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.