MODEL: SR3500 Page 1 - Patterson AeroSales - Aircraft ... · Chap. 9.2 SR3500 Fuselage Assembly - Cabin MODEL: SR3500 ©1997-2006 Murphy Aircraft Mfg. Ltd. ... 26/06/2006 Page 8 12)

Chap. 9.2 SR3500 Fuselage Assembly - Cabin

MODEL: SR3500 ©1997-2006 Murphy Aircraft Mfg. Ltd. All rights reserved

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Parts List for Gear Box

No. Part Number Description Qty Required1,23 FUS0711QL BRACING CHANNEL 22,22 FUS0711QR BRACING CHANNEL 2

3 FUS301QB CARRYTHROUGH 14 FUS0814QR CARRYTHROUGH PLATE 15 FUS0814QL CARRYTHROUGH PLATE 16 FUS0318Q CARRYTHROUGH 27 FUS1003Q ANGLE (CUT RAWST0006 TO 43.25") 18 FUS0310B LANDING GEAR CLAMP PLATE 29 FUS0309B LANDING GEAR CLAMP 210 FL0400 FLOAT MOUNTING BRACKET (OPTIONAL) 0 (OR 4)*11 FUS0331 LANDING GEAR ATTACH BRACKET 212 FUS0307Q CARRYTHROUGH 213 FUS1004Q ANGLE (CUT RAWST0006 TO 39.94") 114 FUS0301QA CARRYTHROUGH 115 FUS0813QR CARRYTHROUGH PLATE 116 FUS0813QL CARRYTHROUGH PLATE 117 FUS0871 SPRING GEAR BRACE FITTING 218 FUS0704 STRUT FITTING 219 FUS0703Q STRUT FITTING 220 FUS0702Q STRUT FITTING 221 W0719 WASHER 1.812 DIA X .125 THK 2

AN3-5A BOLT 24AN3-6A BOLT 24AN5-13A BOLT 16 (OR 6)*AN5-14A BOLT 2 (OR 0)*AN5-15A BOLT 2AN5-16A BOLT 2 (OR 12)*AN5-17A BOLT 2AN5-20A BOLT 2AN6-13A BOLT 8AN6-17A BOLT 4AN6-45A BOLT 4AN9-12A BOLT 2AN9-13A BOLT 2AN9-17A BOLT 2AN365-524 FIBER NUT 24AN365-624 FIBER NUT 16MS21044N9 FIBER NUT 6AN365-1032 FIBER NUT 48AN960-10 WASHER 48AN960-516 WASHER 24AN960-616 WASHER 16AN960-916 WASHER 10RV-1613 AVEX RIVET 42RV-1619 AVEX RIVET 46

* For float option



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9.2 Cabin Assembly

The SR3500 Cabin area is described as a Tail Dragger configuration. Trike Gear differences are

noted. Read through this entire section carefully before you start work to see how the sections fit

together.

1) Cleco two shear webs (FUS0325L and FUS0325R) to the carrythrough (flanges facing out). Ensure

the shear webs are vertical then drill remaining holes to #40. Figure 9.2.4

2) Drill a fifth hole in each FUS0325 and carrythrough. Figure 9.2.4

Fig. 9.2.4

3) Drill each hole out to #11.

4) Place the FUS0325 shear webs aside for now.

NOTE: In the Taildragger SR, there are five FUS0302 carrythroughs. Each of these must have

the rudder cable holes drilled. One at a time, cleco back to back a FUS0302 to a FUS0301 and

drill. Do not drill the wire loom and brake line holes.

5) In the trike SR, there are four FUS0302 carrythroughs and two FUS0301 remaining undrilled. Drill

the rudder cable holes in each.

6) Place the five FUS0302’s aside for now.

7) Cut two lengths of 1” x 1” x 1/8” angle (RAWST0006) to 43 ¼” long.

NOTE: For a trike you will need to cut four lengths at 43 ¼” long.

8) Center one of the 43 ¼” angles on the top of a FUS0301 carrythrough. Figure 9.2.5

9) Ensure the top edges are flush then backdrill through the carrythrough into the angle. Figure 9.2.5



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Fig. 9.2.5

10) Repeat for each FUS0301 carrythrough. There will be two for a taildragger and four for a trike.

