Empennage

Aft Fuselage (2 hrs )

Sect 10-20 - Finished 8 nutplates on RH Access Plate opening.  Added the 12 nutplates along top - rear fuselage (for retention of fiberglass around Horiz Stab later ).  Step 4 completed with 2 Angle Stiffeners in rearmost portion of fuselage along Side Skins.   Small space...so one on each side was hard to reach.   After Nancy helps with last rivets along LH side at joint to Bottom Skin, ready to move to rudder cable install, etc.

Empennage

Aft Fuselage (2.5 hrs )

Jumped ahead to Sect 10-20 to rivet on the Rudder Stops (LH & RH sides).  Challenging access - but perseverance won out.    Since I've chosen the Optional access plate mounting using flush screws...next task is to Machine C'sunk top 2 nutplate locations each side (longeron is too thick to dimple, so instructions are to simply C'S now).  Then riveted on all 8 nutplates on RH side.  Ready to enjoy another beautiful day with mild temps around 77 deg with low humidity  - time to ride the Harley, then fly R/C this evening (essentially no wind today !)

Empennage

Aft Fuselage  ( 1.5 hrs )

After flying our club's C172 to Rochelle and back this am for breakfast (beautiful cooler weather around 75 deg), Nancy helped me rivet along the RH  Side Skin to Bottom Skin joint.  I layed underneath on chaise lounge chair using the flush set in rivet gun, while she used the titanium bucking bar from above.    Worked really well...again, tight overlap with no waviness between rivets.

Empennage

Aft Fuselage (2 hrs )

Cont'd Sect 10-19.  Riveting w/ longer -4 rivets (for extra layer) along LH and RH Aft Fuselage Bottom.  Really satisfying to see final fit along Side Skins to Bottom Skin...no waviness.

Empennage

Aft Fuselage (1 hr )

Cont'd Sect 10-19 riveting along lower curved portion of LH Skin at J-stiffener.  Only very lowest row of rivets along curved Side Skin joining to Bottom Skin, and at "Tail" rear section remain.

Empennage

Aft Fuselage (3 hrs )

Cont'd Sect 10-19 with curved sides.  Nancy helping (yeah!) by bucking while I'm using back riveting tool in gun.  Progress...but lots of rivets in Side Skins !



Thurs, June 23  Aft Fuselage (1.5 hrs )

Cont'd Sect 10-19 on LH side, now at lower curved area along Sides.

Empennage

Aft Fuselage (5 hrs )

Switched to LH fuse side skin - riveted all the flat side area.  Nancy joined me in afternoon to finish mid-section with the harder to reach rivets.  Sweet!  Also riveted the alternate sizes (e.g. at tail the 426  4-4 rivets) where I found I could reach with the Main Squeeze tool.   Ready now for lower curved portions on each side.

Empennage

Aft Fuselage (1.5 hrs)

After enjoying morning taking turns flying around the pattern today in our clubs C172, my wife & I returned home to rivet fuselage side skins.   Good to have her assistance back riveting (she's using the bucking bar on outside, I'm using back rivet set in rivet gun addressing shop heads from inside).

Progress...RH side essentially done on "flat".   Curved bottom next...

Empennage

Aft Fuselage (4 hrs)

Sect 10-19:  Used blue tape to mask over holes NOT to rivet...yet.    Took 45 min to study dwg and designate on LH and RH sides...but saves oops later.     Step 1 - riveting flat sides first (save curved sides for last to help sides lay tight, per instructions).   Slow going, but progress on RH side.  Back rivet seems best.  However, some require flush set in gun with titanium bucking bar on inside to reach.

Empennage

Aft Fuselage ( 1 hr)

Sect 10-17, Riveted (16)  F1411 Bulkhead to Lower Aft Fuselage - with assist from wife using bucking bar from above while I applied flush rivet set/rivet gun from underneath.  Repeated at F1410 Bulkhead with Bottom Skin and forward edge of Lower Aft Fuselage...just 6 rivets.   Now onto both sides...

Empennage

Aft Fuselage (3 hrs )

Sect 10-14 finished w/ cleco'd RH Side Skin...with help from my wife, Nancy.  Finished also 10-16 w/ Priming of Aft Bottom Skin, then rivet on the rearmost Bulkhead F01412 via Sect 10-17.

  Next installed Lower Aft Fuselage assembly into Aft Fuselage - Great Fit !   Really a puzzle to align layers all at once...but really pleased with outcome.   Ready to rivet the fuselage !

Empennage

Aft Fuselage ( 3 hrs)

Sect 10-14;  routed Aft Fuselage Harness & Phone Cable along F01486A-L J-Stiffener. Challenging to insure correct cable leads are routed appropriately, per diagrams in 10-25 and 10-26.  

Need helper to position RH Skin onto assembly, so worked ahead on 10-15 Aft Bottom Skin:  Used band-saw to remove extra material both sides, "sanding" flush to line with belt sander.   Then deburred all edges & holes, drilled larger diameter holes, and finally dimpled #40 holes. Ready to prime and rivet next.

Trimmed pieces (scrap).   Cleco'd rearmost bulkhead as test fit...A-OK.

Empennage

Aft Fuselage ( 2 hrs )

Sect 10-14, Steps 8-9 completed after first priming all 4 of the long J-Stiffeners.   My brother-in-law, Rex was great help aligning and cleco'ing the LH Side Skin onto the Aft Fuselage Assembly.   Lots of clecos, but fit up was really good.  Ready to run the wiring, etc.

Rex after we flipped the assembly over.

A new builder is born...?

My wife Nancy with her brother Rex.  Thanks for the help!

Empennage

Aft Fuselage (1.5 hrs )

Finished dimpling LH Side Skin.

Sect 10-14 Steps 5-7 completed adding LH side J-Stiffeners and c-channel Longeron.   Cleco'd F1410 & F1411 Bulkheads.   Ready to add LH Side Skin, but need to lay couple wires first on one of the J Stiffeners (apparently better now, vs after Side Skin added).

  I'll prime the J-Stiffeners prior final assembly...

Empennage

Aft Fuselage (2.5 hrs )

LH Side Skin...repeat.  1st "break" edges with edge forming tool (rollers) , then deburr edges, then deburr all holes.   Dimple #27 (6 holes), #30 holes (few exceptions), and all #40 holes.   But only partly done since beautiful day @ 75, clear sky with low humidity = perfect to take Harley for cruise in afternoon.

Above pic shows inside curved skin, requiring reduced diameter female die.  Still leaves marks, but no "dings".  Didn't get to polished finish on die surface.  Requires continuously monitoring alignment so die "nests" in the curve with sides modified, and holding skin at appropriate angle.

Empennage

Aft Fuselage  ( 3.5 hrs )

Sect 10-14, Step 1 & 2  - dimple RH Side Skin, after deburring all holes and edges.   Switched to "sanding" edges for these extra large pieces (vs holding and guiding along grinder, or using air drill with smaller Scotchbrite wheel.   Also, I first put in the edge "breaks" per instructions using Cleaveland's roller tool.  Planning repeat for LH Side Skin tomorrow.

Empennage

Aft Fuselage  ( 3 hrs )

Nancy was a huge help today as we Back Riveted the Aft Fuse skin to J-Stiffeners, 2 Bulkheads, and the Bellcrank Rib Assembly.   Yeah ! Sect 10-13, Step 6 now done.   The Bellcrank Rib Assly required switching to Flush Rivet set from outside, w/ Nancy holding titanium bucking bar inside (all done while Aft Fuselage is upside down...so bulkheads "hang" down).   For those rivets, my Back Rivet tool couldn't be aligned straight - needed an extra long version apparently.

But much of the Aft Fuse was Back Riveted with Nancy holding the new round bucking bar while I took my turn riveting from underneath "upside down".  Whew...glad this is done.

Empennage

Aft Fuselage ( 3 hrs )

Finished machine countersinks on longeron per Sect 10-14, plus dimpled other J-Stiffeners.  Back to scuffing, cleaning w/ acetone and spraying 7220 Primer.  Time consuming, but progress.   New Back Rivet Bucking Bar from Cleaveland Aircraft Tools delivered today (also Static Air Kit to replace Van's "cheaper" version).  Planning Saturday to rivet Aft Fuselage Bottom Skin, Bulkheads, etc  with my wife's assistance.  

Empennage

Aft Fuselage ( 3 hrs )

EAA Tech Counseler, Sam Sisk inspected build progress (2nd visit).  Good discussion w/ positive feedback.   Thanks Sam !  

Postponed Step 6 pending delivery of Round Bucking Bar for Backriveting Skins...from Cleaveland Aircraft Tools.  So skipped ahead to Sect 10-14 to more dimpling of side J-Stiffeners, plus machine countersinks long C channels (1 of 2 done).

Shop A/C unit added

A/C for Airplane Factory

Purchased from Menards for $278 this portable 10,000 BTU A/C.  Runs on 115 a/c at 9.3 amps max...so readily accommodated.   Used 1x8 board from Van's Empennage Kit crate to allow 6" diameter exhaust ...and extra hole for water drain hose.    This is good option vs blocking my man door at other end of garage with window unit, etc.

Really pleased it's relatively quiet with lots of air flow, and puts out considerable cold air.   First day was not above 80's outside, but was very humid.  Kept the shop very comfortable even not "on" all the time.  AMEN !

Note:  removed guide wheels from top section, so could hold upper section "tight" against door frame seals.  Rigged door so can't be opened, and unplugged door opener for the summer or until needed...

Empennage

Aft Fuselage  ( 5 hrs )

Yesterday bought, then installed portable A/C  unit for shop - exhausting under garage door.  Used 1x8 board from Empennage kit crate.  Works great !  (see shop posting for info)

Sect 10-13, Step 1 riveted Battery Angle and Bellcrank Rib Assembly to Bulkhead with 6 rivets.  Two required rivet gun and titanium bucking bar to reach.    Then dimpled per Steps 2 & 3, which required first deburring all holes, and edges while at it on Bottom Skin and six J-stiffeners.  ( 2 longest are actually part of next section, but identified in this section by Van's to dimple ).  C-Frame hasn't been used for awhile, but works great.   Lot's of time to deburr and dimple all these holes.

Step 4 & 5 cleco'd Bulkheads, J-stiffeners to Bottom Skin.  Marked perimeter for "no rivets", too. Beginning to look like a fuselage...finally.