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The Boo

Aft and Center Fuselage

10/14/03 This thing is starting to look like something!  Trimmed the J-channel longerons.  Forgot to do both ends so I'll have to pull them out and work the front ends, no biggie but it kept me from clecoing the most forward bulkhead in place.  Garage now holds two vehicles and all plane parts.

10/15/03 Finished the J-channel longerons.  Started to rivet them to the skins.  Is anyone else having problems getting the aft bulkheads and the lower tail skin to match.  What a tight fit.  Managed to massage the bulkheads so that it fits but it took a bit of fuss for sure.

10/16/03 Made sure the fuselage was straight with no twist per the instructions using a plum bob.  Nice and straight.  Match drilled the J-channel riveting every forth rivet.

10/17/03 Friday, payday and time to drill 4 gazillion holes.  Drilled out every hole in the aft fuselage except the 706 bulkhead as per plans.  Now to debur and dimple every last one of them.  No need for a picture of that boredom.

Tomorrow I get the second inspection of my kit so far at my local EAA chapter 96 by Dave Bristol, our local Technical Counselor.  Dave's inspected my work so far and it passed.  Dave has an awesome RV6 hangared there at Compton.  Drop by on any third Saturday of the month for an enlightening monthly meeting, which just happens to be tomorrow.

10/18/03 Dave noticed a few rivets which were a bit too flat on the firewall but overall he said my work was very good.  We had some confusion about whether the bushings on the control stick mounts should be a bit longer than the part around it so the bushing does not rotate about the bolt.  I'll post a question to "the group". 

Came home and countersunk, dimpled, deburred, etc, etc, etc.  Here are the aft and lower fuselage skins ready to go.  Damn now I just remembered that I didn't debur the edges.

10/19/03 Today I had my worst day ever.  I couldn't put a rivet in correctly if my life depended on it.  Spent almost the entire day trying to get the rivets set correctly in the 711, 712 tail assembly.  I realized that my 3x rivet gun is having problems.  I just can't get "a little" air through the gun.  It either liquefies the rivets or just doesn't work at all.  I'm fed up with it, damn Sioux gun.  I'll use it to buck solid steel instead.  It will probably do an excellent job at that or titanium.  I'm tired of seeing rives 1mm in height.
10/20/03 Giving it a rest today.  Yesterday beat me up.  I ordered a new Taylor 2x rivet gun today for $150.  I didn't want to do it but I know that Sioux gun is trashed.  Ordered a few other parts as well.
10/21/03 Waiting for the rivet gun before tackling the aft fuselage.  Decided to work on the center section.  Fabricated the four small spacers.  I cut the 1.5 " diameter holes in the rails with a hole cutter, and boy does that work slick.  Just make sure you have your part secured to some wood before drilling. 

The plans don't *say* to cut four of the eight but that's how many you need, two R and two L.  You *REALLY* should get a pair of nippers.  Cutting the excess off right to the line took only 1 minute per piece.

10/23/03 Started to put the center section together for riveting.

10/24/03 Here it is with the baggage compartment ribs in place.

10/25/03 Time to put the center section skin on and complete the drilling, deburring and all the other monotonous stuff.  I put the seat covers on to make sure I get the contour perfect on the F715.  Tomorrow I'm ready to prime all the parts and hopefully get some riveted.

10/26/03 Smoke and ash and soot was falling like rain all day so today was not a good day to prime/paint.  I resigned myself to finishing all the dimpling and to study the plans in advance.  Here's the center section skin and a stack of dimpled parts.

11/1/03 Drove to Corona to get some more Alodine.  Spent the rest of the day alodining all the center section parts and making sure I was ready to paint tomorrow.
11/2/03 Painted all the center section parts.  Started to rivet the seat braces to the aft bulkhead.  Found that my compressor (4hp 13 gal.) was on the fritz.  Bought a new 6hp 33 gallon compressor (175psi).  This think kicks ass.

