Date

I drilled and trimmed the slot for the shoulder harness cables.  Finally, I marked a line on the F-751 lower bulkhead where the F-652 upper bulkhead will fit.  I match-drilled and clecoed the lower bulkhead using the pre-drilled holes as a guide.  Holding the F-652 upper bulkhead to the line, I drilled and clecoed it in place.

I test fit the F-749 forward baggage side covers and clecoed in place.
 

The next step is to install the guide blocks for the shoulder harness cables.  I marked out the AL strip for the eight washers and cut with my snips.  I then drilled the baggage bulkheads and installed the guide blocks with LP4-3 blind rivets.

I then removed the aft fuselage top skins and riveted the F-707 to the support angle.  I also riveted the platenuts to the F-749 forward baggage side covers and temporarily installed.

I also drilled, deburred and riveted the aft F-656 bulkhead braces.  I also test painted the upper support ribs to get a feel for the hammered gray color... We'll see.

 

I have already installed my servo bracket for the TruTrak AP in the wing but needed the bracket for the elevator servo.  Stein fixed me up. 
 

I also received my Airflow Performance fuel injection pump assembly as well as an Andair fuel valve.

I was able to drill the hinges for rivets using the drill press.
 

I also alodined a lot of additional bits and pieces while I was at it.  I also installed platenuts on the outboard seat ribs, installed the aft bulkhead-to-longeron brackets, installed the shoulder harness brackets and riveted the F-741B tunnel cover to the support brackets.

I clecoed the aft seat floors and seat hinges and used LP4-3 blind rivets to install.  I also cut to length and bent the hinge pins that will attach the seat backs to the floor.  All went well other than my back is really sore from bending over the fuselage to install the 100+ rivets.

TruTrak Autopilot Elevator Servo Bracket Install

I was initially stymied when I attempted to install the servo bracket I received from SteinAir because the installation instructions show no dimensions for installing the bracket.

 

I decided against drilling and riveting through the bottom skin so I added a second row of rivets near the bottom of the bracket.

I dimpled and installed the platenuts for the tunnel cover as well as the control access in each front seat floor.
 

I began installing the Airflow Performance filter and high pressure fuel pump but had to stop due to not being able to find my tubing cutter.

 

I drilled and cut the center bearing block and installed the flap actuator rod.

 

Next, I assembled the motor in the F-766A channel and drilled the F-766B bracket.  After disassembly, I deburred and riveted the F-766B bracket  and re-assembled the flap mechanism.

I installed the F-785 Backrest Brace and clecoed the side covers and match-drilled.  I disassembled, deburred and riveted the platenuts.  Finally, I scuffed, primed and re-assembled.

 

Terry Tibbits, a fellow EAAer and RV-9 builder, came by to help out.  I have heard from several other builders that it is much easier to route the fuel lines from the tanks to the fuel selector valve if you do it before the landing gear mounts are installed.  I also have been debating what to do about the F-983A Fuel Valve Plate.  I had cut off the forward section since I will be using electric trim, unfortunately, this leaves an ugly gap where the forward edge meets the F-983C Fuel Valve Cover.  My solution was to make another fuel valve plate out of .063 with a 1" forward lip.

Terry cut the plate, match-drilled and bent the lip with the sheet metal brake.  It fits perfectly with the Andair Fuel Valve.  Oh, did I mention that Terry is an A&P?  You're welcome to come by and help anytime Terry.

Next, before the landing gear mounts can be installed they have to be match-drilled with the landing gear legs.  The plans say to drill with a .311 bit... Whoever heard of a .311 drill bit?  We drilled to 5/16" and deburred.

When trying to fit the mounts through the hole in the floor we quickly discovered they would not fit.  I had cut the holes way back when I was deburring the floor skin and the plans state that the hole will need to be "tweaked" in order for the mounts to fit.

 

Before I mount the gear leg mounts permanently I will install the fuel lines which route through the gear legs.

 

While taking a break, I decided to shoot a few forward covers with the Rustoleum hammerite paint.

I installed the left fuel line by first bending the 3.5" "jog" and then running the tubing through the landing gear mount, then the small cover bracket, then through the cover bracket riveted to the spar.  I then slid the outboard section through the hole in the fuselage and slid the gear leg mount into place.

 

In preparation for fitting the wings to the fuselage, I need to finish a laundry list of details on the wings including installing the Gretz pitot line and electronic control unit (ECU) as well as pulling the various wiring and antenna coax.  Details can be found here.
 

I also installed the right fuel line from the tank through the gear mount to the fuel selector.  I then got a good start bolting in the gear legs.  The Plans call out AN4-12A bolts through the gear mounts but even with thin washers there is not enough thread showing past the nut.  I used AN4-13A bolts and the problem is solved.

 

One hole on the side brackets was obscured by the bulkhead flange so I just drilled through it.  These holes are drilled in assembly so once they were drilled (#30) and opened to full size (3/16"), I was able to install the AN3-6A bolts.

Finally, I back-drilled the five lower mount side attachment holes and installed the bolts and torqued.

I will be jumping over to the wings now but will be back in a few days.
 

Elevator Servo Speed Controller Switch

I began fabricating a bracket for the micro switch near the flap actuator rod that will control the Ray Allen servo speed control module.  The design is pretty simple and will use an Adel clamp around the flap actuator rod which, when the flaps are fully retracted (as in Cruise Mode), will activate the switch which is connected to the servo speed controller.  The result is that the elevator trim servo will run at about half the speed it does when the flaps are deployed (as in Landing Mode).

I had ordered the lever switch from Aerocraft Parts and Avionics so with the Adel clamp installed all I needed to do was fabricate a bracket to hold the lever switch.  I used a scrap piece of .063 1.0x.75 AL angle and drilled for the switch as well as platenuts for attaching to the back of the F-905 bulkhead upright.

 

Total Hours this Page

Total Hours Fuselage (as of 11/4/07)