35 - Upper Fwd Fuse (almost complete); 36 - Aileron & Elevator Sys. (complete); 37 - Roll Over Struct. (started); OP56 - Garmin AP Servos (installed pitch servo)

Lots accomplished since the last post ~13 days ago - see below for details.  Most importantly (not shown here), I've ordered the engine, prop, firewall forward kit, put a deposit down on a SteinAir panel, started talks with Abby at Flightline Interiors, and ordered a crapload of materials from Aircraft Spruce for the fiberglass work (esp. the canopy transition).  However, for the past couple of weeks, I specifically accomplished the following:

- installed idler arms; drilled, primed and assembled elevator pushrods and stick link pushrod
- riveted center section of forward top skin to fuselage structure (back-riveted as much as possible with my wife bucking); first time under the panel section - pain in the back; installed bushings into hinge ribs; primed and painted canopy cradles
- a half hour to torque ONE nut/bolt to attach control arm to fwd elevator pushrod; fabricated elevator bellcrank assembly; trimmed and installed AP pitch servo bracket; installed bellcrank mount; installed mid elevator pushrod to bellcrank assembly; installed elevator pushrods to idler arms; checked match-drilling of Tosten control stick with stick bases
- Installed pitch servo
- greased and installed canopy cradle assemblies (4 difficult-to-reach bolts);  attached gas springs to canopy cradle assemblies; installed canopy release mechanism and tested action (very nice); prosealed rest of top forward skin to fuselage; also, prosealed gaps in the firewall and subpanel, but instead of sealing from the inside, after placing a fay seal on the flanges and clecoing the skin, I sealed the remaining holes from the outside, pushing the sealant through the holes. Next proseal session, I may fillet seal from the inside as well (belt-and-suspenders, incase there is a small gap I couldn’t see)
- Final-drilled both Tosten control sticks; attached control stick bases; attached link stick pushrod; worked on control column travel to get both sides to hit stops at the same time; aligned control sticks
continued working on control column travel to get both sides to hit stops at the same time
riveted rest of top forward skin to fuselage; added final bead of sealant to subpanel and plugged any other holes with sealant, taking care to not make it too thick (may impede canopy)
- attached brace brackets to brace; riveted fwd and aft roll bar frame assemblies; clecoed roll bar frame assemblies, roll bar straps and window shims; #30 final-drilled outboard #40 holes
- #30 final-drilled inboard #40 holes; deburred holes; machine countersunk outbd roll bar strap where bar brace attaches; countersunk #30 holes in window shims; primed the inside of the frame assembly

Elevator pushrods (3) and stick link pushrod:

33 - Rudder & Brake Sys (rudder trim and pedal extensions); 35 - Upper Fwd Fuse (subpanel, panel frame); Avionics (fabricated avionics shelves)

Lots of little tasks done in three separate sections, including figuring out how the massive amount of remote avionics boxes and other avionics components will be mounted between the panel and subpanel.  Thanks a bunch to Ken B., whose subpanels I have mimicked - his new website can be found at:   rv-14a.com.   Final major painting of the interior was completed as well (last bits will be the roll bar and associated structure).  Specifically, the following were accomplished since the last post:

- fabricated release pins; assembled release mechanism; installed forward top skin doublers (AD2-2 rivets); trimmed cowl shims
- broke edges of top forward skin; dimpled #40 and #30 holes in skin; countersunk #30 holes in forward parts of longerons; dimpled shims and firewall flanges
- attached Aerosport Products rudder pedal extensions
- fabricating two shelves for avionics that fit under the avionics bay
- fabricated two 2” angle aluminum brackets in the map box - drilled for AN3-3A bolts
- painted panel frame, subpanel, panel standoffs, circuit breaker channel, and canopy rails
- temporarily attached rudder trim arms (only to find out I’ll need to attach them later, permanently, after the rudder cables are attached to the rudder)
- prosealed forward top skin to subpanel and firewall

Fabricated release pins:

35 - Upper Fwd Fuselage (subpanel, panel frame, avionics shelves/angles, canopy release mechanism)

It is very satisfying to see the panel frame attached to the front end of the fuselage - I can easily envision all those expensive doodads on the SteinAir panel sitting right in front of me as I whiz across the country at 200mph. But, that's still a long time in the future, so for now, back to earth - here's what I accomplished since the last post:

- Riveted sub-panel assembly together
- installed instrument panel stand-offs and connector brackets; installed seal angles; installed upper fwd fuselage assembly to fuselage; temp. attached canopy hinge brackets; installed cowl pin retention bracket (prob. won’t use); installed wiring channel assembly; match and final-drilled fwd and aft canopy decks (both sides)
- deburred and dimpled (CS4) canopy decks; countersunk longerons; prosealed longeron-deck space; riveted instrument attach brackets to fwd decks; clecoed and riveted canopy decks to fuselage; riveted wiring channel and cable support; installed instrument panel attach plate; separated panel frame angles; deburred panel frame
- Machine countersunk holes in panel frame and panel flange doubler; riveted nutplates to panel frame; riveted panel angles to doubler and frame; clecoed panel frame assembly to fuselage
- fabricated a couple parts of avionics shelves/angles; another 2 hrs (not logged) spent cogitating over the placement of remote boxes, etc.
- cut another shelf for avionics; radiused/chamfered pivot block; drilled release mechanism; fabricated left and right release mechanism pushrods (pain in the ass!)

Masking the side skin, prior to filling gap with Proseal - sealant is used here to prevent water from intruding into the cabin: