Where is that part....................

Light rain and wind in Angaston today, no chance of flying. I think I need rearrange my work life to have days off during the week and work on weekends. There was no such problem in the ACF though so it proved to be  a quite useful day with only a couple of stuff-ups, fortunately minor and lots of learning.

So following some domestic chores and assisting Tim who picked up the camper for a tip to Berri for the weekend, it was full steam ahead. The first job today was to cleco in place the upper and lower control horns to the spar box assembly, just like this.

Let me tell you, this is far from the most difficult construction task, but it was made almost impossible by the fact that the lower horn is currently at a place unknown somewhere between Oregon and Angaston. Indeed this is the infamous missing part from the original shipment.  An email on Thursday to Vans elicited the following response:

Mr. Moen,

Thank you for your email.

Your package shipped via regular USPS 1st Class Mail on May 31st.

I'm sorry, there is no tracking for this service. Delivery to Australia can take anywhere from 2-6 weeks for this service. On very rare occasions it can take longer.

If the package has not arrived by July 12th, Van's will replace the shipment at our cost.

thank you,

Jessica V.

I replied:

Thanks for following this up.

Given that this is the first 'ad hoc' shipment to me, no doubt not the last, I need to ask, is this the normal mode of shipment with up to 6 weeks, or longer delivery time?

Regards

And the reply:

Mr Moen,

No it it not, but sometimes this does happen.

I am sorry for the trouble.

Theresa

Vans shipping

So I wait impatiently and desperately trying to find work-arounds so work can proceed. I final drilled and pre-fitted the horn that is to hand and moved on to preparing and installing the counterbalance brackets and counterbalance arm. Here are the brackets clecoed temporarily in place to allow drilling of the counterbalance arm.

The counterbalance arm was drilled to take the bolts that will hold it in place (forgot to take a photo) Here are the brackets riveted in their proper place

 The next step involves fixing the dreaded nutplates and doublers to the forward and aft spar in this fashion.

 Due to the absence of the lower horn (did I mention it is not here!) I was unable to install four of the nutplates that will hold it in place, but I finally managed to get the others in place. I say finally because  I managed to rivet  in four locations omitting the nutplates. This gave me some more practice in drilling out rivets, I'm approaching expert status with this make-good technique. I hope there are plenty of spare rivets................

Onwards and upwards. Step 7 is mercifully simple, just installing a nutplate in each of the outboard hinge brackets.

Step 1 on page 09-05 has you cutting four hinge stops, precisely measured from a length of aluminium tubing.

 

Step 2 on the same page requires the separation of  6 Rib Clips from a single piece (love that band saw) and deburring. Here they are:

And that folks, brought proceedings to a halt for this day. A quick tidy and sweep up of the ACF  and celebration of a good day's construction with a glass of excellent Barossa Red.

Looking ahead. I'm in a bit of trouble. The next step involves clecoing and riveting together the spar box and the front and rear spar caps. Unfortunately I can't do that until I have the absent lower horn. I can do some preparation work on the ribs and perhaps the hinges. Perhaps I will be able to do some preparatory work on the tailcone, which is the next section. We shall see.