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dactel
03-11-2019, 11:38 PM
Almost done with inventory! Being on the road all the time is not helping but I'm getting there...:cool:

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aviator79
03-12-2019, 05:59 AM
"A journey of a thousand miles begins with a single AN3-4A bolt."

I'm sure someone's already told you this, but my advice is to leave it all in the sub-kit boxes it came in. It makes parts easy to find when you need them.

dactel
03-12-2019, 09:17 AM
Thanks, Brian. Yes I had schemed up all sorts of ways to organize and store the parts but I did realize as I took my inventory that KFA took care of that already! :)

I have also been working on my 2 car garage which was only an exterior shell that was built back in 1936, to convert it into a workable shop. Installing insulation, boarding up the interior wall with OSBs, updating the electrical system, etc., etc. Also, before I can dive into building the plane, I will still have to build a shed to reduce the clutter in my 2 car garage.. There is just way too much "stuff" in there... Phew, so much to do!

Frontier Fox
03-12-2019, 09:12 PM
Terry
I went through similar contortions getting my work space ready.

Sorting through 25 years of accumulated stuff, didn’t know I was a hoarder till then. I have sold several thousand in tools, camping equipment, and some of my archery gear. New air compressor, lighting, shelving, and some tools for the build. Also put up OSB and painted it white to brighten things up.

Keep bangin away at it. One step at a time. 👍

dactel
04-01-2019, 08:40 AM
Building a shed so that I will be able to pile-shift all the clutter from my garage shop...

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bbs428
04-04-2019, 08:31 PM
More space for the airplane stuff is a good thing! Keep on charging ahead! :D

dactel
04-23-2019, 09:51 AM
My shed project is coming along... Now I just need to put the roof, the door and windows and finishing touches on...

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dactel
04-26-2020, 11:20 PM
It has been a year since my last post but I am happy to report that I have restarted my build today. In the past year, a lot has happened in terms of life, however, the spirit hasn't been lost.

I am also tracking my progress using the EAA's new online build log (https://eaabuilderslog.org?s=Kitfox7SS).

The shed project I've mentioned previously blew up into a three month project but it was well worth the effort as it freed up a lot of space in the garage.
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I made the first fork for the wing rotisseries and tested for fit today. I used a 1-½” PVC tube cut into pieces, a T joint, two elbow joints and three end caps. The spacing between the two pipes that go into the wing spars is exactly 27.5” on center. The outer diameters of the elbow joint sockets are perfect fit with the inside diameters of the spars with a little bit of play.

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Tomorrow, I hope to finish building the rotisseries.

Frontier Fox
04-27-2020, 08:55 PM
Terry, great to see you back to work on your build. My advice is to try and get at least one thing done every day. Little steps add up!

dactel
04-27-2020, 10:26 PM
Thank you, Joe. Yes that is a good advise.

dactel
04-30-2020, 02:01 PM
Here's my wing rotisserie setup. Simple but it works. Now I can move wings around by myself.

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bbs428
05-07-2020, 10:43 AM
Great to see you back in the mix Terry. Shed and the wing jigs look nice!

dactel
05-08-2020, 11:37 AM
Thanks you, Brett. It's been rather a frustrating year just get to the point where I can actually start building the plane but I'm happy that I am finally able to do that.

dactel
05-17-2020, 02:19 PM
Yesterday, I reamed all elevator hinge tabs and the elevator control horn. It was rather difficult to turn the reamer so close to the tube but I managed by first finger feeding it and finishing it with a vise grip. I applied them some Boeshield T9 prevent corrosion.

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Now, to get ready for the dreaded bushing reaming, I grinded the non-cutting end of the reamer to hex shape using my angle grinder so that it would fit a ¼ inch ratchet socket.

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dactel
05-17-2020, 10:32 PM
I reamed the all 7 Horizontal Tail Hinge Bushings and the 2 Horizontal Tail Bushings. It was well worth making the hex shaped end on the reamer as it took only an hour or a little less to finish these tasks with a ¼ inch ratchet socket and a flexible shaft adapter.

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dactel
05-18-2020, 10:26 PM
Fitted two center most horizontal tail ribs. It took a while to remove some material from them with a Dremel tool to fit around the weldments.

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Shadowrider
05-19-2020, 07:28 AM
Looking good! I used a die grinder to take off the large material and get them close then a Dremel tool to final fit them. Helped speed up the process. Glad to see you put the two inner most ribs on the inside of the metal support. Doing that it covers better IMO.

dactel
05-19-2020, 09:04 AM
Glad to see you put the two inner most ribs on the inside of the metal support. Doing that it covers better IMO.

