F27-09 Fairlead Assembly -
Today I used the band saw to cut the 3/4" Phenolic stock into four 1 9/16" square blocks. I then used the drill press to drill the holes per the plans to fabricate F27-10 Fairlead Mount Blocks. I then inserted the Fairlead halves and attached the retaining clips. This resulted in the completion of the F27-09 Fairlead Assemblies.

F27-01 thru F27-05 Vertical Zee and Vertical Channels 2 -5 -
I used a hack saw to cut the Zee and Channel stock to the rough lengths. I then used the belt sander to trim then to the length per the plans.

F27-01R and F27-01L Right and Left Hand Vertical Zee.
Used Sharpies to mark the layout of the holes and cuts on the Vertical Zees. I then drilled holes for the radius in the corners of the cut outs. I used the band saw to make the rough cuts. I started to file the edges to finnal shape and size. I didn't get to far, only one end of the left hand zee.

F27-01R and F27-01L Right and Left Hand Vertical Zee.
I finished filing the edges and corners to their final shape and size. I used the drill press to drill all the holes to their size and location per the plans. These parts are done except for cleaning off all the ink markings.

F27-02R and F27-02L Right and Left Hand #2 Vertical Channel.
Today I used sharpies to draw the locations of the cut outs and holes.

F27-03R, F27-03L, F27-04R, F27-04L, F27-05R and F27-05L Right and Left Hand Vertical Channels #3, #4 and #5.
Today I used sharpies to draw the locations of the cut outs and holes.

F27-02R, F27-02L,F27-03R, F27-03L, F27-04R, F27-04L, F27-05R and F27-05L Right and Left Hand Vertical Channels #2 thru #5
Today I also used the drill press to drill all the #40 pilot holes. I also drilled the corners of the cut outs to a rough size radius. The larger holes were also started but will need to be updrilled to there final sizes.

F27-02 thru F27-05 Right and Left Hand Vertical Channels #2 thru #5.
Today I used the drill press and step drill bits to updrill the 5/16th, 3/4th and 1 inch holes to their final size. I used the band saw to cut the cut out to a rough size.

F27-05R and F27-05L Right and Left Hand Vertical Channel #5.
I used files to shape the cut out to its final shape and size. I also used files to deburred all the edges, corners and the 1 inch hole. Next I will do the same for the remaining Vertical Channels #2 - #4.

F27-04R and F27-04L Right and Left Hand #4 Vertical Channels.
Today I tried using the Die Grinder with 1/4" Dia X 3/4" Long point to smooth out the rough cut outs to their final size. I found that it did not work as well as using files. I think I will go back to the files for the rest of the channels. I also used the files to debur the edges and the larger holes. I then deburred all the pilot holes.

F27-02R F27-02L F27-03R and F27-03L Righ and Left Hand Vertical Channels #2 and #3.
Today I used the files and scotch brite wheel to finish shaping the cut outs to their final size. I also deburred the edges and holes.

F27-01 thru F27-05 L and R,
I cleaned off all the ink markings.

F26-08 Rudder Stop Plate.
I used the band saw to cut 2 Rudder Stop Plates from 1" x .125" stock provided with the kit. I then used the scotch brite wheel to smooth and shape the cut edges. I also used a fine sanding block to clean up and smooth all sides and edges.

F26-07 Lower Vertical Splice Plate.
The basic shaped stock was provided with the kit. I used the drill press to clean out the pilot holes. I used the arbor press to bend the parts to the 7/16" (13.6 deg) per the plans. I also used files and the scotch brite wheel to add the 1/16th inch chamfer as required per the plans. Files and the scotch brite wheel were also used to clean, polish and debur all the edges.

F26-06 Lower Horizontal Splice Plate.
The basic shape was provided with the kit. I used the drill press to clean out the pilot holes. I used the arbor press to bend the parts to the 11/64" (5.2 deg) per the plans. I also used files and the scotch brite wheel to add the 1/16th inch chamfer as required per the plans. I still need to clean, polish and debur all the edges.

F26-05 Upper Vertical Splice Plate.
The basic shaped stock was provided with the kit. I used the drill press to clean out the pilot holes. I used the arbor press to bend the parts to the 7/16" (13.6 deg) per the plans. I also used files and the scotch brite wheel to add the 1/16th inch chamfer as required per the plans. Files and the scotch brite wheel were also used to clean, polish and debur all the edges.

F26-06 Lower Horizontal Splice Plate.
I finished cleaning, polishing and deburring all the edges and surfaces. I used files and the scotch brite wheels.

F26-04 Upper Horizontal Splice Plate.
The basic shaped stock was provided with the kit. I used the drill press to clean out the pilot holes. I also used files and the scotch brite wheel to add the 1/16th inch chamfer as required per the plans. Files and the scotch brite wheel were also used to clean, polish and debur all the edges.

F26-03R Right Hand Lower Longeron.
I used the hack saw to cut the forward end to the two angled cuts per the plans. Using the hack saw I cut the other end to the total length per the plans. I used files and the small scotch brite wheel on the die grinder to smooth and debur the cut ends.

F26-02R Right Hand Upper Longeron.
I used the hack saw to cut the forward end to the one angled cut per the plans. Using the hack saw I cut the other end to the total length per the plans. I used files and the small scotch brite wheel on the die grinder to smooth and debur the cut ends.

F26-01R Right Hand Aft Side Panel Skin.
I marked on the skin the location and shape of two holes. These are the access 4" hole and the rudder cable hole/slot. These are not done as part of the kit. I used a drill to create starter holes. For the rudder cable hole I used the cut off wheel to cut the rough length shape. I then used files to finish the hole/slot. For the access hole I used the nibbler to get the rough shape. I then used a file to finish the shape. I also used the small scotch brite wheel to smooth out and finish the hole. I used the Harbor Freight bending brake to bend the 14 degree bend at the forward end of the skin.

F25-01R Right Hand Aft Side Panel.
Today I drilled #40 pilot holes in F26-03R Right Hand Lower Longeron using the pilot holes in F26-01R Right Hand Aft Side Panel Skin to locate the holes. I clecoed the skin to the longeron as I drilled the holes. I used a piece of scrap .025 to measure the skin over hang. The over hang is so that the bottom skin will be flush with the bottom of the side skin.
I also drilled pilot holes for F26-08 Rudder Stop Plate. I used the side skin pilot holes to locate the holes.

F25-01R Right Hand Aft Side Panel.
Today I drilled #40 pilot holes in F26-02R Right Hand Upper Longeron using the pilot holes in F26-01R Right Hand Aft Side Panel Skin to locate the holes. I clecoed the skin to the longeron as I drilled the holes.
I also installed the F27-09 Fairlead Assemblies on the F27-05 #5 Vertical Channels anf F27-01 Vertical Zees.
I trimmed the right hand Vertical Zee and Channels #2 - #5 to properly fit the F25-01R Right Hand Aft Side Panel.
Then I drew a blue line on the flangs of the vertical channels #2-#5 to be used to align them with the pilot holes in the Aft Side Panel Skin.

F25-01R Right Hand Aft Side Panel.
Today I located the vertical channels #2 thru #5 using the blue lines on the flanges lined up with the pilot holes in the aft side skin, The channels were also located down 1/4th inch from the top of the upper longeron. I then drilled the #40 pilot holes in the channels using the pilot holes in the aft side skin as a guide for location.

F25-01R Right Hand Aft Side Panel.
Today I located the vertical Zee #1 using the blue bend line on the aft side skin, The Zee was also located down 1 and 1/8th inch from the top of the upper longeron. I then drilled the #40 pilot holes in the Zee using the pilot holes in the aft side skin as a guide for location.
I also up drilled to #30 those holes that will be riveted on this assembly. There is 4 holes that were up drilled that will not be riveted at this time. I placed some blue tape on those clecos to remind me not to rivet those holes.

F25-01R Right Hand Aft Side Panel.
I located and drilled pilot (#40) holes for the upper and lower splice plate. I used a piece of scrap angle to create an extension of the side panel on which the required measurements could be made per the plans. I started with the vertical splice plates. They were clamped in place and then pilot holes drilled using the existing holes in the splice plates as guides. Then the horizontal splice plates where clamped in place and pilot holes drilled. The two bolt holes in the lower vertical splice plate were step up drilled to 3/16th (#30, #21 and 3/16th).
The 5 inch cover plate (W18-02) was installed over the 4 Inch access hole per the plans.
All the clecos were removed so all the parts can be deburred and preped for riveting.

F25-01R Right Hand Aft Side Panel.
I deburred all the parts. I used clecos to reassemble the skin, longerons, rudder stop plate and the vertical channels. I riveted the locations called out in the plans.

F25-01R Right Hand Aft Side Panel.
I installed the two AN525-10R12 bolts holding the lower vertical splice plate to the assembly. I torqued the nuts to 25 in/lbs. I also clecoed the lower horizontal, upper vertical and horizontal splice place to the assembly. I used clecoes to attach the vertical zee to the assembly. I also attached the cover plate using screws. This assembly is now complete per the F25 plans page.

F26-01L Left Hand Aft Side Panel Skin.
I marked on the skin the location and shape of two holes. These are the access 4" hole and the rudder cable hole/slot. These are not done as part of the kit. I used a drill to create starter holes. For the rudder cable hole I used the cut off wheel to cut the rough length shape. I then used files to finish the hole/slot. For the access hole I first used the cut off wheel to create a large access area, Then I used the nibbler to get the rough shape. I then used a file to finish the shape. I also used the small scotch brite wheel to smooth out and finish the hole. I used the Harbor Freight bending brake to bend the 14 degree bend at the forward end of the skin.

F26-02L Left Hand Upper Longeron.
I used the hack saw to cut the forward end to the one angled cut per the plans. Using the hack saw I cut the other end to the total length per the plans. I used files and the small scotch brite wheel on the die grinder to smooth and debur the cut ends.

F26-03L Left Hand Lower Longeron.
I used the hack saw to cut the forward end to the two angled cuts per the plans. Using the hack saw I cut the other end to the total length per the plans. I used files and the small scotch brite wheel on the die grinder to smooth and debur the cut ends.

F25-01L Left Hand Aft Side Panel.
Today I drilled #40 pilot holes in F26-03L Left Hand Lower Longeron using the pilot holes in F26-01L Left Hand Aft Side Panel Skin to locate the holes. I clecoed the skin to the longeron as I drilled the holes. I used a piece of scrap .025 to measure the skin over hang. The over hang is so that the bottom skin will be flush with the bottom of the side skin.
I also drilled #40 pilot holes in F26-02L Left Hand Upper Longeron using the pilot holes in F26-01L Left Hand Aft Side Panel Skin to locate the holes. I clecoed the skin to the longeron as I drilled the holes.

