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| I started the day by making a bit more space in the workshop - cutting up one of the rolls of lexan into (rough) window and door shapes. This was mainly to see how easy it will be to cut them to shape - this lexan is THICK! Much thicker than the stuff on my Rans. |
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The tail needs setting up carefully. First goes the stabilising fin - it drops in place, check that the rudder hinges are in line, then pilot drill, final drill, ream and fit a securing bolt. If the hinges line up, the rudder will swing freely. The rudder stops need shortening so that the rudder can travel 30 degrees in either direction. I took off a surprising amount with an angle grinder. |
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Another job I thought would take 5 minutes, and ended up being over an hour! The rudder cables (I am holding one end of the right one) fit inside a plastic outer tube. This tube needs to be fed through nine locating bushes along the length of the fuselage - these need to be reamed out first, and a couple cannot be reached with my drill. You can just make out the white outer cable a few inches above floor level.
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| Terry said to make the footwell floor in two pieces to get around the heelbrake mounts (I've got toe brakes, so don't need the heelbrake mounts). At last! Carpentry! I know about carpentry! I made templates out of 300gsm card, then transferred onto the 1/8 plywood. Neat job - no cut line in it since it's in one piece. I just hope this is OK and won't get in the way later. |
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| Same process for the rear floor and two side pieces, next to the seats. Make sure you lay out all the templates to ensure they fit on the plywood - I nearly cut the two sidepieces before I realised that I would then not have the right shape of plywood left for the rest! |