Jessen RV-10 Tailcone Page 4

Page 10-4

Step 1. In this step you fabricate the F-1010A from a piece of AA6-125 x 1 x 1 aluminum angle stock. Cut it to length, then cut in on one edge slightly, 5/32, so that there remains one edge longer than anything else.

11/14/05 - 30 minutes Bandsaw

Step 2. First deburr the F-1010 bulkhead, which means all the holes and edges and crevasses. Then take the F-1010A, on the longer of the two sides away from the bend, draw a thin line down 1/8 inch from the top, so that when you fit the piece it sticks up proud of the top edge of the F-1010. Use C-clamps to hold it in place. Mark one of the outside holes. Mark the other holes for kicks. Take it off. Make a punch hole in the middle of your mark. Put it under your drill press and drill a #30 hole. Put it back on the F-1010, cleco it, line up the other hole marks and make sure the marking line is still correct, then after securing it, start at one end and proceed to finish match drilling. Make sure the first #30 is also match drilled.

11/14/05 - 2 hours Clamps

Step 3. Not much here, just some tedium. Deburr the F-1008 left and right pieces, as well as the F-1085 Cable Bracket that guides the rudder cables. It says to flute if necessary. I could not determine if it was necessary. I will see how the holes line up using a straight edge and also with the skins. I think that's about the only way. Match drill common holes as directed.

01/06/06 - 1 hour

Steps 4 & 5. Same as Step 3, but this time for the F-1007 left and right pieces. For Step 5, take the Unibit and drill out the holes indicated to 5/8" for the rudder cables to pass through.

01/07/06 - 1 hour

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