19 JAN 15: Redo baffle/skin rivets, Prekote parts: 9.5 hours

Well…on this tank a bunch of my baffle rivet heads were too proud for my liking – I believe this was due to using a bit more proseal on this baffle than on the left tank.  I probably drilled out ½ - ¾ of the rivets on each side of the baffle.  Took a while, but I’m glad I cleaned it up.  Finished the session by beginning the Prekote prep of all the flight control parts.  Some of the rivets drilled out:

 

20 JAN 15: Prekote: 1.5 hours

Continued Prekoting flight control parts – no pics.

21 JAN 15: Final sealing of the right tank: 1.75 hours

Finished prosealing the right tank.  Hopefully this tank will not leak just like the left and I’ll be done with proseal! No pics.

23 JAN 15: Page 23-2 steps 1-3, page 23-3: 1.5 hours

Cut the torque tube to bellcrank pushrods:

Drilled the ends of the pushrods for the VA-169 rod ends.  Match-drilled the rod ends using the pushrod as a drill guide:

25 JAN 15: Priming setup and priming: 3 hours

Cleaned and set up the downdraft table in prep for priming:

Vent tubes running outside through the garage window:

 First batch of parts drying:

26 JAN 15: Page 23-5 steps 1-4: 1 hour

Constructed the aileron torque tube assemblies:

28 JAN 15: Page 23-5 steps 3-4, page 23-6 steps 1-5: 1.5 hours

Match-drilled the torque tube collars to the torque tubes:

29 JAN 15: Page 20-4 steps 4-6, priming: 4.25 hours

Today marks the 1 year anniversary of the build!!!  Dimpled and riveted the skin to fairing rivets of the W-1024 flap gap fairings:

Continued priming parts for the rest of the work session.

30 JAN 15: Page 23-6 steps 1-5, priming: 1.25 hours

Clocked the torque tube assemblies using the 5/16” shim on one side of each assembly.  I measured several times before drilling, but still saw this upon final assembly:

I put out the question to VAF and Jesse Saint of Saint Aviation hinted that I should be able to remove the slight difference with push-rod bearings – makes sense; reason for the threaded rod-end bearing.  If not, it will be easy enough to create another torque tube.

31 JAN 15: Priming: 2.25 hours

Another session of priming all the remaining flight control parts and lower wing skins.  One more session, and I should be complete:

Doesn't look like much all stacked up, but it’s a lot of parts!