Aft Fuse Splice Plates

More splice plate creation. Here's the lower vertial splice plates as provided with the kit.

The edges have to be chamfered so it fits snugly into the longeron with the other clips. I measured 1/8" from each edge on the chamfered side to make a "file-to" line.

The part gets clamped to my handy-dandy 2"x4" jutting out from one of my table legs.

After filing down one edge.

The view from the end - a nice 45 chamfer.

Both edges filed down. The lines folow the marker lines a bit closer than it appears in the picture.

The other end.

Both plates filed and ready for bending.

The black lines are the bend tangency lines and the blue line is a measurement reference line.

I clamped the plate down to the bench with a block of wood and bent it to the proper angle.

Came out pretty good - about a 1" radius as called for in the plans.

Both clips bent and filed. They just need sanding to remove all of the "tooling" marks.

The next set of splice plates to file and bend.

According to this picture they are the lower horizontal splice plates. Just in case you didn't believe me.

The view of the chamfer - done the same way. The camera angle makes it look like it hasn't been done. It has, trust me.

Both plates filed and ready for bending.

Because the ends of the part are angled there isn't a good reference point for measuring the bend lines.

So I just set the part on the full size prints and marked the reference line.

Both lower horizontal plates bent.

Now that all of the splice plates are fabbed, its time to start cutting access holes and rudder cable slots in the aft fuse skins.

I started out by marking the slot, access hole, and bend line on the skin. This is easy to mark now before the skin is bent.

The bend line and the longeron end lines.

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