Bottom Stringer

Measured, cut, deburred 10 bushings (stand-off posts) for lower stringer.  Hours 1

Main Landing Gear Bottom Stringer Clearance

Came to a final conclusion on how "big" to make the bottom stringer bow to allow Grove gear clearance and how "big" the fabric hole will need to be to allow the the Grove gear to be installed without interfering with the fabric. (EB & MC).  Hours: 0.5

Reamed Strings Stem Holes

The attach points for the bottom stringer stems had to be reamed to 5/16" to allow the aluminum tube stems to fit tightly.  Hours: 0.5

Determining of fabric opening size and location for gear

Working on determining size of bow in bottom stringer, and size of hole that will be needed in fabric to feed the Grove gear through the hole.  We tested a few different positions of the bottom stringer, used paper to simulate the fabric, and then fed the gear through rectangular holes in the paper to determine if the hole would be large enough to get the gear through.  We determined that this method of installing the gear will work, but still need to finalize the position of the bottom stringer and the location/size of the hole in the fabric.     EJB, MHC  Hours: 0.5

Main Landing Gear Bottom Stringer Clearance

Trying to determine how big the bow needs to be made in the bottom stringer.  The bow needs to be large enough to clear the landing gear for installation.  Just Aircraft factory was contacted for more information. (MC & EB)  Hours: 1

Attached Main Landing Gear

The Grove Aluminum landing gear was installed into the brackets to check for fit and allow us to judge how large to make the attach stems for the bottom stringer.  All temporary fasteners were used.  Hours: 0.75

Fitted and adjusted landing gear brackets

Fitted the landing gear attach brackets (for Grove landing gear). Both brackets (left and right side) were close, but did not quite fit initially into the welded steel attach points on the fuselage.  To fix this, we milled off a slight amount of the aluminum gear brackets until they fit into the slots in the fuselage.  Removed about 0.05" from two inside edges of the right landing gear bracket, and removed 0.025" from the outside edges of the left landing gear bracket. With these minor adjustments, the brackets now fit properly.  EJB, MHC  Hours: 3

Glued Side and Top Stringers to Fuselage

Cleaned parts with Acetone and then affixed them to the fuselage using Hysol 9460 structural adhesive.  The stringers were held in place using cable-ties as clamps until the epoxy cures. (EB & MC)  Hours: 1

Side stringers fitted

Side stringers were fitted, drilled, and set in place.  Side stand-off posts for stringers were cut to length to match the curve of the stringers. (EB & MC).  Hours: 3

Top stringer fitted

Top rear stringer was cut, trimmed, and fitted. The back end was carefully filed so that it matched the profile of the tail fin tubing.  Two holes were drilled in stringer for the two center spigots that are welded to the frame.  The center spigots were also cut shorter to fit the shape of the stringer. Stringer was cleco'd to the tail fin, and will be epoxied in place later. (EJB, MHC)   Hours: 2

Installed Horizontal Stabilizer Front Attach Brack

The Horizontal Stabilizer front attach bracket (F-1020) was installed.  The AN4-12A bolt indicated in the manual was replaced with a AN4-13A for a correct fit, The AN3-12A bolt fit perfectly.  The Part originally had holes drilled on both sides which made it difficult to drill correctly.  Ed filled in one side of the holes with a TIG weld.  This allowed for a nice tight bolt fit. MHC & EJB.  Hours: 3

Tail Installation

Vertical fin fitted, leveled, and installed.  Some powdercoat had to be removed and tubing length trimmed slightly for fit. (MHC, EJB)  Hours: 4

Cockpit Floor Installation

The cockpit floor was trimmed to fit and then pilot drilled and cleco'd in place. (MHC)  Hours: 0.5

Flooring

Alum. sheets for flooring of front and rear baggage area were trimmed, fitted, and Cleco'd in place.  Two smaller side flooring pieces were also fitted (next to the seats). (MHC, EJB).  Hours: 4

Rotisserie jig strengthened

Added angle bracket on side of Rotisserie.  Also changed the angle steel piece to a square tubular piece for added strength.  These changes were made to eliminate some swaying of the fuselage from left to right when placed in the jig.  Jig was then repainted (brown and white) (EJB)  Hours: 3