Fuselage

Bellcrank Assembly ( 4 hrs )

Built Bellcrank Mount and AutoPilot Pitch Servo Bracket per Sect  36-06 and -07.  1st trimmed bracket, added optional 1.25" dia lightening hole.  Deburred holes & edges on both.  Machine C'sunk Mount for flush rivets holding 8 nutplates.  Primed both.   Riveted K1000 nutplates using my "Main Squeeze" - sure works great.  Although time to install Pushrods, decided to wait another day for paint curing before I remove masking  on Fuse interior (after touch ups yesterday).   Jumped to Sect 36-10 to assemble Control Sticks into Control Bases. These are the optional (upgrade) Sticks with Grips & wiring.  They're pre-drilled for mounting to base, which is good news.  Ready for Steps 4-8 @ Sect 36-10 (match drill and enlarge to enable bolting at joint).

 

 

Fuselage

Elevator Pushrods ( 3 hrs )

A few locations on the interior needed some re-painting.  Simply sanded with 400 grit, cleaned and sprayed a couple light coats.   These blended perfectly...so very satisfied with overall results.   Completed Elev. Bellcrank Assembly at Sect 36-06, Step 5.  Finished Fwd, Mid, and Aft Elev Pushrods by blind riveting Rod Ends, then installed Rod End Bearings / Jam nuts to specified lengths per Steps 7-9 Sect 36-03 and Steps 7-8 Sect 36-04   (Aft Elevator was to 1/32" over 6 ft length).

 Marshall County Flyers 50th Annual Father's Day breakfast / fly-in was another big success (Sunday, June 18).  Served over 1,500 people!   My wife and I worked along with 50 other volunteers from 6am to 3:30.  Lot's of work, but fun to see the enthusiasm from the community.  Lots took advantage of airplane rides for $15.

Fuselage

Elevator Pushrods ( 3 hrs )

While waiting for interior paint to fully cure 48 hrs, prepared Fwd, Mid, and Aft Elevator Pushrods per Sect 36-03 & -04.  Used drilling template to drill holes into Rod End Fittings.  Deburred holes, scratched/buffed  with scotchbrite, cleaned all w/ acetone, then primed with Napa 7220.  Ready to rivet when primer cures.

ready to prime

Fuselage

Interior Painting ( 3 hrs )

Finally completed all masking by covering 2 air vents.  Cleaned surfaces again with acetone, then used tack rag to get remaining dust.   After one more test spray yesterday, decided to not use RustOleum Hammered Silver (inconsistency, appearance concerns).  Switched to RustOleum High Performance Enamel Spray - Aluminum #7515838 in 14oz Spray cans.  Less than $5 per can at Menards.   Glad we decided to switch - it covers really well, and provides nice satin finish.  Actually has aluminum particles as part of it's formula, too.  My work shop seemed to be A-OK as a giant paint booth using 2 fans on high out the back door of garage.  Paint looks fine with two light coats.  Applied overhead, vertical and horizontally.   Waiting 48 hrs per instructions to decide to apply 3rd coat.  Used only 2 1/2 cans so far.

 

Fuselage

Masking for Interior Paint ( 2 hrs )

Great help from Nancy today masking forward areas, including hard to reach firewall area. Decided to not paint SS firewall, only aluminum angles and framework/structure at perimeter.  Applied Primer (Napa 7220) to Aft Fuse in zone above baggage area.  All surfaces in QB Fuse are factory primed. Two fans facing out back door, with 6" opening of garage door, and entire shop worked well as paint booth.  Only 2 air ducts to mask, then ready to paint interior.

 

Small area on Aft Fuse needed primer

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