Chapter 6 Cozy Mark-IV Ser. #0991 Work-In-Progress
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CHAPTER 6 - FUSELAGE ASSEMBLY
 Sides attached to seat back, IP, and F22

I decided to assemble the fusalage on top of my workbench because it is dead flat and level. Here you see F22 screwed to a 2x4 that is clamped to the table; F28 being held in place by a 1x2 and a spring clamp; seat back is already in and temporary fire wall in the rear.

The plank to the right on the floor is sitting on 5 gal. cans and acts as my scaffolding so I can reach inside and also climb up more easily.

Temporary Firewall Braced Into Position Here is the temporary firewall securely clamped, braced, and screwed to be perfectly plumb and square with the center line down the center of the bench.
Rear Landing Gear Bulkhead The rear landing gear bulk head is trimmed and shimmed up to a snug fit against the bottom longerons.
Upper and Lower pieces of Fwd LG Bulkhead OK, the lighting is a little week! However, these are the 2 pieces of the forward landing gear bulkhead. I clamped some wooden blocks to the rear LG bulkhead so that the top of the foreward LG bulkhead would have a firm place to rest while the flox cured.
The fuselage has been moved to saw horses in preparation for placing and marking the bottom foam.
Assembly of the seatback support can be a real pain. The little nails called out in the plans to hold things together just don't seem to cut it. Here I have a square and plumb corner clamped to the bench against which the top and bottom support pieces will rest. Then it was a matter of getting all the interior dividers in the right position; setting the top down; and, weighting things down so they didn't move.
The fuselage bottom takes shape. The yellow foam is micro'ed onto the flat PVC foam to give it depth, but also to provide some thickness along the edges where it will be cut down later to round the bottom edges.

Reflections

1. Level, flat, plumb, square - pay close attention to these at every step. Time taken here will save lots of grief and time later. 

2. When trimming interior bulkheads, IP, and seatback to fit in the fuselage - make sure to take a little off of each side - not all on one side. It's easy to get focused on getting the part to fit in the fuselage and forget that it has to be symetrical.

3. Draw center lines on all the interior pieces prior to installation. Make a strong black line with a extra-fine felt tip marker so it will show up even after a layup has been done on top of it. These references will help tremendously later on.

Now on to Chapter 7 fuselage exterior!!

 

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