Category: Fuselage

I cutout the second doubler and sanded it. Next I drilled the pilot holes and then scotch brited both parts

I cut out the first longeron doubler and sanded it.

I cut, filled, sanded and drilled the trim lever. I still haven’t sorted out the exact drill sizes for AN3 and AN4 hardware yet so I stuck with pilot holes for the time being. I also put the first two bends into the lever. These are the ones that look like a joggle at the bottom where the cable attaches.

I worked some more on the fittings today. Again working from a rough cut part to a near finished part.

I made a template and rough cut one fitting on the band saw.

I started today by cutting strips from the 1/8" aluminum sheet to be used for fittings.

I followed the same process as for the flap handle and this part comleted fairly quickly.

I made the flap handle today. Using one of the previously cut strips, I cleaned up the edge using the vixen file. I then cut the strip to length and added the radii at the ends using the bench sander. A little sanding, bend and scotch brite and the handle was complete.

I made the small spacer block. It was fairly straight forward. I used the bandsaw to cut the material and then files, sandpaper and scotch brite to finish it.

I drilled 3 pilot holes in the idler plate. All are 3/32" dia. I’m not exactly sure what size to drill the final holes. Two of the holes are called out at 1/4" and one is for an AN3 bolt. I haven’t figured out what goes in the 1/4" holes and I have found conflicting information on the AN3 bolt. Some literature says to drill it 3/16" and some info says I should drill it smaller so that I have a tighter fit on the bolt. I left the part with the pilot holes and will open them up later.