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 the flap actuation system (Section 34)

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Picked and inspected all four parts.

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

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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

Work continues on baggage area

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

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Deburred, Scuffed, and primed all of the parts.

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

 

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

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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.

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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.

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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

 

Started assembling the lower skins and muffler shroud.

Dimpled the bottom skins and riveted the com antenna doublers and skin stiffeners to them. I’m only installing a single com radio so I only drilled out the right side skin for the antenna. The left side I installed some rivets to fill the starter holes. I did install the left side antenna doubler in case i want to add another radio later. I can just drill out the rivets and upsize the holes to install another antenna.

 

Dimpled the muffler shroud parts. Riveted the doublers and muffler hanger brackets to the shroud sides. Riveted the nut plates to the fuel pump brackets and then riveted the brackets to the shroud ramp.

 

Today’s Time (hours): 2.0
Fuselage Time (hours): 65.0
Total Time (hours): 519.5

 

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

 

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