1077- Tailcone- p.10-12 step 8-9 & p.10-13 step 1-7

Tailcone- 4 hrs 21 mins (Tailcone 33:02, Empennage 208:34, Total 229:30)
Rivet count: 0 (Total 3,686)

We started by finishing yesterday's work of match-drilling the stiffeners to the forward top skin. With a limited number of clecos, there was some creative reshuffling to have enough of them to properly match-drill. After, we match-drilled the remaining holes of both top skins to all the frames and longerons.

Next, we spent an hour and a half to fabricate two braces. No clue why it took so long, but they came out looking dang good...! The rest of the work today was spent match drilling the top deck into the longerons, and the remaining spacers, frames, and the two brackets that we just created.

This was the last of the major construction for the tailcone. The next step has us starting to take things apart... which means the arduous dimpling and deburring steps are just around the corner! -M

1076- Tailcone- p.10-12 step 1-7

Tailcone- 3 hrs 3 mins (Tailcone 28:41, Empennage 204:13, Total 225:09)
Rivet count: 0 (Total 3,686)

We started today by deburring the edges on some skins. Then quickly attached the aft-most frame to the tailcone assembly. We placed the top stiffeners in their location, and then cleco'd the first of the skins on top. As expected, I ran out of the silver cleco's so I had to do some creative re-organizing of the existing ones. After match-drilling the skin to the underlying stiffeners, we attached the second skin. That's all the time I had today, but tomorrow will be a nice opportunity to get some work in since it is a holiday from work! -M

1075- Tailcone- p.10-11 step 3-5

Tailcone- 1 hr 21 mins (Tailcone 25:38, Empennage 201:10, Total 222:06)
Rivet count: 0 (Total 3,686)

The name of the game today was to drill. Every future rivet location that is common between the outer skins and the frames or bulkheads was matched up today. The bottom skin too...
Pretty simple work today. However, I made three significant observations tonight:

1) For every hole that was match-drilled (a lot of them), there are at least 4 surfaces that will need to be deburred. So that's three hours of deburring that will take place in the future that I'm really not looking forward to.

2) Now that I'm done with the side skins, the next stage of building involves adding the top skins to the assembly!! This means more drilling and deburring, yes. However, the aesthetic feedback of seeing a project slowly coming together is what I'm really looking forward to. 

3) I'm low on 3/32" clecos. The tailcone looks like Pinhead, but I'm going to need more clecos for the top skins. This means I'll have to spend some time rearranging clecos to use less while maintaining structural strength. I'm at one cleco every third rivet, so looks I'll be going to 1 per 4. I don't mind, it's just an observation of wasted time.

-M

1074- Tailcone- p.10-10 step 1-6 & p. 10-11 step 1-2

Tailcone- 3 hrs 16 mins (Tailcone 24:17, Empennage 199:49, Total 220:45)
Rivet count: 0 (Total 3,686)

Continued work today by attaching the stiffeners that were fabricated yesterday and match drilling them in place. Then manufactured a spacer out of stock aluminum and taped it in place. I didn't have carpet tape per the instructions, but a few well placed pieces of masking tape will get the job done just as easily. Two more pieces were deburred on the edges and added in place. This is where the horizontal stabilizer will eventually attach to the tailcone. 

Lastly, we added the two longerons that were made and bent months ago. I needed to use the Dremel to file away a bit of the frames that weren't quite big enough to accommodate the longeron edge. After, the majority of today's work took place. We clamped the longerons in place to the skins, and then drilled through them using a #40 drill. Lots of aluminum everywhere and two major structural pieces are now attached and part of the tailcone assembly! -M

1073- Tailcone- p.10-8 step 4-7 & p.10-9 step 1-5

Tailcone- 2 hrs 27 mins (Tailcone 21:01, Empennage 196:33, Total 217:29)
Rivet count: 0 (Total 3,686)

Yeah! Back to building!! It's been five months since I've touched anything in the garage. Pilot training has been consuming my life with 12 hour days and our firstborn made her way into this world six weeks ago. No complaints, though, everything that has happened in the last 5 months has been worth prioritizing over.

Today we started by cutting some pieces to make stiffeners and braces for the back end of the tailcone. Funny enough, I made two braces when I only needed one, so I'll be needing to order a 7 inch piece of angle iron (aluminum) from Van's to make whatever part that extra was going to be originally. At least I screwed up a $3.35 part instead of a $100 skin. I'll take it as beginner's bad luck for getting back in the swing of things.

After, we cleco'd the last frame to the front of the tailcone, and then attached a few supporting parts. Lastly we made more stiffeners for the front of tailcone that will eventually support the plane's battery. After countersinking, and match drilling the platenut holes, it was time to call it a day. G has some beers and working while drinking is never a good idea. I'll continue tomorrow. -M

1072- Elevators- p.9-18 step 3-8 & p.9-19 step 1-2

Elevators- 2 hrs 12 mins (Elevators 71:07, Empennage 194:06, Total 215:02)
Rivet count: 58 (Total 3,686)

The Elevators are finally finished!!! I started them 11 months ago.... Talk about a long time for progress. 

Today's work was the exact thing I did last week, but mirror imaged for the right elevator. Not much to report here other than it's finally done! 

We'll find a place in the house to store these parts, and then continue work on the tailkit that was started months ago. -M

1071- Elevators- p.9-18 step 1-8 & p.9-19 step 1-2

Elevators- 2 hrs 28 mins (Elevators 68:55, Empennage 191:54, Total 212:50)
Rivet count: 58 (Total 3,628)

Wow, I really can't believe it's been nearly two months since I've done work on this. School has been kicking my butt. Christmas was fun, but I spent most of it traveling to see family. I was hoping to get the elevators done before the new year. Now, the past two weeks have just been brutal, and the cold weather makes it even harder to go out and work on things. Enough excuses. I finally got my safety wire and pliers ordered and was ready to finish the elevators. The first part of this video was from 8 days ago on the 11th. I forgot to upload it and the timelapse merged both days into one video.

I've been following the last two pages of the elevator manual. Cut the piano hinge to size and then drilled each half to the elevator and trim tab. The bending of the piano hinge was surprisingly easy, but still took quite some time. Finally, a little bit of safety wire to secure the bent hinge in place and the left elevator is complete. About two more hours and the right elevator will be done too! -M