RIGHT SIDE PANEL

It was my original intent to make a small box-like cover to protect the lower aileron pulleys.  However, when I got down to it I discovered there is a lot going on in that little corner.

So I decided to make a larger panel that spans the frame-members on each side of the aileron cables. 

Like so:

The cut-out is for the lower aileron pulley.  I will be fashioning a cover plat for this opening that will include a bump out for the pulley itself.  It will be fastened to the panel with screws and nut plates to facilitate removal for annual inspections. 

I have been practicing working sheet metal with the collection of hammers I have on hand and using the center of a roll of duct tape for a pattern.  The final product will be tear-drop shaped rather than round.  I will concentrate on that cover once I have the side panels installed on both sides. 

REAR PANEL

The rear panel, the one that covers the opening into the tail cone,is complete.  The first step, as outlined earlier, was to make a "rough sketch" template.  Thusly:

As you can see, it is multiple layers and pieces all taped together.  The challenge of multiple compound curves dictated attempting to match them one at a time.

Once I was satisfied with the rough sketch, a smoother version was produced:

Yes, the little stick of tape actually has a function.  This template proved so close that I decided to go ahead and fabricate the panel.

And this is the final result.  It required a small amount of trimming with a file and the Dremmel, but it is a perfect fit. You will note that the holes for the mounting screws have also been drilled.  I located these holes by painting the existing mounting brackets with black paint and then pressing the template against the brackets.  The result was a perfect, and perfectly aligned, outline of the bracket.


 The next step is to build the templates for the panels that will cover the aileron pulleys.

Well, not quite...throw in a seat and tuck the required papers in a visible location, and...

:)