February 1, 2009

More center section bulkhead work

Category: Bulkheads — Steffen @ 22:32 — Hours: 4

I managed to do a fair amount of progress on the center section bulkhead today. First, I noticed I still needed to make a couple of snap-bushing holes for wiring in the bulkhead frames. There was no pilot holes for these, so I measured out and pilot drilled the holes in the first frame, then used a sheet of aluminium to trace these pilot holes to the other frame.
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All four holes drilled…
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Next I countersank the bulkhead flange rivet holes.
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After that I dug out the control column bracket, measured out the top holes and drilled them.
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Then I bolted them to the bulkhead spar, and squared them to the spar flanges.
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With the brackets firmly tightened and squared to the spar, I could use the spar as guide to back-drill the lower holes. Here they have been drilled, and temporary bolted to the spar. (I intentionally used short bolts, so they didn’t touch to nylon lock in the nuts.)
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Now it was time to arrange the flight sticks. They come with brass bushings that have to be drilled up to ¼”, then adjusted in lenght to fit in the bellcrank openings. The lenght is easily adjusted by putting the bushing in the drill press, then pulling it down onto a file resting on the drill table. I’m sorry, I forgot to take pictured while I did all this.. I will try and take some later to explain.
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Next small project, was to make two spacers out of this piece of tubing.
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They had to be exactly 1.438″
I used the same procedure as with the control stick bushings.
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The spacers installed. I had to enlarge the holes of one of the frames to ¼”, I did this by aligning the two spars by inserting the wing bolts, then using the other spar as drill guide. Worked pretty good!
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Last thing I did today, was to mark the area of the control stick bellcrank brackets, that will be removed for weight savings. I am looking for a bandsaw at the moment, it would make jobs like these a lot easier…
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