EAA Builders Log Site

Project: EaglesWing -
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Purchased a Tube...

Purchased a Tube Bender

Purchased Fluting...

Purchased a hand...

Purchased #30...

Purchased 3/32 clecos

Purchased Plexiglass...

Purchased pancake...

Purchased...

Purchased squeeze sets

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Purchased Tape measure


Builder Name:	Todd Luebstorf -

Project:	Zenith CH750SD - VIEW REPORTS
Total Hours:	496.7
Total Flight Time:
Start/Last Date:	Dec 12, 2019 - No Finish Date
Engine:	Viking 195
Panel:	Dynon

Friendly URL:	https://eaabuilderslog.org?s=EaglesWing

Home or Last Project Picture

Apr 29, 2024 Purchased Screws, Nuts, and Heat-shrink

Category: Lighting

Purchased 16 each AN365-632A nuts, 16 each AN526C-632R6 screws, and 1/4” white heat-shrink tubing. This will be used to secure the recognition wires and nav/strobe wires to the wing rear spar.

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Apr 29, 2024 Purchased Fuel Sender Wire

Category: Fuel System

Purchased 30 feet each of AWG18 Red Tefzel wire and AWG18 Black Tefzel wire for the wing fuel senders from Stein Air. I had them twist them together.

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Apr 28, 2024 R/H Wing Recognition Light and Nav/Strobe Light - (3.4 hours)

Category: Lighting

Used a unibit and drilled a 5/16" hole in the R/H wing leading edge for the recognition light. Installed a MS35489-4 grommets. Made two standoffs out of .032 6061-T6 to hold the recognition lights and nav/strobe lights from the bottom skin. One is for the left wing. Drilled two #40 holes for #3 rivets for attaching the standoff to the bottom skin L angle. Attached with #3 AD rivets. Drilled a 1/2" hole through the front spar and rear spar for where those wires will go through. Installed 3 SA-655 snap bushings that are from Stein Air. These bushings have a 3/8" inside diameter. Laid out where the wire standoffs from Zenith will go on the rear spar, P/N 11-03987. Spaced them one foot apart from each other. For the nav/strobe wires I'm using 20 AWG 4 conductor shielded wire. The recognition lights I'm using 18 AWG 4 conductor shielded wire.

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Apr 24, 2024 R/H Fuel Sender Access Cover - (1.0 hour)

Category: Fuel System

Drilled the screw holes in the R/H fuel sender access cover to a #19 for 6 each #8 Screws (MS24694C4 screws). Used the nutplate jig to drill the nutplate fastener holes. Dimpled the holes and installed 6 each MS21049L08 nutplates using #3 AD rivets.

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Apr 21, 2024 R/H Fuel Tank - (1.3 hours)

Category: Fuel System

Drilled the R/H fuel sender wire grommet hole to a 7/16”. Installed an AN931-4-7 grommet in that hole. Drilled the hole for the fuel vent line to a 1” hole so a socket could fit to install the fitting. Cleaned the chips and dust.

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Apr 20, 2024 R/H Wing Upper Skins - (1.7 hours)

Category: Wings

Started taping the areas on the R/H wing upper skins for primer. Removed the wing tip and skins.

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Apr 20, 2024 R/H Fuel Tank - (2.2 hours)

Category: Fuel System

Added cork to the sides of the R/H fuel tank. Drilled a pilot hole for the fuel vent line and fuel sender wires. Drilled 6 pilot holes in the fuel fill tube finishing ring. The grommets edging won't work because it will hit the welds. Once installed I'll put some sealant around the tube to finish it.

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Apr 10, 2024 Fuel Fill Tube Finishing Covers - (1.4 hours)

Category: Fuel System

Cut out the R/H fuel fill tube close out cover. Traced it and cut one out for the L/H fuel fill tube close out cover. Laid out 6 fastener holes one each. I'll use A4 rivets to attach them to the wing skin. I'm also going to put some grommet edging on the inside circle to protect the fill nozzle.

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Apr 07, 2024 R/H Fuel Tank - (7.0 hours)

Category: Fuel System

Marked where the R/H wing fuel sender is on the top skin. Cut a 3 1/8" hole and made a 5" cover from .040 aluminum for the fuel sender access. Drilled the fastener holes in the fuel sender access cover and matched drilled to the skin. Drilled the holes to a #19 on the cover and dimple for #8 screws. Made the L/H wing fuel sender access cover at the same time. Installed cork in the fuel tank bay. The fuel tank fits perfect, nice and tight. Put the top skin on to check the fit around the fuel fill tube. Needed to sand one side of the hole to get the skin to fit. Because of the gap decided to make a close out cover for around the fuel fill tube to finish it off. Laid out the cover from .040 aluminum.

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Apr 06, 2024 R/H Recognition Light - (.6 hour)

Category: Lighting

Put the R/H outboard slat on to mark where the recognition light wiring will go into the leading edge of the wing and marked it.

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Apr 03, 2024 R/H Wing Tip - (1.0 hour)

Category: Wings

Cleco the R/H wing tip into place and finished drilling the holes to a #30 for A4 rivets. I have two holes that are drilled to a #21. The very forward one on the leading edge. That hole is the one I started with and it got a little oblong from the cleco. The #21 bit did clean up the hole. The other hole is in line with the aft spar. I ended up drilling that one to a #21 as I was drilling the aft spar.

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Apr 01, 2024 R/H Wing Tip - (1.0 hour)

Category: Wings

Sanded the edges and drilled the holes in the new aluminum strip for the wing tip. Glued the strip to the tip with the Chemseal CS3204 B2 sealant.

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Mar 31, 2024 R/H Wing Tip - (2.0 hours)

Category: Wings

Hung the R/H wing tip with help from my wife and daughter. Needed extra hands to push the tip into the leading edge to get a good fit. Drilled the holes to a #40 and #30. Removed the tip to see how the holes lined up on the aluminum strips that were glued to it. One of the strips was off some and needed to get redone. Removed the strip and made a new one. I didn't think the tip would be much work but it's turning out to be,

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Mar 26, 2024 R/H Wing Tip - (1.7 hours)

Category: Wings

Installed 3 nutplates, MS21047-L06K, to the R/H wing position light back plate. Used the same sealant to attach rest of the strips and backplate to the wing tip.

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Mar 25, 2024 Purchased fuel system parts

Category: Fuel System

Purchased 25 feet of 3/8” 3003-0 aluminum tubing, 4 each AN832-6D union, 2 each AN816-6-6D 3/8” nipple, 2 each AN815-6D 3/8” union, 4 each AN924-6D nuts.
The tubing will be used for the fuel vent line.

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Mar 24, 2024 R/H and L/H Position Lights - (2.3 hours)

Category: Lighting

Made two backing plates from .032 aluminum for attaching the R/H and L/H wing position lights. The position lights get attached with 3 screws. Drilled the holes in the plate for the screws and wires. The wire hole I'm using a 1/2” snap in grommet. Dimpled the fastener holes for the nutplates.

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Mar 23, 2024 R/H Wing Tip - (2.4 hours)

Category: Wings

Finished making the .025 aluminum strips for the R/H wing tip. Used Flamemaster Chemseal CS3204 B2 sealant to attach the strips to the wing tip. I ran out of small clamps so only half got done.

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Mar 21, 2024 R/H Wing Tip - (3.0 hours)

Category: Wings

While cutting the R/H wing tip fiberglass a small piece broke off. I used Polyfix to secure the piece back into its place. This stuff worked very well but very strong smelling. Used a hacksaw to cut the tip down a little bit more. Started to cut some .025 aluminum strips to attach to the tip. This will give the tip fasteners more to hang onto.

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Mar 19, 2024 R/H Wing Root Skin - (2.9 hours)

Category: Wings

Finished drilling the holes on the R/H wing root skin to a #21, except for the holes going into the front spar and root nose rib. Those I'm leaving until the wing is fitted to the fuselage. The spar gives a little bit side to side and I want to make sure it fits to the fuselage. I did end up adding a couple of holes on the leading edge by the slat attach bracket. The skin fits nice along the leading edge with the added holes. Removed the skin and attach doublers. The cut out on the bottom didn't line up perfect to the lower skin so I sanded it to make them line up. Also sanded a little bit on the leading edge by the slat brackets. Started to clean all the metal shavings.

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Mar 18, 2024 Purchased bolts, washers, and nuts

Category: Wings

Purchased AN4-10A bolts, AN960-416 washers, and AN365-428A nuts. I've installed and removed the R/H wing root nose rib a few times so I figured those two bolts and nuts should be replaced. Really only need to replace the elastic stop nuts.

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Mar 18, 2024 Purchased nutplates

Category: Wings

Purchased 10 each MS21047L3K nutplates for the L/H wing fuel sender access cover from Aircraft Spruce.

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Mar 18, 2024 Purchased screws

Category: Wings

Purchased 14 AN525-832R6 screws for the L/H wing fuel access cover from Aircraft Spruce.

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Mar 16, 2024 R/H Wing Root Skin - (2.0 hours)

Category: Wings

Removed the R/H wing root nose rib and sanded the edges. There was a couple of corners that were pushing on the wing skin. Reinstalled the rib. Put the skin back on and matched drilled the remaining holes. Used a hole finder for the bottom row of rivets that go through the spar. Each of the holes on the skin are at least drilled to a #40. Need to finish drilling the holes up to size.

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Mar 15, 2024 Purchased Polyfix Plastic Repair Kit

Category: Supplies

Purchased Polyfix plastic repair kit from Aircraft Spruce. Strange on how it was packaged.

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Mar 11, 2024 Purchased a Tube Flaring Tool

Category: Tools

Purchased a Rol-Air 37 degree flaring tool, 507-FB, from Brown Aviation Tool Supply Co.

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Mar 11, 2024 Purchased a Tube Bender

Category: Tools

Purchased a tube bender, 368-FH, that can bend 1/4”, 5/16”, and 3/8” tube from Brown Aviation Tool Supply.

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Mar 10, 2024 R/H Wing Root - (3.3 hours)

Category: Wings

Used a fluting pliers and bent the R/H wing root front angle. Drilled the aft and forward root angles to the ribs. Layed the top inboard skin over the angles and ribs. Started to match drill the skin to the angles.

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Mar 06, 2024 R/H Wing Root Angles - (1.4 hours)

Category: Wings

Sanded the edges and removed the part number sticker from the R/H wing root front and rear angles. Used a hammer and fluting pliers to form the aft piece so it is at the correct angle,

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Mar 03, 2024 R/H Wing - (1.7 hours)

Category: Wings

Removed the R/H wing top skin L stiffeners. Debur and sanded the edges. Taped for priming. Removed the upper fuel tank wing stiffeners.

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Mar 03, 2024 R/H Wing - (2.2 hours)

Category: Wings

Drilled all remaining holes on the R/H wing upper skins and trailing edge skins to a #21. Drilled the skin L stiffeners to a #30.

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Mar 01, 2024 Purchased Fittings

Category: Fuel System

Purchased 8 each AN819-6D fitting sleeves and 8 each AN818-6D fitting nuts from Aircraft Spruce.

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Mar 01, 2024 Purchased Sealant

Category: Supplies

Purchased a pint of Flamemaster Chemseal CS3204 B2 sealant from Aircraft Spruce.

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Feb 26, 2024 R/H Wing Outboard Trailing Edge Skin - (.8 hour)

Category: Wings

Laid out the hole locations for the R/H wing outboard trailing edge tip. Cleco the trailing edge into position and drilled the holes that join the outboard and inboard together to a 5/32”.

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Feb 17, 2024 R/H Wing Trailing Edge - (4.4 hours)

Category: Wings

Put the new R/H wing outboard trailing edge skin on the wing. This took awhile to get it all lined up with no holes in it. Drilled the holes to a 5/32”. I have blocks of wood on the bottom side supporting the trailing edge but these blocks of wood were covering up some holes. I matched drilled those holes by drilling a piece of aluminum from the original skin then transferring the holes to the new piece.

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Jan 17, 2024 Wing OTB Trailing Edge Skin

Category: Wings

Received the R/H and L/H wing outbound trailing edge skins not drilled. Zenith said they might need to put the holes on one side so they could line it up to bend it but didn't need to do that. I'll be able to match drill it once I get it lined up with the inboard trailing edge skin.

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Jan 11, 2024 R/H Wing Leading Edge - (1.5 hours)

Category: Wings

Finished drilling the R/H wing leading edge skins to a #21. The skins sit perfect.

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Jan 10, 2024 R/H Wing - (1.2 hours)

Category: Wings

More drilling on the R/H wing.

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Jan 08, 2024 R/H Wing Spar - (1.2 hours)

Category: Wings

More drilling on the R/H wing spar. It's looking good and getting there.

