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Ch04 - Fuselage Bulkheads
I initiated
for the 25 BID reinforcements of the main landing gear. I confectioned all
parts, but it left with many bubbles. As I mess in the setting of the
reinforcements, I destroyed them and confectioned others.
The second time
I used vacuum and the parts was perfects.
The four
parts weight had reached in the first case 602 grams, while in the second was
548 grams, 8,97% of difference.
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07/12/2007 Step 1 - Front Seat Back. In the tips of security of Eduardo Hilton, I lean that the more
inclined the seat, minor is the load of G jamming the vertebral column in
case of a crash. My seat will have inclination of 42°, against 45° of the
plans.
Initially cut the foam aprox. 1.5" big in
height than the specified size. It is sandpapered with 120 to form a smooth surface.
After it is applied Micron and Epoxy, already with the hardener. It leaves to
reach almost the gel time so that not pass for the cloth. |
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After the lamination comes peel ply, the perforated
film, the absorb film and the film for vacuum. Applied 12 " Hg of vacuum. The upper main
landing gear bulk is being finished in this bag too. Tip: to keep the film for strained vacuum is easier
to stamp with the mail tape. |
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Everything functioning perfectly inside
of the heat tent. Gradually (~2°C/min) temperature is
raised until 60°C, keeping it during the cure time (6h). After 24h of complete cure, they are
exposed to the sun, covered with black constructionplastic
until reaching 80°C, for after cure, during 5h. All this process it`s called German
method of vacuum in composites. |
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Two thermometers in the heat tent to calibrate the
temperature, the central have the connecting rod of 30cm, so is more accurate.
While the vacuum-gauge of the pipe chamber mark`s 20
" Hg, the vacuum-gauge of the bag show`s 12 " Hg. |
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The vacuum pipe
chamber has 1m x 0,10m Ø. |
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12/12/2007 Back of it I lean in aramide
Twaron 2200 HM dtex 1610,
this wire is not ballistic as the Kevlar29 and Twaron
1000, it is for plastic reinforcement, equaling to Kevlar 49. Fabric kk205 of
TEXIGLASS. The
substitutions for aramide will be made where the
tension predominate, and in not structural parts. As the part is big, and the aramide
one is more difficult to impregnate than the glass, I used the wet out
technique. |
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Perforated film,
allows the exceeded resin to pass. |
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All stamped on bag.
The foam that I use is the H80, the plans indicate H45, however, as the
inclination will be bigger, and the foam is the responsible for the distribution
of loads between fibers, the use of one foam with properties 55% superiors
will effectiveness distribute the loads. |
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13/12/2007 The additional aramide
strip, not contemplated in the plans, however the same one will serve to hold
the pressure of leans it of head, in case of an accident or incident, and
that I never wait to need. It is not possible to sandpaper the aramide, untied it amount of fuzzy hairs. To trim with
sandpaper also is impossible. The solution is to plate one
superficially glass fabric for finishing, and to trim use only one stiletto,
up to 3 layers. In this part it will not have painting finishing, only the
leather. |
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The part, but still for trimming the
corners and bevel the center console, what I will make only in chapter 6 for
a perfect adjustment, weighed 2412g, against already beveled of: Wayne Hicks -2204g Bernard Siu
- 2341g Kevin Dove - 2500g Douglas
Walters - 2585g,
without the center hole. Chasing Mars - 2917g, with door and H80 That is, perceivable the use of the
professional vacuum, and also the use of kk205 that is 150% superior to the
glass in tension; inferior to RA7725 in compression only 9%; it weights 32% less than the glass: 200g/m ² against 298g/m
². |
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Already practically in
flight. Only that the seat will not be rose. |
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31/12/2007 Step 2 - F22 Situated at 22" of the nose, this
bulkhead receives a strap foam addition on the opening of the legs. It shields it already is ready to trim.
