Posts Tagged ‘countersink’


January 30, 2012

Today I worked mostly in the baggage area. The floors are drilled, deburred, and dimpled. I’ll just need to prime them now. The F-750 side walls were riveted on. The rudder cables will need to be feed through the bulkheads behind this panel so I left some string sitting in the holes to pull the cable through. Finally I carefully countersunk the side rails above the arm rests. Other than cleaning up a few holes, I should be ready for a mass priming session next weekend. Here’s hoping for a warm front on Sunday.





Still prepping fuse parts

August 29, 2011


For your viewing pleasure here’s the boys enjoying the Blues over Lake Washington earlier this month. As for the project, i’ve been working on it I swear. It’s really just a 1000 little tasks without much visual payoff so I’ll spare you the pics of pretty countersunk holes in a neat little row.

I’m still slowly working through all the final steps before starting the riveting on the main fuse. I’m excited to see if I got a the puzzle pieces made correctly! All the deburring, dimpling, and countersinking including the longerons is done on the internal structures. I’ve primed about 2/3 of these parts. The left forward fuse pieces still need to be etched and primed. The skins still need to be prepped but that should be kinda fun as imam trying to “eat my vegetables”‘first. Also, I have to go back and find a solution for one hole I doubled drilled on a bulkhead. After that I’ll be reassembling the canoe! Work is going to take over this week so hopefully I can hit it hard next weekend. I’m aiming to flip the canoe this fall and order finish kit before the end of the year.

The Great Debur Fest

January 24, 2011

This weekend I was able to finish drilling all the holes on the center section, countersank the four holes in the front 704 bulkhead, and make the attach straps for the F-623 ribs. Now the 776 skin is off. Once the rest of the parts are disassembled, then it all gets deburred, dimpled and primed. That last part is gong to require some better weather than we’ve been getting.

Sunday Summary

July 25, 2010

Beautiful day in Seattle today. The family went on a beach walk/swimming pool day leaving dear old dad to wrestle with the aluminum in the garage. Awesome!

I started by finishing the riveting on the right wing aileron gap faring. I got all the hardware together and mounted everything back on and clecoed on the bottom skin. The trailing edges of the flap and aileron are much closer now (within about 1/16″) than when I tried it yesterday. Whew.

Last cleco standing on the right aileron gap faring.

I moved on to finishing out the left wing aileron and flap mounting. Countersinking all the holes on the flap brace was tedious but otherwise painless. I wnet back and squeezed the leftover aileron mount brackets with the new 4″ squeezer and closed out the day by getting all the left wing parts cleoced and ready to rivet.

The edge difference between the flap and the aileron got much better after getting everything put together.

The internal linkage for the left wing. Yes that is a hardware store nut. Just temporary so I don't waste the aircraft nuts.

An Update Finally!

July 20, 2010

Ok so I ignored the build log for a month. But I have a good excuse. I am actually getting some good hours in on the project without sacrificing family or job time… mostly. Anyway, in my last post I was about to take a week off from work in mid-June to finally focus on the QB wings. I had the optimistic idea that I could get them nearly finished with an 80-hour week put toward the project instead of the 80 hour week I’d put in at the real job. Well I probably only logged about 30 hours in the garage that week and in reality the QB wings at my pace is more like 120 hours worth of work. Still I am making great head way and as of mid July I am closing out a lot of the wing work. Without further ado on to the progress:

With the bellcrank bushing drilled out and the metal prep work finished on the aileron mounts, I started by riveting the aileron mounts together and then on the wing. I have the left a few of the rivets undone as I wasn’t able to squeeze them. After butchering a couple of bucked rivets, I decided to order 4″ yoke to get to these rivets later.

Next up I prepped the aileron and flap braces and matched drilled them to the structure.

The aileron brace fitted and drilled

A down the line shot of the flap brace ready for priming.