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Jan 07, 2024 R/H Wing - (2.4 hours)

Category: Wings

Continued to drill the R/H wing upper spar holes to a #30 and then 5/32”. I'll use the #21 reamer for the final hole size.

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Jan 05, 2024 R/H Wing OTB Trailing Edge Category: Wings

Talked to Zenith about the outboard trailing edge skin holes not lining up. They are sending me a right and left outboard trailing edge skins with no holes on one side. I haven't started the left wing yet but they said I may have the same problem so they will send both sides.

Jan 03, 2024 Purchased Fluting Pliers

Category: Tools

Purchased a fluting pliers (FP21) from Aircraft Tool Supply Company.

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Jan 03, 2024 R/H Wing - (.5 hour)

Category: Wings

Continued to match drill the R/H wing upper skins to the ribs. Drilling the holes to a 5/32” then I'll go back with a #21 reamer. This leaves a very clean hole.

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Jan 01, 2024 R/H Wing - (.9 hour)

Category: Wings

Finished drilling the #40 holes in the R/H wing spar. Need to keep drilling up the wing holes to final size.

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Dec 31, 2023 R/H Wing - (2.5 hours)

Category: Wings

Started to drill the spar on the R/H wing. Also drilled some of the ribs. For the spar I've been using a drill cup to keep the holes perpendicular to the spar.

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Dec 30, 2023 R/H Wing Tip - (1.5 hours)

Category: Wings

With the R/H wing outboard trailing edge skin cleco and taped into position I figured I should make sure the wing tip fits. Started cutting the R/H wing tip with a cutoff wheel on the dremel. I had one side almost cut all the way when all of a sudden a small chunk broke off. It's on the aft section of it and will be inside of the wing but I will need to do a fiberglass repair on it. I need to add some aluminum strips on it anyways to add support for the rivets. I cut rest of it with a hacksaw blade. I recommend cutting this piece this way. It was cleaner and came out better. Sanded the edges smooth and added some cutouts where it was hitting some of the structure inside of the wing. This fiberglass tip fits very well. I still need to drill it up though.

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Dec 29, 2023 R/H Wing trailing edge - (3.0 hours)

Category: Wings

I fabricated a bracket out of 6061-T6 .040 aluminum to hold the fuel lines and wiring along the R/H wing trailing edge. I made it at the same angles as the inboard trailing edge skin but when I put the bracket on the other edge the angle was off. Removed the cleco's on the outboard trailing edge and adjusted it to the same angle as the inboard skin. I reached out to Zenith if the trailing edge pieces should be consistent all the way down, they said yes as I figured. The bottom boles still lined up but the top holes are now off by half a hole. Looks like I'll need a new outboard trailing edge piece. I've triple checked the entire wing and everything else looks great. All holes have lined up great so not sure why this piece is a little off. I could probably leave as is but it will bother me not being right on.

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Dec 26, 2023 R/H Wing - (3.8 hours)

Category: Wings

Cleco the R/H wing top skins, leading edge skins, and put the L angle stiffeners on top. Got some help from the family. Looks like it's ready to be drilled to size.

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Dec 25, 2023 R/H Wing - (5.0 hours)

Category: Wings

Removed the wood support pieces from the work table and rotated the R/H wing. Added different wood supports and leveled the wing. It took awhile to get the wing level. With the flaperon brackets installed I needed to keep the rear spar up higher. It's now ready to put the skins on and drill them.

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Dec 20, 2023 R/H Wing - (.8 hour)

Category: Wings

Installed 10 each MS21047-L3K nutplates with MS20426-3-3 solid AD rivets on the R/H wing fuel sender access cover. My fuel sender will be on the top of the wing do this will be just an inspection panel.

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Dec 16, 2023 Purchased a hand rivet puller - (.8 hour)

Category: Tools

I must have lost my custom ground down A5 tip for the rivet puller that has the head ground down. Purchased a cheap one from Harbor Freight for $5.00 and ground down the tip for A5 rivets. Turned out good and the rivets look the same when pulled. I needed this for a few rivets around the flaperon brackets.

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Dec 16, 2023 R/H Wing Bottom Skins - (2.8 hours)

Category: Wings

Installed the last two nutplates for the fuel sender access cover. Cleco the R/H wing two bottom skins, trailing edge skins, and L angle stiffeners to the wing. Installed A5 rivets everywhere except for the stiffeners, those are A4 rivets. Left rivets out to be able to remove the trailing edge skins. I need to run wires and fuel lines still.

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Dec 12, 2023 R/H Wing Trailing Edge Skin - (2.6 hours)

Category: Wings

Laid out where to cut a hole in the R/H wing inboard trailing edge piece. Without the hole there is no way to get at the wing attach bolt with the trailing edge piece installed. Cut the hole and laid out fastener locations. Cut the panel to size using 6061-T6 .032 aluminum.

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Dec 10, 2023 R/H Wing Trailing Edge Pieces - (.9 hour)

Category: Wings

Debur and sanded the edges of the R/H wing trailing edge pieces. Started to look at where to install an access panel where it meets the fuselage. I'll need access in that area to connect the fuel lines and wiring.

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Dec 10, 2023 R/H Wing - (2.6 hours)

Category: Wings

Cleco the R/H wing lower inboard skin onto the ribs. Cleco the fuel access cover onto the skin. Drilled those 14 holes to a #19 for #8 screws. Used a nutplate jig to drill the holes for nutplates and dimpled them. Installed 7 nutplates onto the skin and 5 on the ribs. Two of the holes in the ribs need one leg nutplates. I have those on order.

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Dec 09, 2023 R/H Wing Panel - (1.7 hours)

Category: Wings

Cut out the L/H and R/H wings fuel sender panels. Sanded the edges and drilled the holes to a #10. Drilled the holes in the skin for the panel to a #10. Drilled the holes for the nutplates and dimpled them.

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Dec 09, 2023 R/H Wing Flaperon Brackets - (1.1 hours)

Category: Wings

Cleco and riveted the 5 R/H wing flaperon brackets to the ribs with A5 rivets.

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Dec 08, 2023 Purchased Nutplates for R/H Wing access covers Category: Wings

Purchased 2each MS21051-08 one lug nutplates for the R/H wing fuel access cover from Wicks Aircraft. These are needed for two of the holes. I wanted the “K” version with the holes dimpled but they were on back order, I'll dimple them myself.
Also ordered 10 each MS21047-L3K two lug nutplate for the R/H wing fuel sender cover.

Dec 07, 2023 R/H Wing - (1.6 hours)

Category: Wings

Started to cleco the R/H wing lower skins in place but realized it maybe easier to rivet the flaperon brackets on before the lower skins get installed. I'll need to keep some rivets out so I can get the trailing edge pieces installed, especially around the aft strut bracket. Removed the clecos. I reached out to Zenith a couple of weeks ago about my wing kit didn't get the fuel sender access panels. I've seen some Super Duty gets with that hole cut and others not, mine was cut. I'm actually putting the fuel senders on top of the tank but I can still use that access panel for inspections purposes. Zenith sent me the nutplates and screws but sent me the fuel access panels instead. Decided I'll just make them instead of bothering them again. Made a template and traced it onto a piece of 6061-T6 .040 aluminum.

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Dec 05, 2023 R/H Wing - (.6 hour)

Category: Wings

Drilled the R/H wing tiedown ring, deburred and installed the 6 A5 rivets.

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Dec 04, 2023 Purchased Screws for R/H Wing Fuel Access Cover Category: Wings

Purchased 14 each AN525-8R6 screws from Wicks Aircraft for the R/H wing fuel access cover.

Dec 04, 2023 Purchased 6061-T6 .040 Aluminum Category: Wings

Purchased a 2'x2' 6061-T6 .040 aluminum from Wicks Aircraft to make the R/H and L/H fuel sender access panels.

Dec 04, 2023 R/H Wing - (1.9 hours)

Category: Wings

Wiped the areas to be primed with waterborne wax and grease remover and wiped with wax and silicone free tack cloth. Because of how cold it was outside and didn't think the garage could maintain above 65 degrees I decided to brush the epoxy primer. My test piece looked great so I figured it would turn out the same but I'm not happy with how it turned out. There is nothing wrong with the coverage just don't like it and it was harder than spraying. I had problems around the holes, primer liked to run. I learned I'll wait to spray the parts next time.

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Dec 02, 2023 R/H Wing - (2.0 hours) Category: Wings

Used red scotchbrite to scuff the bottom skins, jury strut angles and L stiffeners to prime,

Dec 01, 2023 R/H Wing - (.5 hour)

Category: Wings

Debur and sanded the edges of the 4 jury strut angle pieces for the R/H wing. Two go to the front jury strut and two go to the rear jury strut. Sanded the edges of the R/H wing outboard bottom skin. From the factory the bottom outboard skin had something spilled on it so I'll need to sand that area and prime it. It was in between two pieces of skin so I'll need to do the same thing with the other skin once I get to that one.

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Nov 29, 2023 R/H Wing - (2.9 hours)

Category: Wings

Debur the R/H wing ribs and spar. Finished deburing the bottom inboard skin and masked off the area I will prime. Masked off the outboard bottom skin that will get primed.

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Nov 20, 2023 Purchased Epoxy Primer

Category: Supplies

Purchased a quart each of gray epoxy primer (6610-4) and epoxy activator (6700-4) from Southern Polyurethane.

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Nov 15, 2023 R/H Wing - (2.2 hours)

Category: Wings

Started to debur the holes and sand the edges of the R/H wing bottom skins.

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Nov 11, 2023 R/H Wing - (8.5 hours)

Category: Wings

Drilled rest of the R/H wing bottom skins to a #21. Taped the tie down ring to the height I wanted. I'll drill the holes after I remove the leading edge skin. Opened the cutout for the strut bracket bolt a little more so the bolt can clear the skin. Cleco the trailing edge skins to the rear spar. Needed to remove more material from the inboard trailing edge skin outboard end where the outboard trailing edge overlaps it. This took awhile to get the two pieces to fit good. Cleco the flaperon brackets and L angles to the ribs. Drilled the L brackets to a #30 in the skin. Taped the skins where I'm going to prime. All set to remove the skins to sand the edges, debur, and prime the mating surfaces.

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Nov 10, 2023 Purchased Locktite 567 Thread Sealant

Category: Fuel System

Purchased Loctite 567 Thread Sealant from Zoro. It's a 1.69 fl oz tube,

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Nov 09, 2023 R/H Wing - (.7 hour)

Category: Wings

I had the holes going through the R/H wing lower skin into the spar drilled to a 5/32”. I used #21 reamer to bring those holes to a #21 hole. Makes a very nice hole. I'll be drilling the other holes that need an A5 rivet using this method. First I noticed that on the inboard end I have an oval hole that looks to be an access panel. The drawings don't show this so I just sent an email to Zenith asking the question.

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Nov 08, 2023 Purchased Fuel Supply Lines

Category: Fuel System

Purchased two fuel supply lines from Aircraft Specialty. These are the lines that will go from the wing fuel tanks to the side of the fuselage.

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Nov 08, 2023 R/H Wing - (2.8 hours)

Category: Wings

Continued to drill up the R/H wing bottom skins and leading edge skins.

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Nov 04, 2023 R/H Wing bottom skin - (4.1 hours)

Category: Wings

Started to drill up the R/H wing bottom skin and leading edge skins.

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Oct 23, 2023 R/H Wing - (1.0 hour)

Category: Wings

While putting the R/H wing bottom skin on I had one rib that the holes were off a little so I decided to remove the three rivets where it attaches to the rear spar. Lined up the holes and installed the three A5 rivets. All holes line up on the skin now.

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Oct 10, 2023 R/H Wing skins - (3.6 hours)

Category: Wings

Cleco the leading edge skins on the nose ribs and finished cleco the bottom skins. Removed the part number stickers from the skin stiffeners and marked with blue tape. Cleco the ones for the R/H wing bottom skin.

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Oct 09, 2023 Purchased #30 tapered reamer Category: Tools

Purchased a #30 tapered reamer from Yardstore.

Oct 09, 2023 Purchased 3/32 clecos Category: Tools

Purchased 50 each K series spring cleco 3/32 from Yardstore.

Oct 09, 2023 R/H Wing - (4.5 hours)

Category: Wings

Attached 2x4's to the work table with some brackets. Added wood supports to the wing trailing edge area and leveled it to the main spar with them. Dug out the R/H wing bottom skins from the bottom of the work bench and laid them on top of the ribs. Started to cleco the skins to the wing skeleton.