F25-01L Left Hand Aft Side Panel.
I drilled the #40 pilot holes for F26-08 Rudder Stop Plate. I used the side skin pilot holes to locate the holes. I marked blue lines on the flanges for the vertical channels #2 thru #5. I then located the vertical channels #2 thru #5 using the blue lines on the flanges lined up with the pilot holes in the aft side skin, The channels were also located down 1/4th inch from the top of the upper longeron. I then drilled the #40 pilot holes in the channels using the pilot holes in the aft side skin as a guide for location.

F25-01L Left Hand Aft Side Panel.
I up drilled to #30 those holes that will be riveted on this assembly. There are 4 holes that were up drilled that will not be riveted at this time. I placed some blue tape on those clecos to remind me not to rivet those holes.
I located and drilled pilot (#40) holes for the upper and lower splice plate. I used a piece of scrap angle to create an extension of the side panel on which the required measurements could be made per the plans. I started with the vertical splice plates. They were clamped in place and then pilot holes drilled using the existing holes in the splice plates as guides. Then the horizontal splice plates where clamped in place and pilot holes drilled. The two bolt holes in the lower vertical splice plate were step up drilled to 3/16th (#30, #21 and 3/16th).
I located the vertical Zee #1 using the blue bend line on the aft side skin, The Zee was also located down 1 and 1/8th inch from the top of the upper longeron. I then drilled the #40 pilot holes in the Zee using the pilot holes in the aft side skin as a guide for location.

F25-01L Left Hand Aft Side Panel.
I removed all the clecos. I deburred all the parts. I used clecos to reassemble the skin, longerons, rudder stop plate and the vertical channels. I installed the two AN525-10R12 bolts holding the lower vertical splice plate to the assembly. I torqued the nuts to 25 in/lbs. I also clecoed the lower horizontal, upper vertical and horizontal splice place to the assembly. I used clecoes to attach the vertical zee to the assembly. I riveted the locations called out in the plans. I need to install the cover plate to complete this assembly.

F25-01L Left Hand Aft Side Panel.
I installed the cover plate. This assembly is now complete per the plans. Plans Page F25 is now completed.

F24-02 thru F24-09 Upper and Lower Cross Ties.
I cut all the cross ties to rough lengths using a hack saw. I then squared one end using the scotch brite wheel and belt sander. I cut the final length using the band saw. I finished up the final length using the scotch brite wheel and belt sander. I made sure that the corresponding upper and lower cross ties were the same proper length called for in the plans. I still need to cut -09 to the final length.

F24-06 thru -09 Lower Cross Ties.
I used the band saw to trim the longer flange to the 3/4 in required per the plans. I layed out the notches / cut outs per the plans, I drilled holes in the corners and then used the band saw to do rough cuts. I used files and the scotch brite wheel to get the finished size, shape and radius. I trimmed the angle on the flanges required in the plans.
F24-09 Lower Cross Tie #5. I layed out and drilled the #40 pilot holes per the plans.

F24-02 thru -04 Upper Cross Ties.
I trimmed the angles on the flanges as required per the plans.

F24-05 Lower Cross Tie #1.
I cut the Z04-03 channel stock to a rough length using the band saw. I finished it to the final length using the belt sander and scotch brite wheel. I bent the one flange to the 5 degrees per the plans. I cut the cut out notches to a rough size using the drill and band saw. I finished to the final size using the die grinder, files and the scotch brite wheel.

F24-10 and F24-11 the forward and aft channels.
I cut the Zo4-03 channel stock to rought lengths using a hack saw. I finished to the final size and shape using files, the belt sander and the scotch brite wheel.

F24-01 Cross Tie Box Assembley.
I built a jig using some scrap angle. I got this idea from Bob Meyers web site. The jig holds the forward and aft channels at the required 3 inches and squaire to each other. I then used squares and levels to be sure there was not any twist. I started drilling the #40 pilot holes.

F24-01 Cross Tie Box Assembly.
I up drilled all holes to #30 size. I deburred all holes and edges. I used the table top and jig to hold the assembly while I riveted the upper web to the forward and aft channels. I removed the assembly from the jig and clecoed the lower web to the assembly. The assembly is complete to the plans. This plans page is now complete.

F23-12 Support Angle.
There are 2 of these parts. I cut the rough size and shape from Z02-03 angle stock using the band saw. I finished the final size using the scotch brite wheel and belt sander. I then used the drill press to drill the #40 pilot holes per the plans. I then bent the one side to 10 degrees as called out in the plans.

F23-10 and F23-13 Forward and Aft Support Channel.
I cut the rough length from Z02-04 Channel Stock using the hack saw and band saw. I finished to the final length using the scotch brit wheel and belt sander. I located the position of the 1 1/8th in holes and started drilling pilot holes.

F23-10 and F23-13 Forward and Aft Support Channels.
I drilled the 1 18th inch holes. I also drilled the #40 pilot holes per the plans. I deburred all edges and holes.

F23-09 and F23-11 Forward And Aft Push Rod Support Assemblies.
I inserted the plastic snap bushings to complete the assemblies per the plans.

F23-07R and F23-07L Angles.
I cut the shape and lengths from Z02-03 Angle using the band saw and hack saw.

F23-08 Fitting.
I used the arbor press to bend this kit part to the required 10 degrees.

F23-07 Angles.
I rounded the inside corner using a round file. I also debured all the edges.

F23-05L and F23-05R Left and Right Mount Assemblies.
I aligned the -07 angles to the -06 webs and clamped them to the tables. I drilled the #40 pilot holes using the web as a guide. I then clecoed the web, angle and fitting together for the assemblies. I up drilled to #30 the holes that will get riveted at this stage.

F23-02 Bulkhead.
I cut the kit provided channel stock to the proper length using the band saw. I layed out the two large holes and the 14 pilot holes. I used the drill press to drill the 14 #40 pilot holes. I also used the drill press with a step drill to drill the larger holes to as close a size as I could. I then used a cut off wheel to cut the straight part of the large oval cut out. I then used files to get the 15/16th hole to its final size. I also used files to get the oval cut out to its final size and shape.

F23-02 Bulkhead.
I used the band saw and drill to cut the rough size and shape of corner cut outs. I then used files and the scotch brite wheel to finish to the final size and shape. I deburred all holes and edges.

F23-05L and F23-05R Right and Left Hand Mount Assemblies.
I deburred all holes and edges. I then riveted the assemblies per the plan.

F23-01 Tail Skid Mount Assembly.
I used the drill press to drill the required 1/4 in hole.
The F23 Plan Page is now complete.

F22-04 Angle.
I used the band saw to cut to the rough size. I then used the scotch brite wheel to finish to the final size.

F22-02 Aft Shear Web Assembly.
I clamped the -04 angle to the -03 web. I drilled the #40 pilot holes using the web pilot holes as a guide. I clamped -05 Aft Angle to -03 Web. I lined up the center pilot hole with the center of the web and the edge of the angle lined up with the aft endge of the web. I then drilled the #40 pilot holes. I up drilled to #30 the holes that were to be rivited. I riveted the -04 angle to the web using CCP42 rivets. I riveted the aft angle to the web using CCP44 rivets. All other parts on F22 are kit provided.
The F22 Plan Page is now Complete.

F21-01 Fuselage Tail Cone Box.
I started putting together the parts that will make the Fuselage Tail Cone Box. On the tables up side down I clamped together the F25-01 side panels with the F24-05 Lower Cross Tie #1 and Lower Vertical Fin Post. I squared the side panels and lower cross tie #1. I made sure that the outside distance at the bend line of the side panels was exactly 40 inches apart. I the drilled the #40 pilot holes for the lower cross tie #1 using the pilot holes of the vertical zees as a guide. I placed the lower skin in place to check for fit. I also started to locate lower cross tie #2. I am taking my time to be sure that every thing is square and straight.

F21-01 Fuselage Tail Cone Box.
I located and drilled #40 pilot holes for lower cross ties #2 thru #5. I used two squares clamped together to make sure the sides were square at each location. I also test fit the lower skin several times as I went along. I also located the aft bulkhead (F23-02) and Forward Lower Mount Angle (F23-03). I drew a blue line on the flanges of the bulkhead to locate the holes in the side skins. I clamped them in place and drilled #40 pilot holes. I did not drill the holes for the bolts that will attach the Mount Angle to the Longerons and lower skin. I will wait to do that when I drill the holes for the lower skin,

F21-01 Fuselage Tail Cone Box.
I spent some time studying the plans to determine how to prep the vertical fin post assembly, How the tail skid mount and spacer should be drilled. I also looked at how the vertical post assembly will be installed in the Tail Cone Box. How the lower mount angle will be drilled and attached. I also up drilled all the lower cross ties to #30 holes.

F21-01 Fuselage Tail Cone Box.
I drew blue lines on the flanges of the lower cross ties to aid in the proper placement of the lower aft fuselage skin. I placed the lower aft fuselage skin on the assembly and aligned the pilot holes with the blue lines. I drilled the #40 pilot holes into the lower cross ties and logerons using the lower aft fuselage skin pilot holes. I removed the #1 lower cross tie, the Zee channel and slpice plate to gain access to drill the holes at the lower splice plate locations. I first drill the skin holes at the logeron location using the pilot hole in the longeron as a guide. I then attached the Zee Channel and the #1 lower cross tie. I temporarily clecoed the splice place to the top of the skin at the longeron locations. I then used the splice plate as a guide to drill the #40 pilot holes through the skin and #1 lower cross tie. I then clamped the spacer to the splice plate to use it as a guide. I drilled #40 pilot holes in the spacer. I then clecoed the splice plate and space back into the proper location. I up drilled the two holes for the AN525-10R bolts to 3/16th. I up drilled the other three holes on the splice plate to #30. I also up drilled all the holes on the #1 lower cross tie to #30.

