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Project: ranss19 -
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Show All Entries - (460)
Ailerons - (14)
Autopilot - (1)
Brakes - (6)
Canopy - (7)
Cowling - (4)
ELT - (23)
Electrical - (5)
Empennage - (4)
Engine - (66)
FinalAssembly - (31)
Firewall - (3)
Flaps - (29)
Fuel - (2)
FuelTank - (8)
Fuselage - (17)
FuselageCenter - (31)
FuselageForward - (28)
Panel - (19)
Rudder - (10)
Seats - (6)
Spar - (15)
Stabilator - (20)
Tailcone - (38)
TrimTab - (12)
VStab - (13)
Windshield - (2)
WingSkin - (13)
Wings - (31)
Auto Entry - (1)


Builder Name:	Ken Jordan -

Project:	Rans - S-19 Venterra - VIEW REPORTS
Total Hours:	3
Total Flight Time:
Start/Last Date:	Jan 06, 2012 - Aug 02, 2015
Engine:	Lycoming IO233
Propeller:	Sensenich
Panel:	Dynon Skyview; Garmin 430

Friendly URL:	https://eaabuilderslog.org?s=ranss19

Home or Last Project Picture

May 15, 2020 Parking Brake

Category: Brakes

Removed the factory cable driven linkage to the parking brake. Installed rigid rod driven linkage.

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Mar 21, 2020 Moved Lights from Under the Wing to In the Wing

Category: Wings

Fabricated brackets and cut holes in the wing to accept the wig-wag / landing lights. Patched and painted the old holes.

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Aug 01, 2015 Installed a CO detector in the panel

Category: FinalAssembly

Installed a CO detector in the panel.
Installed extended pedals to replace the wooden blocks we had been using.

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Jul 08, 2015 Painting

Category: FinalAssembly

Got our 'new' plane back from Hawk Aviation Painting!

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Jul 08, 2015 Got our 'new' plane back from Hawk Aviation Painting!

Category: FinalAssembly

Got our 'new' plane back from Hawk Aviation Painting!

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May 23, 2015 40 hours have been flown on the plane

Category: FinalAssembly

40 hours have been flown on the plane. Flew the RANS to Tampa Executive to be painted!

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Apr 22, 2015 Canopy assembly

Category: Canopy

Clecoed canopy frame assembly together and fitted to airframe. Marked placement for angle brackets, removed and drilled through longeron. Bolted brackets to airframe. Drilled and attached canopy latches. Drilled spacer and capture strips, then drilled and clecoed to canopy frame.

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Apr 21, 2015 Seats assembly

Category: Seats

Drilled the seat bottoms, countersunk the glide plates, and installed the glide plates.

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Jan 01, 2015 Various activities

Category: FinalAssembly

Fixed the problem with the fuel gauges by running new wire from the gauge to the Dynon panel. Installed snap-on control lock, sun shades in the canopy, Rosen sun visors, and wheel pants. We ordered a new spinner (12") as the one we got from Sensenich was too small for our cowling. The spinner we got had a normal flange instead of the forward facing flange, so we've sent that back to the manufacturer to be re-worked.

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Jan 01, 2015 Fixed the problem with the fuel gauges by running new wire from the gauge to the Dyn ...

Category: FinalAssembly

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Dec 01, 2014 Dynon tachometer readings Category: Panel

Ran a new wire from the P-lead of the magneto to pin 33 of the Dynon D37 connector. Also set the adjustment for the tachometer in Skyview to 2. RPMs are reading correctly now for both the magneto (on pin 33) and the Electronic Ignition (on pin 34). Still have a problem with the fuel gauges.

Dec 01, 2014 Ran a new wire from the P-lead of the magneto to pin 33 of the Dynon D37 connector Category: FinalAssembly

Nov 29, 2014 Finished riveting the wing fairings

Category: FinalAssembly

Finished riveting the wing fairings. Tried moving the tach wires from 35/36 to 33/34 on the Dynon 37 pin EMS connector since the tach is reading double what it should. On the new pins we weren't getting any reading.

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Nov 28, 2014 Plugs and engine run Category: Engine

Tech Counselor stopped by with the cleaned plugs. Replaced all plugs. Tested the electronic ignition to identify correct HT wires for each plug. Tested engine which ran much more smoothly

Nov 28, 2014 Tech Counselor stopped by with the cleaned plugs Category: FinalAssembly

Tech Counselor stopped by with the cleaned plugs. Replaced all plugs. Tested the electronic ignition to identify correct HT wires for each plug. Tested engine which ran much more smoothly

Nov 27, 2014 Started working on the wing fairings Category: FinalAssembly

Started working on the wing fairings. Tried to calibrate the fuel tanks, but we're getting 0 voltage on the Dynon system.

Nov 26, 2014 Sensor and air induction Category: Fuel

Reconnected the fuel sensor in the correct place - that works now. Finished the connections for the air induction system and the cooling to the oil cooler. Weighed the plane.

Nov 26, 2014 Reconnected the fuel sensor in the correct place - that works now Category: FinalAssembly

Reconnected the fuel sensor in the correct place - that works now. Finished the connections for the air induction system and the cooling to the oil cooler. Weighed the plane.

Nov 21, 2014 Air filter install Category: Engine

Cut and drilled the lower cowling for the install of the air filter. Riveted a doubler on the front to support the filter frame.

Nov 21, 2014 Cut and drilled the lower cowling for the install of the air filter Category: FinalAssembly

Cut and drilled the lower cowling for the install of the air filter. Riveted a doubler on the front to support the filter frame.

Nov 20, 2014 Plugs & lubing Category: Engine

Our Tech Counselor stopped by to help with the engine. Several spark plugs were fouled. Our TC took the aviation plugs with him to clean them and we bought 4 new plugs for the electronic ignition. Discovered that the fuel pressure gauge was connected to the wrong place, so plugged the old place and order a T connector to connect it correctly. Lubed all the hinges.

Nov 20, 2014 Our Tech Counselor stopped by to help with the engine Category: FinalAssembly

Nov 14, 2014 Re-installed the air hose to the oil cooler

Category: FinalAssembly

Re-installed the air hose to the oil cooler. Attached decals. Disconnected gas line from engine and ran the booster pump to flush about half a gallon of gas from each tank. Re-attached the gas hose and fired up the engine. First time it was running too fast so we adjusted the throttle linkage. Didn't get a cylinder/exhaust gas temperature reading on cylinder #3. Will check that next time. Started working on the air induction system.

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Nov 07, 2014 Finished installing the servo push-pull rods

Category: FinalAssembly

Finished installing the servo push-pull rods. Added a jumper to bypass the built-in relay on the starter motor as we have a separate relay on the firewall. Added gas and tried to start the engine, but apparently the gas is not getting to the engine.

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Nov 04, 2014 Prop and oil

Category: Engine

Started cutting and attaching the servo push-pull rods, but realized one of the rod ends needed to be 1/4", so have ordered those from Spruce. Installed the prop. Filled the engine with oil and cranked to move the oil through the engine. We have oil pressure and temperature!

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Nov 04, 2014 Started cutting and attaching the servo push-pull rods, but realized one of the rod

Category: FinalAssembly

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Nov 03, 2014 Wiring and gas lines Category: Engine

Drilled separate holes in the side skin for the gas lines and clipped them away from the aileron control lines. Replaced the landing light switch with a dual landing/taxi light switch. Ran the wires out to the engine compartment.

Nov 03, 2014 Drilled separate holes in the side skin for the gas lines and clipped them away from ... Category: FinalAssembly

Nov 01, 2014 Finished the air lines

Category: FinalAssembly

Finished the air lines. Rigged the stabilator and trim tab.

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Oct 31, 2014 Rigging Category: Ailerons

Continued working on the air lines - waiting for another T compression fitting. Rigged the flaps and ailerons.

Oct 31, 2014 Continued working on the air lines - waiting for another T compression fitting Category: FinalAssembly

Continued working on the air lines - waiting for another T compression fitting. Rigged the flaps and ailerons.

Oct 27, 2014 Stabilator assembly and trim tab layout

Category: Stabilator

Finished installing stabilator and attached rod for the trim tab. Drilled a second hole in the side skin for pitot/AOA lines and wing wiring. Started running the pitot/AOA lines back to the ADHRS units.

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Oct 27, 2014 Finished installing stabilator and attached rod for the trim tab

Category: FinalAssembly

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Oct 25, 2014 Finished installing the new heated pitot tube

Category: FinalAssembly

Finished installing the new heated pitot tube. Installed in-cabin fuel lines. Finished installing the left flap. Hung the stabilator.

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Oct 24, 2014 Glareshield Category: Panel

Made a template to cover the underside of the glareshield with cloth. Removed the old pitot tube which has been recalled. Drilled and tapped the new tube and screwed into its frame. Did miscellaneous engine tweaks.

Oct 24, 2014 Made a template to cover the underside of the glareshield with cloth Category: FinalAssembly

Oct 21, 2014 Attach flaps & ailerons

Category: Ailerons

Attached the flaps and aileron on the right wing. Attached the aileron on the left wing but had trouble getting the hinge pin through for the left flap. Corrected the oil pressure/temperature issue on the Skyview - turned out to be a programming issue.

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Oct 21, 2014 Attached the flaps and aileron on the right wing

Category: FinalAssembly

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Oct 18, 2014 Put tow bar brackets on Category: FinalAssembly

Put tow bar brackets on. Measured for fuel lines. Hooked up wing wiring and tested strobe and nav lights. Tech counselor came to inspect. Moved Lance to new hanger at Shady International.

Oct 17, 2014 Installed and torqued the wing bolts. Category: FinalAssembly

Installed and torqued the wing bolts.

Oct 14, 2014 Installed and pinned the wings

Category: FinalAssembly

Installed and pinned the wings. Maneuvered the planes to get both to fit in the hanger - very tight!

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Oct 11, 2014 Worked on the throttle bracket

Category: FinalAssembly

Worked on the throttle bracket. Installed remaining receptacles on the cowling.

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Oct 09, 2014 Moving Day!

Category: FinalAssembly

Moving Day! Trailered the fuselage from our garage at home to Umatilla Airport.

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Oct 09, 2014 Moving Day! Trailered the fuselage from our garage at home to Umatilla Airport.

Category: FinalAssembly

Moving Day! Trailered the fuselage from our garage at home to Umatilla Airport.

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Oct 07, 2014 Got the rivets and trim strip from RANS

Category: Canopy

Got the rivets and trim strip from RANS. Installed the right canopy and trim strip. Installed the canopy latch and D cell foam.

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Oct 06, 2014 Wiring and exhaust

Category: Engine

In checking some of the wiring, we found that the MAP sensor wires were loose. Got new pins and soldered them in addition to crimping and re-installed. Installed the exhaust hangers and completed work on the exhaust system.

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Oct 06, 2014 Cowling assembly

Category: Cowling

Drilled #40 holes for the rivets for the receptacles and nut plates. Cleaned all the holes. Installed the receptacles and nut plates. Installed the studs. We ended up with 4 extra holes, so ordered 4 more sets of studs from RANS!

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Oct 06, 2014 In checking some of the wiring, we found that the MAP sensor wires were loose

Category: Engine

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Oct 04, 2014 Cut the hole for the oil check door Category: Cowling

Cut the hole for the oil check door. Drilled #30 for the rivets. Cleaned and primed and riveted. Formed the flexible baffling strips around the top on the baffle and riveted. Continued work on the exhaust system.

Oct 03, 2014 Drilled #40 holes for the rivets for the receptacles and nut plates

Category: Engine

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Oct 02, 2014 Finished fitting the top cowling Category: Cowling

Finished fitting the top cowling. Drilled all holes to #11. Took the cowling off and drilled the receptacle holes to 5/16" and stud holes to 1/4"

Sep 29, 2014 Finished fitting the lower cowling

Category: Cowling

Finished fitting the lower cowling. Reconfigured some parameters in the Dynon system (with Aerotronic's help!). Started fitting the upper cowling. We had to remove the engine hoist points to get the upper cowling to lie flat.

