Top Fuselage Log 
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 April 11, 2017

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Top Fuselage

August 20, 2002 - 2 hours
Had to re-level the plane since my little 2x4 clamped to the tail idea won't work because I need to install the aft deck back there. :-( Anyway I just used the false spar stand to level the plane with nothing more than a sawhorse on the back. I also went ahead and riveted the aft side skins to the longerons up to where the top skins will go. Trimmed the F-757 gussets and dug out the seat belt anchors and other gussets from storage.

This is how the aft canopy side rail and the F-757 gusset go together

August 21, 2002 - 1.75 hours
Drilled the little angles to the F-710 and F-711 bulkheads. Fabricated the spacer and the forward elevator stop that goes under the aft deck and got the aft deck clamped onto the fuse.

The aft deck clamped into place.

August 24, 2002 - 1 hours
Drilled the aft deck to the longerons and bulkheads

The aft deck drilled to the fuse.

August 25, 2002 - 8 hours
Drilled the shoulder harness anchors to the longerons. Drilled the forward firewall gussets to the firewall and longerons. Installed the corrugated nylon tubing in the fusealge as a wire run. Installed the rudder cables and drilled the little Avery rudder cable fairings to the side skin. Finished up the bellcrank support rib and fabricated the little tubing spacers for bellcrank. Finished the stringers for the top fuselage. Started fitting the top skins and drilled the little gussets to the F-706 and F-707 bulkheads.

The shoulder harness anchors.

The forward fuselage to firewall gusset.

Corrugated Nylon tubing run through the fuselage for running wires to the tail.

August 31, 2002 - 2 hours
Drilled the top skins to the Fuselage.

Top fuselage skins drilled to the fuselage bulkheads.

September 1, 2002 - 1 hours
Started getting some of the baggage compartment walls ready to install.

September 2, 2002 - 5 hours
Installed another support under the baggage compartment for my fuselage wiring run. Rivted in the two side walls and the two floor skins of the baggage compartment. Started installing the rear baggage compartment bulkhead walls.

I decided to install an extra support for the wiring run under the baggage compartment floor since it was about to be covered for good.

This baggage compartment side wall installs permanently with blind rivets. There will be another forward of this one that installs with screws.

September 22, 2002 - 1.7 hours
Still deburring and preparing parts for priming

September 25, 2002 - 1.6 hours
Deburred and dimpled the top fuselage skins.

October 6, 2002 - 5 hours
Finished preping and priming that pile of parts I've had around for months, and riveted together a seat back.

October 15, 2002 - 1.4 hours
Finished riveting the forward fuse gussets, installed the rudder cable fairings and started riveting on the aft deck.

Forward fuse gusset that connects the longeron to the firewall

Rudder cable fairing from Avery. I trimmed it a little to make it look more streamlined.

October 19, 2002 - 3.5 hours
Finished riveting the aft deck. Hung the canopy from the ceiling, finished the details on the baggage compartment bulkhead.

The aft deck is on and the fuse is now rigid.

I had to hang the canopy from the ceiling to get it out of the way. Nothing fancy just some wire and a couple of boards from the shipping crate.

These little platic blocks are where the seat belt anchor cables transfer through the baggage bulkhead.

October 29, 2002 - 1 hours
Got the wife to help me finish a few rivets that still needed to be done on the bottom of the fuse and piddled around with the flap mechanism a little more.

December 29, 2002 - 4.5 hours
Finished checking the electric aileron trim. Pressure tested the Pitot tubing in the left wing. Mounted the NOVA strobe power supply, and ran the shielded strobe wire down the rear of the fuselage to the tail. I also installed a small aluminum clip to hold the static line under the longeron.

I installed this little aluminum clamp to hold the static line. The little black wire ties are to keep it from moving fore and aft.

I installed the Nova X-Pak 904 powersupply right behind the rear baggage compartment bulkhead.

January 12, 2003 - 1 hours
Installed the mount for the Tru-Trak pitch servo. I'm not buying the servo just yet but Tru-Trak gave me the mount so that I could put it in while it was still fairly easy to get to.

Tru-Trak pitch servo mount installed at the elevator bellcrank

March 24, 2003 - 1.5 hours
Countersunk the longerons where the aft canopy decks will rivet. Clecoed the forward fuselage structure together to make sure that everything would fit. I am trying to get what I need installed so that I can paint the inside of the cockpit.

March 26, 2003 - 1 hours
Trimmed the plastic from the rivet lines on the top fuselage skin. Installed the nutplates in the bulkhead for the emp fairing and started riveting the top fuse skins on.

March 31, 2003 - 1.2 hours
Did some more riveting of the top skins.

April 1, 2003 - 1.25 hours
Riveted the armrests in, and started riveting the aft canopy deck.

Here is a shot of the right armrest.

April 2, 2003 - 1.5 hours
Did some more riveting on the top fuselage skins.

April 3, 2003 - 1.25 hours
Trimmed and fit the F-6111 L&R skin stiffeners.

