Forward Section Log 
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Forward Section
The lower fuselage is made up of two main pieces the Aft section or the Tail Cone and the Forward section. They are joined together by the skins at the baggage compartment bulkhead. The forward section has the firewall, center section, seat ribs, baggage compartment and the skins that hold it all together.

May 25, 2002 - 9 hours
Modified the four inboard seat ribs. Deburred the edges of the seat and baggage floor ribs. Clecoed the seat ribs, baggage ribs, to the bulkheads and clecoed the center bottom skin to this assembly.

Here you can see the modified seat ribs. The inboard rib has the lightening hole enlarged for control column clearance and a piece of the top of the rib is made removable for installation of the controls. The second rib just has the lightening hole enlarged.

May 26, 2002 - 6 hours
Finished drilling all of the parts of the center fuselage section.

This is what the center fuselage section looks like clecoed together and standing upside down on the bench.

May 27, 2002 - 6 hours
Deburred, dimpled all the center fuselage section parts, and got them almost ready to prime.

May 28, 2002 - 1.2 hours
Primed the seat and baggage floor ribs as well as the other little parts of the center fuselage section

June 1, 2002 - 3.5 hours
Riveted the seat ribs to the center section bulkhead and the seat back bulkhead. Also riveted the baggage floor ribs to the seat back bulkhead.

June 2, 2002 - 1.5 hours
Riveted the center bottom skin onto the skeleton.

June 3, 2002 - 1.5 hours
Clecoed and drilled the seat and baggage floor skins to the skeleton as well as drilling the outside seat ribs to the center section bulkhead.

June 5, 2002 - 1.4 hours
Cut the notches in the longerons so that they will fit around the bars that hold the HS to the Fuselage. I also mounted the longerons on the aft fuse section.

The longeron has to be notched to fit around the HS attach bars.

June 6, 2002 - 1.5 hours
Finished riveting the last of the seat ribs to the center bottom skin and bulkheads. Clecoed the center fuselage section to the tail cone.

This is the center fuselage section clecoed to the tail cone.

Here is the fuse with the forward side skins clecoed on.

This thing is starting to take up a lot of room in the garage.

Another view of the fuselage assembly.

These good looking girls are my rivet helpers.

June 8, 2002 - 2 hours
Drilled the arm rests to the side skin and bulkhead. Fit the F-623's to the bottom skin and bent the curve on the back of the F-770 side skins.

Here is one of the arm rests drilled and clecoed to the fuse.

This is the setup that I used for bending the side skin.

This is what the bend looks like when finished.

June 11, 2002 - 1.2 hours
Finally got around to cutting the notches in the aft canopy decks. Started drilling the longerons.

June 13, 2002 - 1.1 hours
Finished drilling the longerons up to the aft edge of the center section bulkhead.

June 15, 2002 - 2.5 hours
Trimmed the forward end of the longerons to fit. Finished drilling the longerons forward of the center section. Started fitting and clamping the firewall

June 16, 2002 - 4 hours
Finished fitting and drilling the firewall to the fuselage assembly. Fabricated the F-717 longerons and the F-719b clamp pieces and started trying to fit the F-713 longerons. I ran into a little snag on the F-713 see the note.

The firewall is drilled to the side skins.

June 17, 2002 - 2.5 hours
Fitted and drilled the F-713 Aux. Longerons and the F-719 stiffeners to the side skin. Also started preparing and twisting the F-717 lower longerons.

Here is that joint where the F-713 meets the F-704 bulkhead.

June 19, 2002 - 3 hours
Fabricated the F-684 gussets and drilled them to the lower longerons. Fluted and straightened the F-902 forward bulkheads and clecoed them to the skins. Fitted the F-7101 gear attach plate and clecoed it in place.

F-684 L&R gusset plates

F-684-L gusset plate clamped in place with the top drilled and clecoed

F-902 Forward bulkhead clecoed in place.

June 22, 2002 - 5 hours
Installed the angle and spacers where the fuel tank attach bracket will attach. Finished drilling all of the forward fuselage structure and started putting the brake pedals together.

This little angle pieces is the structure that the fuel tank attach brackets will later be attached too.

One completed brake pedal

June 23, 2002 - 6 hours
Finished building the brake pedals and assembled the whole brake/rudder pedal assembly. Also trial fit the rudder pedal assembly to the fuse.

I clamped a piece of angle to the bottom of the rudder pedals to hold them still while I worked.

I clamped a straight edge to hold the pedals together while I figured out where to drill the holes for the master cylinder.

The completed rudder/brake pedal assembly

June 24, 2002 - 1.4 hours
Still trying to fit and install the rudder pedal assembly. Trimed the center bracket that holds the rudder pedal assembly.

