Installed Brake Lines - Crossover and Main Brake Lines per Sect 33-08 & -09/. Prepped Cable Links for priming per Sect 33-12. Installed nylon Cable Guides.
Friday, June 23, 2017
Fuselage
Brake Lines ( 3 hrs )
Installed Brake Lines - Crossover and Main Brake Lines per Sect 33-08 & -09/. Prepped Cable Links for priming per Sect 33-12. Installed nylon Cable Guides.
Installed Brake Lines - Crossover and Main Brake Lines per Sect 33-08 & -09/. Prepped Cable Links for priming per Sect 33-12. Installed nylon Cable Guides.
Thursday, June 22, 2017
Fuselage
Rudder Pedal Assembly ( 4 hrs )
Installed 8 Brass Elbows to Brake Master Cylinders on Rudder Pedal Ass'ly ( Sect 33-04). Installed first set of Brake Lines between Reservoir to Slave fittings. Pic shows instructions in Sect 5.22 to drill end of tubing and press in a brass insert --that's a first for me. Installed entire assembly into Fuselage per Sect 33-05 & -06. Pedals swing freely w/ light effort - super smooth. Ka-Ching !
Installed 8 Brass Elbows to Brake Master Cylinders on Rudder Pedal Ass'ly ( Sect 33-04). Installed first set of Brake Lines between Reservoir to Slave fittings. Pic shows instructions in Sect 5.22 to drill end of tubing and press in a brass insert --that's a first for me. Installed entire assembly into Fuselage per Sect 33-05 & -06. Pedals swing freely w/ light effort - super smooth. Ka-Ching !
Wednesday, June 21, 2017
Fuselage
Control Sticks & Elev Pushrods ( 5 hrs )
Completed Steps 4 - 9, Sect 36-10 for Align & Drill LH & RH Control Sticks into Bases. Prepped Control Stk Bases per Steps 1 - 2, Sect 36-11. Removed all masking from Fuse for the big reveal. Looking good. Installed Fwd & Mid Elev Pushrods per Sect 36-05, -07, -08, -09 attaching to Control Column, Idler Arms between, and Bellcrank. Super smooth with zero drag and no interference. Sweet !
Completed Steps 4 - 9, Sect 36-10 for Align & Drill LH & RH Control Sticks into Bases. Prepped Control Stk Bases per Steps 1 - 2, Sect 36-11. Removed all masking from Fuse for the big reveal. Looking good. Installed Fwd & Mid Elev Pushrods per Sect 36-05, -07, -08, -09 attaching to Control Column, Idler Arms between, and Bellcrank. Super smooth with zero drag and no interference. Sweet !
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| left SS firewall unpainted |
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| un-masked... |
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| challenge to reach. Washer "wrenches" very helpful |
Tuesday, June 20, 2017
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).
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).
Monday, June 19, 2017
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.
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).
Saturday, June 17, 2017
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.
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.
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| ready to prime |
Friday, June 16, 2017
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.
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.
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