Section 29 Fuse Side Skins
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Page 29-2
Step 1: Cut the F-1046-L and -R Mid Fuse Longerons from AA6-125X3/4X3/4 per the dimensions in Figure 1.
Step 2: Mark the skin rivet line on both the F-1046-L and -R Mid Fuse Longerons as shown in Figure 1.
NOTE the F-1046 B Longeron Bending Template is used for both the F-1046 Mid Fuse and F-1013 Fwd Fuse Longerons. Mark it as shown in Figure 2. to eliminate future confusion. The marking on the other side of the other side of the template are shown on Page 29-3 Figure 1.
Step 3: Place one of the of the F-1046-R Mid Fuse Longeron in a padded vise and preload the free end. Using a rubber mallet, firmly strike it adjacent to the vise to produce a bend. Repeat the process at one inch intervals to produce a curve that matches the F-1046B Longeron Bending Template within a sixteenth of an inch. See figure 3.
Lance came over to help and he pulled the angle through the vise and I hit it with the mallet. Bending is a learning experience, and about all I can tell you is how we did it. We made some marks about 1 inch apart and slid the angle and stopped at each mark and gave it a tap. It does not take a heavy blow a couple of light blows and by the time you have gone the length of the bend there is a lot of bend and you will probably have to put it in the vise and pull some of it out.
Check the curve often to prevent over bending. The Mid fuse Longerons can be placed in a six-inch vise without removing any of the bend so it is easy to add more curve later. Remove curve by clamping the mid fuse Longeron at the required point and pulling back slightly.
Check that the mid fuse Longeron does not bend out of plane vertically as it is being bent in the horizontal direction. If this occurs rotate the mid fuse Longeron 90 degree, clamp it in a vise, bend it back straight with your hands, then recheck the curve with the template.
Repeat this step to curve the F-1046-L Mid Fuse Longeron.
Step 4: Flush the side edge of the F-1046B Longeron Bending Template with the vertex of the F-1046-R Mid Fuse Longeron (see Figure 2 for the proper orientation of both parts), flush the aft edge of the Longeron bending templates with the aft end of the mid fuse Longeron, then clamp the parts together. Match-Drill # 30 the mid fuse longeron using the longeron bending templates as a drill guide. do not drill the holes marked "F-1046-L only" in Figure 3. Take care when drilling to ensure that the drill is perpendicular to the longeron bending template. Trim the forward end of the mid fuse longeron flush with the edge of the longeron bending template. Flip the longeron ending template over and repeat this step top match-drill the F-1046-L Mid Fuse Longeron.
Note some of the holes are not drilled on the F-1046-L part, be sure to mark them not to drill. You can see them in the picture. the first four aft the aft end are drilled and then some in the center are drilled. I think the instructions have a slight mistake as it says see Figure 3 when it should be Figure 2.
Step 5: Deburr the F-1046-L and -R Mid Fuse Longerons.
Step 6: Cut the F-1013-L and -R Fwd Fuselage Longerons from AA6-125X3/4X3/4 per the overall length dimensions in Figure 3.
NOTE: Figure 3 shows marks on the flange of the F-1013-R Fwd Fuselage Longerons which are made in Step 7. The marks on the F-1013-L Fwd Fuselage Longerons are made on the opposite flanges.
Step 7: Mark the F-1013-L and -R Fwd Fuselage Longerons at the four locations shown in Figure 3.
Mark the rivet line, shown in Figure 3, on both Longerons.
Page 29-3
Step 1: Using the technique employed to curve the F-1046 Mid-Fuselage Longerons, curve the F-1013-R Fed Fuse Longerons between the "start of the curve" mark and the "end of the curve" mark. The curve must match the F-1046B Longeron Bending Template within a sixteenth of an inch. See Figure 1.
Repeat this step to curve the F-1013-L Mid Fuse Longeron.
Step 2: Clamp the F-1013-R Fwd Fuse Longeron to the F-1046B Longeron Bending Template. Match the fwd edge of the longeron bending template with the "start of Curve" mark and flush the long edge of the longeron bending template with the vertex of the fwd fuse longeron. Match-Drill #40 the mid fuse longeron using the longeron bending template as a drill guide. Repeat this step to match-drill the F-1013-L Fwd Fuse Longeron.
Step 3: Clamp the F-1013-R Fwd Fuse Longeron in a padded vise at the "forward twist mark". Twist the fwd fuse longeron with a crescent wrench as shown in Figure 2. to obtain the dimension shown in Figure 3. Clamp the fwd longeron at the "aft twist mark". Repeat this process using the twist direction shown in Figure 1 to obtain the dimension shown in Figure 3.
Step 4: Deburr the F-1013-L & -R Fwd Fuse Longerons.
Page 29-4
Step 1: Make a Clamping Block from hardwood or tightly grained equivalent per the dimensions given in the three view in Figure 1.
Step 2: Fabricate the F-1070A and B Roll Construction Angles per the dimensions in Figure 2 (he F-1070A is shown, and the F-1070B is a mirror image). Drill #40 hole in the end of both roll construction angles per the dimensions in Figure 2.
Step 3: Cleco the #40 hole in the F-1070A Roll Construction Angle to the alignment hole (called out in Figure 3) in the F-1070-R Mid Side Skin. With the roll construction angle parallel to the bottom edge (indicated in Figure 3) of the mid side skin,
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Match drill #40 all of the holes along the bottom edge of the mid side skin into the roll construction angle. Separate the two parts.
Cleco the original #40 holes in the F-1070A Roll Construction Angle to the #40 hole in the F-1070B Roll Construction Angle, and clamp the remaining portions together (see Page 29-5, Figure 1 for their orientation). Match-Drill all of the holes in the F-1070A Roll Construction Angle into the F-1070B Roll Construction Angle. Separate the two parts and set them aside.
Step 4: Draw a line between the two rivet holes shown in the detail view in Figure 3. Offset this line per the dimension in the detail view and extend the line to intersect the trailing edge. Draw the "Start of Roll Line" between this intersection and the center of the relief notch as shown in Figure 3.
Page 29-5
Step 1: Note: Again I recruited Lari Clark to help me with this. He is a very accomplished builder and is really good at metal bending and forming, fiberglass or just about anything you need help with. He is always ready to help and I want to thank him very much. Align the " Start of Roll Line" (see Page 29-4, Figure 3". then clamp it and the mid side skin to the table. As shown in Figure 1, Cleco the F-1070A and B Roll Construction Angles to the mid side skin, and clamp two vise grips onto either end of the roll construction angles. Double check that you are about to bend the skin in the correct direction; the outboard face of the skin should be down against the table with the inboard face up.
Step 2; Roll the sin into a cone that terminates in a sharp bend at the forward end. The roll created with the aft vise grip handle, and the sharp bend is naturally formed at the forward end (the sharp bend is finished in Step 3). Twist the F-1070A and B roll construction angles with the aft vise grip and at the same time push the aft end down and inwards toward the table. Use the extra roll construction angle which extends aft of the vise grips as a handle for your other hand. The twisting and pushing motion must be balanced. Twisting too much will create a crease along the edge of the roll construction angles, pushing to hard will create a sharp bend in the middle of the roll. Do not try to complete the roll in one iteration. The finished roll should look similar to Figure 2.
Step 3: Remove the four, forward most clecos from the F-1070A and B Roll Construction Angles. Twist the roll construction angles with the forward vise grip, then strike the roll construction angles with a rubber mallet to finish forming the sharp radius at the from to of the roll
Thanks again Lari for the help. the roll turned out perfectly on both sides
Very nice roll on both sides of the aft skins.
Step 4: Remove the F-1006B Bulkhead from the Tailcone Assembly. Cleco the F-1070-R Mid Side Skin and the bulkhead to the underlying structure and check that the mid side skin is properly formed. See Figure 4.
Page 29-6
Step 1: Cut the F-1020A and B Baggage door Seat Angle from AA6-063 X 3/4 X 3/4. Use the dimensions given in Figure 1.
Step 2?
Step 3: Cleco the F-1034B Seat Back Brace and F-1034E Seat Back Brace Gusset to the F-1046-L Mid Fuse Longeron as shown in Figure 2. Butt the forward end of the F-1002A Baggage Door Seal Angle against the aft edge of the seat back brace gusset. Offset the entire length of the baggage door seal angle 1/16" inboard of the mid fuse Longeron as shown in Figure 3, then clamp the baggage door seal angle to the mid fuse Longeron.
Step 4: Match-Drill #30 and Cleco the holes in the F-1046-L Mid Fuse Longeron into the F-10102A Baggage Door Seal Angle.
Step 5: Butt the aft end of the F-10102B Baggage Door Seal Angle against the forward end of the F-10102A Baggage Door Seal Angle (see Figures 2 and 4) Offset the F-10102B Baggage Door Seal Angle a 1/16" inboard of the mid fuse longer and clamp it in position.
Step 6: Match-Drill #30 and cleco the six holes common to the F-1046-L Mid Fuse Longeron, F-1034-B Seat Back Brace, and F-1034E Seat Back Brace Gusset into the F-10102B Baggage Door Seal Angle.
Step 7: Draw a line on the flange of the F-10102A and B Baggage Door Seal Angle 3/8" from the lower face of the F-1046-L Mid Fuse Longeron as shown in Figure 4. Remove the baggage door seal angles and trim off the portion of the flange below this line. Note that once trimmed, the flange on tF-10102B will be shorter than the flange on F-1012A.
