Weeks offers a rare, unvarnished look at the industrial muscle and logistical choreography required to build a sanctuary for aviation history. It is a fascinating study of how modern robotic precision scales up to meet monumental structural challenges.
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NEW HANGAR - ROOF BEAM CONSTRUCTION VISIT追加:
Okay, Kermit Weeks here, Fantasy of Flight, and I am about to leave Fantasy of Flight. Um, I am heading up to check out the construction of the beams for the new hanger, which is going up over there. And it's going to be a long journey, 2.4 miles to where they're making them. in Pulk City. Anyway, um this is going to be Anyway, I'm excited to see how they put all this stuff together. They're really big. You can see the hanger going up right there. And uh anyway, so we'll go see how they're going to put all that together.
I'll be there in 4 minutes.
Okay, here we are in beautiful downtown Pulk City, a booming metropolis of Central Florida.
And uh anyway, got some interesting businesses here. I think that's the bait and sushi shop.
A lot of rednecks live here. Anyway, I'm driving along. Are you not going to believe this? This is a new Suburban for Kermit. It's my fifth one. And uh my last one was 15 years old. Oh my gosh.
Anyway, car is nothing for me. I need something that is functional. And uh anyway, so here we are leaving Pulk City.
Let's see where we're going here.
Be turning right up here. I've never been to this place, so it's going to be interesting. Um I'm being met by Brentton. He's the main uh I guess this is it right here.
I've flown over this when I'm flying around. Here we go.
I don't know what that is.
Oh, that must be where I'm going.
Okay, cool. Wow. I'll steal that spot right there.
Still trying to figure this car out.
It's got way too many crazy things in it.
Pretty nice, though. Check it out.
Four-wheel drive.
Anyway, okay.
Let's see what we got here.
That looks like the construction place.
Dixie Southern Industrial, Inc. What's happening, Brandon?
>> Hey, Kermit. How's it going? Yeah, yeah, yeah, yeah, yeah, yeah. Austin. Yeah, yeah, yeah. Nice to meet you. Austin, that's my middle name.
>> Oh, really? It's my middle name, actually.
>> Oh, no way. Oh my gosh. So, I've been to Austin, Texas, and they have a Kermit, Texas.
>> Okay.
>> Just west of uh Midland, believe it or not. All right, let's check this out.
>> Yeah, here's some safety glasses for you.
>> We'll walk back to the office and then >> All right, cool. How long you guys been here?
>> Man, this is way nicer than I expected.
>> Longer than what I know, but >> God, how much am I paying for this?
>> Every bit.
>> Every bit of it.
>> All right.
>> This is Mike Junior.
>> Hey, Mike. What's happening, Junior?
Who's the big one?
>> He's in there.
Hey, Big Mike.
>> How you doing?
>> How you doing?
>> Anyway, Kermit, >> how are you, sir? Eric, >> good to see you again.
>> DM, >> man.
>> I've flown over this place a lot.
>> Oh, yeah.
>> Yeah.
>> So, is this all your property, too?
Yes.
>> Yes.
>> All the way to the the fence right there behind those trailers that are over there.
>> Yeah. Okay. Wow.
>> And then it about doubles on the other side of those trees. You got to keep that where Swift mud and whatnot.
>> Yeah. Yeah. Yeah. Okay. Are we going to go driving or we walking?
>> We're walking right into the shop. Just just this way.
>> Okay.
>> Wow. Oh. Oh my gosh. I cannot believe they extrude that.
That's a pretty big aircraft tube. I'm saying.
So, how many tons of day do y'all normally push out of here?
It it varies really >> just the size of them.
>> But they're 151 ft long, right?
>> You got radius angle, too. So that throws a wrench in there, too.
>> Oh yeah, without a doubt.
>> Oh my god. I had no idea, >> man. This is way massive.
Everything's fed in from the outside over here and it's all automated. Um Mike can probably run you through the spectrum a little bit better than I can, but it's all, you know, automated steam line. It's got a 807 blaster. It's got a robotic arm. Um and then the uh that boardman, we just added that. That's the addition there.
Um You got X Y and rotation.
