point: radius on a 3.5-inch diameter roll), spots repeat every 12 inches or so, The lower rolls are cut in certain allowing for crowns of many differ- then it is the lower roll causing the overall diameters, with traditional ent radii to be worked. problem, and if they show every 30 sizes being 3.5 and 2.5 inches. Newer Here is the kicker. Flats of differ- inches or so, then it is the upper. If designs compromise at 3 inches, ent widths are then cut across the

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Proprietary Software Systems 950 Iris Circle The top skin shows start and stop lines for passes, the "no fly zone," www.angle-of-attack.com and the fact that forming in only one direction was necessary. centers of the rolls that are specifi- cally designed to provide a working contact area based on an average material spring-back. This is why We mean to very soft metals will mark from the clean it. shoulders of the roll flats more than slightly harder metals will, and why also some very hard ones can be Typical Lycoming Installation worked to a higher crown (smaller 0-235 thru 10-720 radius) with a wider contact area The leader in cleaner oil since 1963, Airwolf filter systems keep the oil in your aircraft cleaner, cooler and safer from particulate damage. Remote- (larger radius). If the rolls had no mountina makes filter changes a convenient, no-mess snap, and our systems flats, then the contact area would be are STC d on every opposed Lycoming and Continental engine in the sky. very nearly the same for every single Endorsed by the engine OEMs, our filter systems clean your oil best, while one of the five or six roll contours, our filter cutter allows you to track abnormal engine wear. The Northern enabling work to proceed at a brisk Lights Acrobatic Team uses Airwolf systems exclusively, under the most rigor- glacial pace. (Imagine applying dope ous conditions. Never a failure. Never an AD. We keep flying safer with properly filtered oil. to a Cub with a 1/8-inch brush!) 2024 T3 aluminum has enough spring-back (hardness) to enable it G« our filter cutler to be worked up to a crown with a for half pric« wilfi iKe purthoic of any 15-inch radius with a roll that has fikrkil only a 30-inch radius (#2). The dis- tinct advantage here is that the much wider contact area on the 30- inch roll enables more work with AIRWOLF FILTER COR» each pass, yielding fewer passes and 15369 Madison Road, Middlefield, Ohio 44062 • Tel.; |440) 632-5136 • Fax: (440) 632-1685 lower times to completion. Web: www.airwolf.com • e-mail: [email protected] How to tell how far to go? Go at Call Toll-free: 1-800-326-1534 Also available for Weight, Franklin, Jacobs, and Pratt & Whitney engines it with the first crowned roll (#2—a For more information, visit SPORT AVIATION on the Web at www eaa org 94 MAY 2001 This series of zigzags demonstrates a The Xs are no fly zones, the lakes Borders contain shapes, lines show simple tracking pattern for an offset are used as stop points, the bor- starts/stops as a triple pattern, hazy rise. The starts and stops are stag- ders contain the shaping, and the thin circles are pen marks embedded gered, but I follow them only once edge is marked with the math for by the pressure, and the frosty across, as on the return I will go 2 preliminary starts/stops that estab- straight lines are wheeling tracks. inches short or long of the lines to bet- lish the general overall shape. Pres- ter blend the rise in shape. The tracks sures are marked 1-1/2, 2, 2-1/2, less sensitive to flex, so three or four will have a 50-percent overlap as well, 3, and 3-1/2. Later pressures were pressures may use only one axle shim- not shown with these marks. Note the 7s, more than two tons. ming, and only 0.005 inch at that. start zig and stop zag at the sides. Shimming the axles for full contact Pressures & How to Set Them #1 is dead flat) until you get the first must be done for that pressure be- I set the pressure so that the first whispers of marks from the shoul- cause the machine's frame deflects pass raises a slight amount, but ders, then change to the next con- varying amounts, depending on the leaves no shoulder marks. This set- tour (#3 roll). No, don't start in with pressure. As the frame deflects, the ting varies with alloy, temper, and the roll you would end with, unless contact on the flat away from the thickness. I mark the adjustment you wish to wear out your sneakers throat will open up, requiring shim- wheel with that point and wheel the with all that walkin'! ming to compensate. Stiffer frames are area completely in one pass, once

