Completed Flap Actuation System (Section 34)

Drilled the tiny hole in the linear actuator rod for safety wire. First attempt broke through. Second attempt, I ignored Van’s instructions and started by drilling a hole in the end. Then drilled a hole from the side to meet up with the first hole. Then final drilled at an angle to eliminate the right angle and allow the safety wire to slide through.

Greased up the torque tubes and inserted into the bearing blocks on either side. Then I bolted them to the flap crank in the middle. Finally, I bolted the flap motor in place and tested with a 9-volt battery. Worked perfectly.

Today’s Time (hours):	2.0
Fuselage Time (hours):	173.0
Total Time (hours):	627.5

Began work on the flap actuation system (Section 34)

Screen Shot 2019-12-06 at 9.36.10 PM

Picked and inspected all four parts.

Used the alignment template thing-a-mabob to locate and match drill the holes from the crank to the torque tubes.

I primed the inside of the tubes with SEM. I’ll let them dry tonight and install everything tomorrow.

Today’s Time (hours):	1.0
Fuselage Time (hours):	171.0
Total Time (hours):	625.5

Completed Rudder and Brake Systems (Section 33)

Installed the links that attach the rudder cables to the rudder pedals. Riveted the rudder cable fairleads in place. Not pictured, I also bolted in the four adel clamps that hold the plastic rudder cable routing tubes in place. This was a huge pain in the ass. Very little room to get fingers in to get the nuts started. Plus the angle of the tunnel cants the bolts in toward the adjacent structure making it hard to get a socket or wrench on the nuts. But futzed with it long enough and got it done.

Today’s Time (hours):	2.0
Fuselage Time (hours):	170.0
Total Time (hours):	624.5

Installed rudder pedals and brake lines

Attached the brake pedals and brake master cylinders to the rudder pedals.

Drilled out the mounting blocks and installed the rudder pedal assembly into the fuselage.

Installed the brake fluid reservoir. The threads in the filler neck were galled so I’m going to call Van’s and have them send me a replacement. I mounted it in place anyway so that I could run all the brake lines.

Installed the brake lines.

Separated and painted the rudder cable links. I’ll install these along with the fairleads where the cables exit the tunnel tomorrow and that will complete this section.

Today’s Time (hours):	3.0
Fuselage Time (hours):	168.0
Total Time (hours):	622.5

Finished brake pedals and painted interior

Put a final coat of paint on the rudder and brake pedals. I covered the front of the brake pedals with grip tape that I bought from Amazon.

I finally picked a color! I went with Rustoleum Painter’s Touch Dark Gray Gloss. Changed my mind on the color at least five times. I even bought the paint for what turned out to be the runner up. Hopefully I can return it. The paint came out okay. I think I shot it a bit too heavy and got a pretty good orange peel going. But it’s good enough. Most of it will be covered with carpet. I’m happy with the result.

Today’s Time (hours):	4.0
Fuselage Time (hours):	165.0
Total Time (hours):	619.5

Riveted brake pedals

Riveted the brake pedals together. Decided to machine countersink the front of the pedals and use flush rivets. I plan to put grip tape over the front of the pedals. So the universal rivets wouldn’t have worked for me.

I’ll hit the pedals with a final coat of paint to cover up the rivets tomorrow morning. Once that dries, I’ll apply the grip tape and cut out the lightening holes.

Today’s Time (hours):	1.0
Fuselage Time (hours):	161.0
Total Time (hours):	615.5

Began work on rudder and brake systems (Section 33)

Screen Shot 2019-11-26 at 8.44.59 PM

My sister and brother-in-law were in town for some turkey. So I enlisted John to help with prepping and painting all the rudder pedal parts. I decided to flat black everything. I’m going to go with some grip tape on the face of the brake pedals. We got all the parts cut, deburred and scuffed. Then painted with Rustoleum Painter’s Touch rattle-can.

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We’ll let the paint cure tonight. Then we can assemble tomorrow and shoot another coat to cover the rivets.

Today’s Time (hours):	2.0
Fuselage Time (hours):	160.0
Total Time (hours):	614.5

Interior paint prep

Masked everything off in preparation for painting.

Now if I could just decide on a color. I got one of every shade of gray I could find. Then painted samples using old parts from the box-of-shame. In the center are the carpet and seat material swatches.