Canopy frame part 2

 Worked on prepping the canopy frame for install on the fuse.

First is to drill out the canopy support strut mounting lugs to two different sizes.

Next was countersinking the fwd arms to accept a flush screw.

The screw head must be flush to 1/32" protruding to prevent it from catching on the fwd top fuse skin.

Next was match drilling these 5 holes on each side of the fwd frame.

And then installing these rivets.

Then match drilling the canopy latch stop mount holes.

And then riveting the stop to the frame.

Canopy frame part #1

 Got started on the canopy frame as well today.

The KAI's have you round over this top inside edge of the canopy frame.  Not gonna lie, this sucks and takes a fair amount of time!

I assume this is to prevent the canopy frame arms from catching on the top skin of the fwd fuse.

On her wheels!

 Got the girl down off the workbench and on her wheels for the first time.  This required a ton of rearraigning in the garage to make it all fit and leave me room to work.

Also purchased this Bogert's Bogi-Bar tow bar from ACS.

Why do these gear have so much camber angle?  IDUNO.....

Brakes part 2

 Finished up the brakes today.

Finished up the brakes today by securing the brake lines that connect to the top of the gear legs.

The lines get secured to the aft bulkhead with a zip tie.  My big arms and hands had to work hard to get this done.

And finally the line gets terminated to the gear leg fitting and zip tied to the inner gear leg mounting strap.  Connecting this line was no fun.  Getting the nut started on the fitting was no fun.  Tightening the nut was no fun.  Nothing was fun about this simple task........

To tighten this nut, I had to modify an open end wrench to be able to turn the nut in the limited space.  I had to grind down the sides of the wrench near the open end flats.  Would have been good to cut the boxed end off as well to allow more clearance but I made due without doing that.

Virtually impossible to torque these nuts so I just did it by feel.  Maybe they won't leak!  :)

Brakes part 1

 Worked on installing the brake calipers and the brake lines from the gear let to the calipers.

First was installing and properly clocking the fittings for the brake lines in the calipers.

Super easy to install the calipers.  They are now provided with Nordloc washers instead of needing safety wire.  This is my first time using/trusting them.  My understanding is that they are the bee's knees and that they work as advertised.  We will see!

Other side done.

Next is fabricating up two short brake lines to connect the gear leg fitting to the calipers.

All done.  Easy peasy!

I would much prefer braided teflon hoses for this job but I have to build per the KAI.  Once certified I can switch them out.  Aircraft Specialty/TS Flightlines sells a nice kit that makes this a no brainer.

Pilot side done.  I just shaped the hoop by hand and made it look like the KAI drawing as much as I could.

Co-pilot side done.

These came out looking pretty good.

Installed the wheels/tires/bearings.

 Finished up the main wheel installation.

Packed the bearings by hand.  The integrated seals make this a bit harder to do.

Mounted the wheels and torqued the nut down.  The directions are explicit about how to do this.  These must be tighter than traditional wheels and bearing seals.  They have to be tight enough to prevent the seal from turning with the wheel.  There will be some drag on the wheel when spun.

Main gear alignment check

 Used the procedure from the KAI's to check the main gear alignment.

Installed the axles.  Had to debur/clean up the powder coat around the holes so that the axles would sit flat against the gear leg.

Lucky for me, the gear legs have 0 degrees of toe in or out.  Glad for that since the shims cost like $36 each and were on back order.

Then I removed everything and installed the brake mount plate and reinstalled all the hardware.