Good to know! That’s how it showed in the manual illustration as well.

After grinding off the excess weldment, did you apply some primer on it before applying touch up paint? If so what did you use?

Meyer
05-20-2020, 07:02 PM
Not sure if Shadow was referring to taking off metal from a weldment or taking the wood down to fit. I would think wood. I did not grind any welds on those. If you do, the factory provided a small touch up paint container (small being about 1.5" tall). It is touch up for the powdercoat I believe

Another thing to do at this stage is put both the elevator and horizontal stab back to back, as if the bearings and bolts were installed. Make sure when you secure ribs on one that they will line up without interference on the other. Some of mine did not go exactly as pictured or dimensioned in the manual because to do so would have made them out of alignment between the two. Hopefully all that made sense.

Looks good!!

dactel
05-20-2020, 10:43 PM
I’ve been thinking about grinding off some metal as well but I’m going to wait until the wooden ribs are fitted first to see if it is even necessary.

Thanks for mentioning about putting the horizontal tail and elevator back to back to make sure the ribs can be and are lined up. It had never even occurred to me to do that.

dactel
05-20-2020, 10:48 PM
Not much progress today. I worked on the second center most horizontal tail ribs but, for some reason, I struggled to achieve a clean fit. I will work on it some more tomorrow.

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rv9ralph
05-20-2020, 11:06 PM
Terry, the progress looks good.

The moving blanket in the background looks familiar.

Ralph

dactel
05-21-2020, 07:24 PM
Hi Ralph,

hahaha, yes those are the very blankets!

Hello again!

dactel
05-22-2020, 06:46 PM
Fitted more horizontal tail ribs. In order to preserve the consistent leading edge shape, I have been grinding off only the tail end of the ribs and it has been working well. On some ribs, I ground off extra wood where they conflicted with the weldments.

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I also put the horizontal tail and the elevator together and marked all the rib locations so that all the elevator ribs would line up with the horizontal tail ribs.

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dactel
05-24-2020, 03:54 PM
All horizontal tail ribs are fitted and ready for the stiffners to be glued on. Finally.

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Frontier Fox
05-24-2020, 07:15 PM
Lookin good. Keep going!

dactel
05-24-2020, 07:22 PM
Thanks, Joe!

Kitfox Pilot
05-25-2020, 06:55 PM
Looking good!

dactel
05-26-2020, 08:32 AM
Thanks, Harlan and Susan!

dactel
05-27-2020, 05:37 PM
I purchased a bench-top drill press by WEN yesterday. I put it on a tool stand which sits on top of a wheeled base so that it can be moved around easily as floor layout needs change. (I have only a two car garage.) Also, I've had it for a year but I have acquired a new air compressor. The previous one was hideously loud so I went with a scroll compressor from Eastwood though it was a little pricey. It is amazing how quiet it is!! You can literally have a normal conversation right next to it while it is running. It is only 30 gallons in size but it has a 100% duty cycle so I have a high hope.

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??? Does anyone know how to rotate images? It seems you can post them only in landscape orientation.... ???

dactel
05-27-2020, 05:39 PM
Today, I fitted all elevator ribs and they are ready for the stiffeners to be glued on.

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rv9ralph
05-27-2020, 05:46 PM
?? Does anyone know how to rotate images?

What platform do you work on. Apple and MS has different options

Ralph

dactel
05-27-2020, 06:06 PM
What platform do you work on. Apple and MS has different options

Ralph

I use Apple platform. I even rotate the images before upload them but all images show up in landscape layout no matter.

rv9ralph
05-27-2020, 06:16 PM
After rotating them in Photos, do you save the edit?

Ralph

dactel
05-27-2020, 06:48 PM
Yes I do. (Done automatically.) Even the photos that were take originally in portrait layout get turned sideways in the forum posts though.

rv9ralph
05-27-2020, 07:01 PM
Even the photos that were take originally in portrait layout get turned sideways in the forum posts though.


Hmmm?
Here is a test...
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Images always seem to be correct for me. You click on the "insert image" icon, then choose image... correct? Do you preview post to ensure it is correct?

Ralph

dactel
05-27-2020, 09:52 PM
It shows up only in landscape layout in preview as well. This is very strange. I have tried another browser with the same result.

rv9ralph
05-27-2020, 09:56 PM
This is odd. I just went back to look at your previous post... the one with the drill press on its side. Guess what? It is not standing up!

I guess it's time to carry on.

