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Ch06 - Fuselage Assembly
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05/05/2008 Fake firewall to hold the sides. I used Wayne Hicks method; the fuse is assembled upside
down, simplest than the plans. The hole in the workbench is where the
IP hang`s. I draw one line in the center of the
table and perpendicular lines each 10" . |
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06/05/2008 First trying of the fuselage assembly. |
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Here you can see the
central line. |
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In the ch03, like Burt Rutan LEZ plans, Nat tells you to make one recess of
1/4" to deposit the flox. In Nat Puffer style, he don`t go to
repeat again to make these chamfers. |
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07/05/2008 Same as in IP. |
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08/05/2008 The LG bulkhead in place with flox and chamfer. |
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Spacers of 5"
from the firewall. |
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The torniquet
is to hold and compress until the flox cures. |
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09/05/2008 LG FWD bulkhead from 8" at the aft
LGB. |
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11/05/2008 Hot air duct and seat brace support
fabrication. I used vacuum and aramide
with 2ply UND. |
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13/05/2008 These pieces are very stressful. I will use one sump tank, between
firewall and AFT LG, and no need of the selector valve. |
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14/05/2008 Here is not one deviation from the
plans; I just build my seat belt support. From 2024T3 of 2" length, diameter
3/8, wall of 1/16, to carbon/aramide like below: |
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With 3 layers of tape
in a 1/4 bolt, to pop off the bolt just with the hands. |
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After the aramide
@45/-45 and carbon @0/90. The plastic hold and compress the
laminate. Roll and pull the plastic with a credit
card. |
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Before that one I made 2. I proceeded
with some structural tests. Pilot`s see with the hands. Dimensions: Diam. int. 1/4" Wall 3/16" or 4.76mm Diam. ext. 7/16" or
11.1125mm |
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Carving the foam. Without calcs,
the aramide is great in tension and carbon is 10
times as stiff than steel, I think my piece is 80 times more resistant than
the aluminum, by the tension use, not a compression use. |
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Ready to receive 2 ply
@45 aramide. |
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Inside the aramide
where the bolt touches, the carbon oxidizes with steel. |
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Perfect adjustment
0.09mm of gap. |
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17/05/2008 Here is 7ply UNI starting 24" and
finishing with 5”, I used carbon tapes of 24", 15" and 9", my
reinforcement is 8 times as stiff. |
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Good shape. The carbon
UNI don`t support torsion forces, so is important to make a straight line
with the fibers. |
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18/05/2008 The duct with 2 ply
aramide @45. The piece is very stiff; if I used the
glass until the aramide I can flex the corners. With the aramide I just can`t slacken
that. |
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21/05/2008 5min epoxy the foams. |
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Furrow in the foam to deposit the flox. |
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Here a plan deviation, I will not use
the naca scoop, so I build one flat floor. |
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22/05/2008 Heat duct in place. |
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Bulkheads fixed to receive the P-51
scoop. |
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25/05/2008 I don`t like to weight the epoxy and
hardener. So I just use syringes, easy and more quickly. |
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Rear shape of the
foam, I used 2 H80 of 3/4 and 1 H45 of 3/8. |
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28/05/2008 To make the curve I just put one strip
of 3/4" in the beginning and one 3/8" to conform
the curve. No wood. |
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Like in the front, in the rear I put one
strip of 1/4", that`s the exact height. Same level as the bulkheads. |
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07/06/2008 2ply aramide
@45 and 1ply in the rear seat area. |
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10"Hg of vacuum. |
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Another
shot. |
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Very
good the
result. |
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There you can see the rear shape. I gain
2" of height in the rear area. |
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15/06/2008 That`s what you make with the stuffs in
your shop. |
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Look the foam below the torniquet, flush with the LG bulkhead. |
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18/06/2008 One important detail, the fuse is bullet
proof. |
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Now are the 2” tapes. |
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26/06/2008 Removed foam to the center section spar.
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Holes to the wire duct. |
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05/08/2008 F-28 in place with flox.
At 6.25" from F-22. End of ch06. |
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