I got all of the control horns and torque tubes drilled and primed. Next is to get the bushings blocks cut to size and then mounting everything. Then I have to get the flap motor mounted and this section will be done!
Category: Fuselage
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Rear Seat Backs Complete!
Didn’t take too much additional work at this point as I had everything ready. It just took some riveting which luckily they could all be squeezed instead of bucked. And the pins to mount them were easier to install than I thought as well. It all came out great! Next is the flap system!
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Rear Seat Backs Ready and Primed
I got the seatbacks drilled and ready to go. What took the majority of the time was trimming down the F-637C angle aluminum to nest inside the radius of the upper seat backs. It took alot of material removal with a file. I tried using the bench sander but I couldn’t get a consistent amount of removal like I could with the file. But they are all primed and ready to be assembled on Monday! Oh I tried that new spray can primer which was a pain to get it to go on evenly. It shot out in such a narrow fan pattern that it was impossible to get a good spray pattern. I ended up using 2.5 cans of the stuff just on these parts alone which is outrageously expensive compared to the other primer I usually use.
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Rear Seat Backs Started
I had a chance to talk with John at Van’s about the parts issue for the controls. He said he was going to take the pictures I have and verify the size of the parts they have in inventory. While I’m waiting on that I decided to move ahead and start on section 42 with the rear seat backs. Not a very long section to do but something else I need to complete. Plus I know my daughter has been looking for an opportunity to actually sit in the plane so this will appease her LOL
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Control Sticks Drilled & Column Issues
I got all of the control columns and sticks initially assembled and drilled but I found an issue with the control column. The control column opening where the sticks are supposed to go are WAY too small. It is almost 1/8″ off in size. I’m going to call Vans tomorrow to see if there’s an issue here as the control stick bushing was below their measurements in the document (between 2 1/4 and 2 5/16 but mine was 2 7/64) and then the control stick opening on the control column was only 2 1/64″. Just way too far off to bend it into shape so we’ll see what they say. I might have to cut down the control stick mounts some to make it fit or they might say it is okay to bend it further open to make it fit, but man that’s just a LOT and the bracket will not be anywhere close to square at that point.
Control stick and base match drilled 
Control column opening too small for control stick base 
Measuring the width of the brass bushing that is inserted into the control stick base 
Measuring the control stick base width without the bushing 
Visual representation of the control stick base being too wide for the control column
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Elevator Push Rods Installed
I got everything primed, riveted, and bolted in. Not alot to report here except that it is done LOL
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Aileron Push Rod Assemblies Complete
I got the three aileron pushrod assemblies assembled and I removed the rear bell crank housing so that I could insert the mid elevator pushrod into place, but I realized I should probably prime the outside of these tubes as well. Unfortunately I’m almost out of primer so I ordered some spray cans of primer from Aircraft Spruce instead of ordering the gallon buckets since I’m pretty much down to the wire here on things that need to be primed. I’ll use the little bit of regular primer I have left to finish these tomorrow, but the spray cans I can use to finish the rest of the parts, etc. Most of my time was spent getting the bell crank housing off as I had to remove the rear covers for the empennage cover first before I could get some of the bolts out that held it down. Either way, I plan to get the tubes primed tomorrow and then install them all.
Edit: After hockey tonight I decided I could do a little bit more so I prepped the elevator idler arm assembly parts for priming tomorrow as well.
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Mid Elevator Push Rods Cut & 3D Modeling
I started working on the mid elevator pushrods by getting them cut. I the went to Glen’s page and he didn’t have models already made for these two pushrods so I made my own. Luckily it didn’t take too long but the measurements I was getting from the print out were off by an about .015 of an inch. So I had to print them both twice but I finally got it done. I’ll get the drilling done sometime soon but tomorrow is going to be busy with cleaning the church, going to the movies with the family, and then stake conference for church.
Here are the models if you need to reference them:
– 1 1/8″ Pipe 6 Sided Drill Template
– 1 1/2″ Pipe 8 Sided Drill Template
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Fuel Lines Installed & Rubber Components
I got all of the fuel lines installed that I can until the fuel pump and filter and flow meter come in. I also got the rubber bushing installed for the exterior penetration point for the fuel lines and the mounting brackets for the pump and filter. Took quite a bit of time to get fasteners installed due to their location and angle but it is done.
