Engine bulkhead is cut from a sheet steel using the provided template…. note the indent duct which is for an add on folded exhaust section.

I was not looking forward to this step .. could end up looking a mess if you get it wrong ! and great if you get it right !

Used the template and heavy cutters and big gloves – cut edges double as Stanley knives .. only sharper

Then used the template to align centre vertical and cross check with copius measuring. Then overlayed template to nose and existing engine bolts to get these centre punched and then drilled … top two were spot on.

Next step is the fold in the bulkhead and top pilot holes before positioning to pick up lower engine bolts.

Aileron ribs are CNC pre (part) cut. Thicker ones are 6mm ply and need rubbing down for prep to test fit to aileron spar

Tucked up above my garage as the Force 6 outside winds its way up to  Force 8 its quite cosy cutting out ribs and bracing sections. Supposed to be nipping to Guernsey tomorrow in a Cherokee Six but forecast F7 Northerly’s on an E/W runway is not conducive to keeping the legs straight !

Footrests are largely pre folded metal but require  little shaping to fit between body stringers

Had to loosen and move the two centre bracing bars that were factory fitted so you can get a drill square onto the rear of the footrest and drill into longerons. The bars moved out and then relocated with fresh duralac to fit snugly again.

Front ones next

Moved from the tail end this weekend to start work on the cockpit area.

The first step is to shape and fit throttle support brackets and then start to locate these on the left hand side.

Lay out parts of the throttle linkages before assembly

This picture below shows after initial (first fit) … with bolts securing top two positions … one of these is changed to use a knurled stiffener top which is provided with the kit

Starboard elevator prep an finish

Rib is cut with centre V to allow taper to trailing edge then rounded.

Having prepared the ribs and set the elevator spar in place the trailing edge cap is profiled to fit around elevator spar then fitted to secure inboard edge.

The trailing edge is fed though the outer edge hole and pulled in to fit rib lenghts.

The inboard rib is plated and drilled and cleco’d then the trailing edge is pulled in again to aign the outer rib.

Probably the last of the ‘heavy’ metalwork ! … Mark out the ribs for cutting

then test fit the elevator horn to make sure it looks like it will line up correctly. This needs to be removed and the flange holes  drilled out before bolting the two flanges in place. The stubs of the elevator leading edge will fit into these