July 28 Update - FWD Mid Fuse Side Structure - Starting Section 29

Over the past 2-3 days, joined the forward and aft fuselage sections together.  This is tricky - ended up separating two tables and carefully sliding the two together, overlapping as called out in the plans.  Clecoed per instructions in the plans.

Prepped (deburred, scuffed, primed) the upper & lower drag fittings, and the gear braces, installed these into the structure - amazing how this stiffens things up.

Clecoed side plate and match-drilled, then removed, deburred and clecoed back into place.

Attached the support leg, ready to turn fuselage up to start riveting the two sections into place - but waiting for some help from S-I-L to move this.  Fuse now officially too heavy to move around solo.

While waiting I trimmed (using ScotchBrite wheel) the flange bearings and installed these into the control column assembly.

Very productive and satisfying few days - next step will be riveting bottom skins together, then replacing lower gear braces and torquing all these parts.

July 20 Update - FWD Fuse Lower Structure COMPLETE (Section 28)

Lots of travel since my last update.  Since that update I've completed the battery box, vent assemblies, and riveted these to the firewall.  I'm sealing everything with 3M fire barrier sealant, but haven't decided yet if I will insulate the firewall - if so I'll do that before installing the engine mount.

Heard from Van's today that I may be getting QB wings early - if so that's good news but no where near ready for wings.

In preparation for Section 29, I built a stand for the fuse structure (for riveting) as described on 29-4.  I called Gus at Vans about this - I'm using a piece of aluminum bar to shim size up from a 2x4 which is glued and screwed to a 2 x 2 foot 3/4 inch plywood board.  Should be plenty strong.

July 2-4 Update: Forward Fuselage Lower Structure

Getting near the end of Section 28.  Bulkhead/ cover ribs mated to forward bottom skins, riveted in place.  Had to order a new battery box (bungled the countersinks) and also one small part on the vent door assembly.  The stainless rivets used on this part are tricky.  Some vent parts are not alclad and don't take paint very well.  Ended up just using primer on these parts.

I have been in discussion with TS Flightlines about using their brake hoses (and Beringer brake / wheel kits) - I had to decide whether to open up two of the existing holes in the bulkhead webs or drill a new hole (This hole needs to be 1/2" to accommodate fittings from TS Flightlines).  I discussed this with Vic Syracuse and did a facetime call with him - we agreed that new holes are better and he advised me on location.  After drilling these holes I carefully deburred and then primed the openings for protection.

Riveted cover panels and associated nutplates to the cover ribs.

Starting to think about Section 29.

June 30 - July 1 Update

Mating of firewall and tunnel structures together.

- riveted cover bases to tunnel sides
- apply sealant (3M Fire Sealant) to firewall, bottom skins, tunnel structure
- mate structures, cleco
- rivet tunnel to firewall sides
- rivet tunnel sides to bottom skins
- rivet tunnel angle
- rivet cowl attach plates with shims to firewall sides/bottom skins

June 14-16 Update

June 14:  Continue preparing parts for Section 28.  Small parts and forward bottom skins deburred, dimpled, scuffed, primed and painted.  Ready for assembly.

June 15: Stiffeners and antenna doublers riveted to forward bottom skins.

June 16:  Tunnel top/sides/muffler brackets assembled