Repaint Roll Bar

I spent some time today repainting the roll bar. The reason for this is that the paint on the roll bar seemed to be easily removed by masking tape. So I started by removing the paint, sanding the roll bar, and then applying a rustoleum primer and then the rustoleum paint. This took some short work sessions over several hours. My hope is that the different primer will adhere the paint better.  The metal of the roll bar is a different metal than the rest of the plane. Looking back I probably should have had the roll bar powder coated.

Time: 1.25 hrs.

Rollbar primed

Roll bar baggage bulkhead riveted

Spent an hour this morning riveting the roll bar, and baggage bulkhead.  I also riveted the map box.  At this point I am pretty much at a stand still until I pick up the finish kit in December.  I guess I should have ordered it a little earlier, but I didn't think I would make it this far by this point.  I am waiting on installing the tail section until later in the build.

Time: 1 hr.

Roll bar riveted to base

Roll bar brace

Roll bar brace

Baggage bulkead

Map box

River gun repair / rudder pedals

So the parts for the rivet gun arrived today.  I spent 45 minutes replacing that parts, gun didn't work.  I then thought that I needed to recharge the hydraulics, so I went through the steps and it still didn't work.  I have come to the conclusion that I don't know how to repair a rivet gun.  I am sure there is something simple I have to do, but rather then spend more time repairing a gun when I could be building I decided I would send it in for repairs.  It will take 3-4 weeks to get it back, but in the meantime there are other sections I can be working on.  I would rather hold off riveting the sides until I have the gun as it would be a lot faster then by hand.

I worked on the rudder pedals and brakes some more. The other pedals were drilled and the pedal blocks and brake cylinders installed.

I clecoed the rollbar and braces to the fuselage. I then enlarged the hole in the roll bar attach plates for the canopy light wiring.


Time:  3 hrs

Match drilling pedals

Grease used on brake pedals

Pedal blocks

Roll bar and brace riveted

Hole enlarged for Cockpit light wiring

Roll bar paint / start brakes

I painted the second side of the roll bar and braces.  While I am waiting on them to dry real well I started on section 27.  Started off by cutting the rudder pedal blocks.  The then clamped the rudder pedals to the table and placed the brake torque tubes as per plans.  The brake cylinders were installed and the pedals were drilled.  I was able complete on side today.

Time:  1 hr.

Rudder pedal blocks

Rudder pedals clamped

Brake torque tube placed

Brake cylinders temporarily installed

Brake pedals aligned vertically

Brake pedals drilled.

Baggage bulkhead / roll bar work

Work continues with section 24. I clecoed the baggage bulkhead to the fuselage. I then bolted the roll bar brace to the fuselage and clecoed the angle brace to the baggage bulkhead.  I then primed and painted the roll bar and braces as I thought it would be easier to paint them while they were off and then just touch up as needed once they are on.  I am using NAPA 7220 primer and Rustoleum Dark machine grey for the paint.

Time: 2 hrs.

Baggage Bulkhead

Roll bar brace

Attached Angle clecoed

Roll bar and braces primed and painted

Vents, roll bar brackets

I had a little help from B today in installing the air vents.  It took a little assembly, unassembly to modify the slot enough so that the door would open and shut smoothly.  I then worked on the lower cowl hinge and riveted it to the fuselage. I received the #4-40 tap in the mail so I tapped the switch mount plate on the roll bar.  The roll bar brackets were then bolted to the fuselage and the roll bar was placed over the brackets. It is a tight fit.  The support frames were clecoed and the the roll bar brackets were match drilled from the roll bar.  I disassembled the roll bar brackets and primed them as per plans.

I prepared the parts for the baggage bulkhead and clecoed that nutplates and parts together. They will have to wait until next time to rivet them.

Time: 3.5

Air vent

Air Vent

Lower Cowl hing

Tap Switch Mount plate

Match drill roll bar

Match drill roll bar

Prime roll bar brackets

Baggage bulkhead and nutplates clecoed together

Roll bar / misc

Several miscellaneous items completed today. I first started with assembly of the rollbar with attaching the latch plate.  It calls for match drilling #43 the hole in the latch plate. I did not have a #43 bit so I used a 5/64th bit that is a little smaller. The holes in the roll bar were then enlarged to #30.  The plans call for using a #4-40 tap to tap the hole in the latch plate. I did not have one of those either, so that will have to wait until I order one. T and B helped me rivet the rollbar together.  I then prepared the rollbar braces and the baggage bulkhead.  Trying to get as much ready as I can so once the longerons are complete we can move forward.

I went back through the plans to do some "catchup" of items that I saw needed worked on. Once was the holes for the steps. They were a little tight so I opened them up some to allow the step to insert correctly. I will be waiting until later in the build to permanently install the step.

I had also noticed the hole in the light extensions to be too small for the wiring so I enlarged them some.

I then started on preparing the parts for the vents.  I will assemble them later after the longeron is complete and while working on the side skins.

Time: 3 hrs

Latch plate riveted to rollbar

Riveting roll bar

Completed rollbar

Support frames and bracket

Baggage bulkheads

Step hole tight

Step trial fit

Light opening enlarged

Vents prepared

Mid fuselage skeleton / Start Roll Bar

Continued working on the midfuse skeleton. The fuselage latch pin was riveted to the arm rest and then the arm rest was installed on the fuselage.  At this point I need to wait until tools arrive before I can make the longeron and proceed with the side skins.

I decided to start section 24 - Roll bar, so I prepared the roll bar parts and clecoed them together as per plans so the holes could be match drilled. The outside holes were then countersunk as per plans.

Time: 2 hrs

Fuselage pin latch

Mid fuse skeleton

Match drilling roll bar

Countersinking rollbar

Countersinking rollbar