06. Horizontal Stab

Received from JA the replacement Horizontal Stab Bushings.

E. Tools & Supplies

Received from Aircraft Spruce the Blue Pneumatic Rivnut Gun. Began working with it to set it up for 6-32 Rivnuts. Discovered that the mandrel was not long enough for the rivnuts.

Update: Ordered 5 replacement cap head screws 6-32x1 5/8". These should be the correct size for the rivnuts. Once installed, I whould be able to set the tool up for the rivnuts.

10. Elevator Controls

Pulled all the parts requrired to assemble the control mixer.Reamed all holes. Cleaned up the threads on the pivot rod ends. Installed the lock nuts and fork ends. Attached the pivot rod to the mixer. Assemble the nylon blocks to the mixer and installed the assembly to the fuselage.

I'm not sure from the instructions if I have the correct number of penney washers installed and will check with the factory tomorrow. Also need to see if I have the correct bolt/nut orientation.

On a side note, while pulling the parts for the mixer assembly, I came across the "missing" flying tail fences. They were taped to the back of the instrument panel.

01. Floor Panels

Trimmed to fit the fuel selector mount. Rounded all corners and smoothed the edges. Drilled and cleco'd in place.

01. Floor Panels

Trimmed to fit the left and right seat side panels. Drilled and cleco'd the panels. Smothed the edges and rounded the corners for both panels.

13. Seats & Harnesses

Drilled out the incorrect rivets in the Nylon seat rails and match drilled into new nylon seat rails that were cut correctly to 1/2". Deburred all the holes and countersunk them. Ordered a new set of correct countersunk rivets.

13. Seats & Harnesses

Received the replacement seat adjuster rails and nylon runners from JA. Drilled out the nylon runners and match drilled them with the new nylon runners. Riveted them back in place.

THe reason for the replacement is that the original runners were about 3/16ths too wide and were interferring with the side floor panels as well as the flap handle installation. The new rails were 1/2" and after match drilling fit perfect. The seat adjuster rails were needed to replace the originals that I misdrilled.

02. Verticle Stab

Spent some time trying to figure out how to align  the vert stab with the rear of the fuselage. Eventually, I used two levels, one stuck to the fuse and one stuck to the vert stab. I lifted the fuse in the rotisserie until the rear of the fuse was vertical. Then I adjusted the vertical stab until it matched the bubble on the fuse.

Once I was satisfied that the vert stab was aligned with the fuse correctly, I drilled the 3/16" hole for the front of the vertical stab setting it's position. Inserted the bolt with washer and nylon lock nut without tightening it. Drilled the two holes in the rear vertical stab post to accept the two CCP44 stainless rivets. I did not permanently attach the vertical stab. I will wait so I can rotate the fuse upside down to cover the bottom. I would not be able to do this with the vert. stab attached. Once the bottom is coverted, I will permanently attach it.

I verified the alignment by attaching the rudder and checking for smooth, easy movment throughout it's range of motion. Check.

02. Verticle Stab

I fit the vertical stabilizer to the fuselage. First I reamed out the powder coat from all the hinge points on the Rudder and Vertical Stab. I then cut and installed nylon tubing into all the hinge points on the Rudder and Vertical Stab.

Working at the factory...

Post #2

Building an Aileron. This was the first part I worked on at the factory. Jak spent some time showing me how to do it. Had a blast and wish I could have stayed for a few months.

Post #1