The
quickbuild fuselage doesn't come with any "quickbuild"
instructions. You have to start at the beginning of the regular
instructions and cross off what has already been done. The first
task I found was to fit the firewall recess. |
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Then,
I started fabricating and installing the seat back adjustment
brackets. It would have been nice to do this before the piece was
installed in the fuselage, but it wasn't too bad. I
then worked on the flap bearing blocks. It took some sanding and
polishing of the ends of the flap bar before it would fit in the
bearings. Then it took some work to get everything in position
before marking and drilling the bearing blocks. I positioned and fit
the center block so that the height would be just right. Also, the
area without powdercoat for the center block was not as pictured on the
plans, but it looks like it will be OK. |
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I then started the brake pedal assembly. I
didn't originally order the co-pilot brake option, but I think that I
will. |
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I finished
fastening the brake pedals to the brake cylinders and to the rudder
pedals. Drilling the
rudder pedal bearings to the longerons was fairly difficult with the skins
already riveted in place. Why didn't they think of this earlier?
The large holes in the bearing blocks are drilled at a slight angle.. make
sure you get them right. |
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I
installed the elevator pushrod bellcrank. |
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The seat backs look simple, but they're actually a
lot of work. Here's the left seat, ready to start riveting.
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I decided to
install the landing gear mount next. First, you have to cut a hole
in the fuselage floor. Then, you start to enlarge it using anything
you can.. a drum sander came in handy here. Eventually, you can work
the gear mount in place. (don't forget to remove a bolt in the
center spar first, or it will never fit) |
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It finally fit into place. This is before the
bolt holes into the fuselage side have been drilled and the bolts have
been installed.
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After a while, you get in and out of the fuselage so
many times you just start to leave your tools in there. I also cut a
couple pieces of carpet to put inside because working in there is murder
on your knees, (update - I finally figured out later
it is much easier to work with the fuse on its side) |
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The fuel valve cover and center console covers were
next. I cut off the extra piece where the manual trim would normally
go since I'm installing electric trim. (hope I like it) |
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The front center console covers in place.
I haven't bent the vent openings yet. |
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I thought it would be fun to start the installation
of the top rear skin to see how it looks. |
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And the project I've been dreading, the side steps.
I bought a 1 1/2" hole saw and extension to cut the hole into the
fuselage side. Not too tough... the pilot holes are already there
for you so you can't miss. |
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Getting it to this point took a few hours. I slowly bent the
bottom aft corner to fit the curve in the fuselage, and cut away a
portion as shown on the plans. The easiest way to bend the steel was with a crescent wrench adjusted to the thickness of the
metal. I used a cutoff wheel in the die-grinder to cut the
corner off, and the the same wheel to smoothly bevel all of the edges
so it will blend into the fuselage side as well as possible.
Only one existing rivet needed to be drilled out (3rd from the bottom) |
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This is what the inside looks like. The quickbuild kit has the
baggage side covers already riveted in... and you have to remove them before installing the steps. It would be easier
if they would just leave them unattached and let the builder install them
later if they are installing steps or not. |
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I took the time to install 4 tie-down rings in the 4
corners of the baggage compartment floor. I cut and tapped aluminum
blocks, and was going to just install them in the floor, but I thought
they'd be stronger if attached to the baggage floor ribs. If I would
have been planning ahead, I would have made them longer and thinner, but
they won't be visible anyway. The eye bolts can be screwed in
through a hole in the carpet, and removed if necessary. |
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Since most of my photos are of close-ups, and people
always ask, "you're building an airplane in your garage?"
I thought I'd show you the current working conditions. I hope
this is as bad as it gets. I still have one wing on the wing stand
while I wait for someone to stop by and buck rivets. Then I can move
the wings out of the way and get the fuselage under the lights. |
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I also finally got smart and tipped the fuselage on
its side. I can't tell you how much easier it is to work with the
fuse this way sitting on a chair instead of climbing in and out. I'm also glad I
haven't installed the gear legs yet. I should have done this long
ago. |
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It is time to begin one of the least
popular tasks... the fuel and brake plumbing. Aluminum tubing is
used and there are some tools and skills required to install it.
You'll need a small tubing cutter to get into
small spaces, a tubing bender, a set of spring benders, and a flaring tool to make the flares on the ends of the tubes.
Home depot had everything at a great price except for the flaring tool
which is aircraft specific. |
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I started with the short fuel vent tubes from the
bulkhead fitting through the side skins. (bottom right) This is a good place to
start. Always start from the most difficult end and work your way
to the easy end. Flare the difficult end first, and then add the
necessary bends because you can't flare near a bend. I then tackled
the much more difficult fuel vent tube from the bulkhead fitting (bottom
right) to the external vent fitting (top right). This one took a
while.. the next one took half as much time. |
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