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Date:  1-19-2009
Number of Hours:  4.00
Manual Reference:  Section 8; Dwg 38
Brief Description:  Fabricating Fuel Tank Attach Brackets

The plans have you fabricate angle reinforcements (F-796B- L/R) and two shims (F-796C & D) for each fuel tank attach bracket (F-796A L/R). In the first picture I am removing the five rivets on the fuselaage skin to install the brackets. There's not a lot of room to do this task. If I had to do it all over again , I would have done this before I attached the wing spar and drilled the aft spar holes. The plans are really poorly thought out for this task. It's taken nearly two hours to do what would have taken 15 minutes. In the second picture you can see I have removed all 5 rivets and am ready to fabricate the reinforcement angles and bend the attach brackets. What the plans don't tell you is you need to bevel the top of each angle bracket about 30 degrees to make it fit tight under the fuselage longeron. You can see this bevel on the left angle in picture # 3 (far left side). If you don't make the bevel first the the top bolt hole is too close to the edge of the angle. I had to re-do the first angle because the top bolt hole was out of tolerences. I also super-glued the shims together because when you are drilling the holes to match the holes where the rivets used to be, the shims keep falling down. Because this should have been done before the wings were attached, you can see the reinforcement angle on the right has a couple of elongated holes caused from working in such tight quarters The rivets will fill these holes, but it could have all been avoided if the plans had you do this step before you bolted the wings onto the fuselage. I did a lousy paint job because it's 15 degrees outside and the primer wouldn't dry...so I got the ole heat gun out and the paint blistered. I'll probably redo the priming tomorrow. It's been a long day.
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Drilling out the 5 rivets that shouldn't be there in the first place

Drilling out the 5 rivets that shouldn't be there in the first place

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5 rivets removed

5 rivets removed

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Reinforcement Angles, Shims, & Brackets

Reinforcement Angles, Shims, & Brackets

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