Mar 03, 2023     25-6: Priming and assembling rear fuse bulkheads - (2.5 hours)       Category: 25: Mid Fuse

Got the remaining bulkhead parts prepped and primed. Split time with Sec 26 parts. After much consternation, I have settled on my rules for priming:
- everything center bulkhead and forward will be Ekopoxy
- anything potentially awkward to topcoat with interior paint will be Ekopoxy
- tunnel interior will be Ekopoxy
- all else is Ekoprime
Based on those rules I used Ecopoxy for the bulkhead uprights.

3/4: riveted the rear fuselage bulkhead assembly together with the squeezer. Then riveted the rear spars to the rear spar bulkhead. Tried using the DRDT2 to set the -4 rivets in the rear spar. Worked out but you really have to be careful to keep it level or the rivets would clear over. Got the hang of it and only drilled out a couple. Worked out, but in hindsight I could have just bucked them all.

  Feb 26, 2023     25-4 thru 6: Center bulkhead prime and assembly - (8.0 hours)       Category: 25: Mid Fuse

Prepped and primed all the center bulkhead parts. It was 100% humidity this morning but the forecast said it was going to burn off. It didn't. It was still very humid when I sprayed and the primer just would not dry. Finally did and started assembly in the afternoon once the sun had finally come out. Really just need to avoid priming on humid days.

Assembled the foreword and aft seat support brackets and installed the nut plates for the seat supports and uprights. Installed the screws for the bulkheads and seat supports but have started riveting yet. Most will need to be bucked.

2/27: worked on aft center bulkhead a little. Primed the countersunk holes in the spar and installed the nut plates. Then installed and torqued all the AN bolts through the spar. Inserted the -4 rivets in their holes just to make sure alignment was still good.

2/28: riveted all the -4s on the aft bulkhead and then fabricated the wear strip, carefully measured the centerlines, clamped and drilled it. Riveted in place and I think it good. Aft bulkhead done.

Riveted forward bulkhead. It's done too. Good night in the garage.

  Feb 20, 2023     25-2,3 & 5: Getting started on mid fuse bulkheads - (7.5 hours)       Category: 25: Mid Fuse

After confirming that SB-0007 was taken care of, I proceeded with the two center section bulkheads with the carry-through forward spar. These parts will get epoxy primed so I'd like them ready to go when I do the final prime of the wingtips.

Everything pretty straightforward. Lots of countersinking for nut plates. They also have you countersunk for a #8 screw head. I don't have a #8 counter sink but I remembered that a #30 works well if you use a nut plate to guide it. Temporarily installed nut plates and countersunk away; worked great. For the #10 screw countersunk I drilled a pilot hole in some scrap thick aluminum and that worked great. Overall getting much better at nut plates and countersinking in general. About time.

Some very light fabrication of stiffener angles on the forward spar. The aft spar required just a little bit more match drilling through the spar, but it was not a big deal. Got a lot of progress tonight. And Ben is excited to help me.

The two main spar bulkhead parts are ready for priming.

2/21: A little more work tonight on the rear spar bulkhead and the very rearmost fuselage bulkhead. Just deburring and a little bit of countersinking. More #8 countersinks with temporary nutplates.

2/25: was hoping for decent weather today to do some priming but didn't get it. 45 degrees and very humid. Not ideal for trying out my new spray gun. I did decide to add some additional holes in the spar bulkheads for more wiring runs. Added two holes on each side for a total of four. Disassembled the bulkheads and did a little more debuting in preparation of priming tomorrow.

  Feb 19, 2023     25-2: SB-007 - (1.5 hours)       Category: 25: Mid Fuse

Vans included the templates and drilling dies for completing SB-0007 which, from what I gather, converts the older style three leg gear to the two leg gear. I was expecting to need to drill some holes in the spar before proceeding with the mid-fuselage bulkheads.

Beside running a reamer through the holes on the landing gear mount to clean out the powder coating, I believe everything related to this SB is already taken care of. I test fit all of the bolts and everything seems good. Calling this ok and moving forward.

My carry-through spars were manufactured in January ‘23. I guess Van's is just including the SB templates in case an older spar ships.