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Sport Aviation 05 T^TlTri—Tools, Videos, Trainings I NEW Video: Those Doggonned Reverses * 'raft & Technique This 2+hr. video covers the development and construction of a variety of aircraft fairings, using both hand tools and the Air Hammer. $40 Aircraft Aluminum Gas Welding System across and once back. A second pass Rated as the finest system ever available—Video, Booklet, Torch, Special will then begin to raise the sheet, as Eyewear, Flux and Methods. Items sold seperately or as a kit. ($285) the metal density has now been 4130 Chromemoly All-frame Construction Video 4+ hours. Shows you how to build complete from plans. Table-jig con- raised to a level sufficient to create a struction, bending, fishmouthing, welding and stress relief. See rudder response in the surface area, indicat- pedals and rudder built from scratch. ,/ ing indirect stretching. 11 most-asked questions at .| ^-_ — • '•~~*$~ Direct stretching occurs when the Oshkosh welding workshops. S SfmSm 2-tape set. Sale: $70 panel is stretched through a direct Tools and Methods for Better Metalwork means, i.e., pressing, stretch forming, For our 60- page catalog or info call (530) 292-3506 www.tinmantech.com flow forming, etc. But if hammering or wheeling between two solid anvils, then the result is a stretch indirectly SAFA raised because of compression. Most Helicopter Kit guys wheel a pass or two, see no re- sults, raise the pressure, and then get double results. This is a common er- ror, but after accounting for the den- sity-increase required for the indirect stretch, it is all in the math. When the rate of increase in the crown slows, perhaps after two or Features three passes (forth and back), then Canadian Home Rotors Inc. Pricing Phone: I (807) 222-2474 • Lycoming Engine two more things have happened to- Ask About our Silver, • Gear & Shaft Driven \Vensite: HHW.acehelicopter.com Gold & Platinum • Dual Controls gether. The metal has work-hard- Info Pack & video $35 USD Purchase Groupings • 4130 Chromoly Steel ened, and the panel has thinned a little bit. The wheel must now be re- set to a higher pressure, and so the setting should be nudged forward 1.25 inches on the adjuster. I've used these machines for Fast, Reliable, Fly-Weight Starters. Sky-Tec Starters are now being shipped to years, with many different crafts- aircraft manufacturers worldwide on new engines. The Industry's Standard. men, and the different adjustments Sky-Tec Starters are fully guaranteed and were always made according to feel. For Continental dependable. No periodic maintenance is required This may be fine on a simple even Series Engines Engineered to outlast the TBO ol your engine O-300D & E under normal operating conditions. crown for a round-motor cowling, IO/TSI0360 but on an oddball shape it is treach- 0/IO-470 Sky-Tec Starters are light weight — erous for the unskilled. 1 admitted at 5.8 pounds light far less than the original equipment designs. a critical juncture that I'm unskilled O200 Key-start For Franklin CBS, C90, C145, Series Engine* at this adjusting thing, so I made a and O300A-C (PZL) 4A vernier scale for accuracy. I also converted to key-start 6A4, 6A 9.5 pounds light 8.0 pounds light keep track of what pressures occur at what point on the panel, so I can For Lycoming Engines HT INCREASES repeat passes at any point to level CRANKING TWice NT Mod.i SPEED out the whoopses. the 8.5 pounds light LS As the panel progresses, more Spin... L8 Mod., marks are added to the wheel, shims Half 7.8 pounds light to the axle, and marks to the panel. Jfje. _., PMMod.l Weight! 7.8 pound* light Any spot lagging behind because of a discontinuity in heat-treating, Sky-T*c Lycoming Startars Almost double your engine's cranking speed. This NO thinness from the rolling mill that faster cranking speed eliminates the 'Hot Start" BENOIX created the sheet, or brain fade in problems normally associated with fuel infected PM DRIVE engines, but will not affect impulse-couplers. the biped at the wheel may be www. skytecair.com • 1-8OO-476-7896 • 817-573-2250 quickly and accurately addressed if P.O. Box 1024, Granbury, TX 76O48 • FAX 817-573-2252 the operator has kept track of the

