Elevator Trim Tab

I fit the elevator trim tab hinge to the tab. Cut and trimmed to final fit. Laid out the rivet spacing. Drilled and cleco’d the hinge to the tab.

Control Sticks

I spent some time aligning the new bent control sticks. Once I was happy with the alignment, I drilled them using a Drill Right Jig and a ¼” bit. I deburred the holes and installed two AN4-13A bolts and AN nuts. The bolts will be replaced on final assembly with AN4-11A bolts, AN960- washers, and AN lock nuts.

I gathered all the parts necessary for the installation of both header tanks. I clamped them in place to verify orientation. I then measured and marked the location of the holes that needed to be drilled on the tabs of each tank. Once drilled, I mounted each tank using four Adel Clamps, four AN3-4A bolts, four AN960-10 washers, and four AN nuts. The nuts will be replaced on final assembly with AN lock nuts.

Baggage Tunnel

I installed the floorboards again to redo the rear tunnel section. Used an angle finder to determine the correct angle for the rear section of the tunnel. Once cut I fit the section in place and determined it needed some trimming to make it perfect.

After trimming I set about to determine the positions of the lock plates that I had to install. Once the lock plates positions were determined, I drilled and installed them.

At this point, I attached the right and left rear baggage floors to the tunnel via the new lock plates to verify fit and finish. I installed the assembly into the fuselage and determined the amount of trimming to the front edge of the tunnel to mate up with the front baggage floor assembly. I deliberately left the tunnel long so I could mate the two tunnel sections.

Once trimmed, I reinstalled the rear baggage floor to verify fit and finish. The front of the tunnel would not lay flat against the floor because one of the rivets in a forward lock plate was interfering with a fuselage crossmember. Once ground down it fit without touching.

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.