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Oct 06, 2023 R/H Wing - (1.6 hours)

Category: Wings

Installed solid AD #6 rivets on the R/H wing rear channel strut bracket. Installed the three AN3-5A bolts and torqued them to 20 inch pounds on the R/H wing rear channel strut bracket. Installed the R/H wing inboard and outboard rear channels to the ribs with A5 rivets.

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Sep 30, 2023 Priming Wing Pieces - (5.0 hours)

Category: Wings

Wiped all the wing parts that are ready to prime with SPI Waterborne Wax and Grease Remover and TCP Global wax and silicone free tack cloths. Primed with SPI Epoxy Primer.

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Sep 29, 2023 Wing Pieces - (2.0 hours)

Category: Wings

Finished scuffing the wing pieces that I wanted to prime for now.

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Sep 28, 2023 Wing Pieces - (1.3 hours)

Category: Wings

Started to scuff the wing pieces that I will be priming with red scotchbrite.

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Sep 25, 2023 R/H and L/H Wings - (2.3 hours)

Category: Wings

Deburred the holes on the L/H wing trailing edge pieces, sanded the edges on the L/H wing slat brackets, the 4 L angles that attach to the outboard spar extension, R/H and L/H wing strut brackets, R/H wing tie down ring and main strut bracket. Still need to sand the edges of the L/H wing trailing edge pieces and then scuff all these pieces for primer. Figures I would prime more pieces seeing I wanted to prime the R/H wing rear channel strut bracket that I redid.

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Sep 24, 2023 R/H and L/H Wings - (2.0 hours)

Category: Wings

Drilled the other holes in the R/H and L/H rear channel strut brackets to a #10 except for the three holes that will have bolts. Drilled all the holes in the L/H wing rear spar pieces to a #21 and #10 for solid rivets. I left the holes that mount to the ribs at a 5/32". Deburred the holes in the strut brackets, L/H wing slat brackets, nose ribs that the slat brackets attach to, the 4 L angles that attach to the outboard spar extension.

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Sep 19, 2023 R/H and L/H wing rear channel strut bracket - (.5 hour)

Category: Wings

Drilled the new rear channel strut bracket 3/8” hole on a drill press. Hole came out at the .3750 diameter. Also drilled the L/H side bracket while I was set up.

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Sep 15, 2023 Purchased SD75W4-4 Rear Channel Strut Bracket Category: Wings

Purchased one SD75W4-4 Rear Channel Strut Bracket.

Sep 13, 2023 R/H wing rear channel strut bracket - (.5 hour)

Category: Wings

Drilled the 3/8” hole in the SD75W4-4 rear channel strut bracket with a unibit. After drilling I wanted to check the hole diameter and it measured.3800 instead of .3750. Decided to purchase a new piece and drill it with a regular 3/8” drill bit in a drill press.

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Sep 11, 2023 R/H Wing Rear Spar - (2.1 hours)

Category: Wings

Installed rest of the #5 rivets on the rear spar inner section except for the holes that attach to the ribs with #5 solid AD rivets. Installed #6 solid AD rivets in the rear spar root doubler. All these rivets call for A5 and A6 rivets but figured I would install solid rivets.

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Sep 06, 2023 R/H Wing Rear Spar - (1.2 hours)

Category: Wings

Started to install #5 solid AD rivets in the R/H wing rear spar.

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Sep 05, 2023 R/H Wing Rear Spar - (.7 hour)

Category: Wings

Drilled the holes in the rear spar to final hole size. Three of the holes in the rear channel strut bracket, SD75W4-4, will be AN3 bolts so drilled those to a #12. Drilled the other holes in that bracket to a #10.

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Sep 03, 2023 R/H Wing - (3.8 hours)

Category: Wings

Removed the 4 bolts for the R/H wing spar inboard bracket by the #1 nose rib. Removed the bracket so I have room to rivet the nose rib, L angle, and slat support angle. Installed those parts with A5 rivets. Installed the bracket and bolts that were removed from the spar. Torqued the bolt to 20 in. lbs. Torqued the 8 bolts that attach the nose ribs 4,5,6,7,8 to the spar to 20 in. lbs. Rivet the slat support angles on ribs 4,7,8 with A5 rivets. Cleco and rivet the tank Z angles, SD75W9-2 and 3 shorter trailing edge ribs to the aux rear spar, SD75W3-4, with A5 rivets. Cleco and rivet the aux rear spar to the side of the tank ribs with A5 rivets. Cleco the rear spar parts together to figure out how it goes. Drilled the 3 holes on each of the rear ribs where the rear spar attaches to a #21. They only had pilot holes.

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Aug 28, 2023 R/H Wing - (1.0 hour)

Category: Wings

Installed A5 rivets for where the ribs attach to the spar. Attached the slat attachment support angle to the #10 nose rib with A5 rivets.

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Aug 27, 2023 R/H Wing - (2.2 hours)

Category: Wings

Drilled the 8 holes for the AN3 bolts to a #12 in the spar and nose ribs. Kept going up one size at a time to keep the holes straight. Cleco and installed A5 rivets on the stiffeners to the tank inboard and outboard ribs.

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Aug 23, 2023 R/H Wing spar extension and rear ribs - (1.0 hour)

Category: Wings

Rivet the R/H wing spar extension to the main spar with 15 A5 rivets and 6 A6 rivets. Drilled the 5 holes on each of the R/H wing rear ribs 1,5,6,7,8,9, where they attach to the spar, to #21 holes. They had pilot holes in them so I used a tapered reamer to get a perfect hole.

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Aug 22, 2023 R/H Wing - (2.5 hours)

Category: Wings

Drilled the R/H wing 5 slat brackets and where they attach onto the nose ribs 1,4,7,8,10 to a #21. Installed #5 solid AD rivets except for where the slat attachment support angle will go. Started to lay out the ribs along the R/H wing spar.

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Aug 20, 2023 R/H Wing spar extension - (1.6 hours)

Category: Wings

SD75-WW-01, cleco the upper and lower stiffeners to the spar extension. Cleco the 2 stiffeners on the backside of the spar extension. Rivet those parts with #5 solid AD rivets.

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Jul 09, 2023 R/H Wing - (6.7 hours)

Category: Wings

De-burred the holes, sanded the edges, and scuffed the 5 flaperon arm brackets the 3 tank Z angles, both the inboard and outboard rear spar channels, rear spar trailing edge root doubler, root doubler, rear spar channel splice, rear channel strut bracket, and inboard rear spar channel. Primed all these parts and the remaining nose and trailing edge ribs with the epoxy primer. Before spraying wiped the parts with the waterborne wax and grease remover and wiped parts with a silicone free tack cloth.

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Jul 08, 2023 R/H Wing - (1.0 hour)

Category: Wings

De-burred the holes, sanded the edges, taped and masked the areas not getting primed, and scuffed the R/H wing remaining 6-10 nose ribs.

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Jul 05, 2023 R/H Wing Trailing Edge Ribs - (2.7 hours)

Category: Wings

De-burred the holes, sanded the edges, and scuffed up the R/H wing remaining six trailing edge ribs for primer. Taped and masked the areas not getting primed.

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Jul 04, 2023 R/H Wing - (4.9 hours)

Category: Wings

De-burred the holes, sanded the edges, and scuffed the R/H wing nose ribs 1-5, trailing edge ribs #1 and the three small ones that go by the gas tank, the 4 Fwd and Aft rib stiffeners, and the 5 flaperon arm L angles. Primed the mating surfaces with the epoxy primer. The ribs that the flaperon arms attach to I primed the entire rib.

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Jul 03, 2023 R/H Wing - (6.3 hours)

Category: Wings

De-burred the holes, sanded the edges, and scuffed the R/H wing slat attach brackets, slat attachment support angle, nose rib angle, and tank bay web spacer. Wiped all the parts that are ready for primer with waterborne wax and grease remover, then used a wax and silicone free tack cloth. Primed the parts with SPI epoxy primer. Separated the trailing edge ribs and associated parts.

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Jul 02, 2023 R/H Wing - (2.0 hours)

Category: Wings

Figured out where each of the wing nose ribs go and numbered them 1-10. Set aside the L/H nose ribs for now. I noticed one of the washers on one of the six AN4 bolts for the main wing attach bracket spun. I then decided to check all bolts on the spar for proper torque. Probably about half of the AN4 and AN3 bolts were not torqued. I set the AN3 bolts to 20 in lbs. and the AN4 bolts to 50 in lbs.

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Jun 27, 2023 R/H wing spar - (1.6 hours)

Category: Wings

Cleco the R/H wing spar extension, upper and lower stiffeners for the spar extension to the main spar. Drilled the six holes that need to be drilled to a number 12 hole. Taped off the spar extension, both upper and lower spar extension stiffeners, and the two stiffeners for the back side of the spar extension for priming. Priming the mating surfaces. Scuffed the areas for priming.

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Jun 25, 2023 R/H Wing Spar - (3.5 hours)

Category: Wings

De-burred the holes, sanded the edges, and scuffed up the R/H wing spar for priming.

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Jun 23, 2023 Purchased Epoxy Primer Category: Supplies

Purchased a quart of gray epoxy primer (6610-4) and epoxy activator (6700-4) from Southern Polyurethanes (SPI)

Jun 19, 2023 Decals

Category: Paint / Decals

Picked up the decals for the side of the plane and N numbers. Had them designed and put on some vinyl from Graphic Innovations. I also had some smaller stickers and one of the bigger Flags/Eagle put on a piece of aluminum to hang in the garage.

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Jun 11, 2023 Wing Parts - (2.0 hours)

Category: Wings

De-burred the holes and sanded the edges of the R/H and L/H outboard wing spar extensions (SD75W3-1), R/H upper and lower extension doublers (SD75W3-2), and R/H spar stiffeners (SD75W3-3).

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May 21, 2023 Unboxing Wing Parts - (2.5 hours)

Category: Wings

Removed and unwrapped the wing parts from the crate and organized them in the shop.

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May 19, 2023 Picked up Wing kit

Category: Wings

Drove to Mexico, Missouri to pick up the wing kit, rented a trailer, and drove it back home. Paid the remaining balance for the wing kit.

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May 15, 2023 Flag and Eagle Decal

Category: Paint / Decals

Working with a local graphic company, Graphic Innovations, on designing a decal. They sent me a link to a bunch of different pictures of Flags and Eagles. I picked out one of each, along with a font. We'll see what the combination looks like once they finish it. This decal will go on the fuselage just behind the rear window.

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May 15, 2023 Wing crating Category: Wings

Zenith called and said the wing kit was crated and ready to be shipped or picked up. I decided to pick it up.

Apr 24, 2023 Rudder leading edge cut - (1.0 hour)

Category: Rudder

Cut the leading edge skin on the rudder with a cutoff wheel on a die grinder. For now I left it 1/4” bigger in case I didn't lay out the cutout correct. I'll wait to do the final trim during the install.

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Apr 16, 2023 Rudder R/H Rear Lower Skin - (1.0 hour)

Category: Rudder

On the rudder rivet the patch to the R/H side rear skin and bottom rib with A4 rivets. My rudder was one of the first ones produced and the leading edge was not cut. Laid out the cutout on the skin,

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Apr 06, 2023 Primed access panel - (1.6 hours)

Category: Rudder

Turned on the garage heater and got the temp to 70 degrees. Scuffed the access panel cover and ring along with the rudder close out skin. Cleaned the three pieces with SPI Waterborne Wax and Grease Remover. Then wiped with wax and silicone free tack cloths (TCP Global). Primed pieces with SPI Epoxy Primer,

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Mar 25, 2023 Working on paint design - (2 hours)

Category: Paint / Decals

Used color pencils to lay out a couple of color and design options. Thinking about painting it a satin gray and blue with a picture of an eagle flying in front of a US flag on it. The name of my plane is Eagles Wing so putting that under the flag. On these pictures the flag will be the other direction to make it look like it's blowing in the wind. Blue would be forward.

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Mar 05, 2023 Rudder Access Panel - (2.3 hours)

Category: Rudder

Decided to make another access panel but this time have five fasteners instead of four. The ring is made from 6061-T6 .032 and the cover is 6061-T6 .025. The holes for the #6 screws are drilled to a #28. Dimpled all the holes. Added a piece of 1/8” heat shrink, Stein Air (SA702B), around the tail light wires where the wires will exit the rudder. This is also where the access panel will be.

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Feb 27, 2023 Rudder Access Panel - (1.2 hours)

Category: Rudder

Drilled mounting holes and sanded the edges for the rudder access panel. I'll be using dimpled nut plates (K1100-06) for #6 screws.

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Feb 26, 2023 Rudder Access Panel - (2.6 hours)

Category: Rudder

Laid out the access panel in adding to the rudder. I have a tail light so this will be used to get at the wiring and inspection purposes. Cut those pieces out with a bandsaw and jigsaw.

