Forward Fuselage Assembly

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.

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.


Pedal Bearings Installed

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.


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

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. 

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.

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.

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.

Using the Cutoff Wheel to Trim Extrusions Flush with Skins

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

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.


Drilling Holes into Longeron, Side Skin and Gussets

"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


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.


Inboard Seat Belt Attachment Installed on Inside of Armrest

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.


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.

Using Scotchbrite on Aluminum Parts

4/20/13 - Deburring of the forward cabin area.  Total Time = 3 hours.


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.


Control Tube Painted

5/5/13 - Painted Control Tube with silver paint. Riveted the Baggage Back Assembly together. Total Time = 2 hours.

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.


Riveting the Side Channel Doubler in Place

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. 

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.


Control Tube with Bearings

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.


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.


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.

 


Rear & Forward Fuselage Re-joined Ready for Riveting

Total Forward Fuselage Assembly Time = 93 Hours.

Rear Fuselage Assembly

Rear Fuselage Skins

11/23/12 - Moved from sawhorses back to tables. Placed Bottom Fuselage Skin (75F1-1) on the table and attached to the Rear Bottom Fuselage Skin (75F1-2) with clecoes. Drilled and clecoed the bottom Rear Fuselage Longerons (75F2-2) to the bottom fuselage skins. Total Time = 3 hours.


Drilling Holes in Bottom Skin

  

Bottom Fuselage Skin Attached to Longerons

11/24/12 - Cut "L" Angles to size for the lateral stiffeners. Installed with clecoes to the bottom skin and drilled to proper size. Cut "L" Angles to size for the diagonal stiffeners, clecoed and drilled holes to proper size. Installed Torque Tube Bearing Channel (75F4-5) and fitted horizontal tail frames with clecoes. Cut "Z" Channels to proper size for installation around the access hole and drilled holes to proper size. Cut "L" Angles to proper size for installation on each side of the "Z" channels and drilled holes to proper size. Total time = 9 hours.

Finished Bottom Skin

11/25/12 - Installed Bottom Skin Gussets (75F4-8), drilled holes to proper size and clecoed in place. Finished drilling remaining holes in bottom skin, then removed and set it aside. Installed Rear Fuselage Longeron (75F2-2) to the Fuselage Side Skin (75F1-3) and Rear Fuselage Side Skin (75F1-4), drilled holes and clecoed in place. Total Time = 4 hours.

Longeron Attached to Passenger Side Skin

12/8/12 - Cut "L" Angles to size for the lateral stiffeners. Installed stiffeners, clecoed in place and drilled to proper size. Cut "L" Angles for the diagonal stiffeners, clecoed in place and drilled holes to proper size. Clecoed the Upright (75F3-4) and the Side Channel (75F4-1) to the Passenger Side Skin (75F1-3). Drilled out holes in Longeron (75F2-2) and attached to the Pilot Side Skin (75F1-3). Total Time = 7 hours.

Adding Upright and Side Channel to the Side Skin

12/9/12 - Cut "L" Angles for the lateral and diagonal stiffeners, drilled and clecoed in place. Clecoed the Upright (75F3-4) and the Side Channel (75F4-1) to the Pilot Side Skin. Drilled all holes to their proper size in the stiffeners and longeron. Total time = 7 hours.


Finished Pilot Side Skin

12/15/12 - Aligned the Pilot and Passenger Skin with the Bottom Skin and clecoed the H.T. Section in place. Drilled (2) locating holes on both bottom longerons. Removed the Pilot Side Skin and drilled the remaining holes in the longeron. Removed the Passenger Side Skin and drilled the remanining holes in the longeron. Reassembled the Pilot and Passenger Skins to the Bottom Skin and clecoed them in place. also placed masking tape in place for stability. Cut off excess material from the top longerons so that longerons are flush with the edge of the side skins. Clecoed the Rear Wing Attachment (75F4-4) to the Top Channel (75F3-6) and then clecoed to the side channel and the top channel. Positioned the Top Skin (75F2-1) onto the top of the rear fuselage. Clecoed the top skin into the the top channel and drilled (2) locating holes into the top longerons. Removed the Top Skin and placed on the table for drilling. Total Time = 9 hours.

