Sr3500 Upgarde - Leading Edge Doubler

RJ Thomas · Post by **RJ Thomas** » Fri Feb 17, 2012 9:59 pm

Folks,
Does anyone have an idea as to why Murphy chose to leave the extra aluminum on the leading edge doubler for the 3500 lb upgrade? Mine is currently clecoe'd to the wing and drilled to the correct size as per the rivet map and it appears the next step is to just cut off the extra material prior to riveting. I have yet to figure out why the part wasn't cut to the correct dimensions in Chilliwack.
Any insight from those of you who have been there already would be most appreciated. I fear I have missed something.

Cheers, rj

R J Thomas
Lafayette, LA
rj.thomas@halliburton.com (rj.thomas@halliburton.com)
(337) 849-4136
Super Rebel N140SR (Under construction)

capete · Post by **capete** » Fri Feb 17, 2012 9:59 pm

Our sentiments exactly! We have been asking ourselves the same question. To get a nice straight cut (on a clearly visible section) we are taking it to a shop to get it sheared properly.

Monica & Peter
SR003

----- Original Message -----
From: RJ Thomas (rj.thomas@Halliburton.com)
To: murphy-rebel@dcsol.com (murphy-rebel@dcsol.com)
Sent: Thursday, March 14, 2002 11:02 AM
Subject: Sr3500 Upgarde - Leading Edge Doubler

Folks,
Does anyone have an idea as to why Murphy chose to leave the extra aluminum on the leading edge doubler for the 3500 lb upgrade? Mine is currently clecoe'd to the wing and drilled to the correct size as per the rivet map and it appears the next step is to just cut off the extra material prior to riveting. I have yet to figure out why the part wasn't cut to the correct dimensions in Chilliwack.
Any insight from those of you who have been there already would be most appreciated. I fear I have missed something.

Cheers, rj

R J Thomas
Lafayette, LA
rj.thomas@halliburton.com (rj.thomas@halliburton.com)
(337) 849-4136
Super Rebel N140SR (Under construction)

Wayne G. O'Shea · Post by **Wayne G. O'Shea** » Fri Feb 17, 2012 9:59 pm

RJ, I pulled mine out of the carton to see what you were talking about (haven't done them yet). I presume you are talking about the 2 foot section on the forward edge. I know why it was left there initially, simply to allow enough material to use the slip rolls on the piece after CNC punching. It should have, of course, been sheared off after the rolling process!!

I know it doesn't help you, but anyone in the local area that wants an excuse to drop by (to some I know that have "dropped in", that can be 1500 miles!!) can bring their pieces by and I will shear them off for you.

Regards,
Wayne G. O'Shea
www.irishfield.on.ca

----- Original Message -----
From: RJ Thomas (rj.thomas@Halliburton.com)
To: murphy-rebel@dcsol.com (murphy-rebel@dcsol.com)
Sent: Thursday, March 14, 2002 11:02 AM
Subject: Sr3500 Upgarde - Leading Edge Doubler

Folks,
Does anyone have an idea as to why Murphy chose to leave the extra aluminum on the leading edge doubler for the 3500 lb upgrade? Mine is currently clecoe'd to the wing and drilled to the correct size as per the rivet map and it appears the next step is to just cut off the extra material prior to riveting. I have yet to figure out why the part wasn't cut to the correct dimensions in Chilliwack.
Any insight from those of you who have been there already would be most appreciated. I fear I have missed something.

Cheers, rj

R J Thomas
Lafayette, LA
rj.thomas@halliburton.com (rj.thomas@halliburton.com)
(337) 849-4136
Super Rebel N140SR (Under construction)

Warren Montgomery · Post by **Warren Montgomery** » Fri Feb 17, 2012 9:59 pm

<!doctype html public "-//w3c//dtd html 4.0 transitional//en"> I cut the excess off with a band saw then filed smooth. Another way, which I did for the Cabin sills which are quite a bit longer was to cut with the bandsaw to within about 1/16" of the finished edge then clean up with a carbide bit on a routor, worked great. Furthermore, for the leading edge doubler I filed the full length leading edge at an angle of about 45 degrees to get it more streamlined and put the bandage for the skin splice under the doubler.
Warren
SR 029
Dubai, UAE

To get a nice straight cut (on a clearly visible section) we =
are taking it to a shop to get it sheared properly.

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RJ Thomas · Post by **RJ Thomas** » Fri Feb 17, 2012 9:59 pm

Warren,
Wayne,
M&P,

Many thanks for the responses. If I can find a local shop with a shear, I'll take the parts over (it's quite a drive to Canada from here). Failing that, I'll try my hand with the band saw.

Again, thanks. This forum, and the contributors that make it possible, is fantastic.

Cheers, rj
===========================================================

-----Original Message-----
From: Warren Montgomery [mailto:monty@emirates.net.ae]
Sent: Friday, March 15, 2002 6:51 AM
To: murphy-rebel@dcsol.com
Subject: Re: Sr3500 Upgarde - Leading Edge Doubler

I cut the excess off with a band saw then filed smooth. Another way, which I did for the Cabin sills which are quite a bit longer was to cut with the bandsaw to within about 1/16" of the finished edge then clean up with a carbide bit on a routor, worked great. Furthermore, for the leading edge doubler I filed the full length leading edge at an angle of about 45 degrees to get it more streamlined and put the bandage for the skin splice under the doubler.
Warren
SR 029
Dubai, UAE

To get a nice straight cut (on a clearly visible section) we =are taking it to a shop to get it sheared properly.

Don Boardman · Post by **Don Boardman** » Fri Feb 17, 2012 9:59 pm

Hi Guys,

Before you cut off the extra material on the doubler edge check to see how
the doublers contour matches your wing at the leading edge. Randy and I
decided it needed a slight additional bending to allow the final cut edge to
make a nice tight fit against the wing skin.

Regards,
Don Boardman
& Partner
Randy Bowers
SR3500#130 "The Muskie" M-14PF Aerocet 3400 amphibs, Rome, NY

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RJ Thomas · Post by **RJ Thomas** » Fri Feb 17, 2012 9:59 pm

Don,
I have been looking and worrying about that very thing. How did you manage
to increase the curvature?

Cheers, rj
=================================

-----Original Message-----
From: Don Boardman [mailto:dboardm3@twcny.rr.com]
Sent: Friday, March 15, 2002 9:59 AM
To: murphy-rebel@dcsol.com
Subject: Re: Sr3500 Upgarde - Leading Edge Doubler

Hi Guys,

Before you cut off the extra material on the doubler edge check to see how
the doublers contour matches your wing at the leading edge. Randy and I
decided it needed a slight additional bending to allow the final cut edge to
make a nice tight fit against the wing skin.

Regards,
Don Boardman
& Partner
Randy Bowers
SR3500#130 "The Muskie" M-14PF Aerocet 3400 amphibs, Rome, NY

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Don Boardman · Post by **Don Boardman** » Fri Feb 17, 2012 9:59 pm

Before you cut off the extra material on the doubler edge check to see how
the doublers contour matches your wing at the leading edge. Randy and I
decided it needed a slight additional bending to allow the final cut edge to
make a nice tight fit against the wing skin.

I have been looking and worrying about that very thing. How did you manage
to increase the curvature?
Cheers, rj

Wasn't easy. We borrowed a friends aluminum siding break and clamped the
doubler in tight and worked the break to carefully bend as needed. Being
careful to keep the curve smooth.

There might be easier &/or other ways but this is what we had available.
Good Luck,
Don

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