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801 Front Side Skins

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n85ae

Joined: 14 Mar 2007
Posts: 403

Posted: Wed Aug 06, 2008 7:00 am Post subject: 801 Front Side Skins

Help!



Any suggestions for bending the cabin front side skins (8F14-3)? I have

made a mess out of trying to bend the first one. The sharp 90 which

transisition's to the curved form leading to the firewall is NOT a shape

the aluminum sheet is happy to conform into.



Thanks,

Jeff

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n801bh(at)netzero.com
Guest

Posted: Wed Aug 06, 2008 4:20 pm Post subject: 801 Front Side Skins

That is probably the second hardest piece to fabricate outside of the wing root fairing. What most of us did was to establish the tight 90 degree bend and then nest it into its home, from there you can bend the increasing radius in the aluminum till it conforms to the firewall. It is a pain in the butt though. One of us earlier builders even went as far as to build a die and try to form the piece around it. The memory of the sheet alum was too great to overcome. It was a good idea though..   Good luck. 

do not archive

Ben Haas

N801BH

www.haaspowerair.com



-- "n85ae" <n85ae(at)yahoo.com> wrote:

--> Zenith701801-List message posted by: "n85ae" <n85ae(at)yahoo.com>



Help!



Any suggestions for bending the cabin front side skins (8F14-3)? I have

made a mess out of trying to bend the first one. The sharp 90 which

transisition's to the curved form leading to the firewall is NOT a shape

the aluminum sheet is happy to conform into.



Thanks,

Jeff





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n85ae

Joined: 14 Mar 2007
Posts: 403

Posted: Fri Aug 08, 2008 7:35 am Post subject: Re: 801 Front Side Skins

Update:



Well two days later, and after totally destroying one part I did both sides

again in about ten minutes total time, and perfectly. I guess sometimes

it just requires wrecking a part in order to work out a method.



Procedure that works:



1 - Mark the sheet with a sharpie indicating the bend area at the firewall

and draw a couple lines from these points to the corner where the 90

degree bend goes. These lines are used as reference indicators when

wrapping the sheet



2 - Slight bend from the corner with hand seamers (about 10 degrees)



3 - Using a 2 1/2" diameter pvc pipe, wrap forcefully the sheet. This will 

get the firewall end of the bend about right at first pass.



4 - Add a bit more of the corner bend with seamers. should be at about 45

degrees at this point.



5 - rewrap with the pvc pipe working closer to the sharp corner.



6 - Next hold the sheet tight against a work table (I used the wife's 

freezer in the corner of the shop). Use a block of wood and force the rest

of the bend by pushing along the edge of the sheet.  



Using the 2 1/2" diameter and overwrapping the bend seems to be the key

as the sheet relax's to a close approximation of the final curve. Also NOT

making the full 90 degree corner bend with seamers, but rather by pushing

the bend into the corner it eliminates distortion in the panel. 



Hope this helps somebody save some grief. Using this method My panel 

basically pops in place with no necessity to have to push, pull swear drill

and cleco to get it to fit now. No wrinkles, dents, dimples, etc. It actually 

looks like it was made to fit where it goes.



The first sheet on the other hand is beyond salvage.



Jeff.

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