Wire Piiys T iirne U Bob Hatschek AFTER BALSA WOOD widely used solid material model aviation unquestionably music wire Think about would difficult build model complex hand-launched glider music wire True dont use great quantities music wire model youll find music wire parts kind model airplane Indoor feathers through giant RC monsters using conceivable type power plant rubber bands glow plug Electric jet non-powered sailplanes Its surprising find otherwise expert model craftsmen loss comes convening remarkable material useful components Music wire isnt just metal drawn out wire its just steel Its specific product steel industry high-quality straight-carbon steel fairly high carbon content Its final properties produced cold-drawing after rather unusual heat-treat traditionally involves quenching molten lead molten salt modem wire millsThere types steel wire higher quality music wirerocket wire some grades tool steel drill rod stainless steelbut readily available music wire some grades lower quality thing watch out what some suppliers offer music wire preformed parts such rubber model prop shafts sometimes cheaper lower-quality carbon spring steel doesnt have hardness toughness true music wire reason its easier bend sometimes-complex shapes require model aircraft its easier crack unbend well Some manufacturers may also anneal real music wire facilitate bending preformed parts remember music wire gets its original properties cold-drawing impossible return its original strength toughness further heat treatment heat music wire red hot particularly small sizes likely air-quench too rapidly become brittle Dont try prop shaft landing gear wing joiner could just snap must make steel part requires heat treatment use oil-quenching tool steel such 0-2 drill rod seek expert counsel procedures hobby shop place can buy music wire industrial supply houses good hardware stores carry quarter-pound one-pound coils music wire sizes hobby shop hobby shop easiest place get straight lengths Most hobby shops stock sizes shown Table 1 second column table labeled d2 proportional cross-sectional area wire provides index its weight tensile strength although rarely use music wire pure tension unless fly control line music wire lines often modelers use music wire bending mode hold-down hooks pegs example combination bending November 1994 27 Music wire parts Coupe dHiver front end 078 shaft 1116 5hook Hiborks hub 015 coil spring 025 autorudder pin useful pliers some Special cutter hard wire 9 oclock Text outlines use tool NO OCR TEXT approximate overall length inches tiny 4WR adds liffle weight field kit 5WRs most-used pair pliers other has its jaws reground tapered shape recommend WR version because model has hardened cutting jaws can handle music wire indeed use 10VR regularly cuffing music wire up I32 diameter 3 Two pairs round-nose pliers small large have pair about four inches long another about 7 inches long After will wonder ever did 4 least box-joint hemostat 5-inch longer jaws cut fairly short filed rather flat nose might find yourself modifying several useful tools variety purposes make bending small-diameter wire less 030 just modified hemostat thats unmodified 5 pair flat-nose needie-nose pliers 6 pair slip-joint gas pliers 7 heroic measures demanded bend lot heavy wiresay I32 up jobs cutting bench grinder Dremel Moto-Tool cutoff wheel get two bending tools offered K&S Engineering Mini Wire Bender easily bends music wire up 1/g diameter angles up 180 around 1/4-rnch pin Mighty Wire Bender works wire sizes up 1/4 Coil Winder handles wire up /16 winding number coils its mandrel 8 never use larger wire sizes small bench grinder medium wheel fine wheel desirable Alternately might use small abrasive wheel arbor bench-mounted electric drill Dremel tool horizontal mount clamped bench vise Dremel cutoff wheel often comes handy whenever grind steel wear safety glasses face shield 9 Treat yourself assortment new files fairly fine cut 10 micrometer vernier caliper dial caliper can very useful too machinists protractor measuring bend angles Hooks joggles ubiquitous use music wire course hookstypically little ones hooking rubber bands Too often dangerous fish hooks double wire before bend hook will pierce flesh shank now made two wires wont round wont twist loose easily single wire after has glued Incidentally plans often specify paper-clip wire such hold-down hooks Dont use Music wire much stiffer smaller sizes will less weight little weights add up far end hook should bent over speared solid balsa end anchored thin sheet balsa produce joggle bend sort Z-shaped insert through sheet bend joggle first bend toe right angle grip angle pliers bend another right angle wont aligned shank course now just twist straight Twist slowly therell less chance will break Heres tip attaching little bits metal like hooks hinges made aluminum tubing unglueable plastic parts balsa cyanoacrylate glue CyA Just wrap shank whatever area will glued fine thread cotton works fine put piece position hit CyA works well sewing part lot easier Ive using trick years kinds glue havent hook pull loose yet Springs spring winding can often buy tension compression coil springs made lower grade wire local hardware store can usually make faster can find reason beeause spring making no big deal make virtually springs use Think about springs moment Any spring wire has give its twisted its loaded bending stretch compress coil spring youre actually twisting wire want stiffer spring action can get loading wire bending mode applying safety pin type spring November1994 29 Lathe tools I32 music wire Three right bent ground shape Fine aluminum brass plastics Sometimes pays make special tools left jig throwaway S-hooks Towhook mainspring jig right Spring bending special jig coils dropped over vertical pin first foot bent tool steel anvil configuration goes under misnomer torsion spring textbooks because its usually applied twist something pull push also has advantage compactness lighter weightyou never need two thicknesses wrapped around shaft less steel needed because wire loaded bending mode way make coil springs tensile applications simply round-nose pliers Just keep bending circles until have necessary number coils Actually could needle-nose pliers spring will work fine coils squareno kidding Another way pride craftsmanship demands perfect-looking spring wind spring mandrel made heavy music wire nail suitable diameter can use birch dowel Just chuck mandrel lathe end wire trapped under chuck jaw Another way trap wire start spring slot outer end mandrel wind coils back toward chuck hold far end spring wire under tension pair Vise-Grips dont have lathe just clamp crank-type hand drill horizontally bench vise pretend its lathe used way Now turn lathe hand drill hand keep spring wire tension other hand will some springback will open up coil diameter slightly may require bit trial-and-error get exactly right size mandrel tension springs wind coils tightly against other compression springs wind tight coils pull open coils suit needs will also open up diameter bit applications doesnt matter spring coiled leftor right-handed sometimes does aware some pretty good spring-winding tools available have never bothered get Springmaking really too easy Special tooling Sometimeswhen youre going make number identical wire parts exampleits desirable make special bending jig two such cases special jig used bending torsion-type mainsprings Hatschek-style towhooks approximately 2700 interchangeable springs bent jig am currently using make throwaway S-hooks wire sizes 047 P-30 078 FlB Prototypes both towhook springs special S-hooks made using standard tools list above plus bench vise some suitable-size mandrels 067 wire 1/4-inch steel rod principal objectives making special tooling parts 1 make job easier 2 important make parts identical tools simply aluminum blocks steel bending forms affixed forms made variety ways often simply short lengths suitably sized music wire pressed holes drilled aluminum base Sometimes theyre made small bits say 1/8 flat ground tool steel