11) Cleco carrythrough (FUS0307-please note on later kits this is replaced by two laminations,

FUS0307-1) to the trimmed carrythrough (FUS0301) and angle.

NOTE: FUS0307 must go between FUS0301 and the angle. Figure 9.2.6

Fig. 9.2.6



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12) Using carrythrough (FUS0307) as a drill guide, back drill FUS0301 as in Figure 9.2.6. When

drilling the 5/16” and 3/8” holes it is best to drill to “F” first then to final size.

13) Bolt the three Stn 100 gussets (FUS0308, FUS0312 and FUS0313) temporarily to the assembly

with two ¼” bolts. Figure 9.2.7

HINT: When bolting together items that must later come apart, use enough washers under the

nuts to prevent the plastic part of the nut from coming in contact with the thread. This will save

wear on the nuts as well as speed things up. Using castle nuts also will work.

Fig. 9.2.7

14) Drill out the open holes to 5/16”. Use 5/16” bolts to hold together. Remove ¼” bolts and drill out

the two remaining holes. Figure 9.2.8

Fig. 9.2.8



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15) Repeat for other side.

16) Cleco carrythrough (FUS0318-replaced by two FUS0318-1’s on later kits) to the other FUS0301

and angle and drill as in Figure 9.2.9.

NOTE: The two carrythrough structures assembled with FUS0307 and FUS0318 will be used to

build up the landing gear box for the taildragger SR3500. This same box is used to carry the shear

load in the floor structure. Therefore, it is also used in the trike. The trike must also have another

similar box made up but using carrythroughs FUS0317. See step 17.

Fig. 9.2.9

17) Cleco a carrythrough (FUS0317) to a FUS0301 and drill as in Figure 9.2.10. Repeat for both

FUS0317s.

18) Disassemble the FUS0307 and FUS0318 carrythrough structures.



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Fig. 9.2.10

19) Debur, chromate and rivet structures back together with 3/16” avex rivets. Figure 9.2.12

20) Bolt the landing gear brackets (FUS0309) and (FUS0331) in place as in Exploded view at the first

page of this section and Figure 9.2.12. Use AN365 fibernuts and AN 960 washers. The nuts

should go to the inside of the torsion box.

NOTE: It is easier to put all the bolts in place before tightening .



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Fig. 9.2.12

21) If building a trike, repeat steps 18-21 for the two FUS0317 carrythrough assemblies. See rivet and

bolt pattern in Figure 9.2.13.



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Fig. 9.2.13

22) Set the landing gear boxes aside.

23) Cleco an upright (FUS0346 L or R) back to back with a FUS0302 carrythrough. Use a carpenter’s

square to insure the upright is perpendicular. Back drill #30 holes, then out to #11. Figure 9.2.14

Fig. 9.2.14



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24) Repeat for opposite end.

25) Repeat steps 23 & 24 for two more FUS0302 carrythroughs.

26) Make a fourth assembly but with the flanges facing the same direction. To do this you must trim

the inner flange of the uprights.

27) Cutting the flanges off the upright reduces its strength so a doubler must be added to increase it.

Figure 9.2.15. Make the doublers from .032” material (RAWST0010). Later kits have these

doublers made (FUS0811).

Fig. 9.2.15

28) Label the four upright assemblies #5,6,7, and 8 with the one with the flanges facing the same

direction and doublers as #8.

29) The two FUS0302 carrythroughs at station #7 and #8 must have four stringer notches cut out of

each. Cleco #7 and #8 FUS0302 together back to back as in Figure 9.2.16. Scribe the stringer

notches from one FUS0302 to the other FUS0302. Turn the assembly and scribe the other

FUS0302.



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Fig. 9.2.16

30) Move the front facing FUS0302 to the other end of the rearward facing FUS0302 and scribe.

31) Cut out the scribed areas of both parts. The finished part should look like Figure 9.2.17.

Fig. 9.2.17

32) Debur, chromate and rivet together station #5 and #6 carrythroughs and uprights with 3/16 avex

rivets.

NOTE: Steps 38 to 44 are for mounting the float attach brackets. The brackets come standard in

the kit. If the aircraft will never be on floats they are not necessary. Not putting them in will save 2-

3 hours work and approximately 1 pound in weight. WARNING: They will be very difficult to put in

after the aircraft is built.

