First time sitting in Fuselage. Sweet !
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| Hey...it's an open cockpit...for now. |
Monday, July 24, 2017
Monday, July 17, 2017
Fuselage
Elevator Pushrod Attached ( 2 hrs )
Celebrated my dad's 90th birthday! on Sunday... and now back into shop to finish the Fuselage. Completed Sect 36-15 Steps 1-6 and Sect 36-16 Steps 1-4. Re-attached Horiz Stab and Elevators (LH & RH) to Fuse, then connected Elev Pushrod. Needed to climb into Baggage area (first time actually on-board) to check Bellcrank "neutral" position. Used Van's template showing as assembled is "perfectly" at designed 92.4 degree position. Yay - no adjustment to rod end needed ! Also confirmed Elevator Horns hit stops before Control Column hits their local stops...per instructions. As before, getting 29.5 deg Up and 25.4 deg Down travel (within Specs). Joystick moves super smoothly - very satisfying. Counterweights seem to be balanced too. Done w/ Fuselage build - ready for Finish Kit to be delivered from Vans. Supposed to be crated July 10 but seems they're 1- 2 weeks behind - so hoping receive about Aug 3. (after Oshkosh!)
Celebrated my dad's 90th birthday! on Sunday... and now back into shop to finish the Fuselage. Completed Sect 36-15 Steps 1-6 and Sect 36-16 Steps 1-4. Re-attached Horiz Stab and Elevators (LH & RH) to Fuse, then connected Elev Pushrod. Needed to climb into Baggage area (first time actually on-board) to check Bellcrank "neutral" position. Used Van's template showing as assembled is "perfectly" at designed 92.4 degree position. Yay - no adjustment to rod end needed ! Also confirmed Elevator Horns hit stops before Control Column hits their local stops...per instructions. As before, getting 29.5 deg Up and 25.4 deg Down travel (within Specs). Joystick moves super smoothly - very satisfying. Counterweights seem to be balanced too. Done w/ Fuselage build - ready for Finish Kit to be delivered from Vans. Supposed to be crated July 10 but seems they're 1- 2 weeks behind - so hoping receive about Aug 3. (after Oshkosh!)
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| Full Up 29.5 deg. TE is aligned, although this view they seem misaligned. |
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| Full Down 25.4 deg. TE is aligned, although this view they seem misaligned. |
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| access to Bellcrank... |
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| 92.4 deg exactly (no adjusting required) |
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| I'm 6'4".... and barely fit in baggage area... |
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| Joystick (wrapped grip) works ! |
Thursday, July 13, 2017
Fuselage
Skin Stiffeners at Aft Fuse ( 2 hrs )
Completed Sect 37-08 w/ Steps 4-6 riveting Skin Stiffeners to Aft Fuselage Side Skin. Almost done with QB Fuse (yay!) - only need to re-mount Elevator to check up & down travel stops. Vans is supposed to be crating my Finish Kit this week - but probably a week delay - so expecting delivery now after Oshkosh.
Completed Sect 37-08 w/ Steps 4-6 riveting Skin Stiffeners to Aft Fuselage Side Skin. Almost done with QB Fuse (yay!) - only need to re-mount Elevator to check up & down travel stops. Vans is supposed to be crating my Finish Kit this week - but probably a week delay - so expecting delivery now after Oshkosh.
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| instructions have these 2 holes left open for now... |
Wednesday, July 12, 2017
Fuselage
Roll Bar ( 4 hrs )
Nancy helped me lower the Fuse onto new "short" support legs, so easier access to Canopy, etc during Finish Kit stage. Also more secure than reliance on several sawhorses. Completed riveting Roll Bar Brace to Roll Bar (Frame and Aft Fuselage) per Sect 37-07 Steps 1-3. Started Sect 37-08 attaching Skin Stiffeners to Fuse and LH & RH Aft Fuse (below window area).
Nancy helped me lower the Fuse onto new "short" support legs, so easier access to Canopy, etc during Finish Kit stage. Also more secure than reliance on several sawhorses. Completed riveting Roll Bar Brace to Roll Bar (Frame and Aft Fuselage) per Sect 37-07 Steps 1-3. Started Sect 37-08 attaching Skin Stiffeners to Fuse and LH & RH Aft Fuse (below window area).
