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Date:  8-31-2016
Number of Hours:  5.00
Manual Reference:  
Brief Description:  Turtle Back and Gas Tank Stubs

Cut four 1 1/4 inch segments of 1/2 inch steel tubing. Ground one end at a angle of about 15 degrees and cupped to fit over the longeron. Tig welded each segment of steel tubing on top of the longeron at the fuselage cross braces. Cut a segment of 1/2 inch aluminum tubing which was two inches longer that the distance between the two mounting points. Using the tube bender formed the end curve to fit into the mounting point and rise above the fuselage to match the height of the runners forming the turtle back. Placed a bow in the support tube to match the curve of the turtle back at that point along the fuselage. Measured the cross member to fit in the bracket on the longeron and removed the excess tubing. Drilled a 1/8 inch hole into the bracket and cross member on both sides and installed a pop rivet in each. Repeated the above process for the second cross member on the fuselage.

Cut and formed two tabs from the 1/8 by 1 inch steel strap 1 inch long. Tig welded each tab to the aft cockpit cross member. Drilled and tapped each tab for a 1024 screw. Mounted the aft cockpit back onto the cross member of the fuselage and drilled a hole at each tab. Secured the back to the fuselage with two 1024 screws.

Measured down from the top longeron at the front of the fuselage the distance required for the gas tank to fit between the stub and the top cross member. Tig welded a 1 1/2 inch steel tube in place on the right vertical firewall support tube. The stub was angled into the space at about 30 degrees. Repeated the process for the left side. Cut two segments from a half inch garden hose and slipped each on a stub. End of day.
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Turtle Back Cross Member

Turtle Back Cross Member

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Front of the Turtle Back

Front of the Turtle Back

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Gas Tank Bottom Supports

Gas Tank Bottom Supports

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