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Wendells RV-6A
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Date: 1-12-2012
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Number of Hours: 5.00
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Manual Reference: Cockpit
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Brief Description: Forward Seat Pans
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Trimmed and fitted the two forward seat pans. Those require a lot of fitting, trimming, fitting and re trimming. They ended up fitting nicely and I drilled for more nutplates as well. Cut out the control stick opening after nervously marking, measuring, re-measuring. Because these forward floor pans have a couple bends in them, I wasn't sure if the 4 inch opening depth, called for in the plans, was to be measured straight back from the wing spar bulkhead, or 4 bending inches as laid out on the pan, following the bend. I chose the 4 inch bending measurement that follows the floor pan bend. At least when I install the control stick in and test it, I can always enlarge the opening. The difference between the two measuring choices was 1/4 inch on the rear cut line. I cut away the interfering bulkhead and floor rib flanges to achieve a clean opening. Next up will be adding some angle pieces to the outboard side of the cut away rib flanges to restore some stiffness around the openings. Also found, cut, drilled and fitted the flap weldment center brace (UHMW) Used AN960-10L (.027") spacer washers between the cut halves to make the hole1.009 inches after cutting it in half on the band saw. Lubed it with Boelube and temporarily bolted the assembly together to test the resistance of the 1.0 inch flap weldment inside the UHMW when tightened up. Left it clamped up so I don't lose it until I position it and drill for the AN3 nutplates that secure it to the baggage floor. Its surprising how quickly your workspace becomes trashed with scores of tools, hardware and scrap aluminum. Next up is finishing the cutout on the copilot floor pan, nutplates in the baggage floor, install flap weldment, install control sticks and control tubes to check for clearance in all movements.
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Control stick cutout done.
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Positioned gear weldment to allow trimming of forward seat pan.
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Flap weldment UHMW cut in half and temporarilty bolted to test fit.
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