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Entry #	Created	Title	Category	Hours	# Pictures

361	Apr 29, 2024	Purchased Screws, Nuts, and Heat-shrink	Lighting		1
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.

 

360	Apr 29, 2024	Purchased Fuel Sender Wire	Fuel System		1
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.

 

359	Apr 28, 2024	R/H Wing Recognition Light and Nav/Strobe Light	Lighting	3.4	4
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.

 

358	Apr 24, 2024	R/H Fuel Sender Access Cover	Fuel System	1.0	3
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.

 

357	Apr 21, 2024	R/H Fuel Tank	Fuel System	1.3	5
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.

 

356	Apr 20, 2024	R/H Wing Upper Skins	Wings	1.7	2
Started taping the areas on the R/H wing upper skins for primer. Removed the wing tip and skins.

 

355	Apr 20, 2024	R/H Fuel Tank	Fuel System	2.2	6
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.

 

354	Apr 10, 2024	Fuel Fill Tube Finishing Covers	Fuel System	1.4	6
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.

 

353	Apr 07, 2024	R/H Fuel Tank	Fuel System	7.0	6
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.

 

352	Apr 06, 2024	R/H Recognition Light	Lighting	.6	3
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.

 

351	Apr 03, 2024	R/H Wing Tip	Wings	1.0	4
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.

 

350	Apr 01, 2024	R/H Wing Tip	Wings	1.0	2
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.

 

349	Mar 31, 2024	R/H Wing Tip	Wings	2.0	5
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,

 

348	Mar 26, 2024	R/H Wing Tip	Wings	1.7	4
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.

 

347	Mar 25, 2024	Purchased fuel system parts	Fuel System		1
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.

 

346	Mar 24, 2024	R/H and L/H Position Lights	Lighting	2.3	2
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.

 

345	Mar 23, 2024	R/H Wing Tip	Wings	2.4	2
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.

 

344	Mar 21, 2024	R/H Wing Tip	Wings	3.0	7
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.

 

343	Mar 19, 2024	R/H Wing Root Skin	Wings	2.9	13
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.

 

342	Mar 18, 2024	Purchased bolts, washers, and nuts	Wings		1
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.

 

341	Mar 18, 2024	Purchased nutplates	Wings		1
Purchased 10 each MS21047L3K nutplates for the L/H wing fuel sender access cover from Aircraft Spruce.

 

340	Mar 18, 2024	Purchased screws	Wings		1
Purchased 14 AN525-832R6 screws for the L/H wing fuel access cover from Aircraft Spruce.

 

339	Mar 16, 2024	R/H Wing Root Skin	Wings	2.0	6
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.

 

338	Mar 15, 2024	Purchased Polyfix Plastic Repair Kit	Supplies		2
Purchased Polyfix plastic repair kit from Aircraft Spruce. Strange on how it was packaged.

 

337	Mar 11, 2024	Purchased a Tube Flaring Tool	Tools		1
Purchased a Rol-Air 37 degree flaring tool, 507-FB, from Brown Aviation Tool Supply Co.

 

336	Mar 11, 2024	Purchased a Tube Bender	Tools		1
Purchased a tube bender, 368-FH, that can bend 1/4”, 5/16”, and 3/8” tube from Brown Aviation Tool Supply.

 

335	Mar 10, 2024	R/H Wing Root	Wings	3.3	6
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.

 

334	Mar 06, 2024	R/H Wing Root Angles	Wings	1.4	3
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,

 

333	Mar 03, 2024	R/H Wing	Wings	1.7	2
Removed the R/H wing top skin L stiffeners. Debur and sanded the edges. Taped for priming. Removed the upper fuel tank wing stiffeners.

 

332	Mar 03, 2024	R/H Wing	Wings	2.2	1
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.

 

331	Mar 01, 2024	Purchased Fittings	Fuel System		1
Purchased 8 each AN819-6D fitting sleeves and 8 each AN818-6D fitting nuts from Aircraft Spruce.

 

330	Mar 01, 2024	Purchased Sealant	Supplies		1
Purchased a pint of Flamemaster Chemseal CS3204 B2 sealant from Aircraft Spruce.

 

329	Feb 26, 2024	R/H Wing Outboard Trailing Edge Skin	Wings	.8	5
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”.

 

328	Feb 17, 2024	R/H Wing Trailing Edge	Wings	4.4	9
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.

 

327	Jan 17, 2024	Wing OTB Trailing Edge Skin	Wings		3
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.

 

326	Jan 11, 2024	R/H Wing Leading Edge	Wings	1.5	3
Finished drilling the R/H wing leading edge skins to a #21. The skins sit perfect.

 

325	Jan 10, 2024	R/H Wing	Wings	1.2	1
More drilling on the R/H wing.

 

324	Jan 08, 2024	R/H Wing Spar	Wings	1.2	2
More drilling on the R/H wing spar. It's looking good and getting there.

 

323	Jan 07, 2024	R/H Wing	Wings	2.4	3
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.

 

322	Jan 05, 2024	R/H Wing OTB Trailing Edge	Wings		0
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.

 

321	Jan 03, 2024	Purchased Fluting Pliers	Tools		1
Purchased a fluting pliers (FP21) from Aircraft Tool Supply Company.

 

320	Jan 03, 2024	R/H Wing	Wings	.5	3
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.

 

319	Jan 01, 2024	R/H Wing	Wings	.9	2
Finished drilling the #40 holes in the R/H wing spar. Need to keep drilling up the wing holes to final size.

