Note: the top FWD skin and formers 1 R/L are not match drilled and slightly more difficult to install. Take your time to ensure good fit.
1.Un cleco the side skins forward of former 2
2.Un cleco top skin at former 2 R/L
3.Slide P-F-TC-top fwd skin (P6402 qty 2) in between side skin and longeron then cleco along former 2 through top skin and formers 2R/L
4.Test fit former 1 R using plans sheet P-F-TC-tail cone top/formers as a guide noting that the former will sit approx. 1/16 (1.5 mm) above the top forward skin. (This is to help reduce the “sharp” edge of the skin in this area which is exposed with the canopy open.)
NOTE: For a good fit of former 1 R/L you will likely need to “adjust “the angle of the “flange” so it meets the skin and produces a “perfect” fit. Use wide jaw pliers (with jaws taped for part protection) or a 1 inch wide wood block with a “slot” cut into it to slide over flange and bend the desired direction. You may need to add or reduce degree of “fluting” so former stays “flat”. Take your time here so you get a nice looking skin former install!
5. Trim former 1R where it meets former 2 at top. (See below)
6.Line former 1 R up with top fwd. skin centerline and the noted 1/16 (1.5 mm) forward and drill the topmost hole
7.Continue fitting and drill as you work your way down former #1 and the top fwd. skin.
8.As you near the bottom of former 1 tuck the flange below side skin as shown below and clamp FWD top skin side skin former and longeron in proper position (maintain side skin and longeron hole alignment). Top FWD skin front corner should line up at top of side skin/loneron.
9.Repeat steps to fit former 1R
10.When finished verify the outer edge of top longrons are 28” (711mm) inch apart
11.and clamp a scrap of wood or angle across to maintain distance if needed.
12.Starting at former 2 and moving forward drill and cleco #30 along top longeron on both sides
13.Drill the “lap joint of former 1L to former 1R #30 and cleco
14.You can now up drill the forward top skins and formers 1, the side skins along top fwd skins and the top “lap joint” of former 1 R/L to #30
