Fuselage

Prep for Interior Painting  ( 5 hrs )

Installed Idler Arms per Sect 36=02 Step 2 - torqued AN4 bolts.  Sure moves easily.  Riveted Bellcrank Assembly.   Built Stick Link Pushrod with rod end bearings.  Drilled 2 holes in work table exactly 21.5" for AN3 bolts, to serve as a jig.  This made setting correct distance and alignment easy.  Time to prep interior to paint: used Dawn dishwashing soap (recommended by other builders on VAF forums) for oil cutting power to clean all interior surfaces.  Followed by couple hours of masking.  Nancy joined to help where there was room for two at a time.   Still more to do - but getting there (eg  air vents, SS firewall, cowling, exterior perimeter).  Will need to 1st prime some of the Aft Fuselage along upper area.

         

Fuselage

Aileron & Elevator Systems ( 3 hrs )

While I'm pending final decision on interior paint (and procrastinating a bunch of masking), I started Sect 36, Aileron & Elevator Systems (pushrods and bellcranks for inside Fuselage).   Prepared several pieces by final drilling assemblies, then deburring.   Test fit ups went well, such as the Elevator Bellcrank w/ captured bearing per Sect 36-06.  Pleased all three Pushrods were pre-cut to exact length...Yay!   Primed all except pushrod tubes.

pic prior priming bellcrank pieces

Fuselage

Flap Torque Arms ( 3 hrs )

Installed LH & RH Flap Torque Arms.  First sanded bearing surface transition to powder coated paint on tubes.  Then cleaned inside tubes, followed by priming.  Used shotgun cleaning wand - works well to insure coverage with little waste.   Torque Arms installed easily (certainly NOT loose), aligned perfectly.  Torqued four bolts.   Trial fit Flap Motor/Actuator - success !

LH Arm...outside Fuse (inside wing root area)

Fuse still on RH side so easier to reach center area ....so flying knife edge. 

Fuselage

Interior color & Flap Actuation Ass'ly ( 3 hrs )

Getting ready to paint interior color, so I've examined other builders experience and opinions on VAF.  Decided to go w/ simple spray cans, and Rustoleum enamels seems favored (staying away from lacquers ).   Recommendations are to avoid dark colors (gets very hot!), yet not too light (adds many reflections in canopy).  Staying within gray tones.   I narrowed interior colors from initial 6 to the 3 purchased yesterday to trial.  Prepared a scrap piece of aluminum w/ the Napa 7220 self-etching primer I've been using (~ 48 hrs cure), and divided into three sections.  Good results:  Decided the Granite/satin finish is too dark, and the Aluminum/gloss is too bright (although not as glossy as expected).  The one on right side is called "hammered" for it's textured appearance.  It's not as shiny, and seems a good balance between too dark vs too bright.  Plus it will hide minor defects (before and during painting), and goes on easily.   It's finish seems between satin and gloss, with a slight texture and metallic appearance.  Letting it fully cure to test it's toughness while I consider other gray options.

Leaning toward one on right:  Hammered (silver metallic).

Opposite direction in sun.   Satin one on right looks blotchy...

Jumped to Sect 34-02 Steps 1-11 to build Flap Actuation Ass'ly.  First added flat overhanging surface to facilitate clamping.  Template provided (same one used for Aileron alignment, etc) works great.  Ready to prime inside tubes, then assemble into Fuse.

 drilled, temp bolts holding LH side.

Completed LH and RH torque arms.   Temp bolts holding while I admire results

Fuselage

Baggage Side Panels ( 3 hrs )

Completed RH Baggage Side Panel riveting - so both sides done.  Yay !  Looks great.  While still exploring what interior paint to use, I jumped to Sect 33-11, Step 5:  polyethylene sleeves over Rudder Cables (acting as guides, etc).  Attached via 4 "adel" clamps.   Very challenging due to tight space.  Took more than 2 hrs for just 4 bolts!   Pictured some of the tools used for this tight & awkard reach.   Had to be creative and VERY patient, but finally got 'em done.

Looks spacious from inside....

Fuselage

Baggage Side Covers  ( 3 hrs )

Deburred edges and holes, dimpled as needed Baggage Side Covers.   After priming, riveted LH side panels to Fuse.  Cleco'd RH side, ready to rivet next work session.   Note:  top of each panel is supposed to be underneath Fuse Side Ribs, but I installed over - fits OK, and much better/smoother appearance.

trial fit

partially riveted.   Flush rivets at Aft Bulkhead.  Blind everywhere else

LH Side done.   Prefer Side Panel "over" Fuse Side Ribs

Fuselage

Flap Motor Channel ( 2 hrs )

Added nutplates to Channel and Splice per Sect 32-06,  then completed installation of Flap Motor Channel, Splice and Brackets per Sect 32-07 Steps 1-4.

 

  re-oriented pic into upright position.  Trial fit Flap Motor/actuator