Omissions, mistakes and other excuses!!!

There has been a nagging problem since the day I installed the fuel tank, no access after it was installed. I always figured I would correct this problem when I drew up the final set of plans, but I began to realize that if I have any fuel tank issues after I cover the plane, it will take a week to repair it.  So I decided to bite the bullet and just fix it. This is all the more necessary because I just bought a set of beautiful Belite Instruments from Jim Weibe in Wichita Ks. http://www.beliteaircraft.com/avionics/  One of the gauges he makes is an electronic fuel gauge. This requires the addition of a fuel probe. I would need access to the tank anyway. I have decided to make the front turtle deck that covers the fuel tank a separate piece. I will attach the Turtle deck with two hinges. Since the access is not required on a daily basis, this will work well. 

I began the process by removing the Front Turtle deck. I used a tool that has become indispensable in my shop. A Chicago Pneumatic Oscillating multi- tool. The product cleanly separated the turtle deck right through the existing bond. This tool is also very Handy when it comes to trimming cured fiberglass or Graphite. If you use a carbide tile grouting blade, it zips right through cured composites like nobodies business. 

Cut off Turtle deck


After I cut off the Turtle deck, I rechecked the weight. .4 lbs. I will have to rebuild this section by adding two horizontal longerons that will close out the section.
I also needed to "close out" the foam and glass panels at both edges to accepts the fasteners that will mount the hinge




Foam close out being added

 This is a typical Composite detail. When fasteners are introduced into composite, the core is usually increased locally in density to react the bolt clamp up loads, or the core is removed and the inner skin is transitioned to the outer skin or "closed out" I chose this method because this joint will be primarily in shear.

Fuselage sans the turtle deck


Unfortunately I had to remove the engine again. to do this modification.
its was a pain, but well worth the effort if I ever need to service the fuel tank.

Rudder Pedal "bow Sprit"


Another omission I righted this week end was the lack of a Pedal return spring on the rudder Pedals. I had to add a small extension tube "Bow Sprit" to attach the springs to.

I am getting pretty close, once these two jobs are finished, its on to installing the Instruments , throttle and wiring. After that is finished, I will re rig the wings and route the Aileron Cables. Then the last little job will be to make the tip caps of the Vert fin and the rudder. I am not going to make molds for these parts yet because my eyeball engineering and past ultralight experience tells me I may need more rudder. Everything is in proportion to the original RF4D, but the slower speed means the rudder and vert fin may not be as effective as the original. That's what flight tests are for.