shaped hacksaw drill file hardened heating red hot gas stove torch quenching oil typically attached screws tapped holes aluminum block 30 Model Aviation 4This 1/16 music wire S-hook ready cut deburred Dremel Moto-Tool below right dont have have lathe wind coil springs Setup will also work variable-speed electric drill low rpm Removing burr S-hook Moto-Tool Masking tape pads plier jaws avoids raising new burr hook DODDGER DODDGER takes let Place 1990 1991 & 1993 AMA Nationals! Now DODDGER has standard DODDGER kit now includes V-tail & Mid-tail versions Instructions show required modifications create V-tail Mid-tail version Craig Grunkemeyers tricks still included! real GO FAST & TURN LEFT kit market.THE DODDGERU Engine 25 45 Span 50 inches Area 500 square inches $5 rDIRECT9NN6CTIONp~ Lapawne ntI mippilers Inc ao w menrock Rd Westervifle OH 43081 614-899-6313 Fax 614-899-6070- 1800-593-5250 sometimes standard bolt will provide necessary shape depends what youre trying what scraps have junk box mainspring jig Figure 1 consists two pieces 067 music wire fixed base block hardened bending anvil made flat tool steel described above wires secured setscrews would have easier probably just durable merely press tool clamped bench vise longer wire projecting out horizontally clamp 5WR Vise Grips about 5/ inch end length 039-043 music wire holding free end wire left hand simply wrap required number coils around horizontal 067 mandrel release Vise-Grips drop coils over vertical mandrel bend foot spring out around acute angle steel block Next flip coils over same mandrel bend opposite foot Using slip-joint pliers bend both anides align outward-pointing feet Finally cut spring free wire grind ends length S-hook jig Figure 2 demonstrates couple other principles Its made piece /2-inch-square aluminum I32 slot end three /32 music wire pins shown Figure 2 removable /4-inch capscrew tapped hole As noted earlier variety S-hooks can bent tool Heres procedure First jig clamped vertically bench vise slot above jaws across After cleaning up end bench grinder S-hook wire inserted rear just under pin through slot short hook bent 180 Since usually make batch hooks once same other end wire make two setup Next jig repositioned vise short hook placed over short pin trap holding loop wrapped around vertical pin closest short pin make small S-hook jig turned over capscrew inserted finger-tight Diameter Cd 010 0151/64 020 025 031 1/ 039 1mm 047 /64 055 063 ills 078 5/s 2mm 093 /32 125 156 5/ 4mm 188 3Iis Notes d2 proportional weight per inch tensile load capability d3 proportional torsional load capability d4 proportional stiffness bending d2 x 1O d3 x 1O d4x1O 101010 22533851 4816 62515639 9629892 1539231 22103487 30166915 402501575 614743702 668047480 156195324414 243379659224 3536645124920 holding loop placed over pin thats closest screw rubber hook bent round shank screw its cut length filed remove burr protected inch fuel tubing make large S-hook put screw side giving space vertical pin bend hook 180 aroundpulling back open ealarge diameter before cuffing off Alternately could put short length say 1/4 inch metal tubing under head screw provide larger diameter bending form own ingenuity will suggest specifics tooling need make parts Just remember principle keeping wire under control times Some torsion calculations heart torque meter its sensing element simple length music wire cases Its secret lies two formulas few basic properties music wire 1 find shear stress round piece wire subjected twisting force S d3 rque oz-in d wire diameter inches S stress lb/sq psi 2 find twist wire L/l000OOOd S stress psi L length thats free twist inches d wire diameter inches angle twist degrees important property music wire thats included formulas above its elastic limit torsion value 120000 130000 psi both safe reasonable music wire shouldnt exceeded give feel so-called structural steel around half Coupe dHiver torque meter loading 047 music wire torque 40 oz-tn right ballpark 122600 psi dont have worry about wire failing result tensile load want heavier meter say 120 oz-in capacity FiB big Mulvihill should pass up /16 wire 156500 psi 120 oz-in means will take set permanent twist go 078 80500 psi 120 oz-in 180 twist active length should 1463 inches did buy some 067 wire youll have straighten Perfect straightness would nice isnt necessary case rules also valid prop shaft sizes should generally next larger standard size music wire Please note too 120000-psi limit applies music wire has never heat-treated facts formulas also valid realm Indoor models interesting facts music wire smaller sizes can actually take higher stresses remember thats pounds per square inch pounds tension oz-in torque mber 1994 31 Engineering has steel base bending handle Set up bend 118 wire landing gear
Edition: Model Aviation - 1994/11
Page Numbers: 27, 28, 29, 30, 31
Wire Piiys T iirne U Bob Hatschek AFTER BALSA WOOD widely used solid material model aviation unquestionably music wire Think about would difficult build model complex hand-launched glider music wire True dont use great quantities music wire model youll find music wire parts kind model airplane Indoor feathers through giant RC monsters using conceivable type power plant rubber bands glow plug Electric jet non-powered sailplanes Its surprising find otherwise expert model craftsmen loss comes convening remarkable material useful components Music wire isnt just metal drawn out wire its just steel Its specific product steel industry high-quality straight-carbon steel fairly high carbon content Its final properties produced cold-drawing after rather unusual heat-treat traditionally involves quenching molten lead molten salt modem wire millsThere types steel wire higher quality music wirerocket wire some grades tool steel drill rod stainless steelbut readily available music wire some grades lower quality thing watch out what some suppliers offer music wire preformed parts such rubber model prop shafts sometimes cheaper lower-quality carbon spring steel doesnt have hardness toughness true music wire reason its easier bend sometimes-complex shapes require model aircraft its easier crack unbend well Some manufacturers may also anneal real music wire facilitate bending preformed parts remember music wire gets its original properties cold-drawing impossible return its original strength toughness further heat treatment heat music wire red hot particularly small sizes likely air-quench too rapidly become brittle Dont try prop shaft landing gear wing joiner could just snap must make steel part requires heat treatment use oil-quenching tool steel such 0-2 drill rod seek expert counsel procedures hobby shop place can buy music wire industrial supply houses good hardware stores carry quarter-pound one-pound coils music wire sizes hobby shop hobby shop easiest place get straight lengths Most hobby shops stock sizes shown Table 1 second column table labeled d2 proportional cross-sectional area wire provides index its weight tensile strength although rarely use music wire pure tension unless fly control line music wire lines often modelers use music wire bending mode hold-down hooks pegs example combination bending November 1994 27 Music wire parts Coupe dHiver front end 078 shaft 1116 5hook Hiborks hub 015 coil spring 025 autorudder pin useful pliers some Special cutter hard wire 9 oclock Text outlines use tool NO OCR TEXT approximate overall length inches tiny 4WR adds liffle weight field kit 5WRs most-used pair pliers other has its jaws reground tapered shape recommend WR version because model has hardened cutting jaws can handle music wire indeed use 10VR regularly cuffing music wire up I32 diameter 3 Two pairs round-nose pliers small large have pair about four inches long another about 7 inches long After will wonder ever did 4 least box-joint hemostat 5-inch longer jaws cut fairly short filed rather flat nose might find yourself modifying several useful tools variety purposes make bending small-diameter wire less 030 just modified hemostat thats unmodified 5 pair flat-nose needie-nose pliers 