Thursday, April 26, 2012

A routine skin replacement:
First I fixed the airplane in a support, to keep the fuselage supported while I removed the section of skin.
Next, I fit the new skin to the old holes from the removed skin.
Third, after priming the new skin (this is a floatplane) I convinced my younger brother to climb into the back of the fuselage to buck the rivets.
He had had enough, so I finished the last part of the row myself, which I could reach through the inspection hole.

The finished product.

The hardest part of this installation was convincing my brother to climb into a dark green hole. 
Buying this skin new from Cessna would cost over $200, but I made this skin for under $50
The only tools needed were: Tin snips, 4" hole saw, a table top, and a drill with #30 and #40 drill bits, and a brake to bend the edges. The skin can be rolled by hand on the table top*, and turned out better than the original time I tried to roll it.
*An experienced mechanic with sheet metal experience rolled mine, since I was unsure of the method. But it turned out perfect.


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