Feb 11, 2023     Make and fit panel attach brackets (continued) - (2.5 hours)       Category: Fuselage

Continuing to make small brackets for panel attach and upper forward fuselage ribs.

Cut and drilled F-721C attach angles (holes that fit to rib - holes for nut plates will be drilled after brackets and panels are clecoed together)

Fitted the F-103C (upper) L&R attach angles to instrument panel. Checking curve and flange angle (need consistent 90 degree bend) . Made several small adjustments and I think I have the placement pretty close. My concern is that I get the brackets two low on the panel and then the panel will not fit (too tight panel to fuselage skin.) Double checked and clamped in place but waiting to drill until I do a bit more research / checking (Vans Airforce?).

I'll look at it again tomorrow before drilling holes for screw that goes into nutplates.

  Jan 27, 2023     Installed nutplates on access holes and re attached pushrods - (4 hours)       Category: Wings

Installed nutplates on access holes .
Test fitted covers and final drilled holes to #8 & #6
Prepped and primed access covers
Re attached aileron pushrods.

  Jan 26, 2023     Finished riveting las wing skin - (4 hours)       Category: Wings

Finished last (anout 1/4 of total rivets) on wing skin.
Checked everything the next day and determined that 8 rivets were too flat - drilled out and re set new rivets. Used one Oops rivet - hole got too big.

  Jan 22, 2023     Start riveting last bottom skin right wing - (5 hours)       Category: Wings

Started riveting skin by doing the trailing edge rivets.
Pull skin up get my shoulder under it reach under with bucking bar in one hand, use other hand with gun to reach around and set rivet. Had to switch left and right hand rivet / buck.

About 1/2 done - ~150 rivets set (two drill outs.

  Jan 21, 2023     Checked fit and prepped last bottom wing skin - (6 hours)       Category: Wings

Over the last week I have hung skin on wing then noticed that the accesses holes were not final drilled for platenuts and that I had missed four holes being dimpled (one side of slot that fit around aileron bracket). I marked all rivet holes with needed rivet size and noted direction of rib flange - notes for my self to help me keep track as I'm riveting skin.

Removed skin, final drilled holes, dimpled (skin and nutplates) then read in instructions that it has you install nutplates after riveting the skin on. checked back on previous wing skin install and I did install them after the skin was riveted. Less scraping on hands and arms when reaching through to rivet! So holes are final sized and dimpled for nutplate rivets and dimpled for #8 screws.

Found access plates and marked - they will need to have screw holes final sized drilled and dimpled for 8 #8 screws and 4 #6 (platenuts on spar). Glad I didn't automatically drill the all to #8! When wing skin is riveted I will install

Re hung skin and clecoed every other hole on trailing edge, taped rivets in place in open holes and checked how I could reach under skin with bucking bar as I rivet down ribs from trailing edge to wing spar. Initial rivets are a big stretch but skin bends up enough to allow access.. As you move down the ribs I have to be able to reach through access plate holes and through rib lightening holes to reach last 1/4 of all the rivets. Glad I checked, had to remove aileron pushrods to be able to reach through rib holes.

Re installing pushrods will be "fun" because AP servo and its bracket take up about 1/2 the space in access hole. Going to need good fingers to reinstall long bolts, various washers and spacers by feel!

  Nov 25, 2022     Pulled wire and crimped dsub pins for wing servo - (3 hours)       Category: Fuselage

Decided to split up the wiring harness for the wing servo and pull wire in wing and leave pig tail to connect to harness in fuselage. This will allow me to rivet on the last wing skin.. Tried two routings and decided to use the one with the least inference.

Measured and cut wiring harness for elevator servo and tried to use it (8') for the wing portion of the roll servo harness. Too short.

Cut the roll servo harness (10') and pulled wire through an open holes with plastic bushings. Crimped pins to wing wire (female). Inserted pre crimped pins in servo side (male) into connector.

Will finish up adn check wires / connectors tomorrow.

  Nov 20, 2022     Clean up , prep, prime, paint rudder ears for brake pedal - (4 hours)       Category: Fuselage

When renaking the brake pedals to move hole connecting to brake master cylinder I noticed that the white powder coating on one of the rudder pedal "ears" had been damaged. Cleaned off two sides on one ear and one soide on the other. Sanded, scotch bright, and wire brush finally got a clean surface.

It looks like the powder coat had been damaged installing the brake pedals and some corrosion had started under the coating. Cleaned everything until remaining powder coat would not come off.

Three light coats of self etching primer then three light coats of white (Dupli-color).

Letting dry overnight before putting rudder / brake/ master cylinder assembly back together

  Nov 11, 2022     Finish mini din for ELT / GPS cable - (2 hours)       Category: Fuselage

Finished soldering and continuity check for ELT - GPS cable.
Ordered two extra mini din connectors - practice soldering very small pins.

Verified that connections were good then used silicon RTV to seal the wires inside the connector shell.

After RTV dries will add outer shell, connect to ELT and zip tie GPS, audio alert cable and antenna cable in place

  Sep 04, 2022     Drill & upsize to 3/8 holes for AOA tubing - (2 hours)       Category: Fuselage

Determined that I could use specific holes through the bottom of the seat ribs to rout the AOA tubing to the center channel. From there it will go back to the ADAHARS unit,
Had to use air angle drill to drill pilot hole and then upsize with a step drill. Needed to find a smaller shank drill bit, and Home Depot had one, that would fit into the small drill chuck used by the angle drill. Took longer to find a chuck than it did to drill holes!!
once holes were drilled I cleaned them up and sprayed primer in the cap and used qtip to prime the bare metal of the holes.

  Jul 12, 2022     Rudder stops complete and installed - (4 hours)       Category: Fuselage

Final versions of rudder stops riveted on. Almost riveted without countersinking first. Counter sunk, primed, let dry overnight.
Forward rivets are pulled rivets (new Milwaukee electric riveter works great!) rear rivets are set. Needed to make small doublers for hole that had tab from rear bulkhead- tab was not straight in line with rivet hole - hole ended right on edge of metal. Had to use 426 4-8 rivet to hold it all together. Worked well.
Re Installed Vert Stab, elevators, and rudder to check rudder swing. Right on 35degrees each side (46 1/8" rudder to elevator.
Avery temp pins are a BIG help!