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Cozy Construction Chapters.

 

Chapter 6  Fuselage Assembly

 Started 2/22/2004 finished 5/23/2004 Hours worked :72.5

Here's the temporary firewall and f22 in for a test fit.

  I used strap-clamps to hold the side together in this test fit.   

Taking off f22 and spreading the side a little I worked my way forward until I finished with f22 back in place.       The strap-clamps work great

Here you can see f28 and the canard reinforcement lay-up.

All the joints have been taped and peel plied waiting for cure.

To make sure that the aft landing gear was just right I used 5" spacers clamped in place. 

Floxed and taped with peel & ply.  

Now that the aft landing gear is cured I floxed, taped, peel & plied the forward landing gear using 8" spacer.  

Now I am putting in the upper have of the forward landing gear. The sand bag and 2x6 is there to hold it in place during cure.             

Turning over the fuselage I've taped and peel & plied all the landing gear joint and added the reinforcements, re-drilling all holes.  

Now the that the landing gear are in place it's time to put on the permanent firewall - floxed, taped and peel & plied.

Using those same 5" spacer to make sure everything is right.

 Time for the center keel and seatback brace.  Parts cut and glassed on one inside.

Floxed the heat duct all going well. A lot of little things to keep track of.

Make a paper copy of the fuel valve bracket, glued it to the aluminum

Here's the wooden triangle inserts glued back to back to make sure they are the same.

Heat duct ready for the 7 plies of UND centered over seat belt anchor.

After that 2 ply of BID are applied to both the heat duct and seat brace it time to install it.   

I waited until I built the heat duct and brace before cutting the seat back, make sure I had a good fit and did not remove to much foam.    Installed heat duct and brace.

Building the bottom is much the same as the sides. In this picture you can see the Japanese saw that I use, purchased from Home Depot. It cuts on the pull stroke and has a very small kerf. Best saw in the shop.

Building up the bottom foam.

Bottom glassed ready to be put in place.

Bottom weighted down during cure.  The underside is taped and peel & plied.

On to chapter 7.

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This site was last updated 10/25/05