RV-8 Project N804PT

Fuselage

March 29, 2006: 4.0 hrs - On this date, the fuselage parts arrived. Because I do not yet have a hangar, Jan Martin kindly has allowed me to do the initial jigging of my fuselage in his hangar. To allow the most efficient work schedule, for some time I will be working partially on the fuselage, and partially on the wings. Wing work will appear on the Wings page, while fuselage work will appear on this page. Here is a picture of Jan with his beautiful RV-4 (note my fuselage kit boxes in the background):

Inventory of the fuselage started.

March 31, 2006: 6.0 hrs - Fuselage parts inventory complete.

April 01, 2006: 8.0 hrs - Building fuselage construction jig.

April 02, 2006: 8.0 hrs - Building fuselage construction jig.

April 06, 2006: 4.0 hrs - Building fuselage construction jig.

April 07, 2006: 4.0 hrs - Finishing fuselage construction jig.

April 08, 2006: 4.0 hrs - Fitting and drilling crossmembers and supports to firewall.

April 10, 2006: 2.0 hrs - Drilling firewall parts.

April 14, 2006: 8.0 hrs - Deburring, dimpling and countersinking firewall parts.

April 20, 2006: 4.0 hrs - Riveting firewall.

April 22, 2006: 3.0 hrs - Riveting firewall; fitting firewall to jig.

April 23, 2006: 8.0 hrs - Fabricating attach angles for spar bulkhead.

April 27, 2006: 4.0 hrs - Fitting and drilling parts to spar bulkhead.

April 28, 2006: 5.0 hrs - Cutting crotch strap lot in spar bulkhead; deburring and countersinking spar bulkhead.

April 29, 2006: 3.0 hrs - Riveting side plates and nut plates on spar bulkhead; installation of taildragger spar converson bolts.

May 02, 2006: 3.5 hrs - Fabricating spar bulkhead outer side plates; priming spar bulkhead parts.

May 03, 2006: 2.5 hrs - Priming spar bulkhead parts.

May 04, 2006: 5.0 hrs - Riveting spar bulkhead.

May 05, 2006: 6.0 hrs - Bending and jigging upper longerons.

May 06, 2006: 4.0 hrs - Fabricating shoulder harness doublers and horizontal stabilizer mounting bars.

May 10, 2006: 8.0 hrs - Drilling, edge finishing, deburring and dimpling bulkheads.

May 11, 2006: 9.0 hrs - Drilling, edge finishing, deburring, dimpling and priming bulkheads.

May 12, 2006: 9.0 hrs - Priming bulkheads; fabricating and polishing rear spar carry-through.

May 13, 2006: 2.5 hrs - Fabricating floor parts.

May 15, 2006: 1.0 hrs - Riveting bulkheads.

May 17, 2006: 8.0 hrs - Riveting bulkheads; jigging bulkheads; drilling tailwheel mount.

May 18, 2006: 6.0 hrs - Edge finishing and drilling floor parts and seat belt attach points.

May 19, 2006: 6.0 hrs - Fabricating floor rails; drilling floor parts.

May 20, 2006: 8.0 hrs - Drilling and deburring floor parts.

May 24, 2006: 8.0 hrs - Fabrication of aileron trim parts.

May 26, 2006: 6.0 hrs - Drilling floors to spar bulkhead; deburring floor parts.

May 27, 2006: 3.0 hrs - Edge finishing floor ribs and angles.

May 29, 2006: 2.0 hrs - Edge finishing floor ribs.

June 01, 2006: 4.0 hrs - Priming floor parts.

June 02, 2006: 1.5 hrs - Priming floor parts.

June 08, 2006: 1.5 hrs - Priming floor parts.

June 09, 2006: 2.5 hrs - Priming floor parts.

June 13, 2006: 2.0 hrs - Riveting floor parts.

June 14, 2006: 8.0 hrs - Riveting floor parts.