>> Yeah, it doesn't do really much in in the Z, >> but it it comes in it comes through a blaster, the material gets cleaned. Um, so everything's kind of a cleaner through the shop here. It makes for better welding, better painting, >> right? Just get the rust off and stuff.
>> Yeah. Yep.
>> Um and then from there it's preset to the office if it's going to come over to this side which is a robotic platform arm over here on our left side or it'll come over to the right side or it'll come through a drill and a saw. Um and that's all fully automated. It comes through those machines gets uh then somebody will have to come in and offload it.
>> And what what size holes are you drilling? Um, and are they bolts or what?
>> For this on the on the left, it's a plasma. It could go as big as a hole as you want.
>> Oh, okay. So, it's all pl it's not drilled then.
>> The one on the left is is all plasma.
The one on the right, that is a drill.
>> Okay. And I think our biggest drill bit in that one, I believe, is an inch and 9/16 for an inch and a half hole for bolts.
>> Okay. Anything bigger, we'll just put it over >> over to the plasma.
>> Huh.
>> Yeah.
>> Wow. That's pretty.
>> And back, you can't see back behind there, there is a table for burning all of our plates for all the detail kind of connection plates and things of that nature.
>> And all this stuff you see, >> watch out for arc flashes, too.
>> Oh, yeah. Yeah.
>> Yeah. So these are examples of that's about a inch and a quarter hole, inch and 38 or something.
>> Yeah, probably uh probably inch and 316.
>> Oh, really?
>> Is is for a 1 in bolt probably is what that is.
>> Don't necessarily know what's hot and what's not. So >> yeah. Yeah. Yeah.
>> So these are yours right here, Kermit.
>> Oh my gosh. So that's is that just half the hanger or is there something that goes in between?
>> So these will be uh it's a splice connection. So we'll assemble, you know, we're doing it in three parts, I think.
>> Oh, three parts. Okay. Yeah, that makes sense. Field connect the the members once it's >> Yeah. Yeah.
>> That's your spice connection right there.
>> Yeah.
>> Next one would be one truss.
>> Oh, okay. So this is half.
>> Yeah.
>> A big song, aren't you?
>> It is, man. What's going on, man? Get out of Good to see you, >> Dwayne. Nice to meet you, Brent. I see Joker every day.
>> Yeah, I see him. Every time I go to lunch, he's always over there. We're all eating at the same place.
>> Oh my gosh. Okay, so all the way down there and all the way down here, that's >> 50 ft. Yeah. Unbelievable.
>> Right. The column is 20 ft here. Calm 20 ft. So, yeah.
Yeah. Well, the hanger's 150 ft. So, it's a little bit of a >> You already was crazy to see them out on the trailer. You got a 8ft trailer. You got as much on the trailer as you got off the trailer.
>> Oh my god.
>> We had to cut tubes to put on there because if not, they're just sitting on the memories >> and it's too much weight. They don't collapse.
>> I'll be darn. Yeah. I want to get some video when we move these things over.
>> Oh, yeah. When a matter of fact, probably the first load I go over. The crazy thing is my wife's company is all of them.
>> Yeah. She she's always she's always working the the the trucking industry.
So when I when I call her and say, "Hey, this is" I said, "We need our best drivers. I don't have to worry about it."
>> Oh my gosh. That's >> So you you can't put everybody on 16t wide stuff.
>> Yeah.
>> I I'll let her meet you one day. She's She's a good girl. She's been She's been in the trucking industry. She was in the steel business with me when we used to build Joy. We used to build these in stock. I'll be done.
>> So I spent half my life in Joyce and we used to build both screens and 12 1/2 ft was the tallest we built in our jigs.
>> Oh my god.
>> When we got this big we might just circle.
>> Yeah. Yeah. Yeah. So 16 ft he's saying from there to here >> from here to here >> is the is the depth of this beam. You can see the curve there. And you see where they you know he's been welding right there. So here's our some weld right here.
>> How long did it take?
>> Interesting. So, does this get completed or it's just tacked to a certain point?
>> No, it just tack and then it welds the whole way.
>> Yeah. Right. Yeah. Yeah. It gets welded all the way around. How about on the back side here?
>> Yep. Yep.
