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1956 Cessna 182

Some trimming on the inside of fuselage still required prior to paint on the inside and paint on the hockey sticks. But finally feel like I have some very visible progress!

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Inside of that bulkhead.

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Drummer79 said:
Loving this thread :smokin:
For those not in the know though, (me) what are the hockey sticks?
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The unpainted angle that is exposed there, it has a bend in it and continues up to the next bulkhead forward. Slightly has a hockey stick shape. there are hot item on these for being damaged. I think the new price on them From Cessna is something insane like $6k. Luckily there are now some lower cost aftermarket solutions on damaged ones.

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Bacho said:
The unpainted angle that is exposed there, it has a bend in it and continues up to the next bulkhead forward. Slightly has a hockey stick shape. there are hot item on these for being damaged. I think the new price on them From Cessna is something insane like $6k. Luckily there are now some lower cost aftermarket solutions on damaged ones.

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5/32" on the rivets horizontally through the hockey stick aft of the bulkhead, 1/8" vertically.
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You'll need to countersink the skin a little deeper to account for the bigger rivet head. I've seen the one rivet aft of the stab hinge at the aft end shear quite a few times with no visible damage inside or out, as in the rivet head and tail looked perfect but I put a screwdriver between the skin and stick and can spread them apart. I usually install a structural screw there rather than a rivet. I think an AN5258r6 or 8 will do it.
 
YJLOPES said:
You'll need to countersink the skin a little deeper to account for the bigger rivet head. I've seen the one rivet aft of the stab hinge at the aft end shear quite a few times with no visible damage inside or out, as in the rivet head and tail looked perfect but I put a screwdriver between the skin and stick and can spread them apart. I usually install a structural screw there rather than a rivet. I think an AN5258r6 or 8 will do it.
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Good to know, I’ve been wondering about how I’m gonna buck that particular rivet anyways. A screw will solve that problem.
 
Bacho said:
Good to know, I’ve been wondering about how I’m gonna buck that particular rivet anyways. A screw will solve that problem.
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I like an AN960xxL washer, and a tight tolerance MS21042 nut. It all fits in there really nice, will tolerate the vibes better than a rivet, barely weighs any more than a rivet, and no one will ever know unless it's some idiot like me that never works on anything else.
 
Got most of the paint stripped off the back calf of the fuselage. Already found multiple dents filled in. If I ever do this again, I think paint comes off first thing.

Been working on fabricating the replacement skin at the tail cone. Its .050” and I believe the thickest skin on the airplane. This is my first time trying to use my new slip roll. I’m pretty sure this piece will be scrap and I’m gonna start over. The stock skin has a very pronounced flat spot on the bottom with two bins, make a V shape at the end.

I could close up the metal around the sides of that bulkhead pretty easily, but I don’t think I could close up the arch at the bottom.

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When I left the shop yesterday I was pretty convinced that skin would be scrap. Spent the morning working with it more and doing more head scratching with the slip roll. It now fits 100% better. I determined its probably too much for my roller. The ”corners” there are pretty much max adjustment on the roller.

Anyways, it now fits well enough to start drilling. It still has a good chance of getting scrapped but I would like to learn as many lessons as possible. It still needs some hand massaging at the very aft end.

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Do you still have the old skin? I can walk you through my methods if you want. I've built wings, fuselages, stabs, with no jogs that measured out perfect when I was done.

That particular skin is a bitch for exactly the reasons you describe, so I get the fight you are having.
 
YJLOPES said:
Do you still have the old skin? I can walk you through my methods if you want. I've built wings, fuselages, stabs, with no jogs that measured out perfect when I was done.

That particular skin is a bitch for exactly the reasons you describe, so I get the fight you are having.
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I still have both of the old skins. My method with this one is I have some pattern material that is a clear vinyl. I clamped/taped it around the old skin Traced everything out with a few reference points. I was able to center punch right through it to mark this skin. So far I’ve only put about a dozen holes in it, but it seem to work well. I’m more than open to other suggestions though.
 
Sigh, making the doubler for the very aft bulkhead and spot this difference. I had trimmed this new skin yesterday. Still have to determine if I still have edge distance there for that top rivet. It needs to be two times the thickness of the rivet away from the edge minimum.
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Good idea, the skin always looks better on the second try.

I've been working on a boot cowl for my cub. After ruining one I decided to make a pattern with .040" plexiglass or acrylic. Not sure what to call it but it was flexible and transparent. Saved me from ruining a lot of pricy 2024 sheet.

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Looks like this now.
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Getting any real real shop time in has been a struggle outside of maintaining transportation. That said, I’ve been trying to do something productive on this project every time I go into the shop, although that doesn’t make for much of an update most of the time.