 

318	Dec 31, 2023	R/H Wing	Wings	2.5	3
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.

 

317	Dec 30, 2023	R/H Wing Tip	Wings	1.5	5
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.

 

316	Dec 29, 2023	R/H Wing trailing edge	Wings	3.0	10
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.

 

315	Dec 26, 2023	R/H Wing	Wings	3.8	8
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.

 

314	Dec 25, 2023	R/H Wing	Wings	5.0	11
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.

 

313	Dec 20, 2023	R/H Wing	Wings	.8	3
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.

 

312	Dec 16, 2023	Purchased a hand rivet puller	Tools	.8	1
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.

 

311	Dec 16, 2023	R/H Wing Bottom Skins	Wings	2.8	8
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.

 

310	Dec 12, 2023	R/H Wing Trailing Edge Skin	Wings	2.6	2
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.

 

309	Dec 10, 2023	R/H Wing Trailing Edge Pieces	Wings	.9	2
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.

 

308	Dec 10, 2023	R/H Wing	Wings	2.6	6
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.

 

307	Dec 09, 2023	R/H Wing Panel	Wings	1.7	5
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.

 

306	Dec 09, 2023	R/H Wing Flaperon Brackets	Wings	1.1	4
Cleco and riveted the 5 R/H wing flaperon brackets to the ribs with A5 rivets.

 

305	Dec 08, 2023	Purchased Nutplates for R/H Wing access covers	Wings		0
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.

 

304	Dec 07, 2023	R/H Wing	Wings	1.6	3
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.

 

303	Dec 05, 2023	R/H Wing	Wings	.6	4
Drilled the R/H wing tiedown ring, deburred and installed the 6 A5 rivets.

 

302	Dec 04, 2023	Purchased Screws for R/H Wing Fuel Access Cover	Wings		0
Purchased 14 each AN525-8R6 screws from Wicks Aircraft for the R/H wing fuel access cover.

 

301	Dec 04, 2023	Purchased 6061-T6 .040 Aluminum	Wings		0
Purchased a 2'x2' 6061-T6 .040 aluminum from Wicks Aircraft to make the R/H and L/H fuel sender access panels.

 

300	Dec 04, 2023	R/H Wing	Wings	1.9	7
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.

 

299	Dec 02, 2023	R/H Wing	Wings	2.0	0
Used red scotchbrite to scuff the bottom skins, jury strut angles and L stiffeners to prime,

 

298	Dec 01, 2023	R/H Wing	Wings	.5	3
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.

 

297	Nov 29, 2023	R/H Wing	Wings	2.9	7
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.

 

296	Nov 20, 2023	Purchased Epoxy Primer	Supplies		1
Purchased a quart each of gray epoxy primer (6610-4) and epoxy activator (6700-4) from Southern Polyurethane.

 

295	Nov 15, 2023	R/H Wing	Wings	2.2	3
Started to debur the holes and sand the edges of the R/H wing bottom skins.

 

294	Nov 11, 2023	R/H Wing	Wings	8.5	19
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.

 

293	Nov 10, 2023	Purchased Locktite 567 Thread Sealant	Fuel System		1
Purchased Loctite 567 Thread Sealant from Zoro. It's a 1.69 fl oz tube,

 

292	Nov 09, 2023	R/H Wing	Wings	.7	4
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.

 

291	Nov 08, 2023	Purchased Fuel Supply Lines	Fuel System		1
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.

 

290	Nov 08, 2023	R/H Wing	Wings	2.8	2
Continued to drill up the R/H wing bottom skins and leading edge skins.

 

289	Nov 04, 2023	R/H Wing bottom skin	Wings	4.1	6
Started to drill up the R/H wing bottom skin and leading edge skins.

 

288	Oct 23, 2023	R/H Wing	Wings	1.0	4
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.

 

287	Oct 10, 2023	R/H Wing skins	Wings	3.6	2
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.

 

286	Oct 09, 2023	Purchased #30 tapered reamer	Tools		0
Purchased a #30 tapered reamer from Yardstore.

 

285	Oct 09, 2023	Purchased 3/32 clecos	Tools		0
Purchased 50 each K series spring cleco 3/32 from Yardstore.

 

284	Oct 09, 2023	R/H Wing	Wings	4.5	9
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.

 

283	Oct 06, 2023	R/H Wing	Wings	1.6	9
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.

 

282	Sep 30, 2023	Priming Wing Pieces	Wings	5.0	1
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.

 

281	Sep 29, 2023	Wing Pieces	Wings	2.0	3
Finished scuffing the wing pieces that I wanted to prime for now.

 

280	Sep 28, 2023	Wing Pieces	Wings	1.3	2
Started to scuff the wing pieces that I will be priming with red scotchbrite.

 

279	Sep 25, 2023	R/H and L/H Wings	Wings	2.3	3
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.

 

278	Sep 24, 2023	R/H and L/H Wings	Wings	2.0	8
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.

 

277	Sep 19, 2023	R/H and L/H wing rear channel strut bracket	Wings	.5	1
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.

 

276	Sep 15, 2023	Purchased SD75W4-4 Rear Channel Strut Bracket	Wings		0
Purchased one SD75W4-4 Rear Channel Strut Bracket.

 

275	Sep 13, 2023	R/H wing rear channel strut bracket	Wings	.5	1
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.

 

274	Sep 11, 2023	R/H Wing Rear Spar	Wings	2.1	4
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.

 

273	Sep 06, 2023	R/H Wing Rear Spar	Wings	1.2	3
Started to install #5 solid AD rivets in the R/H wing rear spar.

 

272	Sep 05, 2023	R/H Wing Rear Spar	Wings	.7	4
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.

 

271	Sep 03, 2023	R/H Wing	Wings	3.8	18
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.

 

270	Aug 28, 2023	R/H Wing	Wings	1.0	8
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.

 

269	Aug 27, 2023	R/H Wing	Wings	2.2	4
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.

 

268	Aug 23, 2023	R/H Wing spar extension and rear ribs	Wings	1.0	3
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.

