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Patrick Kelley (Flion)
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Date:  8-30-2011
Number of Hours:  4.00
Manual Reference:  Various
Brief Description:  Miscellaneous fabrication

Most of the time was spent in the fabrication of the F-1091 pushrod as detailed on plans page 11-6. I used a chop saw to cut the tube to length and then polished and deburred the ends with the scotch-brite wheel on the grinder. Next I made a paper drilling template and marked where the rivets would go and then tapped the threaded end caps in with a rubber mallet and drilled them in place. I used a rod end and a long AN3 bolt as a T-handle to pull the caps back out, after marking them so I could return them to their drilled locations. Then I primed the inside of the tube and the caps, replacing them wet before pop riveting them in place. Finally, I primed the outside of the pushrod assembly,

While I waited for the primer to dry (giving it much extra time so the inside of the tube could outgas through the threaded end caps), I started a couple of other miscellaneous tasks. I took the tubing for the F-1082 spar spacers to Phil Cobbin to machine to length. In a rare lapse, he made the first one 3/32" too short. The next three went well but the last one could not be chucked into the lathe (not enough material left, so we tried cutting it the other way, leaving us just slightly short. We ended up shortening it enough to accomodate two washers to make up the length.

I also mixed up some Proseal and glued the static ports in place; holding them in with tape while the Proseal sets. Finally, I began the planning of how to mount the Andair fuel valve. I am hoping I can score an unpunched valve plate from Van's; otherwise I will have to rivet a mounting plate to the existing mount. In any case, with the primer finally dry, I installed the rod ends and jam nuts, set the initial length of the pushrod per the plans, and set it aside. I then stopped to help another pilot troubleshoot the turbe system on his Aztec.
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