INSTALL GUSSETS ON THE INSIDE OF THE FUSELAGE AROUND THE MAIN AND BAGGAGE DOOR OPENINGS TO STIFFEN AND REINFORCE THE OPENINGS. SIX GUSSETS ARE INSTALLED AROND THE BAGGAGE DOOR AND FOUR AROUND THE MAIN DOOR.
1 CUTA 1/2 THICK PIECE OF DIVINYCELL FOAM INTO RETANGLE APPROXIMATELY , 2 HIGH BY 12 LONG.
2 SHAPE ONE OF THE 12 SIDES TO PROVIDE A ROUND PROFILE. THEN COVER IT WITH 2 BID CARBON LAYUP , ALLOW TO FULLY CURE.
3 CUT A TRIANGLE APPROX 4 LONG AND 2 WIDE, OUT OF A 1/4 THICK PIECE OF CARDBOARD OR FOAM.
4 PLACE THE TRIANGLE AGAINST THE FUSELAGE AND THE DOOR FLANGE WHERE THE GUSSET IS TO BE INSTALLED. TRIM THE TRIAGLE TO MAKE A PATTERN THAT FOLLOWS THE CONTOUR OF THE FUSELAGE AND IS 1/2 BELOW THE LIP OF THE FLANGE.
5 USE THE PATTERN TO CUT THE GUSSET OUT OF THE LAYUPCOVERD FOAM. ENSURE THE ROUNDED PROFILE OF THE LAYUP COVERD FOAM THE THE TOP GUSSETS.
6 SURFACE RPEP INTERIOR OF THE FUSALAGE WITH 80 GRIT SANDPAPER,THEM CLEAN WITH ACETONE.
7 BOND THE GUSSET TO THE FUSALAGE USING RESIN AND FLOX MIX TH THE CONSISTENCY OF OATMEAL. RADIUS THE JOINTS.
8 ALLOW THE FLOX TOFULLY CURE .
9 SURFACE PREP THE GUSSET AND FUSALAGE , THEN COVER WITH A 4 BIDLAYUP 0,45,45,0 EXTEND 2" BEYOND GUSSET.
