Step 1. Assembly of
the Fuselage Sides |
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6/17/04 Roy came over with his new (used) truck, and we
went to Lowes to get the lumber for assembling the fuselage sides, plus some extra 2x4's
for the saw horses. |
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6/17/04 Temp. firewall secured in place. |
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6/17/04 Brace on the back side. |
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6/17/04 Everything's floxed in place and drying. I
did the bit from the plans with the ropes and sticks, twisting the rope with small blocks
of wood to get a tight fit with the fuselage sides.
The bulkheads fit pretty well. The front seatback was nice and snug; the IP
wasn't as snug, but a little extra flox filled the gaps nicely. |
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6/19/04 Everything's set up for me to start adding BID
tape to the bulkheads... |
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6/19/04 Here's a shot of the front seat back taped along
the edge, and peel ply'd. |
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6/19/04 F22 taped in place. Next step is to add the
reinforcement to F22. |
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6/21/04 The reinforcement BID on F22. |
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6/22/04 Aft LG bulkhead in place and drying. |
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6/23/04 Installed the bottom part of the foreward LG
bulkhead. |
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6/23/04 A closer look. The 8" squares are in
place ready for drilling. |
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6/23/04 I also installed F28 today. |
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6/26/04 Amy helped me turn the fuselage upside-down and
put it up on the sawhorses. |
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6/27/04 Added the 6-ply UND on the aft-side of the forward
LG bulkhead, and the 2-ply BID tape on the seam. It's drying under the peel ply
here. |
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Step 2. Center Keel
and Seatback Brace |
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10/24/04 Cut the fuel valve brace to shape and drilled the
holes. |
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10/25/04 Putting the fuel valve supports in the keel
sides. |
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10/27/04 I used a block of wood with sandpaper wrapped
around it to adjust the spacing on the front seat for the heater duct. |
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10/27/04 The duct now fits nicely in place. |
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10/27/04 The 7-plies of UNI on top of the duct. |
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10/27/04 The completed center keel, drying. |
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Step 3. Contouring
and Installing the Fuselage Bottom |
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11/26/04 I used a jig saw with a 45-deg angle to cut the
landing brake cutout.
Uh-oh. I realized after the fact that in a dyslexic moment I cut the brake in the
wrong place! Doh!
Read those plans, folks. Make sure you know what you're doing. This mistake
was easy enough to correct, but next time it could be more serious. Read, re-read,
and then check it again. Ugh. If you don't have time to do it right the first
time, you don't have time to re-do it later.
The problem I had was that I had oriented the bottom one way, and the plans had it the
other. The text started by referencing the distance from the front of the front seat
back, so I measured fore instead of aft. I didn't notice until I was working on the
spacers (the following page in the plans), and there's a full-size picture of the bottom
with the brake to the aft. |
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11/26/04 The whole fuselage bottom with the landing brake
in the wrong place.
I simply 5ME'd the wrong cutout back into place, and cut out the brake again, in the
right place. The wrong cutout has become known as the "Secondary Landing
Brake." |
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11/26/04 I was having a hard time visualizing how to cut
out the foam spacers, so I cut out templates from masonite first. I'd rather mess up
cutting masonite than mess up cutting foam. I calcuated the area for the spacers
based on the templates, and came up with around 1,400 square inches. But a single
sheet of 2'x4' foam is only 1,152 inches, so I was ~300 square inches short. (These
are rough numbers; in reality, it was just under 330 in^2 that I was short).
The templates helped me be certain about how to cut the foam with a minimum of waste. |
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11/26/04 I was able to do all the spacers by using pieces
of leftover foam from previous pieces. Save everything!
These are the rough cuts. The blue pieces are old foam, the white pieces are from
the single 2'x4' sheet.
Do you see the mistake I made? |
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11/26/04 The spacers, with the 30-deg bevels added. I
used a table saw for this. Way overkill for the foam, but it gave me super nice
bevels. I had tried this earlier when doing the fuselage side bevels, but this time
I had much better luck.
See the mistake yet? |
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11/26/04 All the spacers in place.
This picture looks deceiving, and in fact I had the same impression looking at the
picture in the plans and on other builders' websites. This shape is concave, not
convex. What I mean is, the fore and aft edges are higher than the middle. But
looking at the picture, it sure looks like the center is raised and the fore/aft edges are
lower. I guess it's just an optical illusion from the spacers and the curve of the
sides, or something. Rest assured, it's shaped correctly and fits the fuselage
sides.
The mistake is pretty obvious at this point, now that the bevels are cut. The
pieces don't overlap. I'm going to have to cut little corner spacers to fill in the
gaps. *sigh* |
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11/26/04 Spacers micro'd in place and drying. You can
see the little corners in place that I had to cut. It took a lot of time, and every
little scrap of foam I had.
You can also see the secondary landing brake pretty clearly here. Heh. |
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11/26/04 Another shot of the spacers drying in place.
Note that the gaps between the spacers (where the spacers meet) have been filled
in. A more careful builder may have realized this before doing the cutting and have
cut the spacers to the correct length, but I realized the mistake only afterwards.
It was simple, but time-consuming, to cut small foam corners to fit the gaps.
This is the kind of thing that would be helpful to have in the FAQ. I hope
describing my mistake here helps some future builder... |
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The bottom of the fuselage is drying.
As it's the middle of winter here in Colorado the garage can get a
little cold. The tarp has a heater under it, which turns the work
table into a kind of oven. |
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After the fuselage had dried it was time to
flox it into position. I didn't have an assistant handy, so I had
to improvise. I suspended one end of the bottom from the ceiling,
applied the flox, and lowered it carefully into place. |
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In order to prevent the strap from damaging
the spacer I used blocks of wood to distribute the pressure over a
larger area. |
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