Bulkhead Construction

Section 5.1    Bulkhead Preparation

Prior to June 10, 2002     -  Chapter 5.1.1 - "Bulkhead Placement"                                      FB   

Most of this chapter was done as part of our Fast Build Fuselage.  In fact, the bolt hole in the nose that is referenced in this chapter for all of the measurements was already removed and the nose closed up prior to taking delivery.  Of note, the canard bulkhead is 39 1/2" aft, the instrument panel is mounted 59" aft, and the firewall is 157 1/2" aft.  The gear bulkhead is then 7 1/4" forward of the firewall.

The only thing referenced in this section that was not completed was the mounting of some bubble levels along an across the fuselage to verify that level is maintained while working in it.

Section    5.2    Install Bulkheads

Prior to June 10, 2002     - Chapter 5.2.1 - "Preliminary fitting of Parts"                              FB   

The section completed as part of Fast Build Fuselage, where bulkheads and wiring ducts were dry-fitted.

Prior to June 10, 2002     - Chapter 5.2.2 - "Bonding Procedures"                                         FB   

The section completed as part of Fast Build Fuselage, where bulkheads where fastened with structural adhesive.

June 11, 2002     - Chapter 5.2.3 - "Glassing Bulkheads"                                                        FB    

In this section the non-flanged side of the bulkheads are fastened with 3" of bid cloth.  The engine bulkhead was done as part of the fast build kit.  We glassed the back side of canard bulkhead while we were in the Head Start Program.

Canard Bulkhead Reinforcement

Back at the ranch, we glassed the front of the gear bulkhead the same way.  This is probably as good a time as any to mention that this is not as easy as it looks.  There's nothing formidable about it, to be sure, but it's not all peaches and cream either.  Once you start working a layup, you pretty much need to finish it, and they don't always just lay down nicely for you...

Gear Bulkhead Glassing

Prior to 10 June, 2002     - Chapter 5.2.4 - "Engine Bulkhead"                                                  FB  

Completed as part of fast build kit.

2002     - Chapter 5.2.5 - "Engine and Gear Bulkheads"                                                             FB  

The main layup in this section is a 7"x39" piece of triax between the gear bulkhead and the firewall, on the floor to support it since there's no foam here.  It's a pretty simple process, it just absorbs a bunch of epoxy, is really awkward to work with, and has to go over the conduits on the floor (under the gear legs).  Overall, a good time to practice your relaxation breathing.  Once it cured, we cut a 1" hole in both conduits for wiring and the like (the brake lines come out here, for example).

2002     - Chapter 5.2.6 - "Miscellaneous Items"                                                                              

This section references Chapters 5.2.8 (installing the battery bulkhead), 17.5 (installing the oil cooler), and the appendix (installing the landing light).  All of these items were started during our Head Start trip.

Battery Tray

Landing Light and Oil Cooler Inlet

Oil Cooler Internal Detail

Oil Cooler Detail - Tongue Depressors to Conform Shape to Fuselage

Prior to June 10, 2002     - Chapter 5.2.7 - "Canard Bulkhead"                                                    FB   

The section completed as part of Fast Build Fuselage, where bulkheads where fastened with structural adhesive.

June 13, 2002     - Chapter 5.2.8 - "Battery Bulkhead"                                                                         

As seen in the above photo, we installed the pre-molded battery bulkhead during the Head Start Program.  This involves the usual light sanding of the bonding surfaces, and in this case attaching the tray with structural adhesive.  We pop-riveted the tray down while it cured.  All that is left is to mount the battery clamps (aluminum brackets) to this piece after we've selected (and fitted) a battery.  The instructions are pretty weak here, showing various non-provide brackets with insufficient dimensions and no indication how they are meant to restrain a battery, so we'll be looking for some flying examples.  I've seen other builders do a lot of different things, but I'd just as soon find something simple.

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