Tailcone fairing again!

From this point on, everything I did was done while ensuring that the pushrod was centered in the slot by using cardboard to keep everything spaced properly.

I also made sure that the top of the fairing was properly spaced below the rudder.

I then used the extension marks from the tape as called out in the KAI's to mark the location for the mounting screw holes.  Before doing this, I made sure the front edge of the fairing parts were more or less aligned with the edge line that was drawn on the tape.

After that, I pulled everything as tight as I could and taped it with Gorilla tape,  Then I drilled and cleco'ed the fairing parts to the tailcone.

Same same on the bottom one.

Double checking the pushrod clearance and centering.

Then I worked my way around the cutouts marking for clearance to allow the stabilator full travel without hitting the fairing anywhere.  I also attempted even up the left side with the left side to make the cutouts more or less symetrical.

Double checking the rudder to fairing gap.

Tailcone fairing continued...

I used a handled laser etching machine to mark my data plate.  Turned out pretty good.  The bottom line is a tad crooked but it will have to do because I am not buying another one!

Make sure that your data plate matches your registration card exactly!  Word for word including any punctuation and case.  If they don't match perfectly, your DAR will likely not certify the airplane.

 

The original scribe lines leave the parts too long in the front.  I trimmed another 1/8" off them.

Also had to cut another 1/8" out of the clearance holes for the stabilator spar.

No pic but I also had to cut additional clearance for the rudder horn and the vertical stabilizer spar as well.

Engine run #2 and Tailcone Fairing

Reinstalled the coolant elbow and hose.  Refilled the coolant and test ran the engine.  No leaks detected!  Score!

I then turned to working on this tailcone fairing again....

I sorta followed the KAI's by cutting and fitting the two parts of the fairing together and drilling the screw holes that will hold them together.

I then used my nutplate jig to drill for the nutplate mounting rivet holes.

And installed the nutplates.  Hopefully my days of installing new nutplates are about done.  There must be a million of these things in these airplanes. 

I then countersunk the screw holes for the flush #6 screws.

Put the two parts on the airplane and screwed them together.  This starts to show just how much of a blast fitting this thing is going to be!  I decided to go ahead and rough cut the slot out for the AST/Trim tab pushrod.  Not sure how one could wait longer to do this and get everything centered.

Just be aware that the directions are kinda wonky, the scribe lines are wonky, and the mold seams are not in the center of these parts.  It takes a ton of put it on and mark stuff and take it off and trim iterations.  I must have done this a hundred times.

First engine start!

 

Completed the first engine start today!  Only one squawk....coolant leak on the top elbow of the #2 cylinder.

So it appears that these are a two piece assembly where the elbow threads into the flange.  The assembly is then sealed to the head by an O'ring.

The straight fine threads on the elbow and the flange are sealed with Loctite 577 from the factory.  Apparently this was not sealed properly or the elbow was turned at the factory breaking the seal.

There is no way that this should have been missed in the test run for over an hour at the factory.  The leak was significant.  It is suppose to take allot of heat and force to unscrew this assembly but I was able to just unscrew it with my hands and no heat.

I have cleaned all the parts and have Loctite 577 arriving Monday.  Will apply and reseal the assembly while clocking the elbow to its original position.  Then it is not to be disturbed for at least 10 hours before reinstall.  I will give it longer than that to cure and then reinstall it and try it again.

Turnbuckle safety clips and starting Emp fairing

 Used this tensiometer to set the cable tension to 45 pounds.

Then installed the safety locking clips on each end of both turnbuckles.  Very important to ensure these are installed per the KAI's!

Then I got started on the work required to fit and install the emp fairing.

Pilot holes are drilled in the inside corners.

Brought these parts back to the house to work on them at home tomorrow.

More aircraft assembly