Tuesday, September 19, 2006

Cleaning Up Enclosure - 5 hours (400 Total)

The enclosure is pretty much done but it needs a little bit of clean up prior to bring it to the painter.

The first thing I did was add a few more rivets. There were a few locations such as the landing gear cuffs and the location pictured below that need a few more rivets. Some of these rivets were needed to go into the steel frame. I need to purchase some sharp new drill bits to allow me to drill into this. I've gone through about a half dozen #30 bits while building the plane.
























Some of the rivets I had placed didn't come out to well. In some cases the mandrel would break off outside the body of the rivet causing a sharp stem to protrude. This only occurred when the rivet only had sheet metal to rivet through. I think the sheet metal holes are stretching which allowed the mandrel to be pulled farther than the rivet was designed for. In some cases the mandrel was pull all the way though the rivet. Those rivets I replaced. As for the stems, I used my Dremel to grind the rivets smooth.












Just prior to rolling the plane to the painter, I removed the wheel pants and some bolts in the tail boom. If all goes well, I should have a sharp painting fuselage in a week or so.

Here is a picture of the plane at the painter's shop.
Cowling - 1 hour (395 Total)

Last week I revisited the welder and had him add a few spot welds to secure the cooler to the cowl. This should hold the cooler in place without requiring me to use rivets or bolts.













I then needed to modify the aluminum angle that I fabricated to cover the rear holes so they would fit around the new weld beads. I then riveted the aluminum angles into place.