After the 9 to 5 work, I headed to the shop for more of the boom work...and completed the installation of all new hardware. I picked back up on installation of the new gooseneck fitting, having just removed and cleaned up the toggle and pin from the original gooseneck fitting. After a few test fits, I needed to hone the new casting a bit to create a good fit, and so I turned to a small 1/2" finger sander and a file to accomplish this. After some iterative work and testing of the fit, I eventually arrived at a good friction fit. With the new gooseneck fitting assembled (pin and toggle) and in situ, I marked the three fasteners holes onto the fitting and drilled them out. With fresh holes pre-drilled, I then tapped the holes for #10-24 machine screws. Two of the screws were bottoming out on the interior gooseneck fitting, and so I removed roughly 1/8" on the fastener length and re-threaded the screws. After a successful dry-fit of the gooseneck, with machine screws, I disassembled and applied thread locker to the threads of the machine screws and completed installation of the new gooseneck fitting.

I then turned my attention to the quick installation of the boom bale - one 1/4" threaded bolt secured with washer and nylon lock nut - easy.

Next up, the small cheek block situated closer to the outhaul end of the boom. The new cheek block was an identical replacement, fastener holes as well and lined up with the original holes on the boom. Two 5/16" rivets secured this boom block - easy.

On to the second small horn cleat near the outhaul, and opposite side of a second small horn cleat. As I did with the first horn cleat installation, I used an existing hole but pre-drilled for tapping a #10-24 machine screw to secure it. I ran the tap in and then followed that by securing the first machine screw. With one of the two fasteners securing the cleat, I manipulated the cleat into position and marked for a second screw. I successively ran through bits, small to large, and opened up the new hole. After tapping this new hole, I did a dry fit of the cleat and then removed it after being satisfied with the install. I applied some SikaFlex 291-lot to the base of the prepared cleat, applied thread locker to the machine screws, and then did a final install of the small horn cleat.

Finally, I marked the location of a new fair lead near and inside of the boom bale. I marked, pre-drilled and tapped one hole at a time to accept #8-32 machine screws. With the dry fit complete, I applied Sikaflex and thread locker, completing this installation. The boom is now complete! I will wrap the boom and store it inside Biscuit's cabin to await her owner. Upon arriving home, I grabbed some time to complete the varnish on the interior fiddles and cover plates. These will be installed in the coming weekend.

Total Hrs: 2.5