fuel_tank_mounts.JPGFuel tank mounting bushings116 viewsWe held these bushings slightly lower than the plans show to allow the t-bolts for the upper straps to clear the sheet metal above. The threaded ends of the t-bolts for the lower straps will have to be cut shorter after the tank is mounted. We will weld the edges of the riveted straps before we are finished.
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walking_beam.JPGwalking beam123 viewsThis walking beam installation is as per plans.
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reverser.JPGReverser118 viewsReverser as per plans below custom battery box
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front_landing_gear_fitting.JPGfront landing gear mount126 viewsWe borrowed an idea from Al Rice's site. We used small copper plumbing couplings over 3/8" threaded rod for jigging the landing gear. This compensates for the 7/16" holes in the front mounts. The rear mounts have 3/8" holes. This is now jigged ready for tacking.
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Rear_cabane_mounts.JPGRear cabane mounts128 viewsThere isn't precise measurements in the Delta plans for these mounts. We wanted them as symmetrical as possible regardless. The scrap piece of oak was cut with the proper angle and used to jig the two mounts at the same elevation and the same distance back from the firewall. These are only tacked at this point and need to be bent with heat around the vertical tubes.
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battery_box.JPGBattery box110 viewsThere is still a bit of welding left at this point. This battery box is built to accept an Oddyssey battery laying down with their cover or a Concorde battery standing up in the recess. The relay mounts on the flat plate and there is a nut welded to the bottom side of a spare hole for a ground. I didn't want to trust a riveted plate nut to complete a good ground here.
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tail_section.JPGTail section137 viewsThis photo shows the plans bracket below the tailpost and the rear tailwire mount.
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rudder_pedal_mounts.JPGRudder pedal mounts132 viewsThis set of bushings is for the standard mounting location for the front passenger. We will be mounting an extra set for each seat that will actually fit the two of us better. The forward locations will rarely be used but we felt they should be there in case someone taller is flying this plane. To align these we just jigged them with a 3/4" scrap tube stuffed all the way through and clamped in place.
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engine_mount.JPGEngine mount142 viewsThis is the 540 mount we purchased from Steen. If you are purchasing a mount, I would highly recommend doing it before installing the two diagonals at station 0-0. Many builders had trouble with their engine mount spools fitting after these tubes were installed. These spools are now tacked ready for finish welding. They fit perfectly.
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belly_former.JPGBelly former128 viewsThis belly former was going to be difficult to weld after the rear landing gear mounts were installed so we decided to weld it in first. The belly formers were bent around a substantially smaller radius cut out of plywood. We will use the mdf jig in the picture to install all of the belly formers so they come out exactly the same.
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seats_and_turtledeck_mockup.JPGAdjustable seats125 viewsThese seats are nearly complete. There are four height locations. The foam board turtledeck mockup is to check which setting is working out best for us.
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cabane_tubes.JPGcabane tubes125 viewsAll four cabane tubes with one end completed with .050 reinforcement plates. The overall measurement will be checked one more time before a similar treatment happens to the other end.
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stringer_termination.JPGStringer termination aft104 viewsWe created this bracket to terminate the stringers. If you look close you will see it is drilled for two nutplates. We plan to fabricate an aluminum bracket to exit the breather tube (from the slobber pot) here and attach it using these nutplates.
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bottom_center_stringer_aft.JPGAft view of the bottom center stringer94 viewsWe are planning on only 3 stringers on the bottom to save weight. Have not decided yet on the side stringer quantity (3 or 5).
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bottom_center_stringer.JPGbottom center stringer108 viewsThis view looking aft shows two special standoffs made to bridge over the 1st push-pull tube from the torque tube.
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handholds.JPGhandholds installed94 views
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hand_hold_construction.JPGMaking a handhold109 viewsMisc bits of scrap steel used to bend up a handhold. The tubing used was 3/8' X .049.
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aileron_stops_2.JPGaileron stops82 viewsWe determined after calculating the geometry that the axis of the stick wants to move approximately 16 degrees left and right of center for full travel. Therefore these stops are 16 degrees from horizontal to hit the stick boot squarely at full travel. The bolts are for minor adjustments. They will each get a check nut.
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aileron_stops.JPGaileron stops clamped and tacked94 viewsCalculating the angle and making the jig to hold everything in place probably took much longer than actually making the stops and welding them in place. The extra tube in the floor is to help support someone placing full weight on the planned carbon composite floorboard here. This is one of the few places someone could do that so it warranted a bit of reinforcement.
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P8231553.JPGmount for throttle quadrant65 viewsThe mount is made from .063 plate with a lightening hole (everything helps). It was attached with 2 3/4" beads on one side and one bead on the other. We made the throttle quadrant. Handles not shown here.
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P8231554.JPGTrim handle mount60 viewsHere you see a mount for the typical trim handle with push-pull cables. To get the mount where we wanted we reluctantly added the 3/4" X .035 tube shown. We realized after it was tacked that the stringer standoff to the left would be in the way of full trim travel. We added the one to the right with the standoff tube mounted at an angle. The first standoff will be cut out.
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P8231545.JPGsheet metal attachments70 viewsThe strip along the longeron is made from .032 4130. It has dimpled holes for dimpled platenuts and 1/2" lightening holes. The 58 holes that will be drilled for this purpose save a total of 4 ounces. Is it worth it? We think so.
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P8231544.JPG3 stringer side76 viewsWe settled on 3 stringers on each side and 3 on the belly. We didn't feel there was enough of an appearance difference to go with 5 stringers and the added weight that comes with it. Also the fabric is being taken as far forward as possible. Save a few ounces here, save a few there, it's all good as far as we are concerned.
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side_stringer_termination.JPGside stringer termination71 viewsTo jig a small tab to attach the aft end of a side stringer, we clamped a piece of 5/16" steel bar stock in place and then clamped the tab to that. The aluminum stringers could not be used to hold the tab because it could not take the heat of the welding.
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