Ralph

dactel
05-27-2020, 10:08 PM
Indeed! Obviously there is a bug somewhere that's not easily fixable...

efwd
05-28-2020, 02:50 AM
Ive been here for what, 4 years. I have this problem as do gobs of others. Im not sure there is a fix. I use both platforms but I can't say I recall one has the problem or if it is both, to be honest.

DesertFox4
05-28-2020, 12:47 PM
I “fixed” the drill press photo orientation yesterday. I never had these issues until I (we) started taking photos with an iPhone or iPad instead of a digital camera. Might have something to do with the auto-uprighting screen feature of these devices but not completely sure. When I see a crooked posted photo I just copy it into my iPad photo location then do a quick edit to rotate to proper orientation then replace the photo. Takes about five minutes. A member would have to catch it shortly after posting to do this edit as our operating software times out for edits on posts after a short time. This editing timer protects our data base from malicious damage like we sustained early on in the forums life. When I see a crooked photo I usually address it. Keep posting photos guys. Others benefit greatly from your generosity. 👍👍

dactel
05-28-2020, 02:02 PM
Thank you for all your work! I certainly have already benefited from TeamKitfox so much and saved myself a lot of trial-n-error related griefs, no doubt. But, most of all, I very much enjoy the community.

I will do my best to try to get the photos righted using your tips as well.

DesertFox4
05-28-2020, 02:57 PM
Your welcome Terry. Happy you’re part of this community and thanks for all you contribute.

dactel
05-28-2020, 10:10 PM
Ive been here for what, 4 years. I have this problem as do gobs of others. Im not sure there is a fix. I use both platforms but I can't say I recall one has the problem or if it is both, to be honest.

Roger that, Eddie. It’s no big deal though. Just wanted to make sure nothing on my end was the cause....

dactel
05-28-2020, 10:18 PM
I cut all the stiffners to the appropriate lengths for the HS and the elevator ribs, then sanded them all for bonding. Nothing hard here. I marked each part where they are supposed to go with a sharpie to prevent some griefs later on.

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dactel
05-29-2020, 10:18 PM
The first day working with Hysol. I bonded several HS ribs with stiffners to cure overnight. It is almost like caulking - the smaller the beads you use the easier and cleaner it is. I also drilled a ½ inch holes on the 310 ribs and enlarged them with a Dremel tool for access to the stabilizer hinge.

To apply Hysol, I did not use a syringe or a baggie. Instead, I cut the end of a tongue depressor at 90 degrees so that it had a flat edge and used it to dab on small amounts of Hysol.

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dactel
05-30-2020, 10:04 PM
Finished Hysoling all HS and elevator ribs with stiffners.

Today, I used syringe method to apply the Hysol. I have a box of 10cc size irrigation syringes which are cheap enough to throw away after a use. They are great for applying small amounts of Hysol to small areas.

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bbs428
05-31-2020, 02:47 PM
Sure like that black frame! Nice hysol work. :)

dactel
05-31-2020, 05:17 PM
Thanks, Brett! Yeah, I figured black frame would probably less reflect off the windshield, etc...

dactel
05-31-2020, 05:30 PM
Today, I installed a half of HS ribs onto the metal frame. I used syringe method again to minimize the mess. Again, putting Hysol was like caulking - you want to keep the beads as small as possible for clean installation. Whenever needed, I cleaned up unsightly messes with a rag or a piece of paper towel wetted in denatured alcohol.

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efwd
05-31-2020, 08:12 PM
Don't cut yourself short on the Hysol. Its useful to have a filet of adhesive worked up onto the wood and some down onto the structure. If your like me you will break a couple of the false ribs free from the structure as you catch a piece of clothing on it while working.

dactel
05-31-2020, 10:29 PM
Don't cut yourself short on the Hysol. Its useful to have a filet of adhesive worked up onto the wood and some down onto the structure. If your like me you will break a couple of the false ribs free from the structure as you catch a piece of clothing on it while working.

Good to know! Thanks, Eddie!

dactel
06-01-2020, 05:13 PM
Finally finished installing all HS ribs today. I'm getting more efficient at hysoling.

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dactel
06-02-2020, 06:27 PM
Today, I installed all elevator ribs in place with Hysol. Tomorrow I will varnish them and get started on the HS/elevator tips.

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bbs428
06-03-2020, 04:00 PM
Sure looks good in the bare bones!

dactel
06-03-2020, 09:25 PM
Sure looks good in the bare bones!