Attaching Side Skins to the Bottom Skin

Drilling Holes in the Top Skin

12/16/12 - Drilled holes through the top skin into the top longerons. Opened up the holes to the proper size. Cut "L" Angles for the lateral and diagonal stiffeners, drilled and clecoed in place. Cut "L" Angles, drilled and clecoed them to the top of the H.T. Frames. Total Time = 8 hours.


Cut "L" Angles and Attached to the Top of the H.T. Frames

12/22/12 - Drilled out holes in the Top Skin to the proper size. Reattached the Top Channels to the Fuselage. Trimmed "L" angles behind rear windows by 20 mm. Attached Baggage Back Channels (75F6-7) to the Baggage Back (75F5-2). Cut three "L" Angles to 675 mm, then drilled holes in them and attached to the back of the Baggage Back with clecoes. Inserted Baggage Back into the rear fuselage. Attached the Baggage Angle (75F6-5) to the top of the Baggage Back, then drilled and clecoed baggage angle in place. Cut "L" Angles to 260 mm, then drilled and clecoed them to the Baggage Floor (75F5-3). Clecoed Baggage Floor to the Baggage Back. Total Time = 6 hours.


Baggage Back Clecoed in Place

  12/23/12 - Reattached the Top Skin to the Fuselage and fitted properly in place. Drilled holes in Horizontal Tail section and the Baggage Top. Drilled holes in the Rear Top Channel (75F3-7) and Top Channel Angle (75F3-9). Total Time = 5 hours.

 

Reattaching the Top Skin to the Fuselage

12/30/12 - Installed Top Doubler (75F4-3) onto the top skin and drilled holes to the proper size. Drilled remaining holes to the proper size in the top skin. Drilled baggage skin to the proper size. Drilled remaining holes in the rear fuselage to the proper size. Total Time = 7 hours.


Drilling Out Remaining Holes to Proper Size

 12/31/12 - Removed the Top Skin. Drilled holes in the H.T. section "L" Angles. Disassembled top skin on the table and started deburring holes. Cleaned the surface with Scotch-Brite and then coated all the surfaces with Cortec anti-corrosion. Total Time = 5 hours.



Deburring Top Skin Holes

 1/1/13 - Happy New Year! Clecoed together the top skin parts and riveted the Top Skin together and then placed it aside. Removed the Passenger Side Skin and placed it on the table. Removed all the clecoes, deburred, cleaned and applied corrosion protection to all the parts. Total Time = 7 hours.


Top Skin Riveted Together

1/5/13 - Riveted Passenger Side Skin together, then set it aside. Removed the Pilot Side Skin from the fuselage and began deburring all the parts. Finished deburring, cleaned and coated all parts with Cortec anti-corrosion. Total Time = 5 hours.

Applying Cortec Anti-Corrosion Protection

  

Side Skin Riveted Together

1/6/13 - Riveted Pilot Side Skin together and set it aside. Drilled holes for the access panel nut plates and then started taking apart the Bottom Skin. Deburred, cleaned all parts and added corrosion protection. Total Time = 9 hours.


All Bottom Skin Parts Ready for Cortec Anti-Corrosion

1/12/13 - Clecoed together the stiffeners and vaious parts to the Bottom Skin. Drilled holes for the Access Panel nut plates then riveted the nut plates to the bottom skin. Riveted all of the stiffeners and parts to the bottom skin. Filed down the edge of the Flap Motor Mount (75C1-1) so that it would fit in between the longeron and the "Z" channel on the passenger side of the bottom skin. Aligned the mount and drilled the appropriate size holes in the Flap Motor Mount and the bottom skin. Removed the mount to be installed at a later time. Total Time = 6 hours.


Bottom Skin Riveted Together

1/27/13 - Riveted the "L" Angles to the top of the H.T. Frames Clecoed the Passenger and Pilot Side Skins to the Bottom Skin. Positioned the Top Skin on top of the fuselage and clecoed it in place. Riveted the Side Skins to the Top and Bottom Longerons. Attached the top doublers to the Top Skin with clecoes. Total Time = 5 hours.


Clecoing the Side Skin in Place

 

Riveting the Fuselage Together

 

The Time Tunnel (Inside of Fuselage)

 

Completed Rear Fuselage

 Total Rear Fuselage Assembly Time = 102 hours.