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Greg's RV-12 Classic N719VA
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Date:  8-11-2015
Number of Hours:  3.25
Manual Reference:  23-02
Brief Description:  Bend and drill longerons

Manual 23-02, step 6, bend and drill and cleco longerons.

Used longeron bend dies I borrowed from Scott Malcomb of "Eagles Nest" (see www.EaglesNestProjects.org). These dies originally came from Avery Aircraft Supply. I paid shipping both ways to/from Scott.

The dies work extremely well and are easy to use. No beating with a hammer was required during the major bend. I used a newly purchased 6" bench vise with magnetically applied jaw pads (orange). I started with the center mark on the die place at the bend start mark. Squeezing the die to about a 1/8" space on the die (see picture 1) seemed to work well at 1" intervals to get the curve about right. I had to repeat the bends after checking once or twice. By hand I bent the longerons to make the top face flat and then recheck bend and redo as needed. I also used the die for the aft end bend with the die at the bend mark line and not moved. I squeezed the die and checked the bend repeatedly. I did use a plastic mallet with the longeron still in the die to make the final bend angle.

I clamped a strip of scrap .025 aluminum skin on the side of the longeron as I clamped and match drilled holes in the longerons. Drilled 3 to 4 holes at once clecoing each before drilling the next.
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bend die squeezed to 1/8

bend die squeezed to 1/8"

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longerons bent

longerons bent

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longerons drilled and clecoed

longerons drilled and clecoed

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