6 pair slip-joint gas pliers 7 heroic measures demanded bend lot heavy wiresay I32 up jobs cutting bench grinder Dremel Moto-Tool cutoff wheel get two bending tools offered K&S Engineering Mini Wire Bender easily bends music wire up 1/g diameter angles up 180 around 1/4-rnch pin Mighty Wire Bender works wire sizes up 1/4 Coil Winder handles wire up /16 winding number coils its mandrel 8 never use larger wire sizes small bench grinder medium wheel fine wheel desirable Alternately might use small abrasive wheel arbor bench-mounted electric drill Dremel tool horizontal mount clamped bench vise Dremel cutoff wheel often comes handy whenever grind steel wear safety glasses face shield 9 Treat yourself assortment new files fairly fine cut 10 micrometer vernier caliper dial caliper can very useful too machinists protractor measuring bend angles Hooks joggles ubiquitous use music wire course hookstypically little ones hooking rubber bands Too often dangerous fish hooks double wire before bend hook will pierce flesh shank now made two wires wont round wont twist loose easily single wire after has glued Incidentally plans often specify paper-clip wire such hold-down hooks Dont use Music wire much stiffer smaller sizes will less weight little weights add up far end hook should bent over speared solid balsa end anchored thin sheet balsa produce joggle bend sort Z-shaped insert through sheet bend joggle first bend toe right angle grip angle pliers bend another right angle wont aligned shank course now just twist straight Twist slowly therell less chance will break Heres tip attaching little bits metal like hooks hinges made aluminum tubing unglueable plastic parts balsa cyanoacrylate glue CyA Just wrap shank whatever area will glued fine thread cotton works fine put piece position hit CyA works well sewing part lot easier Ive using trick years kinds glue havent hook pull loose yet Springs spring winding can often buy tension compression coil springs made lower grade wire local hardware store can usually make faster can find reason beeause spring making no big deal make virtually springs use Think about springs moment Any spring wire has give its twisted its loaded bending stretch compress coil spring youre actually twisting wire want stiffer spring action can get loading wire bending mode applying safety pin type spring November1994 29 Lathe tools I32 music wire Three right bent ground shape Fine aluminum brass plastics Sometimes pays make special tools left jig throwaway S-hooks Towhook mainspring jig right Spring bending special jig coils dropped over vertical pin first foot bent tool steel anvil configuration goes under misnomer torsion spring textbooks because its usually applied twist something pull push also has advantage compactness lighter weightyou never need two thicknesses wrapped around shaft less steel needed because wire loaded bending mode way make coil springs tensile applications simply round-nose pliers Just keep bending circles until have necessary number coils Actually could needle-nose pliers spring will work fine coils squareno kidding Another way pride craftsmanship demands perfect-looking spring wind spring mandrel made heavy music wire nail suitable diameter can use birch dowel Just chuck mandrel lathe end wire trapped under chuck jaw Another way trap wire start spring slot outer end mandrel wind coils back toward chuck hold far end spring wire under tension pair Vise-Grips dont have lathe just clamp crank-type hand drill horizontally bench vise pretend its lathe used way Now turn lathe hand drill hand keep spring wire tension other hand will some springback will open up coil diameter slightly may require bit trial-and-error get exactly right size mandrel tension springs wind coils tightly against other compression springs wind tight coils pull open coils suit needs will also open up diameter bit applications doesnt matter spring coiled leftor right-handed sometimes does aware some pretty good spring-winding tools available have never bothered get Springmaking really too easy Special tooling Sometimeswhen youre going make number identical wire parts exampleits desirable make special bending jig two such cases special jig used bending torsion-type mainsprings Hatschek-style towhooks approximately 2700 interchangeable springs bent jig am currently using make throwaway S-hooks wire sizes 047 P-30 078 FlB Prototypes both towhook springs special S-hooks made using standard tools list above plus bench vise some suitable-size mandrels 067 wire 1/4-inch steel rod principal objectives making special tooling parts 1 make job easier 2 important make parts identical tools simply aluminum blocks steel bending forms affixed forms made variety ways often simply short lengths suitably sized music wire pressed holes drilled aluminum base Sometimes theyre made small bits say 1/8 flat ground tool steel shaped hacksaw drill file hardened heating red hot gas stove torch quenching oil typically attached screws tapped holes aluminum block 30 Model Aviation 4This 1/16 music wire S-hook ready cut deburred Dremel Moto-Tool below right dont have have lathe wind coil springs Setup will also work variable-speed electric drill low rpm Removing burr S-hook Moto-Tool Masking tape pads plier jaws avoids raising new burr hook DODDGER DODDGER takes let Place 1990 1991 & 1993 AMA Nationals! Now DODDGER has standard DODDGER kit now includes V-tail & Mid-tail versions Instructions show required modifications create V-tail Mid-tail version Craig Grunkemeyers tricks still included! real GO FAST & TURN LEFT kit market.THE DODDGERU Engine 25 45 Span 50 inches Area 500 square inches $5 rDIRECT9NN6CTIONp~ Lapawne ntI mippilers Inc ao w menrock Rd Westervifle OH 43081 614-899-6313 Fax 614-899-6070- 1800-593-5250 sometimes standard bolt will provide necessary shape depends what youre trying what scraps have junk box mainspring jig Figure 1 consists two pieces 067 music wire fixed base block hardened bending anvil made flat tool steel described above wires secured setscrews would have easier probably just durable merely press tool clamped bench vise longer wire projecting out horizontally clamp 5WR Vise Grips about 5/ inch end length 039-043 music wire holding free end wire left hand simply wrap required number coils around horizontal 067 mandrel release Vise-Grips drop coils over vertical mandrel bend foot spring out around acute angle steel block Next flip coils over same mandrel bend opposite foot Using slip-joint pliers bend both anides align outward-pointing feet Finally cut spring free wire grind ends length S-hook jig Figure 2 demonstrates couple other principles Its made piece /2-inch-square aluminum I32 slot end three /32 music wire pins shown Figure 2 removable /4-inch capscrew tapped hole As noted earlier variety S-hooks can bent tool Heres procedure First jig clamped vertically bench vise slot above jaws across After cleaning up end bench grinder S-hook wire inserted rear just under pin through slot short hook bent 180 Since usually make batch hooks once same other end wire make two setup Next jig repositioned vise short hook placed over short pin trap holding loop wrapped around vertical pin closest short pin make small S-hook jig turned over capscrew inserted finger-tight Diameter Cd 010 0151/64 020 025 031 1/ 039 1mm 047 /64 055 063 ills 078 5/s 2mm 093 /32 125 156 5/ 4mm 188 3Iis Notes d2 proportional weight per inch tensile load capability d3 proportional torsional load capability d4 proportional stiffness bending d2 x 1O d3 x 1O d4x1O 101010 22533851 4816 62515639 9629892 1539231 22103487 30166915 402501575 614743702 668047480 156195324414 243379659224 3536645124920 holding loop placed over pin thats closest screw rubber hook bent round shank screw its cut length filed remove burr protected inch fuel tubing make large S-hook put screw side giving space vertical pin bend hook 180 aroundpulling back open ealarge diameter before cuffing off Alternately could put short length say 1/4 inch metal tubing under head screw provide larger diameter bending form own ingenuity will suggest