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Christopher's Web Site
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Date: 7-27-2015
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Number of Hours: 4.00
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Manual Reference:
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Brief Description: Aft Kick Panel Layout
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The aft kick panel is one of the larger sheet metal panels to fabricate. I began by taking all of the other panels and the floor out of the heilcopter, with the exception of the side kick panels because I need them to measure the exact fit of the aft panel.
I was able to use the Safari supplied paper template as a starting point, unlike several of the others, but it still required a lot of tweaking. I needed to coordinate the tabs with the other panels I've already made, and the center collective that I'm going to make next. I also needed to account for the thinkness of the cardboard as it compares to the .032 sheet metal.
Once I completed the template, I laid out the pattern onto the raw sheet metal being careful to make the longer and majority of the bends across the grain of the metal to avoid stress cracking. I use a very fine point black sharpie for the cut lines, blue for the fold lines, and red to remind me which areas are removed within the panel. I then mark all of the drill stop hole locations on the bends so I can drill them before I make my cuts. These will help avoid stress cracks at the bends and inside corners.
Unfortunaltely, it was late when I was ready to cut out the panel, and I didn't want to disturb the neighbors with loud tools, so I will have to make my cuts and bends tonight.
I'm not sure if I've posted the new brake I've been using to make my bends, so I've included a phot of it below. Once I was able to adjust for the larger radius required of the aluminum, it has been a great tool. There are much better tools out there, but there are MUCH worse too. The small brake I was using was almost completely useless. The hand seamers are a huge help
More tomorrow...
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Cardboard Template
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Sheet metal layout
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New metal brake
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