Mar 08, 2023     Tips primed       Category: Tail Feathers

My painter applied some primer to the tail tips. Looks great. Now I have to tear apart the trailing edge of the HS to do SB-00036 to replace the outer elevator brackets and add a doubler to prevent possible cracking of the rear HS spar.

  Feb 21, 2023     Sanding - (1 hour) Category: Tail Feathers

Sanded the areas on the HS tips where I filled pinholes. Still have pinholes. Not sure how to fix.

  Feb 15, 2023     Sanding - (1 hour) Category: Tail Feathers

Sanded the primer I applied last week

  Feb 09, 2023     Primed - (2 hours)       Category: Tail Feathers

Filled some pinholes with epoxy and primed the outside ends of the elevators and HS. Also touched up the lower cowling with some leftover primer

  Feb 08, 2023     Priming and sanding - (3 hours)       Category: Tail Feathers

Primed the tail ends and found out from the painter that this primer will not work with the paint he's going to use. Ended up sanding all the primer off. One step forward, two steps back. Worked on routing the elevator trim wires with some tubing for added protection. Also put some RTV around the wires where they exit the trim motor for added strain relief. Leak tested the left tank again and still have a leak around the fuel pick up.

  Feb 06, 2023     Elevator trim wires - (3 hours)       Category: Tail Feathers

Worked on routing the elevator trim wires from the trim motor out to the elevator control horn. Removed the black heat shrink and used some clear to support the wires all the way from the trim motor. Drilled a hole near the elevator control horn to route the tubing for the wires. Installed a snap ring bushing and secured with RTV. Made sort of a mess with the RTV as it was pretty hard to reach. Still not sure how exactly I'll run the wires over or under the HS spar and into the fuselage.

  Feb 05, 2023     Sanding - (.5 hour)       Category: Tail Feathers

Sanded the area around the left elevator control horn where I added a little epoxy yesterday.

  Feb 04, 2023     Empennage fairing and priming - (2 hours)       Category: Tail Feathers

Removed empennage and trimmed and sanded area that I glassed and epoxied yesterday. Tried priming one of the elevator tips to see any imperfections. Applied some 5 minute epoxy to fill some voids on the elevator near the control horn where I epoxied in the foam yesterday.

  Feb 03, 2023     Empennage fairing trimming - (3 hours)       Category: Tail Feathers

Removed empennage and trimmed the epoxy and glass that I applied yesterday. Reinstalled the fairing and reinforced the underside curve around the leading edge of the fairing with a couple layers of glass and epoxy. Cut, trimmed and installed foam around the control horn of the left elevator. Will cut a hole for the elevator trim wires layer. Added another selfie.

  Feb 02, 2023     Empennage fit - (5 hours)       Category: Tail Feathers

Removed VS, HS, and left elevator from the fuselage. Installed rivets and nut plates in fuse to secure the lower empennage fairing. Messed around with the upper empennage fairing to check the fit with the lower fairing. Glassed and epoxied on the lower surface of the HS to extend the leading edge of the fairing that wraps around the leading edge of the HS. Also sanded the HS. Tried some new fiberglass and used the plastic to apply the layers.

  Feb 01, 2023     Empennage fairing trimming - (3 hours)       Category: Tail Feathers

Removed, trimmed and sanded the edges of the empennage fairing. The fit with the tail is way better than before. Decided to fill some of the mounting holes as I don't think they are needed now that the fairing fits better. The fairing still needs some work, but it's getting there. Installed the left elevator to be able to cut the elevator trim wire to length and used the remainder for the aileron trim. Used my new pin tools from Avery to temporarily install the elevator. Worked great. Ran that wire in the fuse.

  Jan 31, 2023     Last epoxy and empennage fairing - (4 hours)       Category: Tail Feathers

Added one last layer of epoxy to the leading edge of the HS tip. Maneuvered the fuse around in the shop to access the tail area to attach the HS and VS. Marked the surfaces of both where the fairing meets and taped off with packing tape. Added a layer of automotive wax to ensure the epoxy would release from the HS and VS. Slathered up the fairing edges to fill any gaps and attached it to the tail. Wanted to get this done before sending the HS and elevators off to paint. EAA webinar on getting the airworthiness cert said to be sure and include pictures of yourself hence the goofy pic of yours truly.

