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While the plans are pretty explicit about how to install
the CS-109 and CS-118 bearing blocks (or in my case control system bearing
assemblies) locating some of the holes through the seatback and the landing
gear bulkheads isn't so clear. So, I made up some fake bearing
assemblies, and, drilled a small hole through them. Through these I
ran a piece of string. Once tied taught, the string defined the
centers of the holes through the various bulkheads. |
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Here's another shot of said string. You can see how I've
opened small holes in the landing gear bulkheads - just enough to allow the
string to run through w/o hitting the sides.
For the seatback, I simply cut a slot. Can't see it in the this
picture. |
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Once the center of all the holes was properly located,
drilling larger holes was done with a bi-metal hole saw fitted to a 12" long
3/16" bit instead of the usual short bit that comes with these hole saws. |
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Here's the CS-118, right side, with the entire right side
control system assembly bolted together and mounted up. Checking fit
and clearance led to some minor adjustments in the hole sizes through the
bulkheads. |
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Here's the front half of the same assembly being test
fitted. You can't tell from this shot but the fuselage is on its side
(I have straps suspended from my basement ceiling / floor joists).
Otherwise, that dumbbell hand weight wouldn't stay on there.... |
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This is the left side, fitted up as the right, looking in
from the very back. Yes, you eagle-eyed builders will notice I haven't
completely finished the landing gear bulkheads. |
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The very aft end of the left side assembly, picture added
just for fun and further clarity. |
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Fits perfect, now that the bulkhead holes have been
adjusted for clearance. Time to permanently mount the CS-109 and CS-118
pieces. |
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To mount the CS-109 and CS-118 mounting blocks, I marked
the bottom and center of the spot on the side of the fuselage, then, drilled
a 1/16" hole. I added a toothpick to the hole (next picture) |
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then CA glued the assembly to the side of the fuselage
after sanding the side, of course, dull with 36 grit sandpaper. The
combination of the toothpick and the CA glue affixed the piece to the
fuselage side almost permanently. |
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Then, I added the flox and let it cure. No need to
hold the assembly in place or worry about it falling off in the middle of
the night 'cause stupid me mixed the flox into the 5-minute the plans call
for. Peel ply is over the flox so I can add the 2-ply BID after the
flox is cured. |
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Here's the 2-ply BID layup after it was installed. No
big deal, but, I sure got tired of leaning over the side of the fuselage,
even though my straps allowed me to rotate it. |
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After cure, I re-drilled the control system bearing
assembly holes, trimmed the glass flush with the inside of the CS-109 and
CS-118 blocks and mounted up the control system assemblies.
Still fits perfect. Nothing moved. Whew! |
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Here's a shot of the right side, forward end. This
shows the bearing assembly, control stick, and CS-109 after it's been
glassed into place and trimmed. |
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Close up shot of the left hand side, same portions.
I have a bunch of washers on the bolts 'cause I ran out of bolts that
were the right length. |
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Last picture for this step. This is a close up shot
of the CS-118 for the left hand side. You can see the bearing
assembly, taper pin 'heads', 2 plies of BID over the plywood and fuselage
wall, flox corner and bolts holding the assembly together - I found the
right sized bolts! For the record, this step is incomplete. I won't
do much more on it before I have the firewall pretty much finished, trim
situation sorted out (leaning towards electric trim) and several other
things figured out I'm not 100% settled on.
More pictures to come. |
| Chapter 16
Step 3 Chapter 16 Step
5 |