Hopefully the finished product will look good also!

dactel
06-04-2020, 05:42 PM
Applied the first coat of epoxy varnish to HS and elevator ribs.

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dactel
06-05-2020, 05:13 PM
I finished varnishing all the HS and elevator ribs today. The varnish was almost clear in color so it was a little hard to judge how well the second coat was laying on and it got a little sloppy.

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DesertFox4
06-05-2020, 07:11 PM
Good progress Terry. I remember sanding off the hardened varnish drips from those ribs before covering.

dactel
06-05-2020, 08:44 PM
Good progress Terry. I remember sanding off the hardened varnish drips from those ribs before covering.

Thank you!

dactel
06-06-2020, 07:28 PM
I invested few hours towards improving my humble little workshop today. Among one of the things I did, I installed an automatic tank drain to my air compressor called Moisture Minder EDV. It has a unique automatic self cleaning feature which eliminates the need for taking it apart every now and then to clean out debris.

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dactel
06-08-2020, 10:30 PM
Cut foams and bonded them to the HS and elevator ends.

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To speed up the Hysol metering and mixing process a little bit, I took a couple of syringes and filled them each with a Hysol part. This made measuring much easier and cleaner than directly scooping out of the cans.

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patrick.hvac
06-09-2020, 07:35 AM
Hey Terry,
I didn't see it mentioned in your thread what covering system you had selected.
I heard the factory foam you are bonding will not withstand the Oratex solvent very well.
Just a word of caution if you were thinking of going that direction. Others have used balsa instead.
Cheers.

jrevens
06-09-2020, 09:33 AM
FWIW, I don’t believe there’s anything in the Oratex glue that is harmful to the foam. It’s basically water-based. Something other than the foam is used by many of us however for other reasons.

dactel
06-09-2020, 09:43 AM
Hey Terry,
I didn't see it mentioned in your thread what covering system you had selected.
I heard the factory foam you are bonding will not withstand the Oratex solvent very well.
Just a word of caution if you were thinking of going that direction. Others have used balsa instead.
Cheers.

That’s very good know. Thanks for letting me know!!

dactel
06-09-2020, 09:51 AM
FWIW, I don’t believe there’s anything in the Oratex glue that is harmful to the foam. It’s basically water-based. Something other than the foam is used by many of us however for other reasons.

I am still planning on using Poly Fiber system but also considering Stuart system as well as it is water based and does not use nasty solvents...

jiott
06-09-2020, 11:12 AM
Hey Terry,
Where in Portland are you located? I am also in the Portland (Happy Valley) area.

dactel
06-09-2020, 11:47 AM
Hi Jim,

I am in Lake Grove area, which is around I-5 and 217..

jiott
06-09-2020, 01:49 PM
OK, across town but not too far.

efwd
06-09-2020, 04:48 PM
That foam will melt under the heat used to get Oratex installed unless your extremely careful. Of course there is only one way to know where the envelope is before it melts. That is to melt it once. That is why we preferred Balsa Wood.

bbs428
06-09-2020, 06:24 PM
Agreed on the balsa over the foam. Easy fix now. I used balsa as my flaperon tips as well. Aircraft spruce has balsa blocks. 2"x 2"x 36"

Thanks for the nugget of info on the Moisture Minder EDV. Just what I need! :D

dactel
06-09-2020, 07:35 PM
OK, across town but not too far.

Jim, great to know a like minded person in the area! I am based at Willamette Aviation at Aurora State Airport. Normally-COVID19 wise, we host “Second Saturday” seminars there. I would love to meet you one of these days. There or elsewhere.

dactel
06-09-2020, 07:37 PM
That foam will melt under the heat used to get Oratex installed unless your extremely careful. Of course there is only one way to know where the envelope is before it melts. That is to melt it once. That is why we preferred Balsa Wood.

Thanks for a great pointer, Eddie. I think you’ve just convinced me to switched to balsa wood anyway!

dactel
06-09-2020, 07:51 PM
Agreed on the balsa over the foam. Easy fix now. I used balsa as my flaperon tips as well. Aircraft spruce has balsa blocks. 2"x 2"x 36"

Thanks for the nugget of info on the Moisture Minder EDV. Just what I need! :D

I’m on it!

I got my Moisture Minder EDV from Amazon. I made that bracket in the photo out of angled aluminum stock. Super easy. You should also order some 90 degree elbowed push to connect tube connector with male ¼ inch NPT fitting and some ¼ inch pneumatic tube.

