MM-DD-YYYY

Hours

Photos

Scope of work

10-25-2004

4.0

Laid out parts for the firewall

Laid out position lines on firewall

Drilled 2 inch hole in upper channel

Laid out rivet line on upper channel, positioned, drilled and clecoed upper channel to firewall

Laid out rivet pattern for firewall stiffeners, drilled and clecoed in place

Laid out channel doublers, drilled and clecoed to vertical lower channel

Drilled center hole to 5/8 inch for bungee pin

Cut lower section of vertical lower channel down to 33mm

Positioned, drilled and clecoed vertical lower channel to firewall

10-26-2004

7.0

Fit, drilled and clecoed both gear gussets to the vertical lower channel and the upper channel

Top channel stiffener cut to size, drilled and clecoed to the upper channel and firewall

Drilled and clecoed the vertical top channel to the firewall

Cut Z angle to size, drilled and clecoed to front of firewall

Cut upper bearing to size, drilled bolt hole pattern and used the nose gear strut to center the upper bearing in the 2 inch hole in the upper channel, drilled the 4 bolt holes and clecoed the upper bearing in place

Fit engine mount to firewall to verify all parts line up correctly

10-27-2004

5.0

Drilled all holes up to #20

Disassembled firewall, deburred all holes

Cut slots for steering rods

Applied Cortec VCI-373 Wash Primer/Corrosion Inhibitor to all mating surfaces of the firewall

Riveted and assembled firewall

10-28-2004

5.0

Cut both nose gear stops to size

Laid out and drilled the holes for the firewall line in the rear lower bearing

Marked and cut the 2’ hole in the rear lower bearing

Clamped the nose gear stops inside the lower channel and back drilled into the rear lower bearing

Marked the center of the front lower bearing and cut the 2” hole in it

Positioned the lower bearing, the front lower bearing and nose gear stops then back drilled the holes thru the nose gear stops

Cut the lower bearing in half

Drilled the 1/8” holes for the cotter pins in the ends of the bungee pin

Marked the stop plate and drilled the two 3/16” holes

Trimmed the stop plate to a circle and installed on top of the nose strut

10-29-2004

5.0

Laid out the parts for the forward fuselage

Marked and cutout both the floor bottom skins

Marked centerline on floor bottom skins

Trimmed the bottom channel to size and marked the centerline

Predrilled the 4 channel doublers and drilled and clecoed to the bottom channel

Marked, drilled and clecoed the floor bottom skins and bottom channel in place

Started the layout of the holes in the seat front doubler

10-30-2004

6.5

Laid out and cut the holes in the seat front

Drilled the hole pattern in the seat front doublers

Back drilled the holes thru the seat front doubler into the seat front

Drilled rivet holes up to size

Drilled holes for grommets up to size thru the seat front and seat front doubler

Disassembled the seat front doubler from the seat front, deburred all holes and applied Cortec VCI-373 Wash Primer/Corrosion Inhibitor to the mating surfaces

Riveted the seat front doublers to the seat front

Installed rudder cable fairleads on seat front

Drilled the 4 channel doublers to bottom channel up to size, removed doublers, deburred and applied Cortec VCI-373 Wash Primer/Corrosion Inhibitor to the mating surfaces

Riveted channel doublers to the bottom channel

11-1-2004

9.5

Smoothed the edges of both gear strut fittings

Fit and clecoed the gear strut fittings to the cabin sides

Cut gauge boards for the front and rear cabin width and set the width of the cabin

Drilled and clecoed the cabin floor to the bottom of the cabin sides

Cut, positioned, back drilled, and clecoed the front and rear floor stiffeners to the floor and bottom of the cabin sides

Laid out, positioned , back drilled the center floor stiffener to the floor

Cut both front bottom lonerons to the proper angles, positioned, drilled and clecoed in place

Drilled all holes up to proper size in floor bottom

Laid out, cut, drilled the 1 1/8” hole in the front bearing and predrilled the rivet holes

Laid out, cut, predrilled the rivet holes in the front bearing bottom

Positioned the front top bearing and front bearing bottom, drilled and clecoed in place

11-2-2004

7.0

Marked, cut, drilled and clecoed the tunnel in place

Cut, drilled and installed the tunnel angles and L angles at the front of the tunnel

Marked, predrilled and positioned the central seat belt attachments

Drilled and clecoed the central seat belt attachments

Marked, predrilled and positioned the lateral seat belt attachments

Drilled and clecoed the lateral seat belt attachments

Laid out, cut out for the flap position and predrilled  the flaperon stop

Positioned, drilled and clecoed the flaperon stop to the seat front and the floor

Cut, positioned and drilled the L angle for the flaperon stop

Drilled all holes up to proper size in the tunnel, seat belt attachments, flaperon stop and front bearing top and bottom

11-4-2004

9.5

Disassembled the cockpit floor area and deburred all holes

Applied Cortec VCI-373 Wash Primer/Corrosion Inhibitor to the mating surfaces

Assembled cockpit floor and pulled all necessary A4 and A5 rivets

Smoothed edges on the engine mount

Shaped lower attachment of engine mount to fit the angle of the lower front longeron