June 15, 2006: 3.0 hrs - Fitting and adjusting floors to fuselage skelleton.

June 16, 2006: 2.0 hrs - Fabricating, drilling and deburring baggage ribs.

June 17 to June 30, 2006 I was out of town participating in the World Class national soaring championships: Contest Details

July 05, 2006: On this date, I left for Europe to fly in the World Soaring Championships.

The scenery was beautiful over the Alps:

But I didn't always make it back where I wanted:

July 30, 2006: I returned from France. For complete contest details: Contest Details

July 31, 2006: 2.0 hrs - Priming baggage ribs.

August 01, 2006: 1.0 hrs - Priming baggage ribs.

August 03, 2006: 1.0 hrs - Riveting baggage ribs.

August 04, 2006: 6.0 hrs - Drilling baggage ribs to skeleton; bending and fitting forward longerons; fitting and drilling forward floor and lower forward fuselage skins.

August 08, 2006: 6.0 hrs - Fitting and drilling forward fuselage gussets; fitting and drilling center fuselage skins.

August 10, 2006: 7.0 hrs - Edge finishing and fluting mid cabin ribs; fitting and drilling aft longerons and aft skins.

August 11, 2006: 2.0 hrs - Fabrication of rear seat belt attachments.

August 12, 2006: 7.0 hrs - Fitting and drilling bottom center skins; fitting and drilling bottom aft skin.

August 17, 2006: 6.0 hrs - Drilling bottom skins; fabricating, fitting and drilling gear tower side plates.

August 18, 2006: 4.0 hrs - Fabrication of gear tower angles; edge finishing and fluting gear bulkheads.

August 19, 2006: 4.0 hrs - Fitting, drilling, deburring and dimpling gear tower parts.

August 21, 2006: 6.0 hrs - Fabrication of gear lower mounting angles.

August 24, 2006: 6.0 hrs - Fabrication of gear lower mounting angles.

August 25, 2006: 8.0 hrs - Riveting gear tower vertical angles; fitting and drilling tail cone skin.

September 04, 2006: 2.0 hrs - Trimming and edge finishing brake pedals.

September 10, 2006: 9.0 hrs - Fitting and drilling gear towers; drilling remaining fuselage holes.

September 14, 2006: 4.0 hrs - Edge finishing and deburring fuselage skins.

September 15, 2006: 7.0 hrs - Edge finishing, deburring and dimpling fuselage skins.

September 16, 2006: 8.0 hrs - Deburring and dimpling fuselage skelleton.

September 17, 2006: 8.0 hrs - Deburring and dimpling fuselage skelleton.

September 18, 2006: 6.0 hrs - Deburring and dimpling fuselage skelleton.

September 21, 2006: 4.0 hrs - Deburring and dimpling fuselage skelleton.

September 22, 2006: 8.0 hrs - Deburring, dimpling, countersinking and priming fuselage skelleton and skins.

September 23, 2006: 4.0 hrs - Deburring, dimpling, countersinking and priming fuselage skelleton and skins.

September 24, 2006: 6.0 hrs - Deburring, dimpling and priming fuselage skelleton and skins.

September 25, 2006: 8.0 hrs - Deburring, dimpling and priming fuselage skelleton and skins.

September 27, 2006: 5.0 hrs - Deburring, dimpling and priming fuselage skelleton and skins.

September 28, 2006: 3.0 hrs - Deburring, dimpling and priming fuselage skelleton and skins.

September 29, 2006: 8.0 hrs - Priming skelleton; riveting skelleton; riveting aft belly skin.

October 02, 2006: 4.0 hrs - Priming fuselage skins and landing gear attach point structure.

October 03, 2006: 5.0 hrs - Priming fuselage skins; fabricating stabilizer attach angles.

October 04, 2006: 6.5 hrs - Priming fuselage skins; riveting aft fuselage skins.

October 05, 2006: 8.0 hrs - Fabricating stabilizer attach angles; riveting aft fuselage skins.

