Aft Fuselage

SB 18-09-17  ( 2 hrs )

My wife Nancy did great job w/ rivet gun under fuselage while I bucked from inside.  I laid down a layer of empty 2 Liter soda bottles, then bags stuffed full of plastic bags (both rescued from recycling).  And a couple pillows helped avoid crushing the elevator bellcrank / pushrod. Once in position it wasn't too bad...but due to my height, getting into and out of position from baggage area was challenging.   After we completed bottom rivets, I match drilled & deburred the four  #30 holes.  Used rivet gun & bucking bar to complete attachment to bulkhead.  Whew, glad that's done !

After riveting, showing notes for rivet lengths.

Layers of 2 L soda bottles & bags of plastic bags
 made "nest" to lay on while reaching way aft

Looks good!  It seems to stiffen skin significantly, bridging
before and after bulkhead as well as directly to bulkhead.

ta - dah !   glad this is done

Empennage

Empennage Fairing ( 3 hrs )

Completed filling pinholes using epoxy/micro balloons, followed by sanding.  Then re-coat with Cromax Quickprime A-4240S (purchased another 14oz spraycan at National Coating and Supplies  store).  Final wet sanded with 600 grit to prep for painting later.   So...H.Stab and V. Stab removed and back into storage.   Laid out strategy for GTX-45R Transponder mounting (on RH area under glovebox) using 2 piano hinges, etc.

Emp Fairing final sanded w/ 600 grit after filling pinholes.   Four Intersection Fairings in background rec'd same process.

Empennage

Empennage Fairing ( 2 hrs )

Finished sanding smooth where I filled pinholes.  Sprayed Cromax Quickprime A-4240S (sandable, acrylic primer) on Emp Fairing and 4 Intersection Fairings.   Looking good!  But some pinholes remain, so another round of fill, sand, prime soon.

Used most of can on canopy transition,  so ran out
 before I could fully cover both Upper Int Fairings...

Tah Dah !

Empennage

Empennage Fairing ( 2 hrs )

Mixed epoxy/flox and filled pinholes on Emp Fairing (also some on 4 Instersection Fairings).   Later, after cured 6 hrs, sanded smooth all 4 Intersection Fairings and Empennage Fairing.    Began exploring where and how to mount various units supporting Garmin G3X system:  GTX-45 ( remote transponder w/ ADS-B in/out), GEA24 (engine monitor), GD-40 (CO detection), GPS20A (remote WAAS GPS), and GAD27 (intergrated controller).   Referenced couple other RV14 builder logs, and Layout provided by Stein Air.

flox mix added to fill pinholes ( prior sand smooth... again)

unpacking Avionics...

Empennage

Empennage Fairing ( 3 hrs )

Completed sanding high spots and contoured at HS leading edge.  Removed Fairing ( Yay !  - some prying required, but did come off...whew...) to sand edges.  Smoothed edges all around using 120 grit.  Removed excess flox underneath using dremel.  Ref Step 5 at 12-13.  Pleased with fit when re-attached.  No gaps !   Got a lot of pinholes opened via removed layer of filler/paint...so will tackle those next.

underside w/ molded flox shown

prior sanding flox on edges & contouring

re-installed after sanding edges

no gaps

Add caption

Empennage

Empennage Fairing ( 1 hr )

Wet sanded most of Emp Fairing with 80 and 120 grit to remove waviness and high spots.   Good progress, but more needed.

Empennage

Empennage Fairings ( 4 hrs )

Per Sect 12-13, final trimmed Fairing edges to within 9mm of holes.  Covered Fuse, HS, and VS contact areas with cellophane packing tape (then applied auto wax for good measure).  Mixed epoxy/flox to smooth, slight sag mix then applied to underside Fairing in marked areas.   Tried not to smear all over VS as I positioned onto Fuse/HS/VS.   Inserted 27 screws followed by major clean up.  Several hours later, I began sanding to eliminate slight waviness and taper toward edge.   Lots of sanding to do next.  (I'm praying the Fairing comes off, but gonna wait until more rough sanding done)

trimmed edges, re-installed

clear tape, then car wax applied as extra release

Underside sanded where flox will be attaching

after clean up, starting to cure.  

later, after cure, began to sand.  Shows how
waviness is being eliminated.  Will have consistent
edge contacting alum, with no gaps.

Empennage

Empennage Fairing ( 4 hrs )

Riveted 7 nutplates to Aft Fuselage per Sect 12-12.  The 4 on lower sides were challenging to reach with my large hands twisting through openings.   Had to remove H.S., loose ELT...then success!   Remounted H.S., replaced temporary nuts on 4 bolts holding VS-01402 VS Bracket, and torqued.  (note in picture, hole for mounting VS is skewed left, giving VS right turning bias in flight offsetting engine torque, etc.)  Re-mounted VS, then added Gap Covers.  Discovered I'd forgotten to install nutplate at aft position.  I'd dimpled earlier, so added K1100-6 nuplates which was easy to do while VS on Fuse.  Re-installed Emp Fairing w/ 27 flat head screws.  SWEET !   Next:  make final trim, and fill few small gaps with epoxy/flox mix per Sect 12-13.

 torq seal (yellow) added once nuts torqued. 
Others are still temp, since will remove HS again

lower nutplates were challenge to reach,
even w/ HS removed

installed aft nutplate for Gap Cover

1st installation with flush screws

Empennage

Empennage Fairing ( 3 hrs )


Riveted 10 nutplates to Horiz Stab and 12 nutplates to Vert Stab after match drilling #40 rivet holes, then mach c'sinking (dimpled on Horiz Stab), per Step 7 at Sect 12-11, and Steps 1-4 2 12-12.  Still need 7 nutplates added to Aft Fuselage (but these were prepped during build of Aft Fuse last year).

Vert Stab nutplates added.
 (applied grey Napa 7720 primer at scuffed areas)

in process of riveting nutplates to H.S.

Able to do w/ HS still mounted to Fuselage

Empennage

Empennage Fairing ( 4 hrs )

Completed Steps 1-6 in Sect 12-11:  Transferred hole centerlines to Fairing, drilled #40, then enlarged with #27 drill.  Process worked very well for the opaque fiberglass Fairing.  Machine C'sunk all holes in Fairing for #6 screws.  Dimpled aft hole in Gap Covers (F14111 L & R ).  Removed Vert Stab so I could drill for nutplates while on bench.  Note:  received Registration for plane from FAA...it's officially N3714R  now ! (quicker than expected - only took couple weeks)

selfie showing centerline marks (where to drill)

RH side - done w/ #40, partially done enlarging
 to #27 with 1/8" cleocs

LH side...pending #27 final hole sizing

Vert Stab on bench, drilling for nutplate rivets

Empennage Kit

Empennage Fairing ( 4 hrs )

Trimmed Empennage Fairing to within 1/8" scribe line per Sect 12-10, Steps 1 & 2.   Retrieved from storage the Horiz Stab and Vertical Stab to mount to Fuselage.  Added Emp Gap Covers F12111 L & R.  Since Fairing is opaque due to primer/filler coating, I marked center-line of nutplate holes along Fuselage, HS, & VS - including mark at 50 mm distance.  Will use to transfer hole center-line to Fairing when drilling (vs light inside which would required sanding off coating at each location, OR using the spherical magnets).    Per Steps 3-5 at Sect 12-10,  I did many iterations of marking interference at leading edge of VS and HS, then grind/sand some...repeat.    I eventually achieved good, tight fit. 

trimmed excess...leaving 1/8" at scribe line

temporary mounting HS and VS

marked line from centerline nutplate holes, with cross mark
 at 50  mm.  Will allow accurately locating blind holes to drill 

first pass... interference at VS preventing Fairing from
contacting HS leading edge...but close

after several iterations of grinding/sanding inside
Fairing, getting good fit around all leading edges

good fit at VS leading edge

Empennage

Empennage Fairings ( 0.5 hrs )

Re-mounted the Horiz Stab, Vertical Stab, Elevators, and Rudder (also Empennage Gap Covers) today to examine fitup...and to take some pics.   I'm considering some blending between Elevator Tips and HS Tips, as well as between Rudder and Vert Stab.   They're really good, but now that they're installed, I can see some variations between front to back.   Won't help plane fly any better, just cosmetic.   Maybe later during Finish Kit, etc.     I do plan to "smooth" between Horiz Stab Tip and HS Skin, but the initial fit is near perfect.    

Hooray !  Essentially done with Empennage Kit. (expecting QB Wings and QB Fuselage delivery in couple weeks)

From Jan 1, 2016...Empennage Kit "completed" Sept 2016.

A long way to go...but closer !