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F.8L Falco Construction Manual
25–1
Revision 4, March 1, 2002
Chapter 25
Fuselage, Preliminary Assembly
This chapter will cover the preliminary assembly of the fuselage. If you wish, you may do this
work simultaneously with the work covered in Chapters 22 “Aileron/Flap Assembly”, Chapter 23
“Wing, Preliminary Assembly” and Chapter 24 “Wing Assembly”. You should consider the
purchase of the instrument panel and instrumentation so that you can proceed with the
installation of the electrical system in the instrument panel. You will be unable to proceed with
the airframe wiring until the instrument panel is wired.
Kits on Hand
To do the work covered in this chapter, you should have the following:
Kit No. 808-3 Engine Mount & Equipment (or 808-1 or -2 as applicable)
Kit No. 809-1 Fuel Tanks & Equipment
Kit No. 811 Nose Gear & Equipment
Kit No. 813-1 Cowling & Equipment
Kit No. 817-1 Engine Controls & Equipment
If you wish to postpone the purchase of the cowling, you may do so. See discussion below on
“Cowling Supports Installation.”
Other Materials
To do the work covered in this chapter, you should have the following:
Nose gear tire and tube
Christen Inverted Oil System (if applicable)
Stainless steel for firewall
Firewall insulation (Fiberfrax or asbestos)
The firewall is made of .015” stainless steel. Asbestos or “Fiberfrax” ceramic paper insulation is
installed between the firewall and the fuselage frame. Fiberfrax is a relatively new material (you
can get it from Wicks Aircraft or Aircraft Spruce and Specialty), and it is very effective. Stainless
steel should be purchased locally—the exact alloy is not important.
Cowling Supports Installation
There are two ways to install the cowling supports—the aluminum angles bent to match the shape
of fuselage frame No. 1. If they are installed now—as we recommend—the firewall must be cut to
the shape of fuselage frame No. 1 and then the cowling supports are installed to match. Because
of the taper of the fuselage, the firewall and cowling supports must be slightly smaller—or you
must add a strip of spruce around the frame for sanding. The cowling supports are easily clamped
in place for drilling.
The alternative is to wait until the fuselage is completely skinned and then the cowling supports
are installed so that the cowling matches the fuselage. Plywood shims—the same thickness as the
cowling—are used to correctly position the cowling supports. The cowling supports cannot be
clamped in place and must be held in place by hand while the holes are drilled—clamping is
preferable since it isn't easy to drill through stainless steel.
We believe that the cowling supports should be installed now for the quickest and easiest
construction, but there is really nothing wrong with installing them later.
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