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The first step on the turtledeck is the skins. I cheated some, I only laid out the outline. I will mark the rib pilot hole locations later. I also goofed a little when I drilled the pilot holes for the ridge channel. I matched drilled the skins stacked one on top the other, closed book fashion. Then when I open the book up and tried to match the holes, I found that any variation of the holes from the center line caused the holes to not line up. I should have match drilled the skins while they were edge to edge as shown in the picture. 3/5/00 |
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To drill the ridge channel, I found it easier to match drill from just one skin. I then assembled the skins and channel and drilled up to #30. The misalignment was not to bad and went away when I drilled up to #30. 3/5/00 |
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Fitting the skins to the fuselage is tricky and it helps to have two people. I marked the skins 1/2" from the bottom edge before I slid the turtledeck skin in between the side skin and the upper longeron. I could then line up the mark with the pilot holes in the side skin. 3/5/00 |
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Once the first side was drilled and clecoed, I folded the other side over and slid it under the skin of opposite side. This is where it helps to have a lot of clecos. 3/5/00 |
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I had a lot of practice making ribs for the wings so the turtle deck formers were a breeze. . 3/5/00 |
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I borrowed a Tony idea and made pull tabs from tape to help align the aft former as I drill it. Just as with the wing ribs I marked the center line so i could be sure I was drilling the right in the center of the rib flange. I started at the top and worked down to the sides. 3/5/00 |
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Don't forget to drill the upper two holes in the aft former. One is used for the trim cable and I will used the other for the tail position light wire. 3/5/00 |
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The next part to fit is the forward formers. I had a hard time clamping it in place but I finally found a hemostat that did the trick (top center). 3/5/00 |
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The flange angle on all the ribs varies from the top to the bottom. It took several trial-and-error fittings to get the angles just right so that I had a tight fit. DO this before you drill, trust me. 3/5/00 |
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Next came the plate to the former to the lower fuselage. 3/5/00 |
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With this plate installed the formers become a very strong roll-bar. 3/5/00 |
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I trial fit the six intermediate formers and marked the flange locations on to the turtledeck skins. I then removed the skins and drilled the pilot holes so that they would fall right in the center of the former flanges. 3/5/00 |
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I had a problem with the #3 formers. They would not fit well next to the shoulder harness mount point. I tried tried to notch the inner flange but ended up making new formers which were narrower. It was still a tight fit.. 3/5/00 |
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I spent a lot of time moving back and forth from inside to outside of the fuselage. It seemed every time I would drill one hole I would have to duck inside again to realign the former so that I could drill the next hole dead center. 3/5/00 |
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It turned out pretty good without any major dips or bumps in the skins. At this point I have not installed the bottom skins and have not installed the nylon rudder cable guides. Others have warned me that there are still a few things to do inside the tail cone. 3/5/00 |
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I marked the locations of the angle doublers where the horizontal stabilizer will attach to the fuselage. I want to be sure I hit them dead center. 3/5/00 |
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