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Sep 27, 2014 Canopy assembly

Category: Canopy

Drilled, cut, primed and installed the trim strip for the left side of the canopy. Cloecoed the right canopy to the frame and started cutting and drilling it. Mis-aligned one of the holes on the trim strip. Ordered replacement! Started fitting the lower cowling.

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Sep 27, 2014 Drilled, cut, primed and installed the trim strip for the left side of the canopy

Category: Engine

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Sep 26, 2014 Drilled out the canopy skirt

Category: Canopy

Drilled out the canopy skirt. Riveted the slides to the angle bars. Clecoed the skirt to the frame and clecoed the frame to the slides. Started riveting the slides and found that the rivets (AAPQ-62) were too long to allow the slide to move. Called RANS and were advised to shave a bit off the rivets to clear the slide. Put foam tape on the frame and attached the left canopy.

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Sep 23, 2014 Canopy assembly Category: Canopy

Installed the rivet nuts on the canopy frame through the lower capture strip and the side rivet nuts captured the trim strips. Trimmed and drilled out the canopy sides.

Sep 23, 2014 Installed the rivet nuts on the canopy frame through the lower capture strip and the ... Category: Engine

Installed the rivet nuts on the canopy frame through the lower capture strip and the side rivet nuts captured the trim strips. Trimmed and drilled out the canopy sides.

Sep 22, 2014 Fitted and drilled #30 the canopy skirt Category: Canopy

Fitted and drilled #30 the canopy skirt. Drilled side holes on canopy sides. Marked canopy side back edge so we have an even line on the back. Drilled frame holes to 1/4" for riv-nuts. Also drilled out upper and lower canopy strips and spacer. Clecoed and primed/painted frame, capture and trim strips.

Sep 16, 2014 Canopy assembly

Category: Canopy

Fitted, drilled and clecoed canopy sides to frame. Cut sides off level with the capture strip on the aft side.

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Sep 16, 2014 Fitted, drilled and clecoed canopy sides to frame

Category: Engine

Fitted, drilled and clecoed canopy sides to frame. Cut sides off level with the capture strip on the aft side.

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Sep 15, 2014 Clecoed canopy frame assembly together and fitted to airframe

Category: Engine

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Sep 13, 2014 Installed windshield and hold-down strip

Category: Windshield

Installed windshield and hold-down strip. Drilled canopy attach angles, slides, lower canopy trip strip and frame.

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Sep 12, 2014 Windshield assembly

Category: Windshield

Trimmed windshield to lay flat against front skin. Marked locations for riv-nuts on windshield and roll bar. Drilled windshield out to 3/8 " and roll bar to 1/4 ". Installed riv-nuts. Installed 1/2 " foam tape to roll bar.

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Sep 12, 2014 Trimmed windshield to lay flat against front skin

Category: Engine

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Sep 09, 2014 Riveted channels and roll bar

Category: FuselageCenter

Riveted channels and roll bar. Riveted top skin to airframe. Fabricated access covers for front interior panel so we can get to side panel wiring.

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Sep 08, 2014 Roll bar

Category: FuselageCenter

Bolted and riveted brace to aircraft and roll bar. Clecoed top skin and roll bar assembly to frame

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Sep 08, 2014 Bolted and riveted brace to aircraft and roll bar

Category: Engine

Bolted and riveted brace to aircraft and roll bar. Clecoed top skin and roll bar assembly to frame

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Sep 06, 2014 Wing Assembly

Category: Panel

Finished moving and cleaning up the wiring on the right side. Moved and cleaned up wiring on the left side. Modified the channels so that we can get to the Bose headset jacks. Drilled the side channels for the other headset jacks and cigar lighter. Installed the KX-99A in the panel and wired. Clecoed and drilled the roll bar parts. Dis-assembled, cleaned and primed/painted all parts.

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Sep 06, 2014 Knob panel

Category: Panel

Installed nut plates for the knob panel and re-installed in main panel. Riveted metal cover onto center interior panel and mounted the fire extinguisher. Started moving wiring on the right side so it will fit in the channel provided in the interior forward panel

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Sep 06, 2014 Finished moving and cleaning up the wiring on the right side

Category: Engine

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Sep 05, 2014 Installed nut plates for the knob panel and re-installed in main panel

Category: Engine

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Sep 02, 2014 Wiring Category: Wings

Started the wiring harnesses for the systems in the wings

Sep 02, 2014 Started the wiring harnesses for the systems in the wings Category: Engine

Started the wiring harnesses for the systems in the wings

Sep 01, 2014 Interior

Category: FinalAssembly

Installed and riveted map pockets to side panels. Installed avionics fan

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Sep 01, 2014 Installed and riveted map pockets to side panels

Category: Engine

Installed and riveted map pockets to side panels. Installed avionics fan

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Aug 30, 2014 Interior

Category: FinalAssembly

Fitted the front interior panels and the control stick covers. Riveted the boots to the control stick covers. Painted the map holder frame and glued the map pocket fabric to them.

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Aug 30, 2014 Fitted the front interior panels and the control stick covers

Category: Engine

Fitted the front interior panels and the control stick covers. Riveted the boots to the control stick covers. Painted the map holder frame and glued the map pocket fabric to them.

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Aug 29, 2014 Pulled the AP panel to look at the wiring Category: Panel

Pulled the AP panel to look at the wiring. Discovered a problem in the P5 plug and corrected. Discovered a loose connection in the pitch servo harness and replaced a pin. No warnings in the Dynon system now. Pulled the knob panel to install rivnuts, but decided they were too big for the panel so ordered mini nutplates and flush rivets.

Aug 28, 2014 Built the two servo plugs

Category: Autopilot

Built the two servo plugs. Installed the servo motors. Updated the Dynon software to version 11 and started testing the system.

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Aug 26, 2014 Attached and riveted the right front skin Category: Brakes

Attached and riveted the right front skin. Finished running the brake lines and filled the system with hydraulic fluid and bled the system.

Aug 25, 2014 Lines

Category: Brakes

Tried to update the Dynon software to version 11, but it wouldn't let us do that without having the servos attached to the network and we're still waiting for the correct caps for the plugs. We did update maps and terrain. Attached the left front skin and riveted. Started running the brake lines.

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Aug 25, 2014 Tried to update the Dynon software to version 11, but it wouldn't let us do that wit ...

Category: Engine

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Aug 23, 2014 Finished running the main power cables

Category: Panel

Finished running the main power cables. Turned on the master switch, then the avionics master .... and nothing! In checking, discovered that the master solenoid was wired backwards. We corrected that and were able to power on the panel. Yeah! Clecoed the forward fuselage side bars and gussets on along with the cowling flanges. Also bolted on the prop spacer, spinner baseplate, and rear mounting bracket for the spinner.

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Aug 22, 2014 Finished wiring the AP panel

Category: Panel

Finished wiring the AP panel. Installed female pins on the servo ends of the wiring harness, but are waiting on the correct caps for the plugs. Ran power to the starter solenoid and onto the starter motor. Installed a diode on the starter solenoid. Ran power cables from the shunt to the alternator breaker and back.

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Aug 19, 2014 Dynon SV-AP-Panel Category: Panel

Installed the Dynon SV-AP-Panel. Fit and drilled out, cleaned and primed the roll and pitch servo mounts. Partially made the plugs/wires for the servo motors.

Aug 18, 2014 Wiring and Dynon Knob Panel

Category: Panel

Connected some of the wires using OLC1 overlap connectors from Electronic International. Installed and wired the Dynon SV-Knob-Panel.

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Aug 18, 2014 Connected some of the wires using OLC1 overlap connectors from Electronic Internatio ...

Category: Engine

Connected some of the wires using OLC1 overlap connectors from Electronic International. Installed and wired the Dynon SV-Knob-Panel.

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Aug 17, 2014 Wiring Category: Panel

Installed 1 amp inline fuses on the two amp meter wires

Aug 17, 2014 Installed 1 amp inline fuses on the two amp meter wires Category: Engine

Installed 1 amp inline fuses on the two amp meter wires

Aug 16, 2014 Battery

Category: Electrical

Fabricated and installed power cables from battery to ground, battery to master relay, master relay to shunt. Also wired the alternator to shunt. Added mag wiring to P1 plug.

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Aug 16, 2014 Fabricated and installed power cables from battery to ground, battery to master rela ...

Category: Engine

Fabricated and installed power cables from battery to ground, battery to master relay, master relay to shunt. Also wired the alternator to shunt. Added mag wiring to P1 plug.

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Aug 12, 2014 Battery

Category: Electrical

Installed the remote charging post near the battery behind the baggage side compartment. Fabricated and installed a grounding plate for the battery.

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Aug 12, 2014 Installed the remote charging post near the battery behind the baggage side compartm ... Category: Engine

Installed the remote charging post near the battery behind the baggage side compartment. Fabricated and installed a grounding plate for the battery.

Aug 11, 2014 Mounted and wired the oil pressure sensor

Category: Engine

Mounted and wired the oil pressure sensor. Finalized the pilot and co-pilot control stick and re-installed. Did some miscellaneous wiring.

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Aug 09, 2014 Wired amp meter leads to shunt Category: Electrical

Wired amp meter leads to shunt. Re-wired pilot's control stick to correct orientation of grip. Installed and timed mags to lower spark plugs with the help of our tech counselor.

Aug 08, 2014 Installed fuel pressure sensor

Category: Engine

Installed fuel pressure sensor. Installed the aux fuel pump. Plumbed and wired the manifold pressure sensor. Plumbed the manifold pressure sensor for the electronic ignition. Installed the fuel line from the gascolator to the mechanical fuel pump.

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Aug 06, 2014 Installed engine crank case oil breather.

Category: Engine

Installed engine crank case oil breather.

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Jul 25, 2014 Wiring Category: Electrical

Ran wires from the ELT and starter motor to the P1 plug and connected

Jul 25, 2014 Ran wires from the ELT, and starter motor, to the P1 plug and connected Category: Engine

Ran wires from the ELT, and starter motor, to the P1 plug and connected

Jul 14, 2014 Engine attachments

Category: Engine

Installed the correct oil temperature probe (UMA 1B9) for the Lycoming IO233 engine. Installed the cabin heater box and connected to the heat shroud on the muffler. Installed cabin heat cable.

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Jul 14, 2014 Installed the correct oil temperature probe (UMA 1B9)for the Lycoming IO233 engine Category: Engine

Installed the correct oil temperature probe (UMA 1B9)for the Lycoming IO233 engine. Installed the cabin heater box and connected to the heat shroud on the muffler. Installed cabin heat cable.

Jul 12, 2014 Control Sticks

Category: Panel

Installed the control sticks and cut/drilled holes in the glare shield for access panels to the back of the panel

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Jul 12, 2014 Installed the control sticks and cut/drilled holes in the glare shield for access pa ... Category: Engine

Installed the control sticks and cut/drilled holes in the glare shield for access panels to the back of the panel

Jul 10, 2014 Control Sticks Category: Panel

Started assembling the control sticks with grips and wiring.

Jul 10, 2014 Started assembling the control sticks with grips and wiring. Category: Engine

Started assembling the control sticks with grips and wiring.

Jul 09, 2014 Mixture Control and Throttle

Category: Engine

Installed mixture control cable and throttle cable

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Jul 09, 2014 Installed mixture control cable and throttle cable. Category: Engine

Installed mixture control cable and throttle cable.

Jul 07, 2014 Installed parking cable and secured

Category: Brakes

Installed parking cable and secured. Ran cabin heat knob through panel

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Jul 05, 2014 Engine attachments

Category: Engine

Installed the exhaust system and dry fit the mufflers. Drilled and installed the EGT probes. Installed the CHT/EGT harness, installed blade connectors and attached to the probes. Clamped and tied all the wires.

