Step 4 @ Sect 46A-26: added nutplates to Wheel Fairings for Lower Intersection Fairings. Took extra time to tweak holes to insure alignment maintained once nutplates installed.
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| prior to machine c'sinking screws |
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| cut off remaining flange after pic.. |
Friday, August 17, 2018
Finish Kit
Intersection Fairings ( 2 hrs )
Step 4 @ Sect 46A-26: added nutplates to Wheel Fairings for Lower Intersection Fairings. Took extra time to tweak holes to insure alignment maintained once nutplates installed.
Step 4 @ Sect 46A-26: added nutplates to Wheel Fairings for Lower Intersection Fairings. Took extra time to tweak holes to insure alignment maintained once nutplates installed.
Thursday, August 16, 2018
Finish Kit
Intersection Fairings ( 4 hrs )
Good news - the screws came out, and Lower Fairings separated. Per 46A-1& 2: Mounted Upper Fairings back onto Fuselage, drilled #27 holes and machine C'sunk 5 holes each (all while under Fuselage - seeing more of bottom of plane than top lately). Cut clearance for alum brake line in Leg Fairings to insure no rubbing/wear issue. Started riveting nutplates to Wheel Fairings to hold Lower Fairings per Steps 3 & 4. Wow...these Fairings sure do take some time. The Finish Kit total hours exceeds any other sub-kit significantly.
Good news - the screws came out, and Lower Fairings separated. Per 46A-1& 2: Mounted Upper Fairings back onto Fuselage, drilled #27 holes and machine C'sunk 5 holes each (all while under Fuselage - seeing more of bottom of plane than top lately). Cut clearance for alum brake line in Leg Fairings to insure no rubbing/wear issue. Started riveting nutplates to Wheel Fairings to hold Lower Fairings per Steps 3 & 4. Wow...these Fairings sure do take some time. The Finish Kit total hours exceeds any other sub-kit significantly.
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| cut clearance to aluminum brake line...LH side |
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| and RH side... |
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| lots of time under fuselage. Selfie into bottom skin... |
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| Machine C'sunk for screws while in place so nutplates guide cutter |
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| essentially done... whew ! |
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| adding nutplates to mount Lower Fairings onto Wheel Fairings |
Wednesday, August 15, 2018
Finish Kit
Intersection Fairings ( 4 hrs )
Removed all 4 Intersection Fairings ( yep, they didn't stick permanently! ). Ground off excess flox per Steps 6 at 46A-24. Completed Steps 1-4 at 46A-25 building lugs with resin/flox on Upper Fairing encapsulating MS21042-06 Nuts that will serve to keep aft ends tight.
Removed all 4 Intersection Fairings ( yep, they didn't stick permanently! ). Ground off excess flox per Steps 6 at 46A-24. Completed Steps 1-4 at 46A-25 building lugs with resin/flox on Upper Fairing encapsulating MS21042-06 Nuts that will serve to keep aft ends tight.
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| green is the turtle wax transferred to resin/flox. Perfect contact with Wheel Fairing |
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| after grinding excess flox. |
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| geesh...more fiberglass dust ! |
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| ready to embed nut |
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| thick resin/flox starting to cure |
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| hoping sufficient wax on threads so I can remove screw ! |
Tuesday, August 14, 2018
Finish Kit
Intersection Fairings ( 3 hrs )
Steps 4-8 at Sect 46A-23 completed for Upper Intersection Fairings: added epoxy resin/flox mix in 1.6 mm layer. First coated Fuselage contact area with wax to avoid gluing permanently ! Then repeated for Lower Fairings per Steps 1-3 at 46A-24. Extra flox at screw locations so feasible to machine c'sink later. Wheel Fairing surface coated with wax - hope they come off after curing !
Steps 4-8 at Sect 46A-23 completed for Upper Intersection Fairings: added epoxy resin/flox mix in 1.6 mm layer. First coated Fuselage contact area with wax to avoid gluing permanently ! Then repeated for Lower Fairings per Steps 1-3 at 46A-24. Extra flox at screw locations so feasible to machine c'sink later. Wheel Fairing surface coated with wax - hope they come off after curing !
