Forming Bulkhead Forms

I spent 40 minutes today making the wooden forms for bulkhead "C", the aluminum bulkhead behind the seat. The bulkhead is 2 inches wider on my airplane so the forms had to be 2 inches wider as well. I am sure about the width of the cockpit so bulkhead "C" and its form blocks are set.

The only other thing that I am certain of are the dimensions of the stainless steel firewall. The plans state that they can not be altered in any way. This gives me two knowns around which I need to adjust the widths of the instrument panel and the bulkheads of the fuselage behind the cockpit.

I will be making a form for the firewall next. Then I will make a mock-up of the instrument panel out of thin plywood to test the changes in dimensions. Aluminum will buckle and wrinkle if it is asked to do anything complex without adequate support or shaping. The Teenie Two's skins are fairly straight on the sides of the fuselage but my changes may introduce some wrinkling.

I will lay out the firewall, instrument panel, and bulkhead "C", all made of wood, and then "skin" this layout with poster board. Hopefully I will be able to identify any areas that may need to be changed before I get to the point of cutting metal.

My deviations from the plans are going to cost me time in the build process but in this case time is something I have more of than money and materials. Modifications only increase my involvement with the airplane so I don't get into a dead spot that may detract from my enthusiasm.

Got a long way to go though :)