I started tonight by fabricating the shims that fit between the aux and lower longerons at F-902. An angle will sit on top of these shims that will serve as the structural support for the forward tank attach bracket.
Unfortunately, when I took the clecos out of the gear web, the holes shifted. It looks like I didn’t get the gear web fully seated in the aux longeron before match drilling it to the bulkhead. This side is about 1/16″ off, the other side is about 1/32″ off. I need to order some things from Van’s anyway, so I’ll go ahead and replace the bulkheads.
I skipped to the next section and began assembling the brake pedals. I made the optional lightening cuts since every ounce counts. Instead of the diagonal cuts at the bottom of the pedals, I cut a 1/2″ radius curve to match the radius of the lightening holes in the pedals. The additional weight savings is negligible obviously, but I think it just looks better.
I drilled the UHMW rudder support blocks for the AN3 bolts that will be used to attach them to the skin stiffeners. I’ve heard other builders complain about drilling this plastic, but if you turn your drill press down low and feed fairly aggressively (3-4 seconds to drill all the way through), the plastic comes out in one single shaving and the hole is perfectly clean. You don’t even need to clamp the block (though make sure you hold it down firmly as you back the bit out).
I mounted the rudder tubes to the support blocks. Make sure you pay attention to the orientation of the blocks. The holes are not drilled perpendicular to the sides since the skin supports taper inward toward the firewall.
I clamped the rudder bars together with a piece of scrap angle and clamped the brake pedals together using a thick steel rule. These are not the stock master cylinders that Van’s supplies (which are made by Matco). These are made by Grove. They are higher quality than the Matco units and are adjustable.
