Session #3
The task here was to add the front seat braces to complete the seat installation. These braces are supplied longer than needed and are drilled at the upper end for attachment to the front of the lower seat braces.
- Use temporary hardware to hang the two front braces so they are vertical and mark the bottom flush with the bottom of the keel.
- Remove the braces and cut the marked ends 0.25 inches above the reference mark for the bottom of the keel.
- Cut the lower angle on each brace and then dress all cut edges and corners with a file.
- Drill a 1/4-inch hole through the center of the inside face of one brace, positioning the hole 0.75 inch inboard from the newly-cut lower end.
- Align the two braces and match-drill the second brace from the first. De-burr the new holes on each brace.
- Temporarily install the braces again, align the pair vertically, and use each brace as a guide to match-drill a 1/4-inch hole in each side of the keel plate.
- Remove the braces and debur the holes in the keel.
- Do the final installation of the front braces with the supplied AN hardware. NOTE: Due to the thickness of the lower seat braces, we had to add a pair of AN970 fender washers between the seat brace and the keel in order for the braces to be straight up and down when viewed from the front or rear. You do NOT want these braces to be angled, so use washers as spacers if required. If you do not have extra aircraft washers available, stainless hardware-store fender washers can be used.

The rudder pedals had been assembled (bolts and pop-rivets) in the previous session, so the bar simply had to be bolted to the nose block.

It didn't take long, but it was a pleasure to sit in the seat when the braces were finally installed. With the rudder pedals mounted, it felt exactly like our original Bee and I couldn't resist making engine noises!
Session time: ~1 hour Total Time: ~9 hours