F21-01 Fuselage Tail Cone Box.
I used my tight fit right angle drill attachment to drill four #40 pilot holes from the T12-05 Angle through the upper longerons. The box is up side down at this point so the holes went into the table top. I clecoed the four holes to the table top. I then drilled the #40 pilot holes through the side skins and the vertical fin channel. I removed the fin channel. I then had intended to use the tight fit right angle with an extension. However the tight fit right angle quit working. So I used my right angle drill with the extention to drill the remaining pilot holes for the T12-05 angle.
I then remove the lower skin. This allows access to drill pilot holes to attach the Forward and Aft Lower Mount angles to the longerons. Next I drilled the pilot hole through F23-03 Forward Lower Mount Angle where it will attach to the longerons. I used the pilot holes in the longerons from the lower skin. Then I drilled the pilot holes through F23-04 Aft Lower Mount Angle. Again I used the pilot holes in the longerons as guides. Next I drilled 1/8th inch holes in the Aft Lower Mount Angle to match the existing holes in the vertical fin channel.
I attached the vertical channel and T12-05 angle to vertical stabilizer assembly. I then located the position of the tail skid mount on the assembly and clamped it in place. Next I drilled 6 1/8th in holes through the tail skid mount using the vertical stabilizer as a guide. I clecoed the F23-04 Aft Lower Mount Angle and the Tail Skid Mount to the Vertical Stabilizer Assembly to start updrilling the bolt holes.

F21-01 Fuselage Tail Cone Box.
I up drilled to 3/16th the 6 holes that go through the Tail Skid, Vertical Stabilizer Assembly and the Aft Lower Mount Angle. I then made the F21-02 Spacer. I used the Tail Skid Mount as a pattern for the holes. I then removed the Lower Vertical Post Assembly items from the Vertical Stabilizer Assembly. I then clecoed all the parts back on the Tail Cone Box. Next I drilled #40 Pilot holes through the tail skid mount bracket at the Forward Lower Mount Angle. I up drilled to #40 the 6 holes that only go through the Bulkhead and Forward Lower Mount Angle. Next I up drilled to 3/16th the 4 holes that also go through the Tail Skid Mount.
I positioned Upper Cross Ties #2, #3 and #4. I made sure the box was level and the sides were square. I then drilled #40 pilot holes I was able to access. On each corner there are three holes that are to close to the table top for me to drill. I will drill pilot holes when I turn the box over.

F21-01 Fuselage Tail Cone Box.
I positioned the Aft Shear Web Assembly and drilled #40 Pilot holes through the longerons. I also drilled a few of the #40 pilot holes through the aft angle using the bulkhead for reference. Next I clamped the forward Angle F22-06 to the channels with it tight against the shear web and the channels. I drilled the holes into the channels using a long 12" 1/8th bit. I used the tight fit long extension to drill down through the angle and shear web. I clecoed it all in place.
Next I debured, Cleaned and riveted lower cross ties #5 to #1 one at a time.
Next I put the Lower Skin back on the box with clecos. I then up drilled all the holes to #30 size. I also up drilled to 3/16th the 2 holes that will get bolts for Forward Lower Mount Angle.

F21-01 Fuselage Tail Cone Box.
I turned the Box over so the top was up. On Upper Cross Ties #2 thru #4 I drilled the #40 pilot holes I was not able to get to when the top was next to the table. I also drilled the #40 pilot holes through the longerons and the top of Upper Cross Ties #2 thru #4. Next I up Drilled to #30 the holes through the longerons and the tops of Upper Cross Ties #2 thru #4. Also on Upper Cross Ties #2 thru #4 I up Drilled to #30 the 5 holes in each corner (total 30) that will be riveted. There are seven holes in each corner that are left at #40 for now. That is where the turtle deck formers will be attached later.
Where the Shear Web assembly attaches to the longerons I up drilled to #30 the holes. I also up drilled to #30 where the bulkhead gets riveted to the side skins. Next I removed the sher web / bulkhead assembly to see if I can put it back in as a completed assembly. It came out OK. Tomorrow I will try putting it back prior to actually riveting it together.

F21-01 Fuselage Tail Cone Box.
Sherar Web / Bulkhead. I test fit putting the Shear Web / Bulkhead in place as an assembly. It worked just fine. So next I riveted the Shear Web Bulkhead together out side of the box. I did not rivet F22-06 Forward Angle to the assembly. Instead I riveted it to the vertical channels in the box bt it's self. I used the holes I had already drilled when the Shear Web was in the box. Next I clecoed the Shear Web / Bulkhead back in position.
Aft Area. I then up drilled to #30 all the rest of the holes in the Aft area that will be riveted now. Next I took every thing a part and deburred all the holes that were up drilled. Then I reassembled every thing with clecos. I riveted every place in the aft area that the plans required.
F24-01 Cross Tie Box Assembly. I trimmed and fit the ends to go around the splice plate. I drilled all the #40 pilot holes. First I did the front of tne box, then the top and last the F23-12 clips on the back. I then up drilled all the holes to #30. I also up drilled to 3/16th the 4 holes on top the will get the AN3-7A bolts. I test fit the bolts.

F21-01 Fuselage Tail Cone Box.
I removed the F24-01 Cross Tie Box and deburred all holes. I clecoed the Cross Tie Box back in place. I riveted the front to the Vertical Zees. Next I installed the AN3-7A bolts and washers at the top of the Cross Tie Box. I torqued the bolts to 25 in/lbs. I then riveted the the locations for the top of the Cross Tie Box.

F21-01 Fuselage Tail Cone Box.
I riveted the clips to the back of the Cross Tie Box. F23-05 Left and Right Hand Mounts. I clamped the assemblies in place and drilled #40 pilot holes and up drilled to #30 all the holes. I deburred the Left and Right Hand Mounts. I also deburred Upper Cross Ties #2 thru #4. I clecoed the Cross Ties inplace. I riveted the 5 holes on each corner that get get riveted now. There are seven holes on each corner that do not get up drilled and riveted until the turtle deck formers are installed. I riveted the Left and Right Hand Mounts in place. I also riveted the tops of Cross Ties #2 thru #4 through the Longerons.

F21-01 Fuselage Tail Cone Box.
I turned the Box over so the bottom was up. I removed the clecos and skin from the bottom. I installed the tail skid mount. I put the mount in position and places the 3/16th spacer between the mount and the aft end of the box. I clecoed that location. I installed 4 AN3-5A Bolts at the bulkhead location. I torqued the bolts to 25 in/lbs. I turned the assembly box on its side. I moved one of the tables out of the way and set up three saw horses to hold the box assembly. I turned the box so that the top was up. I moved the box on to the saw horses. I leveled the forward end of the box. I then used a camera tripod to level the aft end. I placed some foam between the aft end and the saw horse as a precaution in case the tripod does not hold. I used a level to check that the sides, top and bottom were all level and plumb. I am very pleased all locations were correct.
F23-11 Aft Push Rod Support. I installed the support by placing it per the plans. I drilled and up drilled the holes. I deburred and riveted the support as per the plans.

F21-01 Fuselage Tail Cone Box.
F23-09 Forward Push Rod Support.
I installed the support by placing it per the plans. I drilled, up drilled and debured the holes. I did not rivet it in place. The Plans call waiting to rivet until after the push rod is installed.

F20 Turtle Deck Details.
F20-12 Aft Clip. I cut this part from Z02-03 Angle stock using the band saw. I trimmed to final size and shape using the scotch brite wheel. I made a pattern of the holes using tracing paper. I transfered the hole locations to the part using the pattern. I used the drill press to drill the holes per the plans.
F20-11 Forward Clip. I cut this part from Z02-03 Angle stock using the band saw. I trimmed to final size and shape using the scotch brite wheel. I made a pattern of the holes using tracing paper. I transfered the hole locations to the part using the pattern. I used the drill press to drill the holes per the plans.
F20-10 Former Clips. I made 6 of these parts. I cut this part from Z02-03 Angle stock using the band saw. I trimmed to final size and shape using the scotch brite wheel. I measured and located the holes on the larger flange for all 6 parts. I measured and marked the holes on the smaller flange for only 3 of the parts. I used the drill press to drill only the holes I had marked. Since these parts are going to be 3 pairs on the skin splice channel I want the holes on the short side to be match drilled. Next I clamped the short sides together using one already drilled and one not yet drilled. I then match drilled the holes and clecoed them together. I also number the matched pairs so that they won't get seperated.
F20-09 Left and Right Hand Attach Plates. The these kit supplied parts however they needed to be bent 30 degrees. I used the arbor press to bend them to the correct angle. I also cleaned and deburred the part.
F20-08 Splice Plate. This is also a kit supplied part. All that was required was to clean and debur the part.
F20-07 Skin Splice Channel. This part was cut from Z02-04 Channel Stock. It was cut to length using a hack saw. The angles at each end were cut with a hack saw and snips. The end were cleaned and debured with a file.

F19-03 Splice Assembly.
I measured and marked on F20-07 Skin Splice Channel the locations for the F20-10 Former clips. On one side of the splice channel I clamped the clips in location. I drilled #40 pilot holes through the splice channel using the clip for location. I then clecoed the clips on both sides to the channel. Next I up drilled to #30 all the holes for the clips through the channel. I removed the clecos and deburred all the holes. I clecoed the clips back in place and riveted them per the plans.
F19-02 Skin Assembly.
I clamped the splice channel to the edge of the table. I clamped the right hand skin to the channel. Next I drilled #40 pilot holes through the channel using the pilot holes in the skin for location. I then moved the splice channel to the middle of the work table. I clamped the end to the table edges. I also placed some block along the channel to help hold it up right. I clecoed both the left and right hand skins to the splice channel with the left skin on top. I then up drilled all the holes to #30 size. I removed all the clecos and deburred all the holes on both skins and the splice channel. I clecoed it all together with the left hand skin on top. I riveted all 77 holes. With 76 through the splice channel and 1 just through the two skins per the plans.

F19-01 Turtle Deck Installation.
I drew a blue line 1" from the outer edge on F19-02 Skin Assembly.
1. Locate, Pilot Drill and Cleco Left Side Turtle Deck Skin
I removed the clecos along the longeron on the left side of the Aft Fuselage Box. I placed the Skin Assembly on top of the Box. I stood in side the box and raised the skin assembly to an angle that allowed me to slide the turtle deck skin in between the left side skin and longeron. I then proped the skin assembly up by wedging a length of angle between the splice channel and the right side longeron. I then positioned the turtle deck skin per the instructions in the plan. I next drilled pilot holes along the left side through the turtle deck skin. I clecoed the skin in place as I went along.
2. Locate, Pilot Drill and Cleco Right Side Turtle Deck Skin
I removed the clecos along the right side of the box. I slide the turtle deck skin in between the longeron and the right side skin. I made sure that the box was not twisted by checking level and plumb at bothe ends of the box. Next I drilled pilot holes and clecoed the right hand side of the turtle deck skin.
3. Locate, Pilot Drill and Cleco Former #5
F20-05 Former #5. Per the plans I next located Former #5 and pilot drilled holes. I clecoed it in place.
4. Locate, Pilot Drill and Cleco Aft Clip
Then I located, drilled pilot holes and clecoed F20-12 Aft Clip.
5. Locate, Pilot Drill and Cleco Formers #1
F20-01 Formers #1 I started to locate, pilot drill these formers to the turtle deck skin. I was able to get the left former clecoed to the turtle deck skin.

F19-01 Turtle Deck Installation.
I finished locating Formers #1 by drilling pilot holes and clecoing along the front skin edge. I located, drilled pilot holes and clecoed the splice plate and front clip for Formers #1. I also did the same for the Attach Plates. Next I located, drilled pilot holes and clecoed Formers #4 per the plans.

F19-01 Turtle Deck Installation.
I located, drilled pilot holes and clecoed Formers #3 and #2 per the plans. I clamped the left and right formers to the clips at the top. I used some spacers I made to get the ends the proper distance from the center line at the top. I then drilled pilot holes into the formers from the pilot holes located in the skin. Then I drilled pilot holes in the clips at the top. Then I drilled the pilot holes at the bottom of the formers using the verticals pilot holes to locate. Since every thing was now located and pilot drilled per the plans I started up drilling to #30 size. There are a lot of holes. I will finish tomorrow.

F19-01 Turtle Deck Installation.
I finished up drilling all the holes to #30. I then started disassembling the turtle deck. I also started deburring as I go.

F19-01 Turtle Deck Installation.
I finished disassembling the turtle deck. I deburred all the holes. I cleaned all ink marks off of the parts. I riveted the forward and aft to the splice channel. I reassembled the turtle deck using clecos. I riveted the turtle deck skins, side skins and longerons on bothe the left and right side. I did the left side first. I have decided to rivet every thing in the same order that the plans call for the installation. Next I riveted the turtle deck skin to the #5 former. Then I riveted the aft clip to the #5 former. I also riveted the inside bottom of former #5 to the aft shear web on the box.
Today was also an interesting day because I had some visitors. I always enjoy talking to people about my project and planes in general.

F19-01 Turtle Deck Installation.
Today I finished the Turtle Deck Installation. I first riveted the #1 Formers to the skin. Then I riveted the formers to the splice plate and forward clip. I also riveted the angle plates to the #1 formers. Then I riveted Formers #4, #3 and #2 in that order. Also on each I first riveted the skin to the formrs. Then I riveted the formers to the splice channel clips. Last I riveted for each former to the vertical and cross tie channels. This followed the order of assembly in the plans.
F18-01 Tail Cone Assembly.
I installed the four bolts AN525-10R12 called out in detail A. I torqued the bolts to 25 in/lbs. Next I riveted the bottom of Cross Tie #1 as shown in view DD. I clecoed the bottom skin to the assembly. I will leave it that way until the final assembly of the airframe.

F19-01 Turtle Deck Installation.
In reviewing my work from yesterday I found a missing rivet on former #4 right hand side. It was where the former is riveted to the vertical channel. So this morning I removed the bottom skin and installed the missing rivet.

F17 Fuselage Firewall and Misc Detail.
F17-12 Aft Clip.
I cut this from some Z04-03 Channel material. I used the band saw and scotch brite wheel to get the correct size and shape. I used the drill press to drill the pilot holes.
F17-11 Gusset.
Again I cut this from some Z04-03 Channel stock. I used some tracing paper to get a pattern. I then used the band saw and scotch brite wheel to get the correct size and shape. I drilled the pilot holes using the drill press.
F17-10 Upper Clip.
Again the Z04-03 Channel stock was the correct material to cut this part from. I used the band saw and scotch brite wheel to get the correct size and shape. I again used the drill press for the pilot holes.
F17-09 Floor Stiffiner.
I cut his to the proper length from .75" square stock using the hack saw. I cleaned up the ends using a file and the scotch brite wheel.
F17-08 Firewall Stiffiner.
Again I used the hack saw to cut the .75" square stock to the proper length.
F17-07 Doubler is a kit supplied part.
F17-06 Filler Box End.
The cut out shape is provided in the cut. However it is provided as a flat part without the required bends. I used the hand seamer to make the required bends.
F17-05 Filler Box Skin.
Again this part is provided as a flat cutout without the required bends. I clamped the part into the bending brake to hold it I then used a wood block and hammer to make the required bends. I still ned to up drill the hole for the Southco Fastner.

F17-05 Filler Box Skin.
I drilled the 11/32nd hole and the 3/32nd hole on the filler box skin for the Southco fasterner receptcale. I also dimpled the skin for the CCS-32 rivets that will hold the receptcale in place.
F17-02 Upper Firewall Assembly.
I clamped the filler box parts to the upper firewall. I drilled, up drilled, deburred, and dimpled (where needed) the parts making up the filler box and where it attached to the upper firewall. I riveted all places on the filler box except where it attaches to the firewall.

F17-02 Upper Firewall Assembly.
I started off today by seeing that 5 of the rivets I did yesterday were put in with the heads on the wrong side of the assembly. I assume that that is for clearence for the filler neck of the gas tank. So I drilled them out and reinstalled them. No problem.
Next I worked on installing the F17-04 Windshield Strap on the assembly. That took almost all day. The plans call for the edge of the strap to be flat on the table with the web of the former to be up 3/4" on a spacer. So I placed some 3/4" mdf on the table to provide the required distance. The plans also call for the strap to be centered on the former. I tried to keep the former on the spacer and clamp the strap to the former. But it kept coming out with improper placement on the flange of the former. So I marked a blue line on the flange of the former and 3/4" marks on the strap. I then went back and forth between clamping the strap off the table and checking it on the table. I started in the center and worked my way out to the ends of the strap. Next I drilled the pilot holes using the strap pilot holes as a guide. Again I started in the middle and worked my way out to the ends. Next I drilled the holes for the Southco Fasterner Receptcales. I also flatened the fluting where the rivets and fasterners will go. I also up drilled the pilot holes to #32 since they will be dimpled.

F17-02 Upper Firewall Assembly.
I removed all the clecos from the assembly. I deburred all the holes. The 11/32" holes for the Southco Fasterners were rather rought so I used the rotoary tool to polish up all those holes. I dimpled all the holes that go through the windshield strap into the former and filler box. I also cleaned off all marks. I next reassembled the filler box to the former. I riveted the filler box to the former. all of these rivets have there heads inside the filler box. The 5 at the bottom of the filler box I was able to do with the rivet puller but the other 14 I had to do by hand. Then I reassembled the windshield strap and Southco receptacles. I riveted the strap and receptales into place.

F15-05 Rudder Pedal Support Angle.
I cut the rough size from .063 sheet stock using the band saw. I then used the bending brake to bend the 90 degree. I used the band saw, scotch brite wheel and the belt sander to finish to proper size and shape. I then used the drill press to drill the #40 pilot holes.
F15-08 Spacer Plates.
I used the band saw to cut the 2" lengths of 1/2" x 1/8th" bar stock. I finished and smoothed the edges using the scotch brite wheel.
F15-15 Flap Drive Pivot Block Assembly.
I used the band saw to cut the phenolic blocks. Since I am going to install the flap handle in the middle (SNX-C08) I need one more set than this plan calls out. So I cut a total of six (3 pairs).
F15-03 Left and Right Hand Rudder Pedal Mount Assemblies.
I clamped F15-04 Left and Right Hand Rudder Pedal Mount Angles to the table with a 1/8th" spacer between it and the table. This put the side of the angles 3/8th" above the table. This is the proper distance that the F15-05 support angle needs to be offset. So that way I was able to place the support angle on the table and then clamp it to the mount angle in the proper position. I then drilled and up drilled the holes in the support ange using the mount agle as a guide.

F15-03 Left and Right Hand Rudder Pedal Mount Assemblies.
I countersank the #30 holes on the F15-04 mount angles per the plans. I dueburred all holes and edges. Cleaned off all ink marks. I then riveted the F15-05 angles and F15-04 mount angles together using the CCC-44 rivets called out in the plans.
Various Kit Supplied Parts.
F15-06, F15-09, F15-10, F15-11 and F15-14 were provided as part of the kit as cut to shape and with pilot holes drilled. However they needed to be deburred and cut marks on edges removed. I deburred all the holes and edges. I also polished all the edges to remove all the cut marks.

F14-06 Left and Right Hand Lower Firewall Attach Angles.
I used the band saw to cut the Z02-03 Angle stock to the shape and size. I polished the edges with the scotch brite wheel. I used the hand seamer to open the angle to the required 94 degrees.
F14-05 Left and Right Hand Upper Firewall Attach Angles.
I used the band saw to cut the Z02-03 Angle stock to the shape and size. I polished the edges with the scotch brite wheel. I used the hand seamer to open the angle to the required 94 degrees.
F14-04 Left and Right Hand Firewall Attach Angles.
I used the band saw to cut the Z02-03 Angle stock to the shape and size. I polished the edges with the scotch brite wheel. I used the yard stick hinge template to drill the equally spaced 18 holes. I then located the two end holes and drilled them per the plans.
F14-03 Left and Right Hand Cowlling Attach Hinge.
I cut the hinge to the proper length. I used the band saw to cut the shape and to cut off the two lower lugs. I then used the scotch brite wheel to polish the edges.

F14-01 Left and Right Hand Forward Angle Assemblies.
I clamped F14-04 Firewall Attach Ange, F14-03 Cowlling Attach Hinge and F14-02 Forward Angle together arrange per the plans instructions. I drilled and clecoed pilot holes at each end and in the middle. I then clecoed the assembly to the table and drilled the remaining pilot holes. I removed the assembly from the table and clecoed it together.
F14-10 Gussets.
I deburred the pilot holes and polished the edges to remove the cutting marks.
F13-04 Longeron doublers.
I polished the edges to remove the cutting marks.
F13-05 Canopy Latch Strike Plates.
I used the band saw to cut the phenolic to the size and shape per the plans. I used a router table to make the radius on the one edge. I used the drill press to drill the 1/8" pilot holes.
F13-02 Upper Forward Longeron
I then clamped the plates to the longeron lined up with the slots per the plans. I then used used a #30 drill to drill out as much of the corresponding phenolic that I could. I then used a hand copping saw to remove the material between the holes. I then used files to shape and smooth the phenolic to match the slots in the longeron. Next I drilled the 1/8" holes from the phenolic through the longeron. I up drilled these to the 3/16th for the bolts. I clamped the F13-04 doublers to their location per the plans. I drilled the pilot holes, #30 holes and counter sink for the requiered rivets.
Upper Firewall Filler Box. I received the last Southco receptacle. I riveted it in place.

