I laid out the jig on top of a full size drawing of the fuselage using wooden blocks. The same method as I used in the building of the wing ribs
I laid out a straight line on the table and used this to mark the top longeron (the top straight edge). I cut and fitted the top longeron and carefully fitted the curved bottom longeron in between the jig blocks. The braces were cut to size and sanded to fit
After the arrival of the plywood I glued and nailed the gussets. The nails were just to hold the gussets in place whilst the glue dried. When the glue was dry I pre-shaped the tailpost using the dimensions obtained from a Visio drawing
These were set around a center line on the table. I also built up another set of the raised blocks to fit the top side of the fuselage when the fuselage sides were fitted into the bottom set of blocks. I made up a temporary firewall and squared up the fuse sides to it using G clamps. The fuse sides were fitted into the raised blocks. Some positions required inside blocks as well to stop the fuselage form becoming too narrow at that point. Two additional blocks were fitted top and bottom in the 24 inch section to stop the fuselage bowing out when the tail was pulled together. I also made up some temporary squares. These were screwed to the table and clamped to the upper longeron to maintain the square of the fuselage sides. With the fuselage now in its final position and with the firewall and both seat back positions checked diagonally for square, I made up the seat backs from plywood. I also glued the ½” x 1” spruce to the front of the front seat. I glued both seat backs to the upright braces and left overnight to dry
When dry I removed all the raised blocks and turned the fuselage over. I then installed the top cross braces and the seat back top braces. I left the raised blocks in place in the 24 inch section while the stiffeners were fitted and set
The seats, turtle deck and instrument panels are next.
I decided to make the turtle deck height the same as the cowling covers. This meant I had to work out the dimensions of the stringer supports. I again used Visio to produce a drawing of the four supports.