SECTION 8
THE FUSELAGE
RV-8/8A
8-11
8s8PP-1 r1 06/23/11
Cleco the F-804C-AL and -AR Center Section Aft Bulkheads to the F-804B-2 Center Section Aft Bulkhead.
Temporarily install 1/4 NAS bolts through the bolt holes to insure alignment.
Cleco the F-814E-L-1 & -R-1 Seat Ramp Supports, and the F-804J-L-1 & -R-1 Aft Floor Support Angles, to the
aft side of the F-804B-2 Center Section Aft Bulkhead (See “F-804B-2 Assembly”, DWG 64).
Final-Drill #30, the 1/8 holes common between the parts clecoed in the previous step. Final-Drill from the
forward side, the two 1/4 holes at the location of each F-804G-1 Center Section Vertical Bar.
Machine countersink on the
fwd
side, the hole for the rivet that lies under each of the F-804G-1 Center Section
Vertical Bars (See the blow up of the “F-804B-2 Assembly” view on DWG 64).
Match-Drill #12 the top and bottom bolt hole in the F-814E-L-1 & -R-1 Seat Ramp Supports using the common
holes in the F-804B-2 Center Section Aft bulkhead as a guide. Uncleco all parts on the Center Section Aft
Bulkhead Subassembly.
Final-Drill #40, the nutplate attach rivet holes in the F-814E-L-1 & -R-1 Seat Ramp Supports, and the F-804J-L-
1 & -R-1 Aft Floor Support Angles (See “F-804B-2 Assembly”, DWG 64). Machine Countersink the nutplate
attachment rivet holes final-drilled in this step, for flush rivets.
Deburr the edges and holes of all parts as needed and prime the parts that are not anodized.
Rivet the nutplates to the F-814E-L-1 & -R-1 Seat Ramp Supports, and the F-804J-L-1 & -R-1 Aft Floor Support
Angles (See “F-814E-L-1 & -R-1 Seat Ramp Supports”, and “F-804J-L-1 & -R-1 Aft Floor Support Angles”,
DWG 64).
Cleco all parts previously fitted and drilled to the F-804B-2 Center Section Aft Bulkhead Subassembly (See “F-
802B-2 Assembly Exploded”, DWG 64). Use the temporary bolts in the F-804C-AL and -AR Center Section Aft
Bulkheads as done previously. Install the AN470 and AN426 rivets shown in the enlarged view on DWG 64
.
NOTE: The two holes on each F-804C Center Section Aft Bulkhead that also attach the F-804G-1 Center
Section Vertical Bars, do not get riveted at this time.
Install the two bolts in each of the F-814E-L-1 & -R-1 Seat Ramp Supports.
NOTE: Only tighten the nuts on the
bottom bolts finger tight at this time
Rivet the two F-804G-1 Center Section Vertical Bars to the F-804B-2 Center Section Fwd Bulkhead
Subassembly. Use temporary AN4 bolts in the bolt holes to maintain alignment while riveting.
The F-804A-2 and F-804B-2 Center Section Sub Assemblies must be held in correct alignment while they are
being joined and while the fuselage is being assembled. Make two hard wood or particleboard spacers 1 7/16
(1.438) thick. The exact size of these spacers is not important, but the thickness is, as they will simulate the
spar as the bulkhead is fixed in its final position. Drill holes in these spacers to allow the installation of the NAS-
1304-50 1/4 close tolerance bolts. The holes in the spacer blocks may be oversized to allow the bolts to pass
through easily. This spacer will remain in the bulkhead throughout fuselage construction, until it is time to install
the wings. If you choose, make the spacer extra long so that it protrudes out the side of the fuselage. This
would allow for the future attachment of appropriate length legs for the fuselage to stand on while completing
other work on the interior.
Join the F-804A-2 and F-804B-2 Center Section Sub Assemblies using the 1/4 NAS bolts and the spacers
made in the previous step. The NAS bolts that attach the wing spars and join the halves of the F-804 bulkhead,
fit the holes very precisely and may have to be tapped into place. Lubricate the shank of the with Boelube™ (a
dry, waxy lubricant available from Van’s Aircraft and aircraft tool suppliers) or some equivalent. Use washers
and lightly tightened nuts on the bolts to hold every thing in place (
Caution:
to not compress the thickness of
the spacer blocks). Cleco the top plate of the F-804B-2 Center Section Aft Bulkhead Subassembly, to the top
flange of the F-804A-2 Center Section Forward Bulkhead Subassembly.
Final-Drill #30, all of the 1/8 holes in the top plate of the F-804B-2 Center Section Aft Bulkhead Assembly.
Final–Drill #40, all of the 3/32 nutplate attachment holes in the top plate of the Center Section Aft Bulkhead
Assembly.
Machine countersink the nutplate attachment rivet holes in the top plate of the F-804B-2 Center Section Aft
Bulkhead Assembly for flush rivets. Uncleco the top flange and remove the temporary bolts joining the Fwd and
Aft Center Section Bulkhead Assemblies. Deburr all holes drilled in the previous step.
Install the two nutplates on the F-804B-2 Center Section Aft Bulkhead Subassembly top plate, that do not rivet
through the top flange of the F-804A-2 Center Section Forward Bulkhead Subassembly.
