Section 43  Cabin

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Page 42-3

Step 1: Make seven center marks on the F-1015C Mid Cabin Decks centered between the rivets shown in Figure 1These marks are used later to locate the holes for the screws which secure the bottom of the C-1001 Cabin Cover door opening to the fuselage.

Step 2: Extend the center marks to the outboard edge of the F-1015C Mid Cabin Deck, as shown in Figure 2, then transfer the marks to the F-1069 Fwd Side Skins (not shown) and the F-1070 Mid Side Skins.

Page 42-3

Step 1:The C-1001 Cabin Cover needs to be trimmed in order to fit the fuselage. It is shown trimmed at the top of Figure 1.The portions of the cabin cover in the blow-ups are shown untrimmed.

Scribe the lines around the perimeter, the window openings and door openings indicate the extent to which the cabin cover needs to be trimmed, Since these scribe lines are faint, trace over them with a pen point to improve their visibility. The information in the blow-ups s can be used to find the scribe lines or draw new ones if necessary.

The windscreen flange, the flange around the window opening, the mid side skin flange and the forward top skin flange (not shown) in the blow-ups) are 3/4 inch wide.

The scribe line on the lip around the door opening transitions from lip to the vertical web along the bottom portion of the door opening.

Step 2: Trim and sand to the scribe lines the tail cone forward top skin flange, the mid side skin flange and the flange around the window openings.

Step 3: Trim and sand the lip around the door openings if the scribe line is visible. If it is not visible, wait until the door is fitted in a later section.

Trim the windscreen flange and the flange around the lower, outside perimeter of the door opening.

If the scribe lines that are shown joggling onto the windscreen flange in the left blow-up of Figure 1 are not visible, this area will have to be trimmed when fitting the F-1001 Cabin Cover to the Fuselage. For now trim with a margin around the area.

Page 43-4

Step 1: Test fit the C-1001 Cabin Cover on the fuselage. (If the F-1074 Tailcone Forward Top Skin is clecoed to the tailcone, it will have to be removed. Note any area of interference between the lower portion of the door opening and the fuselage structure to which it mates.

Step 2: Remove the C-1001 Cabin Cover from the fuselage, then trim and sand the part to remove the areas of interference

NOTE:  While trimming and sanding the lower portion of the door openings, make sure they remain in place with fuselage structure to which they mate ( the F-1005C and F-1042 Bulkhead Side Channels and the F-1015C Mid Cabin Decks shown in Figure 1). This can be accomplished by spanning the two door openings with square tubing or a straight length of lumber and taping sandpaper to the ends as shown in Figure 2. Don't worry if the door openings are not perfectly "in plane" with the fuselage, structural filler will ultimately be applies to the interface area filling any gaps.

Step 2 (continued) The portion of the cabin door openings which mate to the F-1015C Mid Cabin Deck will have  to be sanded (which will lower the cabin cover) in the lips along the mid side skin flanges rest on the top edge of the F-1070 mid side skins. Make sure the mid side skin flanges are no longer than 3/4", otherwise they will "bottom out" on the F-1046 Mid fuse Longerons before the lops on the mid side skin flanges reach the mid side skins.

As shown in the blow up of Figure 2. the four lower corners of  the door openings will have to have a slight radius and a relief notch sanded into them to prevent interference with the flanges at the ends of the F-1015C Mid Cabin Decks.

Sand the lower ends of the windscreen flange so that they fit flush against the F-1071 Fwd Fuse Top Skin as shown in the blow-up of Figure 1.

Step 3: Repeat step 2 until the C-1001 Cabin Cover fits properly on the fuselage. The lower portion of the cabin cover door opening should have a good fit in the fuselage, but should not be tight that its difficult to get in place.

Page 43-5

Step 1: With the C-1001 Cabin Cover on the fuselage, cleco the F-1074 Tailcone Forward Top Skin in place as shown in Figure 1. Use plenty of clecos to ensure that the skin is tight against the F-106 Bulkhead.

