Haven't done a lot of work on the fuselage lately - busy at work.  What progress has been made isn't very picture worthy!  A lot of match-drilling and deburring.

11 MAR 15: Page 25-2 steps 7-9, pg 25-3 steps 1-7: 4 hours

Match-drilled forward center section bulkhead assembly – no pics.

12 MAR 15: Page 25-3 step 8: 1.25 hours

Match-drilled and deburred forward center section bulkhead assembly – no pics.

13 MAR 15: Page 25-5 steps 1-2: 1 hour

Final-drilled aft seat rail support subassemblies – no pics.

17 MAR 15: Page 25-5 step 4: 1 hour

Match-drilled and deburred aft center section bulkhead assembly.  Cut the F-1004L hat stiffeners.  Rough cut:

19 MAR 15: Page 25-5 steps 4-6: 1 hour

Match-drilled and deburred aft center section bulkhead assembly – no pics.

21 MAR 15: Page 25-5 steps 7-8, pg 25-6 steps 5-6: 1.25 hours

Match-drilled and deburred aft center section bulkhead assembly.  Fabricated and match-drilled the F-1004M wear strip – no pics.

22 MAR 15: Page 25-7 steps 1-3, pg 25-8 steps 1-4: 3 hour

Match-drilled rear spar bulkhead assembly.  A bunch of deburring ahead!

27/29 MAR 15: Deburring: 3 hours

Not a lot to show lately.  Just a lot of deburring fuselage spar parts.

15 MAR 15: Page 21-10 steps 1-2, pg 22-8 steps 11-14, pg 23-7 steps 1-5, pg 23-8 steps 1-4, pg 23-9 steps 1-6: 7 hours

Installed the aileron and flap on the right wing:

Except for fiberglass and wiring, both wings are pretty much done!

On to the fuselage!!!

8 MAR 15: Page 23-9 steps 5-6, pg 21-7 steps 1-7, pg 21-8 step 4: 6.25 hours

Adjusted the aileron pushrods so the aileron bellcrank is in its neutral position.  Bellcrank jig inserted:

Aileron lined up with the flap:

With everything in the neutral position, the forward torque tube subassembly hole center should be 2 9/32”

Left wing complete!

9 MAR 15: Page 21-8 step 4: 1.75 hours

Began to rivet the right aileron.  The plans call for backriveting this rib to the skin and then riveting the flange to the spar web after it is together.  There is very little room to rivet once together, so on the second aileron I riveted the rib flange to the spar web first:

This is the room available for the rivet set if you follow the plans:

Did the same thing to the bucking bar to rivet the skin to the spar:

Adding that to the bucking bar makes it sit parallel to the spar flange for consistent shop heads:

10 MAR 15: Page 21-8 step 4, pg 21-9 steps 1-4: 1 hour

Finished riveting the right aileron except for the trailing edge:

11 MAR 15: Page 25-2 steps 7-9, pg 25-3 steps 1-7: 4 hours

Continued assembly of the forward center bulkhead assembly.  Match-drilled the WD-1021-L/R landing gear mounts:

Countersunk all nutplate attach holes:

12 MAR 15: Page 25-3 step 8: 1.25 hours

Deburred fwd center bulkhead parts – no pics.

13 MAR 15: Page 25-5 step 1-2: 1 hour

Final drilled #30 the four seat rail subassemblies, final drilled #40 the nutplate attach holes and #19 all the screw holes – no pics.

14 MAR 15: Page 21-9 step 4, pg 22-8 steps 4-12: 7 hours

Riveted the right aileron trailing edge.  Used the 3M tape this time as I was sick of messing with proseal:

Finished riveting the right flap.  Used the tape for the flap as well:

Tape worked just as well as the proseal without the mess!  Nice and straight:

3 MAR 15: Page 25-2 steps 1-6, pg 20-5 step 10: 4.25 hours

Made the F-1004N stiffener angles.  Clamped them to the F-1004A center section bulkhead and match-drilled #30 using the bulkhead as a drill guide:

Began to rivet right wing bottom skins with Mike:

4 MAR 15: Page 21-05 step 7 redo, pg 21-07 step 7, pg 20-5 steps 11-2: 4.5 hours

Began to rebuild the right aileron.  Dimpled the skins and back riveted the stiffeners:

Continued riveting the right wing bottom skin with Mike.

5 MAR 15: Page 21-08 steps 1-2 right: 1.75 hours

Riveted the aileron nose ribs to the nose skin.  This time (unlike the left aileron) I riveted the outboard rib to the spar before assembling the aileron.  The plans have you rivet after assembling the aileron, but there is virtually no room to fit the rivet set in between the brackets when built.  Unfortunately, the bottom of the flange began to pull away from the spar web – had to drill out the bottom two and try again:

Pretty good a drilling them out – lots of practice!

6 MAR 15: Page 22-8 steps 9-11, pg 20-5 steps 11-12: 3.2 hours

Cleared the proseal out of the TE of the left flap and began blind riveting the bottom skins to the ribs.  Mike came over one last night and we finished up the bottom skins – both wings done!

7 MAR 15: Page 22-8 steps 10-12, pg 23-7 steps 1-5, pg 23-8 steps 1-4, pg 23-9 steps 1-5: 9.5 hours

Finished blind riveting the flap bottom skin to the rib flanges.  Riveted the trailing edge – was a bit nervous because the size of the flap, but it turned out pretty nice:

Nice and straight:

Spent the rest of the day fitting the aileron actuation and the control surfaces to the left wing.  Took me quite a while to figure out all the steps – a lot of off/on, attaching/detaching pushrods, etc.  All I have left with the left wing is to adjust the aileron pushrod to ensure the aileron aligns with the flap while in the neutral position.  Starting to look like a wing:

1 MAR 15: Primed right aileron skins, page 20-6 step 4, pg 22-8 steps 4-8: 5.5 hours

Primed right aileron skins – for the second time.  Didn’t mess these up.  Had some Devilbiss 3oz containers that a friend gave me – very convenient for this job:

Skins all primed.  Will let them cure a couple days, dimple them, and then back rivet the stiffeners – again!

Installed the W-822PP wing access plates onto the left wing:

Prosealed the trailing edge of the left flap.  Will let it cure for a few days and then finish riveting the flap.  I’ll be glad when the control surfaces are done and I can say good bye to Proseal – more or less.