Section 29 Fuse Side Skins
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Page 29-7
Step 1: Cleco the F-1046-R Mid Fuse Longeron, F-1034B Seat Back Brace, F-1034C-R Fuselage Bulkhead and F-1034E Seat Back Brace Gusset together as shown in the exploded detail view in Figure 1. Temporarily clamp the forward end of the mid fuse longerons to the F-1005E-L and -R Gussets. Final-Drill #30 all holes common between the parts shown in the exploded detail view.
Step 2: Final-Drill #19 the screw holes in the lower flange of the F-1015C-L and -R Mid Cabin Decks. Machine countersink these hoes for the head of a #8 screw.
Step 3: Cleco the F-1015C-R Mid Cabin Deck to the F-1015B-R Foot Well Rib Intercostal and F-1005C-R Bulkhead Side Channel as shown in Figure 1. Cleco the F-1013-L Fwd Fuselage Longeron to the mid cabin deck. Final-Drill #40 the holes common between all parts clecoed together in this step. Repeat this step for the left side of the aircraft. The right is a mirror of the left.
Page 29-8
Step 1: Cut the F-10100 Baggage Door Shim into F-10100A and B Baggage Door Shims as shown in Figure 1. Remove the tabs and deburr the edges of both parts. Set the F-10100B Baggage Door Shim aside until attaching the tailcone.
Step 2: Final-Drill #30 all the holes in the upper flange (flange not common to the skin) of the F-1023-L and -R Baggage Floor Angles. Deburr and dimple (for a flush head on upper side) these holes now.
Step 3: Cleco the F-1023-L Baggage Floor Angle and F-10100A and F-10101 Baggage Door Shims to the F-1070-L Mid Side Skin as shown in Figure 2. Final-Drill #40 the holes common between these pars except the holes marked in Figure 2.
Step 4: Cleco the F-1023-R Baggage Floor Angles to the F-1070-R Mid Side Skin as shown in Figure 3. Final-Drill #40 all the holes common between these parts.
Page 29-9
Step 1: Cleco the F-1070-L and F-1070-R Mid Side Skins and the two F-1015F Spacers to the under structure as shown in Figure 1.
Step 2: Using the callouts on Page 29-15, Figure 1 mark the holes that are not drilled in this section. Final -Drill #40 all the remaining 3/32 inch holes common to the F-1070-L and F-1070-R Mid Side Skins and pre-punched under structure. Final-Drill #30 all the 1/8 inch holes in the wing root area, indicated on Page 29-15, Figure 1.
Step 3: Position the F-1046-R Mid Fuselage Longeron on the F-1005E-R Gusset as shown in Figure 2. Clamp the parts together. Match-Drill #30 and cleco the holes in the gusset into the mid fuselage longeron.
Step 4: Align the lines drawn on the outboard face of the F-1046-L and-R Longerons with the corresponding holes in the mid side skins. Match-Drill the longerons using the skin as a drill guide. AT ONLY THE LOCATIONS FWD OF THE F-1046C FUSELAGE BULKHEAD SEE PAGE 29-15
Step 5: Check the distance betwe4en the aft most rivet holes and the aft end of the F-1013-L and -R Fwd Fuse Longerons per the dimensions in Figure 3. Pull away the F-1070-L and -R Mid Side Skins, then trim the longerons if necessary (or wait until fwd longerons are disassembled, but don't forget).
Page 29-10
Step 1: Create two wooden spacer blocks about one inch in length, similar to those shown in Figure 1. Insert the spacer blocks into the ends of the F-1041-L Lower Fuse Channel. Clamp the forward end of the channel into a vise and the aft end with a crescent wrench. After checking the twist direction, use the crescent wrench to twist the lwr fuselage channel to match the dimensions given in Figure 2. Repeat this step to modify the F-1041-R Lwr Fuse Channel. The right channel is a mirror of the left.
Step 2: After double checking the twist direction, use the same method as Step 1 to twist the F-1040-L Upper Fuse Channel to match the dimensions given in Figure 3. Repeat this step to modify the F-1040-R Upper Fuse Channel. The right upper fuse channel is a mirror of the left.
Page 29-11
Step 1: Remove the vinyl from the inside face of both F-1069 Fwd Side Skins. Using the dimensions given in Figure 1, draw the "Start of Roll Line" on the F-1069-R Fwd Side Skin. Repeat this step for the F-1069-L Fwd Side Skin. The left fwd side skin is a mirror of the right.
Step 2: Modify the clamping block to match the dimensions given in Figure 2. Note the radius along the bottom edge of the clamping block. If using a normal 2 X4 it is permissible to use the manufactured radius though it may be slightly larger than 1/8 "
Step 3: Clamp the F-1069-R Fwd Side Skin to a table, as shown in Figure 3, using the clamping block. Align the "Start of Radius" (See Figure 2) with the "Start of Roll" (see Figure 1). Be sure to align the "start of Radius" not the edge of the block with the "Start of Roll"'! Double check that you are about to bend the fwd side skin in the correct di8rection, the outboard face of the skin should be down against the table with the inboard face up.
Align the flange edges of the F-1070A and B Construction Angles with the "End of Roll Line" on the F-1069-R Fwd Side Skin, then clamp them in place as shown in Figure 3.
Step 4: Roll the F-1069-R Fwd Side Skin into a cone that terminates in a sharp bend at the aft end of the "Roll Lines". The roll is created with the forward vise grip, and the sharp bend is naturally formed at the aft end (the sharp bend is finished in Step 5). Twist the F-1070A and B Roll Construction Angles with the forward vise grip and at the same time push the forward end down and inwards toward the table. Use the extra roll construction angle which extends forward 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 4.
Step 5: Twist the F-1070A and B Roll Construction Angles with the aft vise grip, then strike the roll construction angles with a rubber mallet to finish forming a sharp radius at the aft end of the roll.
We got another nice roll on both sides of the front skins.