Rebel Fuselage building tip - probably applies to Elite as well.
Posted: Sun Feb 19, 2012 12:00 pm
Once you get yourself to the float point of the tail cone...everything
forward of that has a bulkhead that is exactly 44". So when you make
bulkhead "F"...make up every bulkhead set that you have left in the kit at
the same time...... using a simple jig made from plywood and spend rivet
mandrels. Slip the bulkheads into place...drill the overlap...clean them
up...epoxy the joint and rivet.I've lost track of how many bulkheads this
simple jig has done over the last 14 years...but it still holds them tight,
the right width and exactly square.
This way every bulkhead is exactly the same...giving you a perfectly
straight cabin build and all the bulkheads are ready as soon as you need
them while you progress with the cabin section. Doing each one
seperate...measuring and trying to get them the right width as the manual
spells out isn't a great way to do it. Using the jig all 8 bulkhead overlaps
are drilled and cleco'd in less than 10 minutes.
Also...when you build the carry thru cage...Fus 1/2/3/4/5.... DO NOT depend
on the gusset plates Fus-1 and Fus-2 to make your cage square. I always find
that if you cleco Fus 1 to the predrilled holes in Fus 4 that the Fus 4 will
have a minimum of a 1/4" runout from the top to the bottom..READ CROOKED.
Cleco and bolt the Fus-1 to the Fus-3 and bolt only to the Fus-4. Then clamp
a carpenters square in the corner of Fus 4 and 3...then drill a fresh hole
thru the Fus-1 into the Fus-4 and cleco. Do a few to hold it and then drill
the rest out.
Wayne
http://www.irishfield.on.ca/gallery/Bulkheadjig1.jpg
http://www.irishfield.on.ca/gallery/bulkheadjig2.jpg
http://www.irishfield.on.ca/gallery/Bulkheadjig3.jpg
http://www.irishfield.on.ca/gallery/Cagesquaring.jpg
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forward of that has a bulkhead that is exactly 44". So when you make
bulkhead "F"...make up every bulkhead set that you have left in the kit at
the same time...... using a simple jig made from plywood and spend rivet
mandrels. Slip the bulkheads into place...drill the overlap...clean them
up...epoxy the joint and rivet.I've lost track of how many bulkheads this
simple jig has done over the last 14 years...but it still holds them tight,
the right width and exactly square.
This way every bulkhead is exactly the same...giving you a perfectly
straight cabin build and all the bulkheads are ready as soon as you need
them while you progress with the cabin section. Doing each one
seperate...measuring and trying to get them the right width as the manual
spells out isn't a great way to do it. Using the jig all 8 bulkhead overlaps
are drilled and cleco'd in less than 10 minutes.
Also...when you build the carry thru cage...Fus 1/2/3/4/5.... DO NOT depend
on the gusset plates Fus-1 and Fus-2 to make your cage square. I always find
that if you cleco Fus 1 to the predrilled holes in Fus 4 that the Fus 4 will
have a minimum of a 1/4" runout from the top to the bottom..READ CROOKED.
Cleco and bolt the Fus-1 to the Fus-3 and bolt only to the Fus-4. Then clamp
a carpenters square in the corner of Fus 4 and 3...then drill a fresh hole
thru the Fus-1 into the Fus-4 and cleco. Do a few to hold it and then drill
the rest out.
Wayne
http://www.irishfield.on.ca/gallery/Bulkheadjig1.jpg
http://www.irishfield.on.ca/gallery/bulkheadjig2.jpg
http://www.irishfield.on.ca/gallery/Bulkheadjig3.jpg
http://www.irishfield.on.ca/gallery/Cagesquaring.jpg
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List archives located at: https://mail.dcsol.com/login
username "rebel" password "builder"
Unsubscribe: rebel-builders-unsubscribe@dcsol.com
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