Finish Kit

Shoulder Belt Cables ( 2 hrs )

Installed both Shoulder Belt Cables into Aft Fuse lugs per Sect 42-06.  Deburred and dimpled Joystick Boot Doublers per Sect 42-07.  Those essentially complete the "Miscellanea" section since I don't have the shoulder belts nor the Joystick Boots ...yet.  Jumped to Sect 41-04 separating Wing Root Fairing Stiffeners per Step 11.

Glad I have a "washer wrench" to help in these tight spots.

Finish Kit

Canopy Fairing done ( 3 hrs )

Final sanded the primer coat w/ 400 grit to a smooth finish.  Removed tape in front for feathering, then the big reveal - removed last layer of vinyl tape on aft edge of Canopy.  Very satisfying to see clean edge along windshield.  Finally.   ( I didn't cover the front of the canopy, so plastic protection sheet got overspray...)       Also torqued LH & RH Steps.  When I stopped in local Napa store to buy more Napa 7220 primer, I found they had a 5/16" socket/U-joint combo for ~$8 (much lower than some I'd seen on-line).  This worked a little better when using my torque wrench.  I had to use a mirror to see the nut while applying torque seal indicator, so kinda messy.

 

       

Finish Kit

Step installation ( 4 hrs )

Sanded on Canopy Fairing smoothing the micro-balloon/resin added for pin holes and few low areas in transition to alum surface area.  Re-sprayed 2 more coats sandable primer - getting really close to done now.   Installed LH and RH Steps per Sect 42-05 Step 1 - a bear to reach lower back nuts.  My hands are large, so really difficult to reach into mounting area.  Used my bucking bar to tap bolts into place...since close tolerance fit.  Some Boelube helped.   After several failed attempts, discovered a 1/4" drive 5/16" socket on 1/4" U-joint and smallest wrench barely fit so I could tighten the nuts on Aft end (vs special ordering the recommended 5/16" socket/U-joint combo).  The sloped floor prevents inserting the bolts from Aft end which would make tightening the nuts easier.

ready for final(?) sanding...

tennis ball protecting shins while in shop !

LH Step viewed from rear.   Clean !

My hand barely fits into rear access...  small wrench worked 

Finish Kit

Flap Motor Cover ( 3 hrs )

Back on Nov 30 I used extra micro-balloon/resin to smooth over the flush rivets on Aft Tunnel Cover around Fuel Control ( where doubler/spacer was attached).   Sanded today and primed - turned out really smooth with no evidence of rivets.   Completed Flap Motor Cover Ass'ly after 1st deburring & primimg.  Used 12" Back Rivet set and Backplate on bench.  Super easy, and "cleaner"  vs Van's version with round head rivets.  Also buffed then primed LH & RH Steps per Sect 42-05, Step 1.

 

 

Steps primed (covered bolt holes, since tight fit tolerance )

Finish Kit

Interior Covers ( 4 hrs )

Deburred edges and holes on remaining interior covers per Sect 42.  Then Nancy was big help buffing all those panels using scotchbrite and cleaning with acetone.  Enabled me to take advantage of another 60 deg sunny day to use the outdoor "spray booth" for priming with Napa 7220.  Also dimpled Flap Motor Covers, switching from round head to flush rivets for smoother appearance.

...much easier than setting up my temporary booth

a lot of covers primed

prefer to dimple these for flush rivets vs round
head.  Quickly primed along rivet line
(complete priming on assembly later)

Finish Kit

Interior Covers ( 3 hrs )

More deburring of various Covers in Sect 42.  Added 6 nutplates to 2 completed prior.  Riveted Doubler to Aft Tunnel Cover - but changed to flush rivets for smoother appearance around Fuel Control Knob.  Adequate clearance was designed into pieces to clear the required dimpling.  Back to finishing the Canopy Fairing, I sprayed 2 coats of sandable primer - part # A4240 Primer from Cromax. Pleased with overall smoothness and contour...but I have more pinholes to fill.    A Dupont paint rep recommended since acrylic based for better compatibility with assumed exterior paint by local paint shop Byerly Aviation ( vs oil based Rustoleum primer I was considering).  I recently contacted Jerry Piatt at Byerly who recommended I contact Tom, his Dupont paint rep locally at National Coating & Supply).

deburred w/ nutplates installed...  but no
screws yet.  Will prime and finish paint soon.

switched to flush rivets for thin spacer surrounding fuel control

#A4240 primer.   Seems "thick", covers well.   More sanding....

Finish Kit

Seat Backs and Miscellanea ( 4 hrs )

Completed Seat Backs with remaining rivets along LH and RH sides, then Sect 39-06 & -07 for Hinge Pins.   Since I'll probably leave off Seat Back Braces due to using only rearmost position (they're not engaged), I didn't add the safety wire retentions for the Hinge Pins.  But they fit perfectly and work really well.   Also made the bottom Hinge Pins ~ 1/4" longer to allow long taper for easier insertion.  Overall, the Seat Backs fit and look great.  I started Sect 42, called "Miscellanea" - which are the removable interior covers.  Deburred Seat Ramp Cover, and LH & RH Control Column Covers.  Attached the few nutplates (buffed, cleaned and primed just at nutplates for now - so I could install.  Planning major prime and painting session later )

Seat backs fit perfectly between black UHMW
blocks on crossbar

in rearmost position, braces are not used...

alternate brace positions if seat moved to
middle and forward positions

tip forward to access baggage area