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John (Jack) Clark's Web Site
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Date: 8-18-2007
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Number of Hours: 6.50
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Manual Reference:
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Brief Description: Deburred parts for the Mid-Fuselage
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Deburred the F-805 & 806 L&R pieces, the F-860 A&B&C L&R, the F-805B pieces, the F-805G gossets, and the F-815C L&R.
Enlarged the 1/8" pilot hole at the top of the F-805 and F-806 pieces for the static air line and for wires. The instruction does not say what size snap bushing is to be used but the static source line is 1/4" O.D. Therefore, I drilled 5/8" holes for 1/2" I.D. snap bushings.
Final drilled the nutplate holes on the above pieces.
Cut a 2x4 with 2-45 degree angles for the bending of the F-823 skins. Marked a line 5/8" from the skins edge. This line is used to place the "Shaping angles" used for the bending. Marked a line 1/4" from the line of holes shown on the drawing for placement of the cut 2x4. Clamped a 3/4"x3/4" angle at the reference line for the Shaping angles. Drilled a hole in the angle using the first hole as a guide. Removed the angle and clamped it together with a matching angle, then drilled a hole using the hole in the first angle. This pair of angles was then clecoed to the skin and four clamps were used to insure a tight application. A vise grip was used to lift up and pull the skin over the table. The instuctions call for a tight 1/8 radius on the forward part of the skin. After reaching what I thought was the end point, I removed the bending hardware with great disappointment. The skin had a small 3/4" tear along the Shaping Angles' line of bending on the forward part of the skin. My best guess is that the angle made contact with the wood used to clamp the skin to the table and to form the crease. The pulling force and the leverage of the wood lifted and pulled on the forward part of the skin, tearing it.
Needless to say, this is the end of today's efforts. I'll order a new skin and while I'm at it, a throttle control for the rear. Apparently, this is an option where I thought it was a standard for the RV-8. When ordering the fuselage, the rear throttle option isn't listed with the other fuselage option.
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Snap bushing enlarged holes
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Bending F-823
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Torn forward skin bend edge
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