|
On my quickbuild kit, the brackets attached to the
spar where the fuel and brake tubes passed through already had the
grommets installed. However, once the gear attach brackets were in
place, I noticed that the bracket interfered with the bottom grommet hole
for the fuel line. |
 |
|
To fix this problem, I riveted a piece of aluminum to
the brackets, and drilled two new holes for the grommets. |
 |
I
was then ready to try and install the tube from the fuel selector valve
out through the side skins. This looked to be the most difficult
routing by far, because of the bends near the valve, the grommets it must
pass through, and then the tight bends through the gear leg attach
brackets. I cut a 33" piece of tubing, flared one end, and made
the appropriate bends on that end. I then pushed the tubing down from the
valve side, through the center bracket that was temporarily detached from
the spar, towards the gear attach bracket. I used the spring bender
on the tube as it went through the gear attach and out the side, bending
and pushing the tube further inch by difficult inch. It actually
went into place in less time than it took to bend the long fuel vent
tubes! |
 |
Instead
of two 90 degree bends as the fuel line goes through the gear attach
bracket, I used more of a sweeping bend towards the fuselage side grommet
on the right side. (This photo was taken after I had installed the
brake tubing that exits on the bottom) Postscript:
After wing installation, I found that the sweeping bend is not good... 2
bends as close to 90 degrees is best because it gives an opportunity for
the fuel exit tube to move in and out a bit to ease the connection to the
tank. This left side tube pictured was VERY difficult to attach to
the tank. |
 |
The
long tubes from the brake bracket on the firewall to the gear exit
locations was next. This required a long (66") piece of tubing
to be snaked through the gear attach bracket, along the spar, and then
along the floor, where it eventually makes a couple of bends to the
fittings attached to the firewall. Again, I flared one end, and
started pushing the tube bit by bit around corners and through
grommets. You can't even try to keep the tubing straight, it will be
wavy when you're through, but it will be pretty well hidden anyway. |
It starts up from the floor
fitting, through the gear bracket, two grommets, and then down through the
floor tunnel.
|
The
brake tubing finally reaches the front firewall where it attaches to
fittings on a bracket where the flexible brake hoses will join
later. The tubing looks a little wavy because IT IS after all of
that routing, but I was just glad to get it finished. By
they way, I'm planning on painting the interior, tubing and all, after
everything possible has been installed. |
 |
Since
a piece that joins the two control sticks was missing from my kit, I had
put this step off until now. I located all of the nuts, bolts, and
washers, reamed out the brass bushings with a 1/4" drill, and did
some fitting to get everything to go together. This is the final
result. I also fabricated the two elevator pushrods. |
 |
I
started working on the roll bar, and fabricated the numerous angles
necessary to attach it to the fuselage. On my quickbuild fuselage,
where the roll bar attaches to the fuselage, it appears as though they
forgot to trim a piece as required for the tip-up model only. They
did cut the small hole for the latches, however, so I'm not sure why they missed
this step. I'll check with Van's and see if I just need to trim the
shaded area to fix it. |
 |
Van's
said that this is how the quickbuilds are shipped, so they can be either a
tip-up or slider. After this is fixed, it
is time to rivet this together... which is a very difficult job because of
the way everything is already positioned. I'll cut the
hole for the canopy latches here later. |
 |
I
started to construct the rollbar, which is composed of 4 c-channels, a
couple of plates to hold them together, and 2 long strips of thick
aluminum to hold it all together. This was a lot of work, as none of
these parts are pre-punched and they don't necessarily want to fit
together very well. This is the beginning as I'm
drilling through the bottom channel into the joining piece |
 |
Solid,
countersunk rivets are used on one half of the rollbar, and then the top
half is joined, drilled, and fastened with countersunk pulled
rivets. During drilling of the top section, I used pieces of plywood
with a 1.5" cutout to hold the pieces at a uniform distance from each
other. |
 |
After
a LOT of hours, the rollbar is ready to be attached using angles on the
left and right side. Some of the rollbar bottom edge must be cut
away to nestle down on the angles. The angle must also be belt
sanded (off the plane) so the exterior skins will lay flush. Holes
must be drilled, countersunk, and tapped for screws. |
 |
Here's
the reverse view. The holes through the angle aren't finished yet. |
 |
While
all that work at the attach angles is going on, the top bracket must
already be in place to hold the correct angle. |
 |
And
the rear attach point. |
 |
Finally,
when the skin is attached, it will look like this. The rear canopy
window will slip in between the skin and the roll bar. |
 |
I
started to piece together the forward top fuselage just to get an idea of
how everything goes together. I'm also starting to get
ready to prime and paint the interior... still a lot of little things to
finish up though before I'm ready for that. |
 |
|
 |