 

267	Aug 22, 2023	R/H Wing	Wings	2.5	7
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.

 

266	Aug 20, 2023	R/H Wing spar extension	Wings	1.6	3
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.

 

265	Jul 09, 2023	R/H Wing	Wings	6.7	3
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.

 

264	Jul 08, 2023	R/H Wing	Wings	1.0	1
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.

 

263	Jul 05, 2023	R/H Wing Trailing Edge Ribs	Wings	2.7	1
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.

 

262	Jul 04, 2023	R/H Wing	Wings	4.9	2
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.

 

261	Jul 03, 2023	R/H Wing	Wings	6.3	11
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.

 

260	Jul 02, 2023	R/H Wing	Wings	2.0	5
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.

 

259	Jun 27, 2023	R/H wing spar	Wings	1.6	5
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.

 

258	Jun 25, 2023	R/H Wing Spar	Wings	3.5	3
De-burred the holes, sanded the edges, and scuffed up the R/H wing spar for priming.

 

257	Jun 23, 2023	Purchased Epoxy Primer	Supplies		0
Purchased a quart of gray epoxy primer (6610-4) and epoxy activator (6700-4) from Southern Polyurethanes (SPI)

 

256	Jun 19, 2023	Decals	Paint / Decals		3
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.

 

255	Jun 11, 2023	Wing Parts	Wings	2.0	2
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).

 

254	May 21, 2023	Unboxing Wing Parts	Wings	2.5	1
Removed and unwrapped the wing parts from the crate and organized them in the shop.

 

253	May 19, 2023	Picked up Wing kit	Wings		9
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.

 

252	May 15, 2023	Flag and Eagle Decal	Paint / Decals		4
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.

 

251	May 15, 2023	Wing crating	Wings		0
Zenith called and said the wing kit was crated and ready to be shipped or picked up. I decided to pick it up.

 

250	Apr 24, 2023	Rudder leading edge cut	Rudder	1.0	1
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.

 

249	Apr 16, 2023	Rudder R/H Rear Lower Skin	Rudder	1.0	4
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,

 

248	Apr 06, 2023	Primed access panel	Rudder	1.6	2
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,

 

247	Mar 25, 2023	Working on paint design	Paint / Decals	2	6
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.

 

246	Mar 05, 2023	Rudder Access Panel	Rudder	2.3	4
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.

 

245	Feb 27, 2023	Rudder Access Panel	Rudder	1.2	2
Drilled mounting holes and sanded the edges for the rudder access panel. I'll be using dimpled nut plates (K1100-06) for #6 screws.

 

244	Feb 26, 2023	Rudder Access Panel	Rudder	2.6	3
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.

 

243	Feb 13, 2023	R/H Taxi/Recognition Light	Lighting	1.1	8
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.

 

242	Feb 11, 2023	R/H Taxi/ Recognition Light	Lighting	1.5	3
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.

 

241	Feb 01, 2023	R/H Taxi/Recognition Light	Lighting	1.0	4
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.

 

240	Jan 29, 2023	R/H Taxi/Recognition Light	Lighting	.8	3
Layed out where the R/H outboard slat taxi/recognition light cutout and fasteners will be on the slat skin.

 

239	Jan 21, 2023	Purchased #8 dimpled nut plates	Lighting		1
Purchased MS21049L08 (SGP13449-x50) nut plates from SkyGeek. Came in a package of 50. I needed 2 more for the taxi/recognition lights.

 

238	Jan 20, 2023	L/H Taxi/Recognition Light	Lighting	1.5	9
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.

 

237	Jan 15, 2023	L/H Taxi/Recognition Light	Lighting	5.4	9
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.

 

236	Dec 26, 2022	Taxi/ Recognition Lights	Lighting	2.4	7
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.

 

235	Dec 19, 2022	Purchased Plexiglass Drill Bits	Tools		1
Purchased 3/32" plexiglass drill bit (AC55-3/32) and 1/8" plexiglass drill bit (AC55-1/8) from Aircraft-Tool Supply.

 

234	Dec 17, 2022	Purchased Screws P/N AN509C8R7	Lighting		1
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.

 

233	Dec 17, 2022	L/H Taxi/ Recognition Light	Lighting	3.4	8
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.

 

232	Dec 17, 2022	Slat Tips	Slats/Flaps	1.5	4
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.

 

231	Dec 11, 2022	Taxi/Recognition Lights	Lighting	1.5	2
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.

 

230	Dec 11, 2022	L/H Outboard Slat	Slats/Flaps	1.4	7
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.

 

229	Dec 03, 2022	R/H Outboard Slat	Slats/Flaps	1.4	2
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.

 

228	Dec 03, 2022	L/H Inboard Slat Tip	Slats/Flaps	1.1	5
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.

 

227	Dec 01, 2022	L/H Inboard Slat	Slats/Flaps	1.5	5
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.

 

226	Nov 30, 2022	Instrument Panel layout	Instrument Panel	.5	1
Played around with the instrument panel layouts. Trying to decide between Garmin and Dynon. Also which panel size, the STOL or the Cruzer.

 

225	Nov 30, 2022	L/H Inboard Slat	Slats/Flaps	.8	2
Installed A4 rivets on the bottom side of the L/H inboard slat.

 

224	Nov 27, 2022	R/H Inboard Slat	Slats/Flaps	3.7	11
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.

 

223	Nov 26, 2022	Slats	Slats/Flaps	.5	4
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.

 

222	Nov 06, 2022	Instrument Panel Layouts	Instrument Panel	2.2	5
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.

 

221	Nov 05, 2022	Outboard Slats	Slats/Flaps	2.0	6
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.

 

220	Nov 05, 2022	Inboard Slats	Slats/Flaps	2.1	8
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.

 

219	Nov 04, 2022	L/H Inboard Slat	Slats/Flaps	1.8	4
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.

 

218	Oct 11, 2022	Primed Slat Skins	Slats/Flaps	1.6	6
Wiped areas to prime with the tack cloths. Primed with Rust Oleum Self Etching primer. Removed the paper and tape.

 

217	Oct 10, 2022	R/H Outboard Slat Skin	Slats/Flaps	1.7	2
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.

 

216	Oct 09, 2022	L/H Outboard Slat Skin	Slats/Flaps	1.5	1
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.

 

215	Oct 09, 2022	R/H Inboard Slat Skin	Slats/Flaps	2.0	1
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.

 

214	Oct 08, 2022	L/H Inboard Slat	Slats/Flaps	1.4	2
Sanded the edges of the L/H inboard slat skin and taped off the areas to prime. Scuffed with scotchbrite and cleaned surfaces.

