Made paper patterns for the cabane and sway wire holes. Tweaking them.
Jul 31
1.8hrs
Plumbed front edge of UWCS. Marking holes on 1st FWD skin. Screwed on and marked heads for centering over original off centered holes on first skin pattern.
August 1
2.3hrs
Marked forward fuselage skin for the cabane and sway wire holes.
Aug 2
2hrs
More of yesterday's activity... tweaking the hole openings.
Aug 3
1.7hrs
More marking of the skin.
Aug 5
2.1hrs
Marking of drilling of holes. Marked (drew out) the curve I wanted on the back edge of the forward panel. This is to capture the screw holes behind the rear cabanes.
Aug 6
2.8hrs
Drilling and cutting out hole opening in forward panel.
Aug 7
1.6hrs
Filed the openings I made so that they are relatively smooth (it's still just a pattern). Drilled 1/4inch holes. Prepping fuselage by lifting the UWCS so that I can lay the forward skin in place (had to disconnect the cabanes, one side, fit the pattern over those openings, reattach cabanes, then the same on the other side).
Aug 8
1.6hrs
Test fitting continued of the forward panel.
Aug 9
1.7hrs
Figured out a way to mark the holes in the firewall and stringers to the aluminum skin. Made first insert.
Aug 10
1.8hrs
Made 17 more inserts.
Aug 11
1.8hrs
After placing all the inserts that I needed for the firewall hole locations... I tried lightly hammering on the skin with a backer block behind the anchor nut. It failed to mark the hole like it did on the test piece I tried in the basement workshop. DAMN! I didn't want to hammer on it to hard as it may damage the firewall and/or the aluminum skin pattern. Back to square one.
Aug 12
2hrs
Going back to what I orignally did earlier to mark the first skin patterns. I used a rivet location device. The pin on it is only for a number 40 hole. I need to mark it for a 3/16inch hole. When I originally marked the hole with this device I wrapped duct tape around it to take up the gap. Worked but didn't really work. So... I made a cap to go over the number 40 tip: I took a 1/4inch rod drilled a number 40 hole in it then lathed it down to 3/16inch OD. Let's see if this works.
Aug 13
2.2hrs
Match-drilling holes in firewall/FWD upper skin. eed to file down tip for side formrs.
Sept 26
.5hrs
Match-drill holes in skin
Sept 28
1.4hrs
Take off UWCS, begin drilling holes in aluminum skin.
Sept 29
1.8hrs
Drilled all holes in FWD upper skin. Cleaned edges, deburred holes.
Sept 30
1.6hrs
Placed FWD skin in place for fit. 1/8inch off because I didn't hav the next upper skin in place.
Oct 4
1.6hrs
Off with the FWD upper skin. Look at reworking attach points on rear rudder peddles and pivot arm.
Oct 6
1.1hrs
Purchased aluminum sheet. Cut blank for FWD upper skin from the .025 material.
Oct 7
1.5hrs
Print patterns, position hole patterns on FWD upper skin.
Oct 8
1.9hrs
Cut out openings in FWD upper skin.
Oct 10
1.3hrs
Drilled (4) locating holes. Placed FWD upper skin in place. Screwed on. NICE fit!
Oct 12
1.1hrs
Match-drilled holes in FWD upper skin.
Oct 14
2hrs
Took off skin and drilled holes in FWD pper skin.
Oct 15
1.4hrs
Fitted FWD upper skin and side skin for fit. Enlarded FWD hole in 2nd skin to 3/8inch.
Oct 16
1.5hrs
Took off FWD upper skin. Drilled and cleaned holes.
Oct 17
1.1hrs
Fit up FWD upper skin. Remarking 2nd skin (confirming hole locations).
Oct 20
.9hrs
Cut aluminum for 2nd upper skin pattern.
Oct 21
1.1hrs
Cutting second skin pattern.
Oct 22
2.1hrs
Notched (2) slots in 2nd upper skin pattern.Started drilling holes
Oct 24
1.1hrs
Drill holes in upper skin. Start fitting it up on the fuselage.
Oct 25
1.1hrs
Match-drill holes in 2nd skin. Getting ready for 3rd upper skin.
Oct 27
1.4hrs
Cut blank for 3rd skin section.
Nov 2
1.8hrs
Drilled holes in third skin. Placed on fuselage to match-drill location holes.
Nov 4
3.5hrs
Drilled holes in 3rd uppder skin.
Nov 5
2.2hrs
Ground off excess brackets attaching pilot's rudder pedals. Modifying the support (making it extra stiff).
Nov 6
1.1hrs
Design new pieces for rudder pedal brackets. Cut and filed. Ready for use.
Nov 18
1.9hrs
Cut gussets and fit up to fuselage. Figuring out how to move fwd.
Nov 19
1.6hrs
Cut and fit gussets
Nov 22
1.3hrs
Trim brackets on pedal mounts. Fit up gussets
.5hrs
Fit up rudder pedal gussets
Nov 23
1.8hrs
Cut gussets
Nov 24
1.7hrs
More gussets
Nov 25
1.3hrs
File and fit gussets
Nov 26
2.1hrs
more... file and fit of gussets
Nov 29
1.6hrs
still more filing and fitting of gussets
Nov 30
1.1hrs
more filing and fitting of gussets
Dec 2
1.8hrs
Tacking on gussets
Dec 4
1.4hrs
Making display board gusset patterns
Dec 6
1.3hrs
Fitting up gussets
Dec 7
1.1hrs
Cutting gussets
Dec 8
1.5hrs
Trimming and filing gussets
Dec 9
2hrs
file/fit gussets
Dec 10
1.8hrs
File and fit gussets. Burn off patterns.
Dec 13
1.4hrs
Tack on gussets.
Dec 14
1.6hrs
Fitting up gussets. File off excess weld on existing bracket to fit gussets to front rudder pedal brackets.
Dec 16
1.5hrs
Fit and tack on gussets.
Dec 21
1.8hrs
Welding on gussets.
Dec 23
1.5hrs
Clean welds.
Dec 24
1.7hrs
Welding gussets.
Dec 26
1.8hrs
Filing and welding gussets.
Dec 27
.9hrs
Cut out and fit up two more gussets.
Dec 30
1.5hrs
Weld gussets.
Dec 31
1.5hrs
Weld more pedal bracket gussets.
Jan 1
1.8hrs
File and sand gussets.
Jan 2
1.0hrs
Create patterns, and rough cut two additional gussets.
Jan 6
1.6hrs
File, fit and tack on four gussets.
Jan 8
1.3hrs
Weld (2) gussets.
Jan 13
1.3hrs
Continue welding gussets.
Jan 20
1.2hrs
Made pattern for final gusset. Cut out gusset. Grinding off existing gussets that it will be replacing.