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.

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.

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.

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.