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kearney(at)shaw.ca
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 Posted: Sun Nov 18, 2007 9:09 pm Post subject: WD-1002 / F1001B / F1040 Fuse channel rivet holes |
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Hi
A few weeks ago I posted a query regarding the edge clearance on the WD-1002 brackets that tie into the F1004 fuse channel and the firewall. After some discussion with Van’s I decided to install new parts and try again.
The source of my problem seemed to be the F1001B flange that contains a line of pre drilled holes that pretty much determined where the rivets would go in the WD-1002 flange. Attached is a picture of the flanges that I replaced. To my mind, and in the opinion of others I respect, these edge clearances were insufficient. Attached is a picture of the WD1002 brackets I removed & replaced showing the rivet edge distances I initially achieved.
Fortunately my brother who runs a heavy maintenance crew of a regonial airline visited this weekend and help resolve my issue. We ended up fabricating a new F1001B flange but this time without a line of rivet holes. We then aligned all the parts (the F1001B / WD1002 and F1040 channel) clamped everything down and drew a new rivet line on the F1001B that would give better overall edge clearances on the WD1002 flange. The end result was edge clearances of 1.5 - 2D on all rivets (most were 2D). This was far better than what was originally obtained. As a side benefit I learned a great deal about bending AL and how to avoid stress cracks in bends etc.
I guess if I had to do this all over again, I would order the F1001B without the pre-drilled rivet holes. That way I could achieve far better results (now that I know what to do) right out of the gate.
Cheers
Les Kearney
#40643 – Still singing the section 29 blues
From: Les Kearney [mailto:kearney(at)shaw.ca]
Sent: October-27-07 10:16 PM
To: 'rv10-list(at)matronics.com'
Subject: RE: WD-1002 / F1001B / F1040 Fuse channel rivet holes
Hi Again
I have a follow-up question for builders who have / are going through the forward fuse construction. After a couple of emails / calls to Vans, it appears that a reduced edge clearance for the to upper flange rivets is okay. Unfortunately the edge clearances that I have achieved are still woefully inadequate (at least to me).
I have spent quite a bit of time trying sort out what the problem is with the WD1002. It appears that the edge of the top flange runs very close to the line of rivet holes in the F1001B flange. As a result it requires considerable clamping to get any sort of edge clearance when match drilling. This clamping in turn seems to cause a distortion the firewall as it causes a twist in the WD1002 base. I have this problem in both my WD1002 weldments. Fortunately, the WD1003 weldments seem okay and require only a *little* clamping to get good edge distances.
I would be interested in finding out if other builders have had the same problem and if so how did they handle it.
Cheers
Les Kearney
#40643 – Frustrated in the fuse ..
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AV8ORJWC
Joined: 13 Jul 2006
Posts: 1149
Location: Aurora, Oregon "Home of VANS"
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| Posted: Sun Nov 18, 2007 10:10 pm Post subject: WD-1002 / F1001B / F1040 Fuse channel rivet holes |
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Well done Les. And a tribute to my Heavy Check brethren coming to the rescue for proper edge distance achievement. My others benefit by your efforts.
John Cox (Formerly Heavy Check)
From: owner-rv10-list-server(at)matronics.com [mailto:owner-rv10-list-server(at)matronics.com] On Behalf Of Les Kearney
Sent: Sunday, November 18, 2007 9:07 PM
To: rv10-list(at)matronics.com
Subject: FW: WD-1002 / F1001B / F1040 Fuse channel rivet holes
Hi
A few weeks ago I posted a query regarding the edge clearance on the WD-1002 brackets that tie into the F1004 fuse channel and the firewall. After some discussion with Van’s I decided to install new parts and try again.
The source of my problem seemed to be the F1001B flange that contains a line of pre drilled holes that pretty much determined where the rivets would go in the WD-1002 flange. Attached is a picture of the flanges that I replaced. To my mind, and in the opinion of others I respect, these edge clearances were insufficient. Attached is a picture of the WD1002 brackets I removed & replaced showing the rivet edge distances I initially achieved.
Fortunately my brother who runs a heavy maintenance crew of a regonial airline visited this weekend and help resolve my issue. We ended up fabricating a new F1001B flange but this time without a line of rivet holes. We then aligned all the parts (the F1001B / WD1002 and F1040 channel) clamped everything down and drew a new rivet line on the F1001B that would give better overall edge clearances on the WD1002 flange. The end result was edge clearances of 1.5 - 2D on all rivets (most were 2D). This was far better than what was originally obtained. As a side benefit I learned a great deal about bending AL and how to avoid stress cracks in bends etc.
I guess if I had to do this all over again, I would order the F1001B without the pre-drilled rivet holes. That way I could achieve far better results (now that I know what to do) right out of the gate.
Cheers
Les Kearney
#40643 – Still singing the section 29 blues
From: Les Kearney [mailto:kearney(at)shaw.ca]
Sent: October-27-07 10:16 PM
To: 'rv10-list(at)matronics.com'
Subject: RE: WD-1002 / F1001B / F1040 Fuse channel rivet holes
Hi Again
I have a follow-up question for builders who have / are going through the forward fuse construction. After a couple of emails / calls to Vans, it appears that a reduced edge clearance for the to upper flange rivets is okay. Unfortunately the edge clearances that I have achieved are still woefully inadequate (at least to me).
I have spent quite a bit of time trying sort out what the problem is with the WD1002. It appears that the edge of the top flange runs very close to the line of rivet holes in the F1001B flange. As a result it requires considerable clamping to get any sort of edge clearance when match drilling. This clamping in turn seems to cause a distortion the firewall as it causes a twist in the WD1002 base. I have this problem in both my WD1002 weldments. Fortunately, the WD1003 weldments seem okay and require only a *little* clamping to get good edge distances.
I would be interested in finding out if other builders have had the same problem and if so how did they handle it.
Cheers
Les Kearney
#40643 – Frustrated in the fuse ..
[quote][b]
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wcurtis(at)nerv10.com
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| Posted: Mon Nov 19, 2007 9:26 am Post subject: WD-1002 / F1001B / F1040 Fuse channel rivet holes |
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I think Deems was the one that brought this to attention first. I remembered it when I got to that point and rather than letting WD-1002 jsut sit under the F1001B, I applied some outboard presure to the WD-1002 to make sure the required edge clearance was achieved. I drilled the aft most hole first at a marked edge clearance, inserted the cleco and then drilled the remaining holes.
Unfortunately I did not document this on my site.
William
http://wcurtis.nerv10.com/
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kearney(at)shaw.ca
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| Posted: Mon Nov 19, 2007 10:03 am Post subject: WD-1002 / F1001B / F1040 Fuse channel rivet holes |
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William
I tried the approach you used and the end result was the edge distance on
the photos - not very good in my mind. As well, the heavy clamping caused a
noticeable deformation in the firewall which I was unhappy about. I was
afraid that there was too much stress on the base of the flange which could
crack sometime in the future.
I wanted the parts to sit more or less aligned with no more than finger
pressure being required to hold them in the desired position.
I may have been a bit anal about this, but the consensus of the people I
spoke to was that I needed a better solution.
Cheers
Les
#40643 - Still singing the section 29 blues
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