Covering the fuselage...prep work

12/27/03 - For the most part today, I worked with both shop doors open under sunny skies and 55 degree temperatures!

Prep work continues on the fuselage and today, I worked in quite a few areas, starting with removing the tailwheel mount plate, spring and wheel assembly (most of the following images are taken with the fuselage rotated 90° clockwise):

I then disconnected the elevator push pull tube at the forward end and pulled it back inside the tailcone to be secured while covering.

Here, the forward end is secured at the aft seat cross tube:

In the next two photos, I have taped the tail access cover ring (located bottom-side, just aft of the S-6 bulkhead) into it's approximate final location showing the generous working area provided.

This is after I have tied the aft end of the elevator push pull tube at the S-6 bulkhead.

Removing the aileron control cable pulley and shackle assemblies at the S-3 top cross tube:

At this point, I reoriented the fuselage into the normal position and began working to secure the control stick assembly, etc. when I noticed the sticks were locked in the full aft position.

Without having to look far, I saw that one of the bolt ends of the lower pulley assemblies (at S-3) had caught on the forward-stop riveted to the forward push-pull tube.

In the following photo, I reconstructed the setting which caused the control stick to become locked.  You can see the threaded end of the bolt holding the right side (bottom here) pulley hitting the stop:

Worried that this could re-occur if the push pull tube was somehow pushed too far to one side, I reversed the bolts holding the pulleys to the tangs so the bolt heads are on the inside.

I re-checked the manuals and did not notice anything specifying bolt head orientation, but feel safer having them this way.

I can take one or two loops, but continuous full up-elevator smells like trouble to me.  ;^)

Note and disclaimer: Having the cage rolled 90° right caused the situation this time, but I feel there is enough play side to side that it concerned me.

I do not claim to know enough about this to make a specific determination one way or the other, but I am checking with Ed at Rans to get his opinion and will report what he tells me.

Edit: Ed responded that he installs these pulleys with bolt heads towards the inside and that he is planning to make changes to the manual indicating this.

Here is the setup after swapping the bolt-ends:

Back to work then with sticks, cables, etc. secured with strapping tape:

Next, I began cutting the longeron fairing stock for installation.

The fairings act as a former (filler) below the fabric and are installed on the longerons between the cluster gussets to bring things out to a more even plane. This makes the transition from side to top look smooth along the length of the longeron and you don't see the gussets after primer and paint is finished (at least that's my theory).

Following are a few photos of the very simple installation process (note the fuselage gets rotated through to 180° and the clamp in the first couple of photos is holding the fairing in place while a dab of JB Weld is doing it's thing to secure the fairing at the aft end.  It didn't want to snap tight, so I 'poxied it!):

I didn't cut or install the fairings at the forward ends because I was concerned about the ends where the rivets attach the tailcone to the cockpit cage, but an email to Ed provided a quick answer which I'll detail next time out when I install the remaining four pieces.

I was also seriously confused when it came time to install the rudder cable guides located on the bottom cross tube at S-6 and emailed Ed with what I considered to be the dumbest question I have come up with to date (and believe me, there have been plenty...just ask Ed).

Again, Ed came to the rescue (this photo from his personal stash of quick answers) :

Of the two ways I'd thought to install them, I was wrong BOTH TIMES, which is about par for me!  ;^)

We're now just an hour or two from being ready to begin covering the VERY LAST item!  I hope to get out to the shop tomorrow and bring things to that point. 

Thanks again for the extra help today, Ed!

More updates soon...

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Last Update: 12/27/2003