I have gotten a lot done in the last month.  I have fitted and tack welded most of the tubes from the firewall to just aft of the door.  I am currently working on the door bracing tubes.  I started using string to help identify the angles needed for each tube.  When the angle is determined, I go to http://www.metalgeek.com/static/cope.pcgi and use the online tube pattern program to generate a paper pattern.  The sides have been much more time consuming com paired to the top and bottom section.  Each tube has to be made twice, left and right, so progress sometimes seems slow.  I currently have about 130 hours in the project.  Below are current pictures.

Firewall side tubes, these were the first tubes joining the top and bottom sections.

Next is just ahead of the left door opening.

Door opening, left side:

This last picture is just aft of the door opening.  In these pictures you can see how I use the string to see where the next tube will go and the welders magnet to position the last tube cut.

Today I finished setting the top section of the fuselage in the jig I will use to weld in the side tubes.  This was the most difficult step to date!  I worked on and off the past two weeks to get this just right.  I followed the plans with some modifications to the jigs.  I used adjustable blocks to support the tubes.  The plans show notches in the jig at each tube location.  I found it easier to clamp blocks in place then adjust each block up or down until the top section was level, centered, and correct front to back.  When that was established, I glued each block in place then secured the top tubes in place with the blocks used to secure the tubes to the table.  I had to cut holes in the jigs at most of the stations to allow the datum line to run for and aft.  I also used a series of plum bobs to make sure the center line of the top section lined up with the center line of the bottom section.  I then rechecked the measurements, everything seems ok.  Next, fitting more tubes to make up the sides. 

First placement of top section in jig.

This picture shows how I clamped the bop and bottom tubes in place.  The holes in the wood are the correct top to bottom measurement.  I drilled the holes first, then cut the wood down the center of the holes and then screwed them together with the tubes in the middle. Worked great.

This is the front section blocked in place with the plum bob on center line.

This is mid fuselage.  The plum bob is tied off at the firewall top tube, on center and free hanging at the center of the tube shown below.

This picture is toward the rear of the fuselage. Note the hole for the datum line to pass through the bulkhead.

This last picture shows the datum line attached at the aft station where the tail post will be welded in last after all other side tubes are in place.

I have finished tac welding the lower section.  I had some frustration with the welding, I kept setting the table on fire!  I was able to get all tubes tac welded, but I don't want to have the same problem when joining the top and bottom sections. So, I raised the entire lower 1 3/8" above the table.  I did this by taking 2X4's and cutting them 4' long.  I then ran them through the surface planner to get all pieces a uniform thickness (1 3/8")  These blocks were placed under the tubes where they touch the table and screwed down to the table.  I then clamped the tubes down with blocks and re leveled the entire lower section.  The lower section is now ready to be joined to the top section.  The jig for that is my next step. 

These two pictures show the burn areas on the table around the tac welds. 

The next pictures show how I raised the lower section up 1 3/8".  This will make the next welding steps much easier, less burnings.

A few more views of the raised blocks and the tac welding.

Ok, I have the lower section ready to tac weld.  Things are going much faster.  I should have this welding done in the next week or so.

And another view............

Ok, it has been a while since I updated my posting (2 months) but I have gotten a lot done in the past ten days or so.  I took a break over the holidays and built a camping trailer with my son-in-law.  With that done, it is back to the fuselage.  I have made considerable progress due to the use of a new program I found for making patterns for the fish mouth cuts at the end of the tubes for fitting.  The program I am using can be accessed at http://www.geek.casaforge.com/code/cope.pcgi  .  Check it out, it works great.  Simply put in the size of the tube to be cut, and the tube you are fitting it to (called “parent tube” in the program) and the wall thickness and it prints out a pattern.  Then cut it out and fit it around a piece of tube and tape it together.  I do the cutting of the patterns in front of the TV set, 5 or 6 at a time.  Next, check the fit against the actual tube.  Trace onto the 4130 tube and grind to fit.  You will find that this process goes very quickly.   I should finish the fitting in the next week or so, then tack welding.  Ok, time for pictures.  The below pictures span the last ten days.

Longerons rough cut and set in place.

Cross tubes rough cut and set in rough locations

Longerons blocked and tubes numbered

Tubes as of tonight

Use of pattern to prepare tube

Another pattern picture

I have made some significant progress over the past few days.  I completed all the tubes for the top section, including replacing one tube that I wasn't satisfied with.  That tube will become other parts later, so no waste.  Yesterday I completed the vent drilling at each joint.  This accomplishes two things.  First, allows hot gas to move through the entire structure preventing a blow out hole when trying to complete a weld.  Second, these holes will allow preservatives to flow through the entire fuselage when completed.  Today, I tack welded the section.  The pictures might not look like much, but this is the first "milestone", a sub assembly complete and hung from the ceiling awaiting use down the line.  Check out the pictures.