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Jul 05, 2014 Installed the exhaust system and dry fit the mufflers Category: Engine

Jul 04, 2014 Engine attachments

Category: Panel

Installed DB9 plugs on the ends of the Dynon network cables and plugged them in. Installed ADEL clamps to hold the electronic ignition sensing wires. Installed blade connectors in the ends of the electronic ignition wires and connected to the ignition coils

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Jul 04, 2014 Installed DB9 plugs on the ends of the Dynon network cables and plugged them in Category: Engine

Jul 03, 2014 Trim Tab and Electronic Ignition

Category: Engine

Installed Molex connector on the trim tab servo wires and tied to side of tailcone. Ran electronic ignition sensing wire over the engine and through the firewall to the electronic ignition control unit.

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Jul 03, 2014 Installed Molex connector on the trim tab servo wires and tied to side of tailcone Category: Engine

Jul 02, 2014 Installed bungs in the firewall and baffling Category: Engine

Installed bungs in the firewall and baffling

Jul 01, 2014 Engine attachments

Category: Engine

Mounted the oil cooler and ran scat tubing from the baffle to the cooler. Re-mounted the throttle assembly using sealant on the gasket. Installed the throttle, mixture and parking brake knobs

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Jul 01, 2014 Mounted the oil cooler and ran scat tubing from the baffle to the cooler Category: Engine

Mounted the oil cooler and ran scat tubing from the baffle to the cooler. Re-mounted the throttle assembly using sealant on the gasket. Installed the throttle, mixture and parking brake knobs

Jun 23, 2014 Tidied up the cables and lines in the tailcone

Category: Empennage

Tidied up the cables and lines in the tailcone

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Jun 20, 2014 Drilled the tube input for the oil cooler

Category: Engine

Drilled the tube input for the oil cooler. Drilled mounting holes in the firewall and fabricated bushings to give it air movement. Mounted the throttle body assemble to the engine. Installed the cylinder head temperature probes.

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Jun 19, 2014 Finished riveting the baffle

Category: Engine

Finished riveting the baffle. Attached to engine

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Jun 17, 2014 Baffles Category: Engine

Painted the baffle pieces with black engine enamel

Jun 17, 2014 Painted the baffle pieces with black engine enamel Category: Engine

Painted the baffle pieces with black engine enamel

Jun 16, 2014 Finished fitting the baffling Category: Engine

Finished fitting the baffling. Ran out of rivets so we're waiting on those. All pieces are cleaned and ready to be painted.

Jun 14, 2014 Baffles Category: Engine

Started fitting the baffling to the engine and riveting pieces together as needed

Jun 13, 2014 Started fitting the baffling to the engine and riveting pieces together as needed. Category: Engine

Started fitting the baffling to the engine and riveting pieces together as needed.

Jun 12, 2014 Ran coax from various antennas to the panel Category: Electrical

Ran coax from various antennas to the panel

Jun 11, 2014 Nav Antenna

Category: Panel

Fabricated a backing plate and attached the nav antenna to the aft-most bottom inspection plate.

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Jun 11, 2014 Fabricated a backing plate and attached the nav antenna to the aft-most bottom inspe ... Category: Engine

Fabricated a backing plate and attached the nav antenna to the aft-most bottom inspection plate.

Jun 10, 2014 Clamped the static port lines to the aircraft

Category: Engine

Clamped the static port lines to the aircraft. Installed the OAT probes and connected to the ADAHRS units

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Jun 09, 2014 ADAHRS Category: Panel

Ran tubing from the static ports to the ADAHRS units. Installed fittings on the ADAHRS units for AOA and Pitot input.

Jun 09, 2014 Ran tubing from the static ports to the ADAHRS units Category: Engine

Ran tubing from the static ports to the ADAHRS units. Installed fittings on the ADAHRS units for AOA and Pitot input.

Jun 03, 2014 Installed LightSpeed Ignition module

Category: Engine

Fabricated a mounting plate for the LightSpeed Plasma CD Ignition module. Mounted just aft of the firewall. Bolted the ignition coils to the top of the engine. Installed the spark plug adapters.

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Jun 03, 2014 Fabricated a mounting plate for the LightSpeed Plasma CD Ignition module Category: Engine

Fabricated a mounting plate for the LightSpeed Plasma CD Ignition module. Mounted just aft of the firewall. Bolted the ignition coils to the top of the engine. Installed the spark plug adapters.

May 30, 2014 Mounted the engine using Lord's isolators

Category: Engine

Mounted the engine using Lord's isolators. Fabricated a backing plate for the battery box and mounted it behind the luggage closeout. Fabricated a backing plate for the marker beacon antenna and riveted to tail skin. Fabricated a mounting plate for the ADAHRS units and mounted them.

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May 28, 2014 Oregon Aero

Category: Seats

Got the covered seats back from Oregon Aero - they look great!

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May 28, 2014 Got the covered seats back from Oregon Aero - they look great! Category: Engine

Got the covered seats back from Oregon Aero - they look great!

May 27, 2014 Antennas

Category: Fuselage

Installed the second GPS antenna aft of the first one. Also installed two comm antennas, transponder antenna, and ADS-B antenna and started on the marker beacon antenna

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May 27, 2014 Installed the second GPS antenna aft of the first one Category: Engine

Installed the second GPS antenna aft of the first one. Also installed two comm antennas, transponder antenna, and ADS-B antenna and started on the marker beacon antenna.

May 26, 2014 install Panel

Category: Panel

Installed the panel assembly and riveted to firewall & frame. Made a backing plate for GPS antenna #1 and installed in the tailcone just aft of bulkhead #2

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May 26, 2014 Installed the panel assembly and riveted to firewall & frame Category: Engine

Installed the panel assembly and riveted to firewall & frame. Made a backing plate for GPS antenna #1 and installed in the tailcone just aft of bulkhead #2

May 23, 2014 Finished installing the nose wheel

Category: FuselageForward

Finished installing the nose wheel. Clecoed the fwd skin to the panel mount and drilled (carefully!) to #30 and cleaned. Drilled the skin for the avionics fan. Our Lycoming IO-233 engine came - it looks even better in person!

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May 22, 2014 Our panel came from Aerotronics!

Category: Panel

Our panel came from Aerotronics!

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May 20, 2014 Got the AN5-21A bolt and installed it

Category: Firewall

Got the AN5-21A bolt and installed it. Drilled and bolted the nose wheel shaft to the mount.

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May 19, 2014 Engine mounts Category: Firewall

Finished drilling the engine/nose wheel mount holes in the firewall to 5/16" Mounted and bolted the mount to the firewall. Need to reorder one AN5-21A bolt as the threads got messed up

May 19, 2014 Finished drilling the engine/nose wheel mount holes in the firewall to 5/16" M ... Category: ELT

Finished drilling the engine/nose wheel mount holes in the firewall to 5/16" Mounted and bolted the mount to the firewall. Need to reorder one AN5-21A bolt as the threads got messed up.

May 10, 2014 Trim

Category: FuselageCenter

Cut out the center console trim and control stick trim covers. Sanded smooth and removed markings.

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May 10, 2014 Cut out the center console trim and control stick trim covers

Category: ELT

Cut out the center console trim and control stick trim covers. Sanded smooth and removed markings.

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May 07, 2014 Baffles Category: Engine

Cleaned up the pieces and made the compound bends by hand.

May 07, 2014 Cleaned up the pieces and made the compound bends by hand. Category: ELT

Cleaned up the pieces and made the compound bends by hand.

May 06, 2014 Used a break to put the bends in Category: Engine

Used a break to put the bends in. Couldn't do the compound bends with the break.

May 05, 2014 Baggage closeout

Category: FuselageCenter

Got the registration numbers for test flying and attached them to the tail. Drilled the baggage closeout and used #8 self tapping screws to hold to the #1 bulkhead. We used more screws than directed and put them closer to the outsides edge so we have a tighter fit.

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May 05, 2014 Got the registration numbers for test flying and attached them to the tail

Category: ELT

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May 03, 2014 Baffles Category: Engine

Drilled the holes in the baffling except for the #18 holes. We've ordered a #18 bit!

May 03, 2014 Drilled the holes in the baffling except for the #18 holes Category: ELT

Drilled the holes in the baffling except for the #18 holes. We've ordered a #18 bit!

May 01, 2014 Baffles Category: Engine

Punched the center of the holes that need to be drilled in the baffling

May 01, 2014 Punched the center of the holes that need to be drilled in the baffling Category: ELT

Punched the center of the holes that need to be drilled in the baffling

Apr 29, 2014 Baffles

Category: Engine

Used a belt sander to get the baffling pieces to their finished size. Sanded all the edges smooth.

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Apr 29, 2014 Used a belt sander to get the baffling pieces to their finished size

Category: ELT

Used a belt sander to get the baffling pieces to their finished size. Sanded all the edges smooth.

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Apr 28, 2014 Baffles

Category: Engine

Used a band saw to rough cut all the baffling pieces out.

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Apr 28, 2014 Used a friend's band saw to rough cut all the baffling pieces out. Category: ELT

Used a friend's band saw to rough cut all the baffling pieces out.

Apr 25, 2014 Baffles Category: Engine

Marked up the IO233 baffle blueprints so we could read them. Copied them onto letter paper and cut the pieces out. Traced the pieces onto aluminum/stainless steel sheets

Apr 25, 2014 Marked up the IO233 baffle blueprints so we could read them Category: ELT

Marked up the IO233 baffle blueprints so we could read them. Copied them onto letter paper and cut the pieces out. Traced the pieces onto aluminum/stainless steel sheets

Apr 21, 2014 Brakes assembly

Category: Brakes

Installed brake cylinders, reservoir, and parking brake valve and guide.

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Mar 07, 2014 Flaps assembly Category: Flaps

Drilled and installed the flap tube mechanism covers. Cut and fitted the baggage closeout cover

Mar 07, 2014 Drilled and installed the flap tube mechanism covers Category: ELT

Drilled and installed the flap tube mechanism covers. Cut and fitted the baggage closeout cover

Mar 03, 2014 Flaps assembly Category: Flaps

Cut out the flap covers

Mar 03, 2014 Watched the interior video and cut out the flap covers Category: ELT

Watched the interior video and cut out the flap covers

Mar 01, 2014 Seats assembly

Category: Seats

Bolted the seat frames together so they're ready to take with the leather to Oregon Aero at Sun 'n Fun to be finished.

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Mar 01, 2014 Bolted the seat frames together so they're ready to take with the leather to Oregon

Category: ELT

Bolted the seat frames together so they're ready to take with the leather to Oregon Aero at Sun 'n Fun to be finished.

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Feb 27, 2014 Painted the firewall with Dupont's Chromapremier

Category: Firewall

Painted the firewall with Dupont's Chromapremier. Primed and painted the seat frames.

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Feb 24, 2014 Drilled and attached the other headrest frame Category: Seats

Drilled and attached the other headrest frame. Unbolted both seat frames and cleaned so they're ready to be primed.

Feb 22, 2014 Continued working on the seats

Category: Seats

Continued working on the seats. Attached the seat back plates and bolted one seat together and installed . The short pilot gusset will work well for both of us. Attached the seat back stop to the third hole in from the back. Drilled out and attached one headrest frame.

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Feb 21, 2014 Installed all the seat sliders

Category: Seats

Installed all the seat sliders. We had to fabricate additional shims for the aft sliders from stock. Drilled and riveted the seat pans to the frame. Drilled the frame for the short pilot gusset.

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Feb 17, 2014 Drilled the seat bottoms, countersunk the glide plates, and installed the glide plat ...

Category: ELT

Drilled the seat bottoms, countersunk the glide plates, and installed the glide plates.

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Feb 16, 2014 Balance weights

Category: Stabilator

Drilled the stabilator counterbalance rod and shaved the counterweight so that the stabilator is balanced. We added a pound to the middle of the stabilator to compensate for the weight of the finished paint.

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Feb 16, 2014 Drilled the stabilator counterbalance rod and shaved the counterweight so that the s ...

Category: ELT

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Feb 15, 2014 Stinger assembly

Category: Tailcone

Rivet the bottom halves of the stinger together as well as rivet the stinger bulkhead in place. Finished fitting the stinger.

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Feb 15, 2014 Decided to rivet the bottom halves of the stinger together as well as rivet the stin ...

