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Champ window frame
Posted: Thu Jan 15, 2009 21:05
by DMichaels
I received my Champ books today from the Club thanks they are great.
Is there a plans for the rear window frame or does someone have a template? I have nothing to work with at all owner said there was no window.
Dan
Posted: Fri Jan 16, 2009 19:48
by james gevay
Here's a couple of pictures to show what the frames look like. I just used the old frames as patterns and copied them for new ones. Pic 1 shows the overall frame. It's 5 pieces, the front piece on mine is spruce and the 2 bottom pieces are also spruce. The large curved piece is 1/2" plywood with a 1/4" plywood doubler piece behind that.
Picture 2 shows a closer view of the rear of the window and the cutout in it. To make the cutout I used a forstner bit to drill the corners and then a scroll saw to connect the holes. I also used a router bit to make a radius on the opening. A router bit was used to make the relief for the window plastic so that it sits flush with the frame. The bottom piece is not yet glued to the upper frame and you can see the relief in it also.
I ordered aircraft quality spruce from Aircraft Spruce for all the spruce and I found some 1/2" birch plywood at a local woodworkers store for the upper frame, it's cabinet quality and very nice wood. I cut it out with a bandsaw and then used a belt sander to smooth out the shape. The 2' X 5' sheet cost $25.00.
There's another Aeronca web site with a drawing and you can download it but the size is so small you can hardly read it. Jim
Posted: Fri Jan 16, 2009 20:17
by SFC Hiatt
That is beautiful craftmanship!! I can hold my own with flying but, I can't build to save my life.
Posted: Fri Jan 16, 2009 21:20
by Mikek
SFC Hiatt wrote:That is beautiful craftmanship!! I can hold my own with flying but, I can't build to save my life.
Hey Wag-Aero has them for about $200 each, you might be able to learn.
Mike K
Posted: Fri Jan 16, 2009 21:50
by joea
SFC Hiatt wrote:That is beautiful craftmanship!! I can hold my own with flying but, I can't build to save my life.
You just shoot straight and watch your "6" while you are overseas, and we will try to do the rest!
Posted: Fri Jan 16, 2009 23:11
by DMichaels
James you are in Anoka and I work in the summer in Forest Lake for Dave Sampson.
Do you still have the old ones? I could use them for a pattern I'm less than 80 miles away.
If you do not have the new ones installed yet would I be able to come over and trace them out. I can then make a plastic template in case anyone on the group needs to use it.
Dan
Posted: Sat Jan 17, 2009 05:24
by james gevay
Absolutely, you can come over and use the old ones for patterns and look at the new ones. The new ones are at my house in Circle Pines just east of Anoka Co. airport, off of Lake Drive and Lexington Ave.
You work for Dave Sampson the "collector", I've been up to his place a few times. I also soloed at Forrest lake when I was 16 in 1970.
Send me a PM and I will give you my phone number, I will be around this weekend, but Monday I will out of town all week. Jim