 

213	Oct 05, 2022	L/H Inboard Slat Skin	Slats/Flaps	.7	1
De-burred the holes on the L/H inboard slat skin.

 

212	Oct 04, 2022	Primed slat pieces	Slats/Flaps	2.4	2
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.

 

211	Oct 02, 2022	Prepping Slat parts	Slats/Flaps	5.1	7
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.

 

210	Oct 01, 2022	Slats	Slats/Flaps	2.2	7
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.

 

209	Oct 01, 2022	Outboard Flaperons	Slats/Flaps	.3	2
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.

 

208	Sep 29, 2022	Outboard Flaperon Tips	Slats/Flaps	1.5	6
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.

 

207	Sep 28, 2022	L/H Outboard Flaperon Tip	Slats/Flaps	.8	2
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.

 

206	Sep 25, 2022	L/H Outboard Flaperon	Slats/Flaps	1.2	3
Installed A4 rivets to the L/H outboard flaperon bottom side skin. Cleco and installed A5 rivets on the splice plate.

 

205	Sep 22, 2022	R/H Outboard Flaperon	Slats/Flaps	1.3	3
Installed A4 rivets to the R/H outboard flaperon bottom side skin. Cleco and installed A5 rivets on the splice plate.

 

204	Sep 16, 2022	Picked up the Viking Fuel Senders	Fuel System		3
Picked up the Viking Fuel Senders from the Zenith open house.

 

203	Sep 16, 2022	Picked up the Zenith Fuel kit	Fuel System		6
Picked up the Zenith Fuel kit at the Zenith open house. Zenith welded in the Viking Fuel Sender mounts.

 

202	Sep 16, 2022	Picked up LED NAV/STROBE kit	Lighting		2
Picked up the AERO LED Pulsar NAV/STROBE kit (P/N 01-1100-12) at the Zenith open house.

 

201	Sep 11, 2022	L/H & R/H Flaperons	Slats/Flaps	3.8	9
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.

 

200	Sep 10, 2022	R/H Outboard Flaperon	Slats/Flaps	.9	3
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.

 

199	Aug 21, 2022	Flaperons Inboard	Slats/Flaps	3.8	10
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.

 

198	Aug 20, 2022	Flaperons	Slats/Flaps	3.6	7
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.

 

197	Aug 17, 2022	Purchased LED NAV/STROBE kit	Lighting		0
Purchased the LED NAV/STROBE kit from Zenith.

 

196	Aug 17, 2022	Purchased Zenith Fuel kit	Fuel System		0
Purchased the Zenith 750 Super Duty Fuel kit. Viking is shipping the fuel senders to Zenith to weld in.

 

195	Aug 09, 2022	Purchased Wing kit	Wings		0
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.

 

194	Aug 09, 2022	Purchased Fuel Senders	Fuel System		0
Purchased recessed fuel senders with weld in flanges from Viking Aircraft Engine. They come as a set of 2.

 

193	Aug 03, 2022	R/H Outboard Flaperon	Slats/Flaps	1.9	5
Installed the R/H outboard flaperon leading edge ribs, trailing edge ribs, and two hinge brackets to the spar with #5 solid AD rivets.

 

192	Jul 10, 2022	Primed Flaperon parts	Slats/Flaps	3	2
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.

 

191	Jul 02, 2022	Purchased Tack Cloth	Supplies		1
Purchased TCP Global Tack Cloth, TCP TC-12B, from Amazon.

 

190	Jun 27, 2022	R/H Outboard Flaperon	Slats/Flaps	1.0	2
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.

 

189	Jun 20, 2022	R/H Outboard Flaperon	Slats/Flaps	1.8	2
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.

 

188	Jun 19, 2022	Built paint rack	Workshop	1.0	1
Built a 10' x 6' x 3/4” PVC rack for hanging parts to paint.

 

187	Jun 04, 2022	Installed new air system	Workshop	8.0	5
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.

 

186	May 30, 2022	Purchased Canopy and Screen Kit	Workshop		1
Purchased a 10'x20' canopy and screen kit from Menards. Planning on making this into a paint booth.

 

185	May 12, 2022	Purchased S hooks	Workshop		1
Purchased Gray Bunny S hooks, 3.5” long, from Amazon for hanging parts to paint. Bought 2 packs of 20.

 

184	May 12, 2022	Purchased mixing cups	Supplies		1
Purchased TCP Global 10 oz graduated mixing cups, 50 each from Amazon.

 

183	May 07, 2022	Purchased PVC pipe and fittings	Workshop		0
Purchased 3/4” PVC pipe and fittings to make a paint rack from Menards.

 

182	May 01, 2022	L/H Outboard Flaperon	Slats/Flaps	2.5	1
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.

 

181	Apr 30, 2022	L/H outboard Flaperon	Slats/Flaps	1.1	1
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.

 

180	Apr 28, 2022	Outboard Flaperons	Slats/Flaps	.7	3
Layed out the parts for the L/H and R/H outboard flaperons.

 

179	Apr 18, 2022	Purchased Rapid Air Master Kit and associated parts	Workshop		0
Purchased a Rapid Air master kit, air fittings and hose holder from Northern Tool ($218.25), Home Depot ($32.81), and Menards ($9.99).

 

178	Apr 17, 2022	Purchased Air Filter	Workshop		0
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.

 

177	Apr 06, 2022	Purchased primer	Supplies		1
Purchased a quart each of Epoxy Gray Primer (6610-4) and Epoxy Activator (6700-4) from Southern Polyurethanes.

