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Gallery #3 “Fuselage”

Fuselage frames jigged on a sheet of 3/4" chipboard 8'x4'. Hardwood blocks screwed to backing board around the built up frames using rule and large square to set up each frame. After completing the jig the fuselage frames were removed and placed to one side. Plastic lunch wrap was layed over the jigs in areas where glue is used, then the frames were reassembled in the jig with glue and then clamped. This made gluing of each frame very straightforward.
Fuselage frames jigged on a sheet of 3/4″ chipboard 8’x4′. Hardwood blocks screwed to backing board around the built up frames using rule and large square to set up each frame. After completing the jig the fuselage frames were removed and placed to one side. Plastic lunch wrap was layed over the jigs in areas where glue is used, then the frames were reassembled in the jig with glue and then clamped. This made gluing of each frame very straightforward.
Fuselage sides jigged on a sheet of 3/4" chipboard 8'x4' cut in half lengthwise then joined using screwed plates. Both sides were made using the same jig ensuring that the frames are identical.
Fuselage sides jigged on a sheet of 3/4″ chipboard 8’x4′ cut in half lengthwise then joined using screwed plates. Both sides were made using the same jig ensuring that the frames are identical.
Fuselage centre consisting of frames #5, #6 and side frames (#5a left & right) were dry clamped in position to check fuselage centre for squareness and for wing spar spacing. Best relative position of frames was marked with a pencil prior to disassembly in preparation for gluing and re-assembly.
Fuselage centre consisting of frames #5, #6 and side frames (#5a left & right) were dry clamped in position to check fuselage centre for squareness and for wing spar spacing. Best relative position of frames was marked with a pencil prior to disassembly in preparation for gluing and re-assembly.
Fuselage frame #4 clamped in position. Frames #5, #6 and #5a left and right glued in place. Note, protective strips of scrap ply and thin wood are visible between clamps and fuselage.
Fuselage frame #4 clamped in position. Frames #5, #6 and #5a left and right glued in place. Note, protective strips of scrap ply and thin wood are visible between clamps and fuselage.
Checking distance between front and rear wing spar attachment points (frames #5 & #6).
Checking distance between front and rear wing spar attachment points (frames #5 & #6).
Checking squareness of rear spar connection points (frame #6) with front face of frame #5 (back of cockpit).
Checking squareness of rear spar connection points (frame #6) with front face of frame #5 (back of cockpit).
Fin attachment frames #7, #8 and #9 glued in place with fin attached.
Fin attachment frames #7, #8 and #9 glued in place with fin attached.
Fin attachment frames #7, #8 and #9 glued in place with fin attached, side view.
Fin attachment frames #7, #8 and #9 glued in place with fin attached, side view.
Fin removed to allow additional clamping of frames #7, #8 and #9 during gluing.
Fin removed to allow additional clamping of frames #7, #8 and #9 during gluing.
Drilling through rudder post to match rudder atachment bracket and desired assembly location in fuselage.
Drilling through rudder post to match rudder atachment bracket and desired assembly location in fuselage.
Rudder post in position. Fuselage frame #10 glued in place with rudder installed.
Rudder post in position. Fuselage frame #10 glued in place with rudder installed.
Fin and rudder removed to allow additional clamping on frame #10.
Fin and rudder removed to allow additional clamping on frame #10.
Top diagonals of Maya fuselage frame glued in place. Note sandwich wrap used to prevent clamping blocks or clamps from being glued to the fuselage. Also, note plumb-bob hanging from the centre of the fuselage cross piece and aligned with the taught piano wire centre line (diagonals adjusted so that the plumb bob is not pushed away from the centreline).
Top diagonals of Maya fuselage frame glued in place. Note sandwich wrap used to prevent clamping blocks or clamps from being glued to the fuselage. Also, note plumb-bob hanging from the centre of the fuselage cross piece and aligned with the taught piano wire centre line (diagonals adjusted so that the plumb bob is not pushed away from the centreline).
Rear of fuselage with fin and rudder fitted. Top diagonals and bottom surface cross pieces fitted.
Rear of fuselage with fin and rudder fitted. Top diagonals and bottom surface cross pieces fitted.
Front view with control column and seat back fitted. The seat back weighs just 1.05lb (476g) and is actually more comfortable than it looks!
Front view with control column and seat back fitted. The seat back weighs just 1.05lb (476g) and is actually more comfortable than it looks!
View of cockpit area from behind. Seat back, control column and rudder pedals fitted.
View of cockpit area from behind. Seat back, control column and rudder pedals fitted.
Finally seeing the light of day!
Finally seeing the light of day!
Side view of assembled Maya fuselage after removal from assembly bench.
Side view of assembled Maya fuselage after removal from assembly bench.
Rear quarter view of assembled Maya fuselage after removal from assembly bench.
Rear quarter view of assembled Maya fuselage after removal from assembly bench.
View straight on underside of assembled fuselage.
View straight on underside of assembled fuselage.
Strengthening strips for wing strut root connections glued in place. Fuselage frames #5 and #6.
Strengthening strips for wing strut root connections glued in place. Fuselage frames #5 and #6.
Bottom fuselage diagonals and gussets glued in place.
Bottom fuselage diagonals and gussets glued in place.

 


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