Start Masking Fuselage Canopy Area

This evening I spent some time doing some housekeeping.  I used my small vacuum to vacuum out the corners and recesses of the fuselage.  With the fuselage turned on its side there was a lot of small debris on the ribs, formers, crevices and recesses.  I vacuumed and wiped out the areas the best I could.  Next reinstalled the right section of the instrument panel and map box.  I used the screws provided with the kit to attach the panel to the upper fuselage skin and instrument shelf.  I also attached the other panels (center section and left section) to the instrument shelf and upper fuselage skin. 

After attaching the instrument panels I turned the fuselage right side up.  I re-centered it on the work table and adjusted the pads on top of the table.  I am sure when it is time to install the lines, wiring and ADAHRS module in the tailcone it will be necessary to roll the fuselage back onto its side.  When I do I think I will put it on my steel saw horses.  That will make it easier to get into the tailcone and it will make it easier to roll over.  I won't have to worry about the clecoes and the flaperon torque tubes hitting the top of the table.

 

I put blue tape on the canopy attachment coves on each side of the fuselage.  I also put some tape over the top of the instrument panel where it attaches to the upper fuselage skin.

I used some builder paper to cover the instrument panel and the forward section of the cockpit area so when I start to install the fiberglass skirt on the front of the canopy I will not drip any resin on the panel or in the cockpit.  I plan to put some masking paper on the sides of the fuselage, below the canopy before I start doing any fiberglass work.  The next step will be to install the duct tape on the sides of the fuselage and over the top of the upper fuselage skin.

Torque Seal and Carbon Fiber Wrap

 

Today I decided to put torque seal on the fasteners in the fuselage tunnel and lower area.  I put torque seal on the heads of the fasteners where ever possible.  This  is based on a Builder's Hints video I watched on the EAA Website.

 

I also reattached the spade connectors on the AP servos.  I bundled the connectors and put wire cable ties around the servos to hold the connectors in place.  I put a wire tire around the ties holding the connectors to make sure they do not slip off of the servos.  This should hold things together.

 

With the fuselage on its side it is a lot easier to work inside.  I removed the spar pins to repaint them.  I removed the latches and springs and taped and masked them. I recoated the spar pins with black hammertone spray paint.

I turned my attention to the right side instrument panel and map box door.  I want to cover the instrument panel sections with carbon fiber vinyl wrap.  I removed the map box and right instrument panel section from the fuselage.  I removed the camlock from the map box door.

 

I sanded the right panel section and the map box door.  I also decided to repaint the map box door hinge with black hammertone spray paint.  I masked the hinge section and sprayed the hinge at the same time I recoated the spar pins.

 

After the paint dried I took the right panel section inside and applied carbon fiber vinyl wrap to the panel and the map box door.  Using my X-acto knife I cut out the holes for the intercom and ELT switch and mounting holes.  I also reinstalled the camlock on the map box door.

Finished Redoing Air Tubing

 

Last night and this evening I finished installing the Static Air, Pitot Air and AOA tubing.  I cut to length and labeled the AOA and Static Air tubing.  

 

 I ordered and received a ¼" tubing coupling from McMaster-Carr.  I cut the original Static Air line at the rear auto pilot servo location and installed the coupling.  I cut a length of ¼" tubing and inserted it into the other side of the coupling.  I ran the tubing through the wire ties on F-1208 and up to the ADAHRS location.  I cut the tubing to length and labeled it Pitot Air.  This should take care of the Skyview required air tubing modifications in the tailcone.  After I receive the Avionics Kit I will have to modify the forward end of the ¼" tubing at the instrument shelf so it becomes the Pitot Air supply.  I will also install the fittings on the Static Air and Pitot Air tubing in the tailcone.

Miscellaneous Redos and Fixes

 

It is Saturday, the Draper Temple is closed and I have the day to do some work on the RV-12.  After attending the World Wide Training this morning and running some errands with Arlene I spent a good part of the afternoon working in the garage and shop.  The temperature is 59 degrees.  I started by touching up the paint on the fuel tank.  After making the tank modification and repainting the forward end of the tank last week I discovered the Pro-Seal around the sender support ring and the under the screw heads holding the support ring in place did not cover as well as it should have.  I used a small artist's brush and touched up the paint around the ring and on the screw heads.  I took the picture right after doing the touch-up.  Later in the day the paint color matched exactly.  I also used some black RTV sealant and sealed the joint between the fuselage sides and bottom and the firewall.  I then turned my attention to the plumbing and wiring in the tailcone.  Because the Skyview is being installed there needs to be some changes in the Static Air and Pitot Air tubing.  Currently the 1/8" tubing for the Static Air is connected to a ¼" tube which runs through the fuselage to the instrument shelf.  Now an ADAHRS will be installed in the tailcone so the Static Air will not run forward but will be connected to the ADAHRS just in front of fuselage frame F-1208.  I cut all of the wire ties from the rear of the fuselage mid-section back to and along frame F-1208.  I loosely installed new wire ties so I can run new tubing and new wiring through the ties for the Skyview.  I removed the 'T' and the left side Static Air tube.  I cut the 1/8" Static Air tube at the center of frame F-1208 and installed the 'T'.  I ran a new piece of 1/8" tube from the 'T' to the left Static Port.  I then connected a piece of ¼" tube to the 'T'.  I will need to cut the ¼" tube to length and install the connection fitting on the end.  I will do that when I receive the Avionics Kit from Vans.

