Sonex #318

AFT Fuse-Assy
Home
Tools and Shop
Tail Feathers
Flaps and Ailerons
Spars
Wing Skins
Ribs
Wing Assembly
Forward Fuse - Assy
AFT Fuse-Side Panels
AFT Fuse-Assy
Final Fuse-Assy
Cockpit
Engine
Event Photos
First Flight

Click on Pictures to Enlarge

aftfuselage028.jpg

I layed out the dimension of the aft fuselage on my work bench by first snapping a center line using a chalk line, seen here in blue.

 

 

aftfuselage034.jpg

Here you can see all of the lines marked on the table.  Make sure your table is flat and that you are assembling the fuselage upside down at this point.
 
 

aftfuselage029.jpg

aftfuselage032.jpg

Line up the front of the side wall so that the apex of the bend is touching the line you have marked on the table.
 
 
 

aftfuselage036.jpg

Make sure things are square and screw it down to the table.  I used an old cutting board cut into squares with holes drilled in them. 
 
 

aftfuselage037.jpg

At this point I tested to see if my BOTTOM skin fit.  Again the whole assembly is built upside down that is why the skin is on top of the side walls.
 
 
 

fuselageassy005.jpg

Using a carpenters square I made sure that the bottom was square to the sides.  The edge of the square is parallel with the rivet line on the bottom skin.
 
 
 

fuselageassy019.jpg

Using some scrap pieces of aluminum I braced the sides square to the table.
 
 
 

aftfuselage038.jpg

aftfuselage039.jpg

With the bottom skin fit and the side panels secure I checked for square again, added some more clamps and began to install the Cross Ties.  I found I could lay on the table and clamp things in place or...
 
 
 

aftfuselage041.jpg

I could take the kid and put him down in the hole. Actually he wanted to do it because he thought it was cool.  I just sat back and did my best Tom Sawyer impersonation.
 
 
 
 

aftfuselage044.jpg

Once the bottom Cross Ties were done (which are on top because remember we are building it upside down), I could complete fitting the top Cross Ties.
 
 
 

aftfuselage048.jpg

Everything is square and cleco'd. 
 
 
 

fuselageassy015.jpg

Fitting the F-23-03 Angle Mount and the F23-02 Bulkhead.  A 24" long drill bit was the trick for drilling these holes.
 
 
 

fuselageassy017.jpg

Fitting the F22-05 Aft Angle. 
 
 
 

fuselageassy027.jpg

Once everything was secure I removed the clamps that kept the assembly on the table and slid it off the edge slightly in order to install 24-01 Cross Tie Box.
 
 
 

TurtleDeckAssy001.jpg

Starting the process of bending the F-20 Formers.  I first made the 90 Degree bends and then went on to form the flanges over the form blocks.

TurtleDeckAssy002.jpg

Most flanges required that I do a "double" to get a good bend withour distorting the metal.

TurtleDeckAssy009.jpg

TurtleDeckAssy007.jpg

This is what they looked like after being installed.  Make sure you know which end is which as there is a top and bottom.