Fuselage

Bulkheads installed ( 4 hrs )

Completed Step 4 at Sect 30-02 adding 22 nutplates to 3 Bulkheads.  Installed Bulkheads per Sect 30-04 Steps 1-5.  Everything aligned with minimal effort so satisfying to add clecos.  Even the radiused lower corners of the Forward Fuse pulled in to align with floor Ribs.   I can see many rivets are gonna be challenging to reach and use rivet gun/bucking bar.

nutplates added.  Had to be creative to access those
close to the curved flange, but got 'em done.

Fuselage

Forward & Aft Fuselage "married" ( 3 hrs )

Ordered Finish Kit (8-10 wks lead time) since 'needed' by mid to late July at rate going on Fuselage.  Vans to include FWF (firewall forward) Kit in the Finish Kit crate.  

Today I buffed, cleaned with acetone, and acid etch primed the 3 Bulkheads.   Still need to rivet on nutplates before can install.

Big step - "married" Forward Fuselage to Aft Fuselage per 13 Steps in Sect 30-03.   Nancy was terrific help as we carefully adjusted height of 4 sawhorses with towels, pillows, etc.   Then...Yay !   we got alignment and inserted clecos.  Next is installing Bulkheads and lots of riveting.

Fuselage

Bulkheads Aft Fuselage ( 3 hrs )

Finished deburring edges & holes in 3 Bulkheads at Sect 30-02.   Dimpled #40 and #30 holes.   Those for nutplates required using Cleaveland Tools Close Quarter Dimple Dies.  Trial fit with cleco with Nancy's assistance.   Seems good fit-up without needing adjustment via fluting.   Ready to prime and rivet on nutplates.

Close Quarter dimple dies

Deburred and dimpled.

Trial fit success !

Fuselage

UHMW Bushings & Aft Fuselage moved (3 hrs )

Trimmed 2 UHMW Bushings for Inboard Flap locations per Step 2 in Sect 32-02.  Used bandsaw then 6" disc sander   - tough stuff !  Installed per Step 1 & 2 in Sect 32-03 (one more item out of order while Fuse was on its side).   Then Nancy helped move Aft Fuselage from walk out basement (had to remove sliding doors...again) into shop ready to join to Front Fuselage.  Otherwise worked on LH & RH Bulkheads and Top Bulkhead per Sect 30-02.  Deburring, etc.  Discovered Vans mislabeled LH vs RH Bulkheads.  Checked at least 4 different ways in dwgs and test fit, etc  before convinced they'd reversed the labels.

 

 

Fuselage

Sealing Firewall perimeter  ( 4 hrs )

After discussion yesterday with Sterling at Van's Prod Support about daylignt showing at LH & RH lower corners for Firewall (ie air leaks !), decided to seal today.  He confirmed Vans uses Pro Seal (ie Tank Sealant).  He noted notches around perimeter would need sealing, and now would be good time to do both.   So I masked around areas, and used 1 oz Tank Seal.  Wow, kinda forgot how sticky and taffy like - hard to apply "neatly" - but got 'er done.  Checking  (w/ bright light inside & shop darkened)  to confirm all sealed, I discovered about 22 locations where their sealant applied between layers of fuselage skin and firewall flange was insufficient (gaps).  Masked again, repeated with more Sealant.   Finally!  it's sealed around entire perimeter.   Also deburred ELT Antenna Bracket & Shoulder Harness Lugs.  Lugs get special treatment to chamfer upper edges ( assume minimizes "show through" as installed inside curved Aft Fuselage skin).

doing again, sealing gaps in layers between outer skin and firewall flanges

inside showing notches sealed from front

Fuselage

Fuel Lines, etc  ( 4 hrs )

Installed all 4 Fuel Lines per Sect 31-06 to -11.  Perfect fit - Thanks! Aircraft Specialty.  Really challenging to access most of the coupling nuts.  A 11/16" crows foot wrench was essential.  Per 31-08, installed eight  Bracket halves to capture Fuel Lines.   Dug deep into tool box trying variety of attachment combinations...some pretty creative.   Glad when last of those were done.  Van's product support Sterling called late today responding to email about Rudder Center Bearing Block not fitting correctly.  He recommended checking if  assembly was bowed due to heat from welding, and bend straight if more than 6mm off.   But my straight edge revealed hardly any (less than 1mm) bowing.   So OK to trim off top surface.  Used table saw to remove 3.5mm from plastic bearing block top surface.  Now it fits perfectly, with no added drag to Rudders, and zero interference with Center Support.  Yay !

checking alignment prior to joining coupling over flare.  Love my new mirror w/ LED lights !

11/16" crows foot to the rescue!

Brackets installed holding fuel line.  

trimmed off  3.5 mm

All Bearing Blocks installed.   Rotates smootly!

Fuselage

Rudder Pedals & Fuel Lines ( 3 hrs )

Still working on items easier to install with Fuse on it's side.   So I installed the Brake Fluid Reservoir per Sec 33-06 Steps 1 & 2, and Step 1 in Sect 33-07, with T connector attached inside of firewall.   Installed Rudder pedals - just the bare bars - as a trial fit-up.   Required first removing burrs on tube ends, then sanding with 400 grit to polish contact zones (enough to slightly reduce diameter was required to reduce friction).   Discovered Center Bearing Blocks are inexplicably 3 - 4 mm too "thick" and likely require trimming. Otherwise when installed they bow the cross tubes, and add drag.   They did align well fore/aft.   Without the Center Bearings, the Rudder Pedals rotate with minor drag.   I emailed Vans Product Support to check if I'm missing something.

  

    

 Received Fuel Lines from Aircraft Specialty - less than 1week from day ordered.   Look terrific, and better yet,  the one I trial fitted was perfectly aligned with flare fitting.  I'm very pleased I took this route vs bending my own.  Planning to permanently install tomorrow.