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Feb 13, 2023 R/H Taxi/Recognition Light - (1.1 hours)

Category: Lighting

Drilled the 6 holes in the R/H taxi/recognition light bracket and slat skin to a #18. Dimpled the 6 holes in the slat skin for #8 screws. Used a #8 nut plate jig to drill the nut plate holes in the mounting bracket. Dimpled the 6 mounting bracket holes for the #8 screws. Dimpled the #40 rivet holes for MS20426-3-3 rivets. Also dimpled the nut plate mounting holes. Rivet the 6 nut plates to the mounting bracket. I'm as far as I can go on the slats for now. I'm going to wait for the wings to get done so I can see how they fit and attach them together. I want to paint the slats before I install the taxi/recognition lights.

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Feb 11, 2023 R/H Taxi/ Recognition Light - (1.5 hours)

Category: Lighting

Cut 22 mm off the bottom of the light lens with a small diamond cutoff wheel on a dremel. Drilled 4 holes to hold the lens tight against the skin. Drilled 6 pilot holes to hold the light bracket. Still need to upsize the holes for the #8 screws.

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Feb 01, 2023 R/H Taxi/Recognition Light - (1.0 hour)

Category: Lighting

Drilled out the rivets for the R/H outboard slat end rib to gain access for installing the R/H taxi/recognition light. Cut out the area on the slat for the light. Used 320 sandpaper for the finish.

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Jan 29, 2023 R/H Taxi/Recognition Light - (.8 hour)

Category: Lighting

Layed out where the R/H outboard slat taxi/recognition light cutout and fasteners will be on the slat skin.

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Jan 21, 2023 Purchased #8 dimpled nut plates

Category: Lighting

Purchased MS21049L08 (SGP13449-x50) nut plates from SkyGeek. Came in a package of 50. I needed 2 more for the taxi/recognition lights.

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Jan 20, 2023 L/H Taxi/Recognition Light - (1.5 hours)

Category: Lighting

Drilled the 6 holes that will hold the L/H outboard slat taxi/recognition light mounting bracket to a #18 for #8 screws. Dimpled and drilled the slat skin and mounting bracket for nut plates (P/N MS21049L08). Dimpled the nut plate mounting holes. Rivet the nut plates to the mounting bracket.

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Jan 15, 2023 L/H Taxi/Recognition Light - (5.4 hours)

Category: Lighting

I worked for awhile today on the L/H outboard slat taxi/recognition light but didn't get much done. Spent time determining the hole size and how I would attach everything. I didn't want a large hole for the light, just large enough but still look good. Cut a little more off the top side of the hole I already had started. The lens was too long so I cut 22mm off the bottom edge. Used a cutoff wheel on a dremel tool and sandpaper on a block of wood to smooth the edge. This also made the lens fit better. For ease of installation and to secure the lens to the leading edge skin tighter I decided to use A3 rivets. Used a plexiglass drill bit to prevent it from cracking. For now I drilled 4 holes in the corners. I may add 2 more rivets on the top and bottom side of the cutout. Drilled the 6 holes that hold the light bracket assembly with a #30 drill bit. I'm not going to use the 6 sheetmetal screws that came with the kit so I think I'll make those 6 holes in the bracket #8 screws. I think I'll also dimple those holes for flush screws. Also decided that I'm going to paint the bracket the same color as what I paint the slat. I still have more work to do on this light but won't do the final install until I paint the bracket. I'll also need to keep the end rib and end fairing off until then.

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Dec 26, 2022 Taxi/ Recognition Lights - (2.4 hours)

Category: Lighting

Sanded the edges and rounded the corners on the L/H and R/H taxi/ recognition light brackets. Drilled the three holes to a #10 and the other four holes to a #28 for the #6 screws. I used a #10 nut plate jig for the three larger holes and installed the nut plates with #3 solid rivets (20470-3-3). Those rivets didn't need to be flush because nothing will be screwed against it.

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Dec 19, 2022 Purchased Plexiglass Drill Bits

Category: Tools

Purchased 3/32" plexiglass drill bit (AC55-3/32) and 1/8" plexiglass drill bit (AC55-1/8) from Aircraft-Tool Supply.

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Dec 17, 2022 Purchased Screws P/N AN509C8R7

Category: Lighting

Purchased Screws P/N AN509C8R7 from Aircraft Spruce (part number 04-01256-25). It was a pack of 25. Need 12 for attaching the taxi/recognition light bracket to the slat skin.

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Dec 17, 2022 L/H Taxi/ Recognition Light - (3.4 hours)

Category: Lighting

Layed out the hole for the L/H Microsun taxi/recognition light on the outboard slat. Drilled out the rivets for the outboard rib and removed it so I can get the light in the slat. Used a unibit to drill the four corners of the cutout. Used a cutoff wheel on a dremel to cut it out. Used a 1/2” grinding wheel and then sandpaper to smooth the edges. I made the hole smaller than what the drawing shows and will probably make it bigger once I see how the light centers in the cutout.

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Dec 17, 2022 Slat Tips - (1.5 hours)

Category: Slats/Flaps

Sanded the edges on the R/H and L/H outboard slat tips. Marked a 10mm line from the edge on them and cut a diagonal piece off the tip of them so they fit inside the slat better. Drilled the holes to an 1/8” for A4 rivets. Took the tips off and debured the holes in the slat and tip.

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Dec 11, 2022 Taxi/Recognition Lights - (1.5 hours)

Category: Lighting

Spent sometime figuring out how to install the MicroSun Taxi/Recognition lights in the slats. Need to drill out the end rib in order to install the light.

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Dec 11, 2022 L/H Outboard Slat - (1.4 hours)

Category: Slats/Flaps

Installed A4 rivets on the bottom side of the L/H outboard slat. Used 4 straps strapped around the table and slat to get the holes to line up on the top surface. Cleco and installed A4 rivets.

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Dec 03, 2022 R/H Outboard Slat - (1.4 hours)

Category: Slats/Flaps

Installed A4 rivets on the bottom side of the R/H outboard slat. Just like the inboard slats I used 4 straps strapped around it to get the upper holes lined up, cleco and installed A4 rivets.

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Dec 03, 2022 L/H Inboard Slat Tip - (1.1 hours)

Category: Slats/Flaps

Marked a 10mm line on the L/H inbound inbound slat tip from the edge of it. Trimmed the trailing edge of it on an angle so it fits inside the slat better, pushed the end cap into the slat until the line was centered in the holes. Drilled the number 40 holes then drilled up to an 1/8”. Debured holes in both the slat skin and tip piece. Sanded the edges to get rid of the rough edges. Cleco back on and rivet with A4 rivets.

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Dec 01, 2022 L/H Inboard Slat - (1.5 hours)

Category: Slats/Flaps

Clamped 2 2x4's 5.25” from the edge of the table. I added the one 2x4 behind the one that is 5.25” from the edge of the table. First slat I did the 2x4 was flexing in the middle. Got the holes to line up much easier on this L/H inboard slat. Put four straps around the table and slat. Kept tightening until the holes lined up. Cleco and installed A4 rivets.

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Nov 30, 2022 Instrument Panel layout - (.5 hour)

Category: Instrument Panel

Played around with the instrument panel layouts. Trying to decide between Garmin and Dynon. Also which panel size, the STOL or the Cruzer.

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Nov 30, 2022 L/H Inboard Slat - (.8 hour)

Category: Slats/Flaps

Installed A4 rivets on the bottom side of the L/H inboard slat.

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Nov 27, 2022 R/H Inboard Slat - (3.7 hours)

Category: Slats/Flaps

Installed A4 rivets along the lower trailing edge section on the R/H inboard slat. Clamped a 2x4 5.25” from the edge of the work table. Used four straps and strapped the R/H inboard slat down over the 2x4. Kept tightening the straps until the holes lined up on the upper side of the slat. Cleco then rivet with A4 rivets. Sanded the rough edges on the fiberglass slat tip. Trimmed the trailing edge back on an angle. Marked 10mm line from the edge of it. Slid the tip into the slat until I could see my line. Drilled the holes to an 1/8”. Debured holes and installed with A4 rivets.

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Nov 26, 2022 Slats - (.5 hour)

Category: Slats/Flaps

Had help from the entire family. We each pushed the slat skin down around the ribs and cleco to the trailing edge on all four slat sections.

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Nov 06, 2022 Instrument Panel Layouts - (2.2 hours)

Category: Instrument Panel

Layout and cutout the 750 STOL and Cruzer instrument panels on rosin paper. Played around with different Garmin instrument layouts on both sizes of panels. Just starting to think about what I want so I can plan accordingly as I move forward.

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Nov 05, 2022 Outboard Slats - (2.0 hours)

Category: Slats/Flaps

Cleco and rivet the doubler inside of the L/H and R/H outboard slat skins with A4 rivets. On two of the four slat ribs cleco and rivet the slat pickup to them with A5 rivets. Cleco and rivet the four slat ribs to the bottom side of the slat skin. Did this to both L/H and R/H outboard slats.

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Nov 05, 2022 Inboard Slats - (2.1 hours)

Category: Slats/Flaps

Installed A4 rivets in the slat skin and ribs on the bottom side of the skin. Cleco and rivet the doubler inside of the R/H inboard slat skin with A4 rivets. On three of the five slat ribs cleco and rivet the slat pickup to them with A5 rivets. Cleco and rivet the five slat ribs to the bottom side of the slat skin.

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Nov 04, 2022 L/H Inboard Slat - (1.8 hours)

Category: Slats/Flaps

Cleco and rivet the doubler inside of the L/H inboard slat skin with A4 rivets. On three of the five slat ribs cleco and rivet the slat pickup pieces to them with A5 rivets. Cleco the five slat ribs to the bottom side of the slat skin.

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Oct 11, 2022 Primed Slat Skins - (1.6 hours)

Category: Slats/Flaps

Wiped areas to prime with the tack cloths. Primed with Rust Oleum Self Etching primer. Removed the paper and tape.

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Oct 10, 2022 R/H Outboard Slat Skin - (1.7 hours)

Category: Slats/Flaps

De-burred the holes and sanded the edges on the R/H outboard slat skin. Taped off and scuffed areas to prime. Cleaned areas. Missed one area on the L/H outboard slat skin. Taped, sanded, and cleaned area. The 4 slat skins are ready for priming.

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Oct 09, 2022 L/H Outboard Slat Skin - (1.5 hours)

Category: Slats/Flaps

De-burred the holes and sanded the edges on the L/H outboard slat skin. Taped off and scuffed areas to prime. Cleaned with the SPI Waterborne Wax and Grease Remover.

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Oct 09, 2022 R/H Inboard Slat Skin - (2.0 hours)

Category: Slats/Flaps

De-burred the holes and sanded the edges on the R/H inboard slat skin. Taped off and scuffed areas to prime. Cleaned with the SPI Waterborne Wax and Grease Remover.

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Oct 08, 2022 L/H Inboard Slat - (1.4 hours)

Category: Slats/Flaps

Sanded the edges of the L/H inboard slat skin and taped off the areas to prime. Scuffed with scotchbrite and cleaned surfaces.

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Oct 05, 2022 L/H Inboard Slat Skin - (.7 hour)

Category: Slats/Flaps

De-burred the holes on the L/H inboard slat skin.

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Oct 04, 2022 Primed slat pieces - (2.4 hours)

Category: Slats/Flaps

Cleaned the slat ribs, corner doublers, and slat pickup pieces with SPI Waterborne Wax and Grease Remover. Wiped pieces with TCP Global Wax and Silicone Free Tack Clothes. Primed pieces with SPI Epoxy Primer. Nights are getting colder so put the pieces in the basement to dry.

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Oct 02, 2022 Prepping Slat parts - (5.1 hours)

Category: Slats/Flaps

One of the holes on the slat ribs where the slat pickups attach needed to be drilled to a #21. Reamed up to size. De-burred all holes and rounded the corners on the slat ribs. De-burred holes and sanded the edges of the slat corner doublers. Scuffed the slat ribs and corner doublers with 3m red scotchbrite.

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Oct 01, 2022 Slats - (2.2 hours)

Category: Slats/Flaps

Laid out all the slat pieces.
Sanded the edges and de-burred the holes on the 10 slat pickup (SD75S1-4) pieces. Scuffed for priming.
Drilled the 18 slat ribs flange holes to a # 30.

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Oct 01, 2022 Outboard Flaperons - (.3 hour)

Category: Slats/Flaps

Cut down 2 A4 rivets for the last two holes in the L/H and R/H outboard Flaperons and installed them. The outboard Flaperons are now complete.