specifics tooling need make parts Just remember principle keeping wire under control times Some torsion calculations heart torque meter its sensing element simple length music wire cases Its secret lies two formulas few basic properties music wire 1 find shear stress round piece wire subjected twisting force S d3 rque oz-in d wire diameter inches S stress lb/sq psi 2 find twist wire L/l000OOOd S stress psi L length thats free twist inches d wire diameter inches angle twist degrees important property music wire thats included formulas above its elastic limit torsion value 120000 130000 psi both safe reasonable music wire shouldnt exceeded give feel so-called structural steel around half Coupe dHiver torque meter loading 047 music wire torque 40 oz-tn right ballpark 122600 psi dont have worry about wire failing result tensile load want heavier meter say 120 oz-in capacity FiB big Mulvihill should pass up /16 wire 156500 psi 120 oz-in means will take set permanent twist go 078 80500 psi 120 oz-in 180 twist active length should 1463 inches did buy some 067 wire youll have straighten Perfect straightness would nice isnt necessary case rules also valid prop shaft sizes should generally next larger standard size music wire Please note too 120000-psi limit applies music wire has never heat-treated facts formulas also valid realm Indoor models interesting facts music wire smaller sizes can actually take higher stresses remember thats pounds per square inch pounds tension oz-in torque mber 1994 31 Engineering has steel base bending handle Set up bend 118 wire landing gear
Edition: Model Aviation - 1994/11
Page Numbers: 27, 28, 29, 30, 31
Wire Piiys T iirne U Bob Hatschek AFTER BALSA WOOD widely used solid material model aviation unquestionably music wire Think about would difficult build model complex hand-launched glider music wire True dont use great quantities music wire model youll find music wire parts kind model airplane Indoor feathers through giant RC monsters using conceivable type power plant rubber bands glow plug Electric jet non-powered sailplanes Its surprising find otherwise expert model craftsmen loss comes convening remarkable material useful components Music wire isnt just metal drawn out wire its just steel Its specific product steel industry high-quality straight-carbon steel fairly high carbon content Its final properties produced cold-drawing after rather unusual heat-treat traditionally involves quenching molten lead molten salt modem wire millsThere types steel wire higher quality music wirerocket wire some grades tool steel drill rod stainless steelbut readily available music wire some grades lower quality thing watch out what some suppliers offer music wire preformed parts such rubber model prop shafts sometimes cheaper lower-quality carbon spring steel doesnt have hardness toughness true music wire reason its easier bend sometimes-complex shapes require model aircraft its easier crack unbend well Some manufacturers may also anneal real music wire facilitate bending preformed parts remember music wire gets its original properties cold-drawing impossible return its original strength toughness further heat treatment heat music wire red hot particularly small sizes likely air-quench too rapidly become brittle Dont try prop shaft landing gear wing joiner could just snap must make steel part requires heat treatment use oil-quenching tool steel such 0-2 drill rod seek expert counsel procedures hobby shop place can buy music wire industrial supply houses good hardware stores carry quarter-pound one-pound coils music wire sizes hobby shop hobby shop easiest place get straight lengths Most hobby shops stock sizes shown Table 1 second column table labeled d2 proportional cross-sectional area wire provides index its weight tensile strength although rarely use music wire pure tension unless fly control line music wire lines often modelers use music wire bending mode hold-down hooks pegs example combination bending November 1994 27 Music wire parts Coupe dHiver front end 078 shaft 1116 5hook Hiborks hub 015 coil spring 025 autorudder pin useful pliers some Special cutter hard wire 9 oclock Text outlines use tool NO OCR TEXT approximate overall length inches tiny 4WR adds liffle weight field kit 5WRs most-used pair pliers other has its jaws reground tapered shape recommend WR version because model has hardened cutting jaws can handle music wire indeed use 10VR regularly cuffing music wire up I32 diameter 3 Two pairs round-nose pliers small large have pair about four inches long another about 7 inches long After will wonder ever did 4 least box-joint hemostat 5-inch longer jaws cut fairly short filed rather flat nose might find yourself modifying several useful tools variety purposes make bending small-diameter wire less 030 just modified hemostat thats unmodified 5 pair flat-nose needie-nose pliers 6 pair slip-joint gas pliers 7 heroic measures demanded bend lot heavy wiresay I32 up jobs cutting bench grinder Dremel Moto-Tool cutoff wheel get two bending tools offered K&S Engineering Mini Wire Bender easily bends music wire up 1/g diameter angles up 180 around 1/4-rnch pin Mighty Wire Bender works wire sizes up 1/4 Coil Winder handles wire up /16 winding number coils its mandrel 8 never use larger wire sizes small bench grinder medium wheel fine wheel desirable Alternately might use small abrasive wheel arbor bench-mounted electric drill Dremel tool horizontal mount clamped bench vise Dremel cutoff wheel often comes handy whenever grind steel wear safety glasses face shield 9 Treat yourself assortment new files fairly fine cut 10 micrometer vernier caliper dial caliper can very useful too machinists protractor measuring bend angles Hooks joggles ubiquitous use music wire course hookstypically little ones hooking rubber bands Too often dangerous fish hooks double wire before bend hook will pierce flesh shank now made two wires wont round wont twist loose easily single wire after has glued Incidentally plans often specify paper-clip wire such hold-down hooks Dont use Music wire much stiffer smaller sizes will less weight little weights add up far end hook should bent over speared solid balsa end anchored thin sheet balsa produce joggle bend sort Z-shaped insert through sheet bend joggle first bend toe right angle grip angle pliers bend another right angle wont aligned shank course now just twist straight Twist slowly therell less chance will break Heres tip attaching little bits metal like hooks hinges made aluminum tubing unglueable plastic parts balsa cyanoacrylate glue CyA Just wrap shank whatever area will glued fine thread cotton works fine put piece position hit CyA works well sewing part lot easier Ive using trick years kinds glue havent hook pull loose yet Springs spring winding can often buy tension compression coil springs made lower grade wire local hardware store can usually make faster can find reason beeause spring making no big deal make virtually springs use Think about springs moment Any spring wire has give its twisted its loaded bending stretch compress coil spring youre actually twisting wire want stiffer spring action can get loading wire bending mode applying safety pin type spring November1994 29 Lathe tools I32 music wire Three right bent ground shape Fine aluminum brass plastics Sometimes pays make special tools left jig throwaway S-hooks Towhook mainspring jig right Spring bending special jig coils dropped over vertical pin first foot bent tool steel anvil configuration goes under misnomer torsion spring textbooks because its usually applied twist something pull push also has advantage compactness lighter weightyou never need two thicknesses wrapped around shaft less steel needed because wire loaded bending mode way make coil springs tensile applications simply round-nose pliers Just keep bending circles until have necessary number coils Actually could needle-nose pliers spring will work fine coils squareno kidding Another way pride craftsmanship demands perfect-looking spring wind spring mandrel made heavy music wire nail suitable diameter can use birch dowel Just chuck mandrel lathe end wire trapped under chuck jaw Another way trap wire start spring slot outer end mandrel wind coils back toward chuck hold far end spring wire under tension pair Vise-Grips dont have lathe just clamp crank-type hand drill horizontally bench vise pretend its lathe used way Now turn lathe hand drill hand keep spring wire tension other hand will some springback will open up coil diameter slightly may require bit trial-and-error get exactly right size mandrel tension springs wind coils tightly against other compression springs wind tight coils pull open coils suit needs will also open up diameter bit applications doesnt matter spring coiled leftor right-handed sometimes does aware some pretty good spring-winding tools available have never bothered get Springmaking really too easy Special tooling Sometimeswhen youre going make number identical wire parts exampleits desirable make special bending jig two such cases special jig used bending torsion-type mainsprings Hatschek-style towhooks approximately 2700 interchangeable springs bent jig am currently using make throwaway S-hooks wire sizes 047 P-30 078 FlB Prototypes both towhook springs special S-hooks made using standard tools list above plus bench vise some suitable-size mandrels 067 wire 1/4-inch steel rod principal objectives making special tooling parts 1 make job easier 2 important make parts identical tools simply aluminum blocks steel bending forms affixed forms made variety ways often simply short lengths suitably sized music wire pressed holes drilled aluminum base Sometimes theyre made small bits say 1/8 flat ground tool steel shaped hacksaw drill file hardened heating red hot gas stove torch quenching oil typically attached screws tapped holes aluminum block 30 Model Aviation 4This 1/16 music wire S-hook ready cut deburred Dremel Moto-Tool below right dont have have lathe wind coil springs Setup will also work variable-speed electric drill low rpm Removing burr S-hook Moto-Tool Masking tape pads plier jaws avoids raising new burr hook DODDGER DODDGER takes let Place 1990 1991 & 1993 AMA Nationals! Now DODDGER has standard DODDGER kit now includes V-tail & Mid-tail versions Instructions show required modifications create V-tail Mid-tail version Craig Grunkemeyers tricks still included! real GO FAST & TURN LEFT kit market.THE DODDGERU Engine 25 45 Span 50 inches Area 500 square inches $5 rDIRECT9NN6CTIONp~ Lapawne ntI mippilers Inc ao w menrock Rd Westervifle OH 43081 614-899-6313 Fax 614-899-6070- 1800-593-5250 sometimes standard bolt will provide necessary shape depends what youre trying what scraps have junk box mainspring jig Figure 1 consists two pieces 067 music wire fixed base block hardened bending anvil made flat tool steel described above wires secured setscrews would have easier probably just durable merely press tool clamped bench vise longer wire projecting out horizontally clamp 5WR Vise Grips about 5/ inch end length 039-043 music wire holding free end wire left hand simply wrap required number coils around horizontal 067 mandrel release Vise-Grips drop coils over vertical mandrel bend foot spring out around acute angle steel block Next flip coils over same mandrel bend opposite foot Using slip-joint pliers bend both anides align outward-pointing feet Finally cut spring free wire grind ends length S-hook jig Figure 2 demonstrates couple other principles Its made piece /2-inch-square aluminum I32 slot end three /32 music wire pins shown Figure 2 removable /4-inch capscrew tapped hole As noted earlier variety S-hooks can bent tool Heres procedure First jig clamped vertically bench vise slot above jaws across After cleaning up end bench grinder S-hook wire inserted rear just under pin through slot short hook bent 180 Since usually make batch hooks once same other end wire make two setup Next jig repositioned vise short hook placed over short pin trap holding loop wrapped around vertical pin closest short pin make small S-hook jig turned over capscrew inserted finger-tight Diameter Cd 010 0151/64 020 025 031 1/ 039 1mm 047 /64 055 063 ills 078 5/s 2mm 093 /32 125 156 5/ 4mm 188 3Iis Notes d2 proportional weight per inch tensile load capability d3 proportional torsional load capability d4 proportional stiffness bending d2 x 1O d3 x 1O d4x1O 101010 22533851 4816 62515639 9629892 1539231 22103487 30166915 402501575 614743702 668047480 156195324414 243379659224 3536645124920 holding loop placed over pin thats closest screw rubber hook bent round shank screw its cut length filed remove burr protected inch fuel tubing make large S-hook put screw side giving space vertical pin bend hook 180 aroundpulling back open ealarge diameter before cuffing off Alternately could put short length say 1/4 inch metal tubing under head screw provide larger diameter bending form own ingenuity will suggest specifics tooling need make parts Just remember principle keeping wire under control times Some torsion calculations heart torque meter its sensing element simple length music wire cases Its secret lies two formulas few basic properties music wire 1 find shear stress round piece wire subjected twisting force S d3 rque oz-in d wire diameter inches S stress lb/sq psi 2 find twist wire L/l000OOOd S stress psi L length thats free twist inches d wire diameter inches angle twist degrees important property music wire thats included formulas above its elastic limit torsion value 120000 130000 psi both safe reasonable music wire shouldnt exceeded give feel so-called structural steel around half Coupe dHiver torque meter loading 047 music wire torque 40 oz-tn right ballpark 122600 psi dont have worry about wire failing result tensile load want heavier meter say 120 oz-in capacity FiB big Mulvihill should pass up /16 wire 156500 psi 120 oz-in means will take set permanent twist go 078 80500 psi 120 oz-in 180 twist active length should 1463 inches did buy some 067 wire youll have straighten Perfect straightness would nice isnt necessary case rules also valid prop shaft sizes should generally next larger standard size music wire Please note too 120000-psi limit applies music wire has never heat-treated facts formulas also valid realm Indoor models interesting facts music wire smaller sizes can actually take higher stresses remember thats pounds per square inch pounds tension oz-in torque mber 1994 31 Engineering has steel base bending handle Set up bend 118 wire landing gear
Edition: Model Aviation - 1994/11
Page Numbers: 27, 28, 29, 30, 31
Wire Piiys T iirne U Bob Hatschek AFTER BALSA WOOD widely used solid material model aviation unquestionably music wire Think about would difficult build model complex hand-launched glider music wire True dont use great quantities music wire model youll find music wire parts kind model airplane Indoor feathers through giant RC monsters using conceivable type power plant rubber bands glow plug Electric jet non-powered sailplanes Its surprising find otherwise expert model craftsmen loss comes convening remarkable material useful components Music wire isnt just metal drawn out wire its just steel Its specific product steel industry high-quality straight-carbon steel fairly high carbon content Its final properties produced cold-drawing after rather unusual heat-treat traditionally involves quenching molten lead molten salt modem wire millsThere types steel wire higher quality music wirerocket wire some grades tool steel drill rod stainless steelbut readily available music wire some grades lower quality thing watch out what some suppliers offer music wire preformed parts such rubber model prop shafts sometimes cheaper lower-quality carbon spring steel doesnt have hardness toughness true music wire reason its easier bend sometimes-complex shapes require model aircraft its easier crack unbend well Some manufacturers may also anneal real music wire facilitate bending preformed parts remember music wire gets its original properties cold-drawing impossible return its original strength toughness further heat treatment heat music wire red hot particularly small sizes