33) Cut off flush the two center tabs on each end of station #8 carrythrough. Figure 9.2.18



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Fig. 9.2.18

34) Cleco station #8 carrythrough, uprights and float attach brackets (FUS0347) together as in

Figure 9.2.19.

Fig. 9.2.19

35) Cleco station #7 carrythrough and uprights to the float attach brackets. The flanges of both

carrythroughs will face the same direction.



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36) Drill out the float attach brackets from both sides to #11.

37) Drill out the two mounting holes on each side to 5/16” as shown in Figure 9.2.19.

38) Disassemble.

39) From the firewall channel (FUS0386) make up two elevator horn brackets as in Figure 9.2.20. Later

kits have this part made, FUS0812.

Fig. 9.2.20

40) Rivet a bell crank bearing (MI0025) to each horn (FUS0304) as in Figure 9.2.21. Make one left

and one right assembly. Use 1/8” S.S. rivets.



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Fig. 9.2.21

41) Bolt the horn assemblies and horn brackets together as in Figure 9.2.22.

Fig. 9.2.22

42) Drill four #40 holes in station #8 carrythrough as shown in Figure 9.2.23.



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Fig. 9.2.23

43) Cleco a FUS0321 shear web with the flanges facing out to two of the holes just drilled. Drill back

through the shear web the three open holes. Repeat for the other two holes in the carrythrough.

44) Cleco station #8 and #7 carrythroughs back to back and transfer the holes just drilled into station

#7 carrythrough. Disassemble.

45) Center the horn-bracket assembly over the holes in station #8 carrythrough and back drill the

brackets. Notice the center of the horns should be offset vertically 1/8” from the center of the

carrythrough. Figure 9.2.24

Fig. 9.2.24

46) Drill two extra holes in the ends of each bracket . Figure 9.2.24

47) Cleco the FUS0321 shear webs back in place and take all holes out to #11. Disassemble.



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48) Bend the tabs over 90º on the shear webs as in Figure 9.2.25. The exact location is not important

for it is done only to provide some stiffness.

Fig. 9.2.25

49) Rivet the two shear webs, horn-bracket assembly and station #8 carrythrough together with 3/16

avex rivets.

50) Rivet the uprights and doublers to station #8 carrythrough with 3/16 avex rivets. Do not rivet in the

area where the float attach brackets will go.

51) Rivet station #7 uprights and carrythrough together. Do not rivet in the area of the float attach

brackets.

52) The floor structure can now be clecoed together. Start at the front with the FUS0325 shear webs

and work towards the back. The shear web flanges will have to be drilled out to #30 before being

clecoed in place. A rule of thumb is the flanges always face the side of the aircraft they are closest

to. Figure 9.2.26. NOTE: For trike gear see Figure 9.2.27.



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Fig. 9.2.26

Fig. 9.2.27



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53) Drill out all shear webs and carrythroughs to #11.

54) Rivet the shear webs in place with appropriate length 3/16” avex rivets.

NOTE: If building a trike, use AN3 bolts, fiber nuts and washers instead of rivets to connect the

two center FUS0325’s to station #2 carrythrough..

55) Cut two 56 ¾” lengths from FUS1044(formerly RAWST0005 3/4 x 3/4 x 1/8 angle). These will be

used as shear web caps on the outer side of the outside shear webs.

56) Clamp the two angles to the outside edges of the outside shear webs. Figure 9.2.28. NOTE: The

top surfaces of the angles should be level with the carrythroughs, not with the shear webs.

Fig. 9.2.28

57) Using the shear webs as drill guides, back drill the angles to #40. Remove.

58) Cut two 92 1/4” lengths of angle. Position and drill as in Figure 9.2.29. Do not drill any holes aft

of station 8.

Fig. 9.2.29



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59) Reposition the two 56 ¾ lengths with the 92 1/4” lengths and drill out to #30.

60) The two longer angles must be notched at station 8 to allow them to bend inwards with the

FUS0315 shear webs. Figure 9.2.30 and Figure 9.2.31.

Fig. 9.2.30

NOTE: Do not bend the angles at this time. The amount they are bent inwards will be determined when

the tail cone is attached.

61) Cut four lengths of angle to go from station 6 to the aft end of the two center FUS0315 shear webs.

Figure 9.2.31.



