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Paint Redo and Installed Baggage Floors – 8 hrs

October 16, 2011 Leave a comment

Sunday Oct 16, 2011

After seeing how nice the jetflex looks on the baggage floors and the F-750 side covers I really wished I had painted the other baggage parts using the Jetflex. Repainting those parts on the airplane is possible but not as easy now that they are riveted together. But if I am going to do it now is the time because I am about to rivet the baggage floors down. I couldn’t help myself. I used sandpaper and scotch bright to remove the top layer of the rustoleum on the right side up to the longeron and on the left side up to the mid rib.  Then I brushed on a light coat of primer and let it dry.

While it dried I installed the nutplates on the bottom of the F-750 side baggage covers and cleaned up the shop. Then I sprayed the Jetflex on the side panels of the baggage area and the F-706 bulkhead.

After lunch I removed the masking. The paint looked pretty good so I cleaned up the area to get ready to install the baggage floors. Before closing that area up I remembered that I needed to put ProSeal around the conduit to prevent the brackets  from vibrating and cutting thorough conduit over time. I mixed up a batch and put it in a syringe which I used to inject a bit around each joint. It doesn’t take a lot – just enough to tack it in place.

Then I riveted the baggage floors down to the floor ribs. This uses LP4-3 pop rivets. The forward row will be riveted later with the seat pans. The two clecos at the top in this picture are actually going into #8 nutplates. The aft flange has nutplates installed as does the row along the center tunnel.

Here is another view that shows the inside of the skin which I painted over. Except for the fact that the rivet heads are painted over it’s hard to tell that it was not painted this way from the beginning.

I installed the plastic guides in the rear baggage bulkhead for the seat belt cables. These simply pop rivet together plus there are four nutplates where the upper panel screws to the lower panel.

I couldn’t resist putting the baggage bulkhead panels in (at least with clecos because I didn’t want to put all those #8 screws in now). In this picture you can see the darker Rustoleum on the right side of the image. I will repaint that later. It looks bigger in there already with the lighter paint.

For more fun I cut and finished the ends of the seat back stiffeners. There is a chamfer on one end and a round on the other.

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Seat Hinges, Part 2 & Painting – 8 hrs

October 15, 2011 Leave a comment

Saturday Oct 15, 2011

I did a lot of work today but the photos don’t really show it. I started by laying out the positions of the hinges on the seat pans. This is done from dimensions on the drawing. Then I match drilled the hinges to the seat pans using  #40 drill. Once all the hinges were drilled and cleco’d I opened all the holes to #30.

Next I decided to paint a batch of interior parts that have been ready for a while. Some needed priming so I spent time preping everything and cleaning parts with water and Simple Green to make sure there are no oils on the surfaces. This process can easily kill a day with cleaning, drying, setting up the spray gun, spraying and allowing drying time. After a while I had a good set of parts primed and ready for the Jetflex. I was a little anxious about how it would go. I read about some builders having difficulty getting good results at first. I may have gotten lucky because it went on very nicely in two light to medium coats. I really like how it looks. They way I had the gun set up it gave a fine slightly textured finish that just looks really professional. I really like this paint. I just wish I had bought it sooner – like when I started on the F705 bulkhead.

Deburring, Ordered Jetflex – 1.5 hrs

October 11, 2011 Leave a comment

Tuesday Oct, 11, 2011

OK, a confession. I have been grappling with the interior paint selection lately. The Rustoleum Hammered is inexpensive and easy to apply but the color is a bit dark and it is not very tough. So after looking into it a little more I decided to order some Sherwin Williams  Jetflex and give that a try. I looked at Sherwin Williams Genesis a while back but it was over $100 a quart and with the primer and reducer it would run close to $200 to even give it a try. Plus it is oil-based and clean up is a pain. The Jetflex is water reducible and clean-up is easy. Plus the paint is $42 per quart and $30 for the primer. So today I called Advanced Aircraft Coatings in Oklahoma City and ordered one quart of paint and one quart of Sprayfil primer. The color I chose is called Dark Gray 09014 seen on color card below (click to enlarge it). It’s not really dark – I’d call it a medium to light gray. And it is slightly warm in tone. The folks at AAC were easy to deal with on the phone and they kindly agreed to ship it out today.

Other than that I deburred the baggage bulkhead panels and tunnel cover tonight. No pictures of that.

