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Saturday, August 20, 2016

3 hrs. doing misc center fuselage tasks.

Peter Calley alerted me to the fact that I shouldn't have riveted together the main spar control bracket because the bushing is already on the joystick assembly as you can see here.  Oops...  Time for some de-riveting....

De-riviting...

The beautiful Garmin servos.

The joystick sits in an assembly that the bushing slides into (Here are the two back to back).  One slid right in, but the other was too tight.  You can see the one on the right is narrower.  So I took a file to it until the joystick bushing slid in.

The aileron servo has to attach here so those two rivets I did yesterday had to go...

The main spar control bracket was also too tight so I took a file to that until it slid in comfortably (the stick could rotate freely (but not too lose...)).  Flat file for the flat area and a half-round for the curved area which also required filing.

Several test fits to get it just right.

I like the way this looks. :-)

Pushrod for the aileron servo.

Pushrod for the elevator servo.  The manual says to use M5 bolts that come with the servos to attach the servos to the brackets, but mine did not... So I don't have those parts...  Grumble grumble...   EDIT: Help from others and a read of the Garmin install manual says you use AN3-4A bolts, etc, so I probably have that... Off to check in the garage.... NOPE, don't have those...  Every size except that one... :-/

Started reaming out the landing gear attachment holes to 10mm (they came out of the factory too small).  Not done with this as I need to move the main spar to get to the front holes.

NEXT TASKS:
  1. Make dimensionally correct dummy wing spars to insert and bolt into position in the center fuselage so that the slot and it's uprights are properly spaced when it's being riveted into position.  Do this while the main spar is not cleco'ed to anything so that it's free to move.  This was recommended by various people so that the side skins don't buckle when the wing is finally installed (I saw this on the Sling 4 at OSH).  DONE.
  2. Fix landing gear uprights.  I have to reverse brackets that attach to the uprights. DONE.
  3. Redo rivets in rear cone.  I have 1 short vertical line of rivets that need to be up-sized to match the other side. DONE.
  4. Rivet rudder cable guides in place. DONE.
  5. Run wires through rear fuselage (see paper note #3). Peter's 6-8-2016 entryDONE.
  6. Fit aux. luggage floor gusset (needed for original rearward seat location?)  WAITING FOR ANSWER FROM SA.
  7. Fit rear seat backrest stops for rearward location (see paper note #7).  See Gordon's 4/3/2016 entryCLECO'ED ON.
  8. Rivet main spar control and autopilot brackets (pg. E2).  Some holes should be drilled out to 4mm.  DONE.
  9. Install servos and connections (see various paper notes).  Maybe next step first??
  10. Install pushrods to servos.
  11. Install CF-BKT-019-L/R on landing gear box.
  12. Ream out landing gear holes to proper size before main spar is in place. STARTED.
  13. Rivet gear mounting channel before main spar is in place.  But, don't rivet to floor as that will have a cover installed later.
  14. See paper note #6.
  15. Install luggage floor cross brace.
  16. Install RF-LGN-303-C-C-O as seen on Peter's 5-17-2016 entry.
  17. Install RF-ANG-019 Luggage Floor Support (see paper note #4). Peter's 6-13-2016 entryCLECO'ED IN PLACE.
  18. Where do these parts go?:
    1. RF-BKT-023-L/R
    2. CF-BKT-027-L/R 
  19. Install joystick control column.  See Peter's 5-13-2016 entry.
  20. Install elevator control stop on the torque tube (see paper note #2).
  21. #8 locking rings for torque tubes?  See Peter's 5-4-2016 entry
  22. See Gordon's 4/3/2016 entry concerning flap torque tube installation.
  23. Test fit all control torque tubes
  24. See Peter's 5-18-2016 entry on the control bush mounting bracket install.
  25. Complete any work on Pg. E3 of manual (main spar & undercarriage channel).
  26. Pg. E6 Forward Floor Sub-structure.
  27. Work on parachute box and rear bulkhead.
  28. Flap actuator bolted before riveting - investigate further.
  29. Rear/Center Fuselage Join heads up: Need room to rivet 2nd longeron from the top on the center fuselage, so next one below shouldn't be installed until that is done.  See paper notes: #1, #5 and #8.
  30. Luggage support/strengthening channel - See Peter's 7-20- 2016 entry and 7-15-2016 entry.
  31. Sound proofing installation. 
  32. Test fitting of forward fuselage side skins.
  33. Make sure you understand where various spacers go in the center fuselage.
  34. To be continued... ;-)

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