likely air-quench too rapidly become brittle Dont try prop shaft landing gear wing joiner could just snap must make steel part requires heat treatment use oil-quenching tool steel such 0-2 drill rod seek expert counsel procedures hobby shop place can buy music wire industrial supply houses good hardware stores carry quarter-pound one-pound coils music wire sizes hobby shop hobby shop easiest place get straight lengths Most hobby shops stock sizes shown Table 1 second column table labeled d2 proportional cross-sectional area wire provides index its weight tensile strength although rarely use music wire pure tension unless fly control line music wire lines often modelers use music wire bending mode hold-down hooks pegs example combination bending November 1994 27 Music wire parts Coupe dHiver front end 078 shaft 1116 5hook Hiborks hub 015 coil spring 025 autorudder pin useful pliers some Special cutter hard wire 9 oclock Text outlines use tool NO OCR TEXT approximate overall length inches tiny 4WR adds liffle weight field kit 5WRs most-used pair pliers other has its jaws reground tapered shape recommend WR version because model has hardened cutting jaws can handle music wire indeed use 10VR regularly cuffing music wire up I32 diameter 3 Two pairs round-nose pliers small large have pair about four inches long another about 7 inches long After will wonder ever did 4 least box-joint hemostat 5-inch longer jaws cut fairly short filed rather flat nose might find yourself modifying several useful tools variety purposes make bending small-diameter wire less 030 just modified hemostat thats unmodified 5 pair flat-nose needie-nose pliers 6 pair slip-joint gas pliers 7 heroic measures demanded bend lot heavy wiresay I32 up jobs cutting bench grinder Dremel Moto-Tool cutoff wheel get two bending tools offered K&S Engineering Mini Wire Bender easily bends music wire up 1/g diameter angles up 180 around 1/4-rnch pin Mighty Wire Bender works wire sizes up 1/4 Coil Winder handles wire up /16 winding number coils its mandrel 8 never use larger wire sizes small bench grinder medium wheel fine wheel desirable Alternately might use small abrasive wheel arbor bench-mounted electric drill Dremel tool horizontal mount clamped bench vise Dremel cutoff wheel often comes handy whenever grind steel wear safety glasses face shield 9 Treat yourself assortment new files fairly fine cut 10 micrometer vernier caliper dial caliper can very useful too machinists protractor measuring bend angles Hooks joggles ubiquitous use music wire course hookstypically little ones hooking rubber bands Too often dangerous fish hooks double wire before bend hook will pierce flesh shank now made two wires wont round wont twist loose easily single wire after has glued Incidentally plans often specify paper-clip wire such hold-down hooks Dont use Music wire much stiffer smaller sizes will less weight little weights add up far end hook should bent over speared solid balsa end anchored thin sheet balsa produce joggle bend sort Z-shaped insert through sheet bend joggle first bend toe right angle grip angle pliers bend another right angle wont aligned shank course now just twist straight Twist slowly therell less chance will break Heres tip attaching little bits metal like hooks hinges made aluminum tubing unglueable plastic parts balsa cyanoacrylate glue CyA Just wrap shank whatever area will glued fine thread cotton works fine put piece position hit CyA works well sewing part lot easier Ive using trick years kinds glue havent hook pull loose yet Springs spring winding can often buy tension compression coil springs made lower grade wire local hardware store can usually make faster can find reason beeause spring making no big deal make virtually springs use Think about springs moment Any spring wire has give its twisted its loaded bending stretch compress coil spring youre actually twisting wire want stiffer spring action can get loading wire bending mode applying safety pin type spring November1994 29 Lathe tools I32 music wire Three right bent ground shape Fine aluminum brass plastics Sometimes pays make special tools left jig throwaway S-hooks Towhook mainspring jig right Spring bending special jig coils dropped over vertical pin first foot bent tool steel anvil configuration goes under misnomer torsion spring textbooks because its usually applied twist something pull push also has advantage compactness lighter weightyou never need two thicknesses wrapped around shaft less steel needed because wire loaded bending mode way make coil springs tensile applications simply round-nose pliers Just keep bending circles until have necessary number coils Actually could needle-nose pliers spring will work fine coils squareno kidding Another way pride craftsmanship demands perfect-looking spring wind spring mandrel made heavy music wire nail suitable diameter can use birch dowel Just chuck mandrel lathe end wire trapped under chuck jaw Another way trap wire start spring slot outer end mandrel wind coils back toward chuck hold far end spring wire under tension pair Vise-Grips dont have lathe just clamp crank-type hand drill horizontally bench vise pretend its lathe used way Now turn lathe hand drill hand keep spring wire tension other hand will some springback will open up coil diameter slightly may require bit trial-and-error get exactly right size mandrel tension springs wind coils tightly against other compression springs wind tight coils pull open coils suit needs will also open up diameter bit applications doesnt matter spring coiled leftor right-handed sometimes does aware some pretty good spring-winding tools available have never bothered get Springmaking really too easy Special tooling Sometimeswhen youre going make number identical wire parts exampleits desirable make special bending jig two such cases special jig used bending torsion-type mainsprings Hatschek-style towhooks approximately 2700 interchangeable springs bent jig am currently using make throwaway S-hooks wire sizes 047 P-30 078 FlB Prototypes both towhook springs special S-hooks made using standard tools list above plus bench vise some suitable-size mandrels 067 wire 1/4-inch steel rod principal objectives making special tooling parts 1 make job easier 2 important make parts identical tools simply aluminum blocks steel bending forms affixed forms made variety ways often simply short lengths suitably sized music wire pressed holes drilled aluminum base Sometimes theyre made small bits say 1/8 flat ground tool steel shaped hacksaw drill file hardened heating red hot gas stove torch quenching oil typically attached screws tapped holes aluminum block 30 Model Aviation 4This 1/16 music wire S-hook ready cut deburred Dremel Moto-Tool below right dont have have lathe wind coil springs Setup will also work variable-speed electric drill low rpm Removing burr S-hook Moto-Tool Masking tape pads plier jaws avoids raising new burr hook DODDGER DODDGER takes let Place 1990 1991 & 1993 AMA Nationals! Now DODDGER has standard DODDGER kit now includes V-tail & Mid-tail versions Instructions show required modifications create V-tail Mid-tail version Craig Grunkemeyers tricks still included! real GO FAST & TURN LEFT kit market.THE DODDGERU Engine 25 45 Span 50 inches Area 500 square inches $5 rDIRECT9NN6CTIONp~ Lapawne ntI mippilers Inc ao w menrock Rd Westervifle OH 43081 614-899-6313 Fax 614-899-6070- 1800-593-5250 sometimes standard bolt will provide necessary shape depends what youre trying what scraps have junk box mainspring jig Figure 1 consists two pieces 067 music wire fixed base block hardened bending anvil made flat tool steel described above wires secured setscrews would have easier probably just durable merely press tool clamped bench vise longer wire projecting out horizontally clamp 5WR Vise Grips about 5/ inch end length 039-043 music wire holding free end wire left hand simply wrap required number coils around horizontal 067 mandrel release Vise-Grips drop coils over vertical mandrel bend foot spring out around acute angle steel block Next flip coils over same mandrel