Saturday April 30th, 2005|
Continued Working on Bulkheads
This morning I got up and continued working on the seat back adjustment stuff. Here I've match-drilled the spacer and the piece of .040 using the pre-punched stuff in the cross member.
...and here are the two pieces together. The one closes to me is the pilot's side. Yeah...I scratched the crap out of this stuff 'cause the gap Van's has you put in there is actually a little small. I ended up grinding down the .040 a little to allow the seat back piece to fit in there.
Then I started looking at the plans to make sure I had countersunk everything on the 705 before moving on. This hole (one on each side) needed to get countersunk so that the seat belt attach bracket would sit on top of it.
The vertical members of the 705 get doublers installed on the inside of them. Since they get riveted together, I decided to go ahead and match-drill the 3/32 holes that rivet to the skin. The reason is that it would be impossible to dimple them after the web rivets are riveted together. The only problem is that my dimple dies would fit in there...the holes are too close to the web. My vice grip dimpler wouldn't fit either...so I decided to grind down the vice grip dimpler.
Ok, this picture is blurry..but here's the vice grip dimpler after I gorunded it down a bit.
The modified dimpler worked perfectly. Here's the doubler in question.
Then I started working on the rest of the bulkeads. These things are rough! It took a lot of fluting and seaming to get 'em flat.
Next I fabricated this angle....
Here it is.
After a lot of drilling and clecoing, I was able to put the hole thing together. There were two other angles that had to get fabricated....one on the horizontal piece running toward the camera and one on the vertical piece.
...and here are the three 'two-piece' bulkheads after fluting and clecoing.
..And here's the next bulkead. The big notch at the top gets cut out. At this point I started yawning way too much so I decided to go in. I'm flying up to see my aunt tomorrow (and probably give her a quick ride in the spam can) so I needed to go in a check the weather/notams anyway.