Jun 10 2003 - I installed the outboard battery box z-angle to the floor now that the lower skin rivets are complete. The battery box was a kit from Todd Rudberg that I slightly modified to better fit the smaller PC625. I also moved the box a bit outboard by reversing the outer angle.

The rivets in the floor tie two stiffeners below the skin that run from the outboard fuselage longeron to the rudder pedal angles. This significantly reduces flexing when the battery is installed.

Here the battery box floor is in place ready for the battery.

Battery installed. The misalignment of the tiedown bar is because it is still loose at this point, not because of a builder error (for once).

Jun 18 2003 - I fit the top skin with its doubler strips for the baggage door and instrument panel. The panel fit was less than perfect along the sides near the longerons. A call to Vans confirms this is not unusual and that shims are in order.

Here is a shot of the shims (one each side). The shim is 0.1" at the thickest point and tapers toward the top to a very thin amount. Not super pretty but also not worth fabricating my own replacements that are wider above the longeron.

Another problem area. If you look close, the rivet holes in the skin are visible at the plate bend line. They should be 5/16" forward in the middle of the flange! I'm dumbfounded here - my rollbar measurements are right on and the top skin is positioned very close as well. I'm still deciding what to do here.

With a long wait for the finish kit (13 weeks!), I have decided to take the fuselage to the airport and mate the wings. I'll also do all the flap rigging, wing tip fitting, fuel plumbing, and everything else I can before taking it all apart and returning home with the fuselage. At that point I'll do as much panel work (instrument installing and wiring) as possible before the kit arrives.

June 27 2003 - Moving day. Everything is ready to go to the airport and I have a lot of my tools and supplies packed as well. Here is a final shot in the garage until I return in a couple months.

Jim borrowed a trailer and we're about to depart. The trailer was perfect, and we easily loaded it up and tied off the main gear and tail spring.

Enroute. No problems at all along the highway.

A couple hours later and the wings slid together perfectly! This was a huge relief as the real test on the rear spar placement is when they go together. The spar slid right into the fork with no side loads at all. The coiled tubing is the pitot line.

Another shot of the mated wings. I'll drill the rear spar after I get the fuselage leveled and the wing sweep and incidence set. This will probably happen next weekend.

<back home next>