Floorboards and Re-Welded Seats

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While my main effort was to complete all the welding on the fuselage I had to re-focus my attention to the wood floorboards and seating attachment issues.  That’s because metal tabs and seat mounts had to be welded on the fuse to hold them down.  I chose 5/16″ exterior grade plywood and carefully cut it out to fit around tube joints and around the control sticks.  This was not to be the final finished floorboard.  In fact I ended up fabricating three different floorboard patterns until I ended up with a suitable design that evolved with other changes I made along the way.

During this early phase of construction I was reminded of the labor intensive method used for annual inspections for my Cessna Skyhawk.  My A&P (Airframe & Powerplant) Mechanic at the time had the complete cockpit interior removed including the seats and carpeting and all the floorboard inspection panels were also off.  This close up inspection is to check for airframe corrosion, control cable integrity, pass through wiring integrity, fuel line integrity, etc. But my mechanic also found a large mouse nest which certainly did not belong there!

This led me to think how easy or difficult it would be to inspect my homebuilt when it was finished. The plans specified that all interior sidewall sheet metal panels have a lip or 90 degree edge to be used to attach to the wood floorboards.  This would require me to completely remove all the metal sidewalls just to get to the floorboard removal and that would be incredibly difficult and time consuming.  The plans also specified a fabric belly and Yes, I could have added several removable inspection rings but they are very small and difficult to get into. Thus I decided in the months ahead to design a system of easily removable full width belly panels and omit the fabric belly altogether.

During this phase of building was the time I also purchased and modified a pair of Cessna 172 seats and removed the upholstery and removed 3 inches of metal frame width and re-welded them back together.

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