Title: Longerons in process
Back a couple of weeks ago, I had a go at the longerons, and while the shallow curve came out fine with the beuller dies, I wasn't happy with the sharp downward bend. In a previous log entry, I think I included a photo, but basically, the bend radius was too big or maybe just too far aft and it seemed like I would have potential problems with fitment of the F-721B canopy deck. I have a theory that a lot of the canopy frame fitment issues that people complain about may be caused by variation in the longeron bends, so I made the decision to redo the longerons. I'm going to try my best to get these dimensions as perfect as possible, with the hope that I'm making it easier on myself on down the road. I originally thought that I could source the raw stock for the longerons here locally, but after calls to several parts houses, I struck out. There are literally piles of the correctly dimensioned structural angle down at the Yard ($3 a pound!) but they couldn't verify what alloy it was. I went down and took a peek and I'm pretty sure it was 2024-T3. Van's calls for 6061-T6, so that was out. The other parts suppliers here in ICT all had it, but not in the correct length without having it shipped in. I'm sure that someone here in town has a big pile of this stuff sitting on a shelf, but I couldn't find it. Bottom line, I ordered 4 sticks of new stock from Vans. I only need two, but they were cheap & shipping is a killer so I wanted a couple of spares. I will sleep easy knowing what I have in my airplane. The first order of business today was to find a better way to secure the angle in my vise. My previous problems with the radius on the sharp bend were likely the result of the hardwood jaws on my cheap vise deforming during bending, so I fabricated new jaws out of aluminum bar with nicely radiuses corners. Bent the first longeron using the bueller dies, and took a LOT of time to make sure that it was as perfect as possible to the template and the F-721B. Drilled it to the F-721b, then clamped it back into the vise with various bar stock that was also radiused as needed and c-clamps to make sure it wasn't going anywhere before completing the sharp downward bend. Checked the bend a couple of times against the side skin, and when I had it where I wanted, clamped it back in the vise again and completed the 17* twist with a couple of crescent wrenches, measured with a digital protractor. Completed the shallow curve on the second one, but had a little hiccup along the way. Was cleaning up the tooling marks along the curved edge of the F-7721B when I caught the aft tab on the polishing wheel and bent it. It's meant to be a pretty solid piece, and when I bent it back, I developed a 1/8" crack in the radius. I could stop drill this and move on, but that radius provides some structural integrity and its a cheap part, so I ordered a new one which is supposed to be here in a couple of days. Since that part gets match drilled to the longeron prior to making the sharp downward bend, that put he brakes on the longeron work for a couple of days. disappointing that I wasn't able to get these both knocked out in one session, especially with how well the first one turned out, but it was a good day overall and I'm pretty happy with the progress so far. My rivet partner is out of town, so I'm waiting until she comes home to rivet the belly skin on the center section, which means that I'm at a standstill on the big fuselage chunks for a few days. Until then, I'll read ahead in the instructions and see if there is anything else that I can work on for the next few days.


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