F13-02L Left Hand Upper Longeron Assembly.
I made the counter sink for the bolts holding the Canopy Striker Plates. I sanded and deburred the longeron. I installed the bolts holding the canopy striker plates. I installed the rivets holding the loneron doubler.
F13-02R Right Hand Upper Longeron Assembly.
I sanded and deburred the longeron. I installed the rivets holding the longeron doubler.
F12-01R Right Hand Forward Side Assembly.
I cleaned off the manufactures ink markings on the F13-01 Forward Fuselage Side Skin. I laid the skin flat on the work table. I clamped the F13-02R Right Hand Upper Longeron to the table in position over the side skin. I then drilled #40 pilot holes using the holes in the longeron as a guide. I also made sure to maintain a distance of 22" from the bottom of the skin and the top of the longeron.

F12-01R Right Hand Forward Side Assembly.
I started adding more parts to the Side Skin by locating per the plans and drilling the pilot holes:
F13-03R Lower Longeron
F14-01R Forward Angle Assembly
F14-07R Rudder Pedal Assembly
F14-08R Forward Wing Attach Angle
F14-09R Aft Wing Attach Angle
F14-13R Horizontal Angle
F14-11R Gear Attach Angle
F14-12R Seat Belt Attach Angle.
I also clamped the F15-01R Upper Motor Mount Angle with .032 shims to the upper longeron.

F12-01R Right Hand Forward Side Assembly.
Located, Pilot Drilled and clecoed:
F15-01R Upper Motor Mount Angle,
F15-02R Lower Motor Mount Angle,
F15-14 Doubler Support Plate,
and the 6 F14-10 Gussets.

F12-01R Right Hand Forward Side Assembly.
Located, Pilot Drilled and clecoed:
F15-03R Right Hand Rudder Pedal Mount,
F15-07R Right Hand Flap Drive Mount with F15-08 Spacer,
F15-09 Lower Gear Gusset Plate,
F15-10 Upper Gear Gusset Plate,
F15-11 Seat Belt Attach Gusset Plate,
and F15-12R Right Hand Angle Clip.

I also started to up drill the pilot holes to the #30 size.

F12-01R Right Hand Forward Side Assembly.
I finished up drilling the holes to #30 size. I also up drilled the holes for some of the bolt holes to 3/16th. Per the assembly instructions I did not up drill the holes where the firewall flanges/ clips will go or the holes where the F15-06 Doubler will go.
I removed all the clecos and deburred the holes and edges. I also cleaned off all the ink markings.

F12-01R Right Hand Forward Side Assembly.
I first assembled the assembly with clecos. I then located, pilot drilled and clecoed F15-06 Doubler. I then up drilled those pilot holes to the #30 size.
Next I located, pilot drilled (#30 size) and clecoed F14-05 and -06 Firewall Attach Angles. I then up drilled those holes to 3/16th.
I also up drilled the hole through the Seat Belt Attach Gusset to the required 5/16th.
I clamped the clecoed assembly to the aft fuselage to see how it is going to look.

F12-01R Right Hand Forward Side Assembly.
I removed the clecos and parts that had holes up drilled yesterday. I deburred the holes and used clecos to complete the assembly. I used blue painters tape to mark the clecos that do not get rivets at this time. I installed all the rivets called out in the plans. I installed all the AN525-10R12 bolts and torqued them to 25 in/lbs.
F12-01L Left Hand Forward Side Assembly.
I layed the skin flat on the work table. I clamped the F13-02L upper longeron in place (22") from the botton skin edge. I drilled the #40 pilot holes and clecoed the longeron in place.

F12-01L Left Hand Forward Side Assembly.
I located, pilot drilled and clecoed:
F13-06L Lower Longeron,
F14-01L Forward Angle Assembly,
F14-07L Rudder Pedal Angle,
F14-08L Forward Wing Attach Angel,
F14-09L Aft Wing Attach Angle,
F14-13L Horizontal Angle,
F14-11L Gear Attach Angle,
F14-12L Seat Belt Attach Angle,
F15-01L Upper Motor Mount Angle,
F15-02L Lower Motor Mount Angle,
and F15-14 Doubler Support Plate.

F12-01L Left Hand Forward Side Assembly.
I located, pilot drilled and clecoed:
6 F14-10 Gussets,
F15-03L Rudder Pedal Mount Assembly,
F15-07L Flap Drive Mount along with F15-08 Spacer,
F15-09 Lower Gear Gusset Plate,
F15-10 Upper Gear Gusset Plate,
F15-11 Seat Belt Attach Gusset, and
F15-12 Angle Clip.

I also up drilled to size #30 all holes except for those where F15-06 Doubler will attach.

F12-01L Left Hand Forward Side Assembly.
I up drilled all the bolt holes to 3/16th except where the firewall attach angles will be attached.
I also removed the clecos and deburred all the holes.
I also cleaned off any ink markings.

F12-01L Left Hand Forward Side Assembly.
I clecoed all the parts back in place on the assembly.

I also located, drilled, up drilled, deburred and clecoed:
F15-06 Doubler,
F14-05 Firewall Attach Angle and
F14-06 Firewall Attach Angle.

I marked all the holes that do not get rivets at this time with blue tape. I then installed all the rivets called out in the plan.

I also installed the AN525-10R12 bolts for the Rudder Pedal Mount Assembly.

I still need to install the rest of the AN525-10R12 bolts.

Today I reach 1200 hours into the project.

F12-01L Left Hand Forward Side Assembly.
I finished installing the rest of the AN525-10R12 bolts. I torqued all the bolts to 25 in/lbs.
Both Forward Side Assemblies are now complete.

F16-10 Lower Forward Cross Tie.
This is a kit supplied part. I cleaned and sanded this part.
F16-09 Upper Forward Cross Tie. This is a kit supllied part. The cut edges on this part required use of a file to remove cutting marks. I also cleaned and sanded this part.
F16-08 Side Clips. I used the band saw to cut these clips from Z01-03 Angle Stock. I used the drill press to drill the pilot holes. I deburred the edges and holes.
F16-07 Shear Plates. These are kit supplied parts. I removed the cut marks on the edges using the die grider with the small scotch brite wheel. I sanded and cleaned the parts.
F16-06 Right and Left Hand Vertical Angles. These are kit supplied parts. I cleaned and sanded these parts.
F16-05 Aft Tunnel Angle. I used the band saw to cut the Z05-02 Kit Stock to the proper length. I used a file to smooth and clean the cut edge. Next I cut the notches out of the lower corners. I used the drill to provide relief in the corners. I then used the hack saw to cut out the rough shape. I finished the notches using file to get the proper shape and size.
F16-04 Support Angle. This is a kit supllied part. The cut edges on this part required use of a file to remove cutting marks. I also cleaned and sanded this part.

F16-03 Aft Tunnel Web Assembly.
I located, drilled and clecoed on the assembly:
F16-04 Support Angle,
F16-06 Vertical Angles, and
F16-07 Shear Plates.
I also up drilled most of the holes.
I practiced counter sinking and dimpling on some scap material.

F16-03 Aft Tunnel Web Assembly.
I finnished up drilling the holes to the #30 size. I deburred all the holes and edges. I counter sank some of the holes. I decided to get a new counter sink cutter before I do any more.
F16-02 Forward Tunnel Zee.
I cut the basic shape. I used files to get a more finnished size.

F16-02 Forward Tunnel Zee.
I did some more filing to get the shape and size correct. I drilled the 70 #40 pilot holes. I also drilled to 3 3/8ths holes.

I also rearranged the shop / work area. I positioned the Aft Fuselage upside down supported by the three work tables. This is the position I will use to start attaching the forward sides.

F11-01 Fuselage Box Assembly.
I clecoed the side panels to the Aft Fuselage Assembly using the pre drilled holes in both.
I made the 5 degree bend in the lower skin. I place the skin in location on the assembly. I clamped the upper and lower cross ties to help hold the box shape. I up drilled the holes in the lower skin where it attachs to the aft fuselage. I clecoed the skin in place as I drilled. I positioned the side panels so that the lower skin was properly located. I then drilled and celcoed the pilot holes that go through the lower skin and the logerons of the side panels. I used the pre drilled holes in the lower skin for locations.

F11-01 Fuselage Box Assembly.
Located, Pilot drilled, and clecoed:
F16-10 Lower Forward Cross Tie, and
F16-09 Upper Forward Cross Tie.

F17-01 Lower Firewall. I used the hand seamer to make the two required bends.
I then located, pilot drilled and clecoed the lower firewall to the Fuselage Box Assembly.

I placed the motor mount in place just to see how it fit and looked. It appears to fit very well.

F11-01 Fuselage Box Assembly.
I made a strap duplicator to locate 6 holes (3 ea side) where the lower skin and aft lower skin overlap. I drilled #40 holes and up drilled to #30. That completed the holes joining the lower skin and aft lower skin.

I drilled the pilot holes through the splice places and upper and lower longerons.

I started to locate, pilot drill and celco the F16-02 Forward Tunnel Zee.

F11-01 Fuselage Box Assembly.
I finished locating, pilot drilling and clecoed the F16-02 Forward Tunnel Zee.
I located the F16-03 Aft Tunnel Web Assembly. I pilot drilled and clecoed the assembly to the lower skin. I also pilot drilled and clecoed the assembly at the Aft Wing Attach Angles.

F11-01 Fuselage Box Assembly.
I pilot drilled and clecoed the top where the Forward Tunnel Zee and the Aft Tunnel Web Assembly join.
I located, pilot drilled and clecoed:
F16-08 Side Clips,
F17-08 Firewall Stiffener,
F17-09 Floor Stiffener,
F17-11 Gusset,
F17-10 Upper Clip and
F17-12 Aft Clip.
For the Upper Clip I had to make a spacer to fit the radius of Upper Cross Tie. I also removed and reinstalled the firewall to gain better access for drilling the Upper Clip. Since I had access I went ahead and up drilled the upper clip and part of the gusset.

F11-01 Fuselage Box Assembly.
I located, pilot drilled and clecoed the Upper Firewall Assembly. I had to do some trimming to get it to fit.
I made the P13-08 Hinge Half that go on the lower firewall. I located, pilot drilled and clecoed the hinge half to the firewall.

I up drilled to #30 the Firewall.

