Tail Cone

July 12, 2004

Page 10-21

Step 1: Rivet the nutplate shown in Figure 1 to the F-1037B & C Bellcrank Rib Angles using the rivets called out.

Step 2: Rivet the F-1037 B & C Bellcrank Angles to the F-1029R &-L Bellcrank Ribs respectively using the rivets called out in Figure 1. Don't install rivets into the two forward holes of the the F-1037B Bellcrank Rib Angle (see figure)

Step 3: Cleco the F-1029 Bellcrank Ribs to the F-1078 Forward Bottom Skin, the F-1006 Bulkhead, and the F-1007 Frame. Rivet the Bellcrank ribs to the skin using the rivets called out on Page 10-25, Figure 1. Rivet the Bellcrank Ribs to the F-1007 Frame using AN470AD4-4 rivets. Do not rivet the F-1006 Bulkhead.

Step 4: Using the rivets called out on Page 10-25, Figure 1, rivet the F-1073 Side Skins to the portion of the F-1032 Longerons under the aft deck. The figure also points out the empennage fairing attachment screw holes; make sure not to install any rivets in these holes.

Step 5: Cleco the parts shown in Figure 1 then. 

 

Using the rivets called out, rivet them together.

 

 Leave the F-1009 Frame for last so it's not in the way while riveting the rest of the  parts. As indicated in the figure, don't install any rivets in the F-1014 Aft Deck in the area of the F-1011 Bulkhead.

Page 10-22

Step 1: Rivet the F-1011B Stop/Doubler to the F-1014 Aft Deck and the flange of the F-1011 Bulkhead using the rivets called out in Figure 1.

Step 2:   Temporarily bolt the F-1011D Attachment Bar Support Angle to the F-1011B Stop/Doubler, the F-1014 Aft Deck, and the F-1032 Longerons using the hardware shown in Figure 2. (For clarity, the F-1073-L Side Skin is not shown in Figure 2.)

Match-Drill the two holes indicated in Figure 2 into the attachment bar support angle from the F-1011C Horizontal Stab Attachment Bar using a #30 drill. Final drill the holes using a #12 drill.

Remove the support angle, then deburr the holes in the support angle and the horizontal stab attachment bar.

Rivet the support angle to the stop/doubler and aft deck using the rivets called out in Figure 1.

Step 3: Install the hardware shown in Figure 2. The optional eye bolt, which is screwed into the F-1012E Tie Down Bar, is not supplied in the kit, but can be purchased through Van's Aircraft.

Page 10-23

Step 1: Lay the F-1047A, 1047B-L, and 1047B-R J-stiffeners back in place in the notches of the frames and bulkheads as shown in Figure 1.

 

Step 2: Cleco the F-1075 Aft Top Skin in Place.

Using rivets called out on Page 10-26, Figure 1, rivet the aft top skin to the three F-1047 J-Stiffeners and to the F-1008& -1009 Frames. When riveting to the frames, rivet from the center of the skin out to the sides. DO NOT rivet the skin to the F-1007 Frame. It will be riveted to the frame, along with the F-1074 Forward Skin, when the tailcone is attached to the forward fuselage.

Rivet the sides of the aft top skin to the F-1073 Side Skins and the underlying F-1032 Longerons using the rivets called out on Page 10-25, Figure 1. Do not rivet the front corner holes in the aft top skin which are common to the F-1007 Frame.

 

Step 3: Attach the F-635 Elevator Bellcrank to the two F-1037A Bellcrank Angles using the hardware called out in Figure 2.

 

Step 4: Bolt the two F-1037A Bellcrank Angles to the F-1035 Battery/Bellcrank Mount using the hardware shown in Figure 3.

 

Step 5: Attach the F-1035 Battery/Bellcrank Mount to the F-1037B & C Bellcrank RIb Angles using the hardware shown in the Figure 3. Do not secure the fasteners in this step completely; the battery/bellcrank mount will have to be removed later.

Page 10-24
Step 1: Secure the Concord Battery to the F-1035 Battery/bellcrank Mount using the F-1036A Battery Channel and the hardware shown in Figure 1. The top hole in each F-1036B Battery channel may be enlarged if it is difficult to install the bolts. Note: I am going to wait to order the battery closer to the time I finish the Kit.
 
Step 2:  Secure the ES 24115 Master Relay to the F-1035 Battery/Bellcrank Mount using the hardware shown in Figure1.
 
Step 3: Bolt the F-636 Shoulder Harness Anchors to the F-1032 Longerons using the hardware shown in Figure 2.

This completes the construction of the tailcone. The F-1028 Baggage Channel, the F-1074 Forward Top Skin, and the F-1006 Bulkhead are riveted after the tailcone is attached to the forward fuselage.

 

Completed final riveting, it took a long time. Needed to have Ferney buck the rivets around the center frame. I was able to reach most of the others.

 
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