October 07, 2006: 2.0 hrs - Riveting landing gear towers.

October 09, 2006: 1.0 hrs - Riveting landing gear towers.

October 14, 2006: 3.0 hrs - Riveting landing gear towers; priming fuselage cross members.

October 16, 2006: 6.0 hrs - Riveting fuselage skins.

October 17, 2006: 6.0 hrs - Riveting fuselage skins.

October 18, 2006: 4.0 hrs - Riveting fuselage skins.

October 19, 2006: 6.0 hrs - Riveting fuselage skins; fuselage removed from jig.

October 21, 2006: 1.5 hrs - Edge finishing aft fuselage deck; fabricating tie down ring holders.

October 22, 2006: 1.0 hrs - Fabricating tie down ring holders.

October 26, 2006: 6.0 hrs - Drilling and deburring aft deck and stabilizer attach angles.

October 28, 2006: 3.0 hrs - Priming aft deck and stabilizer attach angles; fabricating cockpit floor supports.

October 29, 2006: 2.0 hrs - Priming aft deck and stabilizer attach angles; fabricating cockpit floor supports.

October 30, 2006: 6.0 hrs - Riveting aft deck and stabilizer attach angles; drilling cockpit floor supports.

October 31, 2006: 8.0 hrs - Fabricating, deburring and dimpling cockpit floors and footwells.

November 01, 2006: 10.0 hrs - Fabricating, deburring, dimpling, and priming cockpit floors and footwells.

November 02, 2006: 8.0 hrs - Deburring, dimpling, and priming cockpit floors.

November 04, 2006: 3.0 hrs - Priming and riveting cockpit floors and footwells.

November 06, 2006: 3.5 hrs - Priming cockpit floor parts.

November 07, 2006: 4.0 hrs - Priming cockpit floor parts.

November 08, 2006: 2.0 hrs - Riveting cockpit floors.

November 09, 2006: 8.0 hrs - Riveting cockpit floor supports; fitting floors and footwells; installing rudder cables.

November 11, 2006: 3.5 hrs - Edge finishing armrests and bulkhead channels.

November 12, 2006: 7.0 hrs - Drilling floor nutplates; fabricating control column hangers.

November 13, 2006: 8.0 hrs - Drilling, deburring and countersinking floor nutplates; drilling, deburring and dimpling armrests.

November 14, 2006: 10.0 hrs - Fabricating cockpit consoles; priming and painting armrests.

November 15, 2006: 8.0 hrs - Riveting floor nutplates; riveting armrests.

November 16, 2006: 3.0 hrs - Fitting and drilling rear cabin covers; fitting and drilling control column mountings.

November 18, 2006: 6.0 hrs - Edge finishing, drilling, deburring, dimpling and priming forward baggage compartment parts; fabricating rear baggage compartment bulkhead.

November 20, 2006: 4.5 hrs - Fabricating elevator bellcrank mounts; deburring and dimpling rear baggage compartment parts.

November 21, 2006: 8.0 hrs - Fitting and drilling forward baggage compartment parts and cockpit consoles.

November 22, 2006: 6.0 hrs - Priming cockpit parts; drilling, deburring and countersinking cockpit nutplates.

November 23, 2006: 3.5 hrs - Priming cockpit parts; fabrication of elevator bellcrank.

November 24, 2006: 4.5 hrs - Priming cockpit parts; fabrication of rudder pedal thrust bearings; design and fabrication of forward bulkhead avionics hatch.

November 26, 2006: 2.5 hrs - Drilling, deburring, countersinking and dimpling avionics hatch parts.

November 27, 2006: 5.0 hrs - Priming avionics hatch parts; riveting cockpit nutplates.

November 28, 2006: 8.0 hrs - Riveting cockpit nutplates; priming aft baggage parts; riveting upper part of gear towers.