Tailwheel rudder cables needed an extra hole in the belly skin. Managed to get those cut out and a layer of primer down inside the tail. I don’t know how I’m gonna buck these rivets going back on. I need to find a small helper.

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While the paint was drying I decided to blast the landing gear legs I bought. I also managed to straighten out the bent gear to where it matches quite well. I have some measurements from Cessna that I still need to verify. Took a little more than 30 tons to straighten out the leg.

Unfortunately, the blasting revealed more/deeper pitting than I had in mind. So I think they’re intolerance to blend out though, but this is gonna be a big job. The SRM will also require a peened surface when done.

I think there has to be a method to weld up pits in Spring steel, and then have them re-heat treated. Internets coming quite short on answers for that though outside of don’t weld springs.


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Bacho said:
Getting any real real shop time in has been a struggle outside of maintaining transportation. That said, I’ve been trying to do something productive on this project every time I go into the shop, although that doesn’t make for much of an update most of the time.

Tailwheel rudder cables needed an extra hole in the belly skin. Managed to get those cut out and a layer of primer down inside the tail. I don’t know how I’m gonna buck these rivets going back on. I need to find a small helper.

IMG_8032.jpeg



While the paint was drying I decided to blast the landing gear legs I bought. I also managed to straighten out the bent gear to where it matches quite well. I have some measurements from Cessna that I still need to verify. Took a little more than 30 tons to straighten out the leg.

Unfortunately, the blasting revealed more/deeper pitting than I had in mind. So I think they’re intolerance to blend out though, but this is gonna be a big job. The SRM will also require a peened surface when done.

I think there has to be a method to weld up pits in Spring steel, and then have them re-heat treated. Internets coming quite short on answers for that though outside of don’t weld springs.


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Just find another set. Not worth it if they are pitted. You might be surprised who can fit back there. We throw a sleeping bag or two in the bottom, and wiggle back there, even my fat ass…
 
Bacho said:
Getting any real real shop time in has been a struggle outside of maintaining transportation. That said, I’ve been trying to do something productive on this project every time I go into the shop, although that doesn’t make for much of an update most of the time.

Tailwheel rudder cables needed an extra hole in the belly skin. Managed to get those cut out and a layer of primer down inside the tail. I don’t know how I’m gonna buck these rivets going back on. I need to find a small helper.

IMG_8032.jpeg



While the paint was drying I decided to blast the landing gear legs I bought. I also managed to straighten out the bent gear to where it matches quite well. I have some measurements from Cessna that I still need to verify. Took a little more than 30 tons to straighten out the leg.

Unfortunately, the blasting revealed more/deeper pitting than I had in mind. So I think they’re intolerance to blend out though, but this is gonna be a big job. The SRM will also require a peened surface when done.

I think there has to be a method to weld up pits in Spring steel, and then have them re-heat treated. Internets coming quite short on answers for that though outside of don’t weld springs.


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I have the latest manual from Cessna on maintaining flat spring steel gear. I don't think there are any allowances for repairing pitting. It has the spec for shot peening them as well. If I were you I'd send them to Jim Hayden in Seattle and have him give them the once over. Whatever you do, don't say you're in the middle of the project and have time. Tell him you're AOG and need them back ASAP and he'll get you taken care of. I think it will run around $1000 last I heard.
 
I think I might’ve spoken to that guy about another set of gear I was looking at in San Diego.

$1000 bucks, i’m guessing that only covers arching if required? I guess I didn’t actually take a picture, but they have pretty widespread pitting in the area near the bend where it goes into the fuselage.

From the manual, I understood I could remove up to .063” between either side?
 
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inspect, re-arch, and shot peen as I recall. I think you may even get a yellow tag.
 
Thank you I confirmed that’s the same guy. I had previously talked to. I’ll reach out to him regarding the pitting and see what he says.
 
YJLOPES said:
inspect, re-arch, and shot peen as I recall. I think you may even get a yellow tag.
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I reached out to him. Sounds like he can fix me up. Thank you for the tip. I have an awful lot of time and retrieving this gear hopefully all that wasn’t wasted.
 
I hope you said you were AOG. Thats' the only complaint I've ever heard about him. He's a sharp old guy. When he goes west, there will be a lot of good info lost. The SEA FSDO goes to him with questions.
 
When you go out to the project with a simple task in mind. I will rebuild the fuel selector today, easy job and something accomplished. :shaking:

The fitting on the left is an oddball I think. -6AN to 1” x 14tpi UNS. Cessna has them $700 each. :eek: I have a couple more from a salvaged valve but they have some damage to the flare. I did find some tools that could clean them up though. I also have this fitting drawn in Fusion, might be a good learning experience to try and machine them on the mini mill.

I really hope I can clean up the valve housing. I have a tap for it on the way.

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