 

176	Apr 03, 2022	L/H Inboard Flaperon	Slats/Flaps	1.8	1
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.

 

175	Apr 02, 2022	L/H Inboard Flaperon	Slats/Flaps	3.3	3
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.

 

174	Mar 31, 2022	L/H Inboard Flaperon	Slats/Flaps	.7	1
Slid the L/H Inboard Flaperon skeleton into the skin. Cleco the top surface with the leading edge hanging over the table.

 

173	Mar 30, 2022	L/H Inboard Flaperon	Slats/Flaps	1.4	3
Sanded the edges of the L/H Inboard Flaperon skin. Taped off the mating surfaces, scuffed mating surfaces with red scotchbrite, and primed.

 

172	Mar 28, 2022	Purchased pancake adapter	Tools		1
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).

 

171	Mar 28, 2022	L/H Inboard Flaperon skin	Slats/Flaps	.7	0
Debured the holes on the L/H Inboard Flaperon skin.

 

170	Mar 27, 2022	Flaperons	Slats/Flaps	4.3	8
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.

 

169	Mar 26, 2022	R/H Inboard Flaperon	Slats/Flaps	3.1	9
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.

 

168	Mar 24, 2022	R/H Inboard Flaperon	Slats/Flaps	.6	2
Cleco the R/H inboard flaperon skin to the skeleton assembly (top side). Leading edge hung over the side of the table.

 

167	Mar 23, 2022	L/H Inboard Flaperon	Slats/Flaps	.5	4
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.

 

166	Mar 20, 2022	Flaperon parts priming	Slats/Flaps	1.5	3
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.

 

165	Mar 20, 2022	Purchased Primer	Supplies		0
Purchased a can of Rust-Oleum self etching primer from Meijer.

 

164	Mar 19, 2022	Flaperons	Slats/Flaps	2.2	1
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.

 

163	Mar 18, 2022	L/H Inboard Flaperon	Slats/Flaps	1.3	1
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.

 

162	Mar 14, 2022	Purchased Waterborne Wax and Grease Remover	Supplies		1
Purchased a gallon on SPI 700-1 Waterborne Wax and Grease Remover from Southern Polyurethane, Inc.

 

161	Mar 08, 2022	L/H Inboard Flaperon	Slats/Flaps	.8	2
Debured holes, rounded the corners, and sanded the edges on the L/H Inboard Flaperon 7 rear ribs.

 

160	Mar 07, 2022	R/H Inboard Flaperon	Slats/Flaps	1	4
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.

 

159	Feb 28, 2022	R/H Inboard Flaperon	Slats/Flaps	1	4
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.

 

158	Feb 16, 2022	R/H inboard flaperon	Slats/Flaps	1	4
Installed A5 rivets on the R/H inboard flaperon nose ribs and rear ribs where they attach to the spar.

 

157	Feb 13, 2022	Purchased Primer	Supplies		0
Purchased a can of Rust-Oleum self etching primer from Meijer.

 

156	Feb 13, 2022	R/H inboard flaperon	Slats/Flaps	1	1
Debured holes and scuffed the R/H inboard flaperon spar, then primed it.

 

155	Feb 07, 2022	R/H Inboard Flaperon	Slats/Flaps	1	1
Cleaned previous R/H inboard flaperon pieces with mineral spirits and primed with self etching primer.

 

154	Feb 06, 2022	R/H inboard flaperon	Slats/Flaps	2.7	3
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.

 

153	Jan 10, 2022	Purchased additional brackets	Workshop		1
Purchased some more brackets for the wall shelf to hold slats and flaperon parts.

 

152	Jan 09, 2022	R/H Inboard Flaperon	Slats/Flaps	1.0	2
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”.

 

151	Jan 09, 2022	Flaperons	Slats/Flaps	2.6	5
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.

 

150	Jan 08, 2022	Unwrapped slats and flaperons parts	Slats/Flaps	1.0	1
Unwrapped and got the slats and flaperons parts organized.

 

149	Jan 07, 2022	Elevator and Trim Tab	Tail	1.5	5
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.

 

148	Jan 05, 2022	Trim Tab Horn	Tail	3.3	7
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.

 

147	Jan 03, 2022	Wiring Trim Tab	Tail	1.8	5
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.

 

146	Dec 30, 2021	Purchased 3/32" Black heat shrink tubing	Tail		0
Purchased 4 feet of 3/32" Black heat shrink tubing (SA-701B) from Stein Air.

 

145	Dec 30, 2021	Trim Tab push rod paint	Tail	.2	1
Primed and painted the trim tab servo push rod with zinc phosphate primer and Rustoleum flat black.

 

144	Dec 30, 2021	Trim Tab	Tail	.8	1
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.

 

143	Dec 29, 2021	Trim Tab	Tail	3.4	5
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.

 

142	Dec 12, 2021	Purchased D-Sub contacts	Tail		0
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.

 

141	Dec 12, 2021	Purchased 1/4" Clear Heat shrink tubing	Tail		0
Purchased 1/4" clear heat shrink tubing (SA-704C) from Stein Air.

 

140	Dec 11, 2021	Purchased Storage Shelving	Workshop	1	2
Purchased some hanging shelving and pipe insulation to hold the horizontal stabilizer and elevator. Put together and hung on the wall.

 

139	Dec 05, 2021	Trim motor cover plate	Tail	1.4	2
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.

 

138	Dec 05, 2021	Elevator Horns	Tail	1.7	3
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.

 

137	Dec 05, 2021	Priming elevator horn mating surfaces	Tail	.7	2
Primed the mating surfaces that the elevator upper and lower horns attach to the elevator skin doubler.

 

136	Dec 04, 2021	Wood beam	Workshop	.8	1
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.

 

135	Dec 02, 2021	Vortex Generators	Tail	1.1	2
Rivet the vortex generators to the leading edge of the elevator with A3 rivets.

