Continued assembling the firewall

Riveted the angles and lower gusset to the right firewall side. Used tank sealant to Seal the top of the firewall to the sides and clecoed in place along with the top firewall angle and riveted them together. Clecoed the tunnel sides to the firewall assembly. Sealed the firewall center to the sides and top and clecoed in place. Clecoed the upper top angle and gussets in place. Final drilled the nose gear brackets.

 

Today’s Time (hours): 2.0
Fuselage Time (hours): 61.5
Total Time (hours): 516.0

 

Riveted the angles to the left firewall side

Received the new firewall angles from Van’s. Deburred, scuffed, and primed them. Then taped the holes I shouldn’t countersink and countersunk the rest.

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Clecoed the angles and gussets to the firewall. Then back-riveted the left firewall side.

 

Today’s Time (hours): 2.0
Fuselage Time (hours): 59.5
Total Time (hours): 514.0

 

Riveted the baggage ribs to the aft bulkhead

Riveted the step weldment and step rib to the baggage ribs and riveted the nut plates to the weldments.

 

Clecoed then riveted the baggage ribs to the aft bulkhead.

 

Ready to rivet the skin to the baggage ribs.

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Today’s Time (hours): 3.0
Fuselage Time (hours): 43.5
Total Time (hours): 498.0

 

Dimpled the bottom skin and riveted stuff to it.

Dimpled the bottom skin. Today’s word of the day: unwieldy.

 

 

Riveted the doublers and stiffeners to the bottom skin.

 

 

Dimpled the gear brace bracket and machine countersunk the gear brace bars. Riveted the gear brace assembly together and then riveted it to the skin.

 

 

Clamped the lower fuselage substructure to the bench and clecoed the skin to it. Ready for riveting.

 

 

Today’s Time (hours): 6.0
Fuselage Time (hours): 37.0
Total Time (hours): 491.5

 

Assembly continues

Fluted the outboard seat and baggage ribs to mach the curve of the bottom skin. Riveted nut plates to the seat ribs.

 

Bolted and riveted the seat ribs to the bulkhead assembly.

 

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Riveted the seatbelt lugs and routing angles to the baggage ribs.

 

Riveted the aft bulkhead to the seat rib assembly. Drilled and riveted the doubler to the bulkhead. Fabricated and riveted together the idler bearing assembly and riveted to the bulkhead.

 

Clecoed the bottom skins together and match drilled some holes. Cut the landing gear leg openings in the forward skins. Machine countersunk the doublers and dimpled the skin stiffeners. Drilled the 9/16″ hole in the skin with a step drill. This hole will be used to mount the transponder antenna.

 

 

Today’s Time (hours): 5.0
Fuselage Time (hours): 31.0
Total Time (hours): 485.5

 

Completed Right Wingtip

Laid out the cut the left and right wing tips. I made over-ran on of the cuts by an inch or so on the left wing. So I did a little patch and fill with some fiberglass and micro and set it aside to cure. Then continued work on the right wingtip.

 

Cut and installed the nav light lens.

 

Installed the nav/strobe light. Used the template from the plans to drill the wingtip. Terminated the wires with Molex .062 pins. Unfortunately Vans provided a 4-pin molex housing instead of the 5-pin one that matches the wiring harness in the wing. <sigh> Now I get to pay $10 in shipping for two $1 moles housings. Mounted the bracket and installed the light. Tested it out with a 9-volt. That sucker is bright!

 

Fit the wingtip to the wing and set it in place with a ratchet strap. Match drilled the holes from the wing skins to the wingtip. Final drilled and dimpled the holes in the wing for #6 screws. Final drilled the screw holes in the wing tip and then used a nut plate, a screw, and a cleco as a drill jig to drill the nut plate attach holes. Machine countersunk the screw and rivet holes and riveted the nut plates in place.

 

Fit the wing tip rib to the wingtip. Laid out and match drilled rivet holes. Riveted the rib in place.

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Bam! Right wingtip done.

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Today’s Time (hours): 8.0
Wing Time (hours): 293.0
Total Time (hours): 445.0

 

Fitted the aileron trim and inboard bottom skins

I finished inventorying and stowing parts from the fuselage kit and avionics.

Crimped the pins onto the aileron trim wires, added a heat shrink tube, and inserted them into the molex connector.

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I centered the set the aileron trim using a 9-volt battery to drive the servo. I set the  assembly in place on the wing and set the aileron to the neutral position. Then I marked the point where the aileron trim arm rested over the  push tube. I remove the push tube and located the tabs 6 inches either side of the center mark. I match drilled and blind riveted them to the push tube. I attached the springs to the tabs.

 

I clecoed the inboard bottom skins in place on the wings. Ready to rivet.

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Today’s Time (hours): 4.0
Wing Time (hours): 264.0
Total Time (hours): 416.0