Finished Upper Forward Fuselage

I have a lot of things going on right now so working on the plane has moved to the back burner. Building slowed to a near halt and I haven't gotten much completed. And if I don't complete much there isn't anything to write about, and this leads to a lack of posts. I did round up several consecutive hours last Sunday and finished the Upper Forward Fuselage Assembly. I had postponed building this part until I finalized my plan for the instrument panel and all the avionics installing behind it. Once I had the plan I felt comfortable finishing up this section. I hope to get back into the swing of things soon. I have another long weekend coming up, so hopefully I can make some good headway then.

Dates and Times
Sat 19 -1.75hrs- finished rudder pedal install except the brake lines. Installed more access covers and floor panels
Sun 20 -4.0hrs- Prep tunnel close out panels
Install fuel selector valve
Locate fuel pump install location
Make brackets for fuel pump install Measure for fuel lines
Note brake line requirements
Prep order for Bonaco
Tues 22 -1.0hr- worked on side panels
Wed 23  -1.0hr- worked on side panels
Sat 26  -3.0hrs- worked on upper fwd fuselage
November
Sat 2 -1.25hrs- worked on upper fwd fuselage
Sun 3 -5.25hrs- finished upper fwd fuselage

I borrowed this tool from one of our mechanics at work. I would say something like this is a requirement when installing the nutplates for the rear seat closeout panels.

Upper Forward Fuselage clecoed in place ready to drill out the holes.

All riveted together...section complete.

My helper reading the plans.

Instrument Panel Plan

I found myself constantly wondering what to do about the instrument panel and all the avionics. The question constantly popped into my head and it was followed with more questions. Do I just build the upper forward fuselage section and worry about all the avionics later? Will it all fit? Do I want to buy or build a center console? Stock panel or expensive aftermarket panel? Layout? Shape? Size? Install now or wait? etc...etc... So I decided to model the entire system to allow me to formulate a plan and resolve a lot of the questions and concerns I had.
So here is my plan...


This is the 3D model I created to show the aircraft structure and how I want to integrate my avionics; a Dynon Skyview system with a Vertical Power ECB and a Garmin GTN 635. I will be using Van's instrument panel and new fuel selector. I will be making the center console, side console closeout panel, and fuel valve enclosure. The center console mounts an iPad mini that is removable, and when removed reveals a small storage compartment for sunglasses etc. The instruments and avionics are shown below.

This is a diagram showing all the avionics, instruments, and antennas required for the aircraft. This does not include: switches, probes, lights, or sensors.

This is a diagram showing the location of each component along with other view orientations.
Note:
- There are mount angles attached to the ribs directly aft of the firewall. These angles are there to install the panels shown. The panels stand off the firewall 1.0in (no new holes in the firewall) and will be lined on the forward side with sound proofing. The other advantage to having the removable panels in this area is the avionics can be mounted to the panel, outside the aircraft, and then the panel screwed into place.
- The VP-X will be mounted on a plate that spans the instrument panel lower angle and sub panel lip. This allows easy access to the component for the large quantity of wiring that will be going to it.
- The ribs do not need to be modified. Only the subpanel will need to be modified to allow the GTN 635 installation.
- The Transceiver and Transponder are mounted directly to the existing tunnel cover side by side.
- The new center console will be made from fiberglass and can be relatively thin since the only thing that is installing to it is the iPad mini.

This is the plan for now...subsequent to change at any time : )

Steps, Antennas, and Stuff

A lot of work has been completed, but I lack that exemplary feeling of joy after completing a section or part that I normally get. I suppose this felt more like a lot of small chores that needed to be done in order for me to move on to those larger tasks. Don't get me wrong, this was still a lot of work.

Tues 13th - 1.75hrs- Started upper forward fuselage section
Wed 14th -0.5hrs- Measured for antenna install, made spacers for step
Thur 15th -1.0hrs- Worked on upper fuselage, bent panels, drilled out holes
Sat 17th -6.5hrs- Made antenna doublers, drilled skin for antenna install, primed parts, installed stainless steel heater boxes, made clips for wiring conduit
Sun 18th -5.25hrs- Installed side panels, installed steps


I didn't get very far on the upper forward fuselage section. I just clecoed parts, drilled holes, made a stiffener out of extrusion, and then clecoed to the aircraft.

I ordered and installed the stainless steel heater boxes instead of Van's aluminum ones. Stainless Steel's thermal conductivity, or K-value, is a fraction of aluminum's; meaning that the stainless steel heater boxes will insulate the tunnel from the heat better than aluminum. Hopefully, this keeps the tunnel's heat cooler than what it would originally be. Also, in the event of an engine fire the aluminum would just turn into a puddle from the heat but the stainless steel would still be there. I also installed the boxes with a high temp silicone gasket (note the white tube in the pic below was shipped with the boxes) and some 3M fire barrier sealant around the edges to help keep the fumes out.

The Com Antennas Install has begun!
See my previous post for what my plan is for these antennas as well as dimensions and a discussion on the doubler sizing. I made the doubler first, per the dimensions I show on the previous post, and then I drilled out the rivets on the outboard frame since they will be incorporated into the doubler install. I match drilled the existing holes into the doubler and then match drilled the doublers holes to the skin.


I then drilled the large center hole in each part, deburred, dimpled, and primed everything. Here is a pic looking down and forward on the left hand installation location.

 

The doublers and shims dimpled and primed.

  The antenna clecoed in place.

 I finally got around to installing the side vent doors.

The step install.
I am installing these a little differently than what the plans say to do. I am using 1/4in hardware instead of #10 and I am installing it at angle instead of straight up and down. This will allow removal of the bolt in the future through the access panels I will be installing in the luggage compartment floor. I also made spacers from delrin rod to insert into the step tube to reinforce the tubing and prevent it from being deformed while tightening the bolt. I made them from delrin because it's cheap, I think it was around $3 for the rod I bought, and it wont cause dissimilar metal corrosion sitting inside the step.

 I made a makeshift insertion and positioning tool from pvc and safety wire.

 The step installed. It's a little scratched from sliding it in place, but I can touch that up later.

 View from the outside and the "shin protector" is installed.