 

134	Nov 26, 2021	Elevator VG's	Tail	1.3	4
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.

 

133	Nov 24, 2021	Vortex Generators	Tail	.9	2
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.

 

132	Nov 22, 2021	Elevator	Tail	.8	3
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.

 

131	Nov 05, 2021	Picked up Slats and Flaps kit	Slats/Flaps		2
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.

 

130	Sep 09, 2021	Elevator	Tail	.8	1
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.

 

129	Sep 08, 2021	Elevator skin riveting	Tail	1.7	3
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.

 

128	Sep 07, 2021	Elevator	Tail	.9	1
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.

 

127	Sep 04, 2021	Elevator Trim Tab	Tail	2.1	5
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.

 

126	Aug 23, 2021	Purchased Primer	Supplies		0
Purchased Rust-oleum self etching primer from Home Depot.

 

125	Aug 23, 2021	Elevator trim tab	Tail	.1	1
Primed the other side of the trim tab pieces.

 

124	Aug 22, 2021	Elevator trim tab	Tail	1.8	3
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.

 

123	Aug 20, 2021	Elevator trim tab	Tail	1.1	3
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.

 

122	Jul 05, 2021	Vortex generators and elevator trim tab	Tail	1.4	4
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.

 

121	Jun 26, 2021	Vortex Generators	Tail	1.9	4
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.

 

120	Jun 20, 2021	Elevator	Tail	2.8	7
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.

 

119	Jun 06, 2021	Elevator nose skins	Tail	.7	2
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.

 

118	May 12, 2021	Purchased 2 each landing light kits	Lighting		0
Purchased 2 landing light kits at $425 each.

 

117	May 12, 2021	Purchased Slats and Flaps kit	Slats/Flaps		0
Purchased the 750 SD slats and flaps kit.

 

116	May 01, 2021	Elevator	Tail	1.1	5
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.

 

115	Apr 29, 2021	Purchased .025 aluminum sheet	Supplies		0
Purchased 6061 T6 Aluminum .025 1'x4' from Airparts Inc.

 

114	Apr 28, 2021	Elevator leading edge skins	Tail	1.0	1
Debured the holes and edges on the elevator leading edge skins. Taped the skins so I can just prime the mating surfaces.

 

113	Apr 27, 2021	Elevator trailing edge skins	Tail	1.3	5
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.

 

112	Apr 26, 2021	Priming elevator skins	Tail	1.0	2
Primed the mating surfaces on the elevator trailing edge skins with self etching primer.

 

111	Apr 25, 2021	Elevator	Tail	1.8	0
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.

 

110	Apr 14, 2021	Elevator skins	Tail	.8	2
Taped and masked the R/H elevator trailing edge skin so I can prime just the mating surfaces.

 

109	Apr 11, 2021	Elevator	Tail	3.0	6
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.

 

108	Apr 06, 2021	Elevator ribs	Tail	1.6	3
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.

 

107	Apr 05, 2021	Elevator	Tail	1.5	5
Rivet the ribs to the spar with # 5 AD solid rivets.

 

106	Apr 04, 2021	Elevator nose skin	Tail	1.3	1
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.

 

105	Apr 03, 2021	Purchased 5/32” reamers	Tools		0
Purchased two different 5/32” reamers from the Yardstore. Chucking reamer- $11.00, threaded reamer- $5.

 

104	Apr 03, 2021	Purchased 5/32” clecos	Tools		0
Purchased 50 each 5/32” clecos from the Yardstore. Needed some additional clecos of this size. .50 each

 

103	Apr 02, 2021	Elevator	Tail	.6	3
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.

 

102	Apr 01, 2021	Elevator	Tail	2.6	6
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.

 

101	Mar 18, 2021	Purchased Anchor Nuts and Stainless Screws	Rudder		0
Purchased pack of 5 K1100-06 Anchor Nuts and 10 each MS24693C26 (AN507C632R6) Flush Stainless Screws from Aircraft Spruce.

 

100	Mar 18, 2021	Elevator	Tail	1.0	3
Painted one side of the elevator tip pins with flat black paint. Dimple and installed rivets in the outboard elevator ribs tooling holes.

 

99	Mar 17, 2021	Purchased AN526C-632R6 screws	Tail		0
Purchased 6 AN526C-632R6 SS screws for the trim tab cover plate from Aircraft Spruce.

 

98	Mar 17, 2021	Purchased MS21047-L06K nut plates	Tail		1
Purchased 6 each MS21047-L06K nut plates for the trim motor cover plate from Wicks Aircraft,

 

97	Mar 17, 2021	Purchased rivets	Supplies		1
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.

 

96	Feb 28, 2021	Elevator	Tail	1.2	5
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.

 

95	Feb 27, 2021	Stabilizer skin	Tail	3.8	5
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.

 

94	Feb 22, 2021	Stabilizer	Tail	.9	1
Reamed the open holes that are between the clecos on the bottom surface of the stabilizer to a #21, .1590.

 

93	Feb 08, 2021	Stabilizer skin doubler	Tail	.4	2
Primed the stabilizer skin area where the skin doubler attaches with zinc phosphate primer.

 

92	Feb 01, 2021	Stabilizer skin	Tail	2.5	7
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.

 

91	Dec 28, 2020	Purchased squeeze sets	Tools		1
Purchased squeeze sets from the Yardstore. 11 piece set- $25 #8 set- $14.95 3/32” set- $14.95

 

90	Dec 28, 2020	Purchased Torque Wrench	Tools		1
Purchased a 1/4” drive 20-150 in lbs from Yardstore.

 

89	Dec 24, 2020	Horizontal skin	Tail	.3	2
Removed the tape and paper from after painting the horizontal skin. Turned out great.

 

88	Dec 23, 2020	Painting Horizontal Skin	Tail	1.3	1
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.

 

87	Dec 21, 2020	Purchased flat black spray paint	Supplies		0
Purchased a can of Rust-Oleum flat black paint from Home Depot.

 

86	Dec 21, 2020	Purchased Mineral Spirits	Supplies		0
Purchased a quart can of Mineral Spirits from Home Depot.

 

85	Dec 21, 2020	Purchased Primer	Supplies		0
Purchased 2 cans of Rust-Oleum Self Etching primer from Home Depot for $5.28 per can.

