Cover
A cover was manufactured from 2024-T3 0.020'' aluminium to fit the available area on the underside of the elevator and mounting holes marked then drilled 3/32".
A duplicate panel was manufactured from the same material with additional width to provide 15 mm flanges on both sides and matched drilled from the front cover.
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| Match drilling |
Using the cover as a drilling template, it's positioned on the skin and holes transferred then drilled 3/32''. Once the holes are drilled a center-line's was marked through the hole's centers and a offset marked in 10 mm to become the opening.
At each corner of the opening a 3/32'' hole was drilled and the edges cut with the Ofla knife, a hole was drilled at the center then aviation snips used to cut from the center to the corner holes.
Once complete the 4 [four] waste pieces are removed and the edges dressed.
The holes were enlarged to suit the selected riv-nuts.
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| Elevator opening |
The reinforcing panel had it edges folded at 90 degrees and the hole's were enlarged to suit the riv-nuts. These were used to locate the panel over the opening which was transferred to the reinforcing panel with a felt tip pen and removed.
A 3/4'' diameter hole was drilled on the center-line of the opening then 3/32'' holes drilled at each corner. The Ofla knife was use to mark the perimeter and the aviation snips used to cut to the corners and the 4 [four] waste pieces removed and the opening was dressed smooth.
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Once the the component are finished and primed the reinforcing panel was re-installed and M3 riv-nuts used to fix the two components. The front cover had all the holes enlarged to 3.5 mm and panel fixed with dome head screws supplied with the kit.
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| Finished doubler |
To be covered in the next blog
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| Trial lower faring - Cover installed ready to be modified to take drive Note the pop rivet shown fouled on cover |
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