Mike

Monthly Construction Log - September 2008

Date
1	Finished deburring and polishing - parts ready for cleaning and priming.
2	No work.
3	No work.
4	No work.
5	Cleaned parts for priming.
6	Primed all parts. Assembled floor channels and braces, then riveted the assembly. Riveted the lower steel supports to the firewall. Modified floorboard and access panel for clearance around rivets in firewall channel and around the brake mounting blocks - see image below showing areas that need to be modified. Clecoed instrument panel assembly onto firewall/floor assembly. (Note that 06E-02 shows a wrong rivet location for the instrument panel center support.)
7	No work.
8	No work.
9	Laid tail cone sideskin parts. Fabricated joggling tools and joggled stringers where required.
10	Fit up left side tail cone skin assembly before bending skin. Note that the lower stringer needs to be drilled for 9 rivets into the stabilator attach channel, but no holes are predrilled for these rivets. (These holes are also much easier to drill before the skin is bent.) The stringer fit at the aft end is difficult to get lined up correctly, but by slightly tightening the stringer angle with padded pliers a reasonable fit was obtained. Obtained diagram of required rivet locations. Put aside side skin to mark lower stringers, and laid out belly skin parts.
11	Began assembly of the tail cone belly section. Marked lower stringer rivet locations.
12	No work.
13	Drilled lower stringers #40. Installed access panel into tail cone belly assembly. Transfer drilled belly assembly.
14	No work.
15	Reassembled tail cone left skin for transfer drilling. Test fit bulkhead #5 into position to verify fit and confirm which holes should be transfer drilled until later in the assembly.
16	Transfer drilled left and right tail cone skin assemblies. Disassembled in preparation for bending. Clecoed right side skin for bending - just need to round up some strong-armed help to get it done.
17	Started fitting pillow blocks for rudder pedal torque tubes.
18	Finished fitting pillow blocks for rudder pedal torque tubes.
19	No work.
20	Bent lower edge of both tailcone side skins. Cut fingers into both skins (Figure 07-04). Reassembled both sides, and found radius was bent too tight when trying to fit to belly assembly. Had used a 2"O.D. PVC pipe, but a 2.5" O.D. pipe looks like it would work better. Will get another piece of pipe and reshape radius. Disassembled right side skin for rework.
21	Reworked right side skin to larger radius using 2" PVC (~2.5"OD). Reassembled. Disassembled left side for rework.
22	Reworked left side skin and reassembled. Assembled skins to belly assembly. Installed bulkhead #5, but hit a stoppage due to stabilator attach bracket being on backorder. Installed bulkhead #1. Test fit upper bulkheads 1-3. Finished transfer drilling of bellcrank channel cover.
23	Installed tail cone longerons and transfer drilled to side skins and bulkhead gussets (KPFU0514). Assembled and installed bulkhead #4 top section.
24	Transfer drilled bulkhead #5 to skins. Installed interior channels on bulkhead #5 and transfer drilled. Test fit foot steps. Assembled rear deck closeout skin.
25	Test fit pulley brackets to bulkhead #4. Made bushings for rudder pedal pins. Prepped all rudder pedal parts and brake cylinder brackets for priming.
26	No work.
27	Prepped bulkhead #4 assembly and tailcone access panels for priming. Primed rudder pedal parts, brake cylinder brackets, foot steps, control sticks, access panels, and bulkhead #4 parts. Riveted bulkhead #4 and reinstalled in tailcone. Reinstalled access panels. Installed rear deck closeout skin. Mounted vertical stabilizer and transfer drilled. Transfer drilled closeout skin. Removed vertical stabilizer.
28	Cut bushings for rudder cable pulleys. Finished painting of rudder torque tubes and control sticks. Modified floorboard to position brake cylinder brackets per new detailed drawing from Rans. Installed right side rudder pedals and brake cylinders.
29	No work.
30	No work.