I also up drilled the lower skin those holes required to be #30. I marked with blue tape those side holes that do not get up drilled at this time.

F11-01 Fuselage Box Assembly.
I finished up drilling the holes that will get rivets to #30 size.
I also up drilled the holes for the bolts to 3/16th".
I need to do the counter sinks and dimples.

F11-01 Fuselage Box Assembly.
I removed, debured, and cleaned all the ink marks off:
F16-01 Lower Forward Skin,
F16-10 Lower Forward Cross Tie, and
F16-09 Upper Forward Cross Tie.

I also removed the Right Hand Side Panel to debur all the holes. I started to counter sink the Right Hand Wing Attach Angle. The tip of the counter sink cutter broke off so I had to stop. I ordered a new cutter and will finish when I receive it.

F11-01 Fuselage Box Assembly.
I removed the Left Hand Side Panel and debured all the holes. I attached the side panels to the aft fuselage skins using clecos. I installed the side bolts through the side panel skins, longerons, aft fuselage skins and splice plates. I temporarily placed bolts through the top and bottom longerons and splice plates.

F10 Aft Lower Cabin Details.
I removed cut marks from the edges using files from the kit supplied parts:
F10-25 Gusset Spacers and
F10-24 Gussets.
For F10-22 Idler Plate I removed cut marks from the sides using files. I also up drilled the pilot holes to their final sizes of 1/4" and 3/16".
Using the band saw I cut F10-20 Spacer. I usde files to remove cut marks from the edges.
I then clamed F10-19 attach angle to the spacer and match drilled the holes to #13 using the holes in the angle for location.
F10-17 Idler Support Assembly.
I clamped F10-18R & L Pivot Angle together with the F10-20 Spacer and F10-19 Attach Angle in between. I used a drill bit to hel align the holes. I up drilled the holes untill I was able to insert the two AN3-7A bolts. I also had to round the one edges of the Right Hand Pivot Angle to allow it to rest in the radius of the Attach Angle.

F10 Aft Lower Cabin Details.
F10-16 Idler Assembly -
I used the arbor press to press the bushings into the F10-18 Pivot Angles. I put the assembly together without the Idler Plate. I line drilled a 5/16th reamer through the bushing. I put in the Idler Plate with the pivot bushings. It was too tight so I added some shims at the spacer to get a proper spacing and movement of the Idler.
F10-14 and F10-15 Gussets.
These are kit supplied parts. All Ineeded to do was clean the edges and debur the holes.
F10-13 R&L Seat Belt Attach Channel.
I used the band saw to cut the length corner notches and end flange. I used files and the scotch brite wheel to get the final size and shape. I used oak blocks and a clamp to bend the end flange to 90 degrees. I still need to layout and drill the pilot holes.
F10-12 Center Support Channel.
I used the band saw to cut to a rough length. I used the scotch brite wheel to trim to final length.

F10 Aft Lower Cabin Details.
F10-13 R&L Seat Belt Attach Angles.
I located and drilled the pilot holes to #40 size.
F10-08 and F10-11 Clips.
I used some left over Z03-02 .032 Channel to make these clips. I used the band saw to cut the rough dimensions. I then used the scotch brite wheel to finish to the final sizes. I marked and drilled the required pilot holes to the #40 size.
F10-10 R&L Support Channels.
I used the hack saw to cut the rough length of the Z02-04 Channel Stock. I used the band saw and files to cut out the required notches. I used the scotch brite wheel to finish to final dimensions. I marked and drilled the pilot holes to #40 size.
F10-09 R&L Support Channel Assemblies.
I clamped the F10-11 Clips to the F10-10 Channels and drilled and up drilled the required holes. I deburred and cleaned the parts. Then I revited the clips to the channels to complete the assemblies.

F10 Aft Lower Cabin Details.
F10-07 R&L Idler Attach Brackets.
I used the band saw to cut these from some left over Z03-02 .032 Channel. I used the scotch brite wheel to clean the edges. I then drilled the required #40 pilot holes. I used the hack saw to cut to length. I measured and drilled the required #40 pilot holes. I also used the band saw to remove the two center lugs.
F10-02 Cap Assembly.
I clamped the Seat Attach Hinge and the F10-03 Angle to the table. I drilled and updrilled the holes to #30 for the rivets. I deburred all the holes. The plans call for CCP-42 rivets but that is based on the F10-03 angle being made from .032 angle. The F10-03 Angle is now provided in the kit as 1/8th angle. So I decided to up size the rivets to CCP-44. I then installed all the rivets holding the hinge to the angle using CCP-44 rivets.
F10-01 Angle.
I used a hack saw to cut Z04-03 Channel Stock to the required length. I then used the band saw to remove one of the flanges and cut the two corner notches.

F10 Aft Lower Cabin Details.
F10-01 Angle.
I used files to make the radius in the corners of the notches. I located, drilled and deburred the pilot holes on the ends. I used step drills and files to make the cut out for the control rod path. I then used the hand seamer to make the 4 degree bends on each end.

F11-01 Fuselage Box Assembly.
I finished counter sinks on the forward wing attach angles. I was able to use the micro stop on all but 3 holes on each side. I attached the counter sink cutter to the tight fit extension and was able to do those holes "free hand".
I then started the reassembly with clecos.

F11-01 Fuselage Box Assembly.
I continued reassembly with clecos.
I riveted the side panels to the aft fuselage.
I riveted the clips and gusset to the firewall and floor stiffeners.
I riveted the lower skin to the side panels, forward tunnel zee, floor stiffener and lower cross tie / firewall.
Next I riveted the rest of the lower firewall. I used the bent rivet mandrel tool to get in around the motor mount brackets.
I used CCP-46 rivetes to attach the upper clip to the upper cross tie. The plans call for CCP-44 but since I added the spacer I needed to use CCP-46.
I installed the 4 AN3-5A bolts that hold the upper cross tie. I torqued them to 25 in/lbs.
I revited the hinge halves to the firewall.
I installed all the remaining AN525-10R12 Bolts. Laurie helped by holding the heads while I did the nuts. I torqued them also to 25 in/lbs.
I riveted the 3 CCC-42 rivets from the tunnel zee to the aft clip.
After today I am at hour 1,299 on the project.

F11-01 Fuselage Box Assembly.
I installed the CCC-42 and CCC-44 rivets on the Forward Tunnel Zee.
I also clecoed the Aft Tunnel Assembly back in its location.
I also clecoed all the parts for the Side Panels.
Plans Page F11 is almost done.
The 3 remaining items that I will do later -
After I flip the fuselage I will install the MS24694-S54 Screws through the top longeron and splice plates,
Also after I flip the fuselage I will rivet the upper firewall in place, and
When I rivet the aft lower skin I will rivet the forward lower skin to the aft lower skin and the fuselage tail cone.

F09-02 Seat Belt Attach Assembly.
I located, pilot drilled, up drilled, deburred and riveted
F10-08 Clips,
F10-05 R&L Seat Belt Attach Brackets, and
F10-06 Hook Mount
to the F10-01 Angle.

I also located, pilot drilled, up drilled and deburred F10-07 R&L Idler Attach Brack to the F10-01 Angle. I did not rivet them at this time.

I also installed temp bolts to hold the upper longerons and splice plates until I flip the fuselage and install the MS24694-S54 Screws.

F09-01 Aft Lower Cabin Detail Installation.
I located, Pilot Drilled and Clecoed:
F09-02 Seat Bet Attach Assembly,
F10-24 Gusset Plate with F10-25 Gusset Spacer,
F10-02 Cap Assembly, and
F10-09 R&L Support Channels.

For F09-02 Seat Belt Attach Assembly and F10-09 Support Channels I used a line drawn on the flange to line up with the holes in the lower skin.

I also clamped the F10-02 Cap Assembly to the F09-02 Seat Belt Assembly to be sure that there was a constant height from the lower skin.

F09-01 Aft Lower Cabin Detail Installation.
I located, Pilot Drilled and Clecoed:
F10-12 Center Support Channel,
F10-13 R&L Seat Belt Attach Channels,
F10-14 and F10-15 Gussets, and
F10-16 Idler Assembly.

I also up drilled all the holes in the lower skin for this installation.

F09-01 Aft Lower Cabin Detail Installation.
I up drilled the holes for the Idler Assembly. I deburred all the holes on the Idler Assembly and the F10-07 Brackets. I riveted the F10-07 Brackets to the Idler Assembly. To do the riveting I had to loosen the bolts and slide the two halves a part. I then had to file the tails on the rivets until the was clearence between the rivet tails. I then tightened the bolts and torqued them. I repositioned the assembly to be sure it would fit properly and it did.
Next I started up drilling the holes to the #30 size.

F09-01 Aft Lower Cabin Detail Installation.
I finished up drilling all the holes to their proper size.
I also started deburring all the holes and parts.

F09-01 Aft Lower Cabin Detail Installation.
I finished deburring all the holes and parts. I clecoed all the part together out side of the fuselage. I then check to see if it went back in place and lined up with all the holes etc. It did. So then I installed all the rivets out side of the fuselage. It was a lot easier than it would have been with every thing back in place.
I clecoed the partial assembly back in place. I then riveted the lower skin to the assembly. I then riveted the places on the inside of the assembly.
My friend Robert came over and help Laurie and me turn the fuselage right side up.

F11-01 Fuselage Box.
Today I finished up a couple items left from plans page F11.
I clecoed the upper firewall to its location.
I replaced the temp bolts in the upper longerons / splice plates. I counter sunk the longerons and installed the correct screws/bolts as called out in the plans.
I also installed the tail skid and the bolt holding it in place.

F08-03 (C05-04) Seat Sling.
Since I am doing dual controls my Seat Sling is actually per the plans C05-04.
Also since I will be doing the Optional Dual Center Controls I need to further modify the Seat Sling per C09-07. This is for placement of the flap and brake levers in the middle.

I cut the .025 sheet to the size. I then marked the layout of the cut outs. I used the drill and jig saw to do the cut out for the control sticks and seat belts. I started using files to finish to the final size and shape.

F08-03 (C05-04) Seat Sling.
I have decided that for now I will not make the modifications for the Optional Dual Center Controls in C09. I am thinking that I will do electric flaps and the brakes either on the side or on the stick. I do not want the levers in the middle. I will decide later. I finished filing the cut outs to the final sizes. I used the small scotch brite wheel on the die grider to polish the edges.

F08-04 and -05 Hinges.
I cut them to length, drilled the #40 pilot holes, removed the required lugs and deburred the edges and holes.