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Fig. 9.2.31

62) Drill only #40 holes to position and cleco in place. The final drilling will be done after the tail cone is

installed.

63) Remove the floor assembly from the workbench.

64) It is necessary to turn the floor assembly upside down on the workbench. If your workbench is less

than 32” in width, you will only need to raise the height of the workbench with 2” x 4”s so the

FUS0346 uprights clear the floor. If your workbench is over 32” wide, place 2” x 4” s so they

overhang one end 18”. Figure 9.2.32 and Figure 9.2.33.



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Fig. 9.2.32

Fig. 9.2.33



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65) Measure and cut angles for the bottom of the outside shear webs. These angles should go from

the front edge of the FUS0325 shear webs to the back of station 8. Figure 9.2.34.

Fig. 9.2.34

66) Clamp into position. Flush with the top of the side to side carrythroughs, not the shear webs.

67) Drill to #40 from station 3 to station 8. Mark each angle where it should be notched to follow the

bottom of FUS0325 shear webs before removing. After removing, notch as you did for the upper

angles. Figure 9.2.35.



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Fig. 9.2.35

68) Replace the four angles and drill out to #30. Do not drill into the FUS0325 shear webs until the

firewall is installed later.

69) Measure and cut four angles for the bottom of the inside shear webs from station 6 to the end of

the FUS0315’s. Figure 9.2.34.

70) Drill only between stations 6 & 8 and notch just aft of station 8 as you did for the front of the outside

shear web angles. Aft of station 8 drill only a couple of holes to hold the angle. Final position will

be determined when the tail cone is installed.

71) Assemble bottom side stringers as Figure 9.2.34.

(Note: Figure 9.2.36 omitted by manual update)

72) Drill to #40 then #30 and cleco in place.

73) Remove each angle and debur, then replace and rivet together with 1/8” Avex rivets. Rivet angles

only from station 2 to station 8.

74) On the station 2 carrythrough bottom flange, drill a #40 hole as in Figure 9.2.37.



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Fig. 9.2.37

75) On each of the other carrythrough flanges draw a center line. Figure 9.2.37.

76) Position FUS0376 bottom floor skin and cleco in position using the #40 hole just drilled in the

station 2 carrythrough.

77) Ensure the center line on each carrythrough is visible through the center holes in the bottom skin

then drill to #40. Figure 9.2.38.



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Fig. 9.2.38

78) Ensure the assembly is square and level then drill out completely to #40 , then to #30, all but

perimeter holes, which should stay at #40.

79) Remove and debur.

80) Chromate, replace and rivet together with 1/8 Avex rivets. Do not rivet around the perimeter or

from station 6 back.

81) Carefully flip the assembly back over and place on level 2” x 4”s.

82) Draw a line down the outside flange of station 5 upright and draw a horizontal line 5/16” up on each

upright as in Figure 9.2.39.



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Fig. 9.2.39

83) Cleco a FUS0337 fuselage side skin into position using the key hole shown in Figure 9.2.40.

Fig. 9.2.40

84) At station 5 drill each #40 hole into the upright ensuring the holes are on the line drawn in step 82.



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85) Ensure station 8 upright is parallel to station 5 upright. Align station 8 keyholes with horizontal line

drawn in step 88 and drill to #40. Cleco.

86) Repeat step 85 for station 6 & 7 uprights.

87) Remove the side skin. On station 6, 7, and 8 uprights, draw vertical lines from the key holes just

drilled to the top of each upright. The lines should be parallel to the web of each upright.

88) Replace the side skin and drill the remaining holes. Start at the bottom and drill every 5th or 6th

hole. Cleco as you go. Go back and finish drilling all the #40 holes on the upright. Do not drill to

#30 at this time.

89) Repeat for the opposite side.

90) Remove the FUS0337 side skins.

(From step 91 to 96 is omitted by manual update)

SILL INSTALLATION

97) Position a FUS0314 sill as in Figure 9.2.41.

Fig. 9.2.41

98) Mark the sill so there is 1/16” clearance for each upright. Ensure the front end of the sill is flush

with the front edge of the station 2 carrythrough.

99) Cut out each slot. File smooth and position in place.



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100) Clamp the top flange of the sill to the carrythrough flanges.

