Cuting Bulkheads with a Router & Templates VIDEO

[Cozy1200]

I was introduced to this method of cutting the bulkheads by the gang at the now famous "Plane Day". I really like how clean the bulkheads turn out. The edges are perfectly square, the lines are straight, and the curved edges are gentle. Personally it makes sense to make a part over sized and then bring it down to shape.

 

Opponents of this method claim that is too messy and you get covered in glass dust. I'll put forth that the mess is no worse than any other wood routing. In fact the dust is probably less than I've seen on some woods. Cutting the parts outside will reduce the amount of dust to cleanup. And sure I'm covered in itching fiberglass dust, but no worse than insulating a house with fiberglass. A good soapy shower will take that away.

 

Here's a video demonstrating the technique from start to finish. It's 10 minutes long and about 25 megs. Enjoy!

 

http://www.cozy1200.com/geeklog/article.php?story=RouterTemplate

[mfryer]

Very well done.

[aviator_edb]

Great video. I almost busted my gut when you quoted Norm on shop safety (True words!)

[Cozy1200]

Great video. I almost busted my gut when you quoted Norm on shop safety (True words!)

Thanks, I was waiting for someone to say something about that. I thought it was funny.

[Marc Zeitlin]

... I really like how clean the bulkheads turn out. The edges are perfectly square, the lines are straight, and the curved edges are gentle.

Very clean, very straight, nice edges. None of that matters, however, as almost all the edges of every bulkhead will get taped to something, filled with something, attached to something, or covered by something. Except MAYBE the instrument panel, since the leg holes are pretty visible. Nothing else, though.

 

Personally it makes sense to make a part over sized and then bring it down to shape.

Agreed. A hacksaw, Fein sander, Dremel cutter, sharp knife (in "green" stage) or air grinder with cutting blade will do the same thing, along with a sanding block.

 

Opponents of this method claim that is too messy and you get covered in glass dust.

Don't remember those claims, but as one of the (not opponents, but) detractors of this method, I would claim that it's a total waste of time. You get perceived quality you don't need, and parts that are perfectly shaped to paper templates that aren't perfect, so you may/will need to adjust the size/shape of the bulkheads later anyway (with the sanding block) to get them to fit.

 

Perfect edges that get buried in flox/micro corners and 2 BID tape joints is NOT where I want to spend my time.

 

It's just time. If I was going to build three or four airplanes at once, I'd probably do this, because THEN there would be some economy of scale, but otherwise...

 

Here's a video demonstrating the technique from start to finish.

Nice video, though.

[Cozy Girrrl]

Got to agree with Marc on this, its too easy to get lost in pouring perfection into a part that would be just as well bandsawed in a minute or two, chase a Permagrit block around the edges and you are good to go.

Fuss with the panel, attack the rest

Also you will cover up or cut away an amazing amount of the fuselage sides.

If you are doing our strake mod forget the stick depressions on the fuselage sides.

...Chrissi

[HatSwitch]

Ahhhh, with all of the above taken into consideration and noted (point for point), I’ll still say: Nice job, Drew! VERY NICE JOB!

Everyone has their own way of doing whatever it is “they” do. Based on content and my own perceived subtext in your video, my best estimate is your Cosy will roll-out looking more like it was born of a precision factory, not like one that came out of a blender between margarita batches. I also predict: For project hours actually worked (not necessarily elapsed calendar days start to finish), and in spite of the attention to detail, you will probably end up with a record short time build. Call it a hunch. Keep up the good work and keep doing the Drew Show Videos. Ya Nevva know, you may just bump one of those silly a** reality shows right out of a cable slot and help ignite a new firestorm of interest in Canards.

 

Well Done!

Hat

[Cozy1200]

Very clean, very straight, nice edges. None of that matters

Understood. Most of the edges will be buried in tapes. I'm not becoming anal with creating perfect parts. The nice edges are a positive, but I think the real key point is the ease at which the router cuts. In my opinion it cuts just as fast as the Fein. And for a little extra effort, it creates a very nice looking part.