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Sep 29, 2022 Outboard Flaperon Tips - (1.5 hours)

Category: Slats/Flaps

Laid out a line 10mm from the edge of the R/H outboard flaperon tip. Sanded the leading edge of the tip to make it fit better. Decided to add 1 hole on each of the flaperons tips because there was a little gap between the tip and the skin. Used a rivet spacer to match the existing hole spacing. Drilled holes on both L/H and R/H flaperons to 1/8". Deburred the holes and rivet with A4 rivets. One hole on each flaperon still needs to get riveted. I'll need to cut 2 rivets down for those 2 trailing edge holes.

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Sep 28, 2022 L/H Outboard Flaperon Tip - (.8 hour)

Category: Slats/Flaps

Layed out a line 10mm from the edge of the L/H outboard flaperon tip. This line is where the rivets will line up with. The flaperon skin will overlap the flaperon tip by 20mm. Sanded the leading edge of the flaperon tip to make it fit better.

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Sep 25, 2022 L/H Outboard Flaperon - (1.2 hours)

Category: Slats/Flaps

Installed A4 rivets to the L/H outboard flaperon bottom side skin. Cleco and installed A5 rivets on the splice plate.

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Sep 22, 2022 R/H Outboard Flaperon - (1.3 hours)

Category: Slats/Flaps

Installed A4 rivets to the R/H outboard flaperon bottom side skin. Cleco and installed A5 rivets on the splice plate.

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Sep 16, 2022 Picked up the Viking Fuel Senders

Category: Fuel System

Picked up the Viking Fuel Senders from the Zenith open house.

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Sep 16, 2022 Picked up the Zenith Fuel kit

Category: Fuel System

Picked up the Zenith Fuel kit at the Zenith open house. Zenith welded in the Viking Fuel Sender mounts.

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Sep 16, 2022 Picked up LED NAV/STROBE kit

Category: Lighting

Picked up the AERO LED Pulsar NAV/STROBE kit (P/N 01-1100-12) at the Zenith open house.

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Sep 11, 2022 L/H & R/H Flaperons - (3.8 hours)

Category: Slats/Flaps

Cleco the L/H flaperon ribs, L angle, and hinge brackets to the spar. Installed #5 solid AD rivets. Slid the skeleton into the skin, cleco the top side and installed A4 rivets to the top side of the L/H outboard flaperon. Pulled the nose skin over and cleco the skin to the spar. Also on the R/H outboard flaperon pulled the nose skin over and cleco the skin to the spar.

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Sep 10, 2022 R/H Outboard Flaperon - (.9 hour)

Category: Slats/Flaps

Rivet the L angle to the R/H outboard flaperon skeleton inboard end with #5 solid AD rivets. Slid the skeleton into the skin, cleco the top side and installed A4 rivets to the top side of the R/H outboard flaperon.

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Aug 21, 2022 Flaperons Inboard - (3.8 hours)

Category: Slats/Flaps

Cleco and rivet the end ribs and splice plates on the R/H and L/H inboard flaperons. A had to cut down a few rivets because they were too long. They were hitting the other rivets. Also needed to pull some with my modified rivet puller head. These two flaperons are complete and put on the storage rack.

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Aug 20, 2022 Flaperons - (3.6 hours)

Category: Slats/Flaps

Sanded the edges, debured the holes on the L/H outboard flaperon. Masked the areas of the flaperon skins that needed to be primed and primed those areas. Squeezed the solid rivets that hold the splice plate to the rib on the R/H outboard flaperon. I didn't like how this turned out so I'll going to drill the holes to a #21 and install the A5 rivets per the drawings.

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Aug 17, 2022 Purchased LED NAV/STROBE kit Category: Lighting

Purchased the LED NAV/STROBE kit from Zenith.

Aug 17, 2022 Purchased Zenith Fuel kit Category: Fuel System

Purchased the Zenith 750 Super Duty Fuel kit. Viking is shipping the fuel senders to Zenith to weld in.

Aug 09, 2022 Purchased Wing kit Category: Wings

Purchased the 750 Super Duty Wing kit from Zenith. Has a lead time of May 9, 2023. Hopefully it will be ready before that. Paid part of the invoice now and will pay the remainder when it's ready.

Aug 09, 2022 Purchased Fuel Senders Category: Fuel System

Purchased recessed fuel senders with weld in flanges from Viking Aircraft Engine. They come as a set of 2.

Aug 03, 2022 R/H Outboard Flaperon - (1.9 hours)

Category: Slats/Flaps

Installed the R/H outboard flaperon leading edge ribs, trailing edge ribs, and two hinge brackets to the spar with #5 solid AD rivets.

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Jul 10, 2022 Primed Flaperon parts - (3 hours)

Category: Slats/Flaps

Cleaned the L/H & R/H outboard flaperon skeleton pieces with SPI waterborne wax and grease remover. Also cleaned the L/H & R/H Inboard splice pieces. Wiped the parts with a tack cloth. Primed parts with the SPI epoxy primer.

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Jul 02, 2022 Purchased Tack Cloth

Category: Supplies

Purchased TCP Global Tack Cloth, TCP TC-12B, from Amazon.

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Jun 27, 2022 R/H Outboard Flaperon - (1.0 hour)

Category: Slats/Flaps

Drilled the R/H outboard end rib and splice plate holes up to a #21. Debured the holes and sanded the edges of the R/H outboard skin.

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Jun 20, 2022 R/H Outboard Flaperon - (1.8 hours)

Category: Slats/Flaps

Drilled the R/H outboard flaperon splice plate holes that go through the end rib. Instead of 4 holes I added 2 so there will be 6 rivets. Countersunk the six #30 holes for solid rivets. Sanded the edges, debured the holes, and scuffed the R/H outboard flaperon skeleton pieces. I still need to put the skeleton in the skin and drill up the splice plate and skin to #21 for A5 rivets.

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Jun 19, 2022 Built paint rack - (1.0 hour)

Category: Workshop

Built a 10' x 6' x 3/4” PVC rack for hanging parts to paint.

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Jun 04, 2022 Installed new air system - (8.0 hours)

Category: Workshop

Installed the Rapid Air master system from my shop to the garage. Also installed the new air filters. Planning to set up a movable paint booth made from a 10'x20' canopy tent with a screen kit on it.

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May 30, 2022 Purchased Canopy and Screen Kit

Category: Workshop

Purchased a 10'x20' canopy and screen kit from Menards. Planning on making this into a paint booth.

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May 12, 2022 Purchased S hooks

Category: Workshop

Purchased Gray Bunny S hooks, 3.5” long, from Amazon for hanging parts to paint. Bought 2 packs of 20.

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May 12, 2022 Purchased mixing cups

Category: Supplies

Purchased TCP Global 10 oz graduated mixing cups, 50 each from Amazon.

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May 07, 2022 Purchased PVC pipe and fittings Category: Workshop

Purchased 3/4” PVC pipe and fittings to make a paint rack from Menards.

May 01, 2022 L/H Outboard Flaperon - (2.5 hours)

Category: Slats/Flaps

Drilled the L/H outboard flaperon splice plate holes that go through the top of the end rib to a #21. Added 2 more holes on the face of the splice plate. The holes were already in the rib. Countersunk the six #30 holes for 1097 #4 solid AD rivets. Dimple and installed a rivet in the tooling hole on the end rib. Sanded the edges, debured holes, and scuffed the surfaces on the L/H outboard flaperon except the skin.

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Apr 30, 2022 L/H outboard Flaperon - (1.1 hours)

Category: Slats/Flaps

Cleco the L/H outboard flaperon skeleton to the skin. Sanded the skin, with 180 sandpaper, on the inboard end so the splice plate would sit flush on the rib. The skin was just a little long. Next I need to drill the holes to a #21 for A5 rivets on the splice plate.

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Apr 28, 2022 Outboard Flaperons - (.7 hour)

Category: Slats/Flaps

Layed out the parts for the L/H and R/H outboard flaperons.

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Apr 18, 2022 Purchased Rapid Air Master Kit and associated parts Category: Workshop

Purchased a Rapid Air master kit, air fittings and hose holder from Northern Tool ($218.25), Home Depot ($32.81), and Menards ($9.99).

Apr 17, 2022 Purchased Air Filter Category: Workshop

Purchased a Rapid air filter Regulator, Eastwood Air CFS, and DVB QC3 Air Filter Desiccant Cartridge. Needed a new filter in the shop and I'm going to run an air line up to the garage.

Apr 06, 2022 Purchased primer

Category: Supplies

Purchased a quart each of Epoxy Gray Primer (6610-4) and Epoxy Activator (6700-4) from Southern Polyurethanes.

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Apr 03, 2022 L/H Inboard Flaperon - (1.8 hours)

Category: Slats/Flaps

Cleco the L/H inboard flaperon control horn and drilled the holes to the final hole size, #21. Some of the holes were only drilled to a #30. Dimple and installed a rivet in the tooling hole on each of the end ribs. Just finishes it a little more instead of seeing an extra hole. Deburred, sanded the edges, and scuffed all the parts for both outer rib assemblies. Ready for primer.

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Apr 02, 2022 L/H Inboard Flaperon - (3.3 hours)

Category: Slats/Flaps

Installed A4 rivets on the top surface of the L/H Inboard Flaperon. Flipped it over and cleco the skin to the spar and ribs. Installed A4 rivets. Cleco the inboard splice plate to the outboard section and drilled the holes to a #21 for A5 rivets.

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Mar 31, 2022 L/H Inboard Flaperon - (.7 hour)

Category: Slats/Flaps

Slid the L/H Inboard Flaperon skeleton into the skin. Cleco the top surface with the leading edge hanging over the table.

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Mar 30, 2022 L/H Inboard Flaperon - (1.4 hours)

Category: Slats/Flaps

Sanded the edges of the L/H Inboard Flaperon skin. Taped off the mating surfaces, scuffed mating surfaces with red scotchbrite, and primed.

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Mar 28, 2022 Purchased pancake adapter

Category: Tools

Purchased a pancake adapter $75 (13029), 3 each 5/32” threaded drill bits (17092, 17093), and 3 each 1/8” threaded drill bits (17089, 17090).

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Mar 28, 2022 L/H Inboard Flaperon skin - (.7 hour) Category: Slats/Flaps

Debured the holes on the L/H Inboard Flaperon skin.

Mar 27, 2022 Flaperons - (4.3 hours)

Category: Slats/Flaps

Installed solid AD #5 rivets on the L/H inboard flaperon end L brackets and the 3 hinge brackets.
On the R/H inboard flaperon needed to drill some of the end ribs and brackets for #5 rivets. They were drilled for #4 rivets. Dimple and installed rivets through the end ribs tooling holes. Decided to install flush rivets on the outboard splice plate on the face of it. There were only 4 holes drilled through the splice plate but the rib had 2 extra holes drilled in it so drilled those 2 holes through the splice plate. Deburred and sanded the edges of all the end pieces.

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Mar 26, 2022 R/H Inboard Flaperon - (3.1 hours)

Category: Slats/Flaps

Rivet the R/H inboard flaperon skins with A4 rivets. Needed to trim a little bit of the skin around the hinge brackets. Some of the holes on the rib and upper L angle (SD75A2-5) were drilled for an A4 so reamed them to a #21 for A5's.

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Mar 24, 2022 R/H Inboard Flaperon - (.6 hour)

Category: Slats/Flaps

Cleco the R/H inboard flaperon skin to the skeleton assembly (top side). Leading edge hung over the side of the table.

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Mar 23, 2022 L/H Inboard Flaperon - (.5 hour)

Category: Slats/Flaps

Cleco nose ribs, rear ribs, 2 L end brackets, and the 3 hinge brackets to the L/H inboard flaperon spar. Installed A5 rivets that hold the ribs to the spar.

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Mar 20, 2022 Flaperon parts priming - (1.5 hours)

Category: Slats/Flaps

Primed the R/H inboard flaperon skin mating surfaces. Primed the L/H inboard flaperon spar, nose ribs, rear ribs, 2 L angle spar end brackets, and 3 hinge brackets.

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Mar 20, 2022 Purchased Primer Category: Supplies

Purchased a can of Rust-Oleum self etching primer from Meijer.

Mar 19, 2022 Flaperons - (2.2 hours)

Category: Slats/Flaps

Debured and sanded the edges of the R/H Inboard Flaperon. Masked off the mating surface areas that will get primed. Scuffed those ares with red scotchbrite. Wiped down all parts that have been prepped for primer with SPI 700-1 waterborne wax and grease remover. This remover works great to clean the parts.

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Mar 18, 2022 L/H Inboard Flaperon - (1.3 hours)

Category: Slats/Flaps

Debured holes, rounded the corners, and sanded the edges on the L/H Inboard flaperon 7 nose ribs, spar, 3 hinge brackets, and 2 L brackets on the ends of the spar, used red scotchbrite to lightly scuff all the skeleton parts for the L/H inboard flaperon. Ready to be wiped down and primed.

