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Safari Helicopter Construction
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Date:  9-3-2006
Number of Hours:  9.00
Manual Reference:  
Brief Description:  Construction of Horizontal Stabilizer

As mentioned on Bill's site, I added 1/2" to the overall width of this skin panel beyond what the construction prints called for. This is to allow for the bend radius. After laying out the flat pattern, I found it easier to bend the skin evenly after I put a slight bend with the brake at the center line. Be careful not to bend too much or you're likely to end up with a crease at the center of the radius. After that I clamped a 1" plastic pipe against the inside radius and used even hand pressure to form the bend. You may also wish to put to small bend (in oppossite directions)about an inch in from the trailing edges. This will allow the two surfaces of the trailing edge to meet nicely and provides a flat surface for your row of rivets. I placed the first rivet location on the support tube 1" outboard from the flange. With the flexing of the shaft I don't want the holes acting as stress risers close to the point of attachment. I also staggered the hole pattern on the bottom of the tube by 1/2" as compared to the top row.
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Using a plastic pipe to form the bend

Using a plastic pipe to form the bend

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Laying out for the support tube

Laying out for the support tube

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Drilling the first side

Drilling the first side

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