Chapter 5

Building the Fuselage Sides

Began December 2,2005

Finished January 28, 2006

Time Spent: 75 hours

The first step in Chapter 5 is to build jigs from wood. It took 3 – 1”x8”x8’ white pine pieces. I had to be very picky at Home Depot to make sure that the wood was straight in all dimensions.

The first use of the jigs is to form the upper longerons from the wood supplied from Aircraft Spruce. Below is a picture of the longerons after being epoxied together. I am using some old yard edgings as weights. I clamped the longerons as well as wedged them with nails to hold them against the jigs.

The jigs are then rearranged to provide the shape of the mold surface for the fuselage sides. 1/8” Masonite is used to provide the mold surface.

The 3/8” foam is cut and fitted together on the mold surface.