Chapter 16 - Step 4

This step has you install the bearing blocks and controls into the fuselage.

Left CS-118 floxed and glassed February 27, 2004. Here is CS-118 on the left fuselage wall after being floxed into place and 2 layers of BID added to both sides. The installation of CS-190 and CS-118 are easier with the use of the FMN10 bearings because they allow rotation in three dimensions instead of one. I had the fuselage on its side. I marked the location of the bearing blocks, assembled everything and layed it all in place. The blocks stayed in place on there own. I just lifted them up enough to put on some flox and layed it back in place. I doubled checked their location, made them square to the sides, cleanup up excess flox, and let it cure overnight. No need for two people or 5-minute epoxy. Of course I could only do one side at a time this way. Next night I flipped the fuselage onto its other side and repeated the process. Next night I set the fuselage on its belly and glassed all the blocks. This was made easier by wetting out two big layers of glass on plastic on the workbench, then cut out eight rectangles big enough for each block with 1" overlap to fuselage. I then simply applied the wet out glass to the block, brushed out bubbles, and removed the plastic and then peel plied. The hardest part was the forward face of the aft block. You can't see it or get to it very well since the block is under the top of the seatback.

Front Right controls March 2, 2004. After the bearing blocks were floxed and glassed, all the glass was trimmed and then all the controls were mounted in place. This was more a puzzle than expected. It took an hour or so to install all the controls on one side but 10 minutes on the other (of course I had it figured out by then). The problem is trying to reach all the bolts and nuts with wrenches, especially behind the seatback.

Front Left controls March 2, 2004. A view of the left controls mounted in place. Nothing too complicated here.

Aft left bearing block March 2, 2004. Here is the assembly at CS-118 on the left side.

Installing CS122/124 March 9, 2004. The last part of the controls is to position CS-122/124 in the correct place and orientation and drill it to CS-121. In this picture I have blocked CS-124 to be vertical and the proper distance from the firewall. One thing I had to take into account is that later on I will be adding fiberfrax and metal over the firewall. I made sure to leave about 5/16" extra space between CS-124 and the firewall in addition to the amount needed for the bolt head clearance.

Installing CS123 March 9, 2004. Here is a shot after floxing CS-123 into the firewall. I added a rather large fillet of flox on the forward face as you can see here.

Elevator Pushrod March 14, 2004. Here is the elevator pushrod after being installed. I had to open the hold in the instrument panel a bit more on the inboard edge. It was so much fun to get to wiggle things and make the elevator move at this point. I was sorry the fuselage was on saw horses instead of the wheels. It would have been nice to sit in the pilot's seat and make more vroooom noises.

Elevator Pushrod March 14, 2004. Another shot showing the quick disconnect and the attachment on the elevator. Yes, I'm aware that the quick disconnect is upside down in this picture. This was a temporary installation. This is all apart now and I will be sure to reconnect all this properly when the time comes.

IP Hole March 18, 2004. Another shot of the pushrod going through the IP. Make sure you have complete movement of the control handle without the pushrod hitting the sides of the hole.

CS-125L March 18, 2004. Here is the CS125 pushrod connecting the left and right aileron controls. This is fun because when you wiggle one control stick the other moves too.

CS-125L and CS-124 March 18, 2004. Here is a close-up of the bend at the firewall. Keep in mind that you need to allow for the extra thickness of the fiberfrax and aluminum that will be added onto the firewall later.