 

I just checked the time stamp on the video. It took 9 minutes to router each half of the IP which has 4 holes and the complete outer edge. I don't see even the Fein cutting it out in that timeframe given that the radius corners still need to be done another way. Aligning the template takes less then 5 minutes. So I'd guess it would take someone with a borrowed template less than 30 minutes to bring it to shape.

 

If the process took significantly longer, then I would say it would be questionable. Minus the making of the template, I don't see the time evolved using a router to take any longer than other methods. I made the template 6 months before I started so it took no time away from the build and they are very handy to have for reference and to use for tracing. I have the Fein, but still like this technique for this particular task. I

 

I have to admit a certain level of satisfaction with it. Granted it may be a perceived quality. I took the IP & F-22 to the SAAA meeting last week (EAA equiv in OZ). The parts here a huge hit and drew a lot of questions. Even the RV builders kept a very open mind and asked lots of questions.

 

Agreed. A hacksaw, Fein sander, Dremel cutter, sharp knife (in "green" stage) or air grinder with cutting blade will do the same thing, along with a sanding block.

 

Sure all are viable options. This is just another technique to consider. Personally the only other one I would even consider now is the Fein.

 

Don't remember those claims, but as one of the (not opponents, but) detractors of this method, I would claim that it's a total waste of time.

 

There has been one or two, but some bias probably played in there. It can' be a complete waste, I do have finished plane parts!!

 

Nice video, though.

Thanks, Whether or not I agree with you, I always appreciate the input.

 

Fuss with the panel, attack the rest

I could certainly entertain the argument that if you have the tools use the technique on only the IP.

 

 

If you are doing our strake mod forget the stick depressions on the fuselage sides.

 

Aye, Aye Captain.

I should be doing that in January after I spend the better part of December back home in the states.

 

 

I guess the video has done was I hoped for. I wanted to everyone to as least see it being done and then make a judgment call. Personally I like the option, but can understand how some don't see the value. Many builders have spent far more time early on figuring out what works and doesn't work. The first builder I ever met at Osh told me about he carefully sanded the edges of the bulkheads on the belt sander, and then chuckled when he learned that it's all would be covered up.

 

This is a little different; I'm not after a perfect part. I'm just using with what I feel I'm most comfortable and will get the job done in the most reasonable timeframe. I like the flexibility of routers and understand their value.

 

 

At this stage, it's all about the learning curve. It's not a steep learning curve, but defiantly a curve.

 

 

BTW, who wants my template when I'm done?

[Cozy1200]

HatSwitch,

Thanks for the kind words. Did someone say Margarita?

 

I don't see my Cozy taking awards at Osh, I'll leave that up to people like the Cozygirrls & the StaggerEZ. I do like to pay attention to details and to an above average job.

 

I'm guessing I'm just under the average for time spent. I'm at 45 hours and guess another 10 to finish CH4. That's considering redoing the back of the seatback. But I am only counting real work; cleaning the shop, counting parts, and reading the plans don't count.

 

Sorry no regular video business here. I would like to finish someday. Besides most of the "HOW-TO" shows are extremely lame and mother-in-law basic. (no offense intended to said mother-in-law)

[TMann]

I tried the router technique. The bearing slipped off the template and ate my part.

 

I ended up doing it over and then cut to size. In retrospect it was EZer for me.

Others have had good success with the router template method.

Still others will criticize it.

 

Bottom line, have fun and have pride!

[Jason Heath]

If the process took significantly longer, then I would say it would be questionable. Minus the making of the template, I don't see the time evolved using a router to take any longer than other methods. I made the template 6 months before I started so it took no time away from the build and they are very handy to have for reference and to use for tracing. I have the Fein, but still like this technique for this particular task

While spending plenty of my own time trying to make a perfect part, I've learned as many have, that time can be counted however you want, but it's still time. If using templates and such to make your parts and there perceived quality helps to keep you motivated, cool, but time is time. Personally I count everything as time spent, you can't build an airplane without reading, cleaning, setting up etc. so why try to believe that building a template 6 months ago wasn't part of building?? If I only had an employer as leaniant as you!

 

Yes, I would have to be one of the detractors of this, unless someone want to make a video of the plans method for all to see how EZ it can be so others can decide. While you made a great video and a great looking part, it also LOOKS far more complicated than it should and might scare away some???? Maybe!