Shadowrider
06-09-2020, 10:55 PM
I second balsa. It shapes really good and will hold up much better. Order some superfill. Shape the balsa ruff then fill in holes and gaps with superfill.

dactel
06-10-2020, 01:15 AM
So it looks like I will need to undo the bond that holds the foam pieces. What would be the most efficient way? Solvent? Brute force?

Denalifox
06-10-2020, 07:41 AM
I used expanding foam, Hysol, then Superfil, worked fantastic.

bbs428
06-11-2020, 01:46 AM
So it looks like I will need to undo the bond that holds the foam pieces. What would be the most efficient way? Solvent? Brute force?


Yes! Just carve it off and clean it up with acetone. Many ways to do the tips. Here is the way I did it.

dactel
06-11-2020, 07:49 PM
Thanks, all! I did some running around today and procured some balsa blocks at a hobby shop.

Brett, that’s a beautiful job you did on your tips!!

I ripped off all the foam pieces and sanded away as much Hysol as possible with a Dremel tool. I am getting a small band saw in few days so I am going to work on the balsa blocks with it then. I think band saw would be a handy tool to have through out my build.

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bbs428
06-12-2020, 10:36 AM
Thanks! Those tips require a lot of finishing. The balsa sands down fast so easy going as you get close to your profile.
Any flaws will be noticed through the covering.

I did not have a band saw and finally caved when it was time for the tips.
So much nicer to have one and I use it all the time for other projects. :)

efwd
06-13-2020, 08:22 AM
https://link.shutterfly.com/1gq7dFTRh7
There is something to say for building your own. Gratifying. However, they are soft Balsa so I suspect that one day I will probably have more hangar rash on them than I care to
to look at. If I were to do it again I would just purchase the tips from Kitfox.

dactel
06-17-2020, 06:26 PM
https://link.shutterfly.com/1gq7dFTRh7
There is something to say for building your own. Gratifying. However, they are soft Balsa so I suspect that one day I will probably have more hangar rash on them than I care to
to look at. If I were to do it again I would just purchase the tips from Kitfox.

I know what you mean. I thought about that too. I might even make fiberglass tips for them...

dactel
06-17-2020, 06:30 PM
I am thinking about making the HS feather's tip in round shape. Today, I created a couple of cardboard templates in an anticipation of my new band saw's arrival this week. They are drawn freehand other than the straight lines.

I may even decide to make fiberglass parts for those tips.

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jiott
06-17-2020, 09:06 PM
Be aware that without your HS tip extensions the width of the HS is about 8'. If you ever plan to transport in an enclosed trailer the extra width may give you problems that are totally unnecessary.

dactel
06-17-2020, 09:30 PM
Be aware that without your HS tip extensions the width of the HS is about 8'. If you ever plan to transport in an enclosed trailer the extra width may give you problems that are totally unnecessary.

That is a GREAT pointer! Thanks, Jim!!

efwd
06-17-2020, 09:56 PM
OOHhhhh that was a nugget Jim.

dactel
07-05-2020, 04:34 PM
I finally got around to hysoling the balsa HS & elevator tips on and put some superfill between the gaps. I will sculpt them tomorrow.

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dactel
07-07-2020, 06:03 PM
I finally finished the HS and elevator tips. Still rough but I'll fine tune them before I cover them.

In these pictures, the shapes look warped but it's just the way the pictures came out.

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bbs428
07-08-2020, 08:52 AM
The tips are looking nice. I sure like that black powder coat. :D

dactel
07-14-2020, 08:22 AM
The tips are looking nice. I sure like that black powder coat. :D

Thanks, Brett!

dactel
07-14-2020, 08:25 AM
Both halves of the wing are on rotisseries and ready to be worked on.

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dactel
07-18-2020, 05:28 PM
All elevator hinge bushings and bearings are sanded to fit. I did this by chucking the parts to a drill press and putting a sand paper against it, as suggested n the manual.

Interestingly, in the manual, I noticed during the process that they refer to the brass tubes as bearings And the smaller steel tubes as bushings.

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dactel
07-20-2020, 09:56 AM
All seven brass bearings are now installed with Locktite 680 retaining compound. Since the compound sets up very fast, I had chosen to sand down the brass bearings just enough so that they could be slipped into the hinges with my fingers rather than pressing them in.

I had read some documents online about how to apply Locktite 680 compound and they recommended You apply a bead all around the outside near the “leading edge” of the part being inserted and slide it in using a rotating motion. It worked very well.

Also, I applied some Boeshield to the both ends between the brass bearings and the hinges to seal them against corrosion in case the Locktite didn’t cover the entire bare metal inside the hinges.

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