tail fairing WXB T0-01-02

[wingnut99]

Does anyone have a good technique for forming the fairing between the ruddervators? I have it cut out and the edges bent 82° and drilled but that .025 aluminum is really stiff and doesn't want to bend. I've tried untempering it with torches and even threw it on the BBQ grill for 20 minutes at 400° or better and it doesn't soften up at all. I do have access to a number of rollers and English wheel machines at our VAA chapter 16 hanger and hopefully someone who knows how to use them, but in the meantime maybe someone has already discovered a simple way to put a nice turtle deck bend in it. It's over 5" at the forward end and about 2 1/2" at the small end. Thanks

[Bryan Cotton]

I have a couple of pictures on page 101 of my thread.
viewtopic.php?f=39&t=578&start=1000

I made a paper template, polished the sheet, bent the flanges, and I think I used the basketball pole plus a broom to bend it up. I don't think I annealed it at all.

Edit: check your PMs, shoot me an email and I'll send pics.

[wingnut99]

Bob Mika and I bent and worked it back and forth for quite a while but it just wasn't cooperating at all. That's some really stiff metal. We're going to try to get someone at the chapter hanger to demonstrate how you roll it on one of the machines.
I was getting to much crease in the small end bending it around a pipe. If it was the same diameter from end to end it wouldn't be a problem. I'll let you know how it goes. Thanks

[Bryan Cotton]

The pictures I was going to send showed a broomstick clamped in a vise. The secret is to slide it back and forth with pressure on it. I didn't find it that hard to bend. Just go slow.

[gregsonex]

Bryan--would you mind sending me those photos of the tail fairing as well? i'm gonna work on it tomorrow.