Forward Fuselage - Back to the basement.
2/2/13 - Clecoed the Floor Stiffener (75F10-4) to the underside of the Cabin Floor (75F10-3). Clamped the Lower Longeron (75F13-1) to the Cabin Floor and drilled holes into the Lower Longeron. Total Time = 2 hours.
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| Cabin Floor |
2/3/13 - Trimmed 20mm off the forward edge of each longeron. Trimmed 120mm off of the rear edge of each longeron. Attached the Pedal Bearing Channel (75F10-7) to the floor skin with clecos. Installed the Bottom Pedal Bearing (75C3-6) by drilling out bearing holes to 3/16" inch. Held the bearings in place with t(2) AN3-16' bolts. Placed Pilot Side Rudder Pedal (75C3-4) onto the Bottom Bearing Channel.Trimmed Rudder Pedal Bearing (75C3-7) by 3/16" so that it would fit into position and drilled holes to 3/16" into bottom of bearing and cabin floor. Placed Passenger Side Bearing in place and drilled holes into the Rudder Pedal Bearing to 3/16" size. Total Time = 2 hours.
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| Pedal Bearings Installed |
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| Installing the L.H. Arm Rest |
Installed the Brake Cylinder Support Extrusions (75C3-8) by placing the brake cylinder into the extrusions to space them properly. Drilled holes in the cabin floor. Installed the Heel Support (75F10-5) with clecoes. Installed the Seat Channel (75F11-1) with clecoes. Installed the L.H. and R.H. Seat Supports (75F11-2)with clecoes. Installed the Gear Channel (75F11-3) after trimming the corners with clecoes. Installed the L.H. Arm Rest (75F12-1) and the R.H. Arm Rest (75F11-6) with clecoes. Installed the Pilot Side Cabin Skin (75F-7) and the Passenger Side Cabin Skin (75F-7). Total Time = 7 hours.
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| L.H. and R.H. Cabin Side Skin Installed |
2/10/13 - Cut two pieces of "L" Angle and installed them against the Seat Supports flush with the back of the Gear Channel.
Back to the Garage
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| Shoulder Harness Attachment Installed |
Drilled all the holes in the Baggage Back (75F5-2) and the Baggage Floor (75F5-3) to the proper size. Clecoed the Baggage Back and the Baggage Floor into the Rear Fuselage. Installed the Shoulder Harness Attachment (75F3-8) with clecoes and drilled holes to the proper size. Installed the Flapperon Control Covers (75F3-5) with clecoes and drilled all the holes to the proper size. Installed the Right Baggage Upright (75F5-4) and the Left Baggage Upright (75F5-5) with clecoes. Total Time = 2 hours.
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| Baggage Back, Floor & Uprights Installed |
2/17/13 - Cut (2) "L" Angles to 55 mm and 100 mm long and installed them on the Flapperon Control Cover under the baggage floor and drilled the holes to the proper size. Installed the Torque Tube Bearing Support (75F5-1), Right Control Tunnel Side (75F6-2), Left Control Tunnel Side (75F6-3) and the Control Tunnel Top (75F6-4). and clecoed them in place. Total Time = 7 hours.
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| Baggage Floors Installed |
2/23/13 - Cut (2) "L" Angles to 270 mm and 240 mm long, drilled holes and installed them on the bottom of the baggage floors. Installed the Gussets (75F4-6) to the side skin and the Torque Tube Bearing Channel. Installed the left and right Baggage Floors and then drilled all the holes to the proper size. Total Time = 3 hours.
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| Drilling the Side Channel Covers |
2/24/13 - Installed the Side Channel Doubler Extrusion (75F6-6) behind the upright, then drilled and clecoed in place. Installed the Side Channel Cover (75F4- 2) with clecoes. Used the cutoff wheel saw to trim the corners of the extrusions to match the side and bottom of the fuselage and filed down the corners smooth. Guided the extrusions of the forward fuselage into the rear fuselage and clecoed into place. Total Time = 7 hours.
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| Using the Cutoff Wheel to Trim Extrusions Flush with Skins |
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| Forward Fuselage Joined to the Rear Fuselage |
3/23/13 - Installed Longeron Gussets (75F4-9) on both the left and right hand sisde. Total Time = 1 hour
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| Added Longeron Gussets |
3/24/13 - Dilled holes in the Longeron, Side Skin, Longeron Gussets and the Side Skin Gussets (75F4-9). Installed 40 mm side "L" Angles and drilled to proper size. Clecoed to the Seat Front and the Cabin Side. Installed 90 mm side "L" angles, drilled to proper size holes and clecoed to the Front Seat Front and the Cabin Side. Total Time = 5 hours.
