Ron's Flitzer Construction Videos

Many thanks to Ronny Gosselin for all of the videos documenting the construction of his project!

Title
Description Length
1 Flitzer intro fin-rudder jig Design of jig, wood strips 0:01:05
2 Flitzer steaming for lamination Steaming system for strips 0:01:10
3 Flitzer pre bending of rudder-fin laminations Clamping strips to jig to dry before gluing 0:03:50
3.5 Flitzer gluing lamination Gluing up strips and clamping them in the fin/rudder jig 0:07:23
3.8 Flitzer jointing cutting lamination Using jointer to clean up fin/rudder lamination and ripping to width with a table saw 0:06:42
4 Flitzer rudder lamination Fin and rudder laminations glued up and clamped to jig. 0:01:26
5 rudder flitzer .AVI Fin and rudder lamination result. 0:00:51
6 flitzer lam and pieces done for rudder Details bits and pieces for fin and rudder ribs, diagonals, etc. 0:02:32
7 flitzer rudder prep for glue Placing spacer for hinge hardware, etc. in prep for gluing 0:04:24
8 flitzer rudder glue part1 Details cam clamps, initial gluing for stirrup blocks 0:04:55
9 Flitzer answers from designer rudder-fin Ron reviews various questions he had sent to Lynn and relates his answers 0:08:42
11 Flitzer rudder ribs Laying out and fabricating built-up rudder ribs 0:06:24
12 Flitzer rudder ribs gluing Assembling and gluing up rudder ribs 0:07:24
13 Flitzer rudder questions Using a router to trim off excess plywood web length, poses question (answered in Yahoo group) 0:05:32
14 Flitzer answers rudder Reviews emailed answers 0:04:42
15 flitzer rudder ribs gluing Preparing rudder ribs for assembly to spar 0:04:16
16 Flitzer gluing rudder ribs Ron reviews the emailed answers from Video 13, gluing rudder ribs to spar 0:06:33
17 flitzer rudder base thickness Discussion about and lamination of blocking to widen the rudder bow at the spar 0:01:22
18 flitzer questions rudder Ron poses more questions about corners blocks, etc. for the rudder 0:01:22
19 Flitzer rudder gluing the lamination Prepping for and gluing up the rudder lamination 0:07:22
20 Flitzer rudder off the jig The fin-rudder assembly is off the jig with very minor damage, additional blocking is added 0:01:38
>21 Flitzer sanding the rudder Tips and tricks including masking tapes, large format sanding block 0:12:19
21.5 Flitzer sitka grading Reviews prepared examples of spruce and its characteristics/flaws 0:05:04
22 Flitzer orbital sanding of rudder Demonstrates hand and orbital sanding of fin/rudder outines while masking the ribs/spars to protect them 0:03:20
22.5 Flitzer sitka samples Representative samples with grain, slope, etc. demonstrated 0:06:31
48 Flitzer Hstab sanding hinge Adding ply cap strips, sanding/filing leading edge, mounting hinge hardware 0:02:27
49 Flitzer Staple remover and visual timer for epoxy Using a BBQ fork for removing staples, big face timer for epoxy work 0:01:47
50 Flitzer round of corner of Hstab Rounding the inboard trailing edges of the elevator 0:00:15
50.5 Flitzer fuse assembly table Self-explanatory 0:00:19
51 Flitzer fuselage side Building table with fixed and cam blocking, fitting/cutting, etc. 0:02:24
52 Flitzer gusset fuselage Cutting gussets on a table saw, tips for layout 0:01:22
53 Flitzer fuselage sides Additional layout, set-up and then glue up of crosss pieces and gussets; also shows glue test pieces 0:05:22
53.5 Flitzer - clamp storage Milk crate-style storage bins for all those clamps 0:00:18
54 Flitzer destructive testing of fuse gussets Testing glue strength 0:00:19
55 Flitzer color codes storage Color coding of drawings, assemblies 0:02:09
56 Flitzer fuse repair Adding in a forgotten doubler by cutting the structure apart, etc. 0:00:56
57 Flitzer cutting wood at Pierre and humidity Reviews humidity testing, sawing and planing rough stock down to usable bits 0:01:25
58 Flitzer wheels from Ian Wasey Wheels, brakes, etc. from Ian 0:01:15
59 Flitzer sanding fuse sides Cleaning up a fuselage side prior to removing it from the table with filing, scraping, sanding 0:06:00
60 Flitzer organizing plans Ron's organization system, color coding, etc. 0:03:01
