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Chapter 5: Fuselage Sides

The fuselage sides had many steps required in building them.  These sides mount up to the bulkheads as shown in the next chapter.

Date Started: 8/15/2012

Date Completed: 10/30/2012

Total Hours to complete: 72.5

Jigs

These fixtures had to be built before the sides could be constructed.  They are used as a form for the sides of the fuselage.

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Longerons

The longerons were expoxied together using the jigs shown above.  It’s a good idea to have plenty of clamps available here!

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Once the epoxy cured, the doublers were added to the longerons for added stiffness and support:

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Completed longerons, sanded and ready to be installed in the sides:

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Foam Sides

The sides were tacked into the jigs using 5 minute epoxy as shown below.  The white foam was then cut and contoured to give the sides a hollowed out look.

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Here, the sides have the large inside layups completed and the longerons attached.  That took me and my father 5 hours.

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Now the upper longerons have been glassed over and the lower triangular longerons have been floxed into position.

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Rear Buildup areas for added support in rear of plane.

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This shows the foam and formed glass used in the buildup area above:

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Rear of fuselage sides completed:

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Trimming of the front of the fuselage sides:

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Trimming of rear of fuselage sides:

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Yay, chapter 5 completed!  Now for the assembly…

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