101) Using a long #30 drill, back drill through the carrythrough tabs into the sill. Start at the top and

cleco as you work down.

102) Drill downwards through the shear web angles with a long #40 drill.

103) Scribe the landing gear and float hard point slots on the sill.

104) On the inside of the sill draw a line flush with the backside of the station 4 carrythrough.

105) Remove the sill and cut out the landing gear and float hard point slots. Make sure the corners are

radiused.

NOTE: Steps 106 to 116 are for taildragger only.

106) Drill a STEP0004 (Step insert) as in Figure 9.2.42.

Fig. 9.2.42

107) Position the step insert into the STEP0006 (Step assembly) drill and bolt together as in Figure

9.2.43.



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Fig. 9.2.43

108) Hold the assembled step to the back of station 4 carrythrough so the step is parallel with the floor.

Draw a line on each side of the step insert. Figure 9.2.44. The step can be moved in or out on the

carrythrough as you like.



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Fig. 9.2.44

109) Replace the sill and transfer the two lines to it.

110) Remove the sill and cut out a 1 1/8” x 1 1/8” square hole with rounded corners where the step will

go.

111) Replace the sill and insert the step. Back drill the #30 mounting holes into the station 4

carrythrough.

112) Remove the step and position a STEP0005 (Step bulkhead) back to back with the carrythrough

and back drill the #30 mounting holes.

113) Remove the sill. Cleco the step, step bulkhead and carrythrough together.

114) Drill out the mounting holes to #11.

115) Make a clip from ST0040 material to attach the step bulkhead to the shear web. Use five 1/8

avex rivets in each leg.

116) Rivet the bulkhead into place.

117) Replace the sill and drill out all holes going into the carrythroughs to #11. Drill out the shear web

angles to #30.

118) Rivet the sill in place with 1/8 & 3/16 avex rivets. Do not install rivets in stations 2 & 8

carrythroughs.

119) Do not bolt the steps in place until after the landing gear is on.



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CAGE ASSEMBLY

1) Cleco a FUS0305 inside post skin and a FUS0333 outside post skin together and drill a ¼” hole as

in Figure 9.2.45. This hole will be used to mount a control pulley later.

Fig. 9.2.45

2) Repeat for other two post skins.

3) Cleco four FUS0335 post spacers to a FUS0305 inside post skin as in Figure 9.2.46.

Fig. 9.2.46



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4) Position a FUS0300 channel on the post skin as in Figure 9.2.47.

Fig. 9.2.47

5) With a long #40 drill back drill the channel through the end flanges of the post spacers. Make sure

the post spacers are vertical.

6) Remove and trim the top end.

7) Repeat for the front channel but notch and bend the channel before trimming. Figure 9.2.48.



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Fig. 9.2.48

8) Cleco the assembly back together and using the post skin as a drill guide, drill the channel to #40.

9) Repeat for the opposite post. Make sure you build one left and one right.

10) Cleco a FUS0333 outside post skin to one assembly and drill to #40 and cleco.

11) Repeat for the other post.

12) Drill out the two end holes in the FUS0306 top carrythrough to ½”. Use a drill press and ream if

you can. Figure 5.

13) Drill (ream) out the four FUS0311 corner gussets to ½”. Figure 9.2.49.



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Fig. 9.2.49

14) Bolt the FUS0306 top carrythrough and four FUS0311 corner gussets together as in Figure 9.2.50.

Fig. 9.2.50

15) Position the top edges of the gussets parallel with the top surface of the carrythrough. This will

ensure the vertical legs will be 90º to the carrythrough. Using the gussets as drill guides, drill out

the carrythrough to #30. Use lots of clecos.

16) Center a post assembly between two corner gussets. Use a piece of .025” scrap to separate the

post and carrythrough. Drill to #30. Figure 9.2.51. Use lots of clecos.



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Fig. 9.2.51

17) Repeat for other side.

18) Position the cage assembly on the floor assembly. Use .040” spacers under the post assemblies.

These are needed so the floor skin will fit later. Figure 9.2.52.

Fig. 9.2.52

19) Back drill through the carrythroughs to #30 and then #11.

20) Back drill through the outer post skin into the sill to #30.



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21) Replace the FUS0337 side skins and backdrill into the sill.

22) Draw lines on the outside flanges of four RBULK0001 (Square bulkhead quarters). The lines

should go through the positioning holes.

23) Slide two RBULK0001’s into the top of the station 5 uprights. The other two into the station 8

uprights.

24) Cleco the positioning hole in the bulkheads to the 6th hole down at each station. Each bulkhead will

sit slightly higher than the side skin.

25) Mark the vertical leg of each bulkhead to have a 4” overlap with the uprights. Drill nine #30 holes in

the overlap.

26) Clamp the RBULKS together in the middle of the cabin area so the distance between the

positioning holes is 31”. Drill nine #30 holes in the overlap as you did when building the tail cone.

27) Drill the RBULK flanges using the side skins as drill guides.

28) Remove the RBULKS, trim to length, rivet together with Avex rivets.

29) Reinstall, and bend the upper flanges to be parallel with the top of the side skins. Figure 9.2.53.

Fig. 9.2.53

30) Shrink or crimp the top flange of the FUS0027L (Fuselage Root Rib) so it will lay flat. The flange

should be 90º to the side.

31) Trim the root rib as in figure 9.2.54.



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Fig. 9.2.54

32) Slide the root rib behind the FUS0333 outside post skin and FUS0337 side skin. Rest the front

part of the root rib on a .040” spacer on top of the carrythrough. The top flange of the root rib at

the rear should rest on the station 5 bulkhead. The door jams should be parallel. Figure 9.2.55.

Fig. 9.2.55

33) Back drill through the post skin and side skin into the root rib.

34) Repeat for the other side.

35) On the outside of each root rib draw two vertical lines as in Figure 9.2.56.



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Fig. 9.2.56

36) At the top of each line, drill a #40 hole. Figure 9.2.56.

37) Build up two RBULK0001 assemblies to fit on the lines between the root ribs. The flanges on the

froward RBULK assembly should face forward. Figure 9.2.57.

Fig. 9.2.57

38) Drill the top hole into the RBULK. Through the positioning hole in the RBULK drill a second hole.

Evenly space seven more holes from the bottom to the top. Do not put rivets in the top five holes of

the root rib center bulkhead at this time. They will be installed in the control section.

39) Drill and rivet the typical nine holes at the center overlap.



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40) Make four clips from ST0040 angle to tie the RBULK legs to the root rib channel. Use three 1/8”

Avex rivets in each leg. You may want to use countersunk rivets in the root rib channel for a better

appearance.

41) Make two clips from ST0040 angle to tie the root rib channel to the vertical post at station 3. Use

two of the holes in the corner gusset and 3/16” Avex rivets. Make sure the bottom channel of the

root rib is level side to side.

42) Cut two angles from FUS0035 (Stock material) to fit between station 5 and 8 bulkheads. They

should fit on the inside of the flanges. Figure 9.2.58.

Fig. 9.2.58

43) Position the angles and drill back through the prepunched holes in the side skin. Rivet with 1/8”

Avex rivets.

44) Center the FUS0028 (Cabin top) over the assembly. The top is wider than the fuselage and will be

trimmed later. Tuck the front flange of the cabin top under the front carrythrough corner gussets.

Figure 9.2.59.



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Fig. 9.2.59

45) Drill back through the corner gussets into the cabin top. Cleco.

46) Hold the cabin top down securely with 2”x 4” or tape.

47) Back Drill the cabin top through the positioning holes in each RBULK. Ensure the RBULK legs are

straight.

48) On the outer surface of the cabin top lay out and drill to #30 a nominal hole spacing of 1” between

positioning holes. Work from the center out and use lots of clecos. NOTE: At station 8 drill only

the two positioning holes.

49) With the same spacing, drill from the positioning holes to the sides. Do not drill at station 8.

50) Drill #30 holes through the cabin top and carrythrough with a nominal 1 ¼” spacing. Figure 9.2.60.

Fig. 9.2.60



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51) Drill a 1” nominally spaced row of #30 holes in the cabin top, root rib and angles.

52) Drill out the FUS0311 corner gussets to #11.

Documents

MODEL: SR3500 Page 1 - Patterson AeroSales - Aircraft ... · Chap. 9.2 SR3500 Fuselage Assembly - Cabin MODEL: SR3500 ©1997-2006 Murphy Aircraft Mfg. Ltd. ... 26/06/2006 Page 8 12)