61 Flitzer ply gusset on fuse Prep, layout and gluing of fuselage gussets 0:02:18
62 Flitzer epoxy T 88 info Discusses issues with popsickle stick test glue-ups, West Systems 0:02:19
63 Flitzer firewall etc Gluing up the firewall 0:02:51
64 Flitzer floor Gluing up the cockpit floor 0:01:16
65 Flitzer engine turning-bouchonnage Engine turning aluminum sheet with valve grinding compound and a cork in a drill press 0:01:13
66 Flitzer forward floor assembly Forward cockpit floor assembly 0:03:10
66.5 Flitzer tank support and floor Making and gluing support bits from spruce and plywood 0:03:25
67 Flitzer engine turning tool bouchonnage Using a cork in a drill press with a rigged foot pedal 0:00:56
68 Flitzer fuse side inspection hole Gluing up and fly cutting the inspection port framing 0:02:03
69 Flitzer firewall take 2 Forming upper curve lamination, gluing it to internal structure 0:02:49
70 Flitzer curved member STA 2 Station 2 lamination 0:01:33
71 Flitzer remake of side fuse ply Clean up then gluing new ply 0:00:57
72 Flitzer inspection hole update gaz tank holder engine turning Gluing in inspection port ring, tank support structure, engine turning 0:00:39
73 Flitzer hints Sanding on the table saw platform, using weight bags, router tricks 0:01:33
74 Flitzer firewall part deux Skinning the firewall 0:02:27
76 Flitzer fuse doubler Fitting and gluing double pieces 0:01:24
77 Flitzer firewall patch Correcting a building error by patching in blocks 0:01:21
78 Flitzer floor pedals brake Fitting up brake pedals 0:01:44
79 Flitzer carry trough part 1 Squaring up the sides to fit the spar carry through, optical guide for center punching holes 0:03:54
80 Flitzer fuse parts Firewall revisited, more brake pedal stuff 0:00:47
81 Flitzer pedal modification Self-explanatory 0:00:54
82 Flitzer fuse going 3D + air stapler Fitting up the fuselages sides, various clamp types, pneumatic pin nailer 0:03:31
83 Flitzer cockpit area Fitting miscellaneous cross pieces, doublers, corner blocks 0:03:19
84 Flitzer bending with hot pipe and lamination Prebending strips to laminate them for forward decking support 0:02:41
85 Flitzer Veritas test Testing glue strength/bond 0:01:32
87 Flitzer gas tank Fitting up sheet metal, cradle to support assembly 0:03:23
88 Flitzer water cut fittings and powder paint Water jet cut metal fittings, prep 0:02:58
89 Flitzer Thanks Giorgio and Octavian for computer rib drawing CAD drawing of main rib 0:00:53
90 Flitzer 4130 metal preparing dressing metalprep Sand blasting, Scotchbrite treatment, tumbling then treating with metal prep solution 0:02:31
91 Flitzer underbelly cover Paul Daudin Metal forming of fuselage belly fairing 0:23:26
91.1 Flitzer top wing gussets Cutting ply gussets for top wing ribs (mass production) 0:03:39
91.2 Flitzer top wing rib making Prebending the upper strips, cutting additional bits, jig details 0:08:57
91.3Flitzer pre shaping cap strip Using a Conair steamer for rib cap strips 0:00:20
91.4 Flitzer finishing ribs Cleaning up glued ribs, trimming to length, adding opposite side gussets 0:01:28
91.5 Flitzer compression ribs Fabricating compression ribs 0:02:35
91.6 Flitzer ply covered ribs Temporarily attaching strips across upper and lower chord to permit plywood covering of proper shape 0:05:12
91.7 Flitzer leading edge finishing Shaping and slotting the leading edge ribs/false ribs 0:01:38
91.7 Flitzer false ribs Making the false ribs in a router table 0:01:26
91.8 Flitzer Wing tip ribs Making the smaller tip ribs 0:00:10
92 Flitzer windshield Design and fabrication of windshield framing, riveting lexan, leather/cord grommet for base 0:04:13
93 Flitzer gas cap Fitting vent tubes, etc. 0:01:09
94a Flitzer cowling part 1 Wireframe layout of cowling, English wheel metal forming, fluting, shrinking, etc. 0:06:06
94b flitzer cowling part 2 More cowl forming 0:10:47
94c Flitzer cowling part 3 Even more cowl forming 0:07:28
94e Flitzer cowling buck fabrication Fabricating the cowl forming buck 0:04:01