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| Drilling Holes into Longeron, Side Skin and Gussets |
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| "L" Angles Installed |
3/29/13 - Reached under the Seat Base and drilled (2) holes through the Seat Base Side and into the Cabin Side on both the Pilot and Passenger Sides. Fitted all pieces of the interior together with clecoes so that all parts were square. Total Time = 4 hours
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| All Parts Fitted Together With Clecoes Until Square |
3/31/13 - Installed the Lower Seat Belt Attachment (75F13-1) on the aft most vetical extrusion on both sides of the Cabin Walls and then drilled holes to the proper size. Also installed the Inboard Seat Belt Attachment (75F13-7) on the inboard side of the Gear Channel against the Arm Rest on both the pilot and passenger side and drilled the holes to the proper size. Total Time = 6 hours.
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| Inboard Seat Belt Attachment Installed on Inside of Armrest |
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| Lower Seat Belt Attachment Installed |
4/6/13 - Drilled out all holes in the cabin area to the final hole size. Installed the forward side skin (75F12-2) on both the pilot and the passenger side. Total Time = 8 hours.
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| Installed Forward Side Skin |
4/7/13 - Finished drilling out all holes in the forward cabin to the proper hole size. Trimmed both ends of the cabin extrusion on the pilot and passenger side. Began deburring process on the cabin. Total Time = 8 hours.
4/14/13 - Continued with the deburring process on the cabin area. Total Time = 2 hours.
4/16/13 - Deburring of cabin area. Total Time = 3 hours.
4/18/13 - Deburring of cabin area. Total time = 3 hours.
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| Using Scotchbrite on Aluminum Parts |
4/20/13 - Deburring of the forward cabin area. Total Time = 3 hours.
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| Deburring Aluminum Parts |
4/21/13 - Deburring of the forward cabin area. Total Time = 4 hours.
5/4/13 - Prepared and primed the suface of the Control Tube (75C1-6) to get it ready for painting. Added corrosion protection to the Baggage Back Assembly. Total Time = 3 hours.
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| Control Tube Painted |
5/5/13 - Painted Control Tube with silver paint. Riveted the Baggage Back Assembly together. Total Time = 2 hours.
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| Baggage Back Riveted Together |
5/6/13 - Prepared and primed the Flaperon Bracket (75C1-1) to get it ready for painting. Added corrosion protection to the Baggage Floor. Riveted the (3) "L" angle stiffeners to the backside of the baggage floor. Total Time = 2 hours.
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| Riveting the Side Channel Doubler in Place |
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| From the Backside |
5/7/13 - Painted the Linear Actuator Bracket. Added corrosion protection to the Side Channel Doubler Extrusion, installed and then riveted in place. Added corrosion protection to the R.H. & L.H. Lower Baggage Floor and also to the "L" angles. Riveted only the forward 'L" angle stiffeners in place at this time. Total Time = 2 hours.
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| Linear Actuator Bracket Painted |
5/11/13 - Cut "L" Angles for the Bearing Mixer Support (75C1-5). Drilled holes into the "L" Angles and the Bearing Mixer Support. Drilled holes in the Flaperon Bellcrank Bearing (75C1-8) and the Flaperon Bellcrank Bushing (75C1-9). Total Time = 7 hours.
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| Control Tube with Bearings |
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| Linear Actuator Mounted in Place |
5/12/13 - Riveted Linear Actuator Mount to the fuselage. Bolted together the Mixer Bearing to the Bearing Support. Mounted the Linear Actuator (75C1-2) to the Actuator Mount. Drilled holes to the proper size in the Rear Torque Tube Bearing (75C2-3) and the Rear Torque Tube Bearing Doubler (75C2-4). Bolted assembly to the Torque Tube Bearing Support. Total Time = 3 hours.
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| Riveted Fair Leads to Torque Tube Bearing Support |
5/19/13 - Prepped all baggage area parts with anti-corrosion material. Installed Fair Leads on the Torque Tube Bearing Support. Riveted the Fair Leads in place. Re-installed Baggage Area back into the Fuselage and started to rivet parts in place. Total Time = 7 Hours.
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| Torque Tube Bearing Support and Control Tube Assembly Installed |
5/26/13 - Reassembled baggage area with clecoes after applying anti-corrosion protection. Reassembled forward fuselage assembly with clecoes after applying anti-corrosion protection. Re-joined the forward fuselage to the rear fuselage and prepared to rivet. Total Time = 5 hours.
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| Rear & Forward Fuselage Re-joined Ready for Riveting |
Total Forward Fuselage Assembly Time = 93 Hours.