>> Unreal.
>> Tap one one full truss.
>> Uh, a little over two days.
>> Little two days. Yeah.
>> Is this the first one?
>> No. No, no, no, no, no. There's a lot of parts in this thing.
>> No, no, no. But it's the first made the first full trust.
>> No, no. This is number seven.
>> Number seven. Oh my god. When we walk down, I'll show them to you on the truck. You can look at how many pieces in there we spent.
>> Now, think about this start to finish.
All right. So, we ordered, we got these cord, just this regular material. Bring it in.
>> So, you got uh 38 halves. So, 19 trusted, 38 halves on each side, right?
So, then you double that. That's 72 bottom and 72 tops. And all of them got to be spliced together. So, you talking about 156 pieces. And these aren't big pieces that you got to splice all these cores together. Splice all these cores together.
>> Wow.
>> It took my down with it must have took him two weeks to cut all these dirt.
>> Oh my gosh. Look how much shop space this takes up.
>> This takes up one whole set of >> Oh my god. Is this the biggest beam you've ever done?
>> No, not the biggest, but this this is probably one of the longer ones. No, this is not the biggest. Some of the bigger ones we've done were um uh lots of cancer. We built some 16footers and we built some 22 quarters. The 22footers we sent broke down.
>> But when you they put them together at the job site stick built them and those were big. Those maf cancer centers.
>> Huh.
>> Those are some big saw guns.
>> So now Okay. This is the middle. I thought you said it was in three pieces.
>> No, two pieces.
>> Two pieces.
>> Two pieces. Okay.
>> Two halves.
>> Two halves. Okay. So my plate machine right back here cutting all these plates was tied up for >> man probably a solid month. There is a >> Wow.
>> A million plates in these damn thing.
>> Oh my goodness.
>> So you got all the plates here. You got all the plates in between the uh the members.
>> Yeah. We spent months putting all this stuff before we ever started building.
>> There's a lot of people.
>> Wow. So you you got to play by ear.
That's what you got to do.
Unbelievable >> angle, man. I I don't remember how many pieces of angle for all your members. He spent a solid month >> between cutting the members for this and all the horizontal and and the egg braces. A solid month run one solid month.
>> And there ain't where's Randy? That guy right there.
>> Yeah.
>> They're in the main in this shop out work that s 10 hours a day.
>> Is this all part of my stuff? Uh, that's not, but that's not all the stuff we painted. We preainted it because, you know, it's getting back to back. You'll see when we get down there. It's pretty tight. So, if you don't paint it like these, if you don't paint these, when you put them together, you only got 38 of a gap. So, you can't get paint in there. We don't want them to bleed.
>> So, anytime you like this, you paint the inside. So, when you put them together side, it has a good coat on. So, so what happens when you weld it where it was painted? They just go back and repaint it?
>> Yeah, they'll repaint the whole thing.
When we get down there, we'll walk down the paint down.
>> Yeah. Okay.
>> It's pretty interesting to see these big song guns.
>> Uh, it is. No, I f I mean, you know, we build airplanes. So, this the these are like bigger airplane ribs is what they are. They're airplane ribs for a for a >> You got to see when we stand these guns up. When we stand these up, we have to choke our chains down as low as much as we can. When we stand these sun guns up off the top of these stands, we're maxing that clean up. It's all the way up till it hit the limit.
>> Wow.
>> Yeah, these are big guns.
>> The only thing that we've ever done that with the Muppets, trust me.
>> Oh, yeah. So, okay. So, that makes sense. So, you've got this crane here.
You see the big chain right there and then you've got a beam going across and there's beams that go all the way down the middle of this thing. Oh, you see one new one right there. Oh, that is too cool.
>> I think they will stand whatever they can look at. You'll see what I'm talking about.
>> Yeah, it's crazy to see.
>> So, when they move this, are they going to move it vertically or horizontally?
So, we they move them horizontally because they're 75 70 something foot long. We'll put a crane down there.
We'll put a crane down there. Two cranes and we'll move them to the paint bay.
Move the other section. We'll put one on the stand. put one on the ground cuz they take up so much room and then when they flip them they'll hook them. I'll show you how we hook them the panel. We stand them up with one crane to flip them over.
