Started the Fuselage!

Got started on the fuselage kit since I am now waiting on the right wing spar to be sent to me.

Had to machine countersink the center section for some nutplates.  The center section parts are pre-assembled at the factory from clear anodized parts.  The factory has done a poor job of deburring and cleaning up the edges and holes on these parts.

I went ahead and deburred all the smaller holes.  Will hit the larger ones with some of the other tools.

These nutplates in the center get flush blind rivets.

These on the outside ends get squeezed flush rivets.

Other side.

Blind rivets done.

Next these upright pieces get machine countersunk for a couple nutplates.   Have no idea what attaches here.  I looked ahead but did not see it.

Both done.

These two holes get reamed up to #12.

Hit a snag because the pre-assembled center section was incorrectly dimpled at the factory.  These are supposed to remain flat and get reamed up to #12.

The community has informed me that this issue has been around a long time and the advice from Van's is to drill the dimples out to #12 and build on.  I decided to smash them flat and then drill/ream to #12.

Even with smashing them flat, and then drilling/reaming up to #12, a bit of the dimple remains on the backside.  This should not be an issue with the bolt/washer/nut that ends up here to hold the plastic spar guide block.  It is a shame that even though the factory knows this mistake is happening, they continue to make them wrong.....

Next I dimpled the first three holes on the corners of the F-01204D-1.

 

Finishing Kit Ordered!

Finishing kit ordered!  

This is the canopy, cowling, landing gear, wheels and brakes, engine mount, seats and interior finishing, etc.  This is the most expensive of the airframe kits.

Will be working directly with Flightline on the customization of the interior package.

I don't need this kit anytime soon but I wanted to get ahead of the lead time so I don't end up waiting on it once the fuse and wings are done.

Right spar destroyed :(

So in following the directions of Van's support, I cut up the right wing spar to ensure that it is never used in an aircraft.  Never dreamed I would ever do this to a spar! 

Remember the sketchy wing spar? It's a no go!

A few post back I mentioned some observations I found on my right main wing spar upon checkout during inventory.  I heard back from Van's and the engineering team declared that the spar should be destroyed.  Van's is sending me a new right wing spar.  That being said, I have to destroy the bad spar and send them pictures for proof.

I know this will be a very expensive ordeal for Van's in losing half a wing spar, shipping and crating cost, etc.  That must mean they are definitely not comfortable with the spar that was shipped to me and if they are not, I certainly am not!

All good things must come to an end!

 Well our Hawaiian Cruise was EPIC!  We are back home now and time to get back to work!