 

84	Dec 19, 2020	Horizontal tip ribs	Tail	.2	1
Dimpled and riveted the tooling holes in the horizontal tip ribs (SD75H1-1) with AN426 3-3 solid rivets.

 

83	Dec 19, 2020	Dimpling jig	Tools	.7	1
Built a dimple jig to dimple the tooling holes on the two horizontal end ribs. SD75H1-1

 

82	Dec 19, 2020	Horizontal skin	Tail	.9	2
Finished taping off the mating surfaces on the horizontal stabilizer skin for paint.

 

81	Dec 14, 2020	Horizontal skin	Tail	1.1	1
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.

 

80	Dec 13, 2020	Stabilizer	Tail	3.0	2
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.

 

79	Nov 16, 2020	Stabilizer top side of skin	Tail	1.8	3
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.

 

78	Nov 15, 2020	Stabilizer skin	Tail	3.0	6
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.

 

77	Nov 14, 2020	Stabilizer rear bracket	Tail	1	2
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.

 

76	Nov 13, 2020	Stabilizer aft spar	Tail	2.1	4
Riveted the stabilizer aft spar angles and ribs to the spar with #5 solid (AD) rivets.

 

75	Nov 12, 2020	Purchased a palm hand file	Tools		1
Purchased a vixen palm hand file from Yardstore.

 

74	Nov 12, 2020	Purchased #21 tapered reamer	Tools		1
Purchased a #21 tapered reamer from Yardstore.

 

73	Nov 12, 2020	Purchased 8 inch rivet set extension	Tools		1
Purchased an 8” rivet set extension from Yardstore.

 

72	Nov 12, 2020	Riveting the stabilizer	Tail	3.4	9
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.

 

71	Nov 11, 2020	Stabilizer assembling	Tail	4.9	5
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.

 

70	Nov 10, 2020	Primed and drilled holes	Tail	6.5	7
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.

 

69	Nov 09, 2020	Elevator outboard hinge pin	Tail	2.3	3
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.

 

68	Nov 08, 2020	Elevator parts primed	Tail	4.3	4
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.

 

67	Nov 07, 2020	Elevator parts	Tail	1	1
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.

 

66	Nov 07, 2020	Primed stabilizer parts	Tail	2.5	3
Primed the mating surfaces on the stabilizer parts with zinc phosphate primer.

 

65	Nov 03, 2020	Stabilizer rear ribs cleaning	Tail	.7	1
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.

 

64	Nov 02, 2020	Stabilizer rib cleaning	Tail	.6	1
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.

 

63	Oct 31, 2020	Prepping Stabilizer Parts	Tail	1.1	1
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.

 

62	Oct 27, 2020	Prepped more stabilizer parts	Tail	1.1	0
Removed the part number stickers, debured holes, and cleaned up the edges on the H2-8 spar doubler and H2-11 stabilizer rear bracket.

 

61	Oct 26, 2020	Cleaned stabilizer doubler	Tail	.7	2
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.

 

60	Oct 22, 2020	Debured stabilizer doublers	Tail	.5	0
Debured the holes and sanded the edges on the stabilizer front spar upper and lower doublers.

 

59	Oct 14, 2020	Primed tail spar pieces	Tail	.7	1
Primed the other side of the elevator spar and stabilizer rear spar pieces.

 

58	Oct 12, 2020	Purchased MS21049L08 Anchor Nuts	Lighting		1
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.

 

57	Oct 12, 2020	Purchased zinc phosphate primer	Supplies		0
Purchased 4 cans of A-702 Valspar zinc phosphate primer from Aircraft Spruce.

 

56	Oct 10, 2020	Horizontal Stabilizer spar angles	Tail	1.0	0
Started cleaning up the holes and edges on the Horizontal Stabilizer angles.

 

55	Oct 10, 2020	Primed the spar pieces	Tail	2.0	3
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.

 

54	Oct 08, 2020	Purchased Acetone	Supplies		0
Purchased a quart of acetone from Menards.

 

53	Oct 08, 2020	Purchased cleaning rags	Supplies		0
Purchased painters choice 9”x13” cotton paint & cleaning rags from Menards.

 

52	Oct 07, 2020	Elevator Spar deburring	Tail	.9	1
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.

 

51	Oct 06, 2020	Horizontal Stabilizer spar deburring	Tail	1.0	0
Debured holes and sanded the edges with 320 sandpaper on the stabilizer rear spar (SD75H3-6) and stabilizer front spar (SD75H3-7).

 

50	Sep 21, 2020	Unwrapped tail kit parts	Tail	1.2	1
Unwrapped the parts and took inventory of them.

 

49	Sep 08, 2020	Purchased the STOL 750 Super Duty Vortex Generators Option Kit	Tail		0
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.

 

48	Sep 08, 2020	Purchased the Tail Kit	Tail		1
Purchased the STOL CH 750 Super Duty Tail Kit. I'll be picking it up on Friday, September 18 at the Zenith Homecoming.

 

47	Aug 10, 2020	Purchased 3.5" round access panel	Rudder		2
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.

 

46	Jul 20, 2020	Rudder Tail Light Install	Lighting	2.5	8
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.

 

45	Jul 09, 2020	Riveted the rudder horn and left rear lower skin	Rudder	2.2	3
Installed the rudder horn with #5 solid AD rivets. Installed the left rudder rear lower skin with A4 rivets.

 

44	Jun 21, 2020	Riveting	Rudder	1.2	1
Finished riveting the trailing edge skin and the leading edge skin with A4 rivets.

 

43	May 10, 2020	Riveted skins	Rudder	3.3	3
Started to rivet the trailing edge and leading edge skins with A4 rivets.

 

42	May 10, 2020	Installed riv-nuts to tail light bracket	Lighting	.3	3
Installed #6 riv-nuts to the tail light bracket.

 

41	Apr 30, 2020	Primed and cleco nose skin	Rudder	1	4
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.

 

40	Apr 28, 2020	Purchased Rivet Nut Tool	Tools		0
Purchased a rivet nut tool 12-00968 for 6/32, 8/32, and 10/32 from Aircraft Spruce.

