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Jims Web Site
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Date: 3-29-2010
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Number of Hours: 4.30
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Manual Reference: 6K2
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Brief Description: Cut & clecoed stbd side fairing
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When I opened the craft-paper wrapped packages, with the part number of the side fairings (6K2-3) on it, I was surprised to find two rectangular sheets of aluminum. Neither was cut to size, nor marked with anything but the aluminum part number. Now I know where all the tolerance build-up in the cockpit goes!
I decided to make a cardboard markup, and do a test fit on it, befor cutting metal.
1. Measured critical dimensions in cokcpit for the side fairings.
2. Laid out dimensions on packing cardboard.
3. Cut to fit, and positioned in place.
4. Some trimming was required, and it appeared the part could be extened backwards about 3".
5. Cut new cardboard part, and positioned. Minor trimming made for a fit.
6. Traced cardboard onto supplied .025 6061T6.
7. Cut on bandsaw, with knife, and shears.
8. Deburred edges.
9. Set in place, marked areas needing trimming.
10. Trimmed to fit.
11. Sheet lacks stiffness. Although not on plans, cut stiffners to surround control opening, from "L" angles.
12. Drilled mounting holes in "L" angle with #40 bit.
13. Back drilled to side fairing, and clecoed.
14. Opened holes with #30 bit, and clecoed.
15. Measured bottom edge(s), and cut two "L" angles to mate fiaring to fuselage bottom.
16. Drilled #40 pilot holes in bottom of "L" angles.
17. Back drilled to floor, and clecoed "L" angles in place.
18. Opened holes with #30 bit.
19. Removed side fairing, and creted rivet line along bottom, using #40 bit.
20. Back drilled to "L" angle, clecoing as holes were created.
21. Opened holes with #30 bit, and clecoed.
22. Removfed and deburred all parts. Primed mating surfaces with zinc chromate primer.
23. Re-clecoed all parts in place.
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Cardboard tool in place
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Side fairing in place, port view
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fairing in place, stbd view
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