More riveting on the fuselage - 8.5 hours

 Very long day on the build. Progress was slow because lots of the work was really finicky. I managed to get all of the riveting on the F-704 bulkhead that was tricky to reach. I also was able to finish the rivet line on the F-705 bulkhead and the F-724 bulkhead.

 

Feeling like I'm actually progressing, I decided to start bolting the F-633 control column mounts. Getting the washers and nuts on was tricky as there is not much space to work with between the F-704 bulkhead. Washers were ok as I have a tool that I taped to a screw driver....but getting nuts on the bolts was not that much fun. I ended up using tape on the end of a wrench which helps hold the nut in place, enough to get the nut started.

The most difficult part was how to torque the nuts. I have a very small torque wrench however its not that small. I ended up running to the store and bought a 3/8" socket and ground it down shallow enough so that I could get it slipped over the nut and torque it.

Finally, I finished the installation of the two bolts on the F-705 bulkhead. I slipped the F-705H spacers in place and I installed the bolts. Fortunately the fit was really good and installation was smooth.

Finished riveting the F-772 fwd bottom skin - 5.5 hours

 Finally motivated to continue riveting. I managed to finish of the F-772 forward bottom skin. Slow going for sure, but it looks soo good.

Primed parts and assembled the F-635 bellcrank - 5 hours

 Started today's build session by prep'ing and priming all of the various aft deck parts from yesterday. I also cleaned up and primed the F-796A fuel tank brackets. Since they are unfinished steal, after a couple of years they are starting to show signs of rust forming. 

Next I had assembled the F-635 bellcrank. Looks so good and assembly is so quick.
 

Next, I need to drill the bellcrank for the Dynon auto-pilot servo. Getting precise measurements here is a little tricky, as finding exact center on the protruding bearing tough.

This ended up being an easy fix as I drew a template in AutoCAD, and cut out the hole for the bearing. I was easily able to locate the pilot hole correctly and accurately. I finished the hole on the drill press with a reamer. 

 

Worked on Aft fuse parts - 5.5 hours

 Lots of work tonight with little in the way to show for it. Needing a change from the riveting, I decided to start prep'ing some of the Aft fuselage parts. The F-714Aft deck, F-636 harness anchors, F-635 bellcrank, and the F-757 gusset.

I started in by breaking all of the rough edges and smoothing them out (with a file and then scotchbrite). 

Next, I measures out the dimensions on the F-757 gusset to allow for the arcing cut in the piece needed for the sliding canopy. 

 

Next, I started working on the elevator bellcrank parts. Getting those spacers done take a little time to get to the right dimension. I gut them close to size and then put then in the drill press. Sandpaper under the piece and slowly they get to size and the ends are square. A slow process but it works great. 

Lastly, I decided to prep and flute the F-709 bulkhead. 

Started riveting the F-772 fwd bottom skin - 4.5 hours

 Spent some time riveting the F-772 fwd bottom skin. I started with the line of rivets along the firewall and then worked aft. Also managed to set the AD4 rivets on the side skin all the way back to the F-704 bulkhead. Not much to show, but it was a good riveting session. 

 

 

Installed bolts in the lower engine weldment - 2 hours

 Putzing in the garage tonight I decided to install the bolts in the lower engine weldment. Typically most builders choose to do this first before the put the bottom skin on, but you would notice just how tight the bolt heads make bucking the rivets in the side of the weldment. In the interest of good clearance for a bucking bar, I held off installing the bolts till now.

 The plans call for AN3-5A bolts but it become very obvious that these will be too long. 

 I tried a bolt size down with the 4A's but they are too short.

Looks like I will need to go with the 5A bolts but add an extra washer. I put one under the bolt head and checked the grip, looks really good now.

I installed the nut and everything looks great. So I finished the job.

 

 

Worked on the F-796 angles - 2 hours

 One of the items on the to-do list is to get the countersinks completed, and install the screw and nut for the F-796 tank attach angle. 

I opted to follow the drawings an countersink, although I see some on the build logs choose to dimple this hole. I made my first countersink shallow, and worked up to the proper depth little by little. The area is so tight and snug to fit the nut. Fortunately I have a 3/8" socket that I have ground down for such tight spaces and it has done the trick of tightening the nut.

 

Started riveting the forward bottom skin - 4 hours

 Lots of hours compared to little amounts of rivets. This isn't the easiest area to rivet. Lots of anxiety to make the rivets good and not mess up a fairly important structural area.  Not to mention accessibility is not entirely the best but I managed to pull it off. I'm extremely pleased with the rivets on the steel engine mount.

Assembled the F-772 forward bottom skin - 4 hours

 I fitted the F-772 forward bottom skin onto the fuse. It was a bit of a long build session primary because I had to apply 3M fire barrier 2000+ around the flanges of the fire wall.  It takes a bit of time to apply it, and then spread it out for good coverage with Popsicle sticks. 

Another delay, as I started clecoing the floor skin I noticed I had missed one dimple. So pop-rivet dimple die to the rescue. I was really happy with the fire barrier coverage. I have a nice bead inside the fuse.

Prep'd the fuse for the forward bottom skin - 1.5 hours

 Spent a couple of hours in the evening to prep and prime the matting surface on the bottom center section to accept the forward bottom skin. 

On a roll riveting - 6 hours

 Im on a good roll of riveting. I'm to a point where I want to get the bottom forward floor skin on. I was dreading this part a little when reading other blogs. Seems that the floor stiffeners can be a little tricky to rivet onto the aircraft. 

All that anxiety was for nothing as the riveting of the 2 floor stiffeners went really well. Yes, it is a little tricky, but I was mentally prepared to tackle the task. I used a very long rivet set to buck the most aft rivet next to the center spar.

 

Next I opted to move back to fuse skin riveting and I started in on completing the top most rivets on the aft side skins up to the longerons. 

Still in a good rhythm I finished off the top most section of the center/aft fuse sections.

 

Lots more riveting of the fuse - 8 hours

 Spent the day riveting on the fuse. I started in by bucking the rivets on the arm rests. 

Next I started fitting the F-902 bulkhead/F-796 attach angles. Little bit of futzing with that but once I was happy with the fit. I began riveting. Then I decided to move on to the longeron riveting. I had marked out the section that needs riveting. Certain portions are not riveted as they are left open for the final fitting of the turtle deck and forward top skin. I started riveting up the F-705 bulkhead. 

 

Next step, I started riveting the aft baggage ribs.

 Continuing aft, I set the few rivets on the longeron aft of the baggage section.