F08-06 Hinge Pins.
I cut them to the proper length (including the bent length) using the cut off wheel. I used the bench grinder and scotch brite wheel to finish the ends. I then used vise grips to hold and bend the end per the plans.

F08-02 Seat Assembly.
I located, pilot drilled, up drilled, deburred and riveted the F08-04 Seat hinges to the F08-03 (C05-04)Seat Sling to complete the F08-02 Seat Assembly. I did this with the F08-05 Structure Hinges attached to the Seat Hinges by the hinge pins. This helps keep the hinges straight.

F08-01 Seat Installation.
I placed the Seat Assembly in the fuselage with the Structure Hinges still attached. I inserted the hinge pins that attach the seat assembly to the hinge already installed in the fuselage. I then located, pilot drilled, up drilled, deburred and riveted the F08-05 structe hinges to the spare tunnel and cross tie box.

I was then able to sit in Favorite Lady for the first time.

F07-08 Fuel Tank Stop Angles. F07-09 Center Firewall Attach Angle. F07-10 Side Firewall Attach Angles.
I cut the required lengths from Z02-03 Angle Stock.
I used the band saw to cut the sides to the required widths.
I used the scotch brite wheel the smooth the edges.
I used the drill press to drill the required #40 holes.
For the firewall attach angles I clamped the 90 degree stock to the bending brake. I then used the hand seamer to bend one side to open up the angle to 66 and 60 degrees per the plans.

F07-05 Instrument Panel Cross Tie.
I cut the required length from the Z03-02 Channel Stock.

F07-07L & -07R Left and Right Hand Corner Plates.
The part is provided as a kit part. However they needed to be bent 30 degrees. At first I thought I could do the bend with the arbor press. But that did not work because the one side is to short a distance from the bend, I ended up put them in the wood vise on the Harbor Freight work bench, I the used rubber/plastic hammer to make the bend.

F07-06 Cross Tie Attach Plates.
These also were provided as kit parts. I I needed to do to them was polish the edges and debur the holes.

F07-05 Instrument Panel Cross Tie.
Yesterday I had cut the channel stock to the correct length. Today I used the band saw to cut the one flange to the 1/4 in size. I also used the band saw to cut the angles on both ends. I used the small scotch brite wheel on the die grinder to polish all the cut edges. Next I used the table saw to cut a 2x4 with a 30 degree ange to use as a form. I clamped the part with the form to the work bench. I then used the rubber/plastic hammer to form the 30 degree flange bend.

F07-03 Instrument Panel.
The kit proved the part as a flat item with the pilot holes done. I used a combination of bending with the hammer and bending brake to make the required bends.

F07-01 Glare Shield.
The kit provided a preform part. The bends were already done. It needed to be trimmed to the correct size and shape. I used the snips and files to trim and shape the part. It still need the pilot holes drilled.

F07-01 Glare Shield.
I drilled the #40 pilot holes per the plans.

F06-02 Glare Shield Assembly.
I located the F07-03 Instrument Panel to the F07-01 Glare Shield. I clamped the glare shield to the table and the instrument panel to the glare shield. I drilled the #40 pilot holes. As i drilled I clecoed the panel to the glare shield.

F06-02 Glare Shield Assembly.
I fit the location of the Cross Tie Plates and the Instrument Panel Cross Tie. I clamped the Cross Tie Plates in location. I drilled the pilot holes that attach to the Glare Shield. I clamped the Instrument Panel Cross Tie in its location. I drilled the pilot holes throught the Cross Tie Plates and Instrument Panel Cross Tie. I used a yard stick ruler to be sure the cross tie was straight across the assembly. I drilled the pilot holes through the panel and the cross tie.

F06-01 Glar Shild Install.
I removed all the clecos from the glar shield assembly and put it into the fuselage with clecos. I drilled the 4 holes on each side through the cross tie plates, longerons and glar shiled. I then drilled all the remaining pilot holes through the glare shield and longerons. I filr the firewall attach angles in their locations. I drilled a few pilot holes through the attach angles and glare shiled. I then removed the upper firewall to gain access to the remaining pilot holes for the glare shield. I drilled all the holes to #40 and then #30. I then deburred abd riveted the attach angles to the glare shield. I put the upper firewall back in place with clecos. I drilled all the #40 pilot holes through the attach angles and the upper firewall.

F06-01 Glare Shield Installation.
I located, drilled pilot holes and clecoed the F07-07 Corner Plates to the Glare Shield Assembly and the Fuselage. I up drilled all the holes to their final size, #30 for rivet holes and 3/16th for bolt holes. I removed the panel and cross tie.
I inserted the fuel tank to check for fit. I also check the locations where the F07-08 Fuel Tank Stop Angles will be attached. It appears that all will be OK for the fuel tank fit. I removed the fuel tank and removed all the rest of the clecos. I deburred all the holes for the Gare Shiled and where it attach to the fuselage.

Placed the Fuel Tank in place.
Clecoed the panel in place,
Organized the shop for the summer.

F08-07 Flap And Trim Quadrant Installation.
I will be using the Aerovee Trim system so I am not installing the the trim lever. I am only installing the the flap portion. I am using the side flap position because I plan on changing to electric flaps at some time.
The F08-10 and -11 attach angles were supplied as kit parts.
The F08-08 Flap Detent Angle was also a kit supplied part.
I located the position of the attach angles on the wing attach angles on the side fuselage. I drill the required #40 pilot holes. The aft attach angle does not lay flat on the detent angle. I will need to adjust the angle of the aft attach angle.

F08-11 Aft Flap Attach Angle.
Found that the pilot holes I drilled yesterday did not allow the angle to be the proper distance from the side panel. The plans had a 3/8th in measurement for the hole distance on the wing attach angle. The plans did not provide a measurement number for the distance on the flap attach angle. Yesterday I centered the holes on the aft attach angle. When I tried lining up the flap detent angle I found that the tip was not the required 37/64th from the side as called out in the plans. When the tip was at the 37/64th the detent angle had a 1/8th in gap from the aft attach angle. Further investigation and measurement of the plans showed that the holes on the aft attach angle should have been 3/8th in from the outside edge rather than the 1/2 in.

So I made a new F08-11 Aft Flap Attach Angle from 1" angle stock. I used the old angle as a pattern for the spacing of the pilot holes on the new aft attach angle.

F08-07 Flap Quadrant Installation.
I then clecoed all the parts in place and check for proper location. I drilled the 1/8th pilot holes in the attach angles using the 1/8th holes in the detent angle. I up drilled all the bolt holes a rivet holes to the final sizes. I deburred all the holes. I installed the rivets the hold the flap attach angles to the wing attach angles on the side panel. I installed the bolts holding the detent angle to the attach angles. These will need to be removed during the wing rigging.

F06-02 Glar Shield Assembly.
I located F07-08 Fuel Tank Stops on the glar shield. I drilled the #40 pilot holes and up drilled to #30 size holes.
F06-01 Glar Shield Installation.
I installed the 6 AN525-10R12 bolts per the plans. I torqued the bolts to 25 in/lbs. Laurie was a big help holding the heads of the bolts while I climbed into the fuselage to tighten the nuts.

I decided that it was time to finish some of the riveting.
F11-01 Fuselage Box Assembly.
I riveted the upper firewall F17-02 to the fuselage.
F06-01 Glare Shield Installation.
I riveted the glare shield to the longeron except where the panel cross tie is located. I will wait to rivet the panel and cross tie after the tank is installed and the panel layout is determined.
I also riveted the glare shield to upper firewall.
I also riveted the cross tie attach plates to the cross tie.

P32-01 Engine Mount Installation.
I made some shims from the .063 sheet stock.
The rest of the day I worked on trying to get the mount in the correct location per the plans. I have been filing on the lower portion of the mount to try to get it a little closer to the fuselage. The ends are suppose to be out 22 13/16ths from the bottom front of the fuselage. At this point it appears to be about 22 15/16ths. It is interesting trying to measure to that point.

P32-01 Engine Mount Installation.
I filled the lower portion of the mount and got it clamped in the proper location. I drilled, up drilled and counter sunk the holes for the MS24694-S100 bolts. I installed the bolts but I used AN310-4 Castle Nuts instead of the AN363-428 Stop Nuts. This is temporary. I want to be able to remove the engine mount if needed. When I am sure I will leave the engine mount on I will replace the nuts with the required AN363-428 Stop nuts.

F03-08 Shear Angle.
Used the hack saw to cut the Z02-03 Angle stock to the rough length. Used the band saw to cut the sides of the angle to the rough widths.
F03-07 Spacers.
Used the band saw to cut the .032 sheet to the rough size.
F03-04 Spacers.
Used the band saw to cut the 3/16th by 1.5 inch bar stock to the rough length.
F03-02 Channel.
Used the hack saw to cut the Z04-03 Channel Stock to the rough length.

F03-08 Shear Angle.
Used files and scotch brite wheel to get to final shape and size. Drilled the #40 pilot holes per the plans.
F03-07 Spacers.
Used the scotch brite wheel to get to the final shape and size.
F03-04 Spacers.
Used files and the scotch brite wheel to get to the final shape and size.
F03-03 Fittings.
The kit provided the part cut to the proper shape and with pilot holes drilled. I up drilled the three 1/8th and one 1/4th inch holes. I used files and the hand scotch brite wheel to clean cut marks from all the edges.
F03-02 Channel.
I used the band saw to cut to proper length and finished to proper length with files and scotch brite wheel. I drilled and up drilled the two 1/4th inch holes. For the 1-3/4th inch hole I drilled using a step drill up to 7/8th inch hole. I then used the nibler to get close to the final size. I finished to the final size using files and the hand scotch brite wheel. For the notches at the lower corners I drilled the corners to get an approximate radius. I then used the band saw to cut the notches into the holes drilled in the corners. I finished to final shape and size using files and the scotch brite wheel.

F03-01 Rear Spar Carry Through Assembly.
I first lined up the F03-03 Fitting with the F03-05 Angle Fitting using a AN4 bolt in the 1/4th inch holes. I clamped the two parts together. I used the drill press to drill three #30 holes in the angle fitting using the 1/8th holes in the fitting as a guide. I clecoed the holes as I went so I was able to remove the clamp to get the third hole.
Next I lined up the fitting and angle fitting with the F03-02 channel again using a AN4 bolt in the 1/4th inch hole. I made sure the bottom edges were parallel and clamped them in place. I then drilled the 1/8th and 3/32nd holes through the channel using the other parts as a guide.
Next I remove the angle fitting and aligned it with the F03-04 Spacer. I clamped it in place. I used the drill press to drill the 1/8th inch holes in the spacer using the holes in the angle fitting as guide. I clecoed as I went and removed the clamp to drill the final 3rd hole.
I clecoed the angle fitting and spacer back on the -02 assembly. Next I up drilled the 3/32nd holes to #30 size for future rivets. Then I up drilled the three 1/8th inch holes to 3/16ths for the AN3 bolts.
Next I took the assembly apart and deburred all the holes.
Then I assembled the assembly using clecos for the rivets and AN3-7A bolts in the three holes.
I then repeated the process for the other end of the assembly.

