Messing with nutplates - 0.5 hours

 I need to figure out the forward nutplate for the F-680 bearing block. I don't have a standard one leg nutplate, but after searching I do have a compact MK2000-3 nutplate. Not going to enjoy trying to rivet this, but oh well.

 

Installing the Flap Actuator Weldment - 5.5 hours

 I'm ready to fit the WD-613-EF flap actuator weldment. In order to start I need to drill the F-680 flap bearing block according to the plans. I made a drilling template to help start the holes in the correct spot. I used a palm drill to start a hole and finish the holes on the drill press.

Next I need to trim the block down on one end.

The bearing block is ready to cut in half. Using a piece of oak as a band saw guide I am ready to cut.

The instructions have you open the clevis ends of the flap weldment to 1/4". I used drills to open up the holes with the final step using a 1/4" reamer. I'm really happy with one of the clevis ends, but the two outside clevis ends, the holes are a bit loose for my liking. It has everything to do with I used a palm drill to do the holes and not a drill press. I will order a new one and do it right. (bit of an expensive mistake). 

 Fitting the WD-613-EF flap actuator weldment in the airplane is a head scratch-er. In the end you have to fit one bearing block on one end. Turn it 180deg so the shortest side is pointing up. (see pic below)

Fit the weldment into the plane and then you will just be able to slip the other bearing block on the end. Turn the bearing block so the short side is pointing down (see pic below)

In this configuration, the weldment assembly is at its shortest dimension allowing it to slip into the plan. The bearing blocks are then rotated into their proper orientation and then can be bolted in place.

 I need to notch the forward edge of the F-680 bearing block. Using the band saw and going slow does a decent job.

The bearing block can now be fit and once the final location is set, I used a drillbit to dill an initial hole for the mounting bolts.

Finish the holes with the palm drill and a reamer...good to go. 

I am ready to start fitting the nutplates.

Fitted the F-785A backrest brace - 1 hour

 Small job today was to fit the F-785A backrest brace. The plans call for a 1/8" space between the backrest brace and the baggage tunnel cover. I used two Popsicle sticks as a spacer, clamped the brace to the F-785A angle and drilled the center hole. There was a nice space left at the top. The brace did not interfere with the inside radius of F-705F.

Once the top of F-705F is leveled, I clamped the top and drilled the topmost two mounting holes using center lines that I drew in before placing the brace.

 

 

More fitting F-748 baggage tunnel cover and started flap assembly - 6 hours

 I noticed that the F-748 baggage tunnel cover needs to be fit with the baggage bulkhead panels installed. When I did this, the baggage tunnel cover fit wasn't great at all. Towards the aft, the very thin skin of the cover has quite a bow to it and a decent gap between it and the floor. I spent some time with it, uninstalling and reinstalling but nothing worked. 

After reading about it on other blogs, seems this a very common issue. It seems that others have simple re-bend the end of the piece and then oblong-ed the two aft mounting holes. Since this is not a structural part I see no reason to do the same.

I set up the piece in the vice and I will re-bend the end of F-748 about the thickness of a popsicle stick. Once clamped and set up, I used a rubber matter to re-shape the bend. Once the mounting holes were filed oblong. The cover mounted to the floor so much better.

Next I need to start in on the flap assembly. I need to fabricate F-767. The plans do not give you dimensions to work with so I imported the shape into AutoCAD. Drafted the part and then I could reproduce the part with the use of a template.

With F-767 fabricated and drilled to the F-766A cover. I am now able to back drill the top most holes in F-767.

With the rough fitment of the front flap assembly complete. I was ready to fabricate the F-785B. At this point I realized there was no need to dimple the two mounting holes in the baggage floor. Im not the only builder to have done this. (I could always dimple the two mounting holes in F-785B - It works...i've tried). but I chose to leave it for now. 

Since the band saw is set up, I began fitting the F-983A fuel valve plate and F-983C valve cover.

I trimmed the valve plate on the band saw and flipped it upside down. 

Fitting the F-748 baggage tunnel cover - 1 hour

 Wasn't entirely motivated to build today. I worked on fitting the new F-747-L baggage floor I had ordered some time ago. The one I have (The one painted dark gray - has some cracks in a couple of dimples). I've needed to get this new floor prep'd and dimpled and tonight I decided to get it done. 

 

With the baggage floors fitted. I am now ready to drill, dimple, and fit the F-748 baggage tunnel cover. (One item that I should have done was to use an edge rolling tool on the edges). Not required but it would have worked well here.

 

Fabrication of the F-741A angles - 3.5 hours

 I started the build session by installing the forward and aft seat floors. In order to fabricate the center tunnel cover (and F-741A angles) the seat floors need to be installed.

I also installed the fuel valve cover and plate just to see how it all looks and fits.

I started fabrication of the F-741A angles according to the dimensions given in the plans. I chose to leave the material long at this point and I will trim to fit as needed rather than rely on the length given on the plans.

Once the first hole is defined, I clamped the angle to the seat floor and back drilled the next holes using the seat floor as a template. 

I only used the seat floor to define the hole and i finished drilling on the drill press. 

I put the seat floors back together, cleacoed the parts in, and took measurements. I was ready to start trimming the Aft of the F-741A angles. 

In the end, the fit is good. I'm going to stop here and get the flap system set up and then I'll finish the tunnel cover.

 

Adjusted the seat anchor openings - 2 hours

 I spent a couple of hours today enlarging the 4 openings on the F-742 aft seat floor for the seat belt anchors. I sketched out about 1/8" total of extra space on the forward side of the hole. Initial cuts where made with the dremel. Final trimming was done with files.