94d Flitzer cowling aluminum part 4 and final Yet more cowl forming 0:17:59
94f Flitzer annealing alumimun Annealing the cowl sheet metal 0:01:30
95 Flitzer gas strap part 2 aircraft construction building wood avion bois biplane aviation Forming the strap for the gas tank, part 2 0:01:46
95c Flitzer gas strap Forming gas tank strap 0:04:57
95.1 Flitzer joystick support Forming metal control stick supports 0:01:40
95.2 flitzer aileron control Forming aileron control strap prior to welding 0:03:11
95.4 Flitzer drag wires attach Using a press to form drag wire attach straps 0:00:55
96 Flitzer wooden tailskid Gluing up the tailskid, bending the spoon, assembling 0:06:05
97 Flitzer carry trough part 2 Spar carry through revisited with metal straps being fitted 0:04:28
98 Flitzer powder coating part 1 Spraying in cardboard booth, baking the parts 0:03:32
99 Flitzer carry trough part 3 Spar carry throughs assembled to the fuselage 0:03:33
99 Flitzer hints part 2 Tips for marking, clamping 0:02:22
100 Flitzer bending waist belt fitting Bending welded seatbelt fitting in a vise with rawhide hammer 0:00:31
101 Flitzer carry trough part 4 and final Fitting upper steel strap to spar carry through 0:04:45
102 Flitzer closing tail part 1 Joining the aft end of the fuselage, clamping blocks, plumb bob 0:00:57
103 Flitzer closing tail part 2 Adding additional aft fuselage bits 0:02:49
104 Flitzer elevator horn install Self-explanatory 0:00:56
105 Flitzer old way of straitening piano wires Using a bent copper tube and a drill 0:01:21
106 Flitzer powder coating part 2 Parts prepped, primed and powder coated 0:00:27
107 Flitzer welding straps Welding washers to straps, stress relief 0:01:07
108 Flitzer joystick assembly part 1 Fitting various steel fittings/straps to control stick 0:03:38
109 Flitzer rudder horn stopper Fitting packing block at horn location 0:00:55
110 Flitzer adding parts to the rear fuse Planning and adding additional gussets 0:01:36
111 Flitzer joystick part 2 More details of fitting up the control stick base 0:05:20
112 Flitzer lower engine supports Shaping and installing engine support blocks 0:01:02
113 Flitzer varnishing sanding drain holes Sanding drain holes and varnishing various parts 0:01:43
114 Flitzer Hstab adjusting Trimming the gap for the stabilizer lead edge and mounting rear block 0:00:55
115 Flitzer bending metal into existing area Demonstrates bending and adding bent support bracket 0:01:33
116 Flitzer rear bagage and top seat support Fitting up supports, blocks and plywood 0:03:57
117 Flitzer Hstab support platform Adding spruce fill at aft fuselage to support tailplane 0:00:56
118 Flitzer STA 4 pulley support Installing pre-assembled truss then adding diagonals, blocking, ply gussets 0:02:12
119 Flitzer seat rear support Adding the angled seat back uprights and their associated supporting structure 0:04:16
120 Flitzer gusset cutting with POST IT Laying up PostIt squares to make a template 0:01:05
121 Flitzer metal bending for Hstab Demonstrates bending strap for tailplane mounting 0:01:22
121 Flitzer upper engine mount fitting Bending the fitting for installation 0:02:02
122 Flitzer flying wire fitting Fitting, bending and welding flying wire fitting 0:01:26
123 Flitzer pulley holder turnbuckle 180 degree bending Bending a fitting over a shop-made die 0:02:50
124 Flitzerbending pulley holders Self-explanatory 0:01:56
128 Flitzer Tailpost Adding the prebeveled tailpost, then some of the tailplane support structure 0:03:30
129 Flitzer skeg part 1 Assembling skeg bits 0:05:44
131 Flitzer H stab attaching Fitting and mounting the horizontal stabilizer to the fuselage 0:02:21
132 Flitzer Fin attaching Fitting fin, crafting mounting bracket 0:02:52
133 Flitzer belt attaching Seatbelt fittings 0:00:46
134 Flitzer skeg part 2 Assembly and fitting of skeg 0:02:15
137 Flitzer joystick cover underbelly part 2 Part 2 discussing stick set up and cover 0:00:31
140 Flitzer exit holes for rear fuse Planning for cable exits at rear fusealge 0:01:15
142 Flitzer small metal bits Crafting small metal bits 0:01:05
