My previous attempt at fabricating a new aft upper bulkhead (F-810A) was mostly successful, except that the finished product was slightly too wide due to a measuring error on my part. Today, I modified the form block to the correct dimensions, located a scrap of 0.032 aluminum, and fabricated the bulkhead all over again.
This one came out really, really nice. After fluting the tabs, it fit like a glove! Sweet.
All that's left to do is create the stiffener ring around the lightening hole, then drill/cleco the new part in place.
Counterclockwise from top left: Factory part; my first attempt; new part being made; form block.
This is the difference in width between the factory part and my new replacement.
As you can see, my replacement bulkhead fits the skin very well.