>> Oh, okay.
>> You don't realize how big they are until you stand them up.
>> Oh my gosh. Oh my gosh.
>> Yeah, it's pretty.
>> Man, that is unreal.
>> Look at all that.
So this is they're just kind of laying the stuff out now. And then this one, >> this one.
>> Oh my god. So I see. So these little floor stands are just for laying things out. So that and this floor must be fairly level.
Unreal.
I have to ask them if they Yeah. So, this is probably all my stuff here.
>> So, look at this. All of this plate. All of this plate. All of this plate. All of this plate.
>> This is just for one.
>> No, this is for all of them.
>> Oh, for all of them?
>> All of this plate. All of this plate.
All of this plate.
All of that plate. All of that plate.
And we done used up a couple of pounds.
>> Oh my god.
>> And this like all these angles here. You got you got those angles over there. You got all right here. See all the paint on these things? All this angle down through here. Look at these. And when we get out there, I'll show you the ones we still got on the trailer. Some of the uh some of the rollers, >> right? And so when they finally put the metal together, is that connected with bolts?
>> With both.
>> With bolts. Okay, that makes sense. Yep.
So Okay. So, it's got a basic like a gray kind of a paint on it now, but what happens when they finally get it done?
They paint it red here or over painted over there. This is just a primer.
>> This is just a primer.
>> Oh my god.
>> We get down. Let me show you. Let's walk down here.
>> See that?
>> They're pretty cool.
>> That's why we're holding.
>> And then you'll see the tubes that we had to cut because when I'll explain to you when we get down, we see them all hanging off the trailer. Think about these are 16t wide. The typical trailer is 8 foot wide.
>> So again, you got as much off trailers only.
>> You got 4T on each side hanging off the trailer.
>> But see, and then they give you kind of a process like these roll angles. We ordered it from the mill. We sent it straight to White Fab over in um Alabama. And then they have the roller.
So once they see these, you can't buy these angles like this. So they come in from the mill straight.
>> They went from the mill straight to White Fab the roller.
>> Then they bring them here. We got to bring them in and put them together.
>> And where do they roll them?
>> In white pale over in Alabama.
>> Oh, in Alabama.
>> Yep. So from the mill to white fair to roll them and then when they get rolled and they get shipped to us and then we got to splice them together.
>> How do they ship that if they're basically 80 ft long?
>> Well, they they come in hands. We get them here and then we got to weld them together.
>> Oh, I see. I see.
>> So what you see here is one right together.
>> All right. Okay. That makes sense.
Yeah. So, so they splice them together.
>> Yeah. Okay. So, basically you're looking at uh 75 like 30, >> let's call it 40 ft. Yeah. 40.
>> And the reason I say that because when you roll a piece, you got what you call tangible ends.
>> They have to start it in the machine.
So, you'll have >> two foot that we got to cut off to get the machine going.
>> So, you think about all that >> your your stuff over here.
>> We got a trailer out there. I'll show you the trailer that you can't see it behind me. There's a trailer load of cords out there. That's the roll cords.
These are a lot of the straighters. A lot of the straight ones there. It's a lot of pieces. Now, here's one built.
And you see how many plates are in this thing. So, you thinking all these panels, all the plates, there's a >> look at this plates. These are your connection places for your horizontal uh and your X braces.
>> You got plates in there. These plates plates in between the members. And those those members are so tall. So, you have to put those plates in there. So when they load it, them angles don't buckle.
>> Yeah. So this here is just to structurally put these together.
>> Yeah. Well, it's it's to hold them together when they load it, >> right?
>> So if this thing got loaded, you know, it's got so much arc, you ain't got to worry about ponding it on the roof, but if you had a strong wind or strong, it really pushing down on that that keeps them angles from separating. Yeah.
>> Yeah.
>> Unreal.
>> This just one half.
>> This is just a half.
>> And that's the other half.
>> Oh my gosh.
>> I had no idea. So cool.
That's not painted yet. Look at all the welding. Oh my gosh. Look at all the welding.
>> The groins don't do justice while I'm doing it.
>> So, do they stick this MIG welding? MIG.