Category: ELT

Decided to rivet the bottom halves of the stinger together as well as rivet the stinger bulkhead in place. Finished fitting the stinger.

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Feb 14, 2014 Started working on the tailcone stinger

Category: Tailcone

Started working on the tailcone stinger. Got the pieces cut out and glued the bottom halves together.

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Feb 12, 2014 Parts inventory

Category: Fuselage

Received and inventoried seat kit, canopy kit, panel fan kit, key lock kit, grey interior kit, decals, firewall soundproof panels, windshield hold down strip, canopy side strips, remote charging post, seat headrest kit and shorter pilot kit. Missing one of the two shorter pilot kits. Called RANS and they are shipping another one.

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Feb 12, 2014 Received and inventoried seat kit, canopy kit, panel fan kit, key lock kit, grey int ...

Category: ELT

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Feb 11, 2014 Riveted ramp, seat, and baggage floor skins. Category: FuselageCenter

Riveted ramp, seat, and baggage floor skins.

Feb 10, 2014 Belly fairings

Category: Fuselage

Cut out belly fairings and located/drilled/attached the nut plates. Clecoed the baggage and seat/ramp skins

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Feb 10, 2014 Cut out belly fairings and located/drilled/attached the nut plates

Category: ELT

Cut out belly fairings and located/drilled/attached the nut plates. Clecoed the baggage and seat/ramp skins

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Feb 08, 2014 Attached rudder cables to rudder horn

Category: Rudder

Attached rudder cables to rudder horn. Fabricated backing plate for ELT antenna and installed forward of vertical stabilizer. Cleaned oil off wheel bearings and packed with grease. Installed wheels and brake calipers.

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Feb 07, 2014 Riveted tailcone top skin

Category: Tailcone

Riveted tailcone top skin. Installed vertical stabilizer and started installing the rudder.

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Feb 05, 2014 Installed and riveted the top of bulkhead #1

Category: Fuselage

Installed and riveted the top of bulkhead #1. The foam came in so finished putting foam on the skin surfaces between bulkheads 1 & 2 and 2 & 3. Clecoed tailcone top skin in place. Installed gascolater on forward side of firewall.

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Feb 04, 2014 Tech Counselor Category: Fuselage

Tech counselor fuselage inspection

Feb 04, 2014 Our Technical Advisor stopped by to inspect the fuselage. Category: ELT

Our Technical Advisor stopped by to inspect the fuselage.

Feb 03, 2014 Foam Category: Fuselage

Put foam insulation in the tail section until we ran out of foam. Ordered more from Aircraft Spruce.

Feb 03, 2014 Put foam insulation in the tail section until we ran out of foam Category: ELT

Put foam insulation in the tail section until we ran out of foam. Ordered more from Aircraft Spruce.

Feb 01, 2014 Installed main landing gear and wheels

Category: FuselageCenter

Installed main landing gear and wheels. Installed antenna plate

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Jan 31, 2014 Center ribs

Category: FuselageCenter

Finished riveting bellcrank and center ribs to #1 bulkhead and CCPQ-42 rivets in center to tail skin. Started static port lines. Installed foot steps.

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Jan 31, 2014 Finished riveting bellcrank and center ribs to #1 bulkhead and CCPQ-42 rivets in cen ...

Category: ELT

Finished riveting bellcrank and center ribs to #1 bulkhead and CCPQ-42 rivets in center to tail skin. Started static port lines. Installed foot steps.

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Jan 28, 2014 Moving day

Category: Wings

Moved wings and everything else in the hanger from Leesburg to a bulk hanger in Umatilla

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Jan 28, 2014 Moved wings and everything else in the hanger from Leesburg to a bulk hanger in Umat ... Category: ELT

Moved wings and everything else in the hanger from Leesburg to a bulk hanger in Umatilla

Jan 27, 2014 Tailcone assembly Category: Tailcone

Finished riveting the tailcone to the center fuselage except for some CCPQ-42 rivets which we've ordered.

Jan 27, 2014 Finished riveting the tailcone to the center fuselage except for some CCPQ-42 rivets ... Category: ELT

Finished riveting the tailcone to the center fuselage except for some CCPQ-42 rivets which we've ordered.

Jan 25, 2014 ELT Install

Category: Panel

Fabricated a mount for the ELT just forward of the third bulkhead in the tailcone. Drilled, cleaned, primed and riveted the mounting plate.

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Jan 25, 2014 Fabricated a mount for the ELT just forward of the third bulkhead in the tailcone

Category: ELT

Fabricated a mount for the ELT just forward of the third bulkhead in the tailcone. Drilled, cleaned, primed and riveted the mounting plate.

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Jan 24, 2014 Joined tail cone to center fuselage and clecoed

Category: FuselageForward

Joined tail cone to center fuselage and clecoed. Moved fuselage off the tables and onto sawhorses so we could get underneath. Drilled out all remaining holes. Pulled sections apart and cleaned/primed as needed. Clecoed together and started riveting. Installed bolts in the bellcrank and forward/aft push-pull rods.

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Jan 21, 2014 Mounted trim tab servo motor

Category: FuselageForward

Mounted trim tab servo motor. Hooked up to a 12V power source and moved full up and down. Left it centered.

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Jan 20, 2014 Vents & Static ports

Category: FuselageForward

Drilled, sealed and riveted the plastic vent scoops to the forward skins. Drilled and riveted the static ports to the tailcone skins.

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Jan 20, 2014 Drilled, sealed and riveted the plastic vent scoops to the forward skins

Category: FuselageForward

Drilled, sealed and riveted the plastic vent scoops to the forward skins. Drilled and riveted the static ports to the tailcone skins.

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Jan 19, 2014 Clecoed all pieces back on

Category: FuselageForward

Clecoed all pieces back on. Riveted longerons to center fuselage. Riveted upper weldment to firewall. Riveted forward gusset. Riveted inspection rings and nutplates to forward skins.

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Jan 15, 2014 Finished cleaning and primed all the pieces Category: FuselageForward

Finished cleaning and primed all the pieces

Jan 13, 2014 Fuselage assembly Category: FuselageForward

Clecoed the left forward skin on and drilled out to #30. Took apart and started cleaning

Jan 13, 2014 Clecoed the left forward skin on and drilled out to #30 Category: FuselageForward

Clecoed the left forward skin on and drilled out to #30. Took apart and started cleaning

Jan 11, 2014 Fuel lines

Category: Fuel

Assembled fuel shut-off valve and ran fuel line to bulkhead fitting. Pulled cowling attach straps and spacers. Cut/drilled hole in right forward skin for the optional inspection panel. Clecoed the right forward skin on and drilled out to #30.

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Jan 11, 2014 Assembled fuel shut-off valve and ran fuel line to bulkhead fitting

Category: FuselageForward

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Jan 09, 2014 Assembled and bolted the control sticks

Category: FuselageForward

Assembled and bolted the control sticks. We were missing one of the AN4-20 bolts. RANS to send a replacement.

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Jan 08, 2014 Aerotronics

Category: Panel

Packaged up the panel and supporting assemble to send off to Aerotronics Inc, Billings, MT to build our panel.

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Jan 08, 2014 Packaged up the panel and supporting assemble to send off to Aerotronics Inc, Billin ... Category: FuselageForward

Packaged up the panel and supporting assemble to send off to Aerotronics Inc, Billings, MT to build our panel.

Jan 04, 2014 Belly Skin

Category: FuselageForward

Riveted forward belly skin except for rivets that would catch the side or cowling straps. Installed the rudder cable pulleys and attached cables to rudder pedals

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Jan 04, 2014 Riveted forward belly skin except for rivets that would catch the side or cowling st ...

Category: FuselageForward

Riveted forward belly skin except for rivets that would catch the side or cowling straps. Installed the rudder cable pulleys and attached cables to rudder pedals

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Jan 03, 2014 Cut out side skins for the air vents

Category: FuselageForward

Cut out side skins for the air vents. Ordered pieces for forward inspection plates from RANS. Bent side skins

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Jan 02, 2014 Drilled out left side pieces Category: FuselageForward

Drilled out left side pieces. Riveted forward and center fuselage sections together.

Dec 26, 2013 Fuselage assembly

Category: FuselageCenter

Fitted and clecoed forward and middle fuselage sections together. Cut and formed gussets. Drilled out right side pieces.

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Dec 26, 2013 Fitted and clecoed forward and middle fuselage sections together

Category: FuselageForward

Fitted and clecoed forward and middle fuselage sections together. Cut and formed gussets. Drilled out right side pieces.

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Dec 21, 2013 Ran the brake fluid lines.

Category: Brakes

Ran the brake fluid lines.

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Dec 20, 2013 Installed brake cylinders, reservoir, and parking brake valve and guide.

Category: FuselageForward

Installed brake cylinders, reservoir, and parking brake valve and guide.

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Dec 18, 2013 Floor assembly

Category: FuselageCenter

Drilled the bushing and rudder pedal tube for the other two pedals. Installed on the forward fuselage frame. Pedal movement was too stiff, so we removed and re-sanded the blocks until the movement was free. Reinstalled the rudder pedals. Pulled parts for mounting the brake cylinders and parking brake.

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Dec 18, 2013 Drilled the bushing and rudder pedal tube for the other two pedals

Category: FuselageForward

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Dec 17, 2013 Floor assembly

Category: FuselageCenter

Riveted the floor skin of the forward fuselage to the floor. Drilled the bushing and rudder pedal tube for two of the rudder pedals.

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Dec 17, 2013 Riveted the floor skin of the forward fuselage to the floor

Category: FuselageForward

Riveted the floor skin of the forward fuselage to the floor. Drilled the bushing and rudder pedal tube for two of the rudder pedals.

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Dec 16, 2013 Floor assembly

Category: FuselageCenter

Riveted the forward fuselage floor together and to the firewall. Pulled the parts for the rudder pedals and sanded the blocks down so the torque tube would rotate freely.

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Dec 16, 2013 Riveted the forward fuselage floor together and to the firewall

Category: FuselageForward

Riveted the forward fuselage floor together and to the firewall. Pulled the parts for the rudder pedals and sanded the blocks down so the torque tube would rotate freely.

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Dec 14, 2013 Floor assembly

Category: FuselageCenter

Primed the forward fuselage floor and belly skin.

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Dec 14, 2013 Primed the forward fuselage floor and belly skin.

Category: FuselageForward

Primed the forward fuselage floor and belly skin.

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Dec 13, 2013 Floor assembly

Category: FuselageCenter

Finished drilling the forward fuselage floor and belly skin. Took everything apart and cleaned/de-burred ready for priming

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Dec 13, 2013 Finished drilling the forward fuselage floor and belly skin

Category: FuselageForward

Finished drilling the forward fuselage floor and belly skin. Took everything apart and cleaned/de-burred ready for priming

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Dec 10, 2013 Floor assembly

Category: Fuselage

Pulled parts for forward fuselage floor and began drilling and fitting.

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Dec 10, 2013 Pulled parts for forward fuselage floor and began drilling and fitting.

Category: FuselageForward

Pulled parts for forward fuselage floor and began drilling and fitting.

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Dec 09, 2013 Riveted forward fuselage and firewall.

Category: FuselageForward

Riveted forward fuselage and firewall.

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Dec 08, 2013 Firewall assembly Category: Engine

Cleaned/de-burred firewall parts and primed them.

Dec 08, 2013 Cleaned/de-burred firewall parts and primed them. Category: FuselageForward

Cleaned/de-burred firewall parts and primed them.

Dec 07, 2013 Pulled firewall parts and assembled

Category: FuselageForward

Pulled firewall parts and assembled. Drilled out the steel engine mount supports. Took apart.

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Dec 04, 2013 Drilled upper forward fuselage assembly Category: FuselageForward

Drilled upper forward fuselage assembly. Took apart and cleaned.

Dec 02, 2013 Cleaned the tailcone upper skin and tabs Category: Tailcone

Cleaned the tailcone upper skin and tabs. Moved the tailcone to the lanai. Pulled parts for the upper forward fuselage assembly and started clecoing it together.

Nov 26, 2013 Drilled the tailcone skin to #30 and clecoed Category: Tailcone

Drilled the tailcone skin to #30 and clecoed. Took skin off for cleaning/de-burring

Nov 25, 2013 Finished clecoing the tailcone skin to #40

Category: Tailcone

Finished clecoing the tailcone skin to #40

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Nov 23, 2013 Tailcone assembly

Category: Tailcone

Primed pieces for the top skin of the tailcone. When it dried, we riveted the top skins together and riveted on the stiffeners and seat belt gusset. Started clecoing the skin to the tailcone.

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Nov 23, 2013 Primed pieces for the top skin of the tailcone

Category: Tailcone

Primed pieces for the top skin of the tailcone. When it dried, we riveted the top skins together and riveted on the stiffeners and seat belt gusset. Started clecoing the skin to the tailcone.

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Nov 22, 2013 Riveted bulkheads 1 and 4 together

Category: Tailcone

Riveted bulkheads 1 and 4 together. Riveted 2, 3, & 4 bulkhead tops to tailcone. Riveted rear deck together and to tailcone. Pulled top skin parts, drilled seatbelt gusset and cleaned ready for priming.

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Nov 20, 2013 Longerons & bulkhead Category: Fuselage

Primed the longerons and bulkhead tops and rear deck

Nov 20, 2013 Primed the longerons and bulkhead tops and rear deck. Category: Tailcone

Primed the longerons and bulkhead tops and rear deck.

Nov 19, 2013 V stab install

Category: VStab

Drilled the mounting holes for the vertical stabilizer. Checked the alignment of the stabilizer. Clecoed the read deck and drilled out. Took everything off including the longeron and cleaned.

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Nov 19, 2013 Drilled the mounting holes for the vertical stabilizer

Category: Tailcone

Drilled the mounting holes for the vertical stabilizer. Checked the alignment of the stabilizer. Clecoed the read deck and drilled out. Took everything off including the longeron and cleaned.

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Nov 18, 2013 Primed the bellcrank channel

Category: Tailcone

Primed the bellcrank channel. Attached the stabilator bellcranks and pulleys and riveted channel to belly skin and bulkhead #2. Clecoed and drilled top bulkheads #1, 2, & 3. Drilled tailcone longeron #40. Drilled foot steps. Cleaned all parts ready for priming.

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Nov 15, 2013 Finished riveting lower tail cone

Category: Tailcone

Finished riveting lower tail cone. Did not rivet belly corner stiffener per instructions. #3 bulkhead rib (KPFU0453) came and we drilled, primed & riveted that. Pulled parts for bellcrank channel assembly and aft stabilator push-pull tube. Cut cable holders and bushings and drilled parts as required. Primed parts.

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Nov 12, 2013 Lower channels & stringers

Category: Fuselage

Riveted inspection rings and nut plates to side and belly skins. Riveted lower channels to skin stringers. Riveted bulkhead #5 together. Attached to frame and stringers and riveted/bolted together

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Nov 12, 2013 Riveted inspection rings and nut plates to side and belly skins

Category: Tailcone

Riveted inspection rings and nut plates to side and belly skins. Riveted lower channels to skin stringers. Riveted bulkhead #5 together. Attached to frame and stringers and riveted/bolted together

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Nov 10, 2013 Priming parts

Category: Fuselage

Finished cleaning the pieces and primed them.

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Nov 10, 2013 Finished cleaning the pieces and primed them.

Category: Tailcone

Finished cleaning the pieces and primed them.

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Nov 09, 2013 Bulkhead # 5

Category: Fuselage

Assembled bulkhead #5 and clecoed into place on the tailcone. Drilled holes to #30, reamed bolt holes to 3/16 or 1/4 as required. Took everything apart and started cleaning.

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Nov 09, 2013 Assembled bulkhead #5 and clecoed into place on the tailcone

Category: Tailcone

Assembled bulkhead #5 and clecoed into place on the tailcone. Drilled holes to #30, reamed bolt holes to 3/16 or 1/4 as required. Took everything apart and started cleaning.

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Nov 08, 2013 Test with .jpg files

Category: Auto Entry

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Nov 08, 2013 Rudder cable, inspection plates, side skin

Category: Fuselage

Routed rudder cable through fair leads in center fuselage. Pulled parts for the tailcone. Bent side skins - took 6 people total, 2 to turn the tube and 4 to keep the skin firmly pressed down on the bench. Drilled out holes for inspection panels. Clecoed everything together. Discovered that we rolled the skins the wrong way, which puts the inspection panel on the right side. Also KPFU0453 seems to be bent the wrong way. Sent Ed @ RANS a note on both these issues. Also pulled part KPCS0242 to rivet during this phase.

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Nov 08, 2013 Routed rudder cable through fair leads in center fuselage

Category: Tailcone

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Nov 05, 2013 Re-installed fair leads using nuts and bolts

Category: Tailcone

Re-installed fair leads using nuts and bolts. Starting installing the deadening foam.

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Nov 04, 2013 Finished flap release tube Category: Tailcone

Finished flap release tube. Attached hardware for flap actuator - it will need to be re-done when wings are attached. Pulled parts for starting the tailcone.

Nov 03, 2013 Seats & flap mechanism

Category: FuselageCenter

Drilled out the seat belt attach fillings and re-installed correctly. Drilled 1/3" hole before riveting. Riveted nut plates and stiffeners to the seat and baggage skins. Installed flap mechanism and flap torque tube.

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Nov 03, 2013 Drilled out the seat belt attach fillings and re-installed correctly

Category: Tailcone

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Oct 31, 2013 Our technical advisor stopped by to inspect Category: Tailcone

Our technical advisor stopped by to inspect. His comments: 1) replace the thin washer on the bolt in the middle of the gear block from a thick washer to a thin one (to gain the correct number of threads showing after the nuts are tightened). 2) Seat belt attach fittings were installed backwards - need to drill rivets out and re-rivet 3) Recommended putting 1/8" insulation on all outside skins to deaden sounds 4) Recommended replacing Tinnamens for fair leads with nut and bolt. Placed an order with Aircraft Spruce for needed parts.

Oct 29, 2013 Priming parts

Category: FuselageCenter

Primed the seat/baggage skins and flap parts.

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Oct 29, 2013 Primed the seat/baggage skins and flap parts.

Category: Tailcone

Primed the seat/baggage skins and flap parts.

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Oct 28, 2013 Floor assembly Category: FuselageCenter

Clecoed the seat skin and seat ramp back on so we could drill the baggage area skin and center access panel. Drilled #40, #30, #11 or 1/4 " as needed. For the seat area floating nut plates, instead of riveting them through 3 layers of material, we decided after talking to Eddie at RANS to just rivet them to the bottom layer and drill out the shims to accommodate the rivet head. Took everything apart, cleaned/deburred all pieces. Pulled the parts for the flap assembly, drilled what was needed there and cleaned those parts so they're ready to be primed.

Oct 28, 2013 Clecoed the seat skin and seat ramp back on so we could drill the baggage area skin Category: Tailcone

Oct 26, 2013 Floor assembly Category: FuselageCenter

Drilled holes to #40, #30, #11 or 1/4" as needed in floor skins. Took skins and stiffeners off and de-burred/cleaned all pieces.

Oct 26, 2013 Drilled holes to #40, #30, #11 or 1/4" as needed in floor skins Category: Tailcone

Drilled holes to #40, #30, #11 or 1/4" as needed in floor skins. Took skins and stiffeners off and de-burred/cleaned all pieces.

Oct 25, 2013 Carry-thru and gear blocks

Category: FuselageCenter

Added remaining bolts to gear block - one bolt stripped so ordered a new bolt and nut. Riveted seat ribs to carry-thru. Drilled, painted and riveted bearing block attach gusset. Clecoed floor skins to seating area.

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Oct 25, 2013 Added remaining bolts to gear block - one bolt stripped so ordered a new bolt and nu ...

Category: Tailcone

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Oct 23, 2013 Carry-thru install Category: FuselageCenter

Re-installed carry-thru and riveted to center fuselage.

Oct 23, 2013 Re-installed carry-thru and riveted to center fuselage. Category: Tailcone

Re-installed carry-thru and riveted to center fuselage.

Oct 22, 2013 Carry-thru drilling

Category: FuselageCenter

Match-reamed the wings to the carry-thru. Wings were held vertically in a sling so that filings would fall through the hole. Reamed the two miss-reamed holes to 7/16 and the remaining holes to 3/8

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Oct 22, 2013 Belly Skin Category: FuselageCenter

Cleoced together the bottom of the bulkhead #1 from the tailcone section. Took apart and cleaned ready to prime. Rolled the cabin side walls and fashioned the joggle tools.

Oct 22, 2013 Went to the airport to do the match-reaming of the wings to the carry-thru

Category: Tailcone

Went to the airport to do the match-reaming of the wings to the carry-thru. Wings were held vertically in a sling so that filings would fall through the hole. Reamed the two miss-reamed holes to 7/16 and the remaining holes to 3/8

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Oct 21, 2013 Riveted the belly skin except where the carry thru attaches Category: Tailcone

Riveted the belly skin except where the carry thru attaches. Removed the tail section and the carry thru.

Oct 19, 2013 Finished riveting the side skins

Category: Tailcone

Finished riveting the side skins

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Oct 18, 2013 Clecoed the frame together and riveted

Category: Tailcone

Clecoed the frame together and riveted. Riveted nut plates through skin and seat belt attach channels. Started riveting side skins.

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Oct 12, 2013 Cleaned/de-burred and primed all pieces Category: Tailcone

Cleaned/de-burred and primed all pieces

Oct 11, 2013 Drilled and reamed landing gear blocks Category: Tailcone

Drilled and reamed landing gear blocks. Transfer drilled side and belly skins to #30 where needed for riveting. Took apart and labeled prior to cleaning and priming.

Oct 08, 2013 Clecoed the center skins, rib, etc

Category: Tailcone

Clecoed the center skins, rib, etc. in place. Joggled KPFU0428 to accommodate the longerons. Bent forward longerons using the dies. Transfer drilled #40 to bulkhead gusset and side skin. Fabricated shims and clecoed gussets and shims in place. Clecoed belly skin and gussets in place.

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Aug 30, 2013 Cut slots in and fluted the cabin wall rib

Category: Tailcone

Cut slots in and fluted the cabin wall rib. Cut apart clips. Fitted side skins to center section and decided we really need the carry through to make sure everything is in place correctly.

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Aug 26, 2013 Rear spar bulkhead

Category: FuselageCenter

Clecoed all the primed parts back on the center section and clecoed the tailcone bulkhead #1 together. Discovered that the Rear Spar Bulkhead Support Angles were positioned/drilled incorrectly. We repositioned and re-drilled. Partially riveted/bolted the center frame and tailcone together.

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Aug 26, 2013 Clecoed all the primed parts back on the center section and clecoed the tailcone bul ...

Category: Tailcone

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Aug 24, 2013 Primed the tailcone and other misc

Category: Tailcone

Primed the tailcone and other misc. parts

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Aug 23, 2013 Rear spar bulkhead

Category: FuselageCenter

Cleoced together the bottom of the bulkhead #1 from the tailcone section. Took apart and cleaned ready to prime. Rolled the cabin side walls and fashioned the joggle tools.

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Aug 23, 2013 Cleoced together the bottom of the bulkhead #1 from the tailc ...

Category: Tailcone

Cleoced together the bottom of the bulkhead #1 from the tailcone section. Took apart and cleaned ready to prime. Rolled the cabin side walls and fashioned the joggle tools.

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Aug 19, 2013 Reinforce plates

Category: Flaps

Riveted the flap reinforcement plates and nut plates to the center spars. Clecoed the assembly together. Fabricated the fair leads and bolted to the rear spar - put the rest back into their bag until we work on that section. Fabricated the Rear Spar Bulkhead Support Angles.

