Making an Airplane Wing Tip
Work done using the TM Tech Air Power Hammer Model 3000

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  • Making an aluminum airplane wing tip

    The first step was to measure and cut the blank to size. Here the wingtip half is laid out and blanked to a paper pattern. All shaping was done with the TM Air Power Hammer, using an upper Rubber Head Die over a steel Button-Head lower die.

  • Making an aluminum airplane wing tip

    The next step was to stretch the surface so that the blank begins to fit the mock-up or “buck.” The shape is now more developed, using the same gentle roughing dies.

  • Making an aluminum airplane wing tip

    I've now done some planishing, steel over steel, bringing the shape more tightly to the buck.

  • Making an aluminum airplane wing tip

    Comparison of shaped halves for one wingtip. Left half is only roughed-in, while right side is well on its way to fitting.

  • Making an aluminum airplane wing tip

    Pilot on first check ride dumped into the dirt, so I got to fix the boo-boos. Halves are both on their way. Shaping must occur before moving on to planishing.

  • Making an aluminum airplane wing tip

    Next step – planishing (smoothing the surface by light hammering). Each wing tip half was worked enough to fit.

  • Making an aluminum airplane wing tip

    One pair of halves are aligned, trimmed, witnessed, and ready to be tacked.

  • Making an aluminum airplane wing tip

    Both sets of wing tips fit the mock-ups very tightly and the welds will be exposed when polished.

  • Making an aluminum airplane wing tip

    The halves were shaped, planished, and fit to the buck. They were then were fit and trimmed to one another, and the first tack welds were put in place. They are now ready to be joined.

  • Making an aluminum airplane wing tip

    Tack, fit, and tack weld some more. Fit some more. 5 feet of continuous weld was done using only our small Meco torch. Weld complete, end-to-end.

  • Making an aluminum airplane wing tip

    Completed tips, ready to fit to wings.

  • Making an aluminum airplane wing tip

    The Air Power Hammer was used to make the tips — not the Wheel at all, and there was very little hand work.