120 Bulkhead Assembly

Top image is a detail from the client-supplied drawing of a bulkhead assembly for the aft side of a P-3 main gear bay. Bottom image is an exploded view of the assembly created in SolidWorks CAD using the drawing. Except for the seals, the parts shown are formed from 2024-O aluminum sheet and heat-treated to T4 condition prior to assembly. The CAD models of the main bulkhead and stiffeners were used to machine form dies from aluminum plate and flat patterns cut from aluminum sheet. A hydroform press was used to form the sheetmetal over the dies. The gusset and angle were formed from flat sheetmetal using a press brake. Fastener locations were marked for drilling from a full-size mylar drawing. Final steps done by the client included cutting out the rubber seals, chem-film and prime paint for the aluminum parts, and assembly with specified rivets.