Champ Door Step

[seaheli]

Found a little time in the shop today to finish a step project. The drawing specifies to tack weld the step halves in four places.

Would it be wise to weld the entire seam of the halves to help prevent moisture from weeping into the seam?

Charles

[joea]

Considering where this step is going, moisture is not a big issue, but my gut feeling is that yes it would be good to seal it in some fashion, either welding or otherwise to prevent rust inside.

[David Johnson]

I would weld all around. Better to seal it up. The newer airplanes all add a gusset from the longeron to the streamline tube to prevent bowing. Looks like .063 or so. To a big boy, who can bend the steps easily, it looks like a good idea. David J.

[seaheli]

David,

I shaped the streamline tube to the step, it flattens out in the outside radius to match the contour of the teardrop. The drawing depicts that outside radius holding the major radius of the streamline tubing.

Do you have a picture of an original step?

Thanks, Charles

[David Johnson]

Charles, here you go. Hope this helps. If these don't show what you were looking for let me know. David J.

[seaheli]

Thank you David for the pictures, they sure do help a lot!

Charles

[Robert Henley]

Charles

That is one nifty looking step. I can't wait to see it in person.

Robert

[seaheli]

Robert,

Will be in the shop tomorrow afternoon to finish welding. Thank you for being patient with me.

Charles

[seaheli]

The step assemblies seem to take abuse, pictures of a Champ & Citabria step. The assemblies have been repaired, is this how most steps turn out after years of service?

[Robert Henley]

Robert,

Will be in the shop tomorrow afternoon to finish welding. Thank you for being patient with me.

Charles

It will be worth the wait. It appears you could have the opportunity to build additional steps if your schedule permits.

Robert

[seaheli]

I have a lot of respect for the craftsmen in the 1930's and 1940's, gas welding structures. The step is shaped from .031" mild steel, the aero-tubing is .065".

[Robert Henley]

Charles

Beautiful workmanship! I just hope the welder I have can do the attachment weld as pretty as your welds on such thin material.

Robert

[joea]

Looks great!

Cannot wait to see it on the airframe!

Joe A

[Robert Henley]

Looks great!

Cannot wait to see it on the airframe!

Joe A

Joe

No longer do you need to wait. The step was welded on yesterday. Here are some pictures of before and afterwards.



The step the project came with.



The attach point for the new step



The new step tack welded in place



The completed process with the new step in place. It may not be pretty but it seems to be strong.

Charles' excellent workmanship outshines the attachment weld but I am happy with it all.

Thanks to Charles I have an authentic step on my Champ.

Regards

Robert

[joea]

Looks great!

Have you given some thought to "dress grinding" the weld a bit smoother?

That would be the only suggestions I could give for improvements and know you will be a lot happier with it this way.

Joe A