The left side F-6111 top skin stiffener. This had to be trimmed on each end to fit right

Here is the right F-6111

April 5, 2003 - 4 hours
Drilled the forward decks to the longerons and aft canopy decks. I cut the extra material off of the fuel tank selector box (where the manual trim knob would go).

April 6, 2003 - 2.2 hours
Made a little spacer to fill the gap that is left after cutting the extra material from the fuel selector plate. Started getting all of the parts of the cabin ready to prime. Shannon gave me a hand and we nearly finished getting the top skins on the fuselage.

I cut a piece of extra rudder stiffener material to cover the gap that is left when I cut the extra material off of the fuel selector valve box.

This is the inside the fuel selector box.

April 7, 2003 - 2 hours
Finished all the riveting on the top skins. Finished all the side skin to longeron rivets that I could. The ones where the top forward skin goes are still open. I started masking off all the places in the cabin were I don't want paint to go.

The top fuselage skins are finally on.

April 8, 2003 - 2 hours
There were a few parts left that need to be riveted onto the fuselage that needed to be primed so I primed those. Then I finished masking off the rest of the cabin.

April 23, 2003 - 0.3 hours
Didn't feel much like working on the airplane but I did manage to get the bend in the top of the firewall.

I used three C-clamps and a couple of pieces of wood as a brake for bending the top of the firewall.

April 24, 2003 - 1 hours
Fabricated four little funny looking strips of aluminum to back up the rivets on the NACA ducts.

April 26, 2003 - 4.5 hours
Finished installing the NACA ducts on the side of the fuselage. Started fabricating all the little parts for the forward top structure of the fuselage.

Used the pattern that came with the NACA ducts to lay out where to put the duct.

This is the inside view of the NACA duct.

This is the outside view looking aft.

April 27, 2003 - 1.5 hours
Still working on the top forward fuselage structure. I messed up a couple of parts so I have to send off for some more material. This is going slower than I thought that it would.

A lot of little parts for the forward part of the fuselage.

April 30, 2003 - 0.9 hours
Worked on the forward fuselage structure some more. I drilled the holes for the center rib to firewall rivets and tweaked all the flanges to get them to line up a little better

The holes drilled in the firewall for the center rib.

I used a straight edge to help me get all the flanges lined up.

May 1, 2003 - 1 hours
Drilled some of the forward top skin holes.

May 6, 2003 - 1.5 hours
Finished fitting the panel into the forward fuselage, drilled the little angles that go around the forward canopy deck to fasten the panel and started fitting the eye-ball vents to the bottom of the panel.

May 11, 2003 - 5.4 hours
Finally finished fabricating all the parts for the top forward fuselage. Finished drilling all the holes and took it all apart, deburred, dimpled and countersunk all the holes and just nearly got it all ready to prime.

Forward fuselage structure and panel all drilled and clecoed into place.

May 12, 2003 - 1.5 hours
Deburred all the holes in the fuselage where the top forward structure will go. Re-installed (hopefully for the last time) the fuel vent lines. Played around with rudder pedal location until I was comfortable.

May 19, 2003 - 1 hours
Cleaned and primed all the parts of the forward fuselage structure.

The rudder pedals are in and the brakes are tubed up.

May 23, 2003 - 2 hours
Riveted all the structure together for the forward fuselage.

The forward fuselage structure is all riveted in. The top skin will have to wait until I'm done with the panel.

February 24, 2005 - 1.5 hours
Dimpled the top forward skin and peeled the blue plastic off of it. That plastic is hard to get off after all these years.

February 27, 2005 - 2.5 hours
Riveted the small pieces that have the nutplates for the panel to the top fuselage skin. It really beat up the paint. I was kinda hoping this would look good but it doesn't. I guess I'll probably wind up putting some kind of upholstry on top of that thing. I also spent some time setting up the EIS engine monitor with ranges and setpoints, and customizing my aux inputs. I also tested the thermocouples with a heat gun to make sure that the proper cylinders read out in the proper place on the EIS.

March 5, 2005 - 2 hours
Coated the inside of the lower cowling with epoxy / acetone mix (50/50). Prepared the roll bar brace for installation. I had to pull a string through it for the canopy latch switch and I had to feed the compass light wires through it.

March 6, 2005 - 4.5 hours
Shannon came out and helped me rivet most of the top fuselage skin on. We didn't finish before she had to leave but we got enough of it done so that I could install the roll bar brace and wire up the compass light and canopy latch switch.

This is the SIRS compass installed on the roll bar brace.

I ran the wire for the canopy latch switch through the roll bar and then down the roll bar brace with the compass wiring.

March 13, 2005 - 1.5 hours
Shannon helped me finish the top fuselage skin. That's the last big piece of aluminum. It was a real pain. I'm glad that I made a point of leaving plenty of room to reach up from under the panel to get to those rivets. The map box really got in the way and I wound up having to put in one blind rivet.

When Shannon comes to help so do the dogs. Cotton is less than excited.

Curby never gets far from Shannon.


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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