[dirtdox]

Great video!!!

 

I hope to be making bulkheads in 3-4 months. I have experience making templates for other projects and found that I can usually build the actual part in the same time as the template. I have to also agree with Marc. If I was making several I would consider this option.

 

Your parts look excellent !!!!

[BLUE MAX]

Drew...Thanks for sharing that video. I have learned something new and really appreciate it. Nice editing in the video it was entertaining. :D

[Cozy1200]

Personally I count everything as time spent, you can't build an airplane without reading, cleaning, setting up etc. so why try to believe that building a template 6 months ago wasn't part of building?? If I only had an employer as leaniant as you!

I'll admit that these activities are needed. I don't count them because they add no value to the plane and are extremely builder Dependant. Personally, because my shop is so tight, I have to clean it and put tools away a couple times a week. Otherwise it's like trying to work in a teenagers bedroom. Is it required? No, but it's not my style. Also it's easier to track progress of what being accomplished. I guess the point I made about the template was that their construction did not detract from time that could have been spent building the cozy. At the time I not not committed to building. But you're right, time is time, and completed parts are parts. Don't become anal about either and one day a plane is born. (I hope I just didn't violate anyones copyrights)

 

As for my employer and being a salaried employee, my job is service the customer and troubleshoot motors. That's what I get paid for. Reading trade magazines, cleaning my desk, and organizing the shop is all part of the job, but it's not THE job needed to get done and what I'm evaluated on.

 

So I guess is a matter of viewpoint. I don't want to confuse activity for productivity. I can go out to the shop everyday and sweep up and count parts, but that doesn't build a plane. If you want to count all the hours you spend in the shop, more power to ya, I can respect that.

 

Yes, I would have to be one of the detractors of this, unless someone want to make a video of the plans method for all to see how EZ it can be so others can decide. While you made a great video and a great looking part, it also LOOKS far more complicated than it should and might scare away some???? Maybe!

There's certainly nothing as simple as the plans "Chewing Gum" method. A Stanley knife and a partly cured layup. Everything else is more complicated, the method an individual builder chooses has a lot to do with what they are most comfortable with.

 

I would certainly agree with anyone that reaching for perfection at this stage is overkill. That is unless you have the time, money, & motivation to build a Osh Grand Champion(which I don't).

[TMann]

Drew,

I always find it amuzing when people start nit-picking anbout 10 minutes here and 30 there. What is the funniest part is that they usually have a project that has seen as much attention as they have spent being critical of the 'worker bees' !

 

The project killer isn't mods, template routing, vacuum bagging (and on and on.) The project killer is avoidance. A day goes by ....... then it's a week ........ then a month.

 

You're working on your project (more than others) so press on and enjoy!

[Cozy1200]

Drew,

I always find it amuzing when people start nit-picking anbout 10 minutes here and 30 there.

 

You're working on your project (more than others) so press on and enjoy!

Good point. Granted 10 minutes extra a day over a 5 year build is an extra 300 hours. But I think your real point is that definitely regular progress is being made. So far in the build I'm comfortably working 5-6 days a week and generally a couple hours at a time. I'm happy, the wife's happy, and I'm building a plane!

 

Life is good.

[Jason Heath]

But I think your real point is that definitely regular progress is being made. So far in the build I'm comfortably working 5-6 days a week and generally a couple hours at a time. I'm happy, the wife's happy, and I'm building a plane!

Drew, now THAT, and your last post, I would have to agree with...................TMann, you on the other hand, I do my best to disagree with! [sigh]

[HatSwitch]

Drew,

I always find it amuzing when people start nit-picking anbout 10 minutes here and 30 there. What is the funniest part is that they usually have a project that has seen as much attention as they have spent being critical of the 'worker bees' !

 

The project killer isn't mods, template routing, vacuum bagging (and on and on.) The project killer is avoidance. A day goes by ....... then it's a week ........ then a month.

 

You're working on your project (more than others) so press on and enjoy!

 

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Yeah!

What Tmann said!

Press-on Drew, any time spent defending being good at being productive, is time wasted, time that could better be spent slinging goo and kicking glass.

Looking forward to your next installment.

 

Hat