Laid out and drilled the seat back panel to the rear fuselage

11-6-2004

8.0

Squared firewall to floor center line and clecoed firewall to floor

Fit engine mount to firewall and clecoed

Fit and trimmed rear uprights to the cabin sides

Squared the cockpit center line with the rear fuselage using plumb lines and a laser

Fit, drilled and clecoed the bottom channel to the bottom skin

Set the overlap of the cabin sides with the side skins

Leveled the rear fuselage and set floor at proper angle

Made two wing pick-up templates

Positioned the wing pick-up templates and clamped the cabin frame in proper position

Leveled the cabin frame and the upper tubes

Laid out the rivet pattern for the upper tubes

11-7-2004

8.0

Checked that the cabin frame is on the center line with the cabin floor with a plumb line

Rechecked the upper tubes for level and position of the wing pick-up templates

Drilled and clecoed the upper tubes to the top longeron gusset

Drilled and clecoed the cabin frames to the cabin sides

Drilled holes up to size in the bottom of the firewall and rear lower bearing

Disassembled the forward fuselage and applied Cortec VCI-373 Wash Primer/Corrosion Inhibitor to the mating surfaces

Cut out the gussets 7F13-1 and drilled the rivet pattern

Predrilled the rivet line in the rear uprights

Assembled the lower forward fuselage to the rear fuselage

Back drilled the rivet line in the rear uprights thru the side skins and clecoed

Fit the gussets to the side channels, drilled and clecoed in position

Positioned, drilled and clecoed the seat back channel

Began drilling holes in the uprights to proper size

11-8-2004

7.0

Finished drilling all holes in the sides of the fuselage and front cockpit up to size for final joining

Applied Cortec VCI-373 Wash Primer/Corrosion Inhibitor to the mating surfaces

Predrilled all bolt holes in both gear strut fittings

Fit gear strut fittings to side skins and bottom channel and drilled up to proper size holes

Drilled pilot holes for the lift struts and rounded the fitting corners

Cleaned the inside of all the open steel tubes for the cabin frame, engine mount and flaperon control

Cleaned gear strut fittings and primed with self etching primer

Riveted the front edge of the rear fuselage on both sides, top and bottom

Riveted gussets 7F13-1 and seat back channel

Riveted rear uprights to side skins

11-9-2004

4.0

Cut down Yamaha rubber boots and made new retainer plates for use around rudder pedal links to the nose gear

Coated the inside of all open steel tubes of the engine mount, cabin frame and flaperon control with epoxy primer

Sprayed self etching primer on engine mount and cabin frame

11-10-2004

4.0

Laid out rivet line on seat back for the seat back channel and drilled up to size

Cut and clecoed L angles on seat back panel

Riveted firewall to cockpit floor

11-11-2004

6.0

Fit upper diagonal tube to cabin frame and drilled holes to size

Used Poly Fiber  E-2310 Aluma-Dyne Phosphoric Acid Etch to clean the upper tubes and diagonal tube then treated the tubes with E-2300 Aluma-Dyne Conversion Coating

Sprayed one coat of self etching primer on the upper tubes and diagonal tube

Sprayed another coat of self etching primer on engine mount

Disassebled the seat back, deburred all holes and applied Cortec VCI-373 Wash Primer/Corrosion Inhibitor to the mating surfaces

Assembled the cabin frame and upper tubes and diagonal tube to the rear fuselage, cabin sides and firewall

Assembled the seat back and pulled the rivets in the seat back

11-12-2004

5.5

Bent both doubler strips to fit, drilled and clecoed

Laid out rivet pattern on striker plates, drilled and clecoed in place

Drilled all holes in doublers and striker plates up to size

Disassebled the doublers, deburred all holes and applied Cortec VCI-373 Wash Primer/Corrosion Inhibitor to the mating surfaces

Assembled the doublers and striker plates to the cabin sides and pulled the rivets

Laid out gussets for the upper tubes and diagonal tube, drilled all holes up to size

Removed the gussets, deburred all holes and applied Cortec VCI-373 Wash Primer/Corrosion Inhibitor to the mating surfaces

Riveted the gussets to the upper channel

11-14-2004

1.0

Pulled remaining rivets in floor of baggage compartment

11-15-2004

2.0

Primed the fuselage area for the gear strut fitting with self etching primer

Drilled the lift strut holes up to size and sprayed with self etching primer

Installed the gear strut fittings to the fuselage with proper hardware and four A5 rivet in each fitting

11-16-2004

11.0

Laid out, the left front side skin and cut lower corner section and filed the edges

Marked and filed the 3mm notch and made the 10mm bend

Rolled the lower section to follow the curve of the firewall

Positioned, drilled and clecoed the front side skin to the cabin side

Laid out the bottom edge rivet pattern, drilled and clecoed

Positioned, drilled and clecloed the lower Z angle to the side skin

Back drilled the holes thru the firewall to the front side skin up to the L angle location

