HiFly Radio, 10 build N#?

[Fenderbean]

Greetings!

About to restart the build, I have been buying some tools to improve and speed up the process this time around I will try and highlight and when possible, get them on the channel.
I will be doing some cool things on my channel and to learn as a I go and to help anyone I can is what I enjoy most. While doing that I hope to bring in my other love for music and have some famous musicians come buy build and eventually fly with me while doing some basic questions and answer type interviews.
I don't know if it's appropriate to post my channel here so I will hold for now.

If anyone cares my background in aviation is mostly military, started off working on them then transitioned to flying. Had time as an instructor with the bulk as a maintenance test pilot.
retired in 19 and decided against the airline job I had after covid and now just a contractor flying a desk.

Tail kit on hand with vertical and rudder complete about to start the horizontal. Once I get rolling, I will update here and possibly post links to the youtube channel

 

[Fenderbean]

Just a few of the layout, I had sold the kit a few year ago and almost fate like it came back to me! considering current cost I saved a ton on the tail kit at least.

 

[Fenderbean]

A few tool things and trying to finish up the shop before starting......

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[Fenderbean]

Been a few years but getting back rolling this weekend, finally getting the shop to a point of building!

 

[Fenderbean]

First good build day and man I spent all day doing one thing! So the Flyboy rudder stop I bought needs MAJOR modding to work with the new lower rudder hinge/stop bracket. The SB-00002 is done and starting the Horizontal now.

 

[Fenderbean]

SB complete and something to note on the flyboys accessories rudder stop, it was designed for the old style brackets the new one requires extreme modding to fit. The bracket is narrow in the back and opens wider towards the end.
Finished off the rudder and the pillowing fix rivet. My original plans had a screw/nut new version is nut plates. I kept the original bolt, not sure why they changed?

 

[Fenderbean]

Working the front and rear spars on the horizontal. Waiting on TQ wrenches to finish up a few skipped steps but that’s how it goes it seems.

 

[JeffPeters]

I noticed on your rudder top, at least from what I can tell in the pics, the R-1003A and B aren't oriented as shown in KAI (7-9, Step 5) and it calls for AN470AD4-4 for those holes and it looks like you have a pop rivet in there.

 

[Fenderbean]

I noticed on your rudder top, at least from what I can tell in the pics, the R-1003A and B aren't oriented as shown in KAI (7-9, Step 5) and it calls for AN470AD4-4 for those holes and it looks like you have a pop rivet in there.

hmmm good catch, this was started by a different person. I have gone back and checked his work, and I noticed the pop rivets and was wondering but didn't notice the 1003A and B orientation so im not sure. Guess I will have to check on this; this is a 2003 kit so I will look back at the orig plans and see if there is a change. There are some differences in this area, like I mention new plans show nut plates for the weight mounts vs bolt/nut.

 

[Fenderbean]

Mr Peters, thanks for the eye the orig builder did it wrong

 

[Fenderbean]

Welp 1 step forward and 8 steps backwards, going to be replacing the rudder. I will continue on with the horizontal at the moment, may have a replacement lines up thanks to another builder.

 

[Fenderbean]

So found a rudder to replace mine, crisis avoided!
Horizontal is under way and made good progress over the weekend. Did lots of parts clean up and prep work on ribs. Added the rear hinge brackets, front mount brackets are done mine two holes per for mounting.
I received my tq wrenches so I installed the lower hinge stop on the vertical and rear spar hinge bracket. Waiting on my tq stripe to show.
Hate the blue stuff, doesn’t help it’s been on there for over ten years!

 

[Fenderbean]

So yeah I’m definitely building plane muscles, even with a Cleco gun my arms and hands are sore!!!!

 

[Fenderbean]

I final drilled the left horizontal and with me swapping over some clecos now to final drill the right. Should be ready to disassemble, debur holes, dimple and then prime contact areas, inner spar and forward facing rear. I’m leaving all exposed unprimed since evoke would have to remove it.

 

[Fenderbean]

Time to take it apart and debur, dimple and prime a couple things. Then to final assembly.

