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« « Previous Post: Forward Fuselage #1 (Angle material fabrication) | Next Post: » »

Forward Fuselage #2 (Side panel assembly)

Posted by on March 18, 2014

Total Build Time: 556 Hours

My angle component fabrication is complete for the forward fuselage side panels, so now comes the task of aligning the parts into the proper positions on the side panel skins.

Waiex-1306

Waiex-1307

 

For fun, I put the skin into its position relative to the aft fuselage, to get an idea of the shape. It’s clear from this picture that my aircraft is getting ready to grow, a lot.

 

Waiex-1308

 

Unlike many other parts of the build when it comes to putting internal parts onto skins, there are no pre-cut laser-drilled holes in the skins to assist with the process. Everything on the side panels has to be custom fitted using the plans and accurate measuring and positioning.

Here is a sequence of photos of the right side panel being progressively built. I followed the sequence given in the plans, and each part is measured, placed, drilled, clecoed, then up-drilled once everything is in position.

 

Waiex-1309

Waiex-1310

Waiex-1311

Waiex-1312

Waiex-1313

Waiex-1314

Waiex-1315

Waiex-1316

Waiex-1317

 

Once the right panel was fully drilled, I began work on the left side panel.

 

Waiex-1320

Waiex-1321

Waiex-1322

Waiex-1323

Waiex-1324

Waiex-1325

 

Several of the angle parts call for a radius along a certain outer edge, so they they will fit snugly and smoothly into the inside edge of another angle piece. The plans always call for this radius to be 1/8″, but many of the angle components have a larger radius on the inside. This requires the removal of more material than illustrated in the plans.

 

Waiex-1326

 

Here are both side panels fully up-drilled.

 

Waiex-1327

Waiex-1329

Waiex-1330

 

 

I have several more steps to go (besides deburring) to complete the side panels, including polish, cutting NACA vent holes for cockpit ventilation, and slots in the upper longerons for the canopy latches.

 

 

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