I will use the method of Drew Chaplin to contour it. I will not remove the
peel ply until the moment to join the fuselage in chapter 6. |
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07/01/2008 Opposing above detailed. I did not use
the method of Chaplin, I just placed paper carbon on
of peel ply, passed the drawing of the plans for the part and later trim with
the saw and the sandpaper. Later I only removed peel ply. The temptation is
great to see how the part was. But the part was very good. Without defect. Make everything and later trim is much
easy, little work and little time. |
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The verse of the F22
possesses reinforcements where the canard will be mounted and its setting. |
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13/01/2008 F28 - Ready to be
installed. It was strengthened beyond what the plans indicate to contain the
supports of the hinge of canopy, which will also be fixed in the longerons, as Ed Richards made it. For the plans they are 2 BID @45 and 1
UND horizontal line. Mine schedule was of 4 BID @45, 2 UND
horizontal line, as hard points of 7 " had been: 1 covers BID @45 and 1
covers UND @90, of the two sides and in the two extremities. The inferior part also was left wider,
with 5 " for setting of the canopy hinge support. |
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02/01/2008 Step 3 - IP Glue with 5min Epoxy,
it is fixed with ribbon in the style of a hinge, transfers the Epoxy in the opening
of the other side, closes the hinge. I applied pieces of
peel ply to absorb the Epoxy excess. |
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The easy way to trim is to pass the
contours with pens marks compact disc over peel ply. When the plans or the drawings give the
dimensions use them, exist much distortion between the drawings and the
quoted measures. |
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I go to trim the corners when ready to
install it in the fuse. By this way, I don`t take the risk to have to fill gaps
with resin and flox. The inferior part in the drawings is
1/4" minor, many constructors has that to place foam for adjustment to
the deep of the fuse. People make this bulkhead with 0.25 " bigger. It
is much easier to take off. |
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11/01/2008 Dennis Passey
leg cutouts, real cool. Reinforced below the leg cuts. After I will layup one overall carbon BID ply. |
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Almost done, just cosmetic repairs. |
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I removed the above part of the panel,
will install the keys in other parts of the panel, also being able to be
installed in the superior part of the canopy or in the interior of strakes. |
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Contours in all the reinforcements
for comfort of the legs. Still it lacks to trim. |
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09/01/2008 Step 4 - Manufactured with Divinycell
HT110, against the H100 of the plans, superior to this and it is for
aeronautical use. However slightly more weighed, as it can
be perceived in the comparison of FWD LG below (328g). |
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13/01/2008 Ready for installation. It can be perceived
that it was in the weight average of the others, although the HT110. |
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16/01/2008 After cure I trim my pieces. |
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08/01/2008 Upper portion of the FWD LG |
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02/01/2008 Step 5 - Firewall Manufactured with naval plywood of
ferrule and Arana cedar from COMPEBRAS, superior than the indicated in the plans.
It leads you incrust of aluminum in the same thickness of 1/4 ". The
incrust have 2 " x2 ", against 1 " x1 " of the plans. |
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BID.
@45. |
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After the laminate comes the peel ply. |
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I can use the perforated
film 2 or 3 times. |
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Cloth to such the excess of resin. |
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All bag stamped. The film for vacuum can be substituted
by any plastic of construction or greenhouse, only that the professional
material is perfect and can be reused 3 times. |
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07/01/2008 Here the welded screws with flox. |
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Done. |
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08/01/2008 Ready for the installation. I only go to
trim the superior firewall when I decide if I increase the turtleback
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Peso
das peças/parts weight (grams) |
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Ale Souto Naca Scoop |
Ale Souto P-51 |
Wayne Hicks |
Bernard
Siu |
Kevin Dove |
Chasing Mars |
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Seatback |
2412 |
2310 |
2204 |
2341 |
2500 |
2917 |
2358 |
F22 |
1037 |
1029 |
948 |
992 |
1000 |
N/A |
952 |
F28 |
385 |
360 |
303 |
226 |
292 |
N/A |
317 |
Instrument
Panel |
2090 |
2019 |
1700 |
1808 |
1900 |
1944 |
1950 |
Top Firewall |
on
hold |
on hold |
N/A |
1513 |
1500 |
1510 |
1678 |
Center
Left Firewall |
116 |
116 |
N/A |
141 |
145 |
279 |
204 |
Center
Right Firewall |
116 |
116 |
N/A |
136 |
145 |
279 |
204 |
Bottom Firewall |
1005 |
1179 |
N/A |
1672 |
1250 |
1244 |
1451 |
FWD LG
upper |
328 |
328 |
317 |
368 |
500 |
315 |
408 |
FWD LG
lower |
618 |
698 |
598 |
714 |
700 |
628 |
771 |
AFT LG |
1173 |
1323 |
1143 |
1326 |
1000 |
1125 |
1360 |
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