For more information, visit SPORT AVIATION on the Web at www.eaa.org 96 MAY 2001 Your GPS's Are you worried about the silent kip? process. As these highs and lows magically appear, track them with Best Friend black marks as "lakes" and "no fly Feeds your GPS true airspeed, zones," needing either special atten- both indicated tion or no attention at all. and pressure altitudes, plus your magnetic Making Topography heading (with the optional Model 303 Tracking patterns aren't often Compass Module). simple, but you can learn simple The jiEncoder ones to start and then use the "jazz- improv" method once you under- Look What Else it Gives You! stand the relationship between stops Altitude Info. Pressure or density altitude on demand, with sellable alerts for preferred and starts and the amount of rise in altitude, decision height, and more the shape. Airspeed Info. Indicated and true AS in kts or mph. plus trends, sellable Vne. Vno. gear CARBON MONOXIDE DETECTOR A simple pattern is a staggered set speed, flap speed, and stall speeds "Safest way to catch a killer" Vertical Speed. Both graphic and digital Model: Aero-252 l-'catures of stops and starts laid out on two displays, with selectable ranges and damping. lines at each end of the tracks. If Outside Ahr Temperature. Advises you in • 3 Year Limited Vferranty • CO Sensor tested to 13.500 ft you try to start and stop on one both Fahrenheit and Celsius Sends °C to GPS. • 12 to 30 volt DC input • 3 Leveles of EMI Shielding AO for just $879! In a very professional • Loud 85 dB Alarm • 60 Day Money-Back Guarantee line, you will get a shelf or "mesa" kit Also available as a fully assembled unit • 3 Color Vteming Lights • Available with or without display shape with a sudden and steep rise Download full information about This NEW, panel-mounted. 21st century at each end. Nice if you can use it. If all of our products at our web site. detector has built-in humidity and temperature compensating circuits to give you the most you need a gradual rise, then you www.rkymtn.com accurate readings Designed to alarm above need to "blend" the stops and starts 50 parts per million per FAR 23 831 over a distance. This is taught as RMI Order Yours Today: 1-800-639-7139 or on-line at: "topography" in my workshops, ROCKY MOUNTAIN INSTRUMENT and the specific relationships be- Phone 307-864-9300 • Fax 307-864-9264 PO Box 683 • Thermopolis. Wyoming 82443 www.COQuardian.com tween layers of passes and the sub- sequent rise in shape is made clear. Think of making a shape with the wheel as layering a number of passes with heavy paint or fiber- glass resin to make a solid blister A CRASH COURSE shape. What you lay down is what you get to stand up. If you pile on the effort in the center, then you IN MIL-SPEC get an igloo and not the blister. If you lay down the effort with the FLIGHT CONTROL high spot offset to one end with a rapid transition to the edge, and then gradually taper off to the CABLE. HI other end, you will get the blister. Only you cannot sand off to final- ize the shape! In this manner we can see that organizing our efforts Flight control cable that's not QPL certified Mil-Spec is not with marked lines can be a big help, Mil-Spec. And if your distributor claims it is Mil-Spec and it's especially if we follow those lines. not QPL certified, you've been had. Why put your life on the The next installment, "The line. Insist on QPL certified Mil-Spec flight control cable. For Wheel, Part 3," will show odd the name of a distributor that carries QPL certified Mil-Spec forming methods, tracking pat- cable, send us an email: [email protected]. terns, unusual shapes, and related tools. These wheeling processes to form a large skin are being de- isos&co tailed on video and should pro- When it matters. vide significant detail for those wishing to pursue this challenge Supplying the aircraft enthusiast and every major U.S. commercial aircraft manufacturer. further. Keep practicing! g/fc Kor more information, call Loos & Company: 1-800-533-5667.

For more information, visit SPORT AVIATION on the Web at www.eaa org Sport Aviation 97