Fuselage 3

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Back to Building Progress

Back to Fuselage 2

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.

 

 

On to Fuselage 4