Reassemble the F-804A-2 Center Section Fwd Bulkhead Subassembly, and the F-804B-2 Center Section Aft
Bulkhead Subassembly using the spacers and bolts. While joining the two sub assemblies, install the F-849
RV-8/8A
SECTION 8
THE FUSELAGE
8-12
8s8PP-1 r1 06/23/11
Fwd Control Mount, the two F-804L-1 Seat Belt Attach Lugs, and the two F-804M Seat Belt Lug Spacers using
the bolts specified in the “Center Section Assembly” view, DWG 64.
NOTE:
In this step, refer to the “Center Section Assembly” top view on DWG 64 for details on rivet holes to
leave open until joining with other parts later. Rivet the nutplates to the fwd flange of the Center Section
Bulkhead Subassembly. Install the 1/8 rivets in the fwd flange.
Install the eight SB750-10 Bushings in the lower holes provided for future wire routing, etc. (See “Center
Section Assembly”, DWG 64).
RV-8A Only:
Position the WD-821-L & -R Landing Gear Weldments on the fwd side of the Center Section
Assembly and insert a couple of bolts in each to hold them in their installed positions (DWG 67A).
RV-8A Only:
Cleco the two F-804N-1 Bulkhead Caps in place on the Center Section Assembly (See “Left
Cockpit Rail”, DWG 67A). Note the interference between the fwd bottom portion of the bulkhead caps and the
WD-821 Landing Gear Weldments. With the bulkhead cap flanges inserted between the landing gear
weldments and the center section assembly, mark the flange on each bulkhead cap to remove just enough
material to remove the interference.
RV-8A Only:
Uncleco the F-804N-1 Bulkhead Caps and trim to the marks made in the previous step. Remove
the WD-821-L & -R Landing Gear Weldments from the Center Section Assembly.
SEAT RIB SUBASSEMBLY
Make two F-806E Spacers shown in F-806E Spacer view on DWG 65.
Cleco the F-806C-1 & D-1 Rear Spar Attach Bars to the F-806B-1 Rear Spar Attach Bulkhead (See “F-806B-1
Rear Spar Attach Bulkhead Assembly”, DWG 65).
Cleco the two F-806G-1 Seat Belt Attach Lugs, and the F-806F-L-1 & -R-1 Gussets to the F-806B-1 Bulkhead.
NOTE: Proper orientation of the gussets is tipped fwd.
Use a piece of 1/4 plywood (or something of equivalent thickness) for spacers to level the F-806B-1 Bulkhead
on a drill press table to match-drill the bolt hole at each outboard end. With most Drill presses, you will have to
swing the table off to one side and drill at the edge, to provide support for the Bulkhead. Use another piece of
1/4 material as a spacer between the ends of the two rear spar attach Bars. First match-drill #30 through the
Bulkhead, the F-806C-1 Bar, F-806E Spacer and F-806D-1 -1 Bar. Final-Drill the two holes to size with a #12
drill.
Final-Drill #30, all the 1/8 holes common between the parts clecoed to the F-806B-1 Rear Spar Attach
Bulkhead.
Slightly flute the bottom flange of the F-814A-L-1 & -R-1 Fwd Inboard Seat Ribs, between the holes as needed,
to line up the holes when checked with a straight edge.
Final-Drill #40, the nutplate attachment rivet holes on the F-814C-L-1 & -R-1 Inboard Seat Rib Angles (See “F-
814A-R-1 Fwd Right Inboard Seat Rib Assembly”, DWG 65). Machine Countersink the nutplate attachment
rivet holes drilled in this step, for flush rivets
Make the Left and Right F-805D Brackets. A full-scale view of the Left Bracket is shown on DWG 65.
Cleco the F-814C-R-1 Fwd Inboard Seat Rib Angle to the F-814A-R-1 Fwd Inboard Seat Rib (See “F-814A-R-1
Fwd Right Inboard Seat Rib Assembly”, DWG 65).
Cleco the F-814HPPX Fwd Seat Belt Anchor, and the F-814J Fwd Seat Belt / Vent Anchor to the F-814G-1
Seat Belt Anchor. Cleco the Seat Belt Anchor Assembly to the F-814A-R-1 Fwd Inboard Seat Rib Assembly.
Cleco the right F-805D-R Bracket to the F-814A-R-1 Fwd Inboard Seat Rib Assembly and clamp in position as
instructed in F-814A-R-1 Fwd Right Inboard Seat Rib Assembly view on DWG 65. Match-Drill #30, the aft hole
in the bracket then final-drill #30, the fwd hole in the bracket.
Repeat the previous three steps for the Left Fwd Inboard Seat Rib Assembly. It is a mirror image of the right
except for the use of another F-814PPHX Fwd Seat Belt Anchor, in place of the F-814J Fwd Seat Belt / Vent
(See “F-814A-L-1 Fwd Left Inboard Seat Rib Assembly”, DWG 65).
Final-Drill #30, all the 1/8 holes on both Fwd Left & Right Inboard Seat Rib Assemblies.
If you intend to install the optional manual or electric aileron trim, Refer to DWG OP-1 (Electric Aileron Trim) or
DWG OP-6 (Manual Aileron Trim) and complete the bracket fitting and drilling to the Fwd Inboard Seat Ribs at this
