Flap system and tunnel cover work - 6 hours

 I need to re-do the F-785A backrest brace. Originally I had drilled it for the stock RV backrest, but then after installing the Almost an RV14 mod the holes are not the same. I'm sure I could leave it as-is and carry on but it bothers me to leave it like this. 

So, I ordered a new piece and began the fitup process again, but this time with the holes for the almost a 14 mod only. 

 After the backrest brace is all set-up and redrilled. The fit for the seat mod is turning out extremely well. I do have to mess a bit with bending the tabs on the stainless backrest crossbar to tweek the fit, but in the end a have an install I am really happy with. 

 

Now I'm ready to finish the tunnel cover. With the flap assembly complete, I've focused a bit on the final fit of the F-741A z-channels. There is a bit of interference between the rivets on the flap channel and the z-channel. I will have to remove some material so that these parts do not rub.

Next I need to fit and drill the F-741B cover to the z-channels. However I notice that the width of the cover as called for in the plans (2 3/4") is not enough to fully span the width of the tunnel cover. Looks like I am short about 1/8" on both sides. 

So..what to do. 3 options..1 - Leave it, 2 - Make new F-741A z-channels, 3 - Make a wider F-741B cover.  Ultimately since I have spare lengths of z-channel I went with option #2 and I have everything re-cut after about an hour worth of work. I started drilling the new holes for the #8 holes and drilled one too large with a 1/4" bit. Just not paying attention. So annoying. So I scrapped Option 2 and went with Option 3. I just made a wider F-741B tunnel cover. Hopefully this works and won't be rubbing on the seat. All else fails I can always make a new tunnel cover if ever needed.

 

 

 

Finished the end cap installation and fitted the seats - 3 hours

 I am ready to start riveting the seat mod end caps to the F-705 bulkhead. I was kind of dreading this as the location and the configuration isn’t the best for getting great rivets. However it turned out to be not a big deal. I started bucking the rivets using the extra long rivet set and then finished setting using the alligator squeezer. The process was slow going, but the result is excellent.

 Now that the end caps a partly riveted in place. I temporarily installed the crossbar for the seat mod and installed the seat backs. I fashioned up some crude hinge pins, but I will make a second (better set). Looks pretty good. The clearance is good on the sides of the fuse.

 

 

 

 

 

Started riveted the almost an RV-14 mod - 1 hour

Small build session today. I riveted the gusset plate onto the end cap of the Almost an RV14 mod. I then fitted the assembly to the fuselage. Looking good.

 

Notching the rivet holes in the Almost a 14 mod - 2 hours

 One of the items that's a bit of a head scratch-er for me was figuring out how the rivets should work on the Almost a 14 mod where it connects to the longeron. The you-tube instruction video notes that the rivets are to be ground down so the end cap sits flush with the underside of the longeron. I don't like the idea of grinding down rivets, so I chose to install the required rivets, however I will notch the end caps to fit around the rivets.

First I need to open up the rivet holes to the size/diameter of a shop rivet head.

I can now cut openings in the end cap rivet holes so the end caps will slip into place with the longeron rivets in-tact. 

Yup, this will work well.

Fitting the Almost a 14 mod for the flap assembly - 3 hours

 In order to make the Almost a 14 mod center cap fit better on the flap assembly tower, I need to fabricate a new F-767 attachment plate. The attachment plate is a slightly shorter piece than stock. It also requires new mounting holes to be drilled. 

The fit is really good now. 

 

The aft attachment plate doesn't fit so good. There is a gap between the mounting plate and the flap assembly, as well there is very little clearance for the attachment screws. 

I was toying with a number of ideas to make this fit better. I was going to fabricate a new Aft mounting plate out of 0.063" aluminum, but on the advice of my local builder buddy Mike, I fabricated a small spacer. I will cut this down and shape it accordingly but it looks like it will work very well.

 

Installing the new Almost a 14 end caps - 2.5 hours

 My replacement end caps arrived from Anti-splat. Before when installing, I didn't make sure that these were level to the plane....They were clamped tight to the gusset and the longeron, but that didn't mean they were level across the airframe. 

This time, I installed the endcaps and made certain that they were set parallel and perpendicular to the centerline of the fuselage. I used a straightedge and spent a lot of time measuring and marking. 

Once I was satisfied with that placement, I placed a level across the plane and made certain that the end caps and gusset plate are level (perfectly horizontal). Once satisfied, I used the same drilling technique and template that I used before and finished all of the mounting holes. Note the blue lines showing horizontal level on the front of the end cap and the line on top of the end cap that aligns with the edge of the gusset plate.  

 

Installing the Almost a 14 mod - 8 hours

 I need to install the F-760 side panels on the flap actuator assembly. Its simple enough to install but I notice that I have a slight bow on one of the panels and it doesn't want to sit nice and flush.

I tried to adjust the fit, edge roll the edges of the piece. Finally I managed to get it to sit relatively flat without opening up any mounting holes. That was my last resort. Next I was ready to do the final drilling on the F-785A backrest channel. I clamped the assembly, then drilled. 

I am now ready to officially install the Anti-slat Almost a 14 mod for the seats. I need to cut the F-705J crosspiece out.

 

With the F-705J piece out, I took the time and opportunity to fabricate a template of the rivet pattern.

I also want to have the 1/4" hole on both sides of the endcaps to allow for pitot routing and for wiring. If you are ever looking for information on placement of this hole, you fill find it on Page 317 of the "27 Years of the RVator" From Vans. It was in an article from their build newsletter from 2006. For me, I settled on placing it in the same location as shown in the RVator, and I chose to keep equal distance between three rivets.

Once I have the hole opened up to 1/4" I can now transfer that hole accurately to the F-705D bulkhead sides and the seat mod endcaps. 

Next I was ready to drill the seat mod endcaps to the F-705D bulkhead sides. A WORD OF CAUTION HERE.... Be sure that the end caps are square and level before you drill (use a level and take measurements). I didn't and the right end cap was a little crooked. I'm sure it would have been fine but I'm choosing to replace it. 

First you want to clamp the end caps into place. Make sure that you have a good fit, and the end caps sit level and are square. Using the 90 deg drill, or a drill with a long bit, locate at least one rivet hole and drill to #30.

You can now use the template and drill all remaining rivet holes as well as the 1/4" pitot/wiring hole in the endcaps.

Next I need to cut down the F-760 covers as they interfere with the new center cover. I cut the corners off at 45deg.

 I then slipped the center cover over the flap actuator assembly and noticed the fit wasn't that great. The front mounting holes align, but the side mounting holes do not.

Once I remove the F-767 attach plate, the fit is much better. I have to file a bit off the top of the F-766A channel to get a nice tight fit, but it will work. All I need to do is fabricate a new F-767 attach plate to accommodate the new center cover.

Next I notice that the aft stainless mounting plate doesn't quite fit with the F-785A backrest channel. I have two options...get a new channel, or fabricate a spacer. I think ill do both....I need a new channel as the original mounting holes I drilled are soo close to the new mounting holes for the mounting plate. Also, re-drilling the sides of the channel so that it sits flush without the spacer would mean that the backrest channel sits at quite an angle which I think would be ugly.  

Here it is with everything temporarily set in place.