Firewall reinforcing and float fix doublers

[Wayne G. O'Shea]

Hello everyone!

I am currently working away on a another Rebel fuselage, for a customer, and
have posted (once again as they disappeared last week mysteriously after
Wray off-loaded them to his site) pictures of my rendition of the "bullet
proof" firewall and a nice smooth way to do the forward door post "float
fix" gusset that reinforces the FUS-27 to FUS-9 and door post junction.
Doing the gusset this way allows a nice smooth surface for the windshield
and its retainer to sit on, so as not to create any stress points etc on the
Acrylic windshield. It also looks a lot nicer than the "Band-Aid" look, with
the plate out over top as suggested in MAM's directions. The 12 rivets
forward of the door post are countersunk, so the windshield doesn't sit on a
head and the retainer will sit flat. Note that the 3 forward rivets, in the
diagonal row that joins Fus-9 to the Fus-10 (or 70) taper wrap, are also
coutersunk for the same reason. Also note in the picture that the Fus-9's
top point is cut down about an inch or so, from what the manual spells out.
I do this as I find, in most installations, that the windshield wants to sit
against this point and thus causes the windshield to crack in this area.

I would also like to give a heads up to my VERY limited time for the list,
in the foreseeable future, as I now have seven (7) Rebels on site all
needing some attention in one way or another (and I haven't even had the
time to put the wings back on my wife's CH701, since December when I
installed a new windshield for her!). Please post any building questions
only to the list to allow for an open answer from any of the, many,
competent builders. I may not have time to answer any, of the many,
questions I get sent personally. If I have time I will answer to the list,
THANKS!

I'm really starting to think that this "hobby" has gotten out of hand!!!!

Regards,
Wayne G. O'Shea
www.irishfield.on.ca





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[wrayt]

Those pictures Wayne mentioned are on my site under construction with the area's
in question high lighted. For that potential new builder you might want to check
out the hints section for helpful tips from builders. BTW I still welcome tips,
construction or completion pictures

[Terry Dazey]

Wray:

If it would not be too much trouble, could you email me these files with a little
more resolution (size). I tried to open them up in my PhotoShop 5.0 but they are
too small to view and print. Typically, I print modification/change photos and put
them in the related chapter in my 3-ring Rebel assembly binder.

Question: Does this firewall modification supersede O'Shay's previous firewall mod
kit (I purchased from him several months ago)? Looks VERY clean and well thought
out.

Thanks in advance for the information.

Regards,
Terry Dazey
Sumner, Washington USA
Rebel 662

osheafus30dblrtn.jpg
dowhan01tn.jpg
dowhan06tn.jpg
dowhan02tn.jpg
dowhan04tn.jpg
dowhan05tn.jpg
dowhan05tn.jpg
osheaffx2tn.jpg
osheaffx3tn.jpg
osheaffx1tn.jpg
Image3atn.jpg





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[Wayne G. O'Shea]

Terry, if I can butt in on this one, instead of Wray trying to tell you what
I did, I will tell you myself!

The "customer" wanted both the MAM fix and my firewall reinforcing plates
(identical to the ones I sold you previously) installed on his fuselage . It
is slightly overkill, in my opinion, and that is why I dubbed it the "bullet
proof" firewall. It was easy to do as NEW construction. The MAM fix is
almost impossible to do on a currently flying aircraft as the dash brace
brackets, wires, cables etc are all usually in this area on a completed
aircraft. You can work around the channel with your wires, etc, if building
new. Terry you will be fine with just the plates installed,but if you want
to add the channels also, you probably still can if not to far along engine
and panel wise!

I will send you, personally, the original full size digital pictures I took
of both the firewall and the "float fix" gusset.

Blue skies,
Wayne G. O'Shea
www.irishfield.on.ca


----- Original Message -----
From: "Terry Dazey" <dazey@earthlink.net>
To: <murphy-rebel@dcsol.com>
Sent: Thursday, April 12, 2001 3:36 PM
Subject: Re: Firewall reinforcing and float fix doublers


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Wray:

If it would not be too much trouble, could you email me these files with a

little

more resolution (size). I tried to open them up in my PhotoShop 5.0 but

they are

too small to view and print. Typically, I print modification/change photos

and put

them in the related chapter in my 3-ring Rebel assembly binder.

Question: Does this firewall modification supersede O'Shay's previous

firewall mod

kit (I purchased from him several months ago)? Looks VERY clean and well

thought

out.

Thanks in advance for the information.

Regards,
Terry Dazey
Sumner, Washington USA
Rebel 662

osheafus30dblrtn.jpg
dowhan01tn.jpg
dowhan06tn.jpg
dowhan02tn.jpg
dowhan04tn.jpg
dowhan05tn.jpg
dowhan05tn.jpg
osheaffx2tn.jpg
osheaffx3tn.jpg
osheaffx1tn.jpg
Image3atn.jpg

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[Terry Dazey]

Thank you very much Wayne. I think I just got ahead of the power curve again
and didnt realize it was your mod with the MAM fix. Your firewall mod plates
alone looks like it will beef up that area quite nicely. I am not to that
chapter yet, so I will have some time to decide whether I want to go with the
extra beef (weight forward) or not.

Thanks in advance for the photos. It looks like you do some real nice work.

Your Pilot Pal,
Terry Dazey
Rebel 662



"Wayne G. O'Shea" wrote:

Terry, if I can butt in on this one, I will tell you myself!

The "customer" wanted both the MAM fix and my firewall reinforcing plates
(identical to the ones I sold you previously) installed on his fuselage . It
is slightly overkill, in my opinion, and that is why I dubbed it the "bullet
proof" firewall.

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[wrayt]

Terry did you click on the small pictures to get the full size? and were they still
not big enough?

Terry Dazey wrote:

[quote]

[Terry Dazey]

Wray:

Aaaarg! You are quite correct. I clicked and downloaded the smaller image to my hard
drive! Dang! I hate it when that happens. Sometimes I get going way too fast and the
voices in my head keep telling me one thing and I do another. I guess it is back to the
ward and tell them to double up on my Prozac.

I typically save .jpg(s) files from the web to my hard drive and run them through
PhotoShop. Once there I can resize (I usually go to 3x4 or 3x5), sharpen, adjust color
balance add arrows, and any notes/dates etc. directly on the pic. I then export them
into FreeHand where I will paste multiple pics on each page (kind of like a photo
album) and print a copy for my archives.

Sorry if I created confusion. My doctor and nurse Kratchet says that I am doing okay
now . . . .

Thanks for the great site Wray. I have used several of your ideas in my building
process (including the wing wire harness bracket idea). As I am into my second
homebuilt now and have come to the conclusion that . . . "one photograph is worth a
MILLION words".

Thank you again for the great web site and all of the excellent ideas and suggestions
you have.

Thanks to EVERYONE that has input into this great group.

Your Pilot Pal,
Terry Dazey
Rebel 662
Sumner, Washington



wrayt wrote

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Terry did you click on the small pictures to get the full size? and were they still
not big enough?

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[wrayt]

Terry I quite often really compress the .jpg i put up on the site and you usually want
about 3 times as many pixels for printing (they would be about 3 screens wide) so if there
are any pictures you'd like a really good print of let me know and i'll rescan them at a
higher res and send them to you (thats the ones i have the originals of of course.)

Terry Dazey wrote:

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