It's getting too cold to surf, friends are heading back to university, and the mountain bike trails are still beat out from the summer of riding. That means it's time to get back on the build after several months of enjoying life outside the hangar.
First few items to take care of were small things I had been putting off a while, and a great chance to try out some of the new machine tools in the hangar.
My old (1994, non powder-coated) flap handle had some pretty deep corrosion pits on one of the arms. So I ground down the effected areas, and welded on a small patch of tube.
Primed it, and then machined the slot for the manual flap-positioning mechanism, and also shortened the handle a few inches.
I had already fit the flap bearing blocks on the outboard ends, but the middle bearing block sits part on the baggage floor, and part on the seat pan/tunnel. Rather than shim it with washers and have nutplates/fasteners out of plane with the surfaces, I machined a small set of wedges which got riveted to the tunnel cover, and to the seat rib, allowing the nutplates, bearing block, and bolt to all sit flat/vertical.
I don't have a great vise for the mill, so starting with angle makes for easy work holding on small parts.
(Ignore the too short, unset rivet in the above photo. It was used for aligning purposes only)
This should keep the fasteners happy.
I wasn't happy with the previously made angle for the attach of the horizontal stab. Edge distance under the longerons was getting small, and these holes had to be further upsized for the AN-3 bolts.
The mill was already dirty, so I figured I might as well knock out a new one which could maintain every (thousandth) of an inch possible under there.
The original aft baggage side-panels did not fit real well (flanges would not sit flush with all mating surfaces), so I bent a new set on the brake which fit much better.
Next is finalizing the custom seat pans (accommodating the 1" lowered seat ribs), and then some interior items might be going on permanently!
It's been a lot of making parts thus far, but one of these days the rivet gun is going to come out for more than a few whacks
Canopy frame and baggage bulkhead coming soon.