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Aug 19, 2013 Riveted the flap reinforcement plates and nut plates to the center spars

Category: FuselageCenter

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Aug 18, 2013 Primed all the ribs/spars

Category: FuselageCenter

Primed all the ribs/spars

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Aug 16, 2013 Rib assembly Category: FuselageCenter

Started on the rib assembly for the fuselage center section. Drilled out the flag reinforcement plates and deburred/cleaned all pieces

Aug 16, 2013 Started on the rib assembly for the fuselage center section Category: FuselageCenter

Started on the rib assembly for the fuselage center section. Drilled out the flag reinforcement plates and deburred/cleaned all pieces

Aug 13, 2013 Carry-thru drilling

Category: FuselageCenter

Took the carry-thru down to the airport to match ream it with the wings. Did 3 holes - one was OK, one was too large, and one was slightly oblong. Need to ream more slowly and ensure that the reamer is straight going through. After discussions with Eddie at RANS, we're ordering an oversized bolt(30) and a 7/16 " bolt (33) plus associated reamers. Our Tech Counselor will assist us with this step once we get what we need.

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Aug 13, 2013 Took the carry-thru down to the airport to match ream it with the wings

Category: FuselageCenter

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Aug 12, 2013 Carry-thru

Category: FuselageCenter

Started on the carry-thru assembly for the wings. Spray primed the pieces so we could assemble and rivet/bolt. Acquired a bench grinder to make the modified bolts/pins.

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Aug 12, 2013 Started on the carry-thru assembly for the wings

Category: FuselageCenter

Started on the carry-thru assembly for the wings. Spray primed the pieces so we could assemble and rivet/bolt. Bought a bench grinder to make the modified bolts/pins.

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Jul 11, 2013 Kit arrival

Category: Fuselage

Opened the package and counted/stored the contents. Large pieces are in the second bedroom, medium pieces nailed to the plywood in the garage, and small pieces in labeled drawers in the garage.

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Jul 11, 2013 Opened the package and counted/stored the contents

Category: Fuselage

Opened the package and counted/stored the contents. Large pieces are in the second bedroom, medium pieces nailed to the plywood in the garage, and small pieces in labeled drawers in the garage.

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Jul 10, 2013 Kit Arrived

Category: Fuselage

The fuselage kit came! We rolled the building tables out to the truck and the delivery man pushed the box out onto our table. Ken, Dave, Norm & Dan helped roll the table back into the garage.

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Jul 10, 2013 The fuselage kit came! We rolled the building tables out to the truck and the deliv ...

Category: Fuselage

The fuselage kit came! We rolled the building tables out to the truck and the delivery man pushed the box out onto our table. Ken, Dave, Norm & Dan helped roll the table back into the garage.

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Mar 18, 2013 Wing Assembly

Category: Wings

Trailered the wings to the hangar at the airport.

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Mar 18, 2013 Trailered the wings to the hangar at Leesburg Airport.

Category: Ailerons

Trailered the wings to the hangar at Leesburg Airport.

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Mar 17, 2013 Wing Assembly

Category: Wings

Started putting PRC in the left wing rivet holes but decided it was a lot of work with little/no benefit so we're discontinuing that.

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Mar 17, 2013 Started putting PRC in the left wing rivet holes but decided it was a lot of work wi ...

Category: Ailerons

Started putting PRC in the left wing rivet holes but decided it was a lot of work with little/no benefit so we're discontinuing that.

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Mar 16, 2013 Wing tips Category: Wings

The washers on the front cap popped off when we put clecos in, so we riveted the front cap first and held the washers on by hand. Attached and riveted the rear cap and attached/tested the nav/strobe light. Added glue between the front and rear plastic end caps

Mar 16, 2013 The washers on the front cap popped off when we put clecos in, so we riveted the fro ... Category: Ailerons

Mar 15, 2013 Right wing end cap Category: Wings

Started working on the right wing end cap. Cut the rear plastic cap too short such that one end isn't on the spar extension. Glued the washers to the front cap and taped the backing strips to the rear cap.

Mar 13, 2013 Rivets and counter weights arrived today Category: Ailerons

Rivets and counter weights arrived today. Finished riveting the ailerons and drilled/attached the aileron counter-weights. We'll do the balancing after they've been primed.

Mar 08, 2013 End caps

Category: Wings

Attached the plastic end caps and strobe light to the left wing.

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Mar 08, 2013 Attached the plastic end caps and strobe light to the left wing.

Category: Ailerons

Attached the plastic end caps and strobe light to the left wing.

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Mar 03, 2013 Wing Assembly

Category: Wings

Put PRC in all the rivet holes in the flaps and ailerons. With the exception of the AAPQ-43 rivets that we're still waiting for, these parts are done and ready to be professionally primed.

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Mar 03, 2013 Put PRC in all the rivet holes in the flaps and ailerons

Category: Ailerons

Put PRC in all the rivet holes in the flaps and ailerons. With the exception of the AAPQ-43 rivets that we're still waiting for, these parts are done and ready to be professionally primed.

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Mar 01, 2013 Ordered the fuselage kit. Category: Fuselage

Ordered the fuselage kit.

Feb 25, 2013 Riveted the skins to right and left ailerons

Category: Ailerons

Riveted the skins to right and left ailerons

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Feb 23, 2013 Cleaned, de-burred and primed the aileron skins Category: Ailerons

Cleaned, de-burred and primed the aileron skins

Feb 22, 2013 Right rib doubler came yesterday Category: Ailerons

Right rib doubler came yesterday. Drilled and primed that. Clecoed everything together for both aileron frames and riveted. We're short 16 AAPQ-43 rivets, so we've ordered them along with the aileron and stabilator balance weights. Fitted and drilled the aileron skins.

Feb 15, 2013 Fitted and drilled the right aileron frame Category: Ailerons

Fitted and drilled the right aileron frame. Took both aileron frames apart and clean/de-burred them. Primed all parts. Called to get a replacement for the right rib doubler which was miss-drilled.

Feb 13, 2013 Wing Assembly

Category: Wings

Aligned the aileron horn plate to the outer rib by drilling both the aileron horn plate and aileron horn angle to #11 and inserting a bolt to keep them aligned. Drilled all holes in the left aileron frame to their final size.

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Feb 13, 2013 Aligned the aileron horn plate to the outer rib by drilling both the aileron horn pl ...

Category: Ailerons

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Feb 11, 2013 Fitted left aileron together

Category: Ailerons

Fitted left aileron together. Modified spar plate reinforcements and spacer.

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Feb 09, 2013 Riveted the flap skins.

Category: Flaps

Riveted the flap skins.

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Feb 08, 2013 Worked on wing tip for the left wing

Category: Flaps

Worked on wing tip for the left wing. The wing extension stiffener's flange wasn't bent correctly. RANS is sending new ones. Drilled/riveted what we could and cut the plastic for the tip lights (for both left and right wings).

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Feb 07, 2013 Clecoed and riveted the upper leading edge skin.

Category: Flaps

Clecoed and riveted the upper leading edge skin.

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Feb 05, 2013 Wing Assembly Category: Wings

Added an extra skin stiffener forward of the pitot tube on the lower leading edge skin. Changed the grommets for the two pitot air lines to bulkhead fittings at the root nose rib.

Feb 05, 2013 Added an extra skin stiffener forward of the pitot tube on the lower leading edge sk ... Category: Flaps

Added an extra skin stiffener forward of the pitot tube on the lower leading edge skin. Changed the grommets for the two pitot air lines to bulkhead fittings at the root nose rib.

Jan 30, 2013 Wing Assembly

Category: Wings

Riveted both aft skins and the bottom of the leading edge skin.

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Jan 30, 2013 Riveted both aft skins and the bottom of the leading edge skin.

Category: Flaps

Riveted both aft skins and the bottom of the leading edge skin.

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Jan 29, 2013 Wing Assembly Category: Wings

EAA Technical Counselor stopped by to inspect left wing and pitot tube installation. He recommended making a couple of loops on the air hoses (see picture) so that if we needed to get to the pitot tube heating unit that we'd have enough hose to drop the pitot tube out of the way. He also recommended putting bulkhead fittings for the tubes in the root rib so we could route the tube through the fuselage without the wing. He also didn't like the scratching around the rivet holes where we de-burred. Touched-up the scratches and we'll use the countersink tool (lightly!) in the future.

Jan 29, 2013 EAA Technical Counselor stopped by to inspect left wing and pitot tube installation Category: Flaps

Jan 26, 2013 Installed Dynon heated pitot tube with angle-of-attack

Category: Flaps

Installed Dynon heated pitot tube with angle-of-attack. Drilled and ran hoses. Ran wiring through existing tube. Installed Molex connectors for heating wires.

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Jan 23, 2013 Hung all the wing skins up and primed

Category: Flaps

Hung all the wing skins up and primed. Riveted the skin stiffeners and access panel rings.

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Jan 22, 2013 Attached fuel line Category: Flaps

Attached fuel line. Wired fuel sending unit.

Jan 21, 2013 Wing Assembly

Category: Wings

Took the skin off the left wing and cleaned/de-burred all parts. Our neighbor Norm helped.

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Jan 21, 2013 Took the skin off the left wing and cleaned/de-burred all parts

Category: Flaps

Took the skin off the left wing and cleaned/de-burred all parts. Our neighbor Norm helped.

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Jan 20, 2013 Wing Assembly Category: Wings

Attached Molex connectors to the root and tip wiring for the strobes

Jan 20, 2013 Attached Molex connectors to the root and tip wiring for the strobes Category: Flaps

Attached Molex connectors to the root and tip wiring for the strobes

Jan 19, 2013 Drilled leading edge skin to #30

Category: Flaps

Drilled leading edge skin to #30. Formed the torque angle and transfer drilled #40, then final drilled #30.

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Jan 16, 2013 Primed the flap skins and the cover plates. Category: Flaps

Primed the flap skins and the cover plates.

Jan 15, 2013 Wing Assembly

Category: Wings

Taped top edge of leading edge skin so that the ends line up and the spar holes are over the reference line. Starting in the middle, drilled skin to ribs and spar #40. Added leading edge tip and drilled #40

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Jan 15, 2013 Taped top edge of leading edge skin so that the ends line up and the spar holes are o ...

Category: Flaps

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Jan 11, 2013 Drilled top skin to #40, then #30 Category: Flaps

Drilled top skin to #40, then #30. Drew reference line on the top aft skin, then flipped wing over and drew reference line on bottom aft skin. Aligned bottom of leading edge skin to reference line and drilled skin to spar then to ribs #40. Turned wing over.

Jan 08, 2013 Wing Assembly

Category: Wings

Drew center lines on the bottom ribs and clecoed the bottom aft skin to the frame. Drilled out the ribs to #40. Added the fuel tank cover and tip skin and drilled the ribs to #30. Cut the flap and aileron hinges as specified and drilled them with the aft spar and aileron hinge doublers to #30. Flipped the wing over and drew centerlines on the top ribs. Clecoed the top skin to the frame and removed the plastic from around the rows of rivets.

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Jan 08, 2013 Drew center lines on the bottom ribs and clecoed the bottom aft skin to the frame

Category: Flaps

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Jan 06, 2013 Flaps assembly

Category: Flaps

The left flap skin flattened a little and a new one would be $100, so we decided to work with the one we have. We bent it deeper with the 2" pipe and drilled it to #30. Both flap skins are cleaned and ready to prime. We moved the left wing to the work table, squared it, and clamped it to the table. We peeled the plastic from around the rivet holes.

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Jan 06, 2013 The left flap skin flattened a little and a new one would be $100, so we decided to w ...

Category: Flaps

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Jan 04, 2013 Flaps assembly

Category: Flaps

We were unhappy with the fit of the left flap skin, so we clamped it flat to the table and will try re-bending it later. We successfully bent the right flap skin using a 2" plastic pipe, drilled it to #40, then to #30.

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Jan 04, 2013 We were unhappy with the fit of the left flap skin, so we clamped it flat to the tabl ...

Category: Flaps

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Dec 28, 2012 Clecoed the flaps together and riveted Category: Flaps

Clecoed the flaps together and riveted. We had to drill some of the holes (8 on each flap) out to #11 to accommodate the specified rivet. Bent the leading top skin for the flap as specified. For the other flap I think we need a wider diameter pipe to roll the edge. Fitted the left flap skin and transfer drilled #40

Dec 22, 2012 Cleaned/de-burred/primed all the flap frame parts.