 

[Fenderbean]

Dimpled the ribs, had to use
The cad1, Numatx and the vice grip type dimpler to get them all.

 

[Fenderbean]

put off drilling the forward mounting holes, drill up from a #40 to about .015 from the final 3/16 then I used a 3/16 for the perfect holes. Turned out great.
Then I started so prep for the priming I will do, ribs spars not exposed to outside and ribs.
I’m using some aluminum save degreaser with a scotch pads to scuff and clean for the primer.

 

[Fenderbean]

I almost didn’t prime but I figured the places i cannot get to would probably be smart. I absolutely hate painting. Good thing is I get to assemble the horizontal now.
Oh and the Numatx is worth ever penny, it’s great for dimpling on a CAD1 from Clemson aero, perfect dimples and rivets. No wavy skins, or oil cannon? I think they call it.

 

[Fenderbean]

Weekend update, nose ribs are in, front spar connect to those. Currently adding all the skin rivets to front spar and mid spares. Tiny rivets in tight spaces. Barf

 

[Fenderbean]

More

 

[Fenderbean]

Wooohooo one side complete! Three more to go but seems to go much faster once the spar is done.

 

[Fenderbean]

Horizontal is complete and started the layout on the elevators. Seems I am missing one part, and have one extra of another part. I ordered the machined trim cable mounts so they can be a bit nicer and removable, hope to start on it later in the week.

 

[Fenderbean]

Elevator time, a lot to these things X2

 

[Fenderbean]

A little work on the first page of the elevators, trying to not to do much until my missing part arrives. Any day now, so then it’s full speed ahead.

 

[Fenderbean]

More elevator work, bent the closeout tabs today and started assembly for final hole size drilling.

 

[Fenderbean]

More elevator work, missing part came in so finished getting the counter balance parts on. Did some final hole drills on the trim hatch doubler. About to start the trailing edge stuff and the dreaded proseal prep.

 

[Fenderbean]

Manage to get the elevators up to the final hole drill stage, soooo much to these things. Also did the arms and trailing edge wedge stuff.

 

[Fenderbean]

Slow week due to slave day I mean Mother’s Day and a week of spring cleaning around the house but I managed to get the elevators to final hole drill and started the templates for the foam ribs measurements on the page was pretty close I will cut slightly larger just to make sure.

 

[Fenderbean]

Got a little nutty today, well but plates that is.
Time to disassemble and prep!

 

[Fenderbean]

If anyone is interested I do videos as well on youtube channel.

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[Fenderbean]

So while I wait on what I hope to be a game changer for small aircraft building and better wx for priming I moved on to the tail cone. I found this part much more enjoyable and discovered my first oops event. I didn’t realize I had two different length J stiffeners and cut the 6.5 in for the second bulkhead which makes the one about 1.5 inches too short. Minor oops but still an oops

 

[Fenderbean]

More

 

[Fenderbean]

And more

 

[Fenderbean]

And just a couple more

 

[Fenderbean]

I’m waiting on a nice little edge marker for the J stiffeners but went ahead and did as much as I can. I’m also still waiting on something from Clemnson Aero that will allow riveting most things with the c frame.
I used a dremel metal cut wheel to do the J stiffener 45 deg cuts. Put some of the tail cone together as well mainly just to look at and motivate.
And have I mentioned I hate the hitting metal with rubber hammer to bend it? It’s easy enough but I just feel like there has to be a better way. That being said the two L bracket aluminum runners for the top of the side skins are done as well.

 

[Fenderbean]

 

[Fenderbean]

Ready to start match drilling the J stiffeners and I also made the extension for the one that was short. Center cut between the last two bulkheads and made the extension with a doubler made to rivet on top that covers the length between the two bulkheads. I feel
It’s over kill but that what vans recommended for the plane lady.
The little 2 in edge marker is a super duper handy tool, highly recommend this one from wen.

 

[Fenderbean]

how can I already be out of clecos!!!! I just bought another 100!!!!!!