First, the removable gear covers. Pictured below is the installation in progress of installing miniature nutplates into the flanges of one of the fuselage bulkheads. Of special note, is the rivnut installation to the immediate right of the cleco'd miniature nutplate. After breaking loose one of these critters from turning a somewhat tight #8 screw, I decided to abandon rivnuts in favor of the nutplates. I drilled it out and carefully managed my edge distances and positioned it diagonally on the bulkhead flange.
This shot shows both bulkheads that the cover plate spans with their accompanying nutplates and rivnuts.
And finally, a couple of pictures of the finished product - a removable land gear cover.
As previously mentioned, I had decided to postpone installation of the bottom mid-fuselage skin, as I was concerned that I would have clearance to install the landing gear assembly doublers and any other items as yet unspecified in the unresolved service bulletin. After Van's published the details of the modifications imposed by the bulletin, it became clearer to me that I could indeed proceed with the install of the bottom skin. Unfortunately, I never shot any pictures of that installation process and will have to show the bottom fuselage skin with the forward section already installed.
Prior to the mating of the forward fuselage section with the mid-fuselage section, the forward bulkhead and forward floor skins had to be riveted into place. Below are two shots of the final riveted forward section of the mid-fuselage.
Next, came the fit-up of the forward fuselage section to the mid-fuselage section. A separate table supported the forward section, while it was shimmed into accurate position. After a multitude of clecos and some slight wrestling with the two assemblies, riveting ensued....and the result was quite pleasing.
Side bulkheads are riveted to the horizontal fuselage bulkheads with the armrests attached.
The longeron/canopy deck is cleco'd into postion next as a final prerequisite for sizing and fitting the side skins.
After a long session of work, I had to put one of the seatbacks into position to see what it would look like.
Fast forward to the week before Christmas and Van's has delivered some of their last service bulletin kits, of which I am a fortunate recipient. Following are some shots of the work installing the fuselage side parts - the upper channel stiffener and the side skin doublers.
The shot below illustrates the upper channel skin stiffener, which has already been primed, top coated and riveted into place along with the original, lower stiffener.
Next came the process of match drilling the side skins, using the side skin doublers as a template since my skins were not yet attached to the fuselage.
After the relevant detour from the service bulletin work to install some nutplates on the side skins, prior to their installation onto the fuselage.
The final preps for installing the sideskins on the fuselage.
Next is a couple of close ups of the side skin doublers.
One of the previous steps that I believe I failed to document with photos, was the assembly of the fresh air vents. This was another sub-assembly that was installed after the side skins were attached. Below are the requisite interior and exterior shots of the vents installed into the fuselage side skins.
Finally, the lower firewall/cowl hinges were fabricated and installed. First is the passenger side.
Pilot side...
A final view of both hinges.
And the almost-finished canoe!
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