Holes for venting

Final check before tack welding

Ready to tack weld

Tack welding in process

Tack welding complete

Front section tack welded

Removed from jig, front view

Cockpit area

Hung up ready for use latter.

Table repainted and ready for next step.

A couple of days ago I posted some pictures of the shop set up and my scale fuselage.  Here are some additional pictures of getting this process ready to go.  This should bring me up to date.

First, selecting the wood for the wings at a mill in Washington State.

Next, loading the wood on the motor home for the long trip back home.  We stumbled on the mill during our vacation in the area.  What a find!

Now, time to unload the wood and store at home.

Properly stacked wood in shop

Two days latter, the fuselage kit arrives from Wag-Aero.  I had it shipped to a friends store in town to avoid higher shipping charges to my home.  I had to get the tube home, no small task.

Inventory of the fuselage materials kit.

Ready to build .......................................

First step is laying out and bending the longerons.

First cross tubes set in place.

At this point it was the middle of August and I had to take a two month break to do some construction on my house.  As it turned out, I did not get back to it until about two weeks ago.  The next pictures shows current work.  This is the front of the top section.  The tube connecting the two bent sides is the top of the firewall.  I am ready to tack weld all the tubes in this top section.

Ok, time for some pictures of the process.  First, the scale fuselage.

I finished this back in March.  Then I started on setting up my garage with the jig table and room to work.

This took me until about mid April.  I started buying necessary tools and ordered the fuselage kit in late May, with delivery due in late June or early July.  Now, the waiting began.

Ok, a little background on my project.  I purchased the plans for the Sportsman 2+2
from Wag Aero last January.  Life has been crazy the past few years and as
things settled down, my wife said "I deserved it" regarding building
a plane.  Ever hear of striking while the iron is hot?  So I bought
the plans and began to study.  Well, I went a bit farther than most. 
I got out the balsa wood and engineering scale and proceeded to make a 1 1/2”: 1foot
scale of the fuselage, tube for tube.  I even went as far as making scale
jigs as per the drawings. Why?  To make sure I could do it.  This was
the best decision I made.  It took me about a month to build the model but
it was worth it.  i decided that yes, I could understand the plans so, I
guess I could build it.  Now, I had to decide that the 2+2 was the right
plane for me.  More research.  I found the best source of info to be
on the Supercub.org site.  I started reading every thread related to
building and maintaining the Super Cub.  I also noticed how many pilots
out their love the cockpit  room of the
PA-12 and the PA-14.  I know they are different than a Super Cub, but for
the sake of argument, let’s call them a 3 and a 4 place Super Cub.  Don't
shoot me Super Cub drivers, I know nothing is a Super Cub but a Super Cub.  I am simply making some generalizations
here.  I wanted a plane that my wife would be comfortable in with me, and
for her sitting in the back seat won't cut it.  So, as I read more, I
found out that the pilots with PA-14's simply will not give up their
plane.  They love them.  Close to the Super Cub in performance with a
whole lot more room.  I was hooked.

So, here I am building.  I chose after a lot of asking and figuring to buy
the fuselage kit from Wag and weld my own fuselage.  The kit is now about
$1800.  You can not beat the price.  With the number of pre bent and
pre formed fittings, it is one of the true bargains out their.  I would be
happy to give more detail for anyone interested.  I also decided to build
a wood wing.  Why?  Well, I have taught woodworking for 25 or so
years and I know the stuff pretty well.  Also, my wife doesn't mind the
smell of wood and said I could build ribs in the house this winter in front of
the TV with her.  This summer, I was vacationing in Washington
State, attending the Arlington EAA
fly in.  And guess what?  I found a mill that supplies spruce to the
aircraft suppliers "back east" as the owner said.  Well we
picked out a beautiful piece (tree) of spruce and he cut and rough milled it
for me.  He then helped my son and I wrap it in tarp and he loaded it on
top of my motor home for me.  So, I got all the wood for the four spars,
all the cap strips, and miscellaneous wood for the wings.  All I need is
the plywood.  Cost, well less than $500 for all of it.  Yes, I will
need to run it through my plainer and cut it to size but so what.  It all
boils down to time VS money.  The latest thing I did was buy a set of
Super Cub landing gear used for $250.  I am having a ball.  How far
along am I?  I have the upper section of the fuselage all cut and fitted
together, ready to tack weld.  I would be farther along, but I built a
small addition on our house for my wife, a walk in closet.  It took me a
couple of months non stop work but now she tells me to get out in the shop and
work on the plane.
All in all, the 2+2 has been a great decision for me.  I will be posting
pictures here and at Supercub.org as I go along. My reason for this site is
simple.  I have received so much help and support from others as I began
this project that I simply want to pass it on to anyone who might be interested
in doing the same.