Onto the control arms. There are two on each wing. A small steel one connects aileron to the bellcrank. A larger aluminum control rod connects the bellcrank to the center fuse control columns. First, I laid out where the hole needed to be drilled using painter tape to mark the circumference and then evenly divding that for the two rivets on the steel rods or the 6 pop rivets on each end of the aluminum arms. The V-block and some boelube on the drill press made quick work of the drilling.

Measure the circumference then divide by 6 and mark the tape.

Using the V-block to assist in drilling the holes.

Then I matched drill the rod end in place.

I left the riveting till later so I could move on to installing the steel mounting brackets on the ailerons and flaps. These were pretty straight forward, though I used a combination of drill press and match drilling to ensure good line up and clean holes for the all the bolts.

After temp. mounting the ailerons, I got out the primer for the flap and aileron braces and mounts. Done and done. Now onto the flap hinges. I took some time to line up the ailerons into neutral position use the wood stringer and tool hole method Van’s suggests in the instructions. This way I was able to fit the hinge and allow for the 1/4″ space between flap and aileron edges. With that mark on both wings, I could line the hinge up accurately and drill at the holes out.

Priming: The bittersweet moment of building. It means your close to assembling something but it's a PITA.

With that out of the way, I worked on countersinking the flap brace. There’s a small curve ball  for the QB wings at the root end of each wing. The standard build instructions spec universal head rivets but with the QB they want us to use flush rivets. I emailed Van’s. Joe said to just follow the instructions for my kit. OK flush cherry max it is. I couldn’t tell you why though.

Next up more riveting on the braces, finishing out the control rods and getting all the washers and spacers in place.

Catching Up

May 18, 2008

We had great weather in Seattle over the weekend for the first time in ages. I worked here and there on the project this weekend so we could all enjoy the outside as much as possible.

Tasks Completed:

  • Drilled and countersunk the web stiffeners
  • Started drilling the conduit holes in the cover support ribs
  • Dimpled the forward bulkhead for the web stiffeners

Center Section Blah Blah

May 10, 2008

Tonight I started marching through all the remaining parts prep. The center section is proving to be quite tedious. There are a bunch of little items to do and you have to pay attention to the plans much more on the fuselage. I am reading the plans over and over to avoid drilling the wrong hole on these parts.

I almost plowed ahead with drilling a third hole in the small cover support rib before really seeing how it goes together. Also Ken Scott confirmed for me that you actually dimple the web of the forward bulkhead. I had initially assumed this would be countersunk! If I can get a good day’s work in later this week, I should be ready to prime the firewall and center section parts as soon as the weather is good. 

Tasks Competed:

  • Installed all the nutplates to the bulkheads
  • Drilled and prepped right web stiffener
  • Drilled and prepped cover support ribs

Center Section Riveting

May 6, 2008

The right side control mount didn’t turn out to my liking. It didn’t sit flat with the bulkhead because the holes are slightly off 90 degrees. I ordered a new part and moved on to riveting the forward bulkhead and arms together. A couple of rivets look suspect. I’ll drill out and redo tomorrow.

Also I spent time with the plans trying to figure out whether to countersink the bulkhead for the web stiffener riveting or dimple it. The bulkhead is .040. Technically for an AD4 rivet the material should be .050 thick. But if I dimple the material I am afraid I will enlarge the hole on the .063 web stiffener angle. Time to write Van’s.

Tasks Completed:

  • Riveted F704A,C, and D together.

Firewall Countersinking

April 1, 2008

I finished all the countersinking tonight on all the stiffeners and gussets. The hard wood jig I use to hold the part while using the microstop in the cordless drill is working great. I started to dimple the firewall, but after a few holes trying to holding the part and dimple by myself I thought better of it. I’ll get Annabelle to help out later this week.

Tasks Completed:

  • Finished countersinking stiffeners and gussets
  • Started to dimple firewall

Finishing Firewall Drilling

February 24, 2008

Tasks Completed:

  • Finished drilling stiffeners and gussets to firewall
  • Drilled spacers, doubler and L/R F601J
  • Disassembled firewall structure for deburring and countersinking