Okay.
>> Man, you stick weld it. We wouldn't have built one by now.
>> Yeah. Yeah. Okay.
>> Yeah. Yeah. Yeah. Oh my gosh.
>> Let's go out to the trailer. We'll tell you this right here, please.
Yeah. Yeah, that's fine.
>> Oh, I see. Yeah. So, he's actually >> he's standing up.
>> Yeah. So, it looks like he's got the spray gun here.
>> So, he's spraying about 756.
>> Are you going to stand it up?
>> Oh, it's about four times.
>> Come over here, C. You going to stand up so you can see it.
>> Oh my god.
>> Okay, >> that's not bad.
>> You want to see it standing up?
>> Oh my gosh. Awesome.
I can see how big he is. He's already standing there.
>> But watch stand up think how tall they are. See how we got the chain stroke down?
>> Yeah.
>> Because it's so darn tall.
>> Yeah. Let me back up a little bit here.
>> Let's see when they up.
>> That's pretty cool to be able to come down and see your project being built.
>> Oh yeah. Have you been there?
>> I have not been there.
>> Oh, you have to come by. I'll give you a tour. Okay. Oh my god.
>> You can't believe what we do. Awesome.
Yeah, we got to do that.
>> Yeah, this is like an airplane rib except ours are really smaller.
>> Absolutely.
>> Absolutely. Watch that big up.
>> Oh my gosh. Yeah. 16 ft.
Unreal, man. That is one big ass airplane with I'm just saying that's bigger than how it uses scooters.
>> When you're standing up, hold it just a sec. You want to get some pictures?
Oh my god.
So, we got that thing moving right there.
Got it.
>> Yeah. Yeah. That's awesome. I tell you what, can I I can I just walk up there and just stand next to it? Is that not safe?
>> Let it Let him set it down.
>> Yeah. Yeah. Yeah. Yeah. Yeah.
>> Hey, set it down and hold it. You want to take a picture? Kind of stand out this way.
>> Yeah. Yeah. Yeah. We're here. You hold that. You You just tell me where I can go. Close.
All right. Oh, hold it tight. No, no, no. Hold it up. Tighten it up just a little. Yep. Oh. Oh, right there. Okay, you hold on. I'm just going to go. You tell me I >> stand out to the end and I'm standing.
Huh? You want to go down to the very end where it's the deepest? Go down to the very end.
Man, that is a big big dingy.
So that's 150 ft wide deal.
Now my biggest hanger at Fantasy of Flight is actually 200 ft wide.
The airplane stuff you can pick up by yourself. Most of this stuff you can't say.
>> We just added all the old part. You can see the old part, the new part. We just added that on just a little over here.
>> Oh, yeah. Yeah, that's what he said.
We added this uh robotic beam processor probably 3 years ago. We had this on year not quite two years ago. So I kind of got the impression this side does uh one side does drilling, one side does this drilling and this is when you got beams that's got a lot of blockouts in it. We run it over here. Now we can mill it >> for for spooling and turning over here.
>> Huh.
Oh my gosh. So you roll it in that way.
>> It starts back there. See the guy back the green shirt?
>> He replacing those rubber slides.
>> Um it comes in comes in from out the yard rusting material. Whatever size we need it. We put it on our machine. It goes through and it blasts.
>> It's the same as sand blad but it bead blast. We recycle a bead.
>> Okay. This in the middle here, >> right?
Look at that.
>> That's one after it's been blasted. It cleans it up pretty good.
>> Takes a lot of labor out.
>> So, it rolls in here and then they can roll it either over this way or that way. So when the when it when it when we get a cut list, which means if we're working on your building and you had uh x amount of beams, if they had a bunch of blockouts, it come down, it know because it's going to 807, it split it over there and it processes over there.
If it's just a straight cut beams with a lot of holes, it know to send it over here. That's your measuring arm. It brings it down and then if there's a if that measurement is off or that beam is the wrong size, it'll get to this point.
When it hits that sensor, it'll start.
I'll be >> tell you there's something wrong.
>> I'll be over there. It goes to it when that robotic arm it checks that beam. It comes in probe come down. It checks it and checks it checks checks and everything okay. It keeps going. If you happen to put the wrong size beam in there, it just check and it'll shut down. Is there any chance you could apply this technology to relationships?
