Project: Sportsman   -  
            Listing for Category : fuselage (viii)
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Builder Name:Kyle Stone   -  
Project:   Glasair - Sportsman 2+2   -   VIEW REPORTS
Total Hours:1859.9
Start/Last Date:Jul 03, 2019 - Jun 30, 2022
Engine:Lycoming IO-390-EXP
Panel:Garmin G3X w/ GNX375 IFR nav, GNC 255 NAV/COM
 
Friendly URL: https://eaabuilderslog.org?s=Sportsman

Home or Last Project Picture

Aug 07, 2021     Step #25 - Install Control sticks - (2 hours)       Category: Fuselage (VIII)
Finished installing and wiring both control sticks. Check operations and both seem to be working correctly.

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Aug 07, 2021     Step #25 - Install Control sticks - (1 hour)       Category: Fuselage (VIII)
Finished installing RH control stick....now I need to finish wiring these!

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Jul 28, 2021     Install Vents - (4 hours)       Category: Fuselage (VIII)
Painted vents and side of fuselage today. All went well except I got a little carried away with the "spackle" spray and put it on too heavy and it sagged....a lot. So....had to let it dry, sand off, and spray again the next day. Lesson learned...don't over spray the texture product!

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Aug 06, 2021     Step #25 - Install Control sticks - (3 hours)       Category: Fuselage (VIII)
Started the install of control sticks. Drilling went well and measurements seem correct. I borrowed 917X control stick jig (2x4 w/ two holes), which was helpful.

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Aug 04, 2021     Step #8 - Fit the seat pans through Step #25 install seat tracks - (7 hours)       Category: Fuselage (VIII)
Started work on trimming and fitting the seat pans. LIke building the wings, this is a process of "parts on, parts off". Trimming went well and everything fit nicely. Eventually, I'll install a plexiglass bottom in the seat pan so I can see all the controls easily.

It was fun to actually sit in the seats and get a feel for the visibility.

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Jul 30, 2021     Install engine control cables - (6 hours)       Category: Fuselage (VIII)
Fabricated insert and installed Throttle, Mixture, and Prop engine control cables. Used the nut tool from GAOA and it worked great! Had some minor issues with the fit but with the help of Coby and members of the GAOA the problem was quickly solved.

Had to reposition all of the control arms (Throttle, Mixture, and Governor). Not a huge deal but I did not realize this on the Prop Governor until AFTER I had safety wired all the screws from mounting the bracket.....good practice for safety wire tying.

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Jul 25, 2021     Install Vents - (3 hours)       Category: Fuselage (VIII)
Sanded Q-cell today and pretty happy with the flaring of edges. The NACA intakes look nice. Now I have to mask everything and paint the inside. It may not look pretty in these pictures but its smooooth!

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Jul 17, 2021     Install Vents - (4 hours)       Category: Fuselage (VIII)
First time with working with the Resin and took some time to learn the process. It was a pretty warm day (90 degree's) so the pot life was really short (10 minutes). I did one at a time and followed the directions in the Assy. manual and all worked out pretty well. I SURE wish I would have installed these prior to the Firewall being installed...but it all worked out okay. The speckly paint worked out well too. I'll let them cure a while then return to finish the body work around the edges.

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Aug 04, 2020     Step #48- Fab and install control cable pulley guides. - (2.5 hours)       Category: Fuselage (VIII)
Took a little break from building to go play in the backcountry. Back at it this week but with school getting ready to start and my commercial check ride in a week, the progress will slow somewhat until the week of August 17th. I finished up installing the control cable pulley guards. I made a little fixture and the measurements came out nearly perfect according to the SB 63.

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Jul 27, 2020     Removed flaps, ailerons, and wings from fuselage - (3 hours)       Category: Fuselage (VIII)
Took off all of the flaps, ailerons, and then the wings. Bought a nice label maker so I could label all the cables for when I reinstall them. Its nice to have this step behind me. I was pretty nervous about setting the dihedral correctly and crimping all the cables. I'm happy with how everything turned out. Now I can set the workshop back up make the garage a little more useful and less crowded.

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Jul 26, 2020     Step #48- Fab and install control cable pulley guides. - (1.5 hours) Category: Fuselage (VIII)
There must be a better way to install these and maintain the tight tolerances per SB. .04 and .05 is pretty darn tight! I'm going to wait to install these when I have the wings off the fuselage. I made all the brackets but it will be easier to measure when there is no tension on the cables.
 
Jul 26, 2020     Step #47 - Install Cotter Pin cable retainers - (1 hour) Category: Fuselage (VIII)
Seems like this would be an easy task but a few of them needed their heads smashed or they were rubbing the aileron cable.
 
Jul 26, 2020     Step #46 - Secure Aileron cable guides - (.5 hour) Category: Fuselage (VIII)
Done..used #8 screws where I could not fit blind rivets
 
Jul 26, 2020     Step #45 - Make Aileron Travel Stop and set deflections - (3 hours)       Category: Fuselage (VIII)
Re-checked all angles and made a few more tweaks. Crimped all NicroPress fittings and finished cutting and shrink wrapping cables

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Jul 25, 2020     Step #44 - Route Aileron Control Cables - (2 hours) Category: Fuselage (VIII)
I opted NOT to pre-cut all these cables as per one of the many SB's. I've been burned before on cut lengths (struts) and I want to actually measure everything. Its not that difficult to fit up and make them the proper length....of course..that's all before I attempt to tension them when I probably realize they are too long and I can't tighten them enough! I pulled them pretty taught prior to crimping.
 
Jul 24, 2020     Step #43 - Fabricate aileron cable guides - (.8 hour) Category: Fuselage (VIII)
Done...new band saw blade works much better
 
Jul 23, 2020     Step #42 - Complete the Flap Cables - (2.5 hours) Category: Fuselage (VIII)
Flaps work!
 
Jul 22, 2020     Step #41 - Route Flap Retraction cable - (1 hour) Category: Fuselage (VIII)
 
Jul 22, 2020     Step #40 - Route Flap deployment cable - (1 hour) Category: Fuselage (VIII)
 
Jul 22, 2020     Step #37 - Mount Aileron to Aileron hinges - (1 hour)       Category: Fuselage (VIII)
This is tedious work...I know I'll be taking it all off again but I want to make sure everything fits well.

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Jul 22, 2020     Step #36 - Install Flap pushrod - (.5 hour) Category: Fuselage (VIII)
Went as expected
 
Jul 21, 2020     Step #35 - Mount Flap to flap tracks - (.5 hour) Category: Fuselage (VIII)
Went as expected...need to order washer holding tool
 
Jul 21, 2020     Step #34 Bolt the wing strut to the wing - (3 hours) Category: Fuselage (VIII)
Once I was done with mounting the struts on the wings I noticed that my LH strut was about 5/8” longer than my RH strut. I went back through ALL the measurements to verify that I did not make a mistake. I sent an email to the engineers at GA to confirm my suspicion that the cage is not square thus causing the tolerance stack-up to result in the struts being different....they concurred that none of the frames will be perfectly square and the tolerance stack is normal. This is why you measure the dihedral from the waterline of the plane, not measurements from the frame itself. I was relieved to be over the hum of drilling the wing struts!
 
Jul 21, 2020     Step #34 Bolt the wing strut to the wing - (3 hours)       Category: Fuselage (VIII)
Once I was done with mounting the struts on the wings I noticed that my LH strut was about 5/8” longer than my RH strut. I went back through ALL the measurements to verify that I did not make a mistake. I sent an email to the engineers at GA to confirm my suspicion that the cage is not square thus causing the tolerance stack-up to result in the struts being different....they concurred that none of the frames will be perfectly square and the tolerance stack is normal. This is why you measure the dihedral from the waterline of the plane, not measurements from the frame itself. I was relieved to be over the hum of drilling the wing struts!

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Jul 20, 2020     Step #39 - Fab inboard cable guide - (.3 hour) Category: Fuselage (VIII)
Done..installed with #8 screws and stop nut
 
Jul 20, 2020     Step #38 - Install Aileron Pushrod - (.70 hour) Category: Fuselage (VIII)
Went as expected
 
Jul 20, 2020     Step #29 - 33 - Drill and cut the wing struts - (3.5 hours)       Category: Fuselage (VIII)
Used new style ‘Sportsman' jig for this one. While I think there is less room for error the set-up and measuring was not that difficult with the older style jig.