bend opposite foot Using slip-joint pliers bend both anides align outward-pointing feet Finally cut spring free wire grind ends length S-hook jig Figure 2 demonstrates couple other principles Its made piece /2-inch-square aluminum I32 slot end three /32 music wire pins shown Figure 2 removable /4-inch capscrew tapped hole As noted earlier variety S-hooks can bent tool Heres procedure First jig clamped vertically bench vise slot above jaws across After cleaning up end bench grinder S-hook wire inserted rear just under pin through slot short hook bent 180 Since usually make batch hooks once same other end wire make two setup Next jig repositioned vise short hook placed over short pin trap holding loop wrapped around vertical pin closest short pin make small S-hook jig turned over capscrew inserted finger-tight Diameter Cd 010 0151/64 020 025 031 1/ 039 1mm 047 /64 055 063 ills 078 5/s 2mm 093 /32 125 156 5/ 4mm 188 3Iis Notes d2 proportional weight per inch tensile load capability d3 proportional torsional load capability d4 proportional stiffness bending d2 x 1O d3 x 1O d4x1O 101010 22533851 4816 62515639 9629892 1539231 22103487 30166915 402501575 614743702 668047480 156195324414 243379659224 3536645124920 holding loop placed over pin thats closest screw rubber hook bent round shank screw its cut length filed remove burr protected inch fuel tubing make large S-hook put screw side giving space vertical pin bend hook 180 aroundpulling back open ealarge diameter before cuffing off Alternately could put short length say 1/4 inch metal tubing under head screw provide larger diameter bending form own ingenuity will suggest specifics tooling need make parts Just remember principle keeping wire under control times Some torsion calculations heart torque meter its sensing element simple length music wire cases Its secret lies two formulas few basic properties music wire 1 find shear stress round piece wire subjected twisting force S d3 rque oz-in d wire diameter inches S stress lb/sq psi 2 find twist wire L/l000OOOd S stress psi L length thats free twist inches d wire diameter inches angle twist degrees important property music wire thats included formulas above its elastic limit torsion value 120000 130000 psi both safe reasonable music wire shouldnt exceeded give feel so-called structural steel around half Coupe dHiver torque meter loading 047 music wire torque 40 oz-tn right ballpark 122600 psi dont have worry about wire failing result tensile load want heavier meter say 120 oz-in capacity FiB big Mulvihill should pass up /16 wire 156500 psi 120 oz-in means will take set permanent twist go 078 80500 psi 120 oz-in 180 twist active length should 1463 inches did buy some 067 wire youll have straighten Perfect straightness would nice isnt necessary case rules also valid prop shaft sizes should generally next larger standard size music wire Please note too 120000-psi limit applies music wire has never heat-treated facts formulas also valid realm Indoor models interesting facts music wire smaller sizes can actually take higher stresses remember thats pounds per square inch pounds tension oz-in torque mber 1994 31 Engineering has steel base bending handle Set up bend 118 wire landing gear
Edition: Model Aviation - 1994/11
Page Numbers: 27, 28, 29, 30, 31
Wire Piiys T iirne U Bob Hatschek AFTER BALSA WOOD widely used solid material model aviation unquestionably music wire Think about would difficult build model complex hand-launched glider music wire True dont use great quantities music wire model youll find music wire parts kind model airplane Indoor feathers through giant RC monsters using conceivable type power plant rubber bands glow plug Electric jet non-powered sailplanes Its surprising find otherwise expert model craftsmen loss comes convening remarkable material useful components Music wire isnt just metal drawn out wire its just steel Its specific product steel industry high-quality straight-carbon steel fairly high carbon content Its final properties produced cold-drawing after rather unusual heat-treat traditionally involves quenching molten lead molten salt modem wire millsThere types steel wire higher quality music wirerocket wire some grades tool steel drill rod stainless steelbut readily available music wire some grades lower quality thing watch out what some suppliers offer music wire preformed parts such rubber model prop shafts sometimes cheaper lower-quality carbon spring steel doesnt have hardness toughness true music wire reason its easier bend sometimes-complex shapes require model aircraft its easier crack unbend well Some manufacturers may also anneal real music wire facilitate bending preformed parts remember music wire gets its original properties cold-drawing impossible return its original strength toughness further heat treatment heat music wire red hot particularly small sizes likely air-quench too rapidly become brittle Dont try prop shaft landing gear wing joiner could just snap must make steel part requires heat treatment use oil-quenching tool steel such 0-2 drill rod seek expert counsel procedures hobby shop place can buy music wire industrial supply houses good hardware stores carry quarter-pound one-pound coils music wire sizes hobby shop hobby shop easiest place get straight lengths Most hobby shops stock sizes shown Table 1 second column table labeled d2 proportional cross-sectional area wire provides index its weight tensile strength although rarely use music wire pure tension unless fly control line music wire lines often modelers use music wire bending mode hold-down hooks pegs example combination bending November 1994 27 Music wire parts Coupe dHiver front end 078 shaft 1116 5hook Hiborks hub 015 coil spring 025 autorudder pin useful pliers some Special cutter hard wire 9 oclock Text outlines use tool NO OCR TEXT approximate overall length inches tiny 4WR adds liffle weight field kit 5WRs most-used pair pliers other has its jaws reground tapered shape recommend WR version because model has hardened cutting jaws can handle music wire indeed use 10VR regularly cuffing music wire up I32 diameter 3 Two pairs round-nose pliers small large have pair about four inches long another about 7 inches long After will wonder ever did 4 least box-joint hemostat 5-inch longer jaws cut fairly short filed rather flat nose might find yourself modifying several useful tools variety purposes make bending small-diameter wire less 030 just modified hemostat thats unmodified 5 pair flat-nose needie-nose pliers 6 pair slip-joint gas pliers 7 heroic measures demanded bend lot heavy wiresay I32 up jobs cutting bench grinder Dremel Moto-Tool cutoff wheel get two bending tools offered K&S Engineering Mini Wire Bender easily bends music wire up 1/g diameter angles up 180 around 1/4-rnch pin Mighty Wire Bender works wire sizes up 1/4 Coil Winder handles wire up /16 winding number coils its mandrel 8 never use larger wire sizes small bench grinder medium wheel fine wheel desirable Alternately might use small abrasive wheel arbor bench-mounted electric drill Dremel tool horizontal mount clamped bench vise Dremel cutoff wheel often comes handy whenever grind steel wear safety glasses face shield 9 Treat yourself assortment new files fairly fine cut 10 micrometer vernier caliper dial caliper can very useful too machinists protractor measuring bend angles Hooks joggles ubiquitous use music wire course hookstypically little ones hooking rubber bands Too often dangerous fish hooks double wire before bend hook will pierce flesh shank now made two wires wont round wont twist loose easily single wire after has glued Incidentally plans often specify paper-clip wire such hold-down hooks Dont use Music wire much stiffer smaller sizes will less weight little weights add up far end hook should bent over speared solid balsa end anchored thin sheet balsa produce joggle bend sort Z-shaped insert through sheet bend joggle first bend toe right angle grip angle pliers bend another right angle wont aligned shank course now just twist straight Twist slowly therell less chance will break Heres