Finished the baggage bulkhead - 5 hours

 I started off the build session by fitting the lower bulkhead to the upper bulkhead and drilling the holes for the #8 screws and the associated nutplates.

 

I then began the process of drilling ALL of the #8 holes for the require nutplates. I marked out guide lines as best I could so that the nutplates followed the lines of the bulkhead.

Then came the very tedious process of countersinking and riveting all of the nutplates. I prime all of my nutplates so there is a bit of time eaten up by prep and paint of these.

The top skin went back on as I will need to fit the F-6111 aft skin reinforcing ribs.

Fitting the baggage bulkhead - 6 hours

 I still have a few rivets that I need to finish on the lower center part of the F-706 bulkhead. I was dragging my heels a bit on completing this task. It’s a tricky spot and in my head I was building it to be more difficult than it turned out. 

 

Now I am ready to complete the fitting of the Baggage bulkhead panels. I took some time to confirm everything is nice, square and level. Lots of checking and adjustment but I was finally able to commit to drilling all holes in the lower panel.

Now I need to fit the upper panel. First I need to trace the required radius. I drew the radius on AutoCAD, printed out a template and then traced the radius onto the upper bulkhead.

Once cut, I measured out the openings for the seat belt cables and drilled the holes. Then i flipped the bulkhead over and measured out all of the upper mounting holes. Took some time to finish the seat belt cable openings and other little details.

 

I then fitted the upper bulkhead to the assembly and drilled all mounting holes. 

 

Installing the Static ports and taking care of the to-do list - 2.5 hours

 Since I need to uncleco and remove the top skins to get at all the small outstanding items, now is a good time to install the static ports. I dug out the SafeAir1 kit that I've had for some time. I am choosing to bond the static ports with pro-seal rather than rivet. Seems like a lot of builders do this over riveting them.

Next, I located the 1/4" holes for the static ports somewhat close to the dimensions shown on the drawings (Detail #E/Drawing 28). I maintained the 2" dimension from the longeron, but I adjusted the dimension forward of the bulkhead rivet line from 11/16" to 1 1/8" as the Safeair1 ports are a much larger diameter than the standard Van's ports.

I de-vinyled the areas, scuffed the aluminum, cleaned with MEK. I mixed up some proseal and installed a thin layer on the static port. After installing the port and giving it a 1/4 turn twist, I clamped the ports to the assembly and wiped any excess that tried to ooze out. 

With the static ports taken care of, the next item that I need to get done was to install the lower baggage bulkhead nutplates and drill and install the one rivet on the top of the F-728C angle.

 

Started fitting the Baggage Bulkhead - 2.5 hours

I am ready to start fitting the F-751 baggage bulkhead. I cleco'd in the baggage floors and baggage side covers and celco's in the baggage bulkhead. I started checking the fit, making sure all was sitting correctly. 

 

I wasn't loving the fit...the holes along the F-728A bellcrank channel sit just a bit inboard toward the vertex of the channel, as well I want to make sure the bulkhead is sitting level at the top. A few things may help my cause. I still have some riveting to do at the bottom of the bellcrank channel. As well I still need to install the nutplates for the baggage bulkhead along the bottom of the F-706 bulkhead.

 

 

Re-made the F-707B angle - 1 hour

 Small day building, I re-made the F-707B angle and made it slightly longer than the original. I took my time and trimmed it to fit the angle/radius of the F-787 stiffener web.

 

Final fitting of the F-7112 Aft top skin - 5 hours

Started the build session by messing with the fluting on the F-706 bulkhead and now I have a great fit. With all holes nicely cleco'd I match drilled everything (with the exception of the holes along the longeron. I'll do those later).

I am not ready to fit the F-656 gusset plates. Using the same method as before, I clamped everything in place.

Once the #30 holes for the gusset plates are set, I was ready to partially un-cleco the top skin to access the F-707B angle. I drilled the angle, and then noticed that the fit isn't as nice as I would like it to be. I'll have to re-do this part.

To finish off the evening, I riveted the gussets to the longeron and bulkhead.

 

 

 

 

More fitting the F-7112 Aft top skin - 4 hours

 The fit of the F-7112 top skin is really tight. To help with this I de-vinyled top skin.

Next, I need to adjust the J-stiffeners cause they are just a tad long and they do interfere with the bulkhead. They need to be trimmed about 1/8" give or take.

 

I had the F-707B angle fabricated some time ago so I cleco'd that on and installed the F-787 stiffener web. 

I still need to play with the fluting on the F-706 bulkhead to get the fit right. I'm surprised by the amount of flutes needed on these, its more than I thought I would need. But the fit is looking really good.