Interior Install

Over the last couple of weeks I’ve been working on installing the interior. This is a kit from Classic Aero, and everything is well designed and manufactured.

There are a number of holes to be drilled, fittings to install, and a few minor adjustments. The kit comes with a set of templates which make locating the holes a non-issue. Once the fittings are installed, the various components can be fitted into position. Most attach with simple studs and bolts, and some pop rivets here and there.

This wasn’t weeks worth of work, but chipping away in the evenings, I spent around 8-10 hours in total.

With everything installed, the interior looks amazing. Unfortunately I have to uninstall most of it so I can complete the wing attach, so after verifying I had all the right parts, and that the fit correctly, a lot of the components came right back out again.

I’m glad I tackled this now, because I found that the seatbelts were not in the kit. A quick email exchange with Classic Aero, and they confirmed they had forgotten to order the seatbelts. The placed the order, and they should be here in 3-4 weeks.

Drilling holes
One of the fittings
One of the fittings
Some of the fittings
Two studs, with VHB tape holding them in place
The aft baggage bulkhead cover needs modification to allow carpet to be installed on the bottom section of the bulkhead. Here I am riveting the Classic Aero section to the cover,
The JD Air latch fits, but needs a modification to flip the spring to the top of the mechanism. I forgot why I circled the holes in red…
I had to replace the Vans 12V adapter plate with a custom one that comes in the kit. There is a plastic ring that covers the edges of the carpet here.
Seats look great!
Baggage compartment
Seats and baggage compartment
Note the forward pockets visible in this picture.

Elevator bellcrank assembly

Tonight I assembled the bellcrank and pitch servo bracket. Everything was straightforward except the mounting of the two angles onto the bell crank plate. The alignment of the bolts took some negotiating, but after a few attempts, I was able to get it installed and torqued.

Nutplates installed
Bellcrank riveted
Bellcrank installed and connected to the pushrod, ready for installation
Pushrod installed and final torqued

Right bottom skin riveting

Today I made a start riveting the right bottom skin onto the right wing.

It want easier than I thought, perhaps because I’ve done it before on my previous set of wings. I didn’t finish the job, and expect it will take a number of sessions to get this set done.

Tape to hold the skin off the ribs and allow arms to reach up inside

New dog

It’s been a month without work on the plane, partly due to work travel, but mainly because we brought home a puppy, Bruno, and he has been requiring my help in the evenings.

Now he is sleeping in his crate all night, so I can get some time back in the garage.

New garage

My new garage setup is looking good and I’m almost ready to start building again. Everything in the garage is on wheels except for some storage racks in one corner. I’m planning to make up some storage bins for nuts, bolts and washers, but other than that I’m ready to start. My goal is to be back into the swing of things by the end of next week.

New garage. No built-in cabinets, but slightly more space than the last garage.

The move

Sometime in June, Stuart Transport arrived and picked up my wings and fuselage, shipping them back to Vans. With those out of the garage, the remaining parts were relatively easy to pack and stow into a 20 foot U-Haul.

Aft fuse and all the boxes of hardware and some tools enroute to San Diego

I built a wooden crate with shelving for the tail feathers. I lined it with blankets, and used shrink-wrap to secure the parts to the racks. That worked out well, and I am going to put wheels on it and keep it as a storage rack in the new garage. hardware and small parts were wrapped and stored in cardboard boxes. The horizontal stabilizer went into my wing cart, and was strapped firmly against the cart, and the cart against the wall of the truck. I temporarily installed the forward-most bulkhead in the aft fuse, using clecos to secure it in place. Then I set the aft sure on the dolly I had built for my Quickbuild fuselage. I cut some foam strips which ran on the dolly lengthwise to help support the curvature of the bottom of the fuselage. Then I used shrinkwrap to secure the aft fuse to the dolly.

After a 12 hour drive, we arrived at the new house, and everything was still very secure. Unloading was uneventful, but space was limited due to the ongoing construction happening on the house.

Parts stored in the new garage

A few weeks later my new fuselage arrived from Vans, which prompted some cleanup and rearranging in the garage. It’s good to have the new fuse now, it looks great and primer is definitely heavier and looks more like I would have expected.

As far as I can tell, all my parts and tools have made it with no noticeable damage.

Moving Time

We are in the process of moving from The Bay Area south to San Diego county. With everything going on, I’ve not been making much progress on the build. The goal is to be moved by August, although it might be a bit later if the house isn’t ready on time.

In parallel I’ve been talking to Vans about my Quickbuild kit. It’s been found to have defective primer, which isn’t a big surprise as I’ve noticed it runs off easily and I found some corrosion on the wings. Because I’m moving, and because my kit was perhaps the first one impacted, I have priority in the queue. I decided it would be best to replace the kits, and to coincide with my move.

So most of the work I’ve been able to do in the last 6 weeks has been removing systems and components from the wings. This was a bit demoralizing at first, but I quickly started thinking about how to do everything better the second time.

Wings back to their original state
Some of the wing components
I removed the bottom skin I had previously installed. Here I have removed the manufactured heads of a bunch of rivets. The skin came off quite easily in the end

Nutplates

Tonight I installed the nut plates onto the bulkhead parts that make up the aft wall of the baggage compartment. It was trivial, but a little tight around the flanges. I managed ok with my hand squeezer in the vice.

With the hand squeezer in the bench vice, I was able to squeeze all the rivets for these nutplates
Nutplates installed