Section
31 Upper Forward Fuselage Assembly
Page 31-6 thru Page 31-8
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Page 31-6
Step 1: Cleco the Sub Panel/Fwd Fuselage Rib Subassembly to the forward fuselage as shown in Figure 1. It is permissible to slightly spread the F-1040-L & -R Upper Fuse Channels to allow for clearance for installation.
Final-Drill four places F-1068B-L a to F-1002-L and four places F-1068B-R to F-1002-R as shown in Figure 1.
Rotate the F_1044B Angle on the cleco holding it and the F-1044C Spacer to the F-1044A Fwd Fuse Rib until the forward tab of the angle rests on the upper surface of the F-1001B Firewall Upper Angle. Adjust the bend angle of the tab on the angle if/as required to rest flat on the firewall upper angle.
Match-Drill #30 and cleco the angle and spacer to the fwd fuselage rib in two places (once in the middle of the angle and once in the forward end of the angle) using the holes in the fwd fuselage rib as drill guide.
Step 2: Match-Drill #30 upward through the holed in the upper surface of the F-100K Firewall Recess through the pilot hole into the forward tab of the F-1044B Angle. See page 31-5, Figure 2.
Cleco the tab of the F-1044A Angle to the upper firewall angle.
Step 3:Final-Drill #19 all holes in the F-1003A Instrument Panel.
Step 4: Final-Drill #19 all nutplate screw holes in the F-1003B Instrument Panel Lower Flange.
Final-Drill #40 the rivet holes in the end tabs and nutplate attach holes in the panel lower flange. See Figure 2.
Machine countersink the nut plate attach holes to fit the head of an AN426AD3 Rivet. See Figure 2.
Machine counter sink the rivet holes in the end tabs to fit dimples in the fuselage side skin
Rivet nutplate to the inst panel lower flange as shown in Figure 2.
Page 31-7
Step 1: Attach the F-1003B Instrument Panel Lower Flange and F-1003C-L & R Inst Panel Attach Flanges to the F-1003A Instrument Panel as shown in Figure 1
Attach the F-1003D and F-1003E Inst Panel Attach Flanges over the instrument panel and flute the outboard ends as required to match the instrument pane upper edge contour. See Figure 1. Locate the flutes in the inst panel attach flanges between the instrument panel screw holes as shown in Figure 1.
Step 2:Attach the subassembly of the F-1003A Instrument Panel, F-1003B Inst Panel Lower Flange, and the F-1003C-L &R Inst Panel Attach Flanges to the F-1044A, F-1045-L & F-1045-R Forward Fuselage Ribs as shown in Figure 3
Step 3: Cleco the F-1071 Fwd Fuse Top Skin to the flanges of the F-1000A, F-10003C-L & R, F-1068A, F-1068B-L & R Forward Fuse Channels as shown in Figure 2.
Note that the top skin is NOT symmetrical and that it must be installed such that the "slot" is on the left side of the F-1044A Fwd Fuse Skin.
Step 4: Form the F-1071B Hand Hold Doublers to match the contour of the F-1071 Fuse Skin as it is clecoed in place. The forming process will create one "left" hand hold Doubler and one "Right" hand hold Doubler.
Cleco the hand held doublers to the fwd fuse top skin as shown in Figure 2.
Match-drill #40 each of the hand held doublers to the fwd fuse top skin in the four places where there is no hole prepunched in the fwd fuse top skin.
Final drill #40 each of the hand held doublers to the fwd fuse top skin and sub-structure in all the places where there are matching pre-punched holes.
Trace around the perimeter of each of the hand hold doublers with a sharpie pen. This will show where the fwd fuse skin is NOT dimpled.
Step 5: Final-Drill #40 the F_1071 Fwd Fuse Skin to the substructure through all holes not yet final-drilled
Page 31-8
Step 1: Position the F-1000D Inst Panel Attach Flange simultaneously against the F-1071 Fwd Fuse Top Skin and the forward side of the F-1003A Instrument Panel (See Page 31-7), Figure 1.) Match-Drill #40 and cleco the inst panel attach flange using the holes in the fwd fuse top skin as drill guides. Be sure the inst panel attach flange is in contact with the forward surface of the instrument panel when drilling.
Step 2: Position the F-1000E Inst Panel Attach Flange simultaneously against the F-1071 Fwd Fuse Top Skin and the forward side of the F-1003A Instrument Panel (See Page 31-7), Figure 1.) Match-Drill #40 and cleco the inst panel attach flange using the holes in the fwd fuse top skin as drill guides. Be sure the inst panel attach flange is in contact with the forward surface of the instrument panel when drilling.
Step 3: Match-Drill #19 through the screw holes in the F-1003A Instrument Panel and into the F-1003D and F-10003E Inst Panel Attach Flanges.
Step 4: Final-Drill #40 the F-1071 Fwd Fuse Top Skin to the sub-structure through all holes not yet match-drilled or final drilled.
Step 5: Remove the F-1003D and F-1003E Inst Panel Attach Flanges. Using a nutplate as a drill guide, match-drill #40 two nutplate attach holes for each screw holes.
Deburr the holes and edges of the inst panel attach flanges.
Dimple the nutplate attach holes and skin attach holes. See Figure 1.
Step 6: Machine countersink the rivet holes in the F-1071B Hand Held Doublers to fit the head of and AN426AD3 rivet.
Uncleco the hand hold doublers from the F-1071 Fwd Fuse Top Skin and deburr the holes.
Step 7: Uncleco the F-1071 Fwd Fuse Top Skin from the sub-structure. When unclecoing mark the holes in the sub-structure that lie under the F-1071B Hand Hold Doublers with a sharpie pen so that they will not be dimpled later.
Deburr the holes and edges of the fwd fuse top skin then dimple all holes EXCEPT those that are under the F-1071B Hand Hold Doublers.
Step 8: Dimple the holes in the flanges of the F-1001A Firewall Bulkhead that are common to the F-1071 Fwd Fuse Top Skin. See Page 31-7, Figure 2.
Step 9: Machine countersink the holes in the F-1040-L & R Bulkhead side channels that are common to the F-1071 Fwd Fuse Top Skin. Countersink deep enough to fit dimples in the fwd fuse top skin.
Most "micro-stop countersink cages will interfere with the upper edge of the F-1069 Fwd Side Skin. In this case, the countersinking is best done "free hand" with a countersink cutter in a drill.
Step 10: Remove the subassembly of the F-1003A Instrument Panel, F-1003B Inst Panel Lower Flange and the F-1003C-L & R Instrument Panel Attach Flange from the F-1044A, F-1045-L & F-1045-R Fwd Fuselage Ribs.
Step 11: Remove the Sub-Panel/Fwd Fuselage Rib Subassembly from the forward fuselage. See 31-6 Figure 1.
Deburr the holes and edges of all the parts.
Dimple the skin attach rivet holes in the F-1044A and F-1045-L & R Fwd Fuselage Ribs, F-1086A Sub Panel Center, and F-1068-L & R Sub Panel Sides.
Step 12: Prime the 1044B Angle. Prime all other parts if/as desired.
Step 13: Dimple the nutplates that will be attached to the F-1003D & E Instrument Attach Flanges and F-1083 Control Cable Bracket.
Step 14: Rivet the nutplates to the F-1003D & E Instrument Attach Flanges and F-1083 Control Cable Bracket as shown on Figure 1 and Page 31-5, Figure 2.
Step 15: Rivet the F-1044B Angle, F-1044C Spacer, and the F-1044D, E and F Angle to the F-1044A Fwd Fuselage Rib as shown in Figure 2.
