Mr Lawrence O'Connell from NSW at the factory using our Builder Assistance Program.
See his progress in this week by week presentation of pictures.
Check
these 
Technique help
sections Updated Sept
2005
Page 1
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Opening all his boxes it's just like Christmas. |
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Lawrence
first had the opportunity to fly with the Late BJ in 1982
in the original Exec and here he is now building his Exec 162FA Series One. |
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The Workshop and Tool area. |
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The tail boom needs little work before fitting to the frame. |
This is the only cutting paste to use. It really does cut your work load in half with chromemoly. |
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The screws are in the centre 2.5 inches apart.
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The screen fitted and drilled ready for Glass. Do not drill the holes out in the body until you are ready to fit the screen for the last time. You may notice that one side of the screen has a different curve. Well they all have, don't worry, no-one will ever pick it and the dog house does not touch the screen. |
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The bits I made while the air frame was being powder coated. Very easy just stick the template on and cut them out. |
Fuel rail installed with some tape on the frame to stop scratching it. |
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Great to have enough clecos to put the whole body together and now she's looking like an Exec 162 FA |
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Week
3
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Week
three and the body is ready to put all the fasteners in.
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Notice
the cooling holes in the lower rear panel - a very easy job, just
set it out 380 mm from the front of the panel and 100 mm from
the top then mark three inch centres. Drill with a 2 inch hole
saw and join the holes with a diamond saw and clean up with sand
paper. If you're not sure, draw it on the panel before drilling
and cutting.
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The
doors cause a lot of trouble for most builders so here we are
showing you how to build them strong and they don't crack when
you rivet them. This photo shows fitting the frame to the opening
first and you can cut it and re glass it to fit.
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Here's a join, it is rough but does not matter at this point as we will finish the frame later. |
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 ____ The Perspex cleco to the fitted door frame ready to remove.
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Put nitto tape or duck tape on the door to be able to release them from the frame. |
Putting Cotton flocks and epoxy resin mix on the frame. |
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The cotton flocks taking up the shape of the door. We are going to get the frame to match the Perspex perfectly so when the rivets are put in they pull onto a matching surface and this does not crack the door. |
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A busy week all the nut plates and the dzus fasteners are fitted and this is the second time the body has been fitted only one more time prior to final assemble in about four weeks time. |
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Document locker is standard on the Exec 162 FA. |
The dog house inspection door fitted. We used only 4 dzus fasteners but you can put up to 8. Don't forget the more you put in the heavier it is. |
Front inspection cover. |
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Door hardware. |
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