 

39	Apr 27, 2020	Cleco trailing edge skin	Rudder	1	2
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.

 

38	Apr 15, 2020	Purchased Rivet Nuts	Lighting		0
Purchased a 10 package of 6-32 rivnuts from Aircraft Tool Supply Company.

 

37	Apr 14, 2020	Drilled tail light bracket	Lighting	.8	1
Drilled the tail light bracket to the trailing edge skin for the A4 rivets.

 

36	Apr 12, 2020	Installed ribs	Rudder	2.8	8
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.

 

35	Apr 11, 2020	Tail light wiring	Lighting	1.1	2
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.

 

34	Apr 06, 2020	Tail light cut out	Lighting	1.4	2
Cut out the rudder trailing edge skin for the tail light.

 

33	Apr 02, 2020	Purchased 4-way cable tie mount and cable ties	Lighting		0
Purchased 4-way cable tie mount (P/N ABM4) and 7" low profile cable ties (P/N C750LP9) from Wicks Aircraft.

 

32	Apr 01, 2020	Tail light bracket	Lighting	2	3
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.

 

31	Mar 29, 2020	Riveted the doublers to the spar	Rudder	3.2	5
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.

 

30	Mar 28, 2020	Primed rudder parts	Rudder	2.9	2
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.

 

29	Mar 26, 2020	Purchased Zinc phosphate primer	Supplies		0
Purchased 2 cans of zinc phosphate primer from Aircraft Spruce, $9.95 each.

 

28	Mar 26, 2020	Deburring and cleaning parts	Rudder	1.8	2
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.

 

27	Mar 25, 2020	Purchased butt splices	Lighting		0
Purchased 2 each 320559 window type butt splice red from Aircraft Spruce & Specialty Co.

 

26	Mar 25, 2020	Prepping rudder parts	Rudder	3	7
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.

 

25	Mar 09, 2020	Purchased 2"X2" Aluminum Tubing	Workshop		0
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.

 

24	Feb 24, 2020	Work bench total cost	Workshop		0
The total cost to build the 4' x 12' work bench was $256.32.

 

23	Feb 24, 2020	Work Bench	Workshop	1.1	1
Cut and screwed the 8' bottom shelf piece. Work Bench is done.

 

22	Feb 10, 2020	Purchased a wire crimp tool	Tools		0
Purchased an Ideal Crimpmaster ratcheting crimp tool with a 30-579 die set from Fotronic Corporation, Test Equipment Depot.

 

21	Feb 10, 2020	Purchased a wire stripper	Tools		0
Purchased an Ideal #16-26 AWG Stripmaster wire stripper from Fotronic corporation, Test Equipment Depot.

 

20	Feb 10, 2020	Work Bench	Workshop	1.7	2
Cut and installed the bottom shelf 2x4's. Cut the 4' bottom to fit around the legs.

 

19	Feb 08, 2020	Purchased 1/8" and 3/16" heat shrink tubing	Lighting		0
Purchased 2 feet each of HST-1/8 and HST-3/16 heat shrink tubing from Wicks Aircraft Supply.

 

18	Feb 08, 2020	Purchased Rubber grommet	Lighting		0
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.

 

17	Feb 08, 2020	Purchased 12V LED tail light	Lighting		0
Purchased a PSA Enterprises 12V LED tail light (TL918) from Wick's Aircraft Supply.

 

16	Feb 01, 2020	Work Bench	Workshop	1	1
Sanded and painted the top.

 

15	Jan 30, 2020	Work Bench	Workshop	1.2	1
Sanded and painted the top.

 

14	Jan 28, 2020	Work Bench	Workshop	1.0	3
Flipped the work bench over and primed the top. I'm having to prime and paint the top because I used OSB subfloor.

 

13	Jan 25, 2020	Work Bench	Workshop	5.0	1
Finished legs and finished screwing the top op. Installed the bottom supports.

 

12	Jan 24, 2020	Work Bench	Workshop	4.0	1
Nailed the legs together and installed them. Also assembled the bottom shelf.

 

11	Jan 23, 2020	Work Bench	Workshop	2.0	1
Screwed the top together.

 

10	Jan 20, 2020	Work Bench	Workshop	3.0	2
Cut the wood to size. Building a 4' x 12' work bench.

 

9	Dec 21, 2019	Purchased Acetone	Supplies		0
Purchased a quart of acetone from Menards.

 

8	Dec 21, 2019	Purchased tail light bracket	Lighting		0
Purchased a tail light bracket from Zenith.

 

7	Dec 21, 2019	Purchased Lacquer thinner	Supplies		0
Purchased a container of lacquer thinner from Menards for taking off the PN stickers from each individual part.

 

6	Dec 21, 2019	Purchased wire for the tail light	Lighting		0
Purchased 100 feet of 18 gauge wire from Zenith Aircraft for the tail light.

 

5	Dec 12, 2019	Purchased Cortec Primer	Supplies		0
Purchased a quart can of cortec primer from Zenith Aircraft.

 

4	Dec 12, 2019	Purchased a Pneumatic Riveter	Tools		0
Purchased a pneumatic riveter with the special head to pull the Zenith rivets from Zenith.

 

3	Dec 12, 2019	Purchased 750SD Rudder from Zenith	Rudder		1
Drove to the Zenith Aircraft factory and purchased the Zenith 750 Super Duty Rudder kit.

 

2	Dec 12, 2019	Purchased the Zenith 750 Super Duty Drawings	Drawings		0
Purchased the Zenith 750 Super Duty drawings and the upgrades drawings. 750SD Drawings- $575.00 750SD Upgrade Drawings- $125.00

 

1	Dec 12, 2019	Purchased Tape measure	Tools		0
Needed a metric tape measure because the plans are in metric and didn't have one.

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