Started October 03, 2009 Build Time 126 Hours
It is nice to be starting on the tail cone, even under the bad circumstances that it is my only choice since I messed up with the elevators and am waiting for parts. Oh well, here we go.
The first step is to trim and tap the tie downs. I decided to order the pretapped ones from
so the only thing to do was trim the angles and cut to length.
You then move on to drilling the tie down to E-1012A and E-1012B per measurements in the instructions.
next is to make the Rudder Cable Angle and match drill it for nut plates. Then countersink the holes.
Take one of the
foot sections of the stiffeners, make sure it is not one of eight foot sections, and cut to specs.
The horizontal stabilizer attachment bars are slightly bent due to the stamping process so they must be straightened to within 1/16 inch along its entire length. Then cleco to the bulkhead and final drill all holes except for the very bottom ones which will be done when installing the newly cut stiffener. Then attach and drill the rudder angle and the stiffener to the bulk head. Last is to drill out the two 1/8 holes to 5/8 using a unibit.
Next make the F-1010A horizontal stabilizer attachment bracket and then separate the bulkhead doublers, cleco to the bulkhead and final drill the holes.
The next step entail constructing the tail cone frames. This is pretty easy and goes quite quickly. You start to see a lot of progress in just a small amount of time.
This step is a bit more difficult and just takes some time. You first measure and cut each fuselage stiffener to the lengths described in the directions. When doing this, make sure that you have the right length of stiffener before you cut because there are two different lengths, 6 and 8 foot. The eight foot lengths are used for the 90 inch plus cuts.
Once they are cut to length, you must 45 cut the ends. This is a bit hard due to the S shape. What I did was take a scrap piece of angle about 6 inches long, cut each end at a 45 degree angle and used this for a template to mark the lines on the stiffeners then cut with a band saw. Worked great for me.
Once cut and angled, it asks to draw a line down the back side. This is to be used when installing the stiffeners, you have a reference of center when match drilling to the tail cone skins. I started with a ruler, but this was taking way to long. So what I did was took another smaller scrap of angle couple inches in length measured to where the line should be and drilled a small hole just big enough for the tip of the sharpie. Then just insert the tip of the marker, set the angle on the stiffener and pull it down the edge. Leaves a straight line at just the right spot.
You really start seeing this tail cone come together now. Very exciting to see this size of part.
However, you will not be able to see periodic pics of these steps as I did not charge up my camera. It is charging and will start taking pics again. Hopefully I will not be done by the time it is charged.
I know, the suspense is killing you isn't it?????
Guess what, no more suspense, finally got the pictures. Here you go.
Much has been done on the following pics as you can now see. The ribs have been clecoed together, the bottom skin and both side skins have also been clecoed.
Once these skins were attached, the next steps involved drilling all the holes in the stiffeners that run along the bottom and the sides. You use the marks that you placed on them in the previous step to make sure they are aligned as you go. Make sure to cleco as you drill.
Then the F-1011 Rear bulkhead along with the3 F-1012 a and b bulk are attached with clecos.
You then have to cut and deburr the Rudder Stop skin stiffener and then cleco them in place to the side skins. As for the rudder stop, you are required to make it out of AA6X3/4X3/4 angle. Make notice that the length of the angle is shown at the shortest side and you must ad an 1/8" to each side to get total length. Once made cleco in place and drill holes in stiffeners and match drill to F-1012.
Next is to add the last bulkhead to the front of the tail cone by clecoing to the skins and bellcrank ribs. Once completed, attach the baggage bulkhead channel.
Well, not that I have to completely start the elevators over again and wait for a complete set to ship from Vans, I am going to just finish the tailcone.
Everything in the last steps was to cleco the complete tailcone together, manufacture a some of the parts, match drill the hole, deburr and dimple.
All those steps are now completed. I then completely disassembled the tail cone, cleaned everything up, applied alumiprep, and then shoe a coat of Akzo primer on everything except the outside of the skins. It is time to start re-assembling and install some rivets.
The steps to assembly are just about the same as the initial assembly so I am not going to explain every step that I took. Below the pictures will go through the steps.
You will also notice that before installing the top skins, I decided to install the static ports.
Tail cone is just about all together. Today I got to spend some time attaching the horizontal stabilizer and rudder to get them fitted.
This is just a great feeling to see something come together after all the hours of work so far.
Tail cone is finished with everything fit except for the fairing and will be doing those in its own section.
Its off to the wings. They just showed up a couple of days ago.