Empennage

Aft Fuselage ( 1 hr )

Riveting Aft Deck - using Main Squeeze, I can reach majority rivets.   Discovered 2 rivets on each side of F01411D Angle needs to be  -8 long, not specified -7 at Fig 2 on Sect 10-27 (additional layer due to longeron C channel at this location - see sticky note in pic)

Empennage

Aft Fuselage ( 4 hrs )

Cont'd Sect 10-27 at Step 5 & 6:  Match drilled 2 angles, then deburred all holes.  Primed all pieces for Aft Deck assembly.  Started rivets Step 7 - significant variety of sizes and types in one area needing numerous tool set-ups.   Challenging to determine best approach, but trial and error is working,  combined w/ prior experience on what works well, etc.   All these pieces and rivets are critical since this is where Horiz Stab and Vert Stab attach...lots of loading !

 Also jumped ahead to Sect 10-32 to build the rear Access Cover Plates.  Deburred all edges and holes, then used #6 screw size dimple dies to create recess for flush machine screws per the Optional arrangement.  I "broke" the edges with the roller tool to insure Plates lay tight to fuselage skins.  Glad I chose the Optional, even though under HS, it's "slicker" with flush screw heads.

Already mounted once with machine screws...forgot to take pic.

Empennage

Aft Fuselage (2.5 hrs )

Determined needed about 4" more of C1037 and C1036 wires toward front...so entire W00057 Aft Fuse Harness had to have tie wraps removed, re-adjusted position about 5 inches, and re-installed.   Sect 10-25 doesn't provide length of C409P connector/hharness portion at rear.  But while working on Aft Deck installation, determined I had excess length at rear (Sect 10-27 Fig 3).  Other antenna and harness directions clearly show critical length of free ends on installation pages.  So would've been helpful on 10-25 !   Required about 1 hr to re-do.

C1036 & 37 were 4 inches short of bulkhead

Corrected...taped to front of bulkhead

Sect 10-27 cont'd with dimpling and fit up of Aft Deck pieces.  Discovered missed dimpling across top of F0140C bulkhead - but fortunately easily done w/ Main Squeezer (whew).  Re-primed the 8 holes.  Cleco'd and Final Drilled all holes.  I'll prime after Match Drilling the 2 angle reinforcements.

fit is good !

ready to match drill 2 angles

Empennage

Aft Fuselage ( 2.5 hrs )

In between parade and fireworks, I was able to fit in couple hours in shop.   Finished Static Air Kit by installing fittings between Port and tubing (now that bonds had fully cured).

Wiring routed, Air Kit installed

Cleaveland Static Air Kit installed.  

Then Sect 10-27:  deburred three pieces for Aft Deck.  Scuffed since I was already covered in dust, so I'm ready to dimple, etc next.

Empennage

Aft Fuselage ( 5 hrs )

Riveted Rudder Guides into Side Skins w/ specified blind rivets (thin washers critical to withstand loading against nylon blocks).

Inside view after blind rivets

Installed Static Lines - replaced Van's provided with Cleaveland's Upgrade Kit .  Bonded in the 2 Static Source Ports using J-B Weld epoxy (needs to cure 4-6  hrs, w/ full strength in 15 hrs) after cleaning surfaces with acetone.

Outside view of Port (one each side)

Routed tubing using 4" tie wraps - loose to later attach fittings to Ports, etc.  Moved on to Sect 10-23: Installed UAT Antenna Cable.   Sect 10-24: Installed ELT Antenna Cable,   Finished details in Sect 10-25 (prior routing done prior Skins added LH side) for Aft Fuselage Harness.  And finished details in Sect 10-26 for "Phone" Cable.

I will be calling Van's tech support to determine why wires C1036 and C1037 are each about 6 inches short of bulkhead F01406B.  Can't see how I've misrouted, etc.  Everything else fits A-OK and is neatly tie wrapped at designated locations, protecting from rubbing on edges, etc.

Empennage

Aft Fuselage ( 1 hr)

Sect 10-21:   Installed 3 sizes of snap bushings in various locations...some for rudder cable, others for antenna, etc   Then routed the Rudder Cables.    Needed to machine C'sink the "nylon" blocks to fit #30 size dimples on Side Skin.   Ran out of time to rivet these in place...

View inside aft fuselage showing cable guides.

Nancy's ready to go flying !

Empennage

Aft Fuselage ( 1 hr )

Finished Sect 10-19 (finally...a lengthy page with essentially one step...riveting).   Nancy's help was significant for LH Side joint to Bottom.  I was again underneath on a chaise lounge chair brought in from pool area, while she held the titanium bucking bar from top/inside.  Next, Sect 10-21 for installing rudder cables.