Tuesday, July 11, 2017
Fuselage
Flap Position Sensor, Roll Bar install ( 5 hrs )
Bolted on Flap Actuator per Sect 34-04 Steps 3 & 4, and 34-05 Steps 1 & 2. Safety wired jam nut on rod end. Completed optional Flap Position Sensor install (Sect 54-04 Steps 6-9). Works great - used R/C Field Kit 12v starter battery to operate through range of travel. Riveted on Roll Bar Ass'ly per Sect 37-06 Steps 1-9, including Doublers and Bronze Bushing for Canopy retention pin. Added 27" square tubing temporary legs to LH and RH Wing Spars. This positions Fuse lower so easier to work on Canopy and Rear Window during Finish Kit (actual landing gear legs would be too tall, and project out considerably). Bolted in using same bolts, washers & nuts originally holding plywood spacers in Spar from QB shipment. Added "fender washers" to fill width perfectly between front to rear Spar. Those bolts are sheathed in plastic too, protecting holes in Spar.
Note: bottom hole is outward slightly from top hole, probably setting up couple degrees dihedral when Wing is installed. Thus "leg" is not perfectly vertical, but it'll do....
Bolted on Flap Actuator per Sect 34-04 Steps 3 & 4, and 34-05 Steps 1 & 2. Safety wired jam nut on rod end. Completed optional Flap Position Sensor install (Sect 54-04 Steps 6-9). Works great - used R/C Field Kit 12v starter battery to operate through range of travel. Riveted on Roll Bar Ass'ly per Sect 37-06 Steps 1-9, including Doublers and Bronze Bushing for Canopy retention pin. Added 27" square tubing temporary legs to LH and RH Wing Spars. This positions Fuse lower so easier to work on Canopy and Rear Window during Finish Kit (actual landing gear legs would be too tall, and project out considerably). Bolted in using same bolts, washers & nuts originally holding plywood spacers in Spar from QB shipment. Added "fender washers" to fill width perfectly between front to rear Spar. Those bolts are sheathed in plastic too, protecting holes in Spar.
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| single flush rivet under doubler |
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| Built 1.5" sq tubing short legs |
Monday, July 10, 2017
Fuselage
Flap Control / Position Sensor ( 2 hrs )
Started Sect 54, Flap Position Sensor. Modified provided Pushrod to slightly thicker version with threaded end from R/C airplane supplier. Clevis perfectly fits existing hole for attachment to Sensor, and allows adjustment. Was hoping to use angle drill on Flap Control previously installed (per Sect 34), but insufficient clearance. So removed 4 bolts, and drilled hole for pushrod...then re-assembled into Fuse, including re-torquing. Started crimping Molex Micro-fit Pins to Sensor wires. Ugh...so tiny, need lots of patience.
Started Sect 54, Flap Position Sensor. Modified provided Pushrod to slightly thicker version with threaded end from R/C airplane supplier. Clevis perfectly fits existing hole for attachment to Sensor, and allows adjustment. Was hoping to use angle drill on Flap Control previously installed (per Sect 34), but insufficient clearance. So removed 4 bolts, and drilled hole for pushrod...then re-assembled into Fuse, including re-torquing. Started crimping Molex Micro-fit Pins to Sensor wires. Ugh...so tiny, need lots of patience.
Sunday, July 9, 2017
Fuselage
Roll Bar Assembly ( 1 hr )
Removed Roll Bar Ass'ly from Fuse - deburred new holes (on Bases too). Mach C's for CS4-4 rivets in 1 location RH & LH side (under Doubler plate). Final painted same as rest of interior: Rust Oleum Professional color Aluminum 7515 ). Letting cure before mount to Fuse.
Removed Roll Bar Ass'ly from Fuse - deburred new holes (on Bases too). Mach C's for CS4-4 rivets in 1 location RH & LH side (under Doubler plate). Final painted same as rest of interior: Rust Oleum Professional color Aluminum 7515 ). Letting cure before mount to Fuse.
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| deburred holes in Base |
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| Doublers and Bronze bearing. Note C's for one rivet |
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| final paint...Rust Oleum Aluminum #7515 |
Saturday, July 8, 2017
Fuselage
Rollbar Assembly ( 1 hr )
Completed Sect 37-05 Steps 1-4 mounting Rollbar Frame onto Fuse at Bases. Great fit...tight but perfectly aligned...yay! Added Brace to Aft Fuse at top. Then drilled 24 #30 holes on outer and inner Frames at Bases on left and right sides. Ready to dis-assemble, deburr and final paint interior "aluminum" color.
Completed Sect 37-05 Steps 1-4 mounting Rollbar Frame onto Fuse at Bases. Great fit...tight but perfectly aligned...yay! Added Brace to Aft Fuse at top. Then drilled 24 #30 holes on outer and inner Frames at Bases on left and right sides. Ready to dis-assemble, deburr and final paint interior "aluminum" color.
