1. After tail cone is positioned correctly, layout the hole patterns for the mounting bolts and rivets. There will be at least one rivet hole already drilled through the longeron and side skin in the area of the splice tabs toward the aft end. Transfer drill this hole through the steel splice tab and cleco. Repeat for the other 5 rivet holes around perimeter. Later skins may have all the holes drilled in the tailcone skin.
2. Mark and drill #40 holes for the 2 bolt holes and 1 rivet hole in the side of each upper longeron. Make sure the 4 shims are in place between splice tab and lower longerons. Then upsize the holes as shown below on both sides.
3. Mark and drill for 3 #40 holes for bolts on the side of lower longerons (6 holes total). Holes are in line with existing holes in tailcone and are spaced 1 1/8” apart. Then upsize the holes as shown below on both sides.
4. Mark and drill for 3 #40 holes for bolts on the side of lower longerons (6 holes total). Holes are in line with existing holes in tailcone and are spaced 1 1/8” apart. Then upsize the holes as shown below on both sides.
5. On top of both upper longerons mark and drill 2 #40 holes for bolts 1 1/8” apart centered between bolts on side of upper longeron. Holes should be 3/8” from inboard edge of longeron.
6. Transfer drill #40 rivet holes around perimeter of fuselage using the forward side and bottom skins as templates. Upsize the holes to #30
7. Remove forward side and bottom skins. Separate the fuselage halves. Deburr and dimple any holes. NOTE: THE AFT TUBES OF THE FORWARD FUSELAGE WILL NOT BE ACCESSABLE AFTER YOU JOIN THE FUSELAGE HALVES. MAKE SURE ALL HOLES IN THOSE TUBES ARE READY FOR RIVET INSTALLATION. SEE SECTION IN PART 2 OF FUSELAGE MANUAL REGARDING DIMPLING OF STEEL FUSELAGE TUBES.
8. Make a cutout in the Right Side Pushrod cover P6102.
9. Position Pushrod cover right side P6102 before joining fuselage halves. It is difficult to install without bending it after the fuselage is joined.
10. Push the 2 fuselage halves back together, making sure the 4 shims are in place. Cleco fuselage halves together. Install 4 AN525-R11 bolts, 4 AN960-10 washers, and 4 MS21044N3 nuts in the upper longeron sides.
11. Install 6 AN525-R12 bolts, 6 AN960-10 washers, and 6 MS21044N3 nuts in the lower longeron sides. Do not install bolts into splice on bottom of fuselage yet, as aft fuselage lower skin will need to be removed for access.
12. Install 4 AN3-5A bolts, 4 AN960-10 washers, and 4 MS21044N3 in the top of the upper longerons.
