Side Skin Bends

Take two for bending the side skins.  It seems like a simple task, but getting these curves to match is easier said than done.  (The pictures make it look like the primer got really beat up in the process, but actually it held up really well. For whatever reason, the EkoPoxy in this color gets scuffs from any aluminum that touches it, but it's not scratched at all.)

This was about as close as I could get the curve.  It's not as tight as I would like it to be, but I think it'll suck together once it gets dimpled and riveted.  A curve alone would be pretty easy, but since the front end has to be a 90 degree angle, it complicates matters.

I fell prey to what a lot of other builders have - the relief hole at the front 90 degree bend ended up cracking.  I had read about this, so was careful to make sure the hole was well deburred, but no luck.  I think it's due to the amount of back and forth bending that happens as the aluminum is worked to the right angle.

I haven't figured out if I'll just stop drill it and leave the crack or file away the entire thing.  I'll see what I can find out from other people.  I thought I learned my lesson and moved to the other side. I made the bend, and as I was fitting it to the tailcone, another crack.  The left side crack was only about 1/8", whereas the right side was 1/4".  It's irritating, but at least I know I'm in good company.

The last thing I did today was drill the hole that the step goes through.