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| peel back aft fuse skin to access rearmost holes via 12" drill bit |
Friday, July 7, 2017
Fuselage
Rollbar Assembly ( 3 hrs )
Completed Roll Bar Assembly with blind rivets to Aft Frame. Since rear polycarbonate window fits directly onto Window Shims, filed smooth/"flush" (only slight amount required) the CS4-4 blind rivets on top surface. Re-primed Roll Bar. Finish painted Brace and remaining Doubler pieces. Decided to wait for Primer on Roll Bar to cure before top coat.
Completed Roll Bar Assembly with blind rivets to Aft Frame. Since rear polycarbonate window fits directly onto Window Shims, filed smooth/"flush" (only slight amount required) the CS4-4 blind rivets on top surface. Re-primed Roll Bar. Finish painted Brace and remaining Doubler pieces. Decided to wait for Primer on Roll Bar to cure before top coat.
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| prior to final primer. Shown Aft side on top in pic |
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| interior paint added |
Thursday, July 6, 2017
Fuselage
Rollbar Frames ( 4 hrs )
Riveted Outboard Strap (flush rivets) and Inboard Strap ( universal head ) to Fwd Rollbar, then riveted Bushing Doublers to Aft Frame capturing bronze bushing. Started riveting Aft to Fwd Rollbar w/ CS4-4 blind rivets (flush) and LP4-3 blind rivets per Sect 37-04 Steps 5-7. Please with fit up, alignment, etc...as usual with Van's kit.
Riveted Outboard Strap (flush rivets) and Inboard Strap ( universal head ) to Fwd Rollbar, then riveted Bushing Doublers to Aft Frame capturing bronze bushing. Started riveting Aft to Fwd Rollbar w/ CS4-4 blind rivets (flush) and LP4-3 blind rivets per Sect 37-04 Steps 5-7. Please with fit up, alignment, etc...as usual with Van's kit.
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| Outboard and Inboard Straps riveted |
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| Bushing and Doublers on Aft Frame |
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| CS4-4 flush rivets on Window Shim along Aft Frame |
Wednesday, July 5, 2017
Fuselage
Rollbar Assembly ( 5 hrs )
Completed drilling #30 holes, then Mach C'S per Steps 1-4 Sect 37-04. Deburred, buffed, cleaned with acetone, and primed with Napa 7220 acid etching primer including all C'sinks on Rollbars, and "new" Straps and Window Shim.
Completed drilling #30 holes, then Mach C'S per Steps 1-4 Sect 37-04. Deburred, buffed, cleaned with acetone, and primed with Napa 7220 acid etching primer including all C'sinks on Rollbars, and "new" Straps and Window Shim.
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| C'Sinking Window Shim |
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| C'sinking FWD Rollbar for flush rivets |
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| C'sinking for Rollbar Brace.....6 holes |
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| confirm C'sinks are correct depth for Brace. |
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| After priming...ready to rivet together |
Monday, July 3, 2017
Fuselage
Drilling Rollbar Frames ( 4 hrs )
Pre-assembled Outboard & Inboard Straps to Fwd and Aft Rollbar Frame Assemblies per Sect 37-03 Steps 1-6. Lots of #40 size clecos. Delayed priming Straps and Window Shims until after drilling and C'sinking. Lot's of #30 drilling (every #40 hole). Not enough #30 clecos for every hole, but not required.
Pre-assembled Outboard & Inboard Straps to Fwd and Aft Rollbar Frame Assemblies per Sect 37-03 Steps 1-6. Lots of #40 size clecos. Delayed priming Straps and Window Shims until after drilling and C'sinking. Lot's of #30 drilling (every #40 hole). Not enough #30 clecos for every hole, but not required.
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| Outboard and Inboard Straps cleco'd to Fwd Frame |
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| Aft Frame cleco'd |
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| Window Straps cleco'd to Aft Frame |
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| Drilling #30 holes, replacing #40 clecos. 1/4 remain to do... |
Saturday, July 1, 2017
Fuselage
Rollover Assembly ( 1 hr )
Built FWD and AFT Rollbar Frame Assemblies per Sect 37-02 Steps 4 & 5, forty four AN470D4-5 rivets later in Splice plate joining LH to RH rollbars. Using the Fuse as a jig for the first 4 rivets works great. Used Main Squeeze for both initial 4 and remaining back on bench.
Built FWD and AFT Rollbar Frame Assemblies per Sect 37-02 Steps 4 & 5, forty four AN470D4-5 rivets later in Splice plate joining LH to RH rollbars. Using the Fuse as a jig for the first 4 rivets works great. Used Main Squeeze for both initial 4 and remaining back on bench.