Categories: Baggage Area, Fuselage

Fit the F-748 Baggage Tunnel Cover – 1 hr

October 10, 2011 Leave a comment

Monday Oct 10, 2011

After dinner tonight I decided to fit the F-748 tunnel cover. The first step is to cleco the baggage bulkhead panels into the fuselage. It’s kinda cool seeing this together.

When I put the tunnel cover in place the part seemed too long and it clearly did not want to fit with the flange up against the bulkhead. Other builders have described this problem and I had it big time. I think there must be a dimension that is off on this part because you have to force it in and it just does not sit flat. So I took matters into my own hands and I rebent the tunnel cover flange to reduce the distance to the first pair of holes by about .10 inch. When I fit it again it sat flat on the baggage cover but the holes in the flange were now 0.1 inch too high above the floor to mate with the holes in the bulkhead. So I slotted the holes in the tunnel cover just enough to get the holes lined up with the bulkhead holes. Now it sits flat and I can cleco it in place without forcing anything. That’s mo betta.

Here is a close up of the fit at the bulkhead. I can probably work those corners just a little more to make it sit flush all the way across.

Categories: Baggage Area, Fuselage

Right Brake Pedals Installed, Seat Belt Cable Guides – 4 hrs

October 9, 2011 Leave a comment

Sunday Oct 9, 2011

I’m afraid I didn’t do well with the picture taking thing today. I just didn’t think to take in-process shots. I started out working on the right brake pedals, riveting them together and chasing the axle holes with a #12 drill bit. I used the same process to align the right pedals that I used on the left pedals a while back. Then I put them back in the fuselage to see how they look. It does look more official to have dual brakes I guess.

The seat belt should harnesses are anchored to cables that run to the longerons in the aft fuselage. The cables pass through slots in the baggage bulkhead panel. The slots are lined with plastic blocks that prevent the cables from contacting the aluminum skin. The first step was to mark the location for the slots in the upper panel and cut them to the prescribed size. Then you have to notch two of the plastic blocks where the cables run. Then drill holes in the blocks where they will rivet to the panels. After that I made eight “washers” from .040 aluminum strip. Those will prevent the pop rivets from pulling through the plastic. Finally I aligned the parts and match drilled through the panels, including four nut plates that are used to screw the upper panel to the lower panel on each side of the cable slots. Here is one of the two slots with the upper panel on the left.

More Baggage Area Work and Right Brakes – 8 hrs

October 8, 2011 Leave a comment

Saturday Oct 8, 2011

This morning I picked up with the brake pedals again. I finished drilling and deburring all the parts and then I scuffed them up with scotch-brite.

Then I removed the pedals from the fuselage and set them up on the bench so I could match drill the cylinders to the control horns. In this picture you can see the piece of angle I used to hold all four pedals in the neutral position. I lined up all the pedals parallel and used the special screw I made with the sharp point to mark the horn for drilling.

With that done I went back to the baggage bulkhead. The upper panel is a little more work You have to lay out and cut the radius curves on the upper corners. I used a large protractor to draw the curve and then I cut the rough profile with snips. I finished them on the disk sander. Then I laid out all the holes on the upper panel and drilled them on the drill press.

Aligning the upper panel to the bulkhead was a little tricky. There are no holes that are pre-drilled in the bulkhead and there is no way to clamp the panel in place so I used masking tape to hold it while I drilled the first two holes. After that it was easy to drill the rest.

Next I removed the panels and installed twenty one nut plates in the bulkhead.

With that done I went back to the brake pedals and alodined the parts.

Baggage Bulkhead and Dual Brakes – 2 hrs

October 7, 2011 Leave a comment

Friday Oct 7, 2011

Tonight after work I jumped on the baggage bulkhead. The holes along the bottom are the only ones that help you align the bulkhead. The holes along the side are pre-drilled in the corrugated panel only. I drew a line down the center of the vertical rib first to make sure I could see it through the holes in the panel before drilling. After checking the alignment I match drilled the holes.

I was planning on installing brakes only on the pilot’s side but when Denise saw the that she said “Where are my brakes?” I tried to explain that it was $205 more for dual brakes and I was trying to build light but that logic did not fly with her. A few days later I ordered a set of brake pedals for the right seat. You have to pick your battles. The new dual brake kit arrived a couple of days ago so I started preparing the parts tonight. I cut the angles and started match drilling the parts to the pedals.