Category Archives: Fuselage

Fuel/Brake Lines

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Time: 12 Hours

After I ran my errands yesterday morning I grabbed the left forward skin that has the NACA vent in it to prime and paint it. If you remember I had already primed the skin then riveted and Pro-Sealed the bent into position. I left the seal cure for two weeks which was today.

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(null)I also scuffed up and cleaned the seat back roll bar for priming and painting.

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(null)My buddy Glen was able to come over late morning to give me a hand at running the brake/fuel lines and a lesson on flaring the tubes properly. First up we started with part of the brake line system. These parts will be from a fitting under the dash and thru the gear towers down to another fitting exiting the bottom of the aircraft at the gear legs. This is a long task of trial and fit with a million tweaks as you fit the parts. Here is the finished product.

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(null)Next we ran the fuel vent lines. These will run from the fuel tank (I already put the line inside the tanks when I built them) into the gear towers at the bottom and run up to the top of the tower and back down to finally exit out the bottom of the aircraft. This will allow for the fuel to drain out slightly as the fuel heats up during the day and not damage the tanks. For these lines I started with the right and made an exact copy in reverse for the left side. I strayed from the plans a little with the terminating end of these lines. Van’s has you run the vent line thru a snap bushing out the floor skin and eventually the gear cover plate for an inch or so with a 45° cut on the end. I was worried that I would end up bending or damaging this end durning the rest of the build as I moved the fuselage around. So I followed other builders and terminated the vent line to a AN832-4D bulkhead pass thru. This allows me to be finished in the gear tower area and add the last bit later down the road. Here you can see the straight fitting for the vent as well as the 90° that will continue the brake line down the gear legs to the brakes.

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(null)That took me the rest of Saturday and I waited to finish the work until today, Sunday. Next up was to work on the fuel lines that run from the firewall back to the fuel pump to the fuel filter then to the fuel selector valve. From the valve I needed to run a line to each tank. Each fuel tank line terminated at a 90° just outside the aircraft sides. Normally they would just go straight out but since I put inverted fuel pick-ups for aerobatics they need to run to the forward edge of the tanks. The run from the firewall to the pump was a tight space so I copied my buddy Glen’s solution of a 360° tube bend.

(null)The stretch that runs from the pump to the filter travels thru the left gear tower via two 5/8″ holes. This proves to be a problem as the nut and flare will but fit thru the holes so you need to do one end and place it into position and flare the other end in place which is the tough part. I started with the fuel filter end already flared and worked on the S turn bend it needed. The other end would be a straight shot to the pump. This was all easier said than done! You have to work these tubes in a 3D view and each bend affects the others. I strayed from the plans that have you use plastic snap bushings for these two holes and added rubber grommets based on my buddy’s recommendations.

(null)From there I worked on the filter to valve run, the valve to the left tank and right tank. Again this was a trial and error task as I worked all the angles and bends.

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(null)I received my cabin heat cable and red anodized pull knob from McFarlane Aviation and worked on its lay out so I could have access to it will the skins were off.

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(null)Where the cable ends on the firewall will eventually be a box valve that will be open or closed by pulling/pushing that cable. The valve will be connect via a tube to a shroud that will encompass part of the exhaust pipe which will transfer engine heat to the airflow. Again this layout was stolen from my buddy since its a proven design and I like how it looks. One last task to do today was to add a copper strip from the starter contactor to the ANL fuse, this will transfer energy produced by the alternator thru the ANL fuse, down the copper strip and the hot side of the starter contactor back to the battery. I made the required bends and drilled for the two bolt holes. A few passes on the scotch-brite wheel to clean up all the edges and I put it into position. I also had to trim part of the ANL cover to accommodate the copper strip.

(null)Another great weekend in the Hangar! A few more little items and I’m ready to start riveting the fuselage back together. I’m so thankful that I have access and the friendship of my buddy Glen Vokac! He is a proven builder and always willing to lend a hand or advice. I feel privileged to be in his company and able to learn from his award winning building skills (he is one of the most modest guys I know and will not acknowledge his incredible skills). On another fun note my girl just sold her home in Omaha after being on the market for only 5 days! What this really means is she will soon be living with me in the same ZIP code and I can not wait! Congrats T!!!

Ground Adjustable Rudder Pedals

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Time: 5 Hours

While I have to wait until Saturday to do the brake and fuel line plumbing when my buddy Glen can come over and give me some pointers I moved on to some other tasks that needed to be done. I grabbed the parts for the ground adjustable rudder pedals and started their work. Back when I was working on the firewall and forward floor I took care of a couple of rivet changed in anticipation of these parts. First up was to clean up the edges of the floor angles. I then laid out the rivet holes, 12 per side, and drilled them on the drill press.

