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1941 Waco UPF-7 battery box. "Its just a box"
This is battery box we had made for a customer in California. It is for a 1941 Waco UPF-7 biplane.
DSC_0961%20Waco%20UPF-7%20N32135%20cn5767%20right%20front%20taxiing%20l.jpg This is a Waco similar to the customers airplane. The box is mounted aft of the firewall, below the floor boards. It was designed inverted and accessible from the outside of the airplane for maintenance and battery replacement. The customer brought a old corroded box, plus I have the factory drawings for the Waco. Parts that I had formed up. 20170921_171903.jpg The box and lid are made from .040" 5052-H32 and the structural mounts are .080" 2024-T351 aluminum. The lid and box is TIG welded together. 20170921_171925.jpg 20170921_171934.jpg The cross "X" in the lid was done with a MDF form and Delrin tool in the Pullmax. Most of the tooling I make is out of Delrin, it is hard, easy machining, holds up well, easy to get and the most important for aircraft work, tool mark free. 20180512_111516.jpg The lid is double seamed. It was made easy with the Baileigh magnetic brake. I was skeptical at first, about an magnetic brake, but I'm a firm believer now. 20170921_171946.jpg Once the sub-assembly's were built, I had all the parts chromate dipped, for corrosion resistance due to possible acid from the battery. Most aircraft battery's now a days are "RG" Recumbent Gas or sealed battery's. They last longer and for the most part, don't leak. 20171005_151041.jpg 20171005_151034.jpg The lid hold down studs are built from 4130 chrome moly and AN aircraft bolts, per the drawing. Once welded and fitted, they were Cadmium plated to a Boeing aircraft plating spec. 20171031_114326.jpg 20171031_114340.jpg All sub-assembly's riveted together with aircraft -4 (1/8") AD rivets. 20171031_121604.jpg 20171031_121653.jpg For the battery electrical connection. Waco designed there own connectors, which we re-produced in our CNC turning center. We had one sample connector and the drawings. The way it works, a post is threaded onto the battery terminals. The tulip shaped female piece is mounted to the box, insulated with phenolic washers. You set the battery on the lib and push it up into place. Easy. 20180509_174023.jpg 20180509_173955.jpg It's just a box Don't you love it when someone tells you this Thanks for looking, Bill
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Bill Tromblay "A sign of a good machinist, is one who can fix his F$@& Ups" My mentor and friend, Gil Zietz Micro Metric Machine. |
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Very nice box, Bill. Thanks for posting.
fwiw, I hear the "it's just a ....." quite often in my work.
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AC Button II http://CarolinaSculptureStudio.com https://www.youtube.com/channel/UCzSYaYdis55gE-vqifzjA6A Carolina Sculpture Studio Channel |
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Beautiful work Bill. Time well spent.
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David Hamer |
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Yes, nice job, and those words “it’s just a......” are very familiar. They are normally followed with “I’d do it myself if I’d got the tools”
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Gareth Davies |
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I like the rivets!
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Will |
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Bill very nice quality!
I enjoy seeing all the details Thanks for posting Steve
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Steve Hamilton Hamilton Classics Auto Restoration & Metalshaping |
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Beautiful work Bill!
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Robert Instagram @ mccartney_paint_and_custom McCartney Paint and Custom YouTube channel |
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Interesting method of connection. Looks like fuseholder terminals that we use. Nice work!
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Kevin B |
#9
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It's just a box..... yup, the words of the ignorant!
Nice work! Lot's of little details to make this box and the associated parts. Do you have a pic of the old box?
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Brad Currently working on a new garage for the tools... Also a member on garagejournal.com |
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Thanks, I will look for pictures of the old box.
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Bill Tromblay "A sign of a good machinist, is one who can fix his F$@& Ups" My mentor and friend, Gil Zietz Micro Metric Machine. |
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