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Johns Web Site
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Date: 6-6-2015
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Number of Hours: 4.00
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Manual Reference:
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Brief Description: Forward & Aft fuselage Alignment
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Today’s project is to align the forward and aft fuselage in preparation for fastening. The first job is to modify the forward ends of the aft fuselage longerons to allow proper engagement to the mounting features on the forward fuselage. The initial work is to provide clearance on the upper longerons for the weld beads and roll bar tubes. After marking the clearance cuts, the fuselage was pulled back far enough to remove the interfering area on the upper longerons, with a small sanding drum in a Dremel tool.
After repositioning the aft fuselage, I found that the right side engaged perfectly with the aft longerons up against the forward fuselage weldment, and the aft side skin fully overlapping the rear vertical tube of the forward fuselage. However, the left side overlapped only ½” of the 5/8” wide forward fuselage tube. After a careful investigation, I determined that the upper left aft longeron needed to be shortened by 1/8”. After marking the cut line the excess was quickly dispatched with a small jig saw, the cut edge was smoothed with a small sanding drum in a Dremel tool.
After repositioning the aft fuselage, the alignment looked much better, and the overlap matched the right side. To ensure that the aft fuselage remained tight against the forward fuselage during the final alignment and drilling for fasteners, straps were attached between the tail wheel spring and the steel structure at the front spar opening, on both sides, and tightened. After leveling the forward fuselage, the alignment was checked with a self-leveling laser. By setting the laser level about 30” forward and about 18” above the firewall, it is effective from the firewall to bulkhead #5. Fortunately, the alignment all the way through was excellent. This is a little scary. Based on my experience, when things work out this easily, you probably missed something important. So, I will recheck everything again tomorrow, before drilling for the fasteners.
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Straps Providing Tension During Alignment
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Level and Self Leveling Laser Used During Aligmnent
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