Spar Pins, Flap Handle and Flap Handle Mounting Blocks

 

 

 

This morning I had a few moments to kill so I went down to the shop and installed the pushrod on the flap handle.  I also marked and cut the flap handle mounting blocks.   

 

I finished by reassembling the spar pins.

 

This evening turned the fuselage back on its side again.  I installed the flap handle and pushrod assembly in the fuselage.  It fits between the center ribs under the seats.  It was pretty tough getting everything lined up and the bolts started.  The quarters are pretty tight.  I ended up using a box wrench to tighten the bolts.  It was about 1/8^th of a turn at a time.

 

I also installed the flaperon bellcrank halves.  I used super glue to hold the washer on the mixer arm.  I was able to get the bolt through all of the bearings and into the mixer arm nutplate.  I was pretty excited about that.  Things are slowly coming together.

Flap Handle, Tailcone Fairing and Flaperon Mixer Bellcrank

 

This afternoon I started to work on the flap handle and the flaperon mixer bellcrank.  I separated the bellcrank halves and pulled out the bearings.  I also found the flap handle pushrod and the bearing that attaches to the end of the pushrod.  I prepped and primed the bellcrank halves and the flap handle.

 

I also deburred the inside of the flap handle so when the interior push rod and button are installed it will fit and work properly.  While the primer was drying I final drilled the holes in the tailcone fairing and finished cutting the slot in the rear of the fairing.  I sanded the edges smooth and then used the screws and attached the fairing to the tailcone.  It fits.

 

 

I then prepped the ends of the spar tubes that were damaged when I ground them down to make the magnets work.  I painted the ends of the spar tubes and the flap handle with black hammertone paint.

 

Next I riveted the bearings to the mixer bellcrank halves and screwed the bearing into the end of the flap handle pushrod.

Tailcone Fairing

 

This evening I final drilled the holes in the tailcone using a #27 bit.  I used a 6x32 screw to hold a nutplate centered on each hole.  I drilled #40 holes through the ears of the nutplates.  I then deburred all of the holes.  I clecoed a nutplate to each set of holes and used the 3/32 dimple die to dimple the tailcone and the nutplates at the same time.  I then riveted the nutplates to the inside of the tailcone.

 

All 12-nutplates have been riveted in place.  I will need to use the modified #27 drill bit and final drill the holes in the fiberglass tailcone fairing.

Tailcone Fairing to Tailcone

 

This evening it was not raining.  It is the first night since last Saturday that it has not rained.  It has

also been really cold.  The rain has been so bad on some evenings that I have had to pump the water out of the driveway.  I have not wanted to work in the cold or rain so nothing was done this past week.  However, this evening the weather is fine.  It has been good all day.  I move Arlene's car out of the garage, parked the truck to the side and pushed the work table with the fuselage outside.  With the fuselage outside I am able to attach the vertical stabilizer and rudder.  I put these on the tailcone and then clecoed the tailcone fairing in place.

 

Next I drilled the attachment holes into the tailcone and clecoed them as I drilled.  I have the minimum 1/8^th inch clearance required between the fairing and the rudder.  The next step will be to install the nutplates on the tailcone.  I removed the fairing and the vertical stab and returned the fuselage to the garage for the night.

Tailcone Fairing

 

This evening I did some work on the tailcone fairing.  I made the permanent connection between the upper and lower halves.  I started by taping the lower fairing section to the tailcone.  I then clamped the upper section to the lower section and the tailcone.  After making sure the fairings fit the tailcone correctly I removed the upper fairing and clamped, drilled then clecoed the tabs to the lower fairing as shown on the drawings.

 

Next I put the upper fairing in place and taped it to the Tailcone.  I then drilled and clecoed the upper fairing to the tabs previously clecoed to the lower fairing.  I removed the clecoes and the  tabs and cleaned up the chips.  I clecoed the tabs inside of the lower fairing and drilled and clecoed upper fairing to the tabs.

