38-04 -> 05: Side Skin Stiffner Angles (aft window interference) / Canopy Latch Mechanism

Installing the Skin Stiffner Angles

Way back when the tailcone was joined to the forward fuselage, there are a number of rivets left out of the side skins. This was to facilitate the riveting of the roll bar, as well as give space to dimple the skin holes once the window is installed. To close this up, there are a couple of stiffner angles which join the side skins to the roll bar. When i went to install these, i noted that they interfere with the rear window. 

The stiffner clip interferes with the aft window.

To solve this, the rear window had to be trimmed. I found it difficult to mark accurately where to trim, so made up some templates of the skin to window transition. The skin holes were marked so i can reference these to the window, and the stiffner mounting holes were also marked, so i can trace the stiffner to accurately workout where the interference lies. I did seperate templates for left and right.

A slot was then cut into the template, so i could accurately trace around the stiffner angle. 

I was than able to copy this interference to the skin, by aligning the template with the skin holes. The cutout was drilled in the corner (for a nice radius), and trimmed with the Dremel.

I measured and made sure there was the same edge distance at the bottom of the hole, as there was from the hole to the forward edge of the window.

This method worked really well, and i was rewarded with some nice neat cut-outs around the stiffner angles which are not noticable at all. 

The stiffner angles were then riveted to the roll bar, and the final rivets set between the skin and the structure.

Stiffner clips riveted to the skins

Stiffner clips riveted to the roll bar.

I was able to get inventive and by using my standard yoke with some washers, i was able to get around the skin stiffner angle flanges. (The standard yoke has a deeper throat than the longeron yoke). 

Installing the Canopy Latch Mechanism

I had previously prepared the canopy latch mechanism parts, but had held off on installing them until the window could be fitted, as they would have interfered with the above riveting. These were fairly easy to install, but needed some creative use of tools to get into the nooks and crannies. The fuselage rotisserie came in handy in a big way, especially for instlling the cotter pins on the latch links.

Once of my best tool investments for aeroplane work. 

Theres always a combination of sockets and extentions which will reach!

The old - screw a nut on my hand, using feel only, then wonder why it won't tighten up? Oops. 

These nuts were a real PIA

Complex geometry but beautiful. Works awesome.