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.

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Dimpled and countersunk all of the parts except the skins.

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Riveted the roll bar angles to the intercostal ribs.

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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 mid fuselage bulkheads (Section 25)

Received the new bulkhead bars from Van’s. Cut and deburred them. Scuffed them, Machine countersunk and riveted them. Reamed all the holes and bolted them to the aft bulkhead.

 

Today’s Time (hours): 2.0
Fuselage Time (hours): 22.0
Total Time (hours): 476.5

 

Finished the forward and aft center section bulkheads

Riveted the cover ribs to the forward center section bulkhead. Added the AN3 bolts, nuts, and washers and torqued them down.

 

Secured the bearing bracket braces to the bearing brackets with screws, washers, and nuts. The riveted them to the bulkhead and opposing ribs.

 

Reamed the .375 and .311 holes in the center section bulkheads.

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The parts I ordered from vans should be here Tuesday. Then I can finish out this section.

 

Today’s Time (hours): 2.0
Fuselage Time (hours): 13.0
Total Time (hours): 467.5

 

Continued assembling the mid-fuselage bulkheads

I was using the squeezer to do some dimpling and riveting.  About halfway through it started leaking air from the valve. I disassembled the valve and found that the o-ring that prevents the poppet from-over extending had sheared in two. I called Cleaveland Tool and they were more than happy to ship a new o-ring at no charge. Nice folks over there. In the meantime I’ll be using the DRDT-2 and C-frame dimpling duties and shooting all the rivets with the gun.

 

I assembled the bulkhead bars. Unfortunately I screwed up one of them and had to order a new part from Van’s. Here’s the good one…

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I moved on the the aft center section bulkhead. I machine countersunk all the holes then riveted the nut plates in place. Then I riveted the side angles to the bulkhead.

 

I countersunk and riveted the bearing brackets.

 

I dimpled the cover ribs and riveted the nut plates in place. I riveted the bearing brackets to the ribs as well.

 

Machine countersunk the bearing bracket braces and riveted on the attach angles.

 

Moved on to the forward center section bulkhead. I machine countersunk the holes on the flanges and riveted on the nut plates. Then riveted and bolted the side angles in place.

 

 

Today’s Time (hours): 5.0
Fuselage Time (hours): 11.0
Total Time (hours): 465.5

 

Finished attaching elevators. Started attaching horizontal stabilizer

Fabricated a spacer block to act as a drill guide and clamped it between the horns. Double checked that the elevators were still clamped in the trailing position. Match drilled the left horn to the right horn.

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Checked to make sure everything was aligned and nothing was binding. All was good. Nice and smooth through the whole range.

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Positioned the horizontal stabilizer on the aft fuselage and bolted the forward spar to the attach bars. I clecoed the middle holes on the aft spar to the aft attach bars. I drilled the two top holes and installed bolts.

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Unfortunately I could not get the drill squared up to the spar for the lower holes because of interference with the aft bulkhead. I’ll have to head off to home depot to get a long 1/4″ drill.

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Today’s Time (hours): 1.5
Empennage Time (hours): 190.5
Total Time (hours): 190.5

 

Started attachment of elevators to horizontal stabilizer

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Screwed the rod end bearings into the elevator forward spar.

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Fitting the right side was very tight. I’m sure theres a proper tool to do this but I ended up using a cresent wrench to twist the bearings. There was no way I could do it by hand.

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On the left side I couldn’t even get the threads to engage. On close inspection I discovered that the nut plates were a hair off center from the hole in the spar and reinforcement plate.  I enlarged the hole by a 16th being careful not to damage the nut plate. Then I  was able to get them screwed in with the cresent wrench. I screwed them in to the measurement called out in the plans.

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I temporarily attached the left elevator to the horizontal stabilizer. I checked the clearance of the forward edge at the maximal up and down deflections. I used a digital level to fin the maximal deflection points. I had remove the elevator and backed the rod end bearings out three turns to get the necessary clearance.

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I used a clamp to lightly hold the elevator in the trailing position to locate the pivot hole in the elevator horn.

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I made a spacing block as called for in the plans and clamped it in place. I then honed down the drill bushing to get a snug fit in the bearing and used it to drill a #30 hole in the elevator.

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I enlarged the hole hole to 1/4″ with a step drill and deburred the hole. Then repeated this whole process on the right elevator.

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I reattached both elevators to the horizontal stabilizer. I used the appropriate hardware to make up the center hinge. It was extremely challenging getting the washers between the horns and the edges of the bearing. I ended up taping the washers to a small piece of scrap aluminum and using it to shoehorn the washers in place. Then I lightly clamped both elevators into the trailing position.

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I measured and marked the location for the control attach hole on the right elevator and drilled a #40 hole and final drilled it to #12.

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Tomorrow I’ll make a guide block and match drill the hole to the other horn.

Today’s Time (hours): 3.0
Empennage Time (hours): 189.0
Total Time (hours): 189.0