April 11, 2009

More bulkhead work

Category: Bulkheads — Steffen @ 21:26 — Hours: 5.5

Today I continued working on the aft fuselage bulkheads. First I noticed, that the plans call for flush rivets on a part of the F-706 bulkhead.
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I will just dimple the bulkhead parts for this, but the small reinforcement angle from yesterday, had to get countersunk to accept the dimples. No big deal…
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Next I dug out the part for the elevator control bellcrank.
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After some matchdrilling and deburring…
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..those parts were ready too!
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The bellcrank needs two small bushings too, they are made from this piece of aluminum tube.
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At the top of the aft fuselage, between bulkhead F-706 & F-707 is another reinforcement rib. At the rear end goes another small piece of angle. I cut the angle to lenght, matchdrilled it to the F-707 bulkhead and deburred it all.
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Then I moved on to the second aft bulkhead, the F-711 bulkhead. This is a double bulkhead, which will support both the horizontal stabilizer and the tailwheel. Therefore it needs some sturdy alu bars to reinforce it. They are made from this piece of bar.
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Cut to length and tapered in the upper outboard corners. (I know, they are not laid down correctly… sorry!! )
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Matchdrilled to the bulkhead parts…
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A part of these bulkhead parts has to be trimmed away, I marked the cut lines from the reinforcement bars when I had them clecoed on. (Note the slots in the bulkheads, again Van’s lends you a helping hand for trimming. Brilliant idea!!)
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The bulkhead parts trimmed. I clecoed on the bars as guides for the final trimming.
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After trimming, I deburred all the holes and edges. Using small strips of emery cloth help deburring between the bulkhead ‘fingers’.
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Last thing to do on this bulkhead, was to make the upper support angle. Again I cut it to length, aligned it and matchdrilled it to the bulkhead.
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Here are the F-709 and F-710 bulkheads. They are 1 piece bulkheads so the only needs deburring and fluting. Boring!!!
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I only managed to finish the F-709 bulkhead before calling it a night. The in-laws paid us a visit, so off to the kitchen I went…
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