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Bobs Ten
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Date:  3-14-2015
Number of Hours:  4.30
Manual Reference:  
Brief Description:  Prep Cabin Top, Overhead Console, Switch Panel

1412 - 1536 1630 - 1824 1930 - 2030

Install cabin top and temporarily cleco in place.

Install cabin top forward tube brace.

Fabricate a guide from scrap sheet to located tube on switch panel. this guide consisted of two nested pieces of sheet. Eqach sheet was drilled for the tube diameter and then sheared at the major chord of the circle yielding a half circle that fit the tube. These scraps wer then measured and bent to locate the tube and then clamped in place. At this point, the brace tube was removed. The switch panel was now temporarily taped in place. Next, a piece of scrap copper 3/4" pipe was positioned in the two half holes and the edges were marked on the switch panel. I neglected to take a picture while the cabin top was installed, so the photo is for reference and note that it is upside down as the cabin top was sitting on the table.

The switch panel was now removed and the hole was drilled using a unibit.

Re install the switch panel with tape and verify that the brace tube could be installed, verify fit.

Some adjustment was necessary to ensure that the tube could be installed with the switch panel in position.

Remove cabin top from fuselage.

Match drill overhead console and panel inserts using #40 drill, cleco as drilled.

Remvoe all clecos, panels and console from cabin top. I plan on using the click bond nut plates in the console. Many of the holes drilled lie very near to the corner of the console flange making the installation of k1000 nut plates problematic.

Also looked at the possibilty of running a 3/4" conduit for wiring inside console. This can be done, if necessary, after cabin top is installed.

Trimmed aft flange of console to round sharp corners and provide clearance for aft bulkhead panel screws.
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