 

While working in the tailcone I decided to run the 1/16" tubing for the AOA.  This was a bit of a challenge.  I ended up cutting the bottom section out of a coat hanger.  By inserting the end of the piece of hanger wire into the 1/16" tubing I was able to thread the wire and pull the tubing through the snap bushings in the fuselage frames and feed it forward to the area under the control column.  I then used the same technique to tread the tubing to the left side of the fuselage.  I removed the current wing wiring connection (which will be replaced with the Avionic Kit) and pulled the tubing to that area.  I put the ADAHRS fitting on the tubing in the tailcone.  I will put the appropriate connection on the other end of the tubing when I make the wing wiring connection change.

Next I turned my attention to the canopy and upper fuselage skin.  The corner of the upper fuselage skin was bent upwards one day while fitting the canopy.  I removed the instrument panel and removed the screws holding the skin in place.  I was able to straighten the skin as evidenced by the photo.  This corner will be covered by the fiberglass canopy shroud but I still want it to look good.

 

 I then prepped the canopy support arms for paint.  After installing the canopy a few months ago, and lifting it into the open position, I realized the support arms will be seen from inside when the canopy is raised.  I decided because the front canopy bow is painted with black hammertone paint, and the instrument panel will be black carbon fiber warp, it would be good if the support arms were painted to match the front canopy bow. I proceeded to mask of the canopy areas so I could paint the support arms.   After masking everything I discovered my can of Rustoleum black hammertone would not spray.  I removed and cleaned the nozzle with MEK but still it will not spray.  The clog appears to be in the stem on top of the can.  I can't poke anything down the stem or it will release the paint.  I went to Home Depot and bought another can of paint.  This is the 3^rd can of black hammertone I have purchased for this project.  Now I have 3-partially used cans of black hammertone spray paint.  I was able to recoat the support arms after these photos were taken to eliminate the gray primer speckles.

Install POH Tray and Map Holder

This evening I decided to install the POH Tray under the right side of the instrument panel.  It mounts below the Map Box in the right panel.  To do so I decided to roll the fuselage over on its side one more time.  I rolled up a couple of moving pads and placed them under the tail cone.  This will cause the tail cone to be elevated and will support the aft portion of the fuselage at the midsection so the flaperon torque arm and the clecoes holding the top skins together clear the surface of the work table.  I put the moving pads in place and shifted the fuselage to the edge of the work table.  I then pulled the fuselage over and repositioned it on its side.  The moving pads support the tail cone and the fuselage rests on the forward midsection.  I moved the whole thing into the middle of the work table.  I now have access to the interior of the fuselage and under the instrument panel.  I have a lot of work to do inside and this will certainly make my job a lot easier.  I need to cut and replace the wire ties holding the tubing for the static air ports and the pitot air and wire harness to the fuselage frame.  I will have to change the tubing in this area to accommodate the Skyview ADAHRS.  I also want to install some tubing for the AOA.  This tubing will follow the current pitot tube route from the ADAHRS location through the center of the fuselage and out into the left wing.  I might as well get started on these changes while the fuselage is on its side.

 

 

As I began the installation I was surprised to find the instrument shelf pre-drilled for the POH tray.  I suppose that shouldn't have surprised me because the POH Tray is used to replace the Map Box if the second Dynon display screen is installed.  I clecoed and riveted the angle and POH Tray as shown.

 

I then mounted the cover plates on the floor step and the tunnel.  I mounted the Map Holder on the tunnel and match drilled the holes in the step cover.  I removed the Map Holder and installed the map support angle (Pocket Base).  I match drilled the hole for the map support angle in the step cover.

 I removed the map support angle, the floor step cover and the tunnel cover.  I went into the shop and proceeded to prep the floor step cover for the installation of the nutplates that will be used to hold the map support angle and the Map Holder in place.  I final drilled the holes in the floor step cover.  I used a screw to hold the nutplates in place and then match drilled the #40 holes for the flush rivets.  After attaching the nutplates, clecoing and drilling I had all of the nutplates located and the rivet holes drilled.  I used the rivet squeezer to dimple the #40 holes for the flush rivets.  I also dimpled the holes in the ears of the nutplates.  The next step was to rivet the nutplates in place under the floor step cover.  I completed that step without any problems.  I will continue to work on the fuselage interior over the next several days.

 Also, I read in the RV-12 forum that someone who just recently ordered the Avionics kit was told that it would be about 3-months before the kit is shipped.  I decided to try and get a jump on things so this afternoon I ordered the Skyview Avionics Kit.  We'll see what Vans says about delivery.

Paint and Redo Canopy Guide Blocks

 

I picked up the black screws I ordered from Fastenal.  I think they are going to look good against the carbon fiber vinyl wrap on the instrument panel.  I also decided to replace the phenolic canopy guide blocks.  I want to replace the blocks because when I installed them I cut out the lower corners of the blocks to clear the last screw and nut on each side of the canopy.  I think it really looks bad and I noticed on the RV-12 at the Copper State Fly-In last fall that the canopy blocks had not been modified.  The builder replaced the last nut and screw with a rivet.  I am going to do the same.  I cut a ¾" wide strip of the phenolic material with the table saw at work.  

 

  I removed the old blocks and used them as templates to make the new blocks.  I cut them out, radiused the edges with my router, drilled the holes and installed them on the roll bar.  They fit and look a whole lot better in my opinion.

 

 

I then proceeded to paint the POH tray and touch up the inside of the turtle deck skins.  I also masked and painted the forward end of the fuel tank.  Because of the tank modification the forward end was a bit scuffed up and I want it to look good.  I also painted one of the new clip angles installed on the mounting plate.  I think it looks a lot better.

 

This afternoon I covered the Map Holder with some of the carbon fiber vinyl wrap I purchased for the instrument panel.  I think it turned out really great.  I am anxious to put the carbon fiber vinyl on the instrument panel.  I will have to wait until I order the Avionics Kit.  The new panels should be included in the new kit.