 

I removed all of the clecoes and drilled the holes in the upper fairing with a modified #27 drill bit.  I took the tabs into the shop and drilled out the center hole in the  upper half of the tabs with a #27 bit.  Using a #40 microstop countersink I prepared the tabs for the installation of the required nutplates.  I then riveted the nutplates to the tabs.  I used the countersink to prepare the outer skin of the lower fairing and then riveted the tabs to the lower fairing.  I then screwed the fairing halves together.  Next I will need to install the vertical stab on the fuselage, install the rudder and then fit the fairing onto the tailcone.

Tail Cone Fairing

 

Today the two bar I ordered from Aircraft Spruce arrived.  Arlene thinks it is wonderful that it is red.  Thinks the airplane should be painted red.  I also worked for a little while on the tail cone fairing pieces.  I used a sanding disk and an angle grinder to sand the fiberglass to the scribe lines.

Tail Cone Fairing

 

I continued to work on Section 32 of the build.  Yesterday I installed the brake fluid reservoir and attached the brake lines.  This evening I followed the instructions to go back to Section 12 and install the tail cone fairing.  I began by cutting apart and deburring the edges of the fairing tabs with the Scotch Brite wheel.  There are 8-tabs in total.  After prepping the tabs I laid out the masking tape template for the tail cone.  I put the tape on the edge of the work table.  It has a Formica top so it was easy to attach and remove.  I laid out the dimensions with a  Sharpie and then cut the tape apart with a razor knife and a straight edge.  I then put the tape on the tail cone as instructed.

 

 

The fairings are in 2- sections, an upper and a lower fairing.  I set up a small work table on the driveway and proceeded to cut out the fiberglass fairings.  I marked the fairing scribe lines with a Sharpie so I could see them better.  First the upper section.  I drilled the #30 holes at the inside corners as called out on the drawings.  I used the Unibit to drill the ¾" holes on top at at the rear of the fairing.  I used my Dremel  tool with a cut-off wheel to cut the fiberglass.  It worked like cutting through butter.  I put on my lab coat and wore a breathing mask for the dust.

It didn't take long to cut along all of the lines.  I cut close to the lines and will now use a sanding block to remove the material next to the lines.  So far things are coming along very well.

 

Next I drilled and cut out the lower fairing section.  Again, I cut close to the scribe lines.  I will have to remove the material to the scribe lines with a sanding block.  Using tape I put the upper and lower fairings together and then attached the whole thing to the tail cone.  It all seems to fit really well.  I will need to clean up the edges of the fairings with sand paper and then I can proceed to install the tabs and hook the halves together on a more permanent basis.

Tail Cone Fairing

 

I continued to work on Section 32 of the build.  Yesterday I installed the brake fluid reservoir and attached the brake lines.  This evening I followed the instructions to go back to Section 12 and install the tail cone fairing.  I began by cutting apart and deburring the edges of the fairing tabs with the Scotch Brite wheel.  There are 8-tabs in total.  After prepping the tabs I laid out the masking tape template for the tail cone.  I put the tape on the edge of the work table.  It has a Formica top so it was easy to attach and remove.  I laid out the dimensions with a  Sharpie and then cut the tape apart with a razor knife and a straight edge.  I then put the tape on the tail cone as instructed.

 

 

The fairings are in 2- sections, an upper and a lower half.  I set up a small work table on the driveway and proceeded to cut out the fiberglass fairings.  I marked the fairing scribe lines with a Sharpie so I could see them better.  First the upper section.  I drilled the #30 holes at the inside corners as called out on the drawings.  I used the Unibit to drill the ¾" holes on top and at the rear of the fairing.  I used my Dremel  tool with a cut-off wheel to cut the fiberglass.  It worked like cutting through butter.  I put on my lab coat and wore a breathing mask for the dust.  It didn't take long to cut along all of the lines.  I cut close to the lines and will now use a sanding block to remove the material next to the lines.  So far things are coming along very well.

Next I drilled and cut out the lower fairing section.  Again, I cut close to the scribe lines.  I will have to remove the material to the scribe lines with a sanding block.   

 

 

Using tape I put the upper and lower fairings together and then attached the whole thing to the tail cone.  It all seems to fit really well.  I will need to clean up the edges of the fairings with sand paper and then I can proceed to install the tabs and hook the halves together on a more permanent basis.