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page was updated on
10/04/2008
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Mounting Brackets |
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| 1/9/07- I made my
brackets out of .040" 4130 plate that I bent on my 36" Harbor
Freight brake that my wonderful wife got me for Christmas. The
actual dimensions for the brackets are 1 1/16" long, 0.75" wide,
5/16" high sides. I bent them in strips of 4 and then cut them
on my bandsaw. I cut the angled sides with tin snips, but they
could also be trimmed on the bench grinder. Grind a slight
curve into the sides and they are ready to fit the fuselage tubing. |
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| 1/9/07- After
bending and cutting the 42 floorboard brackets, it was time to drill
each one for a nutplate. I used the K1000-08 (MS21047L08)
nutplates from ACS. |
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| 1/9/07- I used the
rivet to hold the nutplate in position while I drilled the 2nd rivet
hole. |
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| 1/9/07- With my
tablesaw, I made 2 cuts in the block to match the sides of each
bracket. Then I countersunk each rivet hole to accept the
Cherry flush head pop rivets from Genuine Aircraft Hardware Co.
The micro-stop countersink is from ACS. |
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| 1/9/07- Here are the
completed brackets. |
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| 1/9/07- Basically, I
used 3 different jigging methods to hold the brackets in place while
I tack welded them. Here, I drilled a hole through an
aluminum strip and bolted the bracket to it. |
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| 1/9/07- The second
method I used was clamping the the bracket to my leveling strip
using vice-grips. |
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| 1/9/07- The
object when jigging the brackets is to keep them all in the same
plane so that the floorboard will sit flat on them. |
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| 1/12/07- The
floorboard brackets on the right side are now all tacked in place.
This is the bracket layout for floorboard #1 at the front rudder
pedals. |
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| 1/12/07- This is
bracket pattern for floorboard #2 just behind the landing gear
truss. I will install the nutplates after I have finish welded
all the brackets. |
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| 1/12/07- This is the
smallest floorboard area just in front of the rear rudder pedals. |
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| 1/12/07- This is the
bracket pattern for the floorboard just behind the rear rudder
pedals. |
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| 1/12/07- This is the
bracket pattern for the last floorboard #5 in the pilot cockpit.
It ends even with the rear of the pilot's seat. |
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|
Floorboards |
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| 1/12/07- I made
my floorboards out of .032" 6061 aluminum. They are 6" wide
with a 5/16" flange for stiffness. This is floorboard #1 of 5
just behind the front rudder pedals. |
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| 1/12/07- This is
floorboard #2 in the forward part of the passenger cockpit. |
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| 1/12/07- Floorboard
#3 is the shortest and is notched for the master cylinder brackets. |
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| 1/12/07-
Floorboard #4 provides foot support for the pilot. |
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| 1/12/07- Finally,
floorboard #5 covers the rear part of the pilot's cockpit and ends
even with the seat legs. These floorboards are the lightest
version that I could think of. I don't plan to cover any more
of the cockpit floor since anything that drops into the bottom of
the fuselage should work it's way to the center of the belly anyway.
I'm going to run my sheet metal on the belly to the rear of the
pilot's cockpit. |
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| 1/16/07- Finished the
floorboards on the other side. To get a nice professional edge
on the .032 aluminum, I cut them at least 1/16" outside the lines,
then sanded them to the lines and rounded off the corners on my 12"
disc sander. Finally, I hand sanded the edges with emery
cloth and they came out smooth with no sharp edges. The emery
cloth sands the 6061 T6 very quickly. |
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