Fuselage
Section 25: Pages25-1 thru 25-4
Mid Fuse Bulkheads
Page25-1PDF
Page25-2 PDF
I put the parts for Section 25 on the table to get a look at where everything kind on goes.
Step 1: Create two F-1004N Stiffeners from AA6-063X3/4X3/4 per dimensions given in Figure 1.
Step 2: Mark a centerline on one outside face of each F-1004N Stiffener Angle, See Figure 2.
\Step 3: Clamp a F-1004N Stiffener Angle to the F-1004A Center Section Bulkhead as shown in Figure 3. Align the edge of the angle with the outboard edge of the bulkhead as shown in Figure 3. Center the centerline on the center hole common to both the bulkhead and stiffener angle. Clamp both parts together.
Step 4: Match-Drill #30 and Cleco the holes common to both the F-1004N Stiffener Angle and the F-1004A Center Section Bulkhead using the center section bulkhead as a drill guide. Repeat this step for the remaining stiffener angle.
Step 5: Remove the F-1004N Stiffener Angles from the F-1004A Center Section Bulkhead and deburr the edges on all parts.
Step 6: Cleco the F-1004P-L and -R Mid Seat Rail Supports together as shown in the exploded detail in Figure 4, forming two Mid Seat Rail Support Subassemblies. Final-Drill #30 all holes common between the mid seat rail supports on both assemblies.
Step 7: There are four nut plate attach patterns in the upper flange of each F-1004P-l and -R Mid Seat Support and three nut plate attach patterns in the inboard flange of the F-10004C-l and -R Center Section Bulkheads, final-drill #19 all the screw hole and #40 all the nut plates attach holes.
Machine countersink the screw holes for the lower two nut plates in the inboard flange of the center section bulkheads for the head of an #8 screw.
Step 8: Cleco the Mid Seat Rail Support Subassemblies and F-1004C-Land - R Center Section Bulkheads to the F-1004A Center section Bulkhead as shown in Figure 4. Final-Drill #30 all the holes common between the F-1004A Bulkhead and the mid seat rail support subassemblies and the F-1004C-l and -R Bulkheads.
Step 9: Match-Drill #12 the holes common between the F-1004A Center Section Bulkhead, F-1004E and F-1004F Center section bars and the mid Seat Rail Support Subassemblies using the holes in the center section as a drill guide.
Final-Drill #12 the holes common between the F-1004A Center Section Bulkhead, F-1004E and F-1004F Center Section Bars and the F-1004C-L and -R Center Section Bulkheads. Mark both mid seat rail support subassemblies so they can be returned to the same position.
Page 25-3
Step 1: Check the dimension on your center section is larger than that shown in figure 1, remove the mid seat rail support subassemblies then remove the hatched areas as indicated in the blow up view in Figure 1. Start by drilling #30 holes as shown in Figure 1, then carefully trim from the quadrants of the hole to the edge of the part.
Marked off the dimensions to cut to.
Carefully cut with a hacksaw
Smoothed off with a fine file
Remove the half moon area along the top edge of the center section. Be careful not to damage the spar bars.
If the F-1004A Center Section Bulkhead was trimmed deburr and prime the trimmed edge.
Went down and bought a high quality cutting tool. It is a Champion SF5NF Tree NF Burr and it works great. It is aggressive so be careful but it really cuts the material away in a hurry and leaves a very nice edge.
Step2: Final-Drill # 12 the holes in the upper flange of both WD-1021 Landing Gear Mounts as shown in Figure 3.
Step 3: Temporarily bolt the WD-1021-L-PC Landing Gear Mount- Left to the Fwd Section Bulkhead Assembly as shown in Figure 3. This will require trimming the outboard portion of the fwd center section bulkhead lower flange to remove interference with the gear leg socket as shown in Figure 2. Figure 2 gives only the general idea of how the final trim will look and is not a final trim template. Trim the fwd center section bulkhead progressively using the landing gear mount left as a guide. Repeat for the WD-1021-R-PC Landing Gear Mount
Mark approximate area to be trimmed
Start trimming away and putting mount on as you go to check for fit
Trim until the Gear Tube clears the flange.
Step 4: Insert the F-Drill Bushing into one of the lower holes in the FWD Center Section Bulkhead Assembly that will be match-drilled into the WD-1021-L-PC Landing Gear Mount Left. See call outs in Figure 3. Match-Drill #30 a pilot hole into the landing gear mount using the F-drill bushing as a drill guide. Repeat this step to create the remaining holes in both landing gear mounts.
Step 5: Remove the W-1021-L and -R Landing Gear Mounts from the Fwd Center Section Bulkhead assembly. Final -Drill #12 the holes match-drill #30 in Step 4.
Step 6: Final-Drill .311 (7.9mm) the upper hole in the gear leg socket. See Figure 3. Do not drill the lower hole at this time.
Step 7: Temporarily bolt the EWD-1021-L and -R Landing Gear Mounts to the Fwd Center Section Bulkhead Assembly and check that an AN3 Bolt will pass through all parts. Remove the landing gear mounts from the bulkhead assembly.
Step 8: Machine Countersink two places each side as shown in Figure 3 to fit the head of a #10 screw.
Step 9: Disassemble all the parts in the fwd center section bulkhead assembly and deburr all edges. Machine countersink all the nutplate attach holes for the head of an AN426AD3 rivet. Using a unibit, enlarge the snap bushing holes in the F-100C-l and --R Center Section Bulkheads and F-1004A Center Section Bulkhead as indicated in Page 25-2, Figure 4. Prime parts if/as desired
Page 25-4
Step 1: Cleco the F-1004P-L and Mid Seat Rail Support together as shown in Figure 1. Rivet the F-1004P-L and -R Mid Seat Rail Support together per the callouts in Figure 1. Repeat this step to create two Mid Seat Rail Subassemblies.
Step 2: Cleco the Nut plate onto the upper flanges of both mid seat rail support as shown in Figure 1. Rivet the nutplates onto the upper flanges of the mid seat rail support a shown in Figure 1. Repeat this step on both mid seat rail subassemblies.
Step 3: Rivet the nutplates onto the inboard flange of the f-100C-L and -R Center Section Bulkheads per the callouts in Figure 2. Install two screws on each side of the fwd center section assembly as shown in Figure 2.
Step 4: Cleco the Mid Seat Rail Support Subassemblies, F-1004C-L and -R Center Section Bulkheads and F-1004N Stiffener Angles to the F-1004A Center Section Bulkhead.
Step 5: Bolt the Mid Rail Support Subassemblies to the F-1004A Center Section Bulkhead per callouts in Figure 2. Install two screws on each side of the fwd center section assembly as shown in Figure 2.
Step 6: Rivet the Mid Seat Rail Support Subassemblies, F-1004C-L and -R Center section Bulkheads and F-1004N Stiffener Angles to the F-1004A Center Section Bulkhead per callouts in Figure 2.
Riveting the F-1004C-L and -R in place
Riveting the F-1004N Stiffeners in place
Riveting the Mid Seat Rail Supports in Place
Step 7: Insert snap bushings into the F-10004C-l and-R Center Section Bulkheads per the callouts in Figure 2.
