FORWARD FUSELAGE CONSTRUCTION
CLICK ON PHOTOS TO
ENLARGE
ENLARGE
The upper and lower firewall assemblies are the first items I built.
Thanks to a great kit, this part was very easy to complete. All bending
was accomplished using a 30" metal brake from Wicks. It sure saves a
lot of time and has already been used to make some channel stock that
I messed up. It came out perfect.It was necessary to redo some of the
crimps in the upper firewall to allow placement of the fastners. After
about an hour the task was done.
Thanks to a great kit, this part was very easy to complete. All bending
was accomplished using a 30" metal brake from Wicks. It sure saves a
lot of time and has already been used to make some channel stock that
I messed up. It came out perfect.It was necessary to redo some of the
crimps in the upper firewall to allow placement of the fastners. After
about an hour the task was done.
The windshield attach point was a little tricky to get just right. Several
clamps were used to hold everything just right until a few holes could
be drilled and some clecos installed. I will not rivet the parts together
until a final fit to the forward fuselage. Not as called for but, just me
wanting to make sure everything fits just right.
clamps were used to hold everything just right until a few holes could
be drilled and some clecos installed. I will not rivet the parts together
until a final fit to the forward fuselage. Not as called for but, just me
wanting to make sure everything fits just right.
At left is the upper forward tunnel cross tie. Other components
pictured are tunnel Z components, forward lower cross tie and lower
firewall and floor stiffners. Layout is critical for the tunnel
components so take your time.
pictured are tunnel Z components, forward lower cross tie and lower
firewall and floor stiffners. Layout is critical for the tunnel
components so take your time.
The aft portion of the spar tunnel is pictured at left.After the initial
holes were drilled and then drilled out to #30 the 04 support angle
holes were countersunk using a 1/4" x 120 degree countersink bit.
the depth was determined on a test piece prior to completing the
support angle. On this part, the aft tunnel skin is dimpled into the
04 support angle, only the male portion of the die is used and nail
head rests on the back side of the angle. Easy to miss this point on
plans.
holes were drilled and then drilled out to #30 the 04 support angle
holes were countersunk using a 1/4" x 120 degree countersink bit.
the depth was determined on a test piece prior to completing the
support angle. On this part, the aft tunnel skin is dimpled into the
04 support angle, only the male portion of the die is used and nail
head rests on the back side of the angle. Easy to miss this point on
plans.
These are some of the many forward fuselage details needed to
construct the forward fuselage. The photo at far left depicts the
upper and lower engine mounts. Although they look complex to
construct, it was really quite simple. I had studied the mounts on
other builders web sites prior to starting.
construct the forward fuselage. The photo at far left depicts the
upper and lower engine mounts. Although they look complex to
construct, it was really quite simple. I had studied the mounts on
other builders web sites prior to starting.
At left is the simple dimple die set into the aft tunnel skin ready for
dimpling. I keep a box of bright 6-D nails as a die puller pin back
ups. I set the pressure on the gun to 42 PSI for this operation and
it works well for me. I went through the complete skin and did not
need to use another pin.
dimpling. I keep a box of bright 6-D nails as a die puller pin back
ups. I set the pressure on the gun to 42 PSI for this operation and
it works well for me. I went through the complete skin and did not
need to use another pin.
This is an idea I got from another Sonex
builders web site and it has saved me a lot
of time. By placing a piece of double sided
carpet tape on the male portion of the die it
remains on the gun through out the dimpling
process.Finished product.
builders web site and it has saved me a lot
of time. By placing a piece of double sided
carpet tape on the male portion of the die it
remains on the gun through out the dimpling
process.Finished product.
This is where taking the advice from other Sonex buidler's web sites has
really helped me. As noted on several sites the pre-cut fuselage side skins
are not quite true. As suggested, I measured and laid out all the required
position lines prior to the initial parts positioning and drilling. Not only
does it help with the correct positions but also provides a reminder of
what parts go where. Keep the upper and lower longeron distance as
required on the plans and parallel, the upper edge of the skin will not give
you the required distance. the slight excess of side skin material can be
easly removed with a file later. After all components were drilled out
using #40 bit, I reviewed the plans again and marked all the areas where
rivets were NOT to be installed, marked the areas and then drilled out all
holes to #30, debured clecoed and started riveting.
really helped me. As noted on several sites the pre-cut fuselage side skins
are not quite true. As suggested, I measured and laid out all the required
position lines prior to the initial parts positioning and drilling. Not only
does it help with the correct positions but also provides a reminder of
what parts go where. Keep the upper and lower longeron distance as
required on the plans and parallel, the upper edge of the skin will not give
you the required distance. the slight excess of side skin material can be
easly removed with a file later. After all components were drilled out
using #40 bit, I reviewed the plans again and marked all the areas where
rivets were NOT to be installed, marked the areas and then drilled out all
holes to #30, debured clecoed and started riveting.
One of the key points everyone and the plan set reminds me to do is
to ensure the sides remain flat with no twist during layout initial
drilling and the final riveting. The side was placed on a support rack
made up of of 2x4 and secured to the work bench while being
checked for flatness. Even during the riveting process I checked and
rechecked at key points to ensure the side panel was flat with no
twist. It may seem like overkill to a lot of others but, it sure gives me
piece of mind knowing that the final product will be just as the plans
dictate. after riveting I checked the side panel in all directions and NO
twist.All bolts were installed as called out and torqued to
specification. Now I get to place the fuselage side panel onto the tail
cone assembly. Too cool. Its starting to look like an airplane.
to ensure the sides remain flat with no twist during layout initial
drilling and the final riveting. The side was placed on a support rack
made up of of 2x4 and secured to the work bench while being
checked for flatness. Even during the riveting process I checked and
rechecked at key points to ensure the side panel was flat with no
twist. It may seem like overkill to a lot of others but, it sure gives me
piece of mind knowing that the final product will be just as the plans
dictate. after riveting I checked the side panel in all directions and NO
twist.All bolts were installed as called out and torqued to
specification. Now I get to place the fuselage side panel onto the tail
cone assembly. Too cool. Its starting to look like an airplane.
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Forward Fuselage Construction page three