Wire Edging

[M Lightsey]

I was talking with Kevin this afternoon about finishing and reinforcing the edges of the cockpit sheetmetal and I dredged up these pictures that I took while restoring Bob Lock's CommandAire. Rather than just send them to Kevin, I thought I'd post them for anyone else who might find it helpful and while not a Hatz, the method is exactly the same. These first 3 shots show the edge being progressively tipped up to 90 degrees.
Mark

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[M Lightsey]

Next the reinforcing wire is formed. I used 1/4" steel. You could use stainless if you wanted, but it would be a lot harder to work with. Get the shape as close as you can so you're not fighting it for the whole process. Hold it in place with clamps and start working the aluminum down with a hammer and dolly. Go a little bit at a time, you don't have to beat it to death.

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[M Lightsey]

Keep working it and use a pair of smooth pliers to tuck in the last little bit. Cover it with a length of 3/8" air hose following with some pipe insulating foam. You've got a reinforced cockpit opening that you can put some weight on that looks pretty cool even if you don't get around to installing the coaming for a while.
Mark

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[M Lightsey]

Last Ones

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[alvinsager]

Hi Mark,
Thanks for the post. Really nice work. I was wondering what alloy you used.
Al

[dougm]

Beautiful job! what is the width of the flange you are bending?