Project: EaglesWing   -  
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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

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 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 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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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     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 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 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 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 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     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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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 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 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     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     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 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 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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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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