Weeks 61-66: Center Fuselage

While waiting for the missing parts I moved forward with the center fuselage. After getting the spar's, gear box and associtated ribs prepped and the center subassembly done I started on the forward floor. I prepped, primed and assembled the channels to the bottom of the floor, then made templates to cut the insulation.

I cutout and installed the insulation provided in the kit, but I had also ordered a more substantial insulation to help reduce cabin sound. After putting the factory insulation in the floor I decided to do a burn test. I was less than impressed with the result of that. The material didn't light easily, but once it did the flame did not self-extinguish. There was also more smoke that I would have liked while trying to get it to light.

I did the same test on the material I bought from Aircraft Spruce and it did not light or smoke significantly. It will add a little weight, but I decided to remove the kit insulation from the floor and replace it with the stuff I bought.

With the final insulation on, I then riveted on the top skin and started assembling the spars and ribs onto it. I used the gap between my two tables to get to the rivets from the bottom. The main spar attaches with stainless steel rivets, so I used the recommended corrosion protection when installing them.

After getting the forward floor riveted to the other parts I slid both the center fuselage and rear fuselage forward so the rear skin holes would be accessible. I angled the rear fuselage as shown in the instructions, then joined the rear spar and ribs to the rear and center fuselage assemblies. This gets the overall fuselage to about the full size, now it is really starting to look like an airplane!

Since I was still waiting on some parts needed for both the rear and center fuselage, I started laying out the control components. After some trial and error with the main control stick I realized that the front floor needed to be at a raised angle to the main spar. One of the missing parts will help set that angle and hold them together, so I am waiting for that before permanently attaching any of the controls componenents.

I did enough test fitting to find that the machine screws holding the rear part of the control stick could not be installed as shown on one side. The screws are supposed to install from the top, but the angle of the main spar prevented this. Access to the screw heads with the allen wrench would be difficult with the screws installed from the bottom. I resolved this by finding an ultra-thin set of allen wrenches that will fit between the control stick and main spar.

I also started working on antenna layouts. Midwest Panel Builders sent me the COM, transponder, and GPS antennas so I could get the mounting holes drilled as well as the coax cable to get it routed while the fuselage is open. I am putting the COM1 antenna on the forward floor, COM2 on the roof behind the luggage compartment, and the transponder below the luggage compartment. I am still finalizing the GPS location, but the G3X touch one will be installed either under the cowling or on the glare shield.

After making a backing plate and drilling the holes for the bottom COM antenna I made a larger cutout in the top floor skin. This will be hidden in the center tunnel when everything is complete, but that way I will have access to all the antenna mounting bolts. With that cutout done I permanently installed the channels and vertical supports that will make up the center console.

With that done I would have been running short on things to do, but most of the missing parts came just in time. I quickly started working on the rudder parts, getting them primed and ready to be installed. I am now working on getting the rudder pedals attached and moving smoothly.