Wednesday, January 30, 2019

Sick again!

Sick again with some sort of creeping crud!  Had to miss work today and that is a big deal for me as I never hardly ever do that.  Hopefully I can shake this stuff soon and get back to work!

Monday, January 28, 2019

Tail Cone Longeron Drilling

 Started tonight by fabing up this spacer that goes on top of the F1010A bulkhead to fill the void between the two longerons.  The aft deck skin sits on top of the whole assembly.  The part gets angles cut on both ends.  Again Van's gives you the long dim on the inside of the angles not the outside so be mindful of that or you could cut the part too short.

 Used the bandsaw to cut the angles.  Goes thru it like melted butter with a sharp blade.

First I placed the two longerons in their proper place on the tailcone assembly.  The bend in the longeron should align with the break point in the side skins.  The aft end of the longerons should be very close or touch the aft bulkhead.   I drew a center line on the part per the directions and then taped it to the top of the bulkhead, centered between the two longerons.  I did not have any double sided tape so I just used blue tape across the top.  It worked.

 Next I clamped the left longeron to the left skin.  The top of the longeron needs to sit flush with the top edge of the skin.  Should be easy if the longeron was bent properly in the prior steps.  Mine fit like a glove with very little effort.  I used C clamps to keep it exactly where I wanted it all long the side of the assembly.
Then I drilled all the holes.  I drilled them in a random pattern.  I just started in a hole somewhere between each clamp and then started filling in the gaps until I had a cleco in approximately every other hole.  Then I drilled all the remaining ones between the cleco's.  I love my new 4000rpm Nova pneumatic palm drill.  This thing made this task a breeze!  The holes are nice and round and the 4000rpm makes drilling through the thick longerons fast!  I had a pile of metal chips/shavings after the left side was done.  I did not have time to finish the right side.

Tuesday, January 22, 2019

Drilling misc. tailcone bits

 Started tonight by separating these rudder stop skin stiffeners

 Then I cleco'ed them to the side skins.

 Next I fabricated the rudder stop brace.  It has angles on the ends.  Make sure you pay attention to which side of the angles the long dimension is referring to.

 Cut the angles on the angle on the band saw.  This is super easy with a sharp blade.

 Next I side grip cleco'ed the brace into position.  It goes under the skin stiffeners and against the bulkhead.

 Next I ensured the entire tail cone was straight using a level at the front and the back.

 Then I match drilled the bulkhead to the rudder stop brace.

Checked for no twist again and then drilled the rudder stop skin stiffeners to the rudder stop brace using a 12" #30 bit.

 Next I cleco'ed the baggage compartment bulkhead to the tail cone assembly.

 Cleco'ed the bulkhead to the bellcrank ribs.

 Match reamed the holes in the bulkhead and bellcrank ribs.

 Added and match reamed this long vertical channel to the assembly.

 Separated these various parts on the band saw.

 You end up with two bellcrank rib flanges/stiffeners and two bellcrank mounts to be used later.

 Final drilled (should have reamed) the nutplate mounting holes to full size on the bellcrank rib flanges.

 Then I countersunk the holes for the nutplates.

 Final reamed all the #12 holes on these parts full size.

 Final reaming the #12 holes on these longer flanges to final size.

 Cleco'ed the bellcrank rib flanges/stiffeners to the bellcrank ribs. One is longer than the other due to the vertical channel on the right side.

Final reamed the holes on these bellcrank ribs and flanges.

Monday, January 21, 2019

Left side tailcone stiffener drilling

All I did tonight was drill the left side skin to stiffener holes.  There are a bunch of them!  Just have to keep the lines in the center of the hole! 

I did have to trim a bit of extra clearance around the relief cuts in the second to last bulkhead
(F-1011) in order to get the centerline in the middle of the hole and have the stiffener lay flat against the skin like it is suppose to.

Saturday, January 19, 2019

More tailcone stiffener drilling

 Started today by adding the right hand stiffeners to the assembly

 Then the right skin.  Cleco'ed the right side skin to the bulkheads and the bottom skin.

 Drilled all the stiffeners to the skins per the directions.  Simple....just align the marks on the stiffener with the holes and drill.  It takes some arm gymnastics to keep the lines centered in the holes.  Just go slow and carefully and keep the lines centered.

 Right side stiffeners all drilled.

I flipped the whole tail cone over on the horses.  Then I cleco'ed the back two bulkheads and the bottom aft skin to the assembly.  It is amazing how tight all these parts are.  At first it seems impossible but the more cleco's that go in, the better things start to align.  It is a testimony to Van's engineering department!  I remember similar pain and agony getting all this stuff in this area to align when I built the RV-7.

 The aft two bulkheads all cleco'ed to the assembly

 Next I added the stiffeners to the left side.

 And then cleco'ed the skin to the bulkheads and the bottom skin.  Also the aft two bulkheads and aft bottom skin.  Had to use a sharp scratch awl to align some of the holes.

Starting to look like airplane parts around here!

Thursday, January 17, 2019

Tail cone bottom stiffener and bulkhead drilling

 Started tonight by adding the vertical extension to my new saw horses.  This gets them up high enough to clear all the bulkheads.  Easy peasy.

 Then I cleco'ed the aft three bulkheads to the bottom skin.  This is a bit challenging to align.

 Then I slid the two fwd stiffeners into place.

 Then I aligned the centerline with the holes and aligned the starting point to the fwd most hole and drilled the stiffeners to the skin with my new 4000rpm drill.  Man I love this thing!  Makes fast work of these holes!

 Here are the fwd end of the fwd stiffeners all drilled.

 And then I drilled the aft end of the fwd stiffeners to the skin.  Go carefully and make sure the line stays in the middle of the holes!

 Then I slid in the aft center stiffener and drilled it the same way.

 Then I cleco'ed these two bellcrank ribs to the assembly.

 And match reamed their holes that are common with the skin.  I could not find anywhere in the directions on when to do this so I did it now.

 Then I match drilled these bellcrank rib flange to bulkhead web rivet holes to #30.  Used a 12" drill bit to make it easier to align.

Here are the stiffeners and bellcrank ribs all drilled to the bottom skin.  I love the new drill!

Tuesday, January 15, 2019

Tail Cone, saw horses and stiffener marking

 Tonight I had to go invest in some adjustable saw horses for assembly of the tail cone.  I will have to add a plank to the top of them to get them high enough while the assembly is upside down.  This is so the largest bulkhead will clear the ground.  I am just going to screw a 2x8 edgewise to the top of them to solve the issue.

 Next I marked the centerline on the J stiffeners along the long edge.  I bought this compass thing at Lowes for $5, added two zip ties and a sharpie pen and walla, instant adjustable edge marking tool supreme!   Doing the marking this way prevents the bow in the stiffener from screwing up the centerline.

Works slick as a ribbon!