Fuselage
Section 25: Pages25-5
PDF Page 25-5   PDF Page 25-6  PDF Page 25-7  PDF Page25-8

Step 1: Cleco the F-1000S-L and -R and the F-1000R-L and - R aft Seat Rail Supports together as shown in Figure 1. and called out in Figure 2 to create four Aft Seat Support Subassemblies. Final -Drill #30 all the holes common between both parts in all four subassemblies.

Final-Drill #40 the nut plate attach holes and #19 all the screw holes in the upper flanges of all the aft seat rail supports.

Upper Flange of Rail Support being drilled for nutplate

Step 2: Final-Drill #40 the nut plate attach holes and #19 the screw holes in the upper flange of the F-100B Center Section Bulkhead

Drill the nutplate holes the inboard flanges of the F-1004D-L and -R Center Section Bulkheads.

  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. (see Figure 3).

Step 3: Cut the F-1004-L Hat Stiffener apart as shown in Figure 2 to form two F-1004L Hat Stiffeners. Trim the hatched area from either end of the hat stiffener as required to allow access to buck the rivets on the lower flange of the F-1004B Center Section Bulkhead.

Step 4: Cleco the Aft Seat Rail Support Subassemblies F-1004D-L and -R Center Section Hat Stiffeners to the F-1004B Center Section Bulkheads.

Step 5: Final-Drill #30 all holes common between the F-1004B Center Section Bulkhead, and the Aft Seat Rail Support Subassemblies, F-1004D-l and -R Center Section Bulkheads

 Drill theF-1004L Center Section Hat Stiffeners. Note that only one flange of the center section hat stiffeners heave holes and the other blank. Match-Drill #30 the holes from the center section bulkhead into the hat stiffener.

Step 6: Match-Drill #12 all holes common between the F-1004B  Center Section Bulkhead, F-1004G and F-1004H Center Section Bars and Aft Seat Rail Support Subassemblies, F-1004D-L and -R Center Section Bulkheads and F-1004L Center Section Hat Stiffeners. Mark the seat rail support subassemblies so they can return to the same position.

Drilling thru Seat Rail Assemblies

Step 7: Align the F-1004J Center Section Upright Bars with the F-1004B Center Section Bulkhead using two AN4 bolts. Final-Drill #30 the three 1/8 inch holes that attach both center section uprights bars to the center section bulkhead. Mark the upright bars forward side so they can be returned to the same position.

Step 8: Disassemble the aft center section bulkhead assembly and deburr all edges. Enlarge the snap bushing pilot holes as indicated in Figure 3 to 3/4 diameter. Machine counter sink all the nut plate attach holes for the head of a AN426AD3 rivet.

Machine counter sink the #30 holes on the forward side of the F-1004J Center Section Upright bars for the head of an AN426AD4 Rivet. Prime the center section upright bars. Prime the remaining parts if/as desired.

Step 9: Cleco then rivet the four Aft Seat Rail Support Subassemblies together per the callouts in Figure 1. Rivet nut plates to the upper flanges of the aft seat rail support subassemblies a shown in Figure 1.

Step 10: Reassemble the bulkhead per Step 4. Align the F-1004J Center Section Upright Bars with the F-1004B Center Section Bulkhead using two AN4 bolts.

Step 11: Rivet the F-1004J Center Section Upright Bars to the F-1004B Center Section Bulkhead per the callouts in Figure 3.

Section 25: Pages 25-6

Step 1: Rivet nut plates to the F-10004B, F-1004D-L and -R Center Section Bulkheads as shown in Figure 2.

Step 2: Bolt the Aft Seat Rail Subassemblies, F-1004D-L and -R Center Section Bulkheads and F-1004L Center Section Hat Stiffeners to the F-1004B Center Section Bulkhead as shown in Figure 2.

Bolting on the Bulkheads, watch for carefully for open holes and bolt lengths. most are AN12 but a couple are AN13

Center Section Hat Stiffeners get bolts in two bottom holes

Aft Seat Rail Supports get bolts in all 4 holes.

Step 3: Rivet the F-1004D-L and-R Center Section Bulkheads, F-1004L Center Section Hat Stiffeners and Aft Seat Rail Support Subassemblies to the F-1004B Center Section Bulkhead as shown in Page 25-5, Figure 3 and per callouts in Figure 1.

Step 4:Insert snap bushings into the F-1004D-L and -R Center Section Bulkheads as shown in Figure 2.

Step 5: Fabricate the F-1004M Wear Strip by cutting a piece of 1/8 inch thick by 1/2 inch wide UHMW plastic to 4 3/4 inches long. The wear strip may be up to 1/32 short but must not be over length.

