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Kurt Haller RV-9A
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Date:  1-1-2012
Number of Hours:  3.00
Manual Reference:  8
Brief Description:  Conical bends in F-970 left skin

Took off the F-970 skins to make conical bends. Reinforced the edge of the workbench with OSH Al angle. The clamped a second piece of angle on top of the F-970, so the skin was sandwiched between the two angles, aligned to the bend line. (Image 1.) The top angle edge was radiused, but alas not enough. Got a crack on the left hand skin bend at the tight corner.

Images 2 and 3 below show the stop-drill hole I made. (Images taken after F-970 left put back on the fuse on 1/2/2012.)

Later in the build, I Dremeled out the skin on either side of the crack, making a round-bottomed slot, as noted on Image 3. Almost looked like the skin was punched out that way in the first place. This area will wind up being smeared with sealant when the external step is installed for good, so the extra gap-osis is no biggie.
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Ready to bend...

Ready to bend...

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D'oh!  Crack!! Stop-drilled it....

D'oh! Crack!! Stop-drilled it....

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How I (eventually) fixed it.

How I (eventually) fixed it.

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