Step 2: Push the aft end of the C-1001 Cabin Cover up against the F-1074 Tailcone Forward Top Skin . If the aft  flange of the cabin cover was trimmed to the scribe line giving a 3/4" flange, the flange should clear the F-1006 Bulkhead. If it does not clear iy will have to be trimmed further. Don't trim it to much though, just enough to clear the bulkhead.

Step 3: As shown in Figure 2, clamp the C-1001 Cabin Cover door openings to the aft ends of the F-1051C Mid cabin Decks and to the top ends of the F-1005C Bulkhead Side Channels (see Page 43-4, Figure 1 for parts call outs).

When clamping to the top of the bulkhead side channels, make sure the cabin cover fits flush against the top edge of the F-1070 Mid Side Skins ( the area above the rear seat vents). The cabin cover should not push the skin outboard, nor should there be a gap between the cabin cover and the skin.

Step 4: Push the aft end of the C-1001 Cabin Cover up against  the F-1074 Tailcone Forward Top Skin. Match Drill #30 the Twenty five holes which are along  the forward edge of the skin and between the rivet lines of the F-1047B Stiffeners see figure 3), into the cabin cover. Start at the center of the cabin cover and work outboard. Make sure to keep the drill perpendicular to the skin, and to keep the cabin cover tight against the skin, cleco each hole as you drill.

Remove the clecos securing the cabin cover to the skin., push the cabin cover away from the skin , clean out any drilling dust from between the two parts, then reinstall the clecos.

Step 5: Match-Drill #30 the holes along the top edge of both F-1070 Mid Side Skins into the C-1001 Cabin Cover. Back up the holes with a block of wood to keep the cabin top tight against the side skins. Initially match-drill about every 8th hole, then go back and finish match-drilling the rest. When finished drilling, remove the clecos, clean out the drilling dust, then reinstall the clecos.

Page 43-6

Step 1: Double check the position of the C-1001 Cabin Cover relative to the F-1070 Mid Side Skins above the rear seat vents. Once again the cabin cover should not be pushing the skin outboard, nor should there be a gap between the cabin cover and the skin. Unclamps and readjust if necessary.

Step 2: Using an angle drill or a long drill bit, match drill # 30 the seven 1/8" holes (see figure 1) in both of the F-1005C Bulkhead Side Channels into the C-1001 Cabin Cover. Drill perpendicular to the bulkhead side channels and cleco while drilling.

Final-drill the holes using a #12 drill.

Step 3:  Remove the clamps from the aft end of the C-1001 Cabin Cover door opening, align the forward end of the door opening with the fuselage, then clamp the cabin cover to the F-1015C Mid Cabin Decks and the F-1042 Bulkhead Side Channels as shown in Figure 2.

Step 4: Using an angle drill or a long drill bit, match-drill the five 1/8th " holes (see figure 2) in both of the F-1042 Bulkhead Side Channels into the C-1001 Cabin Cover. Again make sure to drill perpendicular to the bulkhead side channels and cleco while drilling.

Page 43-7

Step 1:  Bend the top portion of the F-1042 Bulkhead Side Channels until the F-1042F Gussets can be clecoed in place as shown in Figure 1.

Step 5:Clamp the middle, bottom portion of the C-1001 Cabin Cover Door openings to the underlying F-1015C Mid Cabin Decks as shown in Figure 2.

Step 6: Transfer the hole location marks made on Page 43-2, Step 1 to the bottom portion of the cabin cover door openings. The hole location marks are placed a half inch from the outer skin surface as shown in the figure.

Step 7: At the marks made in step 6, drill #30 the bottom portion of the cabin cover door openings, through the underplaying F-1015C Mid Cabin Decks, and into the F-1013 Forward Fuselage Longerons (see Figure 1 for part call-outs). Drill Perpendicular to the mid cabin decks.

Final drill the holes using a #19 drill. Caution these holes are smaller than the holes in the forward and aft portion of the door openings. Don't use the same drill.