Finished rear window and started on Canopy Latch

I used the edge roller to break the edge of the top and side skins where they meet the rear window. I final drilled the skins #27 and dimpled the holes for #6 screws. The squeezer wouldn’t fit into the space between the top skin and the roll bar brace. After a fair amount of ass-scratching I tried using a #6 screw and a K1000-06 nut plate to press the dimple into the center hole. It worked well.

I decided to wait until later to actually install the window. This will enable better access to the fuselage and keep me from beating up the window while I’m working on the rest of the stuff. But everything’s done and all I have to do is add some sealant and screw it in. For sealant I’ve decided to try Lexel. It’s a clear solvent based sealant that is safe for acrylic. Other builders have reported good success with it.

 

I separated, deburred, and painted the stiffener angles. I’ll rivet these in place as soon as the paint dries.

 

I picked and inspected all of the parts for the rest of the canopy.

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I peeled all of the parts for the canopy latch mechanism. I separated the peices that needed parting. I deburred and scuffer all the parts. Then painted everything to match the interior.

 

I test fit the canopy latch pins in the bushings that I installed in the roll bar. I realized that I neglected to mask of the bushings when I painted the roll bar and got some paint in there. I wrapped some sand paper around a brass drift and used it to clear the paint. Everything fits fine now.

 

Today’s Time (hours): 4.0
Finish Kit (hours): 18.0
Total Time (hours): 748.0

 

 

Began work on Roll Over Structure (Section 37)

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Picked, inspected, and peeled all the parts. Cut apart the pieces that needed to be separated on the band saw. Deburred and scuffed all the parts.

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Today’s Time (hours): 1.0
Fuselage Time (hours): 205.0
Total Time (hours): 659.5

 

Began Work on Upper Forward Fuselage (Section 35)

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Picked, inspected, and peeled all the parts.

 

I separated all the parts that required parting and began fabrication. I made the canopy release pins by shortening and chamfering the ends of a couple of eye bolts. I made the canopy release push tubes from some aluminum tubing.

 

Today’s Time (hours): 3.0
Fuselage Time (hours): 176.0
Total Time (hours): 630.5

Began work on rudder and brake systems (Section 33)

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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.

 

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

Began work on Fuel System (Section 31)

Took a break from riveting the the fuselage together. Jared’s lending me his engine-stand-fuselage-rotisserie. So I’ll wait until he drops by next weekend to finish the riveting. It’ll be a lot easier if we can roll the fuselage on its side.

So… Got started on the fuel system tonight. Picked and inspected all the parts.

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Separated the fuel line brackets and riveted to the cover ribs.

 

 

Disassembled the fuel selector valve. Oriented the fittings per the plans but couldn’t screw them in because I didn’t have the Loctite 648 that the instructions called out. Ordered some from Amazon. I riveted nut plates to the flanges of the valve. Finally I machine countersunk the screw holes in the face plate.

 

 

Crimped the connectors on the leads from the fuel pump. Added thread sealant to the fuel filter fitting and screwed it into the pump. Mounted the pump and filter into the into the fuselage.

 

 

Attached the AN elbows to the firewall and fuselage sides.

 

 

 

Today’s Time (hours): 3.0
Fuselage Time (hours): 136.0
Total Time (hours): 590.5