Category: Flaps

Cleaned/de-burred/primed all the flap frame parts.

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Dec 21, 2012 Flaps assembly Category: Flaps

Finished drilling #30 the right flap, then assembled and drilled the left flap. Disassembled ready to clean/debur/prime.

Dec 21, 2012 Finished drilling #30 the right flap, then assembled and drilled the left flap Category: Flaps

Finished drilling #30 the right flap, then assembled and drilled the left flap. Disassembled ready to clean/debur/prime.

Dec 18, 2012 Flaps assembly

Category: Flaps

Pulled the parts for the flaps and clecoed the frame together. Made modifications per instructions and marked/drilled the flap hinge, then transfer drilled into the flap spar.

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Dec 18, 2012 Pulled the parts for the flaps and clecoed the frame together

Category: Flaps

Pulled the parts for the flaps and clecoed the frame together. Made modifications per instructions and marked/drilled the flap hinge, then transfer drilled into the flap spar.

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Dec 14, 2012 Put goop around the base of the fuel filler

Category: WingSkin

Put goop around the base of the fuel filler. Riveted the scupper rings to the skin. Recommended rivets didn't work (too loose) so we used the AVEX rivets. Clecoed the top aft and top leading edge skins to the frame and riveted according to the schedule. Moved the right wing to the lanai.

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Dec 12, 2012 Put Molex connectors on either end of the strobe wires

Category: WingSkin

Put Molex connectors on either end of the strobe wires. Changed the grounding wire on the fuel sending unit to a screw rather than a rivet. Cut the scuppers for both wings an drilled, cleaned and primed the retaining rings for the right wing.

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Dec 11, 2012 Clecoed the bottom aft skin and leading edge to frame Category: WingSkin

Clecoed the bottom aft skin and leading edge to frame. Also clecoed the hinges, hinge support, tank skin and torque angle. Riveted to the frame according to the schedule

Dec 10, 2012 EAA Technical Counselor stopped by to inspect Category: WingSkin

EAA Technical Counselor stopped by to inspect. He and Ken decided to glue foam on the bottom of the fuel tanks so that (a) they wouldn't rub against the skin and (b) we could get air under the tank in case water collected there. We also needed to change the grounding wire on the fuel sending unit to a screw rather than a rivet. EAA Technical Counselor also took the fuel lines to put a bubble in them to prevent the attached line from slipping off.

Dec 07, 2012 Wired the fuel sending unit

Category: WingSkin

Wired the fuel sending unit. Cleaned/de-burred spar and aft ribs, clecoed aft top skin back on. Took leading edge skin and tip skins off, cleaned, de-burred, and primed. Riveted inspection plate retaining rings to leading edge skin.

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Dec 05, 2012 Primed the aft top skin, stiffeners, step and tip skin Category: WingSkin

Primed the aft top skin, stiffeners, step and tip skin. Riveted the stiffeners and inspection plate retaining ring to the aft top skin.

Dec 04, 2012 Re-clecoed aft bottom skin Category: WingSkin

Re-clecoed aft bottom skin. Formed and drilled the leading skin tip. Flipped the wing over, removed the aft top skin and cleaned/de-burred.

Dec 02, 2012 Wing Assembly

Category: Wings

Primed the aft bottom skin, stiffeners, torque angle, fuel bay skin and half of the inspection rings and covers. Riveted the stiffeners and inspection retaining rings to the aft bottom skin.

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Dec 02, 2012 Primed the aft bottom skin, stiffeners, torque angle, fuel bay skin and half of the i ...

Category: WingSkin

Primed the aft bottom skin, stiffeners, torque angle, fuel bay skin and half of the inspection rings and covers. Riveted the stiffeners and inspection retaining rings to the aft bottom skin.

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Dec 01, 2012 Wing Assembly

Category: Wings

Cleaned/de-burred the aft bottom skin, the stiffeners, torque angle, fuel bay skin, and half of the inspection rings and covers.

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Dec 01, 2012 Cleaned/de-burred the aft bottom skin, the stiffeners, torque angle, fuel bay skin, a ...

Category: WingSkin

Cleaned/de-burred the aft bottom skin, the stiffeners, torque angle, fuel bay skin, and half of the inspection rings and covers.

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Nov 30, 2012 Unclecoed the bottom side of the leading edge skin

Category: WingSkin

Unclecoed the bottom side of the leading edge skin. With the aft-most cleco in place transfer drilled #40, then #30 the remaining 3 holes through the torque angle. Fabricated brackets for the plastic tube for the strobe wiring and installed on root and tip nose ribs. Installed fuel line after removing bottom aft skin.

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Nov 27, 2012 Wing Assembly Category: Wings

Looked for leading edge tip skin (KPWI0457) We received a different part - RANS is shipping correct parts to us. Fabricated torque angle bending it using blocks of wood around the angle in the vise. Drilled the bottom aft tow holes by marking them on the angle, then removed the skin panel and transfer drilled #40 then #30.

Nov 27, 2012 Looked for leading edge tip skin (KPWI0457) We received a different part - RANS is s ... Category: WingSkin

Nov 17, 2012 Drilled bottom of leading edge skin to nose ribs

Category: WingSkin

Drilled bottom of leading edge skin to nose ribs. Drilled out to #30. Flipped wing over and taped leading edge in place (Note: use long strips of strapping tape!) Started transfer drilling at the front of the nose ribs in the middle and fanned out to the root/tip to avoid bubbles.

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Nov 16, 2012 Installed tube and wire for fuel sender

Category: WingSkin

Installed tube and wire for fuel sender. Riveted tube support to wing frame. Drew center lines on ribs and transfer drilled upper aft skin to frame and clecoed. Added upper aft tip skin and drilled out to #30. Drew lines on the top and bottom aft skins for leading edge wing skin. Drilled and clecoed #40 the leading edge skin to the bottom of the main spar.

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Nov 14, 2012 Cut and modified flap and inboard/outboard aileron hinges

Category: FuelTank

Cut and modified flap and inboard/outboard aileron hinges. Drilled to #30 and attached to lower aft spar. Also attached hinge supports.

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Nov 07, 2012 Wing Assembly Category: Wings

Clecoed lower aft skin, tank cover and skin tip extension to frame (right wing) Drilled to #40, then #30.

Nov 07, 2012 Clecoed lower aft skin, tank cover and skin tip extension to frame (right wing) Dril ... Category: FuelTank

Clecoed lower aft skin, tank cover and skin tip extension to frame (right wing) Drilled to #40, then #30.

Nov 06, 2012 Ken and EAA Technical Counselor pressure tested the fuel tanks

Category: FuelTank

Ken and EAA Technical Counselor pressure tested the fuel tanks. There was some leakage around the fuel sending units. They removed and re-gooped one bolt and put PRC over the exposed rivets in the left tank.

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Nov 04, 2012 Wing Assembly Category: Wings

Used carriage bolts through the table and clamped the right wing frame to the table, such that the spars are level to the table lengthwise and parallel to each other. Checked the alignment through the alignment holes.

Nov 04, 2012 Used carriage bolts through the table and clamped the right wing frame to the table, ... Category: FuelTank

Nov 03, 2012 Wing Assembly Category: Wings

Drilled and clecoed the stiffeners to the top and bottom aft skins

Nov 03, 2012 Drilled and clecoed the stiffeners to the top and bottom aft skins Category: FuelTank

Drilled and clecoed the stiffeners to the top and bottom aft skins

Nov 02, 2012 Wing Assembly Category: Wings

Using the longer bolts we were able to secure the fuel level sending unit. Installed fuel drain, intake pipe, fuel vent and sending unit in the other tank.

Nov 02, 2012 Using the longer bolts we were able to secure the fuel level sending unit Category: FuelTank

Using the longer bolts we were able to secure the fuel level sending unit. Installed fuel drain, intake pipe, fuel vent and sending unit in the other tank.

Oct 31, 2012 Wing Assembly Category: Wings

First drilling of the fuel tank cover plate was not right - we're using the other cover for now and need to order a new cover. Installed fuel drain, intake pipe and fuel vent in right tank. Used Dow Corning 838 silicone adhesive between tank and rubber washer. We had trouble with locking down the fuel sending unit - need to get longer bolts (try AN3-8).

Oct 31, 2012 First drilling of the fuel tank cover plate was not right - we're using the other cov ... Category: FuelTank

Oct 20, 2012 Wing Assembly Category: Wings

Fabricated round backing plates for the fuel level sending units. Cut a wide circle out of aluminum and used flat rivets to attach 5 single wing nut plates. Also drilled four holes to attach to the fuel tanks. Cut each backing plate into two pieces so we could get the plate through the hole into the tank. Drilled the holes into the tank and maneuvered the backing plate pieces into place and riveted them to the tank. Also drilled holes for the fuel drain, intake pipe and fuel vent. Rinsed both tanks and left upside down to drain.

Oct 20, 2012 Fabricated round backing plates for the fuel level sending units Category: FuelTank

Oct 12, 2012 Wing Assembly Category: Wings

Discovered that we used the wrong rivets which hold the nose ribs to the spar. Drilled out the short rivets holding nose ribs 1 and 4 to spar. Replaced with correct rivets. Assembled and installed left inner and outer belcranks.

Oct 12, 2012 Discovered that we used the wrong rivets which hold the nose ribs to the spar Category: Spar

Sep 15, 2012 Assembled and installed right inner and outer belcranks

Category: Spar

Assembled and installed right inner and outer belcranks. Primed belcranks and bearing covers.

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Sep 12, 2012 Clecoed rear spars to rear ribs and riveted Category: Spar

Clecoed rear spars to rear ribs and riveted

Sep 09, 2012 Primed the rear spar and ribs Category: Spar

Primed the rear spar and ribs

Sep 08, 2012 Cleaned and de-burred all rear spar pieces and rear ribs Category: Spar

Cleaned and de-burred all rear spar pieces and rear ribs

Sep 05, 2012 Worked on rear spar - cut hinges apart, drilled and clecoed

Category: Spar

Worked on rear spar - cut hinges apart, drilled and clecoed. Drilled into rear ribs. Did the left and right rear spars.

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Aug 27, 2012 Picked up the professionally primed empennage parts

Category: Spar

Picked up the professionally primed empennage parts

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Aug 25, 2012 Clecoed and riveted right wing ribs to spar.

Category: Spar

Clecoed and riveted right wing ribs to spar.

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Aug 22, 2012 Primed the spars and ribs.

Category: Spar

Primed the spars and ribs.

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Aug 20, 2012 Cleaned an ddeburred all wing frame parts used so far. Category: Spar

Cleaned an ddeburred all wing frame parts used so far.

Aug 18, 2012 Drilled out the right wing frame Category: Spar

Drilled out the right wing frame. Put the left wing together and drilled that out to #30. Marked all parts and took the wings apart.

Aug 13, 2012 Started drilling and fitting ribs

Category: Spar

Started drilling and fitting ribs. Called Randy - he said that text and drawings were right - parts may be mis-labeled (they were!). He suggested checking RansClan for a picture of the wing ribs. We did and confirmed that we need to use the ribs marked left on the right wing. Clecoed the rest of the ribs to the right spar.

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Aug 11, 2012 Started working on the right wing

Category: Spar

Started working on the right wing. Straightened the ribs using fluting pliers. Modified a couple of the nose ribs to fit around the spar (cut out .2 and .6") Note: next time we need to do this, drill a hold in the corner of the cutout and cut to that. Ribs 6 and up look backwards - need to call RANS on Monday.

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Aug 09, 2012 Wing Assembly Category: Wings

Riveted and bolted the tie downs and angles onto the main spars.

Aug 09, 2012 Riveted and bolted the tie downs and angles onto the main spars. Category: Spar

Riveted and bolted the tie downs and angles onto the main spars.

Aug 06, 2012 Wing Assembly Category: Wings

Drilled, cleaned and clecoed the tie downs and angles onto the main spars. Hand-primed the surfaces that were touching.