November 29, 2006: 8.0 hrs - Riveting forward baggage bulkhead and console mounts; installation of flap actuator and motor; fitting and drilling aft baggage parts.

December 02, 2006: 3.0 hrs - Fabricating rudder pedal mounts and mid cabin cover attach angles.

December 03, 2006: 7.0 hrs - Fitting and drilling mid cabin brace, support and cover, rudder pedal mounts, seat ramps and inboard landing gear weldments.

December 06, 2006: 2.5 hrs - Fabricating battery mount.

December 07, 2006: 2.5 hrs - Fabricating battery mount; drilling mid cabin cover nutplates.

December 08, 2006: 6.0 hrs - Assembly of rudder and brake pedals; edge finishing battery mount parts.

December 09, 2006: 6.0 hrs - Edge finishing and priming misc cockpit parts.

December 10, 2006: 8.0 hrs - Final installation and riveting gear towers; riveting cockpit nutplates.

December 11, 2006: 9.0 hrs - Riveting rudder pedal attach points; riveting mid cabin brace; fitting fuel selector and mid cabin covers; drilling autopilot roll servo mount.

December 15, 2006: 6.0 hrs - Priming cockpit parts; fabricating elevator pushtubes.

December 16, 2006: 6.0 hrs - Priming cockpit parts; riveting cockput nutplates.

December 17, 2006: 2.5 hrs - Priming battery mount; riveting seat ramp nutplates.

December 18, 2006: 10.0 hrs - Riveting roll servo mount, upper longeron gussets and elevator bellcrank mounts; fitting and drilling rear rudder pedal attachments.

December 22, 2006: 6.0 hrs - Priming battery mount; riveting elevator bellcrank and pushtubes.

January 10, 2007: 8.0 hrs - Riveting floor nutplates; installing interior panels; disassembling fuselage construction jig.

January 11, 2007: 6.0 hrs - Installing interior panels; building fuselage stands.

January 12, 2007: 5.0 hrs - Inventory of finsh kit and firewall forward kit.

January 16, 2007: 5.0 hrs - Moving fuselage and stands to new hangar.

January 19, 2007: 4.0 hrs - Setting up new hangar.

January 23, 2007: 2.0 hrs - Fabricating boost pump mounting flanges; fabricating horizontal stabilizer mounting spacers.

January 24, 2007: 3.0 hrs - Fitting, drilling and installing horizontal stabilizer.

 

January 26, 2007: 3.0 hrs - Fitting and drilling vertical stabilizer.

January 27, 2007: 6.0 hrs - Fitting, drilling and installing vertical stabilizer.

February 01, 2007: 6.0 hrs - Fitting and rigging elevators; installing elevator bellcrank and linkage.

February 02, 2007: 6.0 hrs - Prepping control sticks and bushings; fabricating rudder stops; fabricating seat frame angles.

February 03, 2007: 4.0 hrs - Fitting rudder; connecting rudder cables; installing aft rudder cable fairleads.

February 07, 2007: 8.0 hrs - Rigging rudder stops; design and fabrication of ELT mounting; removal of empenage.

February 15, 2007: 6.0 hrs - Design and fabrication of auxiliary battery mountings.

February 16, 2007: 9.0 hrs - Fabrication of aux battery mountings; marking, fitting and drilling aft upper skin.

February 18, 2007: 9.0 hrs - Drilling aft upper skin; fitting and drilling rear shoulder harness attach points.

February 19, 2007: 8.0 hrs - Making temporary floor back-boards; fitting and drilling boost pump attach platenuts.

February 20, 2007: 6.0 hrs - Fabricating and fitting magnetometer mount; drilling and gluing static ports; fitting, drilling and riveting battery mount.

February 21, 2007: 4.0 hrs - Priming fuselage parts.

February 22, 2007: 3.0 hrs - Priming fuselage parts.

February 23, 2007: 9.0 hrs - Assembly and riveting aux battery mounts; riveting magnetometer mount; riveting ELT mount; fitting and drilling engine mount; drilling front seat back.

February 27, 2007: 6.0 hrs - Riveting aft upper fuselage skin and shoulder harness lugs.

March 04, 2007: 8.0 hrs - Fitting, rigging and drilling landing gear assembly.

March 05, 2007: 10.0 hrs - Fitting, drilling, deburring and countersinking belly skins.

March 06, 2007: 6.0 hrs - Dimpling and priming belly skins.

March 11, 2007: 6.0 hrs - Deburring, dimpling and prepping fuselage for belly skins.

March 12, 2007: 7.5 hrs - Riveting and sealing fuselage belly skins.

March 13, 2007: 8.0 hrs - Fabricating and polishing various shims, spacers and brackets.

March 17, 2007: 2.0 hrs - Edge finishing instrument panel parts.

March 18, 2007: 11.0 hrs - Riveting belly skins; drilling and countersinking instrument panel parts; fitting and drilling baggage support strips and upper top skin.

March 19, 2007: 10.0 hrs - Fitting rear throttle and aileron trim components; drilling nutplates for same; installing gear tower screws.

March 20, 2007: 9.0 hrs - Riveting, fitting and drilling instrument panel; drilling upper top skin; cutting glareshield.

March 24, 2007: 1.0 hrs - Edge finishing cockpit rails.

March 26, 2007: 10.5 hrs - Fitting seat back weldment and cockpit rails; drilling, deburring, dimpling and courntersinking weldment and rails.

March 27, 2007: 8.0 hrs - Making instrument sub-panels; drilling switch holes; priming instrument panel and cockpit rails.

April 01, 2007: 11.0 hrs - Riveting cockpit rails; installing seat back weldment and windscreen support weldment.

April 02, 2007: 4.5 hrs - Installation of fuel filter and brake lines.

April 03, 2007: 9.5 hrs - Edge finishing forward top skin; plumbing fuel lines.

April 04, 2007: 9.5 hrs - Dimpling forward top skin; fitting wings; setting wing sweep and incidence; rigging ailerons; trimming inboard flap skins.

April 05, 2007: 9.0 hrs - Fabricating, fitting, drilling and installing front spar attach angle; fabricating and rigging flap actuator linkage.

April 10, 2007: 8.0 hrs - Fabricating and installing wing fuel lines; fitting and drilling wing and flap fairings.

April 11, 2007: 8.5 hrs - Fitting, drilling, finishing and dimpling wing and flap fairings; removing wings.

April 12, 2007: 10.0 hrs - Fitting and rigging rear seat throttle; fabricating and fitting aileron trim.

April 13, 2007: 2.5 hrs - Priming landing gear parts, flap fairings and forward wing attach angles.

April 17, 2007: 10.0 hrs - Designing and fabricating EIS mount; fabricating avionics rack; cutting instrument panel holes.

April 18, 2007: 8.0 hrs - Cutting instrument panel.

April 19, 2007: 5.0 hrs - Fabricating avionics rack.

April 20, 2007: 10.0 hrs - Fabricating and installing avionics rack.

April 21, 2007: 9.0 hrs - Installation of instruments in panel; design and fabrication of AHRS mount.

April 22, 2007: 11.0 hrs - Riveting AHRS mount; installation of tailwheel spring; installation of trim cable; installation of engine control cables.

April 23, 2007: 8.0 hrs - Riveting flap fairings; insstallation of wire conduit.

April 24, 2007: 10.0 hrs - Installation of VOR and transponder antennas; fabricating doublers for com and marker antennas.

April 25, 2007: 10.0 hrs - Running antenna coax; fabrication of wiring harness.

April 26, 2007: 5.0 hrs - Installation of vent inlets in fuselage and right wing; fabrication of wiring harness.

May 12, 2007: 8.5 hrs - Installation of adel clamp platenuts; installation of electrical components.

