Notching Steel Tube at Complex Intersections |
||||||
I started nothing at the aft end and worked forward. When I came to the big 7/8" diameter crossmembers, I encountered what I call my first "complex" intersection -- where two tubes came together at the longeron. I wasn't sure how to handle it, then I found a help video on the EAA web site which demonstrated a technique where you make a paper template, and use that to mark the cross-member where it needs to be cut. In this case, the crossmember on the right was straightforward to notch. Then I made a paper template for the left. Once I had the paper template where it fit against the right crossmember and longeron properly, I used the paper template to mark the left crossmember with a Sharpie. Then I cut the left cross member using a Dremel tool and angle grinder. |
||||||
Notice how radical the left crossmember notch is.
|
||||||
From another angle. | ||||||
Just by itself.
|
||||||
But both crossmembers fit against each other and the longeron real nice. | ||||||
The forward 7/8" diameter longerons transition to 3/4" diameter just aft of the cockpit area. The 3/4" tube slides right into the 7/8" tube. But per the plans, you have to splice the 7/8" tube with a 30 degree cut 45 degrees off the veritical. To do that, I made another paper template, then used that to mark the 7/8" tube, then cut the tube using the Dremel tool and angle grinder. | ||||||
Here is the result: both the forward top and bottom longerons. | ||||||