2.5 hrs on misc. center fuselage.

All back in place and aileron autopilot pushrod reconnected.

I don't have the bushings that go here so I don't want to put this (right seat) back in because it will be difficult to torque this easily if it's installed.

Umm, this rivnut gets covered up by the seat rail, is that right?

The connecting plate behind the seat rail doesn't have a hole.  The manual doesn't say much about this connecting plate.  Like how is it connected to the other pieces? - holes are different sizes (which you can see in the pic on left side).

View forward.

Starting to put together the firewall connecting parts.

Close up.

View forward with the firewall test fitted.

2 hrs. working on the pushrod connections and seat rails.

My first attempt to put the rose joints into the joystick was to glue the washers to the joint...

But an attempt to put it in like this failed...  Just too difficult to get it in there.

So, I disconnected the pushrods from the pushrods (elevator and aileron autopilot) and took out the joystick assembly.

Way easier to put the bolts and joints in when it's out.  But, I don't think that upper bushing is supposed to be there, so I'll have to take that out (though I'll check first to see if I'm right).

EDIT: At least according to Peter's log, there are bushings on both).  If that's the case, then I don't have enough bushings (I think they come with the finishing kit which I haven't gotten yet.  I got 2 separately).

Finishing up the countersinking of the seat rails.  Looking like a machine shop.

Taking a day off to do other things (Like they're important?! ;-)).

Meanwhile I ordered another pair of forceps so I can more easily install the bolts and pushrod rose joints.  Good thing I play a surgeon on TV. ;-)

2 hrs. mostly contemplating my navel in regards to how to install the cross-fuselage aileron pushrod...

Since the joystick is already installed it is very difficult to install the joints for the aileron pushrods.  I wish the manual mentioned this...  Way better to install all the aileron-related joints before installing the joystick into the main spar.

The manual calls for AN4-16A bolts... No way to install that if the joystick is already mounted (unless you install it backwards).

Fortunately an AN4-15A is long enough and can be put in the proper way.

I removed the joint from the pushrod to make it easier to install but this will still be difficult because you can't get your hands in there...  I think I'll have to temporarily glue the washers together (a combo of thick and thin to fit) with the joint to be able to install it.  If that proves impossible I'll have to disassemble the joystick assembly all together - not something I'd like to do because it would involve unwinding a lot of stuff already done. :-(

Wondering where the static ports should go?  The factory has provided that info (I'll post this pic to the factory photos (rear fuselage) page too).

3 hrs. on pushrods and starting to countersink the seat rails.

The manual calls for AN4-12A bolts and thick washers, but I found the -11A and thin washers were a better fit.  Some of the connections I used thick washers or a combo of thick and thin.  Was just looking for snug, but not too tight (I couldn't even get the washers in if it was too tight).  I used tweezers to hold the two washers in place.

The center pushrod was a bit tricky to get to, but this worked.

Getting ready to countersink the seat rails.

Nice!  I continually tested the fit of the rivets to make sure it was just deep enough.

Perfect.

Moved the rear fuselage back and split the workbenches in prep to join the two sections.  Exciting!

Careful when countersinking the plastic - it just takes a few seconds.

One rail all done!

Well, no time to work on it today...  And won't be able to for a few more days...

But, I did finally get my countersink bits!

Until I return you can watch this cool video by Casey Neistat (I follow him on YouTube, he's cool) showing him flying with a drone big enough to lift him!  Maybe I should build that instead! ;-)

Here's a follow-up video he posted yesterday explaining more about the drone.

1 hr. on pushrods.

Elevator autopilot to rear torque tube done.  And torqued properly.

The manual says these are AN4-12A bolts (for most of the pushrod connections), but they seem a bit long.  Notice how the shank sticks out.  I know I could put more than 1 washer there to compensate, but I've got some -11A's coming soon, so I'll try those.

