Clecoed the upper wing fuel tank lower skin and two end ribs into place.
Flipped the two end ribs on the fuel tank so that the lips of the ribs faced the center of the tank. Drilled holes and clecoed. Took Mason stick grip apart to figure out what needs to be done to it.
Confirmed the correct brackets for the sway wires (again). Worked on setting up the firewall so that I could begin laying out the sheet metal but decided against it until I have the actual firewall in place to work off of. Ground down the rudder horn so that it fits on the rudder post. Needs to be welded on now.
Figuring out the flanges on the upper wing fuel tank.
Designed the trim/servo adjustment stick.
Drilled rossette holes in upper and lower fuel tank skins. Weld upper part of rudder horn.
Welded the rest of the rudder horn on. Needed to grind down and sand the excess weld off so as to not to interfer with the pivot of the rudder.
Deburred the skins and baffles and end ribs on the upper wing fuel tank. Worked a bit on the fuel vent line (figuring it all out).
Reading, understanding, figuring out the fuel tank hook ups and fuel system. WOW !
Figuring out and bending the vent tube for the upper wing tank. Work on the tail cone area - need to adjust the cut-outs on the sides and bottom to work with the trim/servo system.
Mar 6 -16
Vacation in Tortola.
Cut wood pattern for servo/trim handle. Cut blank out of .25o aluminum.
Routed first blank. Wasn't clamped good enough and the router wandered far into the aluminum blank. Needed to start over again. Cut new blank. Just about finished routing a nice piece and the bearing went out on the "new" Bosch router bit. Tried to salvage... Handle is a little bulkier than I thought it was going to be. Will re-design slightly smaller and use this one as the blank for the smaller one.
Revised layout for handle. Now 11 1/2inches long and 3 3/4inches top to bottom instead of 12 1/2 and 4.
Working on the tail cone area of the turtledeck. It interferes with the trim/servo horn.
Modification of the tail cone. Lifted it 1/2inch to clear the trim horn. Will need to cut and glue 1/2inch of ply to bottom of existing tail cone (with lightening holes).
New trim handle: made new MDF pattern. Routed new handle. Drilled lightening holes. Ready for final finish and drilling of two attachment holes.
Worked on flooring for turtledeck; raising it 1/2inch. Also... looked over the fuselage to figure out what needs to still be done on it.
More work on the tail cone: routed and glued the false bottom onto the forward and rear sections of the tail cone.
Sanding the trim lever smooth. STILL NOT FINISHED WITH IT !
Figuring out the tail cone area... how to have the back-end of the stringers on the turtledeck free from the tail cone but able to be attached when putting it all back together. I wasn't too happy with attaching the stringers indiviually to the tail cone.
Made the patterns for the overlays on the tail cone. Cut out the overlays (to build up the thickness of the tail cone to 1/8inch) and also the wood plates (1/8inch - same design as the overlays) that the stringers will get glued to. This plate will then get attached to the tail cone. Glued on the first overlay.
Trimmed and glued on the second ply build-up on the tail cone (opposite side of last time).
Figuring out the shape of the instrument panels... still.
Sanding the trim/servo handle; 220, 400, 600 grit.
Re-fitting the tail cone spine and additional build up on the turtledeck spine.
Re-working the connection of the turtledeck stringers to the tail cone. Figured it out... and then figured out a better way (after I re-worked it the first time). Cut the new spine piece that will need to get glued on.
Began re-making the tail cone. The first one had been through so many itterations I decided it was time to make a new one incorporating all the technology that I finally arrived at on the first one.
Patterns for front and rear sides of tail cone. Sealed the insides with T-88.
Cut and glued on the glue strips to the tail cone base plates. Drilled the 3/16inch holes on the trim handle. Figured out the mounting of the trim handle. Need to order the throttles first.
Figured out locations for pilot's throttle and the trim/servo handle. Routed out lightening hole for tail cone base plate and built up glueing blocks to cut a smaller angle for sides of the tail cone. Cut and reamed 3/8 x .o65 tube to 1/4inch, cut and lahted to length tubes for trim/servo handle mount. Took a hole saw cutter and cut both plates for the trim servo handle mount.
Welded up the trim/servo mounting bracket (washers and tubing). Tested and glued on the side-walls on both the front and back tail cone base plates.
Spoke to Bill (guy that works for Andrea's family's company) about the stainless steel for the firewall. Should have that delivered to Burns Company in about a week.
Contined work on tail cone (glued walls of forward section to spine). Confirmed location of trim handle and tack welded it into place.
Worked on glueing on the rear tail cone plate (took much longer than I had anticipated) and sizing up of the rear instrument panel (again).
Still re-working the tail cone (build up of ply on bottoms). Glued additional build up on turtledeck spine (to match height of spine on tail cone. Re-measuring and figuring out of the pilot's heel rails and the front partial flooring and heel rails.
More work on the tail cone. Routing the bottom of the forward plate and sanding and filing the rear plate. Also lengthened the two double-stringers.
Drew up and cut out paper patterns of the forward floor and rear heel rails.
A few things; made and glued/nailed in glue block in the upper-inside of the forward tail cone to strength the contact of the side-walls-to-spine, test fitted the floor/heel rail patterns and made some adjustments, looking at the fuselage and determining how I want the trim/servo cables to run, took the pattern for the rear pit's instrument panel and seeing what works and what I like.
Trim down overhang on top edge of tail cone pieces. Worked on trutledeck stringers... trying to get them to my liking.
Traced and cut out floor/heel rail patterns on display board (phase 2 of the process).
Tweak the display board patterns for the flooring and heel rails. Chopped off the starboard side double-stringer on the turtledeck. Figured out the wire run for the trim/servo system. Made a list of things to do...
Chopped off the turtledeck's port side double-stringer. Squared and cleaned up both port and startboard side cuts. Ready for the new stringer material.
Decided what I needed to do on the rear sway wire brackets. Cut the tack welds on the port bracket and then cut it down. The starboard side was already welded on. Started to cut the one leg of the bracket off.
Cut off leg of starboard rear sway wire bracket. Began welding up the port rear sway wire bracket.
Welded on the sway wire brackets. Just need to run a line on each of them on the inside (which I couldn't easily get to right now). Cut six more fairlead tubes... getting ready for the trim/servo system hook-up. Saw that I needed two more for the rudder cables.
Ripping down stringer material for the turtledeck. Test fit of one of the double-stringers. Looking good.
Tweaked fit of two of the stringers then glued and nailed. Notched and fitted one of the additional heel rail support tubes.
Cut, notched and fitted all of the additional tubes for the co-pilot's front floor and the pilot's heel rails. Tack-welded them on.
Notched, fitted and glue the two remaining stringers on the turtledeck.
Finished welded top sides of the floor and heel rail tubing.
Looking at the fuselage and making decisions about the build: upper fuel tank, firewall, flooring/heel rails, landing gear, battery tray, shoulder harness mount for pilot.
Took the tail feathers off so that I could turn the plane when welding up the additional floor supports and heel rail supports. Finished welding floor and heel rails.
Filed and sanded the tops of the front flooring support tubing. Welded on the additional heel rail support tabs. Welded the tack welded trim tab handle bracket.
Figuring out and making the plates to connect the stringers to the tail cone.
More work on the turtledeck: removed four of the stringer supports to replace them. Change in double-stringer caused this.
Cut, filed and sanded additional stringer supports for the turtledeck. Cut and fitted wood build-ups for nut plates for attaching tail stringer plate to tail cone.