14 SEP 15: Page 29-18 step 2:  2.25 hours

Began riveting the F-1069 side skins – can’t reach all the rivets solo – no pics.

15 SEP 15: Page 29-18 step 2, page 29-17 steps 2-3:  3.2 hours

Continued riveting the F-1069 side skins.  Riveted the mid-cabin decks to the bulkhead side channels:

19 SEP 15: Cut SoundEx, built fuse stand, page 30-2 steps 3-7, 30-3 1-6:  .75 hours

Started off this morning by building a fuse stand.  When…if….I ever get section 29 completed, I will put it on this stand to get the whole fuse lower to the ground.  It will be much easier to work on at a lower height:

I then got to cutting the SoundEx insulation.  I ordered the SoundEx a while ago and decided to forego the premade patterns that they also sell – quite expensive for basically sticky paper.  Well, I got into cutting one piece before I decided to wait and purchase the patterns.  Very difficult and time consuming to get the precise measurements of each individual floor panel.  And no matter how precise I thought I was being, the piece of insulation just didn’t fit perfectly – not good for my OCD.  So after a few days delay, I had this to work with:

Even using the patterns was a bit more time consuming than I had first assumed – most tasks are!  However, I cannot imagine the time it would have taken to get this pile without the patterns:

Then it was back to the steps.  Tight fit to squeeze into the floor to drill the mounting brackets:

Not sure how I would have accomplished this task without an angle drill:

I used the bushing from TCW to hopefully prevent the loose step syndrome in the future.  The way the instructions call for inserting the bushings is pretty JV league, so I copied a friend and fellow -10 builder – Mike Jimenez – and tapped the bushing and used a long bolt to insert the bushing into the step tube.  Tapping the bushing:

Steps complete except for final attachment.  Van’s calls for a -3 bolt, but I drilled for a -4.  Don’t have -4s long enough, so waiting for an Aircraft Spruce order (one of the zillion) to arrive.  Inside:

Outside:

20 SEP 15: Page 29-18 step 2:  3 hours

The day I’ve been waiting for forever!!  Friend and fellow builder (-14) Mike came over to FINALLY finish riveting the fuse skins – getting this done and the fuse on the lower stand is seriously hampering fuse progress.   Unfortunately, a few rivet call outs were too short and I didn’t have any -3s on hand that were long enough – ugggghhhh!  Another Aircraft Spruce order!  No pics.

21 SEP 15: Reprimed step tubes, page 29-19 8, 31-6 1-2, 31-7 2-4:  7.25 hours

As I said before finishing the skins is seriously slowing me down.  I’m trying to find odds and ends to fill the gaps until I can finish up the skins.  Reprimed the step tubes – probably should have shot them while inserted.  Have a feeling I’ll be doing this again after final install:

Final installed the vent door assemblies:

Moved onto the upper forward fuse.  Even though this will not stay on, it’s cool to see the plane this way!

I recently made one of my first big ‘component’ orders of the build – up until this point I have mostly just been plugging away at the airframe.  I really need to get serious about all the systems planning – electric, fuel, etc.  To that end, I decided on the style and location (except for one) of all the antennae.  I’ll have VHF 1 on the bottom, VHF 2 on top, stubby for transponder on wing inspection panel, VOR/GS under rudder on tailcone, and blade for ADSB under baggage floor.  Doesn’t look like $1150 laying there:

22 SEP 15: Page 31-7 steps 4-5, page 31-8 steps 1-5:  2.75 hours

Match-drilled the hand-hold doublers and all #40 holes common to the F-1071 forward fuse top skin and sub-structure.  Drilled the instrument panel attach flanges to the panel and top skin.  Drilled and dimpled nutplate holes into the instrument panel attach flanges – no pics.

23 SEP 15: Page 31-8 steps 6-11, 34-2 1-8, fan doublers, step access panels:  9 hours

Machine countersunk the rivet holes in the hand-hold doublers.  Deburred and dimpled all upper fuse sub-structure components.  Bent and match-drilled the baggage door frame to the door skins:

Finished by making some doublers for fans I’ll be installing in the upper fuse skin and access panels to install into the floors to be able to gain access to the step bolts (hopefully never needed).  I used the panel for the stall-warning device (never installed) and used it as a template to fab a second panel: