August 1, 2015

Roll bar construction, part 4

Category: Forward Fuselage — Steffen @ 20:03 — Hours: 5.5

I have finished constructing the roll bar assembly, and started the installation process.
Thursday evening began riveting the channel splices.
Fuselage 628 [800x]

Fuselage 629 [800x]

As you can see, the rivets in the F-632D angle ended up a little close the radius, so I had to rivet them with the shop head aft. These will not be visible, as a reinforcement channel will cover them.
Fuselage 630 [800x]

Fuselage 631 [800x]

Then I clamped the forward channel to my template table, and clecoed on the straps.
Fuselage 632 [800x]

It took less than 10 minutes to set all rivets, thanks to my pneumatic squeezer.Fuselage 633 [800x]

Fuselage 634 [800x]

Today I continued with the aft channel.
Before I could rivet it to the forward part, I had to install the two small angles that will support the reinforcement channel. First I marked and drilled the holes for the F-632D angle.
Fuselage 635 [800x]

Fuselage 636 [800x]

Then I could place the angles and drill them top the channel.
Fuselage 637 [800x]

..a little bit of deburring and 4 rivets later:
Fuselage 638 [800x]

Now I could close the roll bar…
Fuselage 639 [800x]

The rest is blind rivets.
Fuselage 640 [800x]

Finally done! 😀
Fuselage 641 [800x]

Now it was time to prepare the brackets that attaches the roll bar to the fuselage. I clamped them to the roll bar and drill the holes for 2 small rivets, that will secure the width of the brackets.
Fuselage 642 [800x]

Both done.
Fuselage 643 [800x]

I had to reinstall the fuselage top skins, to align the roll bar in the right position and angle.
Fuselage 644 [800x]

Fuselage 646 [800x]

I marked the correct angle the mounting bracket will have to the roll bar.
Fuselage 645 [800x]

         Then I trimmed the roll bar ends and filed radius, to allow the thick angles to sit correct,..
Fuselage 647 [800x]

…like this:
Fuselage 648 [800x]

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