11/8/03 Decided to get as many rivets in the aft fuselage as I could by myself.  It wasn't easy but I set up three sawhorses.  The center one had the backing plate on it.  This worked very well as almost every rivet came out perfect.  Not for those with weak backs though as you have to continuously look to see if the backing plate is flush with the rivets.  Will need help with the rivets in the corners.

11/9/03 Spent the day doing all the "little" stuff you see on the plans.  Got all the center section parts completed and ready to rivet to the skin.

11/10/03 Barry came over and helped me pound in the last of the rivets in the aft fuselage with exception of the top 5 or 6 so I can get the longeron in place.  Thanks Barry!
11/12/03 Can't do any more until pops gets here in two days.  I sold my 57 Chevy and it's going away tomorrow, bummer.  I'm sulking today.
11/15/03 Pops came into town yesterday.  We're going to make some big progress together.  Today we clecoed the center section to the aft fuselage and mated the side skins for drilling.  Here you can see it's starting to look something like an airplane.

11/16/03 Now it is an airplane.  Turned the canoe upside down.  Mounted the longerons and started drilling from the aft end, and drilling, and drilling and drilling.  Bent the bottom corners of the side skin with no trouble.  Do as the instructions say by drilling and clecoing some angle to the triangle shaped skin tab and bend gently.  It takes some force but in the end it works out fine.  Drilled all holes to size of the side skins.  Mounted the 770 bottom skin and drilled to size. Then mated the firewall.  Made sure the clearances were up to snuff.  Inserted rivets through the side skin and longeron to make sure they were easily inserted and lined up.  Held them in place with some duck tape.  Braced the firewall braces as shown in the picture and removed the rivets one by one and drilled through the metal brace.  Finally, here's the obligatory look at the canoe from the inside.

1/7/04 Well it's been a busy Holiday season.  Pops came out at the middle of November to help me with the riveting job.  He stayed for three weeks.  During that time we had the entire canoe completed except for the final riveting.  Here are shots of the parts we fabricated during that time with notes.  (I'm going to keep this up-to-date from now on :)

Here are a few of the parts after priming.

Control rods completed.  These are very simple to drill with a tube holder and drill press.  You have to sand away some of the primer from the insides of the tubes to get the ends to sit without a ton of force.

I decided to go with brakes on both sides.  It really doesn't cost much more and the resale value will be better.  I will probably cover these with a non-skit product.  Drilling the holes through the cylinder base and into the pedal angle is a bitch.  I ended up taping 4 washers together to use as a shim as I drilled.  This really helps to have two people to do it accurately.   Just try to make sure the pedals are similarly aligned when you drill the holes and all will be right with the world.   I also had to cut the torque tubes to size as they were too long.  Drilling the multiple positions for the pedals is a cinch.  Don't bother doing this while on the plane.  Take the angles off the skins and mount to the torque tubes and just measure.  Dan C. had this well documented on his site.

Here, you pre-rivet the spar end brace to the skins Prior to riveting on the skins.  There is no room to do this afterwards.  Don't forget!  You will also notice that I sprayed rattle-can primer on all interior surfaces of the skins where there are rivet holes.  Doesn't add much weight.  I can see all the other skin surfaces on the inside of the airplane so there is no need to primer all interior surfaces.

Here are some shots of the firewall braces.  You should spend some time to get them to fit nice and flush.  Also there has been some question lately as to the *split* in the white corner braces attaching to the firewall.  That's supposed to be there.  When drilling these for the first time use the technique in the instructions and place a rivet in the holes to line everything up.

Detail of the forward wing attachment point from the inside.  Remember to mark all of the shims on this part top/bottom, inside/outside and order of the parts.  Since you only have to coat them Barely with primer you will be able to see your markings after priming.  If you don't get these right your rivets will not sit or pass through the holes properly.  Also the plans have a very complicated process to get these aligned.  It's really very simple and the instructions are overly complicated.

Here I noticed that the bushing holes didn't line up exactly.  I recommend enlarging these holes after you get the skins on and not piece by piece.

Baggage compartment bracing.  Nothing to it.

