Prep’ing the firewall and the aft fuse - 3 hours

 Managed to get to work on preparing the firewall. The powder coated weldments have taken a little abuse with the fitting of the forward fuse parts. So I de-burred, cleaned and primed the outward faces of the weldments.

 Next I started in on the aft fuse. I deburred all the new holes and cleaned them up. I then dimpled all the holes along the longeron and the new line of rivets where the center section attaches at bulkhead F-706. After dimpling I cleaned the area and primed both the inside face and the outside face. 

 

Finished countersinking fuse parts - 6 hours

Managed a good long day in the garage. I completed countersinking all of the fuselage parts. 

The bottom angle on the firewall.

I countersunk all of the forward fuselage stiffeners and floor stiffeners. 

I started deburring and dimpling some of the primed fuse parts I had like the F-623 corner ribs

I deburred and dimpled the arm rests. Broke the edges and cleaned them all up ready for primer.

Deburring parts and made a countersink test piece - 5 hours

 Nice long day on the build today. I managed to debur all of the fuselage "pieces". I use a combination of deburing tools and maroon scotchbrite on the dremel.

One thing that was bugging me....I'm doubting that my information on countersinks might be incorrect. So I decided to go to work on building test pieces out of scrap to figure out if the info I have is correct or not.

Basically what I did was to cut three different thicknesses of dimpled pieces (0.025", 0.032" and 0.040") and then went to work on determining proper countersinks for those dimpled pieces. After much testing, I found the that proper countersink diameters for me, were ever so slightly smaller than the data I originally had.  Now I have an actual standard for proper countersink diameters.

I then went back and double checked my longerons and I am perfect!

 

 

 

 

 

Completed countersinks on the longerons - 3 hours

 Kept on countersinking....Aluminum shavings everywhere.

Completed fuselage disassembly and started countersinking - 4 hours

I completed disassembly of the fuselage and managed to get all of the pieces laid out in the garage. I began looking over parts and it's staggering to see all of the list of items on the to do list that need to happen before I can start assembly.

 

The item I was most keen on getting dome was all of the countersinking. And there is a lot. First I opened up the #30 holes on the longeron. I was very careful not too countersink too deep. This is always a huge concern for me as the data for a proper countersink is extremely cryptic.
Once I was happy with the #30's I then moved on to the #40 holes....Wow there is a lot of them. 

 

Baggage Compartment work - 3 hours

 I need to do a bit of work in the baggage compartment. Since I am in Canada, I have to make all of my panels removable to aid in inspection. Technically the two aft baggage compartment side panels still allow a view of all rivets with an inspection mirror. But I decided to make it all removable. All of the floor  (with the exception of F-705) with me flush screws. Everything else will be regular screws.

Once all of the side panels were installed. I began opening up all the holes to #19.  

Next I need to work on my new baggage floor skin. The other one I had developed a crack when dimpling for the screws so I decided to replace it. Best method I have found for opening holes is to use MDF. Keeps the holes centred. I opened nearly all the holes to #19.

I am now finished will everything I need to do with the assembly together. Its now time to disassemble everything. And so it begins...

Opened the two holes in F-796B to 3/16" - 1 hour

 One if the items on the to do list that I was avoiding was to open the two #30 holes in the F-796B angle to a #12 hole to allow the AN3 bolt on top and a #10 screw on the bottom. Being that not everything is permanently together, I opted to open the holes to 3/16" to get a tight tolerance. I can always open then to #12 later if needed.

I used my 3/16" reamer and by ATS drill guide. Turned out excellent.