Positioned, drilled and clecoed the L angle to the front side skin

Back drilled the holes thru the firewall to the front side skin up to the Z angle location

Positioned, drilled and clecoed the top Z angle to the front side skin

Back drilled the holes thru the firewall to the front side skin up to the side skin upright location

Predrilled the side skin upright

Drilled and clecoed the side skin upright to the front side skin

Positioned, drilled and clecoed the top aluminum plate and the lower Dzus plate

Positioned the steel angle on the left side and drilled holes for engine mount bolt, front rivet and side rivet

Laid out, the right front side skin and cut lower corner section and filed the edges

Marked and filed the 3mm notch and made the 10mm bend

Rolled the lower section to follow the curve of the firewall

Positioned, drilled and clecoed the front side skin to the cabin side

Laid out the bottom edge rivet pattern, drilled and clecoed

Positioned, drilled and clecloed the lower Z angle to the side skin

Back drilled the holes thru the firewall to the front side skin up to the L angle location

Positioned, drilled and clecoed the L angle to the front side skin

Back drilled the holes thru the firewall to the front side skin up to the Z angle location

Positioned, drilled and clecoed the top Z angle to the front side skin

Back drilled the holes thru the firewall to the front side skin up to the side skin upright location

Predrilled the side skin upright

Drilled and clecoed the side skin upright to the front side skin

Positioned, drilled and clecoed the top aluminum plate and the lower Dzus plate

11-17-2004

4.0

Positioned the steel angle on the right side and drilled holes for engine mount bolt, front rivet and side rivet

Drilled all six engine mount holes to firewall up to 3/16” and clecoed

Laid out, cut and bent the two panel side gussets

Positioned the panel side gussets on each side of the panel, drilled and clecoed

Marked the overhang of the gusset and trimmed the excess off both gussets

Riveted both panel side gussets to the panel

Positioned the panel in proper location, drilled and clecoed the panel side gusset to the cabin frame

11-18-2004

7.5

Cut, laid out and drilled two L angles for each side of the front side skins

Clecoed the two L angles to the top edge of the side skins and 44mm down from the edge for the front top skin to rivet to

Drilled all holes in the front side skins up to size minus the holes for the front top skin overlap

Marked and drilled rivet pattern in the remainder of the firewall and the top of the instrument panel

Marked the front side skins for trimming

11-19-2004

5.0

Disassembled front fuselage, deburred all holes and applied Cortec VCI-373 Wash Primer/Corrosion Inhibitor to the mating surfaces

Masked the firewall off and primed front side of firewall with self etching primer and sprayed with gray gloss paint

Sprayed engine mount with epoxy gloss white paint

11-20-2004

6.0

Primed steel angles for the firewall with self etching primer and sprayed with gray gloss paint

Assembled front side skins to fuselage front and clecoed engine mount in place

Riveted both side skins to forward fuselage

Cut, drilled and clecoed top L angle between the firewall and instrument panel top

Fit, back drilled and clecoed front top skin to firewall and instrument panel

Fit, drilled and clecoed the instrument panel top cover plate to the front top skin and firewall

Drilled all holes in front top skin up to proper size

Marked the front top skin for trimming to size

11-21-2004

5.0

Removed the front top skin, deburred all holes and trimmed  edges to size

Fit, drilled and clecoed the panel bottom channel to the instrument panel

11-22-2004

8.0

Drilled and clecoed L angle to both sides of the tunnel

Cut out both seat pans and fit to fuselage

Drilled and clecoed the front of the right seat to the top flange of the seat front

Drilled and clecoed the aft flange of the right seat to the seat back

Drilled and clecoed the inboard edge of the right seat to the L angle on the tunnel

Drilled and clecoed a short L angle to the right cabin side

Drilled and clecoed the outboard side of the right seat to the short L angle

Drilled and clecoed the front of the left seat to the top flange of the seat front

Drilled and clecoed the aft flange of the left seat to the seat back

Drilled and clecoed the inboard edge of the left seat to the L angle on the tunnel

Drilled and clecoed a short L angle to the left cabin side

Drilled and clecoed the outboard side of the left seat to the short L angle

Fabricated the left and right gussets to close the opening between the cabin side, the seat front and the seat

Drilled and clecoed the right gusset in place

Drilled and clecoed the left gusset in place

Cut and clamped the L angle on the backside of the seat back

Back drilled the L angle and assembled the seats

Cut and shaped the tunnel gusset

11-23-2004

4.5

Drilled all holes up to size in the seats

Disassembled the seats, deburred all holes and applied Cortec VCI-373 Wash Primer/Corrosion Inhibitor to the mating surfaces

Riveted L angles on the tunnel

Riveted the corner gussets to the seat front

Riveted the upper tubes to the cabin frame and the top longeron gusset

12-18-2004

1.0

Riveted lateral and central seat bet attachments to fuselage side and tunnel

Riveted both seat panels to the fuselage

Riveted the tunnel gusset to the tunnel and seat back

Total Time

156.0

Forward fuselage complete until the controls and systems are installed