Finish Kit

Intersection Fairing ( 4 hrs )

Steps 7-11 at 46A-27:  Sanded fillets smooth and flush to Intersection Fairings.  One was A-OK, other needed 2nd pass.  Very pleased with fit and appearance.  Next two pages are instructions for installing Wheel Fairings and related Fairings after paint...which I'll eventually do.  Skipped to start Bottom Cowl Closeout per 46A-30.  Deburred FF0003A and -3B.  Mounted with Cowl to begin marking position and holes to drill.

Sanded to flush w/ edge of Intersection Fairing.
Tape protects primer/filler on Wheel Fairing.

 

Tad Dah !   Really like how this worked.

Close up showing shape w/o Intersection Fairing

Finish Kit

Lower Intersection Fairing ( 4 hrs )

Machine C'sunk Lower Intersection Fairings at ten holes per Step 1 at 46A-28.  Sanded Wheel Fairing surface about 1.5" outside Lower Fairing to prep for epoxy/micro balloons fillet.   Applied vinyl tape to edge each Lower Fairing, then slopped on thick mix creating fillet.  Smoothed as much as practical to reduce sanding later.  When partially cured to "rubbery" stage, cut slots along Fore/Aft split of Wheel Fairing.   I used micro-balloons to make sanding easier, but still will be a lot of sanding.

Sanded w/ 80 grit where mix will be applied

Vinyl tape covers edge -- to sand down to, 
but not through.   I decided to c'sink screw 
heads prior adding fillet, to make sanding easier
 w/o screws above surface.

prior to cutting slots where Wheel Fairing separates

 

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.

prior to machine c'sinking screws

cut off remaining flange after pic..

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.

cut clearance to aluminum brake line...LH side

and RH side...

lots of time under fuselage.  Selfie into bottom skin...

Machine C'sunk for screws while in place so
nutplates guide cutter

essentially done...  whew !

adding nutplates to mount Lower Fairings onto Wheel Fairings

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.

green is the turtle wax transferred to resin/flox. 
Perfect contact with Wheel Fairing

after grinding excess flox.

geesh...more fiberglass dust !

ready to embed nut

thick resin/flox starting to cure

hoping sufficient wax on threads so I can remove screw !

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 !

finger painted with wax 1st

loaded with flox, ready to raise into position. 
(Tape prevents flox from gluing aft end together)

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, 

Lower Intersection Fairing with flox applied...

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.

5 screws installed in nutplates.

Upper and Lower Intersection
Fairings "installed"

4 new holes drilled and cleco'd