Builder's Log
DateAssemblyInstructionPartDescriptionLinks
10/18/2012 Fuselage F21 F27-09

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.

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10/19/2012 Fuselage F21 F27-01 F27-02 F27-03 F27-04 F27-05

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.

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10/20/2012 Fuselage F21 F27-01

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.

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10/22/2012 Fuselage F21 F27-01

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.

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11/14/2012 Fuselage F21 F27-02

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.

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11/16/2012 Fuselage F21 F27-01 F27-02 F27-03 F27-04 F27-05

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.

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11/17/2012 Fuselage F21 F27-02 F27-03 F27-04 F27-05

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.

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11/20/2012 Fuselage F21 F27-04

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.

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11/21/2012 Fuselage F21 F27-01 F27-02 F27-03 F27-04 F27-05

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.

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11/23/2012 Fuselage F21 F26-08 F26-07

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.

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11/24/2012 Fuselage F21 F26-06

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.

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11/25/2012 Fuselage F21 F26-05

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.

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11/27/2012 Fuselage F21 F26-04

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.

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11/29/2012 Fuselage F21 F26-01R F26-02R F26-03R

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.

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11/30/2012 Fuselage F21 F25-01R

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.

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12/01/2012 Fuselage F21 F25-01R

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.

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12/03/2012 Fuselage F21 F25-01R

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.

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12/05/2012 Fuselage F21 F25-01R

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.

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12/06/2012 Fuselage F21 F25-01R

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.

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12/07/2012 Fuselage F21 F25-01R

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.

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12/08/2012 Fuselage F21 F25-01R

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.

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12/09/2012 Fuselage F21 F26-01 F26-02 F26-03

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.

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12/10/2012 Fuselage F21 F25-01L

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.

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12/13/2012 Fuselage F21 F25-01L

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.

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12/15/2012 Fuselage F21 F25-01L

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.

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01/04/2013 Fuselage F21 F25-01L

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.

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01/05/2013 Fuselage F21 F25-01L F24-02 F24-03

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.

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01/06/2013 Fuselage F21 F24-02 to F24-09

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.

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01/08/2013 Fuselage F21 F24-01 F24-05

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.

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01/10/2013 Fuslelage F21 F24-01

F24-01 Cross Tie Box Assembly.
I finnished drilling all the #40 pilot holes on the upper web side of the assembly. I then removed the assembly from the jig, I used the forward channel and upper web to locate and drill holes in the table top portion of the jig, I clecoed the channels and upper web together into the table top and secured the ends of the channels to the jig. This way the assembly is up side down in the jig. I then located and clamped the lower web to the channels. I then drilled all the #40 pilot holes for the lower side of the assembly.

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01/12/2013 Fuselage F21 F24-01 F23-12 F23-10 F23-13

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.

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01/13/2013 Fuselage F21 F23-09 F23-10 F23-11 F23-13 F23-07

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.

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01/14/2013 Fuselage F21 F23-07 F23-08 F23-05 F23-02

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.

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01/15/2013 Fuselage F21 F23-02 F23-05 F23-01 F22-04 F22-02

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.

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01/16/2013 Fuselage F21 F21-01

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.

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01/17/2013 Fuselage F21 F21-01

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,

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01/18/2013 Fuselage F21 F21-01

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.

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01/19/2013 Fuselage F21 F21-01

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.

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01/20/2013 Fuselage F21 F21-01

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.

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01/21/2013 Fuselage F21 F21-01

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.

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01/22/2013 Fuselage F21 F21-01

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.

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01/23/2013 Fuselage F21 F21-01

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.

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01/24/2013 Fuselage F21 F21-01

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.

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01/25/2013 Fuselage F21 F21-01

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.

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01/26/2013 Fuselage F21 F21-01

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.

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01/27/2013 Fuselage F21 F21-01

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.

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01/28/2013 Fuselage F21 F21-01

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.

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