Drill two # 30 holes centered on the width of the wear strip, each one inch from the end.

Step 6: Clamp the F-1004M Wear Strip to the upper flange of the F-1004B Center Section Bulkhead.

Position the wear strip such that the aft edge of the wear strip is flush with the center section bulkhead upper flange aft edge and such that the wear strip is exactly centered on the center section of the bulkhead.

Match-Drill #30 holes through the center section bulkhead upper flange using the holes in the center section bulkhead.

Step 7: Rivet the F-1004M Wear Strip to the upper flange of the F-1004B Center Section Bulkhead as shown in Figure 2.

Section 25: Pages 25-7

Step 1: Final-Drill #40 all the Nutplate attach holes and #19 all the Nutplate screw holes in the F-1005A Rear Spar Bulkhead, F-1005C-L and-R Bulkhead Side Channel and F-1063B-l and-R Idler Arm Brackets as shown in Figure 2.

Drilling Left and Right Bulkhead Channels

Drilling Bulkhead Flange Nutplates

Step 2: Cleco the F-1005B Rear Spar Attach Bars, F-1005C-L and -R Bulkhead Side Channels, F-1005D Crotch Strap Lugs, F-1005E-L and -R Gussets and F-1063B-L and -R Idler Arm Brackets to the F-1005A Rear Spar Bulkhead, as shown in Figure 2. Using Figure 1 as a guide tape over or mark the holes to be left open. Final-Drill #30 the remaining holes common between the parts just clecoed together.

Step 3: Disassemble and deburr all the bulkhead parts. Machine Countersink the Nutplate attach holes in the F-1005C-l and -R Bulkhead Side Channels and F-1063B-L and -R Idler Arm Brackets for the head of an AN426AD3 rivet. Machine Countersink the forward and inboard faces of the bulkhead side of the channels for all the F-1005E-L and-R Gussets attach holes. Machine Countersink the three lower screw holes in the inboard flange of the bulkhead side channels for the head of a #8 screw (see figure 2) Prime parts if/as desired

Countersink Side Channels

Countersinking the nutplates on the Idler Arm Bracket

Countersinking the gusset attach holes for AN4 Rivet

Step 4:  Rivet the nut plates onto the F-1005C-L and -R Bulkhead Side Channel and F-1063B-L and -R Idler Arm Brackets as shown in Figure 2.  Do not rivet nut plates onto the upper flange of the F-1005A Rear Spar Bulkhead.

Riveting nutplates to Side Bulkhead Channel

Riveting Nutplates to Idler Arm

Step 5: Rivet the F-1005B Rear Attach Bars, F-1005D Crotch Strap Lugs and F-1063B-L and-R Idler Arm Brackets to the F-1005A Rear Spar Bulkhead per the callouts in Figure 1 and Figure 2.

Riveting the rear Attach Bars ( Shop Heads go Aft of Spar)

Riveting Crotch Strap to Bulkhead

Step 6:  Rivet the F-1005E-L Gusset to the F-1005C-L Bulkhead Side Channel per the callouts in Figure 2. Rivet the F-1005E-R Gusset to the F-1005C-R Bulkhead Side Channel per the callouts in Figure 2.

Step 7: Install snap bushings into the F-1005A Rear Spar Bulkhead as shown in Figure 2.

Section 25: Pages 25-8

Step 1: Cut the F-10034D-L band -R Gussets apart from one another as shown in Figure 1

Step 2: Cleco the F-1034A Fuselage Bulkhead, F-1034C-L and-R Fuselage Bulkheads, and the F-1034D-l and-R Gussets together as shown in Figure 2.

Step 3: Final-Drill #30 all holes common between the parts clecoed together in step 2.

Step 4: Final-Drill the Nutplate attach holes for both nut plates near the center of the F-1034A Fuselage Bulkheads upper Flange. Final-Drill # 19 the screw holes for these nut plates.

Drill Plate nut holes #40 and Screw Holes #19

Step 5: Disassemble all parts and deburr all edges. Prime parts as/if desired.

Step 6: Rivet the F-1043D-L and-R Gussets to the F-1034A Fuselage Bulkhead per the callouts in Figure 2. To this subassembly rivet the F-1034C-l and-R Fuselage Bulkheads per the callouts in Figure 2.

Rivet Gussets to Bulkhead

Rivet Channel to Bulkhead

Step 7: Install snap bushings into the F_1034A Fuselage Bulkhead as shown in Figure 2.

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