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Safari Helicopter Construction
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Date:  5-28-2006
Number of Hours:  6.50
Manual Reference:  
Brief Description:  More cabin sheet metal work

The first part of the day was spent removing the floor, firewall and doorsills in preparation of fitting the seat panel. In the first photo you can see the 90 degree bend at the top of the panel. I wanted this flange to wrap around the seat support tubes to provide a smooth surface for the drop-in seat pans that I intend to use for underseat storage of small items. I finally came up with an acceptable method to form this lip over the seat frame. I used a solid piece of hickory wood that I routed out a groove in. By using a rubber mallet and a soft piece of leather between the "die' and sheet metal, I was able to roll (hammer) this edge without any creases.The 3rd photo shows an alum. angle that I had to modify to act as a spacer between the back floor rib and the floor panel. It had an 1/8" gap and this angle filled the gap and provides some additional support.
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Starting to fit the panel

Starting to fit the panel

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Forming around the seat supports

Forming around the seat supports

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Spacer for floor rib

Spacer for floor rib

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