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jglazener
Joined: 14 Apr 2010
Posts: 76
Location: Schoonhoven, Netherlands
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 Posted: Sun Sep 19, 2010 11:02 am Post subject: Top fuselage- rear flange gap problem |
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I am trying to get my top fuselage to fit to the bottom. This is a necessity for most before bonding it on, but since I need to incorporate a Hi-top mod, it is even more important to get it right before I start cutting it into pieces.
I find that even with the front flanges aligned to those in the firewall, and the trimline on the back of the tail lined up with the end of the fuselage, I still have a gap at the rear flanges of 9-10 mm (see attached). If I then raise the front fuselage as per mod 64B it only gets worse, with some 11mm at the bottom.
Is this normal? If not, what can I do about it?
Suggestions welcome, Jeroen
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davidjoyce(at)doctors.org
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| Posted: Mon Sep 20, 2010 12:43 am Post subject: Top fuselage- rear flange gap problem |
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Jeroen, It's a long time ago now, but I seem to remember that I had a fair
sized gap in the outer surfaces, which was eventually filled. The overlap as
I remember it was fairly considerable. No doubt your inspector would know
exactly how much overlap he requires for structural integrity, and as long
as you have that I don't think there is any problem about filling the odd
gap.
Regards, David Joyce, G-XSDJ
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jglazener
Joined: 14 Apr 2010
Posts: 76
Location: Schoonhoven, Netherlands
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| Posted: Mon Sep 20, 2010 6:15 am Post subject: Re: Top fuselage- rear flange gap problem |
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David,
Thanks for the reply. I am already feeling a bit better. As for the inspector, we don't really have them in Holland. Everything is based on the principle of self inspection. I do have someone assigned to me, but he is building a wooden plane, and just signed off on my workshop. Sounds easy, but to be honest I would much prefer the UK system, where you have someone you can actually fall back on. Luckily I have the forum....
Regards, Jeroen
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davidjoyce(at)doctors.org
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| Posted: Wed Sep 22, 2010 6:03 am Post subject: Top fuselage- rear flange gap problem |
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Jeroen, I guess that is why UK permit aircraft have the same mechanical
accident rate as certified aircraft, whilst US rates are 3 times higher. I
am pretty sure there are set industry standards as to how much overlap you
need to provide full strength at a joint. There are a lot of things of
consequence that my inspector taught me, such as getting just the right
degree of wetness when laying up glass (to give optimal strength and
lightness) and the critical importance of sanding very thoroughly any
surfaces you are going to bond. If you can find a glider repair firm in your
part of the world it might be worth asking there for a bit of direction.
Best of luck, David
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Troy Maynor
Joined: 10 Jan 2006
Posts: 162
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| Posted: Wed Sep 22, 2010 11:11 am Post subject: Re: Top fuselage- rear flange gap problem |
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Jeroen,
Check that the firewall is not warped forward at the top edge. Mine was and caused the joggle gap at the rear to be too large. I drilled a 1/4" hole at the center of the firewall, threaded an eye bolt thru it and a 2"x4", tied the bolt off to a stick placed in the head rests, to hold it straight up while getting the top molding fitted. Over the course of building, removing and replacing the top for trial fitting things, it became straight as it should before actually bonding the top on. Hope this was relevant to your question. If not, my apologies.
Troy Maynor
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frans(at)privatepilots.nl
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| Posted: Wed Sep 22, 2010 11:38 pm Post subject: Top fuselage- rear flange gap problem |
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On 09/19/2010 09:02 PM, jglazener wrote:
| Quote: | Is this normal? If not, what can I do about it?
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Jeroen, I had it too (and I have the hitop as well). I heard from others
that this was normal, and I have accepted this. I filled up the gap with
flox, and added two layers of bid on the outside (in addition to the
flange on the inner side).
90+ hours and still counting.
Frans
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jglazener
Joined: 14 Apr 2010
Posts: 76
Location: Schoonhoven, Netherlands
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| Posted: Fri Sep 24, 2010 1:44 am Post subject: Re: Top fuselage- rear flange gap problem |
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Thanks for all the input. Troy, you are right about the top of the firewall bending forward- mine does that as well. I did however push it back when taking the photo above. I will certainly try you method to get it straight.
Bottom line is that the gap seems here to stay. It can't really be any other way- pulling the top further back would only make the tail and FW flange misalign. Strange that a systematic non conformance like that is not either corrected (trimming less at the factory) or mentioned in the manual.
Jeroen
http://www.europaowners.org/forums/gallery2.php?g2_itemId=44165
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craigb(at)onthenet.com.au
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| Posted: Fri Sep 24, 2010 2:26 am Post subject: Top fuselage- rear flange gap problem |
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not that it helps you much, but my firewall ended up straight, when i pulled
the top back far enough to make it all line up
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