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Mar 14, 2022 Purchased Waterborne Wax and Grease Remover

Category: Supplies

Purchased a gallon on SPI 700-1 Waterborne Wax and Grease Remover from Southern Polyurethane, Inc.

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Mar 08, 2022 L/H Inboard Flaperon - (.8 hour)

Category: Slats/Flaps

Debured holes, rounded the corners, and sanded the edges on the L/H Inboard Flaperon 7 rear ribs.

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Mar 07, 2022 R/H Inboard Flaperon - (1 hour)

Category: Slats/Flaps

Installed #5 solid AD rivets to hold the 3 hinge brackets to the spar and the L brackets on the end of the spar. The skeleton is ready to get the skin riveted to it. I think I'll work on the L/H inboard flaperon to get it to the same as where the R/H inboard flaperon is now.

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Feb 28, 2022 R/H Inboard Flaperon - (1 hour)

Category: Slats/Flaps

Decided to install solid AD rivets to hold the 3 hinge brackets on the R/H inboard flaperon. Installed the rivets that go through the nose ribs.

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Feb 16, 2022 R/H inboard flaperon - (1 hour)

Category: Slats/Flaps

Installed A5 rivets on the R/H inboard flaperon nose ribs and rear ribs where they attach to the spar.

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Feb 13, 2022 Purchased Primer Category: Supplies

Purchased a can of Rust-Oleum self etching primer from Meijer.

Feb 13, 2022 R/H inboard flaperon - (1 hour)

Category: Slats/Flaps

Debured holes and scuffed the R/H inboard flaperon spar, then primed it.

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Feb 07, 2022 R/H Inboard Flaperon - (1 hour)

Category: Slats/Flaps

Cleaned previous R/H inboard flaperon pieces with mineral spirits and primed with self etching primer.

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Feb 06, 2022 R/H inboard flaperon - (2.7 hours)

Category: Slats/Flaps

Debured holes, rounded the corners, and sanded the edges on the R/H inboard flaperon nose ribs, rear ribs, hinge brackets, and spar L angles. Used red scotchbrite pad to scuff those parts for primer.

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Jan 10, 2022 Purchased additional brackets

Category: Workshop

Purchased some more brackets for the wall shelf to hold slats and flaperon parts.

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Jan 09, 2022 R/H Inboard Flaperon - (1.0 hour)

Category: Slats/Flaps

Put the remaining parts in bags and marked what is L/H and what is R/H sides. Cleco the end ribs on the R/H inboard flaperon to figure out what holes need to be drilled to 5/32”.

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Jan 09, 2022 Flaperons - (2.6 hours)

Category: Slats/Flaps

Spent the time figuring out which parts go on the right side and which parts go on the left side. Each set of parts have the same part number but for each side the parts are opposite. I have the R/H inboard flaperon parts laid out. Looks like the only things not drilled to final hole size is the flaperon root rib and flaperon inboard splice plate.

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Jan 08, 2022 Unwrapped slats and flaperons parts - (1.0 hour)

Category: Slats/Flaps

Unwrapped and got the slats and flaperons parts organized.

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Jan 07, 2022 Elevator and Trim Tab - (1.5 hours)

Category: Tail

Used a Dremel with a sanding disk and file to open the hole that the push rod goes through. Installed 4 A5 rivets to hold the trim motor servo to the elevator skin. The plans called for A4 rivets but my skin was drilled for A5 rivets. My wife and daughter helped to temporarily attach the elevator to the horizontal. I just wanted to make sure everything lines up before moving onto the next kit. All looks good. Took apart and bagged remaining parts for when it gets attached to the fuselage. Put the stabilizer and elevator on the wall shelf.

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Jan 05, 2022 Trim Tab Horn - (3.3 hours)

Category: Tail

My trim tab assembly kit had 2 trim tab horns (8H4-7) in it. One was predrilled for the attach holes and the other was not. I used the one with the predrilled holes but I just noticed that the hole for attaching the push rod clevis was drilled to a #21 not 1/8". The other trim tab horn is drilled to a 1/8" so I decided to remove the other one and install this one. Drilled out the rivets. Used double side tape on the new trim tab horn so I could move it around to where it needs to be and drill the holes. Primed the mating surfaces and rivet it to the tab. Cleco the tab to the elevator to check the deflections. The angles actually increased and was able to get 31.5 degrees up and down. I now need to cut more of the elevator skin where the push rod comes through.

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Jan 03, 2022 Wiring Trim Tab - (1.8 hours)

Category: Tail

I liked the idea of using D-Sub Contacts for connecting the wires to the trim tab servo so I could heat shrink all the wires. Connected the 5 each D-Sub contact pins and sockets together and used 3/32" heat shrink to hold them together. After the heat shrink was done over the connectors, then slid a piece of 1/4" clear heat shrink over all of them to hold everything together. Cleco the servo and push rod assembly into place. Checked the full up and full down deflection to make sure I still have the desired degrees. I'm getting about 28.5 degrees each way. Made the hole in the elevator skin, that the push rod comes through bigger, but still need to trim some more.

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Dec 30, 2021 Purchased 3/32" Black heat shrink tubing Category: Tail

Purchased 4 feet of 3/32" Black heat shrink tubing (SA-701B) from Stein Air.

Dec 30, 2021 Trim Tab push rod paint - (.2 hour)

Category: Tail

Primed and painted the trim tab servo push rod with zinc phosphate primer and Rustoleum flat black.

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Dec 30, 2021 Trim Tab - (.8 hour)

Category: Tail

The trim tab servo mounting holes were 1/8” but the holes in the elevator skin were 5/32” so drilled the servo holes to 5/32”. Marked the top side of the rocker switch and indicator to make it easier when mounting to the instrument panel.

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Dec 29, 2021 Trim Tab - (3.4 hours)

Category: Tail

Worked on wiring and testing the Ray Allen trim motor. I adjusted the push rod and was able to get 28 degrees up and 28 degrees down. I ended up with 155m between the clevis holes on the push rod. Only temp installed the servo to adjust the push rod.

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Dec 12, 2021 Purchased D-Sub contacts Category: Tail

Purchased a pack of 25 each D-Sub pins (SA-1018) and a pack of 25 each D-Sub sockets (SA-1017) from Stein Air.

Dec 12, 2021 Purchased 1/4" Clear Heat shrink tubing Category: Tail

Purchased 1/4" clear heat shrink tubing (SA-704C) from Stein Air.

Dec 11, 2021 Purchased Storage Shelving - (1 hour)

Category: Workshop

Purchased some hanging shelving and pipe insulation to hold the horizontal stabilizer and elevator. Put together and hung on the wall.

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Dec 05, 2021 Trim motor cover plate - (1.4 hours)

Category: Tail

Decided to make a little larger trim motor cover plate because the one in the kit didn't cover up the rivets from the nut plates that I added. Used 6061-T6 .025 and cut it 1/8” larger. Matched drilled it with the original one. Used 6 each AN526C-632R6 screws.

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Dec 05, 2021 Elevator Horns - (1.7 hours)

Category: Tail

Rivet the elevator horns and horn angles with A5 rivets. Did not rivet the hole on the lower horn that attaches to the elevator L angle, SD75H6-7. The lower elevator stop, SD75C5-9, will be getting attached there on the final Assembly drawing SD75-ZZ-05.

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Dec 05, 2021 Priming elevator horn mating surfaces - (.7 hour)

Category: Tail

Primed the mating surfaces that the elevator upper and lower horns attach to the elevator skin doubler.

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Dec 04, 2021 Wood beam - (.8 hour)

Category: Workshop

Found a piece of 2x6, cut 2 each 2 foot pieces and glued a piece of rubber to one side. I'll use these to set the elevator on so I can install the horns.

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Dec 02, 2021 Vortex Generators - (1.1 hours)

Category: Tail

Rivet the vortex generators to the leading edge of the elevator with A3 rivets.

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Nov 26, 2021 Elevator VG's - (1.3 hours)

Category: Tail

Masked off the area around where the VG's go and where the trim tap mounts. Used red scotch brite and cleaned areas for primer. Painted with self etching primer. Sanded the edges of the VG's to remove the rough edges. My son from New Orleans was home for Thanksgiving and helped today.

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Nov 24, 2021 Vortex Generators - (.9 hour)

Category: Tail

I want to prime the elevator skin where the VG's go. Cleco the VG's to the elevator, taped around them, and removed them.

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Nov 22, 2021 Elevator - (.8 hour)

Category: Tail

I found that the rivets along the elevator trailing edge were not going all the way into the hole because they were hitting the rivet from the other side. Took 7 A5 rivets apart and sanded the rivet down a little bit and reinstalled the stems. Installed the 7 trailing edge rivets on the elevator.

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Nov 05, 2021 Picked up Slats and Flaps kit

Category: Slats/Flaps

Drove to Zenith and picked up the Flaps and Slats kit along with 2 landing light kits. I'll be installing the landing lights in the slats.
My wife also got a demo flight in the CH750 Super Duty.

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Sep 09, 2021 Elevator - (.8 hour)

Category: Tail

Finished riveting rest of the holes on the elevator except for the very trailing edge holes because I need to shorten the rivets. They hit the rivet buck tail from the other side. Also did not rivet where the elevator horn attaches.

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Sep 08, 2021 Elevator skin riveting - (1.7 hours)

Category: Tail

Ran the elevator trim tab wire through the grommets. Cleco the bottom half of the elevator skins and leading edges. Installed A5 rivets on the leading edge skins going into the spar. My son was still in town and helped rivet.

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Sep 07, 2021 Elevator - (.9 hour)

Category: Tail

Removed the clecos and cleaned out the metal chips from the inside of the elevator. Primed the leading edge skin where the elevator skin doubler attaches. Got some help from one of my sons today.

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Sep 04, 2021 Elevator Trim Tab - (2.1 hours)

Category: Tail

Decided to use solid AD rivets on the elevator trim tab doublers and horn. Drilled, debured, and assembled the tab with 6 each #5 AD rivets and 3 each #6 AD rivets. Riveted the hinge to the tab with 17 A3 rivets.

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Aug 23, 2021 Purchased Primer Category: Supplies

Purchased Rust-oleum self etching primer from Home Depot.

Aug 23, 2021 Elevator trim tab - (.1 hour)

Category: Tail

Primed the other side of the trim tab pieces.

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Aug 22, 2021 Elevator trim tab - (1.8 hours)

Category: Tail

Drilled the three holes in the center trim tab skin doubler. The 2 outer ones came pre-drilled. Sanded and debured the 3 trim tab skin doublers, trim tab horn, and the hinge. Cleaned and primed one side of those parts. Removed the parts sticker and debured the holes on the trim tab skin.

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Aug 20, 2021 Elevator trim tab - (1.1 hours)

Category: Tail

Laid the trim tab hinge onto the elevator skin and drilled pilot holes. Then drilled to a #30 for A4 rivets, 17 holes. Debured the holes and rounded the corners. Taped the elevator skin around the hinge so I can prime it. Also taped around the elevator skin doubler for priming.

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Jul 05, 2021 Vortex generators and elevator trim tab - (1.4 hours)

Category: Tail

Drilled the second hole for the vortex generators. Reamed the nose skin holes that attach to the spar to a #21. Drilled the nose ribs to the nose skin. Started to figure out the elevator trim tab.

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Jun 26, 2021 Vortex Generators - (1.9 hours)

Category: Tail

Figured out where to install the vortex generators. Made a jig to space them apart evenly. Drilled one of the holes for each of the vortex generators. There are 10 on each side.

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Jun 20, 2021 Elevator - (2.8 hours)

Category: Tail

Installed the A5 rivets on the upper half elevator skins. Flipped elevator over and cleco the skins. I need to drill the nose ribs to the leading edge skin. Also lay out the vortex generators before riveting the lower half.

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Jun 06, 2021 Elevator nose skins - (.7 hour)

Category: Tail

Cleco the top side of the leading edge skins to the front spar. Noticed that the leading edge skins needed to be primed where the skin doubler goes. Cleaned and primed that area with self etching primer.

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May 12, 2021 Purchased 2 each landing light kits Category: Lighting

Purchased 2 landing light kits at $425 each.

May 12, 2021 Purchased Slats and Flaps kit Category: Slats/Flaps

Purchased the 750 SD slats and flaps kit.

May 01, 2021 Elevator - (1.1 hours)

Category: Tail

Primed the mating surfaces on the two elevator leading edge skins. Installed the two rubber grommets for the trim tab servo wiring. Started to cleco the skins to the elevator skeleton.