143 Flitzer fuselage rotisserie Rotisserie to permit rotation of framed fuselage 0:01:59
144 Flitzer turtledeck laminations Laminating turtledeck formers 0:01:38
145 Flitzer underside of fuse and scarfing Layout, scarfing and cutouts for fuselage bottom 0:01:28
146 Flitzer insp hole varnish compression rib Cutting inspection hole with fly cutter/drill, compression rib fittings and details 0:01:45
147 Flitzer under cabane fitting Crafting backup fitting for cabane attachment 0:01:27
148 Flitzer headrest bulkhead Making the bulkhead fitting 0:00:38
400 Flitzer Cabane part 1 Bending and fitting cabane attachment brackets, followed by sandblasting 0:04:25
402 Flitzer cabane part 2 Setting up the welding fixture and fitting the struts 0:03:20
403 Flitzer cabane part 3 Cutting tubing, welding, bending support straps 0:04:40
404 Flitzer foward gear attachment fitting Bending fittings, using a flexible-shaft drill extension, fixing a drilling error with a dowel 0:04:41
405 Flitzer cabane part 4 Cutting the central support tube away and adding bushings 0:01:21
406 Flitzer foward landing gear attachment( landing gear part 1) Flattening and slotting tubing to accept the reinforcing insert prior to welding 0:03:29
407 Flitzer removing powder coat from joystick Removing powder coating from supported end of control stick axial pivot 0:01:06
408 Flitzer landing gear part 2 Fitting up tubing, etc. 0:05:28
409 Flitzer foward gear attachment part 2 Internal and external fitting hardware 0:01:03
410 Flitzer Landing gear part 3 and brake Fitting up the struts and brakes 0:02:03
411 Flitzer remaking Z 205 1 Predrilled component holes did not line up, so he remanufactured the simpler bracket. 0:03:37
412 Flitzer cabane adjustment Minor adjustment to fuselage to improve cabane fit 0:00:21
413 Flitzer engine mount Details jig, weldments and production of engine mount 0:02:19
801 Flitzer wing assembly 1 Cutting spar tapers, spar mounting plates, etc 0:07:32
Flitzer joystick parts Ian Wasey Parts and a peak in the cockpit at an assembled control stick 0:02:56
Flitzer bending metal with Ian Wassey Forming steel fittings with hydralic press 0:16:46
Flitzer top wing center section Making a clamping form from a large block of wood, then laminating up the center section after segment 0:01:32
Flitzer wing tip bow Making the form, then bending and laminating strips for the curved tip bows 0:02:28
Flitzer wood storage Utilizing existing under table space to hold smaller wood strips 0:00:48
Flitzer olive making Making a wooden form block for metal work out of hardwood 0:01:33
Flitzer Vic Long take off Self-explanatory 0:00:48
SK 35 Lynn William design Discussion with Lynn about his design, with model 0:03:33
Flitzer ply storage Rack to vertically store plywood sheets 0:00:44
Flitzer prototype Z 1 D 692 Brief walk around with instrument, engine and landing gear details 0:01:14
Flitzer Laird construction Lynn Williams Drawings, tail and fuselage structure in progress 0:21:51
Flitzer Z 2 Walk around with Simon Walk around of very complete but open structure 0:36:22
Flitzer Z 2 tailwheel Wheel, bearing and assembly details 0:03:08
Flitzer prototype full walk around part1 Self-explanatory 0:14:03
Flitzer prototype full walk around part2 Self-explanatory 0:24:38
Flitzer prototype full walk around part3 Self-explanatory 0:11:43
Vic Long talking Flitzerwith better background Walk around and discussion with Vic about G-ECVZ 0:16:32
Flitzer Vic Long talks about flying his aircraft Vic discusses flight ops 0:16:32
Flitzer Vic Long Cowling Ronny is loud and clear, Vic is a bit harder to hear 0:01:31
Flitzer How it began Lynn Williams Sitting in Lynn's sunroom for a chat 0:05:53
D 692 Flitzer story More with Lynn in his sunroom 0:03:03
Flitzer Manu walk around part 1 Flitzer project (I could not find additional parts) 0:04:34

Notes on new content:
02-Mar-19: Added video 145.
21-Feb-19: Added videos 113, 143 and 144.
13-Feb-19: Added videos 132, 140 and 142.
15-Aug-20: Added multiple missing videos.
20-Sep-20: Added additional missing videos. I think it's current as of today!