Day 174

Today was the day! We finally got to install the front top skin. Even with all the preparation we put into it, it was still quite a job.

We had already aligned and drilled the holes so that we could cleco it all in place. Next we needed to countersink all the holes on the composite piece. The rivets in the front were going to be the 4.0mm rivets, so we needed to drill those out larger and then countersink them. Then all the rest were the 3.2mm.

We also needed to trim the rear sections of the composite part so that it fit inside the canopy window channels.

Lastly in before applying the SikaFlex we taped off everything along the edges of the front top skin to help with cleaning up the squeeze out when we riveted on the part.

Once everything was ready we ran a good bead of SikaFlex 295 UV around the parameter. We then Cleco’ed the top skin in place and set about riveting it in place, starting in the center and working outwards. We then cleaned up the SikaFlex squeeze out and finished riveting the center dash portion.

While waiting for the SikaFlex to cure we started installing most of the avionics that sit on the instrument shelf.

After it cures for about a day we will be able to smooth out the rivets with body filler and then start fitting the motor cowlings as well as the dash.

(Sorry there are not many progression photos. Once the SikaFlex is applied things get messy as you’re working fast to get everything buttoned up before it sets too much.)