Scott & Tanya Card RV9A build log (N4822C)

I got out all of the parts for all of the other fuselage bulkheads and got to work edge deburring all this stuff. Edges are much easier to deburr before fluting so that is what I did. Most of these bulkheads come out of the forming process pretty warped. It is the job of the builder to flute the edges to try to straighten them out. It took a full work session just to get all the parts straightened out enough to start pre-assembly and match drilling. I will probably roughly cleco most of the bulkheads to the fuselage bottom in sequence before priming just to try to get the flange angles as close as possible.

 

  

  

  

 

With the bottom part of the F705 bulkhead done, it was time to move to the top section. There are a bunch of little parts to fabricate and match drill to the upper channel section. Since I’m building the tip-up canopy version, first I made the canopy latch angles. These are made from 3/16″ thick 2×2.5″ angle. It is a good thing that I have a decent band saw or else these kinds of tasks would be a real pain. Three other parts are fabricated to form a sort of long clip for the top of the seat backs. One of these parts is made out of .040″ sheet and requires a 4 degree bend lengthwise. I used my box-pan brake to accomplish this bend. It took a bit of time to get all of this stuff figured out and match drilled to the channel.

Then I moved on and drilled the flap bearing blocks. I just marked them and drilled them in the drill press. Perfect. I installed the four nutplates on the uprights using -3 NAS10?? rivets. They only require a small countersink that can be done with a few turns of the deburring tool. Next, I took it all apart and deburred all part edges and holes, and scuffed everything in prep for primer. I did all the easy to get to surfaces with a piece of scotchbrite to the bottom of a velcro pad on the bottom of my D/A sander. Then Tanya did the rest by hand. It only took her about ten minutes.