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(null)At each outboard end of the rudder pedal assembly there is a triangular shaped bracket. You need to have a spacer/bushing made out of a plastic called UHMW. This will allow smooth movement of the rudder pedal frame. Van’s gives you some blank stock and you need to shape and drill them per the plans.

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(null)Next I match drilled the 1/8″ holes and enlarged them to 3/16″ for AN3 bolts.

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(null)With the holes drilled in the floor angles I placed them into position and carefully lined them up per the measurements on the plans. I matched drilled them to the forward floor and clecko’d them into place. With the fuselage slid forward so the front end was accessible from the bottom I drilled up thru the lower firewall angle and the forward gear tower angle. This gave me matched holes for the two ends as they hit this angles.

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(null)I reamed all the holes in the parts, cleaning out the powder coating. I also scuffed up all surfaces with scotch-brite pads so that I could prime and paint. While I started priming the UPS driver came and delivered my fuel pump/filter from Van’s.

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(null)I located all the parts for the fuel line runs including the fuel vents. So I should be all ready to run the lines this Saturday. For now I just finished up the painting of the rudder pedal parts and will let them cure for a few days before assembling them.

(null)I think I will keep on this painting roll tomorrow and work on the two roll bars and get them done as well!

Fuel Pump Bracket & Power Pass Thru

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Time: 2 Hours

Due to the bad Midwest weather events my UPS shipments have been delayed a day or two so I’m still in a holding pattern for riveting the fuselage skins. I need to run the fuel lines and brake lines before I do anymore riveting as I have great access now. I did however get a couple of things done today. I blind riveted the fuel pump/filter holding brackets to the forward floor after priming and painting them that I did last Thursday. I used the rubber strip that Van’s supplied and trimmed as instructed to give the edges some protection.

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(null)The second item that I took care of was to drill and install the Jegg’s power pass thru. This will allow my “hot” battery cable to pass thru the firewall to the starter contactor and give a nice clean look. Again drilling through the stainless steel firewall is a pain!

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(null)Not a lot of work but still progress. I should have the fuel items this week and Saturday my buddy Glen is coming over to help be make the lines so that I can prep for skin riveting.

More Fuselage Riveting

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Time: 8 Hours

I was back at the riveting progress on the fuselage parts. I needed to finish up the 13 rivets that are on the upper longeron and upper engine mounts. I thought about it last night and was planning on using the rivet gun and bucking bar but figured out that I might be able to use the squeezer and my no hole 4″ squeezer yoke. Turns out that worked like a charm! I did have to drill one rivet out as I let the squeezer move as it was at a difficult angle to hold and operate.

(null)From there I moved on to the first aft bulkhead, this one is where the passengers seat back will be, and started with just the rivets that attach it to the seat support ribs.

(null)I kept moving aft and riveted the rear baggage area support ribs and the angle that runs along the top of these ribs. The aft end of these ribs will hold a pitch bel rank as well as the Dynon pitch servo.

(null)There were 4 rivets that I couldn’t get the squeezer on since the end has a bracket built into it. I decided to try a back riveting technique and drilled a 3/16″ hole in the work bench for a squeezer head. I then laid the parts with the rivet in place and used the back rivet set in the gun. It worked like a charm and made quick work of those 8 rivets.

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(null)I added the 6 nutplates to the ends of the ribs, these would be for the aft location option for the battery. I won’t be using these for that purpose but may need them for something else.

(null)Next up was to rivet the nutplates for the aft end inspection access panels. These will allow for inspection of the elevator and rudder control connections.

(null)The plans then put your attention to the aft two bulkheads and the tail wheel attach weldament. First up was to rivet the rear horizontal stabilizer attach bars to the bulkhead. I was able to get all those with the pneumatic squeezer. I then enlarged the two bolt holes to 1/4″ for the AN4 bolts that tie the bulkhead, attach bars and tail spring mount together. Again I used my 1/4″ reamer to final size these holes.

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(null)The aft skins now get the middle longerons back riveted to them.

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(null)Those skins could now be placed into position on the fuselage.

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(null)I touched up all the primer on the two aft bulkheads since I made a few scratches during the drilling process.

(null)The aft two bulkheads get riveted to the aft bottom skin. I used a couple of spring clamps to hold the tabs tight to the skin and a couple of bar clamps to hold the pieces to my workbench so I could both hands riveting. I was able to get a couple with the pneumatic squeezer and the rest with the rivet gun.

