While waiting for the elevator and trim tab sealant to cure I decided to do some work on the tailcone this evening.
Step 1 has you fabricate the tie-down bar. I decided to tap the hole first (instead of cutting the bar to size) in case I encountered any problems when tapping the hole. That would leave me with enough material to tap from the other end if needed.
![](https://airplane.allanglen.com/wp-content/uploads/2021/01/pxl_20210131_2004347361034590505563240641.jpg)
I have a .311 straight flute reamer from the Cleaveland kit which I used to size the hole first. A 3/8 tap expects a 5/16 hole (.3125) so the reamer was close enough and less likely to grab than a drill bit.
When tapping the hole I used Boelube paste for lubrication and I backed the tap up frequently to clear shavings.
![](https://airplane.allanglen.com/wp-content/uploads/2021/01/pxl_20210131_2020534825934380839646318318.jpg)
The process went well and a 3/8 NC 16 bolt threads in smoothly.
![](https://airplane.allanglen.com/wp-content/uploads/2021/01/pxl_20210131_2026570686907358348172390024.jpg)
I then marked the bracket, rough cut it on the bandsaw, final sized it on the disc sander, and deburred it on the ScotchBrite wheel.
![](https://airplane.allanglen.com/wp-content/uploads/2021/01/pxl_20210131_2033323263117345115162453038.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2021/01/pxl_20210131_2049518893543509235262452031.jpg)
The plans next have you match drill the tie down bar to the fuselage bulkheads. I removed the blueing, deburred them, and clecoed them together. I then marked the bracket, clamped it to the bulkheads, and match drilled the holes on the drill press.
The 3/32nd holes get match drilled to #30 and the 5/16 holes get match drilled at their current size.
![](https://airplane.allanglen.com/wp-content/uploads/2021/01/pxl_20210201_0244147943419401314225060160.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2021/01/pxl_20210201_024435491154382769271178812.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2021/01/pxl_20210201_0459199671865250916413025380.jpg)
I then fabricated the rudder cable angle. This is cut to length from a piece of 3/4″ x 3/4″ x 1/16″ angle. I marked the hole positions with a digital caliper, set the hole positions with a punch, and drilled the #12 holes on the drill press.
I then partially screwed in an AN3 bolt into the nutplates, clamped them to the angle, and match drilled the #40 holes one at a time, clecoing the first hole while match drilling the second.
![](https://airplane.allanglen.com/wp-content/uploads/2021/01/pxl_20210201_0400544196735258372462203697.jpg)
![](https://airplane.allanglen.com/wp-content/uploads/2021/01/pxl_20210201_0403226101745162288946822500.jpg)
After I completed the match drilling I countersunk the holes for flush rivets.
![](https://airplane.allanglen.com/wp-content/uploads/2021/01/pxl_20210201_0410159384762489297357264151.jpg)
Next up is cutting a 6 1/2″ inch piece of J-channel from a 6′ piece to use as a bulkhead stiffener.
![](https://airplane.allanglen.com/wp-content/uploads/2021/01/pxl_20210201_0418185737971730370302588161.jpg)
The plans then have you straighten the horizontal stabilizer attachment bars. These have a bend in them from the manufacturing process and need to be straightened. This was quick and easy to do in the vise.
![](https://airplane.allanglen.com/wp-content/uploads/2021/01/pxl_20210201_0420403913416769273296315237.jpg)
I then cleaned up the edges of both attachment bars. There are a lot of tool marks on these so I clecoed them together and cleaned them up on the ScotchBrite wheel. Clecoing them together makes it easier to keep them square against the wheel while removing the tool marks.
![](https://airplane.allanglen.com/wp-content/uploads/2021/01/pxl_20210201_0445447882964618355462305450.jpg)
Feels good to get started on a new assembly but I’ll be back to the elevators once the sealant cures..