June 25, 2002 - 2.2 hours
Finally finished drilling the rudder/brake pedal attachment holes in the fuselage.

July 1, 2002 - 1.6 hours
Fluted, clecoed and drilled the aft bulkheads to the skin. Clecoed the baggage compartment side skins in.

July 6, 2002 - 5 hours
Remade and drilled the F-684 gussets. Drilled the remaining parts of the forward fuselage compartment structure and finished up drilling some of the other odd and end holes that were still undone.

Here is one of the finished F-684 fuse gussets.

I can't remember the part number but this is the attach point of the middle stiffener of the forward fuselage to the firewall.

July 7, 2002 - 0.5 hours
Realized that the floor stiffeners that I have are wrong and will have to get some replacements from Van's. Not much else to do but I drilled the holes in the forward bulkheads for the rudder cables and went back and drilled the holes in the flap bushings since I had forgotten to do that before.

July 20, 2002 - 2 hours
Drilled the floor stiffeners to the blukheads and the bottom skin

The forward bottom skin clecoed to the fuse and floor stiffeners.

Floor stiffener attach to the firewall.

Floor stiffener attach to the center section.

July 21, 2002 - 9 hours
Disassembled the fuselage for deburring and dimpling. Countersunk the longerons, dimpled the aft section of the fuse where the longerons attach. Deburred and dimpled all the parts of the center fuse section and finished drilling the flap bushings while I had it all apart.

Flap actuator bushing.

July 22, 2002 - 2 hours
Deburring parts of the forward fuse.

July 23, 2002 - 2 hours
More deburring and countersinking of forward fuselage parts.

July 24, 2002 - 1.75 hours
More deburring and dimpling of forward fuselage parts. All I have left are the skins.

July 25, 2002 - 2.4 hours
Deburred the forward fuselage skins.

July 27, 2002 - 1.7 hours
Still dimpling

July 28, 2002 - 8.2 hours
Finished all the dimpling, primed all the forward fuse parts. Installed all the platenuts on the seat ribs and ran a tap through the outer seat ribs since they will be so close to the skins. Started putting the forward fuselage back together and riveting all the things that must be riveted before the side and bottom skins go on.

July 29, 2002 - 2 hours
Finished up the rivets and bolts of the forward fuse that have to be done before the skins go on, and started finishing up all the rivets that were left undone on the tail cone.

Forward fuselage structure before the floor skin and the side skins go on.

July 31, 2002 - 1 hours
Riveted one of the side plates to the side skin and peeled off a lot of plastic.

August 5, 2002 - 2.5 hours
Finished riveting the tail section. Riveted the center section plate to the left side skin, and clecoed both side skins to the frame. Clecoed the floor skin and floor stiffeners to the frame and checked whether the whole thing was straight.

I used a level to check that the center section bulkhead is level.

I dropped this plumb through the bottom tooling hole of the F-711 bulkhead and made sure that it falls in line with the top tooling hole to check how straight the fuse is before riveting.

August 6, 2002 - 2.3 hours
Henry came over and helped me pound a few rivets in the side skins.

August 17, 2002 - 2.1 hours
More riveting of the fuselage. Shannon helped me and we got most of the rivets done forward of the F-704

August 18, 2002 - 6.6 hours
Finished riveting the lower fuselage together, and turned the 'canoe' over. Also installed the false wing spars and built a little castoring stand for it. I temporarily put the seat skins in and sat in my airplane for the first time and made airplane noises.

Now the thing really looks like a boat.

This is just a shot of the inside of the cabin.

I cut slots in my false spar to allow me to level the fuse side to side. I also decided that the castors were a bad idea and took them off.

August 19, 2002 - 2.3 hours
Finished up the last rivets of the bottom of the fuselage. I left the angles off of the F-710 and F-711 bulkheads where the aft deck attach because I thought that I could make them fit better if I waited until the longerons were on. I will be able to make them fit better but I need a better right angle drill to get in there. I made those two angle pieces. Also leveled the fuselage.

May 7, 2003 - 1 hours
Finished the eyebal vents. Did some last minute adjustments on the Rudder Pedals. They seemed to stick more than I would like so I spent some time fine tuning them.

Eyball vent asseblies. I still need to drill them to the side of the fuselage but that can wait until the panel is mounted.


Disclaimer:
This web site and the infomation contained within it are for entertainment purposes only. The opinions expressed on construction techniques are my opinions only and should not be confused with proper construction techniques. There is undoubtedly more than one way to build an airplane and some methods that I use may or may not work in any given circumstance. If there is any question please call the kit manufacturer. I love to help but I am not responsible for the misuse of any information contained on this web site.

 March 3, 2016
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