Panel base

Worked some more on the upper fwd fuselage. Canopy ribs and panel base were prepared and ready to install once fuel line testing is completed.  I spent some time covering the rivets on the firewall with fuel sealant as per plans.  The clip was then prepared as per plans.



Time: 2 hrs.

Canopy Ribs

Panel base

Rivets covered with fuel sealant

Clip

Upper firewall / misc.

Worked on several different areas today.  Picked up some tubing to attached the fuel lines for pressure testing.  I prepared the side stiffeners and clecoed them in place.  The map box interior was then painted with Rustoleum Black hammered.

Then it was fuel sealant time. I placed some fuel sealant in the opening of the step. With the help of N and T we sealed and riveted the upper firewall.  Fuel sealant was then placed around the perimeter of the firewall as per plans.

Time: 3.25 hrs.

Hose line connecting fuel lines for pressure test

Side stiffeners

Spray paint map box interior

Upper Firewall

Sealed steps

Cowl hing

Sealed upper firewall

Sealed perimeter upper firewall

Sealed perimeter lower firewall

Sealed perimeter lower firewall

Canopy ribs / map box

Continued work on the canopy ribs.  Attached the remaining nutplates to the canopy ribs.  Nutplates were then attached to the panel base.  For now I am planning on installing the Garmin G3X so some of the nutplates weren't installed as per plans. I then riveted the engine mount brackets to the panel base.

Skipping ahead a few pages, I started working on the map box.  The parts were clecoed together for match drilling.  The panel was then countersunk for screws. I then primed the inside of the mapbox with rustoleum black primer.  I am planning on using hammered black inside the mapbox and possibly for the whole panel.

Time: 2.5 hrs

Nutplates on canopy ribs

Nutplates on panel base

Engine mount brackets

Map box clecoed for match drilling

Right panel counter sunk

Map box primed with black 

Stiffeners / canopy rib

Started today by separating and preparing the side skin stiffeners, canopy doublers, and attach angles.The doublers and attach angles were then riveted to the canopy ribs.

I am trying to wait as long as I can before putting on the upper firewall and panel base until I can pressure test the fuel lines, but the fittings won't be here until Monday.  Rather than waste time, I will proceed with some of the other steps that can be done now and won't be in the way much when I pressure test the lines.  If there is a leak somewhere I want to have easy access under the panel.

Time: 2 hrs.

Stiffeners

Canopy Doublers

Attach angle

Canopy rib with doubler and attach angle

Canopy rib doubler attached

Pressure gauge / complete page 29A-02

Received the parts to put together the pressure gauge to test the fuel lines.  In opening the parts I noticed that I was sent an AN815-6D (Flare on both ends) instead of a AN816-6D (Flare on one end and pipe thread on the other).  The invoice shows AN816-6D so the part mush have been pulled from the wrong bin. So I will have to wait a few more days until I can pressure test the fuel lines.

I then proceeded working on the FWD upper fuselage.  I placed the nutplates and doubler to the upper firewall.  The cowl hinges were then match drilled and riveted to the doubler.  The left hinge had to be moved slightly from plans in order for all the holes to catch the hinge. This is not a new issue as I have read in other's blogs that the hinge can be moved slightly to catch all the holes in the doubler.  Nutplates were attached to the upper firewall and antennae shelf.  The shelf was then riveted to the upper firewall.  The next step involves fuel sealant for attaching the upper firewall to the fuselage, but I want to wait to do that until I pressure test the fuel lines.  I may have to on other areas of the section 29A until then.

Time: 3 hrs.

Pressure gauge for fuel line testing

AN815 sent instead of AN816 (Notice 2 flare ends, instead of 1 pipi thread end)

Cowl hinge

Nutplates and doubler

Nutplates on firewall upper

Nutplate to antennae shelf 

Antennae shelf riveted to upper firewall

Test return line / start section 29A

I torqued the connections for the fuel return line and vacuum test the line.  Pressure seemed to hold.  I will pressure test the system once I received the parts to put together a pressure gauge.

Since fuel lines are pretty much complete I went ahead and started on the FWD upper fuselage.  I started out by cutting hinges as per plans.A rivet and doubler were then attached to the upper firewall.

Time: 0.75 hrs

Vacuum test return line.

Cowl hinges

Upper fuselage doubler

Connect FWD return line.

Had a few minutes to connect the forward fuel return line with the clamp and connect to the fitting.

Time: 0.25 hrs

Return fuel line

My crowfoot wrenches came in the mail today so I went ahead and torqued the fuel line flare fittings to 100 in lbs. (Ended up reading 89 in lbs on wrench with calculation for crowfoot.  I vacuum tested the main fuel line at 20 in hg for a couple hours and it held vacuum. I will pressure test it once I complete the return fuel line and have received the parts for the pressure gauge.

I then started fabricating the return line. The bulkhead fitting was placed.  A little awkward to get in place and tightened but doable.  The fuel line return aft was fabricated and placed.  The nut was torqued to 55 in lbs (50 on the wrench).  I then placed the hose pieces and clamps to hold the fuel lines together.  I then started fabrication of the return fuel line fwd.  I was able to get it through the fuselage and nuts were placed on both ends.  The aft end was tightened on the bulkhead fitting.  I did not have time today to complete the fwd portion and attach it so that will have to wait for another day.

Time: 2.5

Return line bulkhead fitting

Return line bulkhead fitting

Fuel lines clamped

Fuel lines clamped

Fuel line continued

Continued work on the fuel line today. The FT-60 and the gascolator were installed.  The gascolator I had installed the aft fitting prematurely as it needed to go through the firewall.  I had to adjust the hole through the firewall slightly to allow it to go through properly.  The main fuel lines were fabricated, installed and hand tightened. I am waiting on crowfoot wrenches to I can torque the flare fittings. Overall tube fabrication is going fairly smoothly.

Time: 2 hrs

Flare tool

Fuel line attached to pump

Fuel line attached to valve

Fuel line through bulkhead

Fuel line through bulkhead

Fittings placed on FT-60 fuel flow meter

FT-60 in place

Fittings added to gascolator (aft fitting shouldn't have been placed at this point)

Screw safety wired

Gascolator in placed

Aft fitting of gascolator

Fuel line from meter to gascolator

Fuel line from valve to meter.