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

Finish Kit

Riveted FF00003B to -3A per Step 18 at 46A-30 (done with Sect 46A).  Mounted to Bottom Cowl - great fit.  Used closed cell foam from Garmin avionics packaging to create Inlet Ramp/Prop Gov Foam Seal.  Vans is correct that a bandsaw works well for trimming outline per template provided.  Bonded into Top Cowl with hi-temp RTV per Sect 47-30, Steps 1-6.   Re-installed Prop Gov bracket assembly per Sect 43-07 [ ref: 9/64" allen wrench].   Next:  installation of Empennage Fairing per Sect 12-10 to 12-13 (completed Emp Kit back in Sept 2016 - but Emp Fairing is not supplied until Finish Kit...combined with other fiberglass parts).

-3B riveted.  

Can't install Bottom Cowl w/o extra long slot
...so Closeout gets installed normally
AFTER Cowl is on Fuselage

foam cut to template via bandsaw

Foam seals against Prop Gov, vs baffles on grey
Inlet Ramp.  bonded with hi-temp RTV. 
extra insures sealed at forward edge

re-installed Prop Gov bracket for control cable

Finish Kit

Bottom Cowl Closeout ( 2 hrs )

Riveted nutplates to Bottom Cowl Closeout after machine countersinking, priming and painting.   Also sanded with 320 grit the exterior of Upper and Lower Intersection Fairings, smoothing the light coat of epoxy applied yesterday.