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Jims RV-8
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Date:  11-8-2014
Number of Hours:  7.00
Manual Reference:  8-36
Brief Description:  Final Fuse Assembly - Cleco the fuse back together

Long day in the shop as Teresa is at a dance event and I will be working until my 'HORNS are on TV. After riveting the stab attach bars to the F-811 bulkhead - It's time to drill the 1/4" bolt holes in the bulkheads and tail spring. The plans say to cleco the two holes, clamp it and drill it all together - but since there is only one cleco while drilling, some builders have had issues with the parts moving while drilling...so I decided to drill the parts separately - and it worked really well. Next is to bolt the tail spring mount thru the freshly drilled holes to the bulkhead. I decided to test fit the aft bottom skin/bulkhead assembly with the fuse - and in the end, I decided to add 2 shims to adjust the tail spring back a bit - so that meant un-bolting the tail spring, drilling holes in two shims, and then priming the shims. I let the primer dry while I was riveting the bulkheads - so it had plenty of time to dry...

Next, I torqued the WD-409 tail spring mount bolts to 64 in/lbs. and started riveting. Wow, riveting those bulkhead rivets takes a long time! The skin is a tight curve and there are lots of things in the way inside, mainly the WD-409 Tail spring mount. It seemed like it was two steps forward and one back all the way thru the rivet process. There is no great way to hold the parts while riveting but an extra set of hands would have been key here. I did drill out a higher percentage of rivets in this step but I am happy with the end results. I also up-sized the rivets here from -3.5 to -4.0.

With the aft bottom skin riveted, I clecoed in the remaining bulkheads and riveted the baggage ribs to the 807 bulkhead - (not much room here either) and then worked the big bottom skin into position and clecoed it in place finally. It didn't want to go until I pulled out all the clecos in the center bottom skins.
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aft bottom skin riveted

aft bottom skin riveted

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two shims added

two shims added

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all clecoed back together

all clecoed back together

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