This is a shot of the bottom of the firewall.  Notice that you dimple the firewall and countersink the angle behind it.  You will be placing the lower cowl hinge on the firewall portion which you will countersink.

Barry came over about a two weeks ago to help me start final riveting of the side skins and rest of the fuselage.  We made pretty good progress.  There are plenty of rivets to put in.  I've ordered the finish kit but it won't ship until March 22nd so I have *plenty* of time to get this done.  I'm now in slo-mo mode.

Today I started to get my financing inline for the rest of the airplane; engine, avionics, prop, etc.  Here's a costing of those items.  OUCH!!!!  I haven't placed my backup instruments here but they will include Turn/Bank&Slip/Skid, Altimeter, and Airspeed.  I want to make it similar to the Cirrus panel.  Very logical layout.

QTY

DESCRIPTION

VENDOR

MODEL

UNIT

EXTENSION

1

Engine

Penn Yan Aero

IO-360 horiz induct, LASAR

$23,641.00

$23,641.00

1

Audio Panel w/ 3LMB and Intercom

Pacific-Coast Avionics

Garmin GMA 340

$1,125.00

$1,125.00

1

GPS/MFD/NAV/COMM

Pacific-Coast Avionics

Garmin GNS 430

$6,390.00

$6,390.00

1

VOR/LOC/Glideslope Indicator

Pacific-Coast Avionics

Garmin GI 106A

$1,425.00

$1,425.00

1

Transponder w/ Mode S

Pacific-Coast Avionics

Garmin GTX 330

$3,395.00

$3,395.00

1

Transponder encoder

Pacific-Coast Avionics

Garmin SAE5-35

$349.00

$349.00

1

Wiring Harness - built by vendor

Pacific-Coast Avionics

custom

$740.00

$740.00

1

Autopilot

Pacific-Coast Avionics

Trutrak Digiflight 200VS GPSS

$4,235.00

$4,235.00

1

Firewall Forward Kit

Vans Aircraft

FF-7/7A IO-360 CS

$4,600.00

$4,600.00

1

EFIS

Grand Rapids Tech

Dual Display EFIS w/ AHRS

$8,995.00

$8,995.00

1

ARINC Bi-Directional Interface

Grand Rapids Tech

ARINC 429

$475.00

$475.00

1

Fuel Totalizer

Grand Rapids Tech

Fuel Flow Option

$375.00

$375.00

1

CS prop, Jihostroj P920 Governor

Whirlwind Propellers

WW 151 RV, P920 Gov.

$7,500.00

$7,500.00

 

 

 

 

TOTAL

$63,245.00

 

1/30/04 Well the process of getting financed is complete.  Today I received multiple checks for all the above mentioned products.  I'll mail them out on Monday.  By March my garage is going to be very full of aero stuff.  I can't wait.  Pics of checks.

1/31/04 Dave Bristol, our EAA chapter 96 Technical Counselor, Flight Advisor, and Board Member graciously came by for my third EAA Technical Counselor Visit today.  I always enjoy talking to Dave as his experience building his RV 6 are essential to my successful completion of the project.  Dave gave a good look over and indicated that I was on my way to a nice flying bird.  He also suggested that I get some flying under my belt and not wait till the plane was almost finished.  I concur.  I need to get some air under my wings, and soon.  Tomorrow I will send a little over $63K worth of checks out to get the parts mentioned above.  No progress to mention except cleaning up all the edges of the remaining parts for the interior of the fuselage.  I've still not been able to get someone over here to help finish the fuselage.  I'll be leaving for France from Feb 5-10.  When I come back my parents are going to come for some here for several weeks.  Me and Mom and the Old Man will knock it out then.
2/22/04 Well after a very long hiatus from doing any riveting on the fuselage I was finally able to get some help today.  My very good friend Scott Dewald stopped by this weekend and we shot a few hundred rivets.  After that I prosealed the firewall to the side and bottom skins.  Getting that proseal out of the tube took some work!  Finally back in action.

 

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Last updated: 07/06/05.