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Stevens Web Site
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Date: 12-21-2006
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Number of Hours: 3.20
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Manual Reference:
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Brief Description: Leveled the jig cross braces and fit more bulkhead
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After making the jig firmly fixed to the floor, I had to clear up the problem with the cross braces not all being at the same height. Instead of using string to set a level line, I used wire, so that I could stretch it real tight and get a good solid line. Then, I took each cross brace and leveled each to the line. I fixed the first brace by unscrewing it from the underlying brace and then banging the underlying brace into position so that it would not throw the top cross brace off. The next cross brace had to be rip sawed just a hair to bring it into line. The next brace had to be shimmed up just a little to bring it up. In the end, all of the cross braces were reasonably close to the stretched wire level, so I decided to go with that setup. Next, I started placing the bulkheads in the jig, one by one. Using the overhead plumb bob, I made sure the top center hole lined up with the plumb bob string and then the plumb bob was centered over the center line of the jig. Once everything lined up, I clamped the bulkhead into the jig. The second most aft bulkhead has two bars which interfere with the longerons, so the instructions tell you to notch the longerons. It was scary, but I did it. By the end of the night, only the center section bulkhead and the floor ribs were not in the jig. Reading ahead in the instructions, I see that I will have to cut a new set of boards to act as center section wing spar spacers, which will be bolted into the center section with hardware store (non-close tolerance) bolts.
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A recently shaved cross brace now lines up with the fuselage reference plane wire
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Lining up a bulkhead with a plumb bob
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Aft bulkheads set in the jig.
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