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fklein(at)orcasonline.com
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 Posted: Wed May 25, 2011 10:42 pm Post subject: Bonding of upper fuselage |
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On a related subject, regardless of when its done, I tried something
which may have merit...in my case I'm very satisfied with the results.
When trial fitting the fuselage (using clecoes on 6" ctrs from
firewall to baggage bay bulkhead, 12" ctrs. back towards the tail, and
then 6" ctrs. or as necessary around the horizontal tailplane) I
noticed that the joggle joint between upper and lower fuselage
mouldings did not give a nice vertical plane across the
intersection...an issue easily solved of course with a couple of
millimeters of filler, but one which I'd hoped to minimize.
What I did was use my 3/4" hole saw to make a bunch of FG washers in 2
thicknesses. The pilot drill of the holesaw made a nice 1/4" hole in
the washers. Using a scrap of FG w/ a semicircular 3/4" hole in one
end, I had a nice little tool to push/slide the washers between the
joggle at each clecoe, going down the length of the joint on port and
starboard. In each instance, I could add whatever thickness of washers
was necessary in order to align the adjacent edges of the upper and
lower fuselage along the entire length of the joint, marking the
fuselage w/ the washer count at each clecoe.
Then w/ the upper fuselage removed, I used 5 min. epoxy to bond the
washers around each clecoe hole.
Stiff floxed Redux was applied to the lower fuselage, making sure that
there was a thick enough coat to ensure full bedding w/ some "squeeze-
out". I experienced no bulging between clecoes.
Due to the special qualities of our floxed-Redux, I have no concerns
about using it to fill the gap caused by my FG washer-spacers...If
anyone thinks I'm off-base on this from a structural standpoint,
please say so!
The result is my horizontal fuselage joint finished out smooth w/
minimal filler, except back at where the seam goes diagonal and then
aft above the tailplane.
A couple of pixs below.
Happily building,
Fred
PS: I don't regret having 4 helpers present to place the upper
fuselage in position after the Redux was applied to the joint.
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gregoryf.flyboy(at)comcas
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| Posted: Thu May 26, 2011 4:37 am Post subject: Bonding of upper fuselage |
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Great solution, Fred!
Time spent here, is less time spent filling later, and less weight of
course. I plan to something very similar...
Greg
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AirEupora
Joined: 01 Nov 2009
Posts: 186
Location: Dixon, CA
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| Posted: Thu May 26, 2011 6:38 am Post subject: Re: Bonding of upper fuselage |
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I'll add my 10 cents worth. I had the high MOD and that seem to help when I put the top on, in that, everything was in alignment. I had two helpers and one young one to get inside. I used PVC molding, from the lumber yard, along the whole length with screws, large washers and wing nuts about every six inches.
Here are four pictures and the two helpers. As a note I put the landing gear in before installing the top. This caused some problems with the wing pins. I had to remove the pilot's brushing and then re-install them. Both wing pin now go in with no trouble.
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gregoryf.flyboy(at)comcas
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| Posted: Fri May 27, 2011 4:29 am Post subject: Bonding of upper fuselage |
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| Quote: | 'As a note I put the landing gear in before installing the top. This
caused some problems with the wing pins.'
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_____________________________
I love this type of info. I am doing my wing pins as close to the end as
possible, so the gear is in already and can't affect the positioning of them
(which are still to be done). However, the top wasn't on when the gear was
installed, and the trueness of the stab tube has not been rechecked. I
figured that the landing gear area was so stiff (and not much surface area)
that it should be fine. Now I will have to go back to re-measure all
references, just to make sure my fuse didn't have the same problem. Thanks
for the heads-up!
One note about the top: On my aircraft, when it is installed with clecos
into what will be its final position, it twists the stab torque tube 0.5
degrees (port side moves up). Hence, the top installation -may- cause the
lower fuse to shift slightly. My torque tube bearings were installed and
trued as if the top were on. If your top was installed after the wing pins
were set up, this could cause a shift in the wing pins as well. I am toying
with the idea of cleco-ing the top in place during the whole lift pin
installation (in lieu of gluing..granted, gluing would be better), and hope
to keep the very tight 1/20 of 1 degree tolerance. The gain would be an
easier flap mechanism installation.
It looks like someone is actually enjoying their stay in the dungeon of doom
 LOL
Greg
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