SECTION 29: FUSE SIDE SKINS

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29-2

Note that when bending the longerons, the template has parts that are almost completely straight. It is easiest to identify that and avoid curving that part (don't just start curving everything at the start).

Also, follow the curve templates very carefully. The curve of the longerons affects the shape of your aircraft, the fit of the cargo door, the fit of some interior panels, etc. Even if you spend ten hours per longeron to get it exactly right that's time well spent.

Note that the "Aft Twist Mark" is not applicable for F-1013-L because it is the shorter longeron.

29-3

The instructions don't specify, but you do the FWD TWIST on both longerons since the parts are symmetrical (other than the fact that one is shorter to accommodate the cargo door).

29-5

Folding the skins can be pretty difficult, definitely take your time and get a consistent curve. Note that a 60-degree fold may be insufficient -- ultimately, the bottom edge needs to be a full 90 degrees from the side skin. You can force the final fold later with Clecos, but you can end up with a gap at the edge of the skin on the bottom. Suggestions:

  • The forward (sharp) edge should be pretty much 90 degrees
  • The trailing edge should be 70-75 degrees
  • This applies to the fold on the forward side skin as well.

29-6

Step 2 and especially Step 4 can be fiddly. Note that the thickness of the AA6-063 is 1/16" thick so consider using a scrap piece of that AA6-063 to make sure the 1/16" offset is implemented correctly.

29-7

  • Step 3: The number of holes in the top flanges of the F-1015C Mid Cabin Decks is one greater than the number of holes drilled into the F-1013 longerons using the template. Go ahead and match-drill that hole into the longerons.

29-9

  • Step 3: It is possible to violate the edge distance when match-drilling into the longeron. For example, if your longeron is not perfectly curved then the holes will not line up correctly. It's tough because you are match-drilling from underneath, but make sure that you are not drilling too close to the edge of the longeron. You can draw a line with your Sharpee at 3/16" from the outside edge of the lower flange and the color it in -- then use an inspection mirror when clamping onto the bracket below. If you can see any Sharpee through the holes then you are too close to the edge to match drill that hole.

29-11

  • See this FB Post on how to keep the skin and clamping block in place while bending.
  • See this FB Post on how to use two angle pieces to clamp the skin.

29-12

In the detail bubble for Figure 2, note that later you will be installing flush rivets into the side flanges of the F-1024E brackets. You should countersink for two AN426AD4 rivets into each of F-01042-L-1 and F-01042-R-1, flush on the aft side.

29-13

Consider Markus's write-up to ensure the edge distance is met: 

Step 1:
Match-Drill #40 the holes in the F-01069-L-1 & -R-1 Fwd Side Skins and the F-1040-L and -R Upper Fuse Channels common to the WD-1002-L and -R Upper Firewall Brackets.
Uncleco the Fwd Side Skins from the under the structure. This is not according to plans but makes it simpler to check the edge distance.
Mark the edge distance of 1/8” on the outside of the Upper Firewall Bracket with a Sharpie.



Mark the center of the middle flange of the Upper Firewall Bracket and the Upper Fuse Channel.



Use a small block of wood to hold the flange on the Upper Firewall Bracket tight against the Upper Fuse Channel.



Make sure the center lines still align. Also, make sure that the edge distance lines cannot be seen through the holes of the Upper Fuse Channel. Match-Drill #40 the holes and Cleco as you go.



Match-Drill #40 the holes in the fwd side skins and the F-1041-L and -R Lower Fuse Channels common to the WD-1003-L and -R Lower Firewall Brackets. 
Use the same technique as described above.

29-13 step 3

Separate from Markus's write up above, when I came to drill the four rivets holes on page 29-13 step 3, I had problems which resulted in me having to make F-1013L again. It is difficult to get a clamp in there as detailed in the instructions, and still have space to get the drill in there. So I used a different method which I later verified with Vans as being ok.

Once the #40 holes are drilled from the skin into F-1013, and generously cleco'ed, the F-1013 will be nicely flush with the skin. Then while holding the F-1013 against the F-1001J gusset, drill the rear most #30 hole up from the gusset into the longeron.

Later once the skin is removed (29-14 step 8), the single hole in F-1013 can be cleco'ed, the F-1013 clamped to the gusset and the remaining 3 holes drilled.

29-14

  • Step2
    Instead of drilling F-1013 through the F-1039J jig at this point, it is much easier (and more accurate) to wait until the F-1013 is removed and then drill these holes on the bench. I found it is more important to ensure that the F-1039J jig edge is parallel to the edge of F-1013 than to use the #30 rivet holes to set this. If those #30 holes are slightly off, the error will be magnified in the position of the rudder assembly bolt holes. If the F-1039J is not parallel to F-1013, remove all but one cleco, then make the jig parallel, then drill the most aft of the bolt holes. Cleco this hole and drill the remaining bolt holes.
  • Step 5
    When match drilling from the F-1001B angle into the WD-1002-L / WD-1002-R firewall steel brackets, be aware that it's easy to violate the edge distance in the steel bracket (2 x D, measured from the center of hole). The remedy is to temporarily install a bolt into the engine mount hole to pull the bracket into place and to use a clamp to move the steel bracket to increase edge distance.
    See this build log


See also FB post 4/17/2022
See also FB post 3/27/2023

Also consider Markus's write-up for this page: 

Step 4:
Match-Drill #30 the holes in the lower flange of the F-1040-L and -R Upper Fuse Channels into the WD-1002-L and -R Upper Firewall Brackets.
Mark the edge distance of 1/8” on the outside of the Upper Firewall Bracket with a Sharpie.