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Jul 20, 2020     Step #28 - Mount wings to fuselage - (1 hour)       Category: Fuselage (VIII)
Enlisted the help of another set of hands. My wife and I hung the RH wing but having a third person made it much safer.

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Jul 18, 2020     Step #39 - Fab inboard cable guide - (1 hour)       Category: Fuselage (VIII)
None of my normal cutting tools would cut the plastic material. I had to make a trip to HF and buy a small air grinder and bits. Spent around $20 for tool and bits and it made quick work of the cutting. I have a feeling this tool will become useful when working on the fiberglass.

I'm going to install #8 screws w/ lock nuts as its impossible to rivet these. There is no load on these at all. Double sided tape would probably work too!

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Jul 16, 2020     Step #38 - Install Aileron Pushrod - (.8 hour)       Category: Fuselage (VIII)
Went as planned. Pretty cool to see everything line up. The flaps and ailerons are coming back off once the cables are set so I'm not installing the cotter pins at this time. I am torque and setting all the pushrod components as I'm assuming these are staying on.

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Jul 16, 2020     Step #37 - Mount Aileron to Aileron hinges - (.7 hour) Category: Fuselage (VIII)
Went as planned. One of my holes was just a little off center which cause some difficult in mounting. Nothing major but the bolt did not slide right in and its tight quarters.
 
Jul 16, 2020     Step #36 - Install Flap pushrod - (.5 hour) Category: Fuselage (VIII)
No issues here.
 
Jul 16, 2020     Step #35 - Mount Flap to flap tracks - (.5 hour) Category: Fuselage (VIII)
Went as planned. This is where all of your holes that you drilled when fabricating many of these brackets on the wings and flaps need to line up. Mine did...so far!
 
Jul 15, 2020     Delay- wrong drill jig sent from Glasair - (1 hour) Category: Fuselage (VIII)
So....I sent an email to Glasair on Monday (July 13th) with a few clarification questions: Verify 2 degree dihedral and the correct jig P/N. I did not hear back from anyone so I moved ahead...I should have asked earlier or waited. There is another drill jig that will accomplish the same thing but apparently is easier to use and more accurate. I thought the one I used was pretty easy but they are shipping me the other one and will be here on Monday (July 20th) so I have decided to wait on mounting the LH wing and drilling the strut. I paused for a day and then started the next steps for the Flaps and Ailerons. I don't like delays!!!
 
Jul 14, 2020     Step #29 - 34 - Drill and cut the wing struts - (3 hours)       Category: Fuselage (VIII)
This was pretty tedious work. Measure three times and cut once! I measured 5 times...and cut once. I used a combination of the assembly manual and the TWTT wing strut drill fixture instructions. I like cutting the strut down PRIOR to installing and drilling. I cut the lengths in accordance with the TWTT instructions. Drilled the wing strut holes in accordance with the instructions and was able to maintain 2.0 dihedral. After it was all done and bolts installed I checked the dihedral with the weight 100% supported by the wing strut and realized the fuselage was tipping...which caused the dihedral to be off! With only one wing on its difficult to keep the fuselage level. I made a temporary support....re-leveled the fuselage and everything looks good. Once I mount the LH wing the plane should stay level. I'll mount the LH wing tomorrow!

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Jul 13, 2020     Step #29 - Set the Dihedral angle of the wings - (3 hours)       Category: Fuselage (VIII)
Was no happy with my original set for supporting the fuselage from the bottom and it was not very stable. I was concerned that the weight of the wings would tip the plane over! Can't have that at this point. I scratched my head for about a day and posted on the GAOA forum and received some great ideas. I took a few of them and merged them into my own and created stubby legs from the TD sockets. I feel MUCH better about the stability of the plane now and am ready to move forward with drilling the wing struts.

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Jul 11, 2020     Step #28 - Mount wings to fuselage - (2 hours)       Category: Fuselage (VIII)
Took it nice and slow on this step. I have reworked the support for the fuselage numerous times and I'm still not 100% happy with the support. I can't find pipe that will work in the main landing gear openings. I think what I have will work for not. I just need to be careful to check the level on a regular basis. Lori was a huge help lifting