26 Nov 2023

I was about to rivet the lower 3 holes or the main spar front angles to the top of the front top floor skin when I noticed that the holes in the sides would not accommodate screws for the rivnuts, one of which was already installed in the z section behind it as per the KAI. The setup made no sense at all, and later pages in the manual (and the upholstery) seem to indicate that the rivnut should go through the front angle into the z section. I had to de-rivet the front angles from the main spar and remove the 2 M4 rivnuts at the rear of the z section on each side, then drill the front angles to suit M4 rivnuts (6mm). The front angles were then re-riveted to the main spar, the bottom 3 rivet were installed and then M4 rivnuts installed through the sides of the front angles (with the lower one passing through the z section).

I then de-riveted the 2 sets of rudder pedal brackets and will contact Sling for replacements. I also noticed that the welding on the rudder pedals was wrapping around the sides, thus interfering with the bushings. Sling had sent me a replacement right pedal, but it was worse than the original one. I've thus gone ahead and ground away the excessive weld on the sides using a Dremel, which unfortunately meant the coating was removed too, but it now creates a flush surface against the bushings - makes a big difference to the clearances required, and a far smoother action. Sprayed the pedals black and they look as good as new again. Will check that Sling is happy with this before final fitment.

Fitted the flap and elevator long torque tube and adjusted them by removing small shavings from the ribs and brackets to get binding-free movement as per Evan Brunye's build video recommendation. The elevator is smooth, the flaps need a bit more adjustment, but I will wait until the side skins are fitted before making further adjustments. The elevator short torque tube will be fitted once the fuselage join is completed.

The fuselage halves were cleco'd together to start the join process.