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(null)I riveted the aft end of the rear baggage support ribs to the next bulkhead and clecko’d the bulkhead to the side skins.

(null)There is a small rib that goes between the aft and of the rear baggage support ribs, I riveted that at this time too. On top of the rear baggage support ribs at the aft end is where the bell crank will connect as well as the Dynon pitch servo brackets which I riveted at this time.

(null)I then spent an hour or so putting all the pieces on the fuselage, starting with the two aft bulkhead assembly, the two lower longerons and the two middle bulkheads. With all those parts in place I grabbed the bottom skin and spent a long time getting it in place, the fit at the forward end of the bottom skin where matches up with the rest of the fuselage was very tricky to get all the parts lined up. The job of getting the bottom skin and place is very hard for one person but a cinch strap at the aft end helps hold it up while you work at the forward getting the skin sandwiched between the other skins. Once I was happy with the fit I put a clecko in every other hole on the entire after end of the fuselage in preparation for riveting.

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(null)The skins are now ready to be riveted! What a big day in the Hangar and a lot accomplished. Before I start riveting the skins I need to work on the fuel pump, filter and fuel lines to the wings and fuel valve. I want to do this now as I have good access to the floor and gear tower area to work on the fuel lines. I will also work on part of the brake line runs as well for the same reason. So I ordered my electric fuel pump and fuel filter today from Van’s aircraft. Once I get those lines installed as well as the pump and filter I will have my buddy Glen come over and help flip the fuselage upside down on a couple sawhorses for riveting. Having the fuselage inverted allows for me to sit on a stool inside and do the bucking while Glenn will rivet on the outside. It was midnight so I decided to call it a day which was good because my back was getting a little sore!

Final Fuselage Assembly Begins

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Time: 6 Hours

Today was the start of the rebuilding process. All the priming and paint has been finished and parts are ready to be riveted together. So to start I grabbed the lower forward longerons and slid them into place. They each get 4 AN3 bolts that tie them to the lower engine mounts and angles. They also get 2 screws that tie them to the lower gear tower weldaments.

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(null)With those in place and torqued to the right settings I put a little or he torque seal on the nut side. This will be a visual cue to see if the nut has loosened. After doing that I realized the the 4 bolts at the forward end will be permanently covered with the bottom skin and I won’t have access to check the torque seal. I clecko’d every other rivet hole of the lower longeron and started the riveting. I used some painters tape to minimize any scuff of the new paint as well.

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(null)Next up was the mid cabin braces that get riveted and bolted to the center section. There is also a nutplate that gets riveted here as well. The bolts are AN4’s which required me to open the holes to 1/4″. I started with a smaller drill bit and final sized with my 1/4″ reamer.

(null)The plans next have to work with the forward/aft outboard seat ribs. These ribs get riveted to the aft spar attach point which has a spacer between the two parts to make room for the aft spar of the wings. I first clecko’d the ribs to this bulkhead and place the bolt into positing. I then was able to rivet all the pieces together.

(null)With that task done I moved on to the forward outboard seat ribs to the floor. I slid the fuselage so that the edge hung over and gave me access to the floor rivet holes. Since I was going to be riveting from the bottom up I used scotch tape to hold the rivets in place.

(null)That went fairly fast and I didn’t have to drill out any rivets, surprisingly since I haven’t riveted for a while. I then grabbed all the parts for the mid side skins and all the armrest/bulkheads. I first riveted the lower gussets to the forward bulkhead bottoms.

(null)Then the aftarm rest and mid armrest get riveted to the forward and aft bulkheads.

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(null)Normally the forward arm rests would get riveted as well, but since I’m doing a custom armrests I don’t do them now. With both the left and right done I grab the skins and clecko’d the armrest structures to them. I used my back rivets to rivet the armrest structures to the skin except for the aft armrest which will get done later.

(null)I was real happy with how they turned out and only a couple minor scratches in the paint. Next up was to grab the outboard Cito rib angles, the center section exterior plate in the mid side skins and clecko them into position. With all those parts in position I grabbed a long upper longerons and slip them into position supporting the aft end with my stand.

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(null)I grabbed my pneumatic squeezer and riveted the five rivets at the top of the gear tower structure.

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(null)I was able to get a couple of the rivets the tie the upper longeron to the forward upper engine mount with my squeezer. The rest of the rivets in that section will need to be done with my rivet gun and bucking bar. Since it was getting late and I didn’t want to make a bunch of noise for my neighbors I decide to call it a night at that spot. Another good day in the Hangar and it’s fun to see the parts going back together for good!