Jig: Gusset Cutter

Leo made this nice jig for cutting gussets in half. Lots of gussets are used on each rib, and lots ribs are used. So, if my math is right, lots of ribs X lots of gussets = gazillions of gussets.

A round gusset, and the jig are sitting on the jig saw, sorry for the pun.

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Gusset is inserted into the jig. By design it only goes in halfway.

Jig is flipped over, and jig saw is used to cut gusset in half, guided by the edge of the jig.

Note the nice hole for pushing out the other half of the gusset.

Voila. The process is quick, and accurate.

If you look closely, you can see a piece of cardboard was glued into the slot to make a snug fit for the gusset so it didn't fall out during cutting.

Cool Photo

Paul found this photo.

The photo shows some of the training gliders used during WWII.  If you zoom in, you can read the printing.  The four gliders on the top right are TG-5s, which is the glider we are rebuilding.  The rest are a mixture of TG-19s, TG-15s, PS-2, TG-1, TG-2, and SGS 2-8.  Thanks Paul!

Problem: Wing Strut Bracket

This wing strut bracket is bent on the left side and will need to be straightened.

This bracket has not been damaged.

Bending the bracket may require some heat. Stay tuned.

Problem: Landing Gear Bracket

This is the mounting bracket for one side of the landing gear. Remember, the fuselage is upside down.

Yeah, ugly!

View from the rear of the fuse.

This will be a bit of a challenge. The metal is torn, and will probably have to be replaced (maybe just the left half of the bracket). The bracket is welded into the frame where lots of tubes are joined. Originally, holes in the bracket allowed the tubes to be inserted into the bracket, then the whole joint was welded. It will probably take quite a bit of fabrication (new bracket) and disassembly to make it suitable for reassembly and welding.

Center landing bracket.

This bracket resides between the other two. It is bent, and will need some straightening. Maybe some heat from a gas torch will help.