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.

img_3739

 

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

Started riveting the side skins to the fuselage

Back riveted the side ribs, center section, and forward stiffener to the side skins.

 

Clecoed the side skin and longerons to the fuselage and bolted the upper drag link in place. I ran a bead of fuel tank sealant between the firewall and the skin and the upper longeron and the skin. Unfortunately it wasn’t until after I put the sealant in place that I realized that I hadn’t dimpled the flanges of the firewall.  In my defense, I can’t find where it says to do so in the instructions. What a fucking mess!  Thanks, Vans!

 

Riveted the canopy latch bracket and bulkhead side channel to the left skin.

 

Got about halfway through the riveting on the left side. Slow going. I was hoping to make more progress than I did today.

img_3677

 

Ran into one frigging rivet that necessitated removal of the landing gear bracket. This was a huge pain in the ass with the skin in place. There’s not enough room to get a drift in front of the main bulkhead to knock the outboard bolt out. Ended up using the short end of an allen wrench and hitting it with the long bucking bar that I have. There wasn’t room for a hammer. Once I got it started with this arrangement, I was then able to get a drift into the space and use the bucking bar to knock the bolt out. Would have saved a bunch of time had I removed the bracket before the skins went on. Burned over an hour on this.

 

Today’s Time (hours): 10.0
Fuselage Time (hours): 115.0
Total Time (hours): 569.5

Dimpling, Countersinking, and Assembly continues

Constructed a support leg from scrap wood and bolted to the bulkheads. Then turned the fuselage assembly up on its side to rivet the bottom.

 

 

Put clecos in all holes to be riveted. The final drilled and blind riveted the bottom skins to the drag links. This is as far as I could get without a riveting partner.

 

 

Sealed the muffler ramp to the bottom skins with fuel tank sealant.

img_3609

 

Dimpled and countersunk all of the parts except the skins.

img_3615

 

Riveted the roll bar angles to the intercostal ribs.

img_3610-1

 

Fabricated the seat adjustment guides and assembled the seat adjustment stuff to the cross brace.

 

 

 

Today’s Time (hours): 5.0
Fuselage Time (hours): 94.0
Total Time (hours): 548.5

Completed Forward Fuselage Lower Structure (Section 28)

Applied a bead of tank sealant to the bottom flanges of the muffler shroud sides and riveted them to the forward skins. Riveted the muffler shroud ramp to the sides and added a fillet of sealant to the bottom of each seam.

 

 

 

Positioned the firewall assembly on the forward skins and muffler shroud. Added sealant between the skins and firewall and around the curved area where the muffler shroud connects to the firewall and clecoed everything together. Riveted the cover bases to the skin. Riveted the curved part of the firewall to the muffler shroud sides and ramp.

 

 

 

Riveted the firewall angle to the firewall and skins. Dimpled the cowl places and shims and riveted them in place.

 

 

 

Riveted the tunnel sides to the skins and muffler shroud.

 

 

Riveted the routing bracket and fuel selector bracket in place.

img_3453

 

Riveted and bolted to forward center section bulkhead to the tunnel side. Riveted the skins to the cover ribs.

 

 

Sealed and screwed the firewall penetration fittings to the firewall.

img_3458

 

Fabricated and assembled the cabin heat vent assemblies. Then riveted them in place on the firewall along with their control cable brackets.

 

Machine countersunk the battery box attach holes and riveted it to the firewall.

 

Dimpled the cover panel and riveted it to the forward flanges of the cover ribs along with a gazillion nut plates.

 

Forward Fuselage Lower Structure… Done! On to the side structures!

 

 

Today’s Time (hours): 8.0
Fuselage Time (hours): 73.0
Total Time (hours): 527.5

 

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

 

Completed assembling left tank

Same drill as the right tank yesterday…

 

Both tanks are now fully assembled. I’ll give them a few days and then pressure test them to find and seal any leaks. Then I can attach them to the wings and move on to the bottom wing skins and aileron actuation.

 

Today’s Time (hours): 3.0
Wing Time (hours): 229.0
Total Time (hours): 381.0

 

Finished assembling right tank.

Added a bead of tank sealant for the baffle. Clecoed the baffle in place. Riveted the baffle to the ribs and then riveted the z-brackets in place. Then riveted the baffle to the skin.

 

Installed the fuel drain, the fuel sender, AN fittings, and the fuel cap.

 

Machine countersunk the holes in the tank attach bracket for #8 screws.

img_2881

 

The right tank is now complete and once the sealant has cured, I can pressure test it. Hoping to get the left tank to the same state tomorrow.

 

Today’s Time (hours): 3.0
Wing Time (hours): 226.0
Total Time (hours): 378.0