I decided to make a start on the rear fuselage portion of the kit and the first job was to repair the frame PA-01 that was damaged in shipment due mainly poor crate fabrication and careless handling by shippers.
I had straightened the frame to some degree and had placed it against the rear cabin bulkhead and found that the frame was already nearly a quarter of an inch wider than the width of the rear of the cabin. Both the frame and the cabin width had been set in the factory. I querried Sean about this some months ago and all he could suggest was that the cabin frame base must have been made oversize and that the answer was to cut back the PA-01 Frame.
The real issue here is that Had I started building the Fuselage first, as per the construction manual, I would have ended up with a rear fuselage section that would not have mated well to the cabin structure. With corner skins on, the rear fuselage would have been nearly 3/8 inch wider than the cabin structure. There is nothing in the construction manual that alerts the builder to check the PA-01 frame against the cabin rear bulkhead or the cabin base frame (a fully welded structure). So I was lucky in this instance, but once again this drags into question the QA procedures in the factory.
PA-01 being re-worked.
How it arrived.
The dismantled frame sitting against the rear cabin bulkhead.