F02 Wing Rigging.
I started preparing for the putting the wings into the fuselage. I removed the gear legs and gear mounts. I removed the side gussets and vertical angles. I also removed the aft spar tunnel assembly. I then removed the lower skin of the aft fuselage.

F02 Wing Rigging.
Today I started the wing rigging.
With the help of a good friend I inserted the wings into the fuselage. I had to file a little at the top of the fuselage opening on the left side. With a little raising and lowering of the wing tips I was able to insert the three 1/4" pins in the three alignment holes in the spars. The fuselage is level from side to side.

F02 Wing Rigging.
Continued work on the wing rigging.
First I worked on centering the wing in the fuselage. I measured from the attachment block holes to the side fuselage skins. I was able to get it to within 1/32nd difference. Next I setup the tubing with windsheild washer fluid to check for wing level. I also verified that the fuselage was still level. I tried to insert a shim under the spar to raise the right wing but there was not enough room. I will need to pull out the wing some so I can fill the top of the opening that the wing spars go into the fuselage. This should allow the spar to go up so I can insert a shim to level the wings. I also tried to set the incidence in hope that it might allow enough room above the spar. It did not allow enough room.

F02 Wing Rigging.
More work on the wing rigging. <>br>I removed the leveling tubing.
With some help I pulled the right wing out of the fuselage. Also partially pulled the left wing out of the fuselage. I filled the top of the fuselage opening for the right wing spar. I also up drilled the 3/16th holes on the rear wing spars to 1/4 holes. This matches the holes on the rear spar carry through. Pushed the left wing and then the right wing back into the fuselage.
I then centered the wings in the fuselage.
I set up the wing leveling tubes. I inserted a shim between the lower longeron and right wing spar. This leveled the wings.
Using clecos I put the aft spar tunnel, aft side vertical wing attach angles and gussets back into their place in the fuselage.
I connected the wing rear spars to the rear spar carry through using pins.
That is it for today.

F02 Wing Rigging.
I continued with the wing rigging.
I verified that the wings were still level.
I set the wing incidence by placing a 2x4 and wood shims under the wings next to the fuselage. I measured to be sure that the distance from the bottom wing skin to the bottom of the fuselage skin was 3 5/32 inches. I clamped the wings in that position.
I checked to be sure that the wings were square by measuring from the tail to the out board corner of the top wing skin per the plans.
I started installing the rear spar carry through.
I drill some of the pilot holes from the side attach angles to the fuselage and the rear spar carry through.

F02 Wing Rigging.
Rear Spar Carry Through.
Clamped the shear angle in place. I used the "Tight Fit" drill attachment and a 90 degree attachment to drill the pilot holes.
I removed the rear spar carry through assembly.
I finished drilling the pilot holes for the side attach angle. I then up drilled those holes to the #30 size for the rivets.
I put the assembly back in the fuselage and up drilled the holes through the shear angle and the fuselage cross piece.
I again removed the assembly.
I the attached the shear angle to the spar carry through. I drilled and up drilled those holes to the final size of #30.
I clecoed the side attach angles to the rear spar carry through. I then up drilled the holes to the #30 size. I used the drill press to carefully back drill the 1/4 inch hole through the side attach angles.
I then clecoed the rear spar assembly and side attach angles back in the fuselage to check that the pins alignment. The pins alignment was good.

F02 Wing Rigging.
Rear Spar Carry Through.
I finished installing the Rear Spar Carry Through. I removed the rear spar carry through and angles from the fuselage. I attached the shear angle to the rear spar carry through with rivets. I put the assembly back into the fuselage with clecos. I installed all the rivets I could get to with the wings on. I could not do all the rivets for the side angles. I inserted the bolts to hold the rear spar in place.

F02 Wing Rigging.
Drilling the Main Spar Attach Holes.
I was so busy I did not take any pictures of this process. I will take a few after the fact pictures tomorrow.
I had help from a friend.
I followed the step by step instructions in the plans. I did not use the 3/8 in bit with the 1/4 in pilot. I up drilled from the back to the front in 32nd in increments from 1/4 to 3/8.

F02 Wing Rigging.
Rear Spar Carry Through.
With the wings off I was able to install the remaining rivets for the side attach angles.
Drilling the Main Spar Attach Holes.
After close inspection of the holes today I determined that the hole through the right hand forward wing attach angle on the side of the fuselage was not good. The hole was not a close fit to the bolt. All other hole locations appear to be good. So I have decided to replace the RH Fwd attach angle. Today I carefully drilled out all of the rivets and removed the RH Fwd Attach angle. I ordered a replacement from Sonex. I will install it when it arrives.

F02 Wing Rigging.
In addition to replacing the RH Fwd Attach Angle I have decided to replace the Attach Block that is next to that angle. That is the Attach Block on the Left Wing Main Spar on the right hand side. Today I fabricated that attach block from 1" x 1 1/4" bar stock. I drilled the two 1/4" holes and installed it on the end of the Left Hand Wing Spar. I used a "D" drill bit to get tight fit holes. I will drill the 3/8" hole after I install the new RH Fwd Attach Angle.
Vents.
Today I also started assembling the side vents that I purchased from Van's Aircraft. These are the vents used on the RV-12 and back vents for the RV-10. I have seen a few others use these vents on their Sonex. So I have decided that I will give them a try.

F02 Wing Rigging.
I received from Sonex the replacement Right Hand Forward Wing Vertical Attach Angle. I match drilled holes in the attach angle using the existing holes in the fuselage assembly. I counter sunk the holes where it attaches to the spar tunnel. I deburred all the holes. I then installed the rivets called out in the plan.

F02 Wing Rigging.
I cut a 4 inch piece of steel bushing stock to be used to drill the pilot hole for the new attach block and attach angle. I put it in the drill press and filed and sanded the out side until it would fit into the 3/8th inch hole. I drilled the inside until a 1/4 inch drill bit will go through it.

F02 Wing Rigging.
With the help of a friend I was able to redo the right hand hole for the main spar. First we mated the wings together out side of the fuselage. We left the left wing in the wing stand. We put the right wing in position on top of the left wing spar. I aligned the holes. I put the bolt in the left hole. I put the 1/4 inch pins in the three alignment holes. I put the 3/8 inch OD bushing in the right hole as far as the hole existed from the previous drilling. I clamped the spars together. On this step all that will be drilled is the new attach block. I drilled through the bushing with 1/4 inch drill approximately 1/2 inch into the new attach block. I took out the bushing. I then used the 3/8 inch drill bit that I had dulled all but about 3/4 inch at the tip. I drilled into the new attach block approximately 1/2 inch with the 3/8th drill bit. I then repeated the bushing and 1/4 inch bit for another 1/2 inch. Then the 3/8th for that 1/2 inch and then the rest of the way with the 3/8th inch bit. We the put the wings back in the fuselage. I used the three alignment pins to position the wings and spars. I clecoed the aft spar tunnel and aft vertical angles in place. I inserted the 3/8th inch bolt in the left hand hole. I used the bushing to be sure the right side was aligned. I then used the 3/8th inch bit to drill through the forward RH vertical attach angle. I drilled from the back to the front using the existing holes to guide the drill bit. The holes turned out great. I also noticed that the rivets by the hole in the front vertical would interfere with the nut for the bolt. So I drilled out those rivets and put them back in from the inside.

F01 Fuselage Complete.
Spar Tunnel.
I drilled the holes and inserted grommets in the spar tunnel for the brake lines.
I also clecoed the aft spar tunnel and all the angles, gussets and brackets back into the fuselage. I did all the rivets in the fuselage side panels for these items.

F01 Fuselage Complete.
Spar Tunnel.
Today I installed all rivets for the spar tunnel except for the 6 rivets that will be hard rivets needing to be bucked.
Landing Gear Bracket.
Today I placed the gear bracket into the fuselage. I installed all the rivets and bolts required per the plans.

F01 Fuselage Complete.
Spar Tunnel.
I installed the 6 AN470AD4-5 Rivets. I used a hammer to buck the ends into the counter sunk inside portion of the spar tunnel. That completes the spar tunnel.

P14 Battery Box.
I decided to make the battery box with a removable front panel. So I started cutting out the bottom and the sides. I also decided to use counter sunk rivets. I drilled, up drilled and dimpled the sides and bottom. I riveted them together.

P14 Battery Box.
I cut out the front and hinges. I drilled, up drilled and dimpled the front, sides and hinges. I riveted the hinges to the sides and bottom.
Engine Hoist Plates.
I cut a 6" piece of 3/16th x 3 in steel plate. I drilled 5/16th inch holes that will line up with the bolt holes where the exhaust connects to the engine heads. I also drilled a 5/16th hole where the chain will be attached. I checked this one to the engine and it will work. Tomorrow I will make three more.

P14 Battery Box.
I finished making the battery box. I located the box on the firewall. I drilled, up drilled and riveted the battery box to the firewall.

Engine Mount.
I replaced the temp castle nut with the final locking nuts that attach the engine mount to the fuselage.

Landing gear and hydraulic brakes.
I finished installing the hydraulic brake assembly to the axles. I ended up using a shorter clevis pin. I also used a regular AN960-1216 washer to get the right spacing between the wheel and the bake body. I drilled the hole in the axle for the cotter pins. I also torqued the bolt / nut holding the axle to the gear leg and inserted the cotter pin. I removed the saw horses under the fuselage. The plane is now sitting on its gear.

F07 Panel.
I sprayed a self etching primer to the panel. After the primer dried I lightly sanded the panel. I sprayed a coat of color coat to the panel.

Made and installed bracket tabs to attach the interior side panels.
Made and installed a bracket to clamp the trim cable and com cable in place under the panel.
Started the installation of the side fresh air vents.

Finished installing the fresh air vents.
Installed the main gear wheel pants.

Fabricated and installed a stiffener to the firewall by the gascolator.

Installed rivets for bottom fuselage skin.

Installed N numbers. Installed the painted wheel pants and gear leg fairings.