Upgrade Fuselage - Part 2

With the completion of the upgrade at station 4 the next was station 5. 

This blog is written to record the work undertaken and is standard in the new models as required.

Preparation
The new battery drill was used to remove the rivets securing the existing gussets. To provide better access to remove these rivets a fuselage gusset was first removed then the heads were removed followed by the body's.

To provide a better edge distance at the longeron's new gussets were fabricated from 0.040'' 2024-T3 aluminium. These were dress to fit the odd angle created with the fuselage then primed.

After priming the plate was marked out to match the pattern used on the front gussets and all holes were drilled to 3.2 mm. 

The plates were then primed and painted to match the fuselage and set aside to dry.

Assembly
The gussets were fitted and the first hole drilled from the inside through the fuselage and a cleco added then all the other holes were added, cleoced and finally riveted inside and out. 

Lower packer - tapered

Full Packer

Inside cockpit

Fully Cleoced

Riveted - typical both sides
Both stations shown