The bending brake went into action for the first time today. I'm using 0.050" 6160-T6 aluminium sheet for the seat bottoms. This was cut to shape using the bandsaw and then the rear edge folded up to give additional strength. The front edge was folded up slightly to fit tightly against the fuselage cross member. A cut out was made to allow the rudder cable to pass through. 1/8" holes were drilled in the tabs and then match drilled into the seat bottoms. The holes in the tabs were then opened up to 6mm and clinchnuts installed with M4 threads. Clinchnuts have a bad reputation as they can sometimes loosen and spin in the mounting holes making it impossible to remove the screws but they are easy to install and provide a cheap solution for creating a blind nut. I solved the problem of them ever spinning by tack welding the flange of each clinchnut to the tab. The holes in the seat base were then drilled out for the M4 stainless steel machine screws and the seat bases installed.
The left door frame hinges were then fabricated from 0.090" 4130 steel. The door was positioned in the door frame using clamps and spacers. The frame hinges were then clamped to the hinges already welded to the door and tack welded to the door frame. The pivot hole was then match drilled through from the holes in the door hinge to frame hinge. Finally the door was removed and the door frame hinges final welded
The bending brake went into action for the first time today. I'm using 0.050" 6160-T6 aluminium sheet for the seat bottoms. This was cut to shape using the bandsaw and then the rear edge folded up to give additional strength. The front edge was folded up slightly to fit tightly against the fuselage cross member. A cut out was made to allow the rudder cable to pass through. 1/8" holes were drilled in the tabs and then match drilled into the seat bottoms. The holes in the tabs were then opened up to 6mm and clinchnuts installed with M4 threads. Clinchnuts have a bad reputation as they can sometimes loosen and spin in the mounting holes making it impossible to remove the screws but they are easy to install and provide a cheap solution for creating a blind nut. I solved the problem of them ever spinning by tack welding the flange of each clinchnut to the tab. The holes in the seat base were then drilled out for the M4 stainless steel machine screws and the seat bases installed.
The left door frame hinges were then fabricated from 0.090" 4130 steel. The door was positioned in the door frame using clamps and spacers. The frame hinges were then clamped to the hinges already welded to the door and tack welded to the door frame. The pivot hole was then match drilled through from the holes in the door hinge to frame hinge. Finally the door was removed and the door frame hinges final welded
