RV7 Vern Head 71139 - Page 5

vernh59 · #41 01-30-2020, 07:18 AM

F712 Bulkhead

Thats a pile of bulkheads

Next, The dreaded longeron bend. I could have put this off for awhile but it has to be done. I carefully measured and re measured the bend area and overall length of the longerons. These measurements have to be made BEFORE you make the bends.

LONG

I marked the bend area in inch increments so I would have a way to tell how far I progressed along the bend.

Its a slow process. Probably slower than necessary. The Buller form instructions say to be careful not to over bend the longerons.

SteveL · #42 02-01-2020, 08:18 AM

Great pictures! What photo sharing site do you use? I've been trying to get some great pics attached like that but SmugMug doesn't seem to like my Mac.
Thanks,
SteveL

vernh59 · #43 02-01-2020, 08:47 AM

It is Smug mug and all I have are Macs. Upload the pic, select it and choose the size, then you can get info and copy the link. Paste that in the link for your post and it?s done. A little awkward at first but good results. I select large size for my pics.

vernh59 · #44 02-02-2020, 10:20 PM

First longeron bent to match the 1-1 drawing. It took about 5 passes with the forms but Im pretty sure i didn't use enough force to make a difference on a couple of them.. Here I have attached the cover. Shims were added to the side to simulate the skin.

From the top.

Drilled and Cocos installed.

Starting the bend for the right side.

Checking the downward bend form the forward bulkhead edge.

Checking the inward twist on the right side.

Glad to be done with these. Not as bad as I imagined. The forms worked great (Thanks Steve.)

My shop is a wreck!!!

vernh59 · #45 02-02-2020, 10:28 PM

"Lets assemble some bulkheads" they said...."It will be fun they said!" Well, these are a bear. I fought with this skin for awhile before I could get the Clecos to line up. I suggest you work with the skin to form it so that the bulkhead fits the skin instead of trying to pull the skin with the Clecos. This skin is thick. I put a 2x4 in a vise, thin edge up and gradually worked the bend at the aft end until the bulkhead just fit. This made the clecos alignment almost perfect.

First cut for the tailwheel spring. Lots of smoothing to do.

RV74ME · #46 02-03-2020, 05:52 AM

Lookin? good Vern!

kentlik · #47 02-03-2020, 08:52 AM

Nice work Vern! This part is really very satisfying. Big stuff from small parts!

vernh59 · #48 02-03-2020, 09:49 AM

Thanks guys! I can see how its going to LOOK like its going fast for awhile and then.....

vernh59 · #49 02-04-2020, 04:04 AM

NOW we're getting somewhere. It was good to get this assembly together. Suddenly the shop was pretty crowded. In a good way. I need to remove the J stiffeners and finish the ends and the final dimensions. Then I can drill them together.

Using levels, I found a 1 degree difference in angles between the front and rear bulkheads. Ill check the "twist" using the tooling marks before drilling.

vernh59 · #50 02-06-2020, 10:44 PM

Put the Lazer level and checked the alignment. Everything looked good to me.

Looks better in the dark.

Here we go. i started drilling the bottom skin to the F728 stiffener then worked out to the edges of the bottom skin, then up. Seemed like a good way to start since the bottom skin is the base for all the other skins.

The porcupine look.

The FAA pic. Drilling the J channel.

Done with that. The levels show the fuse is straight. Now to take it all apart.