Empennage

Aft Fuselage (2.5 hrs )

Sect 10-11, Steps 1 & 2:  worked on the two larger forward Bulkheads....doing all the #40 hole dimples around the flanges...with a few exceptions noted.

Lots of lightening holes which take time to smooth edges/deburr.   Tried various tools (eg  dremel to reach inside holes) but mostly the std 6" grinder w/ scotchbrite wheel.  Although instructions don't denote, I smoothed facets of flanges...just as prior bulkheads.  Finding a 4" belt /6" disc sander with fine grit paper works well for that step.

Also enlarged one hole to 5/8" hole w/ step drill...for bushing w/ wire routing.   Seems odd several similar 5/8" holes already pre-punched - must be busy work for builder wrt 51% rule...?

Empennage

Aft Fuselage  (3 hrs )

Cont'd Step 4 at Sect 10-10:  Drilled 1/4" holes in HS Attach bars on drill press.   Finished deburring, scuffed, cleaned and Primed all parts - especially those w/o Alclad.

 Riveted the 47 Universal head rivets (three sizes) using Main Squeeze.

"family" of three aft bulkheads

Empennage

Aft Fuselage (4 hrs )

Sect 10-9 Step 2-7 completed:  finished deburring edges, holes and smoothed flange facets.  Checked fit into Aft Bottom Skin... A-OK!  (no fluting needed ...bulkheads were already straight and fit well)

Also cleco'd rearmost Bulkhead w/ Tie Down Bracket into position on Aft Bottom Skin.  Also good fit.   (prior sub-assembly is already primed)

Dimpled the #40 and optional #27 holes for the flush screws installation later (ordered screws and nutplates from Van's today).  

  Riveted two H.S. Attach Brackets to these two bulkheads w/ 30 universal head size 4-7 rivets.  Appreciated using Main Squeeze again (needed to add 3 washers to lengthen reach of Universal die for flange height clearance).

Sect 10-10 Steps 1-3:  Next bulkhead sub-assembly includes "step drilling the 5/8" hole for bushing, dimpling #40 holes on flanges, deburring edges and holes, plus smoothing facets on flanges...again.    I prefer working each section (bulkhead sub-assembly) as mini-project following instructions in sequence, vs gathering all the bulkhead pieces and deburring, scuffing and priming as major batch.  With nice weather, set up outside to spray primer takes only a minute, so small batches are easy

Empennage

Aft Fuselage (1.5 hrs )

Riveted Tie Down Bracket to 2 Bulkheads 1412A & B in Sect 10-8, Step 2.   Able to use Main Squeeze, but only with a washer added to each die to clear flanges.   Perfect !

Much easier with Main Squeeze mounted to table...

Sect 10-9, Steps 1 & 2:  Cleco'd 1411A & B Bulkheads to HS Attach Bars, drilled #30 holes (lots for these key structural pieces).  Started to deburr edges...here I go again toward priming.   (with simpler spraying now outdoors, I'm closely following instructions vs working ahead to prime parts well in advance).

Empennage

Aft Fuselage (4.5 hrs)

Sect 10-5 Steps 2 & 3:  Drilled 17/64 Systems hole (several layers including steel VS hinge brackets) and Tie Down Bracket 4 holes at #12 size.

  Sect 10-6 Deburred edges, drilled holes, rounded flanges eliminating facets against skins.   Sect 10-7, Steps 1-3:  Lots of dimples in two bulkheads...sizes #30, #40, and #27 (#6 screw dimple dies works well).    With those completed, time to scuf, clean w/ Acetone, and Spray 7220 Self Etching Primer (Napa brand).   Ready to rivet !

Ready to Prime.  Parts on left are Not Alclad, so require Primer.

Empennage

Aft Fuselage ( 1.5 hrs )

Finished Sect 10-4, Step 2 Rudder Stop.  Almost overlooked Countersinking #30 holes at Step 3.  

Sect 10-5, Step 1:  Retrieved Vert Stab from "storage" room....fit up bulkheads with 2 cleco's  -  ready to match drill into VS rear spar.

 

Empennage

Aft Fuselage ( 1 hr )

Another beautiful Spring day - Sunny, 70 degrees, and only 4 mph winds....so went flying instead of building today.  Plus mowed yard, played tennis.  Thus only 1 hr in shop today.    Rudder Stops in Sect 10-4 are crazy shaped pieces !  Required extra caution to insure interpret cut dimensions correctly.   Note the isometric dwg above has parts "flipped" vs 2 view dwgs below.   Need new 18 pitch band saw blade...so only finished RH piece.