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Monday, March 18, 2019

A deep analysis of the MCAS system on the 737 Max.... Here.

Wearing my engineering hat more than my pilot hat, I'd say that Boeing is in deep sh... over this...
Lots of bad engineering and management decisions to push the product out into the market as soon as possible.

Sunday, March 17, 2019

3 hrs. on the interior.

Have I mentioned that you have to do a lot of vacuuming?  Well, you do...  Lots of debris to keep up with....  A portable vacuum works well.  I use ear protection when I'm using it in the cockpit since it can be quite loud.

See the debris... 😁  From reaming it out first to M3 then M4 rivnut size.

Rivnuts in...  BTW, I don't deburr these holes because I think it's actually good to leave burrs on holes for rivnuts - something to dig into the rivnuts to make it less likely they'll ever rotate.  FYI: It's a pretty hard pull to get the rivnuts in the fiberglass.

Don't forget the Loctite 277!

A test of pulling of a rivnut to make sure it's not too little or too much.

After all the rivnuts were in I put in the panels and then the rear seat (at least temporarily).  View from the back. 👌

Me. 😁

Nice view.  For now I only put in every other screw for the rear panels.

Starting to look pretty comfortable...

Saturday, March 16, 2019

3 hrs. on the interior.

A bit of bending and jiggling of the front side panel is required to get it positioned.  It's not quite there in this photo.

I notice that the rudder pedal can touch the side panel, so I need to make sure it's screwed down up there (factory photos don't show where it's connected in that area).

Like my head shadow? 😜  Trying to position the panels as much like the factory photos as possible.

The back of the rear side panel has the holes marked, but I notice it's not really precise...

So I measured them to be consistent all the way across.  10mm from the edge and roughly 70mm between.

Holes drilled and screw test fit through.

Making sure they stay lined up and in position.

Again, checking and rechecking the position vs. the factory photos and between each side.

Checking the clearance.

After being convinced it was properly position it was time to drill.  Started near the seat belt and worked back and forward from there.

Working my way forward...

Again, tried to match what I could see in the factory photos.

Drill, drill, drill....

This area I can't see in the factory photos, but this seems like another good place to pin it down.

These two spots seem like good choice to make sure the panel is pinned against the skin.  Careful with these (and all really) holes when you drill, that you're only drilling through the inner skins....  You do not want to penetrate the outer skin....

That bottom one I can't/don't see in the factory photos, but the side panel sticks out down there if you don't pin it down.  Tomorrow I'll put in all the M4 rivnuts!

Thursday, March 14, 2019

1.5 hrs. on the interior.

I hadn't considered that when you bond the carpet to the soundproofing it gets pretty stiff and hard to bend...  But, put some slits in the soundproofing and it's easy to bend.  This particular piece which goes on the mid right side is very tough to get in...  I actually think in this case it would have been a little bit easier to put in the soundproofing first then the carpet.

In this case I did put in the soundproofing first and then the carpet.

My glue pattern 😁  If you do it like this (soundproofing, then carpet), your challenge is to not get glue on other carpet pieces.  I mostly succeeded.

And it's in.

Except for a few small pieces around the luggage door, it's done!

Another view.

Looking up through the luggage door.

Wednesday, March 13, 2019

1.5 hrs. on the interior last night.

I found that pre-shaping it around the bends before you put the glue helps because the carpet stays somewhat bent.

Glue on and it sticks quite well.

Test fitting and trimming the larger pieces.

Top piece test fit.

Ready to cut the soundproofing to size.


This is a different piece, but here the glue is on and ready to stick the carpet.  Like my pattern? 😁

And it's stuck on!

Side view of the carpet/soundproofing.

And in place after peeling off the backing.  From now on though I'll wait until the glue is dried before putting it in place.  You can see I got a little of the still-wet glue on the carpeting for this piece.  Should brush out though once it's dried.

Monday, March 11, 2019

1 hr. on the interior (I wanted to do 1.5 hrs, but I can only fold up my body and fit into the luggage compartment for an hour at a time...).

Smiling at the beginning....  Not so much after an hour....

Doing the 3rd surface for the stringers wasn't as hard as I thought it might be.  The Gorilla worked well!

Creative use of a ruler...

Letting it set for at least 15 minutes seemed to be sufficient.

Working on the other side.

Reaching the limit of my body-folding time I did a test fit and slight trim of one of the larger pieces.  Hoping to make a lot of progress tomorrow night and fit a few of those pieces.  Meanwhile, I bought some conduit to put around those wires.  Maybe I'll fabricate something to put around the backs of those connectors too.

Crosby this morning. 😊

Sunday, March 10, 2019

3 hrs. on the interior.

Well, despite my best hopes, the toluene-free Barge doesn't seem as good as the nasty stuff.  Despite scrubbing the aluminum is just wouldn't stick to it.  So, at the suggestion of a friend I decided to go back to the Gorilla Construction Adhesive and just stick one surface at a time.  Here's one stringer with just the top glued down.  I waited at least 20 minutes before bending it around and doing the next surface (see the photo a few down).

Other stringers and the bottom piece, one surface glued.


Using strips of thin wood and some spring clamps the second surface is held down.

Here's what I was doing yesterday instead of building. 😎  Good time skiing at Mt. Snow in Vermont with my younger daughter.

Excellent conditions and very nice views. 🌞

And here's a video of something that I hope to do someday in my Sling.  Up in New Hampshire there is an airport that is a seaplane base in the summer, but in the winter the frozen lake has a runway cleared.  It's the only ice runway in the lower 48 states.  Hope you don't mind me posting this Micheal. 😁