For this section I decided to purchase the one time use fuel tank sealant form Aircraft Spruce. I also made a mistake on the piano hinge and had to order a new one. Lastly, I could not find the antennae doublers anywhere, so I went ahead and replaced those as well from Van's. After a week of prep, we have begun.
After dimpling, countersinking and priming all the parts I began by riveting the doubled and stiffer a to the skins and then the muffler shroud covers for the tunnel. Put another dent in the bag if k1000-8D nut plates too. Still about half a million nut plates to go….
One thing I struggled with was countersinking the battery box. This requires you to use an extension for your counter sink bit, which means you cannot use the cage. Even though this worked fine, the bottom set of holes were further interfered with by the flange in the bottom fold. I ended up forcing it open just enough to get the counter sinks in. They were not perfect but they will work.
I also began to modify the pieces to fit the cowl flap for the IO-390-EXP119 engine I am planning for. This also required another piece from Van's (CT-00102) which is a double spherical grommet and cost me an additional $75. I thought this came with the kit, as they know I am planning on the EXP119 engine but it was not in my inventory so I put in the order from the web store.
As for the plans for the IO-390-EXP119 I took them down to Office Depot and had them print them out in color. That cost me $11 but was well worth it to have full size plans which I inserted into my current plan book.
**It's worth to not that this is the first time you actually have to use the KAI OP-62 instructions.
Tomorrow I will crack open the first tube of single use pro-seal.