Curtiss Jenny Restoration

Welcome! We hope you enjoy following the restoration process of a 1918 Curtiss JN4D Jenny. Once completed, the aeroplane will be flown and displayed at the Candler Field Museum in Williamson GA (30 miles south of Atlanta). You can contact me below by clicking on "VIEW MY PROFILE"

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Location: Peachtree City, Georgia, United States

Thursday, February 01, 2007

rudder bar, rudder horn and fitting

I decided to work on the rudder bar today. There were two original rudder bars with our project and when they were disassembled, I noticed that one set of hardware was cut !

The picture below shows the tube that extends through the rudder bar and into the casting. (more about this assembly later).

So, an extension had to be made. I took some .125 tubing and matched it to the original piece. Since this bar rotates in the casting, it would have to be smooth....and straight.

Here's the weld.

A little time on the grinding wheel and sander produced this.

Cut on the saw to exactly 4 inches to match.

Here's the rudder bars after some good cleaning and several coats of epoxy varnish. I kind of like the "used" new look. The above mentioned pieces fit in these holes.

Now it was time to tackle the rudder horns. They are 10 3/8 in. in the back side, which is bigger than the elevator horns. But, my jig worked fine, with a little modification.

Like the other horns, I cut the pattern out of cardboard and transfered to .025 sheet steel. One thing I did differently (I do learn occasionally) was to pre-bend the trailing edge. This gives the horn the nice rounded shape on the spine rather than two pieces of steel at a sharp angle.

I did this by shaping the edge on a spare piece of small tubing with a tack hammer.

Then the steel was placed on the jig and the trailing edge was tapped into the final shape. There's a process here - tap into shape and tack weld a few inches. Move the jig down the vice and repeat.

Here it is after a few tacks.

I'll finish welding this next week.
Also had a chance to rough cut one of the rudder trailing edge brackets. The wire/turnbuckle assembly attaches here.
Till next week


Blogger Stephen said...

Looks great Brian! Your welding is getting really good.

1:35 PM  
Blogger JT said...

Nice work on the rudder bars!

6:32 PM  

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