Firewall - related
The firewall is a sheet of thin stainless steel which forms the most forward bulkhead. It serves to isolate the cabin from the engine compartment with a fireproof barrier. In teh quickbuild kit it is pretty much complete and attached to the longerons by heavy steel brackets and rivets. The Quickbuilder has to finish the firewall with the following tasks -
(2nd August 2006) The first image below shows the firewall from
the front , with the recess on the floor. Image 2 shows, from the cabin
side, the recess installed temporarily, with the grey floor cover with fluted
slots for cabin heat delivery. Note that this cover attaches to the recess
with platenuts and screws. Image 3 shows these platenuts installed. Image
4 shows what happens when you drill a hole in your finger - I must be more
careful! I was holding a reinforcing plate on one side and drilling blind
from the other - stupid. Image 5 shows the positions of four key holes which
need to be cut in the forewall - one large 2" hole for heated cabin
air, and three smaller holes for throttle, mixture and carb heat cables.I
measured carefully rom teh drawing, and used a 1/8" drill to make pilot
holes in the proper locations. I then used a 2" holsay to cut the cabin
heat hole, and my nifty hole-cutters to make the other holes. Image 6 shows
the result. The next job is to make a small plate to reinforce the firewall
where metal fittings need to be attache to carry brake fluid through from
one side to the other. Image 7 shows this plate clecoed in place at the
FRONT. Eventually it goes in the back. I match-drilled all 3/32" rivet
holes before drilling two 1/8" pilot holes where the fittings will
locate.
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Front view |
Rear view - cover/recess |
Recess |
Ouch! |
Holes to cut |
Holes cut |
Brake plate |
Match-drilled |
The hole-cutter was then used to make two 7/16" holes at these locations (see image 1 below). When both holes were cut I removed the plate and used the pop-rivet dies to dimple the 8 firewall rivet holes (image 3). I then countersunk the plate on one side, primed, and used the gun to shoot the rivets in place (image 4). Image 5 shows this plate positioned from behind. Imahes 6 and 7 show the central rudderbar support plate riveted into position. You must do this BEFORE riveting the recess into place for access reasons.
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Cutting 7/16" holes |
Complete |
Dimpling firewall |
Finished (front) |
Finished (rear) |
Rudder bar support |
And from the front |
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