Use a small block of wood to hold the flange on the Upper Firewall bracket tight against the Upper Fuse Channel. Use a small metal plate between the clamp and the upper and lower flange of the Upper Firewall Bracket to push the flanges in.



Make sure that you cannot see the edge distance lines through the holes of the lower flange of the Upper Fuse Channel. Match-Drill #30 the holes. Cleco as you go.

Step 5:
Match-Drill #30 the holes in the F-1001B Firewall Upper Angle into the F-1040-L and -R Upper Fuse Channels and WD-1002-L and -R Upper Firewall Brackets.
Use the same technique as described above.
Match-Drill #30 the remaining holes aft of the firewall brackets common to the firewall upper angle and the upper fuse channels. Remove the Cleco from the aftmost hole common to these two parts and final-drill the hole #30 on both sides of the aircraft.

Step 6:
Match-drill #30 the holes along the upper and lower flanges of the F-1041-L and -R Lwr Fuse Channels into the WD-1003-L-PC and -R-PC Lower Firewall Brackets.
Make a mark on the Lwr Fuse Channel and Lower Firewall Bracket as long as the Fwd Side Skin is still Clecoed to the structure to make sure those parts align properly once the Fwd Side Skin is removed.
Mark the edge distance of 1/8” on the outside of the Lower Firewall Bracket with a sharpie.
Use a small block of wood to hold the flange on the Lower Firewall Bracket tight against the  Lwr Fuse Channel. Use a small metal plate between the clamp and the upper and lower flange of the Lower Firewall Bracket to push the flanges in.



Make sure that you cannot see the edge distance lines through the holes of the upper or lower flange of the Lwr Fuse Channel. Match-Drill #30 the holes. Cleco as you go.
  • Step 9: It's not clear, but when countersinking the #40 outside holes on the F-1013 Forward Fuselage Longerons, you should do all of them -- the #40 holes common to both the F-01069 Fwd Sdie Skins and F-1070 Mid Side Skins. Additionally, do NOT countersink the #30 holes on the F-01004K Center Section Side Plates; only countersink the #40 holes on these pieces.

29-15

29-16

  • Step 5: The most forward rivet on the bottom part of the lower firewall bracket is hard to reach. Some trim the top flange of the bracket to allow for using an offset rivet set, others use a large 16" Knipex pair of pliers with a makeshift die for the manufactured head. See this FB thread.

29-17

  • Some of the holes around the door opening are left open. You will cleco the door to the frame using those in order to 1) get the correct position of the door within the insert and 2) lock in the airframe shape into the door when bonding the door shells together. These blanks allow you a place to insert the clecos to hold it. Once the doors are bonded and door install complete, you then rivet those remaining. See also this FB thread.

29-18

  • On this page, do not rivet the skin holes for the F-01088-L-1 and F-01088-R-1 since you will not be installing those pieces until later.

29-19

  • If you are using the Aerosport interior side panels, don't install the VENT-0004 knob. The Aerosport side vents need a different extension lever which can only be attached once the panel is in place.
  • The kit may not include the nylon washers 5610-90-31. They can be obtained at your local hardware store as #10 Nylon washer.

29-20

  • Don't rivet the forward cabin floor to the center tunnel walls if you are getting electronic injection (SDS or EFII), or intend to install access covers to the side of the tunnel as the rivet holes will be needed. For the SDS pump shelf, you will have 5 stock rivets counting from the front, then the next 11 are to be left out for the fuel pump shelf. For the access covers, see the instructions from Airward.

29-21

  • Around the start of 2021, Vans updated the design of the landing gear mount to address some concerns with cracking. If you received your fuselage kits after this, you received the SB-00007 kit with the fuselage kit. There's no explanation on how to apply this SB to a kit in construction.
  • SB-00007 has been partly applied to new parts in the kit. In particular, the landing gear mount and the forward spar designs have been updated, but the side skins have not. The SB calls for enlarging some holes in the forward spar, however, those holes are already the correct size in newer kits (several 1/4in holes, and one 5/8in on each side). The SB includes two templates (VA-274 & VA-275) and two drill guides. These are not needed at all. The part of the SB that involves drilling into the side skins (F-1069, F-01004K & F-01004T) using the drill templates VA-277 & VA-278 is necessary.
  • All of this is covered correctly in the plans. The instructions that come with SB-00007 do not need to be followed at all. If you have any doubts, please call Van's tech support.
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