Fuselage

Rollover Assembly  ( 3 hrs )

Cont'd deburring edges of Rollover Frames.  Buffed all w/ scotchbrite, cleaned w/ acetone, then primed w/ Napa 7220 acid etching primer.   Riveted Rollbar Brace Brackets to Rollbar Brace - glad able to use "Main Squeeze" from Cleaveland Tools.  Cleco'd Forward LH & RH Rollbar Frames on Fuse.  Ready to rivet 4 places at center splice plate, then remove to complete riveting.  But it's time to swim instead!

buffed, cleaned

primed

using Main Squeeze

first steps to assembling Rollover Frames

Fuselage

Rollover Structure  ( 4 hrs )

Rotated Fuse back to upright position with Nancy's help.   Per Sect 36-13 confirmed Control Base full Forward and full Aft angles are good as is ( Bearing Bracket stops don't need more filed off - Yay! ).   Forward max measures  15.1 deg vs 13.6 + 3.0 deg,  and Aft  max  measures 27.5 deg  vs 23.5 + 3deg.      [ Note:  Although Aft exceeds by 1 deg, when Elev is connected to pushrod later, expect to confirm Elev control horn limits travel Aft before Control Bases hit their stops.  Sect 36-16, Step 4 states Elev Horn hitting structure in Aft Fuselage should provide travel limits, not the Control Bases.   Previously with Elev assembled on Aft Fuse, needed to file clearance so Elev met those travel limits]  Started Sect 37 Rollover Structure by deburring edges and holes, and dimpling 5 locations.   Long edges, but mostly done.

Fuselage

Aft Pushrod, Wiring Channel, Cable Links to Rudder, Bearing Bracket Stops ( 3 hrs )

Wrapping up several steps from various sections that are best done now prior to re-orienting Fuse to upright position.  Installed Cable Links to Rudder Pedals at Sect 33-12.  Ground Bearing Bracket stops at Control Bases per steps 1-2 at Sect 36-13.  (top ones were "easy" to reach, but bottom was very challenging.  Used mirror to position small file).   Now forward and aft stick movements have contact with stops on both LH and RH sides simultaneously.  Installed Aft Elevator Pushrod to Bellcrank Ass'ly per Sect 36-15.  Riveted in Wiring Channel Ass'ly at front center under dash per Sect 35-10.  

 

Fuselage

Control Sticks Aligned & Brake Lines Leak Tested ( 2 hrs )

Aligned Control Sticks to be parallel w/in 1/8" top to bottom (vs slightly more than 1/4" orig) per Sect 36-14.  Torqued Stick Link Pushrod.  Removed Control Sticks to protect Grips/switches.   Decided to perform leak test of brake lines fittings by using schraeder valve supplied for fuel tank leak testing.  Simply replaced breather fitting on top of Brake Fluid Reservoir.  Used soap bubbles on all brass elbows and compression fittings -- no leaks.   Except at schraeder valve (installed w/o thd sealant to avoid contaminating reservoir).  Convenient since this showed what a leak would looks like (see pic).  Checked by removing plastic plug at bottom of Fuse (at gear leg exit) to confirm air flowing all the way through system.  Moved brake pedals/master cyl's to insure air pressurizing all fittings.  Sure was easier now to check for leaks than discovering once brake fluid added later.  Van's Prod Support said hadn't thought about checking for leaks this way, so I sent pics w/ notes

Control sticks interconnected
and parallel

intentionally not sealed at schraeder valve

plugged end of brake line

no leak

no leak

No leaks at all 8 brass elbows, compression fittings

.

Fuselage

Control Stick Bases ( 2 hrs )

Primed, then finish painted 4 Rudder Cable Links and the Wiring Channel Ass'ly (goes under dash in center).  Installed LH & RH Control Stick Bases per Sect 36-11.   LH side required thin shim to take up space between bearings - otherwise bearings bound up when AN4-37A bolt/nut tightened.  Aaargh...  But the RH side fit perfectly.   Installed the Stick Link Pushrod (ties LH to RH Control Bases for Ailerons).  Very challenging to align for the 2 inner washers....struggled nearly 30 min before success.  Thank you washer wrenches !

Limited access, and hard to see to install washers.
Not tightened yet...  waiting to measure if  joysticks 
will be parallel.   Note the Control Base has already 
been installed with long AN4-73A bolt.

Sweet...LH & RH side connected
 via pushrod (grey bar below)

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.

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 !

 

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 !

left SS firewall unpainted

un-masked...

challenge to reach.
Washer "wrenches" very helpful

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.