Aug 06, 2012 Drilled, cleaned and clecoed the tie downs and angles onto the main spars Category: Spar

Drilled, cleaned and clecoed the tie downs and angles onto the main spars. Hand-primed the surfaces that were touching.

Jul 14, 2012 Inventoried the kit Category: Wings

Inventoried the kit. Put small parts on the board or in drawers. Larger parts are out on the lanai.

Jul 10, 2012 Wing kit arrived

Category: Wings

Wing kit arrived. Wheeled the tables down to the truck, then wheeled it back into the garage. A couple of wheels broke off on the table. They took the top off and did a quick visual inspection.

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May 22, 2012 Put the end caps on and riveted

Category: TrimTab

Put the end caps on and riveted. Installed the missing rivets that I had ordered. Installed hinge wires and bent to fit.

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May 18, 2012 Fitted the backing strips onto the end caps with double sided tape Category: TrimTab

Fitted the backing strips onto the end caps with double sided tape

May 16, 2012 Cut and fitted the plastic end caps

Category: TrimTab

Cut and fitted the plastic end caps. Drilled #40. Cut and fitted bluecor foam to the inside and used foam-safe liquid nails to secure. Left the assemblies to set. Primed the backing strips for the end cap rivets.

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May 12, 2012 Finished riveting the rest of the stabilator. Category: TrimTab

Finished riveting the rest of the stabilator.

May 08, 2012 Finished riveting the bottom side of the stabilator.

Category: TrimTab

Finished riveting the bottom side of the stabilator.

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Apr 22, 2012 Stabilator assembly

Category: Stabilator

Clecoed the skin on top and bottom, riveted the skin stiffeners on, started riveting the skin on to the main spar.

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Apr 22, 2012 Clecoed the skin on top and bottom, riveted the skin stiffeners on, started riveting ...

Category: TrimTab

Clecoed the skin on top and bottom, riveted the skin stiffeners on, started riveting the skin on to the main spar.

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Apr 20, 2012 Clecoed the stabilator frame back together and riveted.

Category: TrimTab

Clecoed the stabilator frame back together and riveted.

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Apr 19, 2012 Hung all the parts up and spray-primed them.

Category: TrimTab

Hung all the parts up and spray-primed them.

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Apr 18, 2012 Cleaned/de-burred the rest of the parts Category: TrimTab

Cleaned/de-burred the rest of the parts. Washed everything with acetone ready for priming. Primed the parts

Apr 16, 2012 Stabilator assembly

Category: Stabilator

Our wedding Anniversary! Took the stabilator apart after marking all the parts as top, bottom, right, left, etc. Drilled balancing bar. Started cleaning and de-burring all the parts

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Apr 16, 2012 Our wedding Anniversary! Took the stabilator apart after marking all the parts as top ...

Category: TrimTab

Our wedding Anniversary! Took the stabilator apart after marking all the parts as top, bottom, right, left, etc. Drilled balancing bar. Started cleaning and de-burring all the parts

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Apr 14, 2012 Trim Tab Assembly

Category: TrimTab

Ken's Birthday! Put the trim tab together, drilled #40, then #30, took it apart and clecoed it ready for priming

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Apr 14, 2012 Ken's Birthday! Put the trim tab together, drilled #40, then #30, took it apart and ...

Category: TrimTab

Ken's Birthday! Put the trim tab together, drilled #40, then #30, took it apart and clecoed it ready for priming

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Apr 12, 2012 Stabilator assembly and trim tab layout

Category: Stabilator

Drilled out the second side of the stabilator to #30 and clecoed. Started laying out trim tab.

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Apr 12, 2012 Drilled out the second side of the stabilator to #30 and clecoed

Category: Stabilator

Drilled out the second side of the stabilator to #30 and clecoed. Started laying out trim tab.

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Apr 10, 2012 Drilled one side out to #30

Category: Stabilator

Drilled one side out to #30. Added hinges to top side of stabilator.

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Apr 05, 2012 Stabilator assembly

Category: Stabilator

Heather helping - drilled and clecoed the top side of the forward skin of the stabilator

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Apr 05, 2012 Heather helping - drilled and clecoed the top side of the forward skin of the stabila ...

Category: Stabilator

Heather helping - drilled and clecoed the top side of the forward skin of the stabilator

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Mar 19, 2012 Stabilator assembly

Category: Stabilator

Drilled #40 and clecoed bottom side of the forward skin of the stabilator to the frame and forward ribs. Tied strings to the forward ribs to be able to line them up with the holes in the skin when we do the second side.

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Mar 19, 2012 Drilled #40 and clecoed bottom side of the forward skin of the stabilator to the fram ...

Category: Stabilator

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Mar 08, 2012 Drilled #40 and clecoed the bottom rear skin to the frame

Category: Stabilator

Drilled #40 and clecoed the bottom rear skin to the frame. Also removed plastic from around the rivets.

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Mar 06, 2012 Stabilator assembly

Category: Stabilator

Had to call Randy again with a question on modifying the rear skins for the stabilator. Did need to remove extra material in the center which was not noted in either the text or the figures. Drilled #40 and clecoed the lead skin to the top side of the frame.

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Mar 06, 2012 Had to call Randy again with a question on modifying the rear skins for the stabilato ...

Category: Stabilator

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Mar 03, 2012 Build 3rd workbench table

Category: Stabilator

Build 3rd workbench table. Built jig for stabilator

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Mar 01, 2012 Drilled frame to #30 and clecoed frame together

Category: Stabilator

Drilled frame to #30 and clecoed frame together

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Feb 28, 2012 Stabilator assembly

Category: Stabilator

Fit the rest of the stabilator together (parts diagrams 2 & 3). Called Randy with some questions on which hole rib 1 went into on the rear spar and where the channel stabilizer went.

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Feb 28, 2012 Fit the rest of the stabilator together (parts diagrams 2 & 3)

Category: Stabilator

Fit the rest of the stabilator together (parts diagrams 2 & 3). Called Randy with some questions on which hole rib 1 went into on the rear spar and where the channel stabilizer went.

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Feb 25, 2012 Fit the stabilator frame together

Category: Stabilator

Fit the stabilator frame together. Drilled #40, then #30 and clecoed the frame together.

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Feb 24, 2012 Riveted the rudder together.

Category: Rudder

Riveted the rudder together.

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Feb 11, 2012 Clecoed the rudder back together Category: Rudder

Clecoed the rudder back together. The rivet gun isn't working so we hand riveted the front of the trailing edge. Put rudder in its jig until we get the rivet gun back.

Feb 09, 2012 Rudder assembly Category: Rudder

Took the rudder apart. Deburred, smoother edges. Primed the inside of all parts

Feb 09, 2012 Took the rudder apart and deburred all holes and smoothed all edges Category: Rudder

Took the rudder apart and deburred all holes and smoothed all edges. Primed the inside of all parts.

Feb 06, 2012 Rudder Skin

Category: Rudder

Rolled the front end of the rudder skin and fit it to the frame. Drilled all the holes to #40 then #30 and clecoed the rudder together.

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Feb 06, 2012 Rolled the front end of the rudder skin and fit it to the frame

Category: Rudder

Rolled the front end of the rudder skin and fit it to the frame. Drilled all the holes to #40 then #30 and clecoed the rudder together

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Feb 04, 2012 Sprayed the frame

Category: Rudder

Sprayed the frame. Put the frame back together with clecos and riveted. Dipped the rivets through the steel piece in primer first. Then assembled the jig using a scrap piece of lumber and screwed that to the table. Attached the 4th piece of the rudder jig using wood screws. Cut and filed the skin stiffeners and fit the skins and the trailing edge to the frame in the jig.

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Feb 02, 2012 Attached the tip to the vertical stabilizer Category: Rudder

Attached the tip to the vertical stabilizer. That piece is done for now. Took the rudder apart, deburred and scuffed so it's ready for priming

Jan 31, 2012 Started on the rudder

Category: Rudder

Started on the rudder. Clecoed and drilled the parts together. We didn't step-drill the steel bracket before trying to fit the flange in, so we flattened that. I've called to order a new one.

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Jan 28, 2012 Re-assembled parts with clecos and riveted the skins

Category: VStab

Re-assembled parts with clecos and riveted the skins. We have a finished stabilizer!

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Jan 26, 2012 Skin - (3 hours)

Category: VStab

Drilled and clecoed the skin to the vertical stabilizer frame. Removed and deburred all parts. Removed the plastic from the back of the skin and on the front from around the rivet holes. Sprayed the parts with the 2-part epoxy primer

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Jan 26, 2012 Drilled and clecoed the skin to the vertical stabilizer frame

Category: VStab

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Jan 19, 2012 Clecoed the jigs to the frame and laid the skin on top

Category: VStab

Clecoed the jigs to the frame and laid the skin on top. Transfer drilled the holes along the rear spar and marked the orientation of the side skins. Pulled all the parts needed for the skin installation

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Jan 16, 2012 Clecoed the frame together and riveted.

Category: VStab

Clecoed the frame together and riveted.

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Jan 14, 2012 Cleaning and preping

Category: VStab

Drilled all holes with the #30 drill, cleaned and deburred all holes. Sprayed all parts with 2-part epoxy and let dry.

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Jan 14, 2012 Drilled all holes with the #30 drill, cleaned and deburred all holes

Category: VStab

Drilled all holes with the #30 drill, cleaned and deburred all holes. Sprayed all parts with 2-part epoxy and let dry.

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Jan 12, 2012 Fitting

Category: VStab

Laid all the pieces out and checked how they all fit together. Transfer drilled the stabilizer bars on the rear spar and clecoed the entire frame together

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Jan 12, 2012 Laid all the pieces out and checked how they all fit together

Category: VStab

Laid all the pieces out and checked how they all fit together. Transfer drilled the stabilizer bars on the rear spar and clecoed the entire frame together.

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Jan 10, 2012 Flange Bushings Category: Empennage

Put in flange bushings - doing it with the nut and bolt worked, but the bolt was stuck pretty tightly in the bushings. Clecoed the lower ribs to the front spar of the vertical stabilizer

Jan 10, 2012 Put in flange bushings - doing it with the nut and bolt worked, but the bolt was stuc ... Category: VStab

Put in flange bushings - doing it with the nut and bolt worked, but the bolt was stuck pretty tightly in the bushings. Clecoed the lower ribs to the front spar of the vertical stabilizer.

Jan 08, 2012 General Starting Instructions

Category: VStab

Pulled all the parts for the vertical stabilizer frame and laid them out on our work surface to see how they fit together. EAA Technical Counselor stopped by with a copy of AC 43.13 - 1B/2A - Aircraft Inspection, Repair and Alterations. He went through the basic steps we'll need to follow:
1) fit pieces together & Clec0
2) drill as necessary
3) take apart and clean/debur
4) spray the inside of ALL parts with 2-part epoxy primer (most of the S19's life will be in Florida. This was recommended to reduce the likelihood of corrosion). This will add to the base weight but will be well worth the effort.
5) reassemble and cleco
6) rivet

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Jan 08, 2012 Pulled all the parts for the vertical stabilizer frame and laid them out on our work ...

Category: VStab

1) fit pieces together & Cleco

2) drill as necessary

3) take apart and clean/debur

4) spray the inside of ALL parts with 2-part epoxy primer (most of the S19s life will be in Florida. This was recommended to reduce the likelihood of corrosion). This will add to the base weight but will be well worth the effort.

5) reassemble and cleco

6) rivet

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Jan 07, 2012 Unpacked and inventoried the contents of the kit

Category: Empennage

Unpacked and inventoried the contents of the kit. Long pieces went out on the lanai. Bought hanging bins to hold the small stuff - rivets, washers, clecos, etc. and stapled the rest in priority number order to the cover of the crate. Taped the supplied labels to the front of each bin. Broke up the rest of the crate and took it to the recycling center.

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Jan 06, 2012 The empennage kit arrived today

Category: Empennage

The empennage kit arrived today. We took the lid off and made sure everything looked OK

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