You know, ain't that the true? Ain't that the truth? Just saying.
>> I wish we could.
>> Oh my god.
>> No, no, no. I got a great one. So, that's awesome. So, that goes through, huh, that's pretty cool. You got a business card?
>> No, I don't. But, uh, >> I'll give you one of mine.
>> Yeah. Cool. Awesome.
>> I like Yeah. Yeah. Yeah.
>> I live in Arubdale, so I >> Whoever wants come over. Yeah. Bring Mike and all. Big Mike and little Mike or whatever.
>> Yep.
>> Oh, this guy.
>> Unreal.
Yeah. So, that's the saw right there.
You see the saw blade, >> man. What a freaking That is amazing.
This has been a pretty cool deal.
Anyway, I'm glad I work on little stuff. I'm just saying.
>> They look different on the on the screen than they do in life, don't they?
>> Wow. Well, you know, when you stand down below at the bottom of the hanger, they don't look that big.
>> Yeah. You don't realize how big it is.
>> See, this trailer here, it's going to be nothing but during braces, horizontal braces, vertical braces. It's going to be a trailer load of nothing but braces in between them.
>> Wow. And they've already they've already got the uh you know, the route sorted out. And they they got like a cop or somebody.
>> They going to have they're going to have two escorts, a front rear escort, right?
And matter of fact, Sunday when we was coming back, we had to go back up home.
I live up by uh I was born and raised up around Stark. You know where Stark is?
>> Where state prison?
>> Yeah. Uh up that way.
>> Yeah. North. North Florida up between Gainsville and Gangsterville.
>> Anyway, we we had to go back home and when we was coming back, I was telling Deborah, I think it may be better to turn and go the back way there. We're here at this road here than trying to make that turn up there. But her driver is all big stuff for me for years. So they going to have their two best drivers on it because these things see how we had to make tubes because if not >> all right >> they when we set the first one out just sitting on the members and just the weight of itself yeah it's just too much >> and even even with that even with with as much as we're doing and we she and I talk about it regular cuz she's good. I said the drivers going to have to take their time. We ain't in no damn hurry.
>> So I may follow that first load over this seat. But Mike I'll I'll make sure that Mike comes out. He's He's been here and he's went over he's went over to the job site and seen >> where it's at. But >> well, it's not it's not a long haul.
It's No, it's a one corner haul.
>> Yes.
>> Yeah. So, look, that's an extended trailer. That's awesome.
>> Yeah. So, this is a 5390, which means closed up is 53 extending all the way out is 90.
>> And if they're in 5t anchor, so we got it stretched to 78T.
>> Wow. And it'll go another 12 ft.
>> Yep. Yep.
>> Wow.
>> Ain't that crazy? No, that I know it makes total sense, but you know, this is just not my world.
>> And see, then that's that's the rest of the road cords right there. Those remember I told you we brought all them in when we had to splice them together.
All that's yours. It's a lot of parts.
>> Wow. A >> lot of parts.
And how many total beams are there?
>> There's 19 of these put together. So 19 whole, 38 halves, >> right? Pretty cool. It is pretty cool.
>> Instead of running it uh parallel with the trusses, they're going to do them perpendicular because of that radius.
>> Ah, I got you.
>> What they were saying because if they run it like this and trying to bend it, you'll have creek.
>> No, no, no, no. I know. I know it had to go over it. Uh cuz again, like I was telling you, I spent half my life in the joystick. So, you got to start at the bottom, work your way over. But still, that's a heck of an arch.
>> Oh, yeah. Yeah.
>> Heck of arch.
>> That's awesome. Well, I appreciate you showing me around. And at some point, give me a card or something. I'll show you. I got I get your card cuz I want to go over and check that out.
>> Yeah, I'd love to show you guys what we're up to. So cool, man. Yeah, bring everybody no stunt plane with you and you bless me around.
>> We want to do that.
>> I would never do that.
>> All right, that's pretty cool. We're going to get some videos of when we move these things down the road, too. I can't wait. So, anyway, current weeks over and out.
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