- Fuselage -
The tacked fuselage
arrival
opened the box
first stage at the work shop
structural welding of the entire fuselage, with special rotatable frame
Video
welding of fuselage
Video 1
Video 2
fuselage after complete structural welding back
home
elevator stab mounting tube drillend for support
tubes, reday for welding
elevator front stab mounting tube, after welding
preparing main gear sheet metal plates
tack welding of main gear sheet metals
finish welded main gear sheet metals
preparing engine mount support plates (cutting
& drilling sheet metal to fit fuse hloes)
welding of engine
mount support plates
aligning the fuselage to level to accept wing
top longerons are cutted by my friend Jens (very
concentrated)
... after cutting
special laser
cutted parts
welding of wing attachments in devotional attitude
tack welding of horizontal stab attach tubes
... and mounted stabilizer for check of alignment
after welding of tail section attach tubes and plates to fuselage
preparation of longeron attach tube by using
laser cutted longeron attach plates
and cutted attach tubes
after welding of attach tubes and plates to previous cutted longeron
tubes
preparation of longeron attach assy for
fuselage insertion
... after welding on the right side (as example, but done on both sides)
gear, tailwheel, wing and tail section complete mounted on fuse
front and rear turtle deck frame tubes prepared
... tack welded front frame
plus front frame brace tubes
and tack welded rear frame
welding finished of rear section
preparation of pilot step
(streamline tube covered with sheet metal plate, aerodynamically)
welding of pilot step to fuselage
preparation of battery
mounting brackets (after cutting and bending)
after welding of battery mounting brackets
battery frame mounted on fuse brackets
plywood board installed (to get a clear surface for the battery to sit
on)
bottom view
and total view with installed seat back
cutting of .050 shet metal for battery holder
after bending
and after welding
drilling of holes in battery holder and fuselage
cutting of .025 sheet metal of rear fuselage cover
after bending
after preparation for welding
after welding on fuselage, left & right side
cutting and drilling of a big spar dummy as preparation for fuselage stress test
Now the last chapter for the fuselage: the stress test ;o)
preparation of the fuselage; mounting engine with straps on the ground
set fuse level
putting precutted wood sheet on elevator stab
align laser level measurement tools to measurement points
now the party starts ...
... with 145kg each side
increasing to 265kg each side
and asymmetrical stress test, right 80kg and left 265kg
and the result is perfect; no structural deformation ;o)
all systems go!
and of course, nothing works without helping friends; thanks again guys!
fuselage after powder coating ;o)
done ...