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Apr 29, 2021 Purchased .025 aluminum sheet Category: Supplies

Purchased 6061 T6 Aluminum .025 1'x4' from Airparts Inc.

Apr 28, 2021 Elevator leading edge skins - (1.0 hour)

Category: Tail

Debured the holes and edges on the elevator leading edge skins. Taped the skins so I can just prime the mating surfaces.

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Apr 27, 2021 Elevator trailing edge skins - (1.3 hours)

Category: Tail

Removed the tape and paper from the elevator trailing edge pieces from priming them. Riveted 6 each MS21047-L06K nut plates to the left elevator trailing edge skin for the trim motor cover plate.

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Apr 26, 2021 Priming elevator skins - (1.0 hour)

Category: Tail

Primed the mating surfaces on the elevator trailing edge skins with self etching primer.

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Apr 25, 2021 Elevator - (1.8 hours) Category: Tail

Finished taping and masking the elevator trailing edge skins. Used 3M moderate stripping pads (red) to scuff the areas to prime. Removed the part number labels from the elevator leading edge skins.

Apr 14, 2021 Elevator skins - (.8 hour)

Category: Tail

Taped and masked the R/H elevator trailing edge skin so I can prime just the mating surfaces.

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Apr 11, 2021 Elevator - (3.0 hours)

Category: Tail

Primed the middle section of the elevator skeleton with zinc phosphate primer. Drilled the holes and dimpled for installing nut plates (MS21047-L06K) on the L/H trailing edge skin that will be used for the trim motor cover plate. Sanded the edges and debured the holes on the L/H and R/H trailing edge skins.

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Apr 06, 2021 Elevator ribs - (1.6 hours)

Category: Tail

Finished riveting the ribs to the spar with # 5 AD solid rivets. Drilled 2 each 7/16” holes with a unibit for the rubber grommets that the trim motor wiring will go through. Dimpled and squeezed some #3 flush rivets in the tooling holes that are in the center section nose ribs. One of the tooling holes was where I put the grommet hole.

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Apr 05, 2021 Elevator - (1.5 hours)

Category: Tail

Rivet the ribs to the spar with # 5 AD solid rivets.

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Apr 04, 2021 Elevator nose skin - (1.3 hours)

Category: Tail

Cleco the nose skins to the elevator spar. Drilled the skin to the nose ribs. Took everything apart to rivet the ribs to the spar.

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Apr 03, 2021 Purchased 5/32” reamers Category: Tools

Purchased two different 5/32” reamers from the Yardstore. Chucking reamer- $11.00, threaded reamer- $5.

Apr 03, 2021 Purchased 5/32” clecos Category: Tools

Purchased 50 each 5/32” clecos from the Yardstore. Needed some additional clecos of this size. .50 each

Apr 02, 2021 Elevator - (.6 hour)

Category: Tail

Cleco the trailing edge skins to the frame to make sure the holes drilled in the end ribs line up and the elevator doesn't have a twist. It all looks good.

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Apr 01, 2021 Elevator - (2.6 hours)

Category: Tail

Rivet the elevator end ribs L bracket and steel pins on both ends. The end ribs only had pilot holes so cleco the trailing edge skins onto the frame and drilled to a #21. The bottom side lined up good but the upper side the pilot holes were off a little.

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Mar 18, 2021 Purchased Anchor Nuts and Stainless Screws Category: Rudder

Purchased pack of 5 K1100-06 Anchor Nuts and 10 each MS24693C26 (AN507C632R6) Flush Stainless Screws from Aircraft Spruce.

Mar 18, 2021 Elevator - (1.0 hour)

Category: Tail

Painted one side of the elevator tip pins with flat black paint. Dimple and installed rivets in the outboard elevator ribs tooling holes.

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Mar 17, 2021 Purchased AN526C-632R6 screws Category: Tail

Purchased 6 AN526C-632R6 SS screws for the trim tab cover plate from Aircraft Spruce.

Mar 17, 2021 Purchased MS21047-L06K nut plates

Category: Tail

Purchased 6 each MS21047-L06K nut plates for the trim motor cover plate from Wicks Aircraft,

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Mar 17, 2021 Purchased rivets

Category: Supplies

I needed to restock some rivets so ordered them from Wicks Aircraft supply.
MS20470-5-4 ($3.89) and MS20470-5-6 ($3.10), 1/8 lb of each.

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Feb 28, 2021 Elevator - (1.2 hours)

Category: Tail

Laid out and cleco the elevator frame pieces. A couple of the pieces were not drilled to final hole size so drilled up those holes.

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Feb 27, 2021 Stabilizer skin - (3.8 hours)

Category: Tail

Installed A5 rivets on the horizontal stabilizer skin. Had to modify (grind the head) a hand squeeze for 2 rivets that are next to the stabilizer front brackets (SD750H2-10) because the rivet gun didn't fit. Also had to countersink the set head to dome the A5 rivets.

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Feb 22, 2021 Stabilizer - (.9 hour)

Category: Tail

Reamed the open holes that are between the clecos on the bottom surface of the stabilizer to a #21, .1590.

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Feb 08, 2021 Stabilizer skin doubler - (.4 hour)

Category: Tail

Primed the stabilizer skin area where the skin doubler attaches with zinc phosphate primer.

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Feb 01, 2021 Stabilizer skin - (2.5 hours)

Category: Tail

Installed and torqued the AN3 bolts with AN365-1032 nuts on the horizontal stabilizer center hinge bracket to 25 in lbs. Put a torque stripe on the nuts with cross check torque seal. Cleco the skin to the stabilizer skeleton.

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Dec 28, 2020 Purchased squeeze sets

Category: Tools

Purchased squeeze sets from the Yardstore.
11 piece set- $25
#8 set- $14.95
3/32” set- $14.95

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Dec 28, 2020 Purchased Torque Wrench

Category: Tools

Purchased a 1/4” drive 20-150 in lbs from Yardstore.

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Dec 24, 2020 Horizontal skin - (.3 hour)

Category: Tail

Removed the tape and paper from after painting the horizontal skin. Turned out great.

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Dec 23, 2020 Painting Horizontal Skin - (1.3 hours)

Category: Tail

My son Zachary and I prepped and painted the horizontal skin mating surfaces and center section of the skin with Rust-Oleum Self Etching primer. First time trying this primer and so far I like it.

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Dec 21, 2020 Purchased flat black spray paint Category: Supplies

Purchased a can of Rust-Oleum flat black paint from Home Depot.

Dec 21, 2020 Purchased Mineral Spirits Category: Supplies

Purchased a quart can of Mineral Spirits from Home Depot.

Dec 21, 2020 Purchased Primer Category: Supplies

Purchased 2 cans of Rust-Oleum Self Etching primer from Home Depot for $5.28 per can.

Dec 19, 2020 Horizontal tip ribs - (.2 hour)

Category: Tail

Dimpled and riveted the tooling holes in the horizontal tip ribs (SD75H1-1) with AN426 3-3 solid rivets.

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Dec 19, 2020 Dimpling jig - (.7 hour)

Category: Tools

Built a dimple jig to dimple the tooling holes on the two horizontal end ribs. SD75H1-1

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Dec 19, 2020 Horizontal skin - (.9 hour)

Category: Tail

Finished taping off the mating surfaces on the horizontal stabilizer skin for paint.

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Dec 14, 2020 Horizontal skin - (1.1 hours)

Category: Tail

Started to tape off the mating surfaces on the horizontal skin for primer. I didn't want to prime the entire skin or have overspray everywhere so I'm masking it off.

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Dec 13, 2020 Stabilizer - (3.0 hours)

Category: Tail

Debured the holes on the stabilizer skin with a palm hand file, worked great. Debured the holes on the stabilizer skeleton and sanded the edges of the skin with 220 sandpaper.

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Nov 16, 2020 Stabilizer top side of skin - (1.8 hours)

Category: Tail

Drilled all the holes on the top side of the stabilizer skin to a #21 for the A5 rivets. Also drilled the full ribs on the ends and the skin doubler to a #21.

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Nov 15, 2020 Stabilizer skin - (3.0 hours)

Category: Tail

Cleco the skin to the lower side of the stabilizer assembly. Drilled all the ribs to a #23 and then reamed the holes to a #21. The pilot holes were a little off so I wanted to undersize the holes before drilling to the actual size. Removed the skin and flipped the stabilizer assembly over and cleco the skin to the top side. All the ribs only have pilot holes on the top side as well so these will need to be drilled to a #21 for the A5 rivets also.

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Nov 14, 2020 Stabilizer rear bracket - (1 hour)

Category: Tail

Installed the H2-11 stabilizer rear bracket, H2-12 stabilizer center hinge bracket, and H2-13 stabilizer center hinge gusset with 14 each #5 solid (AD) rivets and 13 each #6 solid (AD) rivets. I still need to install 6 AN3 bolts to complete this rear bracket.

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Nov 13, 2020 Stabilizer aft spar - (2.1 hours)

Category: Tail

Riveted the stabilizer aft spar angles and ribs to the spar with #5 solid (AD) rivets.

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Nov 12, 2020 Purchased a palm hand file

Category: Tools

Purchased a vixen palm hand file from Yardstore.

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Nov 12, 2020 Purchased #21 tapered reamer

Category: Tools

Purchased a #21 tapered reamer from Yardstore.

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Nov 12, 2020 Purchased 8 inch rivet set extension

Category: Tools

Purchased an 8” rivet set extension from Yardstore.

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Nov 12, 2020 Riveting the stabilizer - (3.4 hours)

Category: Tail

Riveted the front spar angles to the spar with #5 solid (AD) rivets. Riveted the nose rib and the two full ribs to the spar with #5 solid (AD) rivets. Riveted the two H2-10 stabilizer front brackets with #5 solid (AD) rivets and #6 solid (AD) rivets in the end holes that go through the spar angles.

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Nov 11, 2020 Stabilizer assembling - (4.9 hours)

Category: Tail

Finished drilling the stabilizer parts to the final hole size. Debured the holes and cleco everything together. Riveted the H2-12 stabilizer hinge bracket and the H2-13 stabilizer center hinge gusset with #5 solid (AD) rivets. Riveted the H2-9 stabilizer L angle to the front spar with #5 solid (AD) rivets.

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Nov 10, 2020 Primed and drilled holes - (6.5 hours)

Category: Tail

Primed the elevator tip ribs, elevator hinge angles, and the elevator outboard hinge pins. Started to cleco the stabilizer pieces together and realized that a lot of holes were not drilled to final size. Worked on drilling everything to final size and debured the holes.

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Nov 09, 2020 Elevator outboard hinge pin - (2.3 hours)

Category: Tail

Drilled the 2 elevator outboard hinge pins, H3-2, to the tip ribs, H1-5, and outboard rib angle, H2-15, with a #21 drill bit. Drilled a hole at the ends of the pin, with a #53 drill bit, for a cotter pin. Sanded the edges and debured the holes on these parts.

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Nov 08, 2020 Elevator parts primed - (4.3 hours)

Category: Tail

Primed elevator parts that were prepped yesterday. Sanded the edges and debured the holes on the seven ribs and two nose ribs for the elevator. Primed the mating surfaces on the ribs. Prepped and primed the following; H6-4 elevator skin doublers, H6-6 elevator channel L angles, H6-7 elevator horns L angle, and H6-5 stabilizer skin doubler.

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Nov 07, 2020 Elevator parts - (1 hour)

Category: Tail

Removed the part number stickers, sanded the edges, and debured the holes on the H2-14 elevator channel, H5-3 horn angle, H5-1 upper elevator horn, and H5-2 lower elevator horn.

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Nov 07, 2020 Primed stabilizer parts - (2.5 hours)

Category: Tail

Primed the mating surfaces on the stabilizer parts with zinc phosphate primer.

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Nov 03, 2020 Stabilizer rear ribs cleaning - (.7 hour)

Category: Tail

Sanded the rough edges and debured the holes on the H1-4 stabilizer rear ribs, 4 each. Also removed the sticker marking the front and added a piece of safety wire to the front of the ribs so I know which end is the front.

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Nov 02, 2020 Stabilizer rib cleaning - (.6 hour)

Category: Tail

Removed the part number stickers, debured holes, and cleaned up the edges on the H1-1 stabilizer end ribs L&R, H1-2 full ribs, H1-3 stabilizer nose ribs.

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Oct 31, 2020 Prepping Stabilizer Parts - (1.1 hours)

Category: Tail

Removed the part number stickers, debured holes, and cleaned up the edges on the H3-1 stab outbound hinge plate, H2-9 stab L angle L&R, H2-10 Stab front bracket L&R, H2-12 Stab center hinge bracket, H2-13 Stab center hinge gusset.