Sometimes I feel like a surgeon...  Scalpel....  ;-)

Quick test fit of RF-LGN-303.  I think I have the right orientation?  The 3 holes from the back seat support don't line up with anything...  Hmmm...

2 hrs. finishing up the new closing brackets and testing the friction in the linkages.

Carefully and incrementally grinding out the opening.  Not too tight and not loose at all...  A delicate balance.

Multiple checks against the bushing to see where it needed some grinding.  I think this was the final check.

I had noticed a bit more pitch friction than I liked the other day, so I started to isolate the various parts of the control chain.  The culprit: The joystick pivot itself.  That's easy to fix.

And the new closing brackets are all done and the torque tubes don't move!  Glad to have that done with, so I can start moving forward again.

3 hrs on the closing brackets, etc.

Old bracket drilled out.  Other side also.

Overlaying the new bracket you can see it's mostly the top that needs to be ground down to get it to fit.

Trying to be very careful to not over-grind it this time.  I de-burred and primed the new brackets, so I'll complete this task tomorrow.

Put in M3 rivnuts in the center channel.

3 hrs. on pushrod related stuff.

Tricky working in these tight spaces.  I think the manual should be changed to have the builder install all the rose joints before these parts are assembled.  It would be way easier to install.

Working it through.  Like a surgeon...

My trick to installing the washers (2 together here).

I took out the elevator pushrod from the joystick so I had a bit more room to work.

Aileron autopilot pushrod installed and I slid in the cross-fuselage pushrod.  This isn't in the fuselage manual at this point - Is there any reason I shouldn't connect this now?  Seems way easier to do now than much later.

Time to rivet down the torque tube sleeves.  Using a clamp to hold it in place while I drill.  I measured so that the torque tube is centered.

Pilot hole drilled.

I put one rivet in each sleeve first, then it was easy to do all the rest.  All done!
Notice I put duct tape facing up under each place I did the drilling.  Makes cleaning up way easier.

Well.... I've been wanting to work on the plane, but it's been too darn cold...  Woke up yesterday and it was 3 degrees out (-16 C).  The highest I could get it in the garage with 2 portable heaters going was about 40 degrees (~4.4 C).  Too cold for me to work in there.  If I can get it to mid 50's I can work, but less than that, forget it.

Tomorrow should be much warmer so I'll definitely work on the plane and try to get a bunch done.

Had a unexpected and nice visit from Jordan of TAF USA yesterday.  He checked out my build and took a bunch of pictures and a video.  Nice to see him!

Until my next post, here's a picture of me doing a happy dance while on vacation in St. Croix last week.  I highly recommend that island! :-)

Back from vacation and ready to get back into it!  Updated my Task List.

Question: Is anybody putting Loctite on the pushrod bolts?  I confirmed that the factory does not, but I was curious if anybody is doing that.  With the self-locking nuts, it doesn't seem necessary, but they're pretty critical connections.

With all the screws that have to be installed (or removed) for the various removable panels I decided I wanted this operation to be fast, so I bought a powered screwdriver and set of bits that has one bit that fits the head of the screws.  Pretty happy with the purchase.

A wise man contacted me with some advice on the torque tube looseness issue, so I've ordered new closing brackets for those end ribs.  My solution is a bit a of hack, so I'll likely go with the better solution.

So until I get those parts I'll move on to other things.  I'll be away from the build for the next week, so nothing happening until I return.  See you then!

Until then, here's a picture of Crosby as he greets me in the morning. ;-)

1 hr. fabricating brackets to secure the elevator torque tube.

I decided to put brackets in front and behind the tube to be able to position in where it naturally wants to sit to minimize friction.  I need to better analyze the overall friction in the whole chain of pushrods before committing to riveting these in place.

Blanks cut out (don't have the thickness in front of me, but it's thicker than typical material).

Drilled and reamed to size (4mm).

Bent and ready for installation (which I'm holding off on until I'm sure about the system friction distribution).