tip attaching little bits metal like hooks hinges made aluminum tubing unglueable plastic parts balsa cyanoacrylate glue CyA Just wrap shank whatever area will glued fine thread cotton works fine put piece position hit CyA works well sewing part lot easier Ive using trick years kinds glue havent hook pull loose yet Springs spring winding can often buy tension compression coil springs made lower grade wire local hardware store can usually make faster can find reason beeause spring making no big deal make virtually springs use Think about springs moment Any spring wire has give its twisted its loaded bending stretch compress coil spring youre actually twisting wire want stiffer spring action can get loading wire bending mode applying safety pin type spring November1994 29 Lathe tools I32 music wire Three right bent ground shape Fine aluminum brass plastics Sometimes pays make special tools left jig throwaway S-hooks Towhook mainspring jig right Spring bending special jig coils dropped over vertical pin first foot bent tool steel anvil configuration goes under misnomer torsion spring textbooks because its usually applied twist something pull push also has advantage compactness lighter weightyou never need two thicknesses wrapped around shaft less steel needed because wire loaded bending mode way make coil springs tensile applications simply round-nose pliers Just keep bending circles until have necessary number coils Actually could needle-nose pliers spring will work fine coils squareno kidding Another way pride craftsmanship demands perfect-looking spring wind spring mandrel made heavy music wire nail suitable diameter can use birch dowel Just chuck mandrel lathe end wire trapped under chuck jaw Another way trap wire start spring slot outer end mandrel wind coils back toward chuck hold far end spring wire under tension pair Vise-Grips dont have lathe just clamp crank-type hand drill horizontally bench vise pretend its lathe used way Now turn lathe hand drill hand keep spring wire tension other hand will some springback will open up coil diameter slightly may require bit trial-and-error get exactly right size mandrel tension springs wind coils tightly against other compression springs wind tight coils pull open coils suit needs will also open up diameter bit applications doesnt matter spring coiled leftor right-handed sometimes does aware some pretty good spring-winding tools available have never bothered get Springmaking really too easy Special tooling Sometimeswhen youre going make number identical wire parts exampleits desirable make special bending jig two such cases special jig used bending torsion-type mainsprings Hatschek-style towhooks approximately 2700 interchangeable springs bent jig am currently using make throwaway S-hooks wire sizes 047 P-30 078 FlB Prototypes both towhook springs special S-hooks made using standard tools list above plus bench vise some suitable-size mandrels 067 wire 1/4-inch steel rod principal objectives making special tooling parts 1 make job easier 2 important make parts identical tools simply aluminum blocks steel bending forms affixed forms made variety ways often simply short lengths suitably sized music wire pressed holes drilled aluminum base Sometimes theyre made small bits say 1/8 flat ground tool steel shaped hacksaw drill file hardened heating red hot gas stove torch quenching oil typically attached screws tapped holes aluminum block 30 Model Aviation 4This 1/16 music wire S-hook ready cut deburred Dremel Moto-Tool below right dont have have lathe wind coil springs Setup will also work variable-speed electric drill low rpm Removing burr S-hook Moto-Tool Masking tape pads plier jaws avoids raising new burr hook DODDGER DODDGER takes let Place 1990 1991 & 1993 AMA Nationals! Now DODDGER has standard DODDGER kit now includes V-tail & Mid-tail versions Instructions show required modifications create V-tail Mid-tail version Craig Grunkemeyers tricks still included! real GO FAST & TURN LEFT kit market.THE DODDGERU Engine 25 45 Span 50 inches Area 500 square inches $5 rDIRECT9NN6CTIONp~ Lapawne ntI mippilers Inc ao w menrock Rd Westervifle OH 43081 614-899-6313 Fax 614-899-6070- 1800-593-5250 sometimes standard bolt will provide necessary shape depends what youre trying what scraps have junk box mainspring jig Figure 1 consists two pieces 067 music wire fixed base block hardened bending anvil made flat tool steel described above wires secured setscrews would have easier probably just durable merely press tool clamped bench vise longer wire projecting out horizontally clamp 5WR Vise Grips about 5/ inch end length 039-043 music wire holding free end wire left hand simply wrap required number coils around horizontal 067 mandrel release Vise-Grips drop coils over vertical mandrel bend foot spring out around acute angle steel block Next flip coils over same mandrel bend opposite foot Using slip-joint pliers bend both anides align outward-pointing feet Finally cut spring free wire grind ends length S-hook jig Figure 2 demonstrates couple other principles Its made piece /2-inch-square aluminum I32 slot end three /32 music wire pins shown Figure 2 removable /4-inch capscrew tapped hole As noted earlier variety S-hooks can bent tool Heres procedure First jig clamped vertically bench vise slot above jaws across After cleaning up end bench grinder S-hook wire inserted rear just under pin through slot short hook bent 180 Since usually make batch hooks once same other end wire make two setup Next jig repositioned vise short hook placed over short pin trap holding loop wrapped around vertical pin closest short pin make small S-hook jig turned over capscrew inserted finger-tight Diameter Cd 010 0151/64 020 025 031 1/ 039 1mm 047 /64 055 063 ills 078 5/s 2mm 093 /32 125 156 5/ 4mm 188 3Iis Notes d2 proportional weight per inch tensile load capability d3 proportional torsional load capability d4 proportional stiffness bending d2 x 1O d3 x 1O d4x1O 101010 22533851 4816 62515639 9629892 1539231 22103487 30166915 402501575 614743702 668047480 156195324414 243379659224 3536645124920 holding loop placed over pin thats closest screw rubber hook bent round shank screw its cut length filed remove burr protected inch fuel tubing make large S-hook put screw side giving space vertical pin bend hook 180 aroundpulling back open ealarge diameter before cuffing off Alternately could put short length say 1/4 inch metal tubing under head screw provide larger diameter bending form own ingenuity will suggest specifics tooling need make parts Just remember principle keeping wire under control times Some torsion calculations heart torque meter its sensing element simple length music wire cases Its secret lies two formulas few basic properties music wire 1 find shear stress round piece wire subjected twisting force S d3 rque oz-in d wire diameter inches S stress lb/sq psi 2 find twist wire L/l000OOOd S stress psi L length thats free twist inches d wire diameter inches angle twist degrees important property music wire thats included formulas above its elastic limit torsion value 120000 130000 psi both safe reasonable music wire shouldnt exceeded give feel so-called structural steel around half Coupe dHiver torque meter loading 047 music wire torque 40 oz-tn right ballpark 122600 psi dont have worry about wire failing result tensile load want heavier meter say 120 oz-in capacity FiB big Mulvihill should pass up /16 wire 156500 psi 120 oz-in means will take set permanent twist go 078 80500 psi 120 oz-in 180 twist active length should 1463 inches did buy some 067 wire youll have straighten Perfect straightness would nice isnt necessary case rules also valid prop shaft sizes should generally next larger standard size music wire Please note too 120000-psi limit applies music wire has never heat-treated facts formulas also valid realm Indoor models interesting facts music wire smaller sizes can actually take higher stresses remember thats pounds per square inch pounds tension oz-in torque mber 1994 31 Engineering has steel base bending handle Set up bend 118 wire landing gear