May 13, 2007: 10.0 hrs - Installation of avionics fan; fabrication of busses; fabrication of wiring harness.

May 14, 2007: 4.0 hrs - Installation of firewall penetrations for heat, manifold pressure, fuel and wiring.

May 15, 2007: 12.0 hrs - Installation of panel pitot and static systems; fabrication of wiring harness.

May 17, 2007: 6.0 hrs - Installation of cabin heat valve; fabrication of wiring harness.

May 19, 2007: 8.0 hrs - Fabrication and installation of engine sensor stand-off; fabrication of wiring harness.

May 20, 2007: 11.0 hrs - Fabrication and installation of essential alternator control circuit; fabrication of wiring harness.

May 21, 2007: 12.0 hrs - Fabrication of wiring harness.

May 22, 2007: 8.0 hrs - Fabrication of wiring harness.

May 24, 2007: 6.0 hrs - Installation of essential and clock batteries; fabrication of wiring harness.

May 26, 2007: 7.0 hrs - Installation and wiring of strobe power supply.

May 27, 2007: 4.0 hrs - Installation and wiring of autopilot servos.

May 28, 2007: 10.0 hrs - Wiring transponder system; fabrication of wiring harness.

May 29, 2007: 8.5 hrs - Fabrication of wiring harness; installation of pitot heat relay and wiring.

May 31, 2007: 8.0 hrs - Installation of sheat heater controls and wiring; fabrication of wiring harness.

June 01, 2007: 8.5 hrs - Fabrication of wiring harness.

June 02, 2007: 9.0 hrs - Fabricating wing connector mounting angles; fabrication of wiring harness.

June 03, 2007: 10.5 hrs - Riveting antenna doublers; installing com and marker beacon antennas; fabrication of wiring harness; first power-up of EFIS system.

June 04, 2007: 7.5 hrs - Installing map light; fabrication of wiring harness.

June 06, 2007: 6.0 hrs - Installing post lights; fabrication of wiring harness.

June 08, 2007: 5.5 hrs - Installing light dimmers; wiring headset and mic jacks.

June 09, 2007: 4.0 hrs - Testing electrical system.

June 10, 2007: 9.5 hrs - Testing and configuring avionics.

June 11, 2007: 8.0 hrs - Lacing wiring harness; installing D-sub strain reliefs.

June 13, 2007: 7.0 hrs - Lacing wiring harness; installing D-sub strain reliefs.

June 15, 2007: 5.0 hrs - Lacing wiring harness; installing ELT.

June 16, 2007: 10.5 hrs - Lacing wiring harness; removing instruments and panel.

June 17, 2007: 5.0 hrs - Fabricating shims for forward top skin; fabricating and fittting cockpit ribs for top skin; trimming and edge finishing top skin.

June 18, 2007: 7.5 hrs - Fabricating forward cockpit air vent mounting angle; paining forward cockpit; fabricating main battery mounting clamp.

June 22, 2007: 2.5 hrs - Priming forward top skin and associated parts.

June 23, 2007: 9.0 hrs - Edge finishing baggage door parts; priming battery hold-down; fitting and drilling baggage door hinge.

June 24, 2007: 11.5 hrs - Priming baggage door hinge assembly; fabrication and fitting baggage door lock mechanism; riveting and installing battery hold-down; prepping and drilling baggage door.

June 25, 2007: 10.5 hrs - Riveting forward top skin; riveting baggage door hinge; fabricating center canopy rail; riveting rear seat back.

June 30, 2007: 9.0 hrs - Riveting baggage door outer skin; drilling, deburring and dimpling inner baggage door skin and frame; riveting baggage door inner skin; trimming, drilling and fiting rear seat top.

July 01, 2007: 6.5 hrs - Fitting and installing baggage door latch blocks; riveting rear seat top; fabricating, drilling, deburring, countersinking and riveting center canopy rail.

This completes the fuselage.

Work now moves on to Finishing.

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