The season’s first snow at DOG Aviation’s Ohio based production facility.
The last couple of days have been spent working entirely on the F-1203A bulkhead or components that will be mounted onto the bulkhead. The F-1203A bulkhead is truly ostensibly a magnet for parts. Preparations for the F-1203A bulkhead are seemingly endless and after the stub spar receptacles were riveted onto the F-1203A bulkhead, riveting of the F-1203E-L&R bulkhead doublers was completed using AN470AD4-4.5 rivets in place of LP4-3 pop rivets.
Riveting of the F-1203E-L&R bulkhead doublers onto the F-1203A bulkhead using AN470AD4-4.5 rivets in place of LP4-3 pop rivets.
Finished riveting of stub spar receptacle assemblies and attachment of the F-1203E-L&R doublers onto the F-1203A bulkhead.
Work continued on the F-1203A bulkhead by way of riveting the two previously assembled control column mounting assemblies onto the bulkhead along with 17 nutplates. A procedure was worked out that allowed the two control column mounting assemblies and all 17 nutplates to be riveted onto the F-1203A bulkhead using solid rivets. The four nutplates that would normally be riveted with pop rivets were riveted with AN426AD3-3.5 rivets and the control column mounting assemblies were riveted onto the F-1203A bulkhead using AN470AD4-5 rivets as opposed to LP4-4 pop rivets.
Using the pneumatic squeezer to rivet the control column mounting assembly onto the F-1203A bulkhead with AN470AD4-5 rivets in place of pop rivets.
Riveting one of the 17 nutplates that ultimately become riveted onto the F-1203A bulkhead.
The F-1203B bulkhead flanges are normally one of the first items which are riveted onto the F-1203A bulkhead …. however, knowing the F-1203A bulkhead would be flip- flopped numerous times during the process of riveting it entirely with solid rivets, instillation of the F-1203B bulkhead flanges was purposely delayed so the tabs would not get bent from all the flip-flopping to get solid rivets in everywhere. The F-1203B bulkhead flanges were riveted onto the F-1203A bulkhead using AN470AD4-4 rivets in place of LP4-3 pop rivets.
Riveting the F-1203B bulkhead flanges onto the F-1203A bulkhead with AN470AD4-4 solid rivets in place of LP4-3 pop rivets.
And just when you think you are finished with the F-1203A bulkhead …. you turn the page and wait … there is more, another pair of bulkhead doublers! The F-1203J bulkhead doublers are the last pieces attached onto the F-1203A bulkhead before it is attached to the forward flanges of the F-1215 seat ribs. There are four rivet holes in each of the doublers which are not be riveted at this time so blue taped Clecos were used to denote the holes to be left open. Of note: Van’s calls for the upper holes to receive AN470AD4-4 rivets and the remainder to receive LP4-3 pop rivets. The 4-4 rivets were shorter than optimum so 4-4.5 rivets were used in their place and also in place of the called for LP4-3 rivets.
F-1203J bulkhead doublers secured to the F-1203A bulkhead with Clecos and ready for riveting … blue tape marks the holes to be left open.
Riveting the F-1203J bulkhead doubler onto the F-1203A bulkhead with AN470AD4-4.5 rivets.
Finally! The finished F-1203A bulkhead is now ready to install onto the forward flanges of the F-1215 seat ribs.
As it turned out, no LP4-3 or LP4-4 rivets were used on the F-1203A bulkhead assembly thus far. Of course, that will soon change because when the F-1203A bulkhead assembly is attached onto the F-1215 seat ribs, pop rivets will be needed to attach the bulkhead to the F-1215 seat ribs. The work session was closed out by securing the F-1203A bulkhead onto the F-1215 seat ribs with Clecos.
Attaching the F-1203A bulkhead to the forward flanges of the F-1215 seat ribs with Clecos.
F-1203A bulkhead secured to the forward flanges of the F-1215 seat ribs and ready for riveting.