Final Prep (Debur, Dimple, and Countersink)
07/25/2021 – 0.3 hours
The rudder cable guides are nylon parts that have to be countersunk to fit the dimples on the inside of the fuselage skin. I used a hole deburring bit in an electric screwdriver to countersink the parts. That method allowed me to control how quickly the countersink developed so I could do a little, test fit the part, then do a little more as needed. I also needed to use a #30 reamer to enlarge the holes enough for the rivets.
[electric Screwdriver with Hole Deburring Bit, Electric Drill with #30 Reamer Bit]
Assemble
07/25/2021 – 1.6 hours
Assembly started by installing the snap bushings as shown in the plans. The SB437-4 snap bushings that go in the aft sides of the bellcrank ribs were too small for the telephone cable to fit through, so I slit the bushings on one side to open them up wider for the cable to fit. With the bushings in place, I routed the rudder cable through the slot at the aft end of the fuselage forward through the bushings. The rudder cables cross left over right at the F-01408 bulkhead, and get coiled just aft of the F-01406B bulkhead and stored between the bellcrank ribs.
The final step in the assembly was to use AACQ4-4 blind rivets and NAS1149FN416P washers to install the nylon cable guides to the inside of the aft fuselage skin. A couple of the rivet stems didn't break off cleanly, and jammed up my rivet puller. I had to take the rivet puller apart to clear the bad stems, taking care not to lose the spring.
[Razor Blade, Rivet Puller]