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Oct 27, 2020 Prepped more stabilizer parts - (1.1 hours) Category: Tail

Removed the part number stickers, debured holes, and cleaned up the edges on the H2-8 spar doubler and H2-11 stabilizer rear bracket.

Oct 26, 2020 Cleaned stabilizer doubler - (.7 hour)

Category: Tail

Removed the part number sticker with lacquer thinner, debured holes, and cleaned the edges with a 2” blue sanding disc on the H2-7 doubler.

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Oct 22, 2020 Debured stabilizer doublers - (.5 hour) Category: Tail

Debured the holes and sanded the edges on the stabilizer front spar upper and lower doublers.

Oct 14, 2020 Primed tail spar pieces - (.7 hour)

Category: Tail

Primed the other side of the elevator spar and stabilizer rear spar pieces.

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Oct 12, 2020 Purchased MS21049L08 Anchor Nuts

Category: Lighting

Purchased MS21049L08 anchor nuts from Aircraft Spruce, part number 04-01725-10. It came in a package of 10. Using these on the taxi/recognition lights.

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Oct 12, 2020 Purchased zinc phosphate primer Category: Supplies

Purchased 4 cans of A-702 Valspar zinc phosphate primer from Aircraft Spruce.

Oct 10, 2020 Horizontal Stabilizer spar angles - (1.0 hour) Category: Tail

Started cleaning up the holes and edges on the Horizontal Stabilizer angles.

Oct 10, 2020 Primed the spar pieces - (2.0 hours)

Category: Tail

Cleaned the three spar pieces with acetone. Deburred a few holes that still needed it. Primed the spars with zinc phosphate primer. Didn't finish, ran out of primer.

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Oct 08, 2020 Purchased Acetone Category: Supplies

Purchased a quart of acetone from Menards.

Oct 08, 2020 Purchased cleaning rags Category: Supplies

Purchased painters choice 9”x13” cotton paint & cleaning rags from Menards.

Oct 07, 2020 Elevator Spar deburring - (.9 hour)

Category: Tail

Debured holes and sanded the edges on the SD75H3-5 Elevator Spar and removed the part number stickers on all three spar pieces that have been prepped for primer.

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Oct 06, 2020 Horizontal Stabilizer spar deburring - (1.0 hour) Category: Tail

Debured holes and sanded the edges with 320 sandpaper on the stabilizer rear spar (SD75H3-6) and stabilizer front spar (SD75H3-7).

Sep 21, 2020 Unwrapped tail kit parts - (1.2 hours)

Category: Tail

Unwrapped the parts and took inventory of them.

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Sep 08, 2020 Purchased the STOL 750 Super Duty Vortex Generators Option Kit Category: Tail

Purchased the STOL CH 750 Super Duty Vortex Generators Option Kit from Zenith. I'll be picking it up at the Zenith Homecoming on Friday, September 18.

Sep 08, 2020 Purchased the Tail Kit

Category: Tail

Purchased the STOL CH 750 Super Duty Tail Kit. I'll be picking it up on Friday, September 18 at the Zenith Homecoming.

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Aug 10, 2020 Purchased 3.5" round access panel

Category: Rudder

Purchased a 3.5" round access kit (P/N RD35-F25) from Experimental Accessories. $32 for the kit and $10 for shipping. I'll use this one as a template to make more as needed. This access panel will be getting installed on the right rudder rear lower skin to give me access to the tail light wiring and for inspection purposes.

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Jul 20, 2020 Rudder Tail Light Install - (2.5 hours)

Category: Lighting

Primed the trailing edge skin where the tail light bracket attaches with zinc phosphate primer.
Used butt splices p/n 320559 (Aircraft Spruce) to connect the tail light to 18 awg. wire. Also used heat shrink p/n HST-1/8 and HST-3/16 (Wicks) to hold the wires together.
Riveted the tail light bracket to the rudder with 10 ea. A4 rivets.
Screwed the tail light to the bracket with #6 screws and tested the light to make sure it works.

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Jul 09, 2020 Riveted the rudder horn and left rear lower skin - (2.2 hours)

Category: Rudder

Installed the rudder horn with #5 solid AD rivets.
Installed the left rudder rear lower skin with A4 rivets.

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Jun 21, 2020 Riveting - (1.2 hours)

Category: Rudder

Finished riveting the trailing edge skin and the leading edge skin with A4 rivets.

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May 10, 2020 Riveted skins - (3.3 hours)

Category: Rudder

Started to rivet the trailing edge and leading edge skins with A4 rivets.

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May 10, 2020 Installed riv-nuts to tail light bracket - (.3 hour)

Category: Lighting

Installed #6 riv-nuts to the tail light bracket.

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Apr 30, 2020 Primed and cleco nose skin - (1 hour)

Category: Rudder

Primed the mating surface with zinc phosphate primer on the nose skin, rear lower skin, and lower spar fairing. Cleco the nose skin, rear lower skin, and lower spar fairing to one side of the rudder.

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Apr 28, 2020 Purchased Rivet Nut Tool Category: Tools

Purchased a rivet nut tool 12-00968 for 6/32, 8/32, and 10/32 from Aircraft Spruce.

Apr 27, 2020 Cleco trailing edge skin - (1 hour)

Category: Rudder

Fabricated a 24mm spacer block and positioned it between the 2” square aluminum bar and the workbench under the aft bottom corner of the trailing edge. Cleco the trailing edge skin to the spar and ribs.

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Apr 15, 2020 Purchased Rivet Nuts Category: Lighting

Purchased a 10 package of 6-32 rivnuts from Aircraft Tool Supply Company.

Apr 14, 2020 Drilled tail light bracket - (.8 hour)

Category: Lighting

Drilled the tail light bracket to the trailing edge skin for the A4 rivets.

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Apr 12, 2020 Installed ribs - (2.8 hours)

Category: Rudder

Cleco and installed the 5 trailing edge ribs and 1 nose rib with #4 solid (AD) rivets. Had to modify one of my bucking bars for the rudder bottom rib because of the tight angle.

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Apr 11, 2020 Tail light wiring - (1.1 hours)

Category: Lighting

Figured out how the tail light wire is going to run inside of the rudder. Installed grommet P/N MS35489-1. Drilled 2 #30 holes and riveted P/N ABM4 wire holder to the spar with #3 solid (AD) rivets.

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Apr 06, 2020 Tail light cut out - (1.4 hours)

Category: Lighting

Cut out the rudder trailing edge skin for the tail light.

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Apr 02, 2020 Purchased 4-way cable tie mount and cable ties Category: Lighting

Purchased 4-way cable tie mount (P/N ABM4) and 7" low profile cable ties (P/N C750LP9) from Wicks Aircraft.

Apr 01, 2020 Tail light bracket - (2 hours)

Category: Lighting

Cleco the ribs and trailing edge skin to the spar so I could figure out where to mount the tail light. Drilled the bracket for the rivets and tail light assembly. I'll be installing riv-nuts to mount the light assembly to the bracket. Laid out where I need to cut the trailing edge skin.

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Mar 29, 2020 Riveted the doublers to the spar - (3.2 hours)

Category: Rudder

Made 3 aluminum shims, 6061-T6 .032, to go under the ribs where they attach to the spar. There was a gap because of the SD75R1-8 doublers.
Riveted the SD75R1-8 doublers to the SD75R2-3 spar with #4 solid rivets.
Riveted the 75R2-5 rudder hinge angles to the spar with #5 solid rivets.

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Mar 28, 2020 Primed rudder parts - (2.9 hours)

Category: Rudder

Used acetone to clean the rudder parts to prime.
Set up a paint area in the garage and primed the mating surfaces on the spar, ribs, and brackets with zinc phosphate primer.

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Mar 26, 2020 Purchased Zinc phosphate primer Category: Supplies

Purchased 2 cans of zinc phosphate primer from Aircraft Spruce, $9.95 each.

Mar 26, 2020 Deburring and cleaning parts - (1.8 hours)

Category: Rudder

Finished deburring and cleaning the edges on rest of the ribs, rear skin, nose skin, lower spar fairing, rudder horn. Cleco the spar and ribs to see how they fit together and tried to figure out where to put the tail light.

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Mar 25, 2020 Purchased butt splices Category: Lighting

Purchased 2 each 320559 window type butt splice red from Aircraft Spruce & Specialty Co.

Mar 25, 2020 Prepping rudder parts - (3 hours)

Category: Rudder

Unpacked rudder parts and took wrapping off of them. Removed the P/N stickers with laquer thinner. Removed burrs from the holes and edges on the rudder spar, hinge angles, and spar doublers. Brushed on cortec primer on the rudder tip angle to see how I like it.

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Mar 09, 2020 Purchased 2"X2" Aluminum Tubing Category: Workshop

Purchased 2 each of 2"X2"X4' Aluminum tubing from Wicks. These will be used to put the rudder on as I'm assembling it so it's not resting on the rivets. This square tubing will also keep the rudder straight.

Feb 24, 2020 Work bench total cost Category: Workshop

The total cost to build the 4' x 12' work bench was $256.32.

Feb 24, 2020 Work Bench - (1.1 hours)

Category: Workshop

Cut and screwed the 8' bottom shelf piece. Work Bench is done.

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Feb 10, 2020 Purchased a wire crimp tool Category: Tools

Purchased an Ideal Crimpmaster ratcheting crimp tool with a 30-579 die set from Fotronic Corporation, Test Equipment Depot.

Feb 10, 2020 Purchased a wire stripper Category: Tools

Purchased an Ideal #16-26 AWG Stripmaster wire stripper from Fotronic corporation, Test Equipment Depot.

Feb 10, 2020 Work Bench - (1.7 hours)

Category: Workshop

Cut and installed the bottom shelf 2x4's. Cut the 4' bottom to fit around the legs.

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Feb 08, 2020 Purchased 1/8" and 3/16" heat shrink tubing Category: Lighting

Purchased 2 feet each of HST-1/8 and HST-3/16 heat shrink tubing from Wicks Aircraft Supply.

Feb 08, 2020 Purchased Rubber grommet Category: Lighting

Purchased rubber grommet (P/N MS35489-1) from Wicks Aircraft Supply. I'll use this grommet to run the tail light wires through one of the ribs.

Feb 08, 2020 Purchased 12V LED tail light Category: Lighting

Purchased a PSA Enterprises 12V LED tail light (TL918) from Wick's Aircraft Supply.

Feb 01, 2020 Work Bench - (1 hour)

Category: Workshop

Sanded and painted the top.

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Jan 30, 2020 Work Bench - (1.2 hours)

Category: Workshop

Sanded and painted the top.

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Jan 28, 2020 Work Bench - (1.0 hour)

Category: Workshop

Flipped the work bench over and primed the top. I'm having to prime and paint the top because I used OSB subfloor.

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Jan 25, 2020 Work Bench - (5.0 hours)

Category: Workshop

Finished legs and finished screwing the top op. Installed the bottom supports.

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Jan 24, 2020 Work Bench - (4.0 hours)

Category: Workshop

Nailed the legs together and installed them. Also assembled the bottom shelf.

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Jan 23, 2020 Work Bench - (2.0 hours)

Category: Workshop

Screwed the top together.

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Jan 20, 2020 Work Bench - (3.0 hours)

Category: Workshop

Cut the wood to size. Building a 4' x 12' work bench.

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Dec 21, 2019 Purchased Acetone Category: Supplies

Purchased a quart of acetone from Menards.

Dec 21, 2019 Purchased tail light bracket Category: Lighting

Purchased a tail light bracket from Zenith.

Dec 21, 2019 Purchased Lacquer thinner Category: Supplies

Purchased a container of lacquer thinner from Menards for taking off the PN stickers from each individual part.

Dec 21, 2019 Purchased wire for the tail light Category: Lighting

Purchased 100 feet of 18 gauge wire from Zenith Aircraft for the tail light.

Dec 12, 2019 Purchased Cortec Primer Category: Supplies

Purchased a quart can of cortec primer from Zenith Aircraft.

Dec 12, 2019 Purchased a Pneumatic Riveter Category: Tools

Purchased a pneumatic riveter with the special head to pull the Zenith rivets from Zenith.

Dec 12, 2019 Purchased 750SD Rudder from Zenith

Category: Rudder

Drove to the Zenith Aircraft factory and purchased the Zenith 750 Super Duty Rudder kit.

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Dec 12, 2019 Purchased the Zenith 750 Super Duty Drawings Category: Drawings

Purchased the Zenith 750 Super Duty drawings and the upgrades drawings.
750SD Drawings- $575.00
750SD Upgrade Drawings- $125.00

Dec 12, 2019 Purchased Tape measure Category: Tools

Needed a metric tape measure because the plans are in metric and didn't have one.