BENDING IN FUSELAGE SIDES
from Doug MacBeth, #647

 

Once the fuselage sides are positioned vertically on the jig and you have the cross tubes in place from station 2 to 4 (square the center and lock it all in!), you're ready to bend the sides to form the nose and the tail. Here's how we did that:

Spend plenty of time determining the EXACT spot you wish the bends to occur. The Universe will only remain in balance if you end up bending the two sides of your fuselage symmetrically. Use a straight-edge on the drawing to extend the horizontal lines of the center section. The exact points where the fuselage bends inward will appear, settling all arguments and winning all bets.

Have blocks in place on the jig to form stop points exactly where you want the tubes to be. Otherwise you may over-bend and kink the tubes. Also, have additional blocks ready to nail down into place once the tubes are in position.

Clamp a large square next to the stop block to insure that both the top and the bottom of the fuselage side are evenly bent.

Go to a larger torch tip (wider flame) and preheat the entire area of where you are going to make the bend.

Once you've put some heat into the area, play the torch vertically at the points of the bends. Work the torch around back and front of the tubes to heat the points to a cherry red. Do both top and bottom, not spending too much time on either one. Rule of thumb: count to three and move! Later on, you'll get a feel for the color of the steel and will know when to go to the other cluster. KEEP THAT TORCH MOVING!

Have someone putting slight pressure on the end of the fuselage in the direction it's suppose to bend - BUT DON'T FORCE IT! The tubes will bend when they're ready. The idea here is to heat the point of the bend all the way around until the bend starts to occur, then maintain the nice orange-red color all the way around the tubes in two places at the same time. Piece of cake!

The tubes will suddenly begin to bend. The person at the end should simply maintain some pressure to move the tubes along. Once the tubes are at the stop you placed earlier (and lined up vertically square with a large square clamped at the right spot) then withdraw your heat to let it all cool while holding the tubes against the stop.

Nail down the last holding blocks to keep it in place.

Repeat as needed around the fuselage until done.

To celebrate, turn the shop radio up loud and sing along to "Stairway to Heaven" as soon as it comes on! "Bad to the Bone" is a suitable substitute.


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