  Jan 30, 2023     Finished sanding - (1 hour)       Category: Tail Feathers

Finished sanding the elevators and HS tip (I think). Orbital sander bit the dust (pun intended). Ordered a new belt to see if that will work.

  Jan 28, 2023     More sanding - (1.5 hours) Category: Tail Feathers

More HS and elevator sanding

  Jan 27, 2023     More tip sanding - (2 hours) Category: Tail Feathers

Sanded and applied more epoxy to bad/low spots and pinholes. The never ending saga ……

  Jan 26, 2023     More epoxy and foam - (2 hours)       Category: Tail Feathers

Applied some epoxy to the low spots on the HS and elevators. Filled in the forward section of the right elevator with foam and epoxy/flox. Want to do the same with the left elevator but not sure about routing of the elevator trim wire.

  Jan 25, 2023     Sanding the primer - (2 hours)       Category: Tail Feathers

Sanded down the Slick sand primer. Still have a few low spots.

  Jan 24, 2023     Sanding and priming - (2 hours)       Category: Tail Feathers

Sanded both HS tips. Mixed up some Evercoat quick sand primer and applied to all the tips and ends. Decide to try and just brush on since the the areas of application were so small.

  Jan 23, 2023     More sanding - (4 hours)       Category: Tail Feathers

Sanded all foam inserts, again. Also sanded the HS tips that I glassed yesterday and applied a feather coat to hopefully finish tomorrow.

  Jan 22, 2023     Still more epoxy and sanding - (2 hours)       Category: Tail Feathers

Sanded and add more epoxy to the low spots on all ends. Hope for this to be last time. Glassed and epoxied HS tips bottom surface at the tip/aluminum interface.

  Jan 21, 2023     More epoxy filling ends - (2 hours)       Category: Tail Feathers

Began the day by sanding the ends of both the elevators and HS. I then mixed up some epoxy and micro to add another layer to all the ends. Ready to be done with the epoxy and sanding for a while.

  Jan 20, 2023     Epoxy filling - (2 hours)       Category: Tail Feathers

Added another layer of epoxy and micro balloons to the elevator ends to fill in some voids and level. Tired to secure the elevators to the bench to make for a level plane for the epoxy. Waited for the epoxy and micro to set up and added some to the lower portion that was angled down. Ended up pretty rough. Gonna take a few more tires.

  Jan 19, 2023     More foam filler - (3 hours)       Category: Tail Feathers

Sanded the HS foam fillers. Cut, trimmed and epoxied both ends of each elevator with foam.

  Jan 18, 2023     HS tips and foam filler - (5 hours)       Category: Tail Feathers

Pull riveted and epoxied the HS tips in place. Used flex epoxy and #40 CS pop rivets to secure the tips. Cut and epoxied in place foam filler to the HS. Also cut and trimmed more foam for the elevator inboard ribs.

  Jan 17, 2023     HS end rib fill in - (1.5 hours)       Category: Tail Feathers

Cut and trimmed foam to fill in end ribs of HS. Will epoxy these in place and fill later

  Jan 06, 2023     Sanding again …… - (2 hours)       Category: Tail Feathers

Sanded the elevator tips. Hoping this is the last time. May need just a little touch up on the forward end. Dimpled the right HS where the tip attaches. Added just a slight amount of epoxy and micro to the HS tips. Would have been able to install these had I not decided to fill in the outer rib. Waiting on foam and epoxy to arrive next week to finish these up. If you can ever say they are finished. Feels like the canopy fairing all over again.

  Jan 05, 2023     More sanding and epoxy - (2 hours) Category: Tail Feathers

No pics today. Just sanded down epoxy filler on elevator and HS from yesterday and applied a thin layer over some small blemishes. Removed elevator from the HS to ease filling of end ribs that I decided to do after watching Stu's YouTube video. Looks simple, but it always does.

  Jan 04, 2023     More epoxy and tip sanding - (3 hours)       Category: Tail Feathers

Sanded the bottom elevator tips and applied a thin coat of epoxy and filler to the edge seams. Also sanded the HS tips again. Ended up using the dremel tool with a scotchbrite wheel to smooth the contour. Not sure what to do about the gap between the aft end of the HS tip and the HS. Removed elevator trim motor in preparation for paint.

  Jan 03, 2023     More epoxy and filler - (3 hours)       Category: Tail Feathers

Mixed up some more epoxy and filler to apply to the bottom of both ends the elevator. One side I mixed up with a little too much filler as you can see in the photo, but I think it'll be ok. Used some extra to add to the HS tips again, which seems never ending. Also sanded down the edges of 3 nutplates of the elevator trim tab to make it easier to install and remove.

  Jan 02, 2023     Tip sanding - (1 hour)       Category: Tail Feathers

Sanded down right tip/elevator transition area

  Dec 22, 2022     Sanding tips - (1 hour)       Category: Tail Feathers

Sanded the left HS and elevator tips. Still need a little more fairing filler.

  Dec 21, 2022     Sanding and epoxy filler for HS and elevator - (2 hours)       Category: Tail Feathers

Sanded the HS tips where I added epoxying filler. Used the oscillating spindle sander, but was a little too aggressive. Hand sanding was better. Sam mixed up some fairing filler for the elevator/tip interface and applied same to the elevator tip.

  Dec 20, 2022     Empennage tip sanding - (2 hours)       Category: Tail Feathers

Sam applied some glass and epoxy to the right elevator tip transition seam. Sanded the previously applied glass and epoxy on both tips. Also sanded the right HS tip area where I filled a void from the factory.

  Dec 19, 2022     MoreElevator and HS tips - (4 hours)       Category: Tail Feathers

Added some fairing filler to the top of the right HS to to fill in a void from the factory. Reinforced the left HS tip after removing the foam with three strips of glass and epoxy per the instructions. Used a heat gun and wedge to spread the HS tips a little to match the profile of the HS. Sam added a strip of glass and epoxy to both elevator tips at the tip/elevator interface. Added some epoxy and fairing filler to the aft surface of the HS tips to sand down and contour with the elevator tips

  Dec 14, 2022     HS and elevator tips - (4 hours)       Category: Tail Feathers

Sam attached aluminum backer strips to right HS and elevator tips. Trimmed the left HS tip of excess fiberglass and epoxy. Also removed the foam insert in the left HS tip and added additional layers of fiberglass and epoxy to support the outer layer of glass. Laid up and epoxied a layer of glass on the left elevator transition betweeen the tip and aluminum edge. Used a strip of plastic to apply the epoxy soaked glass to the tip/elevator transition and to the left elevator tip.

  Dec 13, 2022     More tip work - (2 hours)       Category: Tail Feathers

Sam used pneumatic pull riveter to install the left elevator tip. Plan to glass and epoxy over the joint. Began foam insert technique per the plans on the left HS tip to fill in the aft portion. One layer of glass coated with epoxy on a contoured foam insert.

  Dec 12, 2022     More tips - (5 hours)       Category: Tail Feathers

Sam continued to finish up the left HS and elevator tips by epoxying in aluminum bracket to both tips to support the factory end of the blind rivets. Edge distance is an issue that can't really be resolved, so we'll epoxy the elevator tips in as well. I started trimming the right HS and elevator tips. Match drilled the elevator tip to the elevator and deburred. Laid out the 4 upper and lower rivet lines for the HS stab tip, match drilled and deburred. Installed both right elevator and HS tips and trimmed for 1/8” spacing.

  Dec 11, 2022     Elevator tip - (2 hours)       Category: Tail Feathers

Sanded the left HS tip to provide clearance between the HS tip and elevator tip. Match drilled the elevator tip to the elevator.

  Dec 09, 2022     Empennage tips - (3 hours)       Category: Tail Feathers

Sam finished riveting the upper tip on the rudder. Will apply some glass and epoxy to smooth out the edges. Also finished safety wiring the brakes. Began trimming the HS and elevator tips for installation. Laid out the rivets for the HS tip, drilled deburred and match drilled to the tip. Need to trim the HS tip for 1/8” gap with the elevator tip then glass in the the end.

  Dec 06, 2022     Rudder upppr tip - (2 hours)       Category: Tail Feathers

Sam helped me out while he was home and countersunk the upper rudder tip and match drilled it to a thin aluminum backer strip. Will epoxy and pull rivet the tip in later to fill in with fiberglass and epoxy. It's great to have his help on the project.