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

Work continues on baggage area

Fabricated the seat back hinges and match drilled to the floor skins.

img_3776

 

Deburred, Scuffed, and primed all of the parts.

img_3777

 

Dimpled the floor skins and riveted the nut plates in place.

 

Installed snap bushing and routed the rudder cables, static line, and ELT wire.

img_3780

 

 

Today’s Time (hours): 5.0
Fuselage Time (hours): 149.0
Total Time (hours): 603.5

Completed most of the fabrication steps

In case you haven’t noticed, I’ve settled into a strategy for most sections of the build… First I pick, inspect, and peel all the parts for the section. The I take a first pass through the instructions and perform all of the steps that require cutting, grinding, bending, etc. Then I deburr, scuff, and dimple all the parts. Then I prime everything. Finally I assemble and rivet everything. I’ve found this approach is much quicker then going step by step in the order of the instructions. I can set up the shop and tools for each operation and reorganize after each operation. I kind of get into a groove with each of the operations and avoid frequent tool changes. I also only need to set up for paint, which is a major operation, once per section.

Today I was focused on fabrication steps… I started with the upper longerons. I cut and trimmed according to the plans. The fabricated a couple of clamping blocks that allowed me to secure each longeron in the bench vise and clamp a lever to the end in order to bend a 10 degree twist into them. Finally I clamped and clecoed the upper engine mount brackets to the forward end of the longerons and match drilled them.

 

Drilled and cut the lower longerons and match drilled them to the lower engine mount brackets and longeron doublers.

 

Fabricated the hinges that will attach the cowling to the firewall.

img_3549

 

Separated a whole bunch of parts. Unfortunately my bandsaw blade gave up the ghost early on and I didn’t have a spare. So I used the snips for the thinner aluminum and the Dremel with a cutoff wheel for the thicker parts. A little bit slower but not too bad.

img_3550

 

I managed to lose a part somehow. I turned the shop upside down and couldn’t find the F-01422 Fuselage Side Ribs. I checked it off on the inventory. No idea what happened to it. Ordered a new one from Van’s.

 

Today’s Time (hours): 5.0
Fuselage Time (hours): 80.0
Total Time (hours): 534.5