Step

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Procedure

1

Assembling the F-601 Firewall

8-1

Rivet F-6122-1 brake line bracket to firewall.

2

Assembling the F-601 Firewall

8-1

Cleco and drill the firewall recess to the firewall. Do not rivet.

3

Assembling the F-601 Firewall

8-2

Note on sealing firewall openings after assembly. Leave to late in project, when all openings can be done at once.

4

Assembling the F-904 Bulkhead

8-2

Assemble and fit WD-610/611/612 control stick base and columns.

5

Assembling the F-705 Bulkhead

8-3

Review DWG 20 for the various holes that must left open or riveted. In some places (for slider, at least) a couple of blind rivets are required.

6

Preparing the Center Fuselage

8-6

Install the side steps according to the instructions provided with the steps, but using the guide holes provided in the fuselage. The fit is not perfect, so the skin and rib holes may need enlargement to allow adjustment. Baggage compartment floors and sides must be removed by drilling out rivets.

7

Adding the Forward Fuselage

8-8

Drill and shape landing gear holes as shown on DWG 34A. Enlarge holes for brake lines. Mark brake line holes with orthogonal center lines so that if your Unibit wanders, you can re-center.

8

Installing Rudder and Brake Pedals

8-9

Follow the instructions provided.

9

Installing Side Rails and Gussets

8-10

Follow the instructions for your canopy choice.

10

Fitting the Aft Top Skin

8-11

Draw a centerline on the upper faces of the F786A J-Stringers. Remove the temporary ‘D’ shaped stringer supports, and trim the J-stringer forward end to fit the bulkhead properly (see next step).

11

Fitting the Forward (aft) top Skin

8-11

Install the F-688, F-787, F-774 or F-7112 to the F-707 and F-706. Drill the skin, make sure J-stiffener center lines are aligned with skin holes.

12

The Baggage Compartment

8-11

Fit and drill for the baggage compartment floors, but do not install permanently. It’s better to wait until all the aircraft systems are in place before closing up. It’s also worth considering a removable baggage floor or access panels.

13

8-12

Fit the F-748 Baggage Tunnel Cover.

8-12

Fit the F-749 Forward Baggage Side Covers, then remove for final installation later. Install tie-down rings as specified, or install them in the floor. Fabricate steel nut plates, as aluminum is too soft to hold the coarse threads for the tie-down rings.

14

Aft Seat Floors

8-12

Rivet the aft seat floors in place, except for the aftmost row, which will be riveted in assembly with the baggage compartment floor.

15

Forward Seat Floors and Control Rod Tunnel

8-12

Fabricate the Control Rod Tunnel cover as described.

16

Seat Backs

8-12

Fabricate the Seat Backs as described. I would recommend using –3 rivets to hold the F-637D hinge in place, rather than the –4 rivets specified. The hinge material is quite soft setting the –4 rivets will cause distortion. If you don’t have AN470AD3 rivets, use AN426AD3 rivets and countersink or dimple as required.

17

Forward Covers

8-12, 8-13

Install as described in the plans. Don’t forget to drill the F-982E for engine control cables. If you are installing the Andair fuel selector, be very careful about it’s position—it cannot be centered on the plate. If plate nuts are installed on the flange of the spar carry-through where the F-983C attaches, remove them… they are installed in error.

18

Electric Flaps

8-13

Install the Electric Flaps according to the instructions. Do not rivet the plate nuts for the F-680 bearing block in assembly with the baggage floor. Instead, rivet the plate nuts to the floor rib only. This will simplify the later installation of the baggage floor.

19

Installing the Landing Gear Mounts (RV-9A Only)

8-13, 8-14

Install according to the instructions. It will be necessary to temporarily remove the outboard plate nuts on the spar carry-through in order to slide the weldments in place.

Some builders have replaced the –12 bolts with –13’s to provide a better fit. Check this before final assembly of the gear mounts.

20

Installing Cabin Systems

8-15

Rough in the fuel, vent and brake systems, but don’t torque the fittings until after the wings are installed. Extended the vent and fuel lines approximately 4" out from the fuselage sides.

21

Finishing the Forward Fuselage

8-17, 8-18, 8-19, 8-20.

Fabricate, drill, debur and primer parts as much as possible, but do not rivet in place until you are sure that all interior work is complete. Also applys to the the F-774 or F-7112 aft skin.

22

Fitting the Empennage

8-15, 8-16, 8-17

Install according to the instructions.

23

Wing/Fuselage Assembly

8-14, 8-15

Install according to the instructions. This step is deferred until near the end in order to minimize disruption to the workshop. It can be done earlier per the Van’s instructions.

24

Quickbuild completion

Various

Complete any deferred tasks, such as Forward Fuselage, Aft Skin, Baggage Compartment, installation of various controls, insulation or painting.