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| finger painted with wax 1st |
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| loaded with flox, ready to raise into position. (Tape prevents flox from gluing aft end together) |
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| Screws hold position until flox cures. Some of the holes were elongated when drilled (searching for center of nutplates) Vans anticipated with note in instructions...now odd shaped holes fill in with flox, |
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| Lower Intersection Fairing with flox applied... |
Monday, August 13, 2018
Finish Kit
Intersection Fairings ( 2 hrs )
Working under Fuselage, drilled 5 holes in each Upper Intersection Fairing, adding #6 screws in each to hold position. Bright lights on each nutplate inside Fuselage worked well - after I first drilled through dimples ( primer-filler coating on Fairing limited seeing light otherwise). Drilled four holes and cleco'd Lower Intersection Fairings at Wheel Fairings. This completed Steps 1-3 at 46A-23. Looking great ! I also mailed 3 Registration docs to FAA today ( 8050-1, 8050-2, & 8050-88 ) The EAA's "Step by Step Certification Guide" is an excellent resource. The "kit" from EAA comes with docs, Experimental decal, SS Data plate, and documents needed for about $13 for members.
Working under Fuselage, drilled 5 holes in each Upper Intersection Fairing, adding #6 screws in each to hold position. Bright lights on each nutplate inside Fuselage worked well - after I first drilled through dimples ( primer-filler coating on Fairing limited seeing light otherwise). Drilled four holes and cleco'd Lower Intersection Fairings at Wheel Fairings. This completed Steps 1-3 at 46A-23. Looking great ! I also mailed 3 Registration docs to FAA today ( 8050-1, 8050-2, & 8050-88 ) The EAA's "Step by Step Certification Guide" is an excellent resource. The "kit" from EAA comes with docs, Experimental decal, SS Data plate, and documents needed for about $13 for members.
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| 5 screws installed in nutplates. |
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| Upper and Lower Intersection Fairings "installed" |
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| 4 new holes drilled and cleco'd |
Saturday, August 11, 2018
Finish Kit
Intersection Fairings ( 3 hrs )
Completed grinding & sanding excess resin inside leading edges of all 4 Fairings, and high spots under contact edges. Aligned Upper and Lower Intersection Fairings with Leg Fairings installed per Sect 46A-22. Marked locations on Intersection Fairings on Leg Fairings. Per Step 5, 46A-22: wrapped specific # layers of masking tape to act as spacers between Intersection and Leg Fairings.
Completed grinding & sanding excess resin inside leading edges of all 4 Fairings, and high spots under contact edges. Aligned Upper and Lower Intersection Fairings with Leg Fairings installed per Sect 46A-22. Marked locations on Intersection Fairings on Leg Fairings. Per Step 5, 46A-22: wrapped specific # layers of masking tape to act as spacers between Intersection and Leg Fairings.
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| 1st time Leg Fairing installed. It self aligns, fits well. |
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| Pleased w/ fit of Lower Intersection Fairing to Wheel Fairing. Lots of sanding/filing/grinding to achieve...! |
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| Pleased with fit of Upper Fairing to Fuselage. |
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| another pic of good fit onto Wheel Fairing |
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| Upper, Leg, Lower, & Wheel Fairings |
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| wrapped layers of masking tape at 4 locations |
Friday, August 10, 2018
Finish Kit
Intersection Fairings for Main Gear Legs ( 4 hrs )
Per Sect 46A-21, aligned Upper Intersection Fairings to bottom of Fuselage, then Lower Intersection Fairings to Main Wheel Fairings. Lots of grinding & sanding to get uniform contact. Trimmed mating flanges and Gear Leg openings after drilling/cleco'ing Intersection Fairings into best fit. The diamond encrusted thin wheels on my dremel make this "easy".
Per Sect 46A-21, aligned Upper Intersection Fairings to bottom of Fuselage, then Lower Intersection Fairings to Main Wheel Fairings. Lots of grinding & sanding to get uniform contact. Trimmed mating flanges and Gear Leg openings after drilling/cleco'ing Intersection Fairings into best fit. The diamond encrusted thin wheels on my dremel make this "easy".
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| Upper Fairings trimmed |
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| Lots of fiberglass dust....everywhere ! |
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| Lower Fairings trimmed, sanded smooth. |
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