Building Seamaster Day 4: Pylon and Side Meet

Gluing Pylon to Left Side

February 21st was about finishing off the Pylon and starting to get the fuselage sides attached.  The first step was ensuring the seems of where the spacers meet the formers are secure by applying a bead of medium CA glue long the seems.  This was done for all four areas, inside and out, making for eight beads of glue.

Medium CA Glue
Medium CA Glue
Glue Along Seems
Glue Along Seems

After that was done, this type of glue dries fast!  I did a trial fit of the pylon to each fuselage side.  While doing this I made a line along each side to determine where I needed to apply glue (seen below).  After that was done I placed glue along the left side of the pylon (ensuring sufficient glue on the tabs) as well as on the fuselage side and then put the pieces in place and clamped them together as seen in the picture at the top of the article.

Marking Glue Lines For Pylon Placement
Marking Glue Lines For Pylon Placement

That wrapped up another day as couldn’t go any further until this dried.  Once dried Peter did the same for the other side so that the project wasn’t held up to much as that needed to be done before anymore formers could be trial fitted and glued in place.

Building Seamaster Day 3: Pylon

Re-gluing the sides

Monday the 19th was a day of dang’s and backtracking before nicely getting ahead.  When I first got there and was working discovered that the sides of the fuselage hadn’t stuck together well enough.  Bad batch of glue!  That’s my story and I’m sticking to it… the only other evidence I have is that Peter tossed both parts for mixing it up and the fact they didn’t stick.

To rectify the sides coming apart I had to re-glue it (seen above) and thankfully this time it stuck!  Same process as before (without all the sanding), but unfortunately means not as much progress was made this day.  Also did a lot of sanding (John helped as well) due to the excess glue around the top of the doubler as you want to make sure the wing will sit nicely within the ‘saddle’.

What was suppose to be the main focus of this session was building the pylon, pictured below.  This is the main support for the fuselage and the engine mount (that will be above the aircraft mounted onto the piece of wood sticking out, plus other pieces I’ll get to later in the build).

For this I had to find the 4  pieces that make up the pylon (two of them are formers, F4 & F5).  The front is the smaller of the formers.  I then went to sanding the sides of all the pieces, followed by gluing the pieces that will help hold the main support for the engine (or so I’ll call it) and complete the pylon connecting F4 & F5.

Pylon with spacers all glued together
Pylon with spacers all glued together

That was it for this day as needed to wait for everything to dry before proceeding.  Also to make sure everything stuck together properly as well!

Building Seamaster Day 2: Stab & Doubler

Stabilizer Glued

Playing catch up on my blog posts here as been busy!  Last Saturday, Feb. 17th, was a building session that focused on getting the 3 pieces of each side of the fuselage glued together and stabilizer.

In order to glue the pieces of the fuselage together you mix up a batch of glue as it is made from two equal parts.  Once mixed you glue them together and place weights (with wax paper between the weights and the wood to ensure nothing gets accidentally stuck together that could tear away the wood) to hold the seems together.  The reason for the ‘cartoon teeth’ like look is to provide some interlocking which adds strength as gluing to flat ends together would not hold up well!

In the picture below I’ve glued the doubler to the fuselage making sure the curve lines up with the side of the fuselage.  This piece is on the inside of both sides of the fuselage to provide support for the wing.  You need to make sure that it is flush with the top (as the bottom is right above where a tab for one of the formers fits in) and lined up properly front and back too as there are tab holes there as well that if it covers you’ll be loosing support from where you need it.

Doubler Glued w/ Weights
Doubler Glued w/ Weights

For the stabilizer (shown at the top of the post) used Sig Cement to glue.  The only reason why I’m mentioning this is because the next time I went to Peter’s I discovered the sides didn’t hold, dun dun dun.  But I knew my stab was still OK as I used a different set of glue all together.

For the stab I had to find all the pieces, do some light sanding to remove the laser burns, and then line them up on the plans to ensure everything lines up and lightly sand where necessary.  I then glued and pin the perimeter pieces together followed by the center piece.  I then has to measure and cut all the individual pieces for reinforcing the stabilizer.  This involved cutting and sanding to make sure my angles were right to get a tight fit where the individual pieces of the ‘inside’ touch together along with where they touch with the perimeter of the stab.

Side Glued Together & Weighted
Side Glued Together & Weighted

That wrapped up another day!

Building Seamaster Day 1: Fuselage Sides

Seamaster Fuselage Sides - Front

Woot, woot!  Wednesday this past week I got to start another build.  This time around I am building a Seamaster.  This build has taken some time to get started with all the major life changes that happened over this winter and some hiccups in the creation of the kit itself.  This kit is no longer manufactured so someone Peter knows out of Winnipeg cut the kit for me, so a big thank-you to him!  I got to see the pieces for the first time Wednesday.

Peter put together a manual for constructing the kit, which I am reading through to get a general understanding of the overall process and also in being a guinea pig on the thoroughness / ease of use of the manual. 😉

This will be my first seaplane and I’m excited to experiencing taking off / landing and flying over water.  I’m getting ahead of myself though as I need to build the aircraft first!  To start I read through the introduction of the manual Peter wrote up along with the first bit on the fuselage.  I then laid out the plans on the table, covered it, and pinned it all in place.  I found the 6 pieces making up each side of the fuselage and laid them out.

You can see the front portion laid out in the image at the top of the post and the back portion of the fuselage sides in the image at the bottom of the post.  Due to the kits being laser cut the first step is always to do lots of sanding!  Which is what I did most of this day, was sanding all the edges to get rid of the ‘laser burns’ and give a better edge for the glue hold and allow the pieces to stick together (as shown in the top 3 pieces).

That sums up the first day of this build and am looking forward to Day 2!  I hope others will be interested to follow along on yet another build by yours truly 🙂

Now to reading the manual I go!

Seamaster Fuselage Sides - Back
Seamaster Fuselage Sides – Back


Flying 4 Star 60: A Summary

Time got away from me and I never blogged during the summer about my flying.  It was a very busy summer.  I got out flying ass much as I could and loved it as usual!  Missed some flying time during the summer as my girlfriend (at the time) and I went to Ottawa for a visit to take in the sites and got engaged (technically while in Gatineau)! P.S. what a beautiful city!

Basically my time went from learning the basics of taking off and landing with a taildragger, going through the same basic circuits as I did when learning to fly with my 4 Star 60, to advancing to doing loops and rolls in various combinations.

One thing to remember, which I’ve been keeping in the back of my mind for the upcoming season is to use my rudder a lot more.  This includes for aligning the aircraft on takeoffs and landings as well as when making turns using the rudder to prevent the tail from ‘sagging’.

I had some mishaps, most just coming in a little to hot and hitting the tall grass along the edge of the runway.    Need to ensure I am flaring my landings to aid in slowing the aircraft down.  My worst mishap was when I ran out of fuel in the air and couldn’t make the runway, thus crashing into the tall grass/weeds down the hill on the North side of the runway.  The worst part of the damage was breaking the leading edge of one wing which needed to be repaired and recovered before flying again.

I am looking forward to getting out flying again once this nasty cold weather is behind us.  I will start with my Sig Kadet LT40 to get back into the groove of things before bringing out my 4 Star 60 again.  In the meantime I have finally been able to start another build, a float plane this time, so more to come on that.  Been a crazy winter with getting married in December and getting settled into my (uh-um, our) new normal as I am very much a creature of habit, lol.