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UltraFun AirSports |
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A beautiful Sunday along with a 10X20' workspace bubble that needed major cleaning prompted the 1st move outside for the Titan. From these angles, it's looking almost done. | |
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The Titan's favorite view. | |
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After cleaning out the bubble, I decided to work on the doors outside. | |
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The right sub-panel is all wired and riveted on. | |
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I decided to build the door off the plane. I just couldn't get the frame clamped AND add the aluminum and Lexan on top of it. It was like juggling a half-dozen pieces. Here's how I did it. There are 2 absolutes on the door. One is that the aluminum panel is always going to fit on the frame just one way, the the other is that the straight edge of the Lexan will be at the hinge. Here I drill the aluminum panel under a halogen light (expands it out so everything fits better when it's normal temp). | |
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The Lexan was drilled/clecoed to the hinge. | |
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After this was done, I set in the door and spaced it 1/2" from the fuselage tubes. Some boards on the inside pushed the Lexan out to the door skin and a strap on the outside kept everything from going too far out. After making sure everything was flush against the skin and door frame, it was a simple matter of drilling along the skin/Lexan border every 2". This connected everything to the door frame, and the fit was perfect. | |
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4/8/03. The panels are wired up and done. 282.5 hours so far. | |
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Time for the rear door. The door frame is clamped where it should be, with 1/2" spacers on the bottom & rear. The lower panel is clamped & the frame is traced on the inside. | |
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Holes are drilled in the middle of the trace, and the skin is then laid back on the frame to drill the holes in it. As with the rest of the interior, the inside of the aluminum panel was painted black where the lexan would show through and where the panel would be outside the door frame. | |
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The skin is clecoed to the frame, and then the door is clecoed to the hinge. | |
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An oversize piece of lexan is clecoed to the hinge also, outside the skin for now. This allows me to draw right where everything should be trimmed. | |
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The result of trimming after the lexan was mounted. I have a gap of around 1/16" all the way around the door. | |
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The drawing for the rear trim on the aluminum sheet was too short, so I made my own, matching what I did on the other side. The door came out just as nice as the front one did. | |
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Doh! After fooling around trying to get the right cut, I came up with the brilliant idea of putting the carpet on the outside of the cockpit. It's thin enough that I can feel the rivets through it, and mark each one. Then all I have to do is to follow the dots with a scissors. The result is a piece that's about a half-inch too big, which leaves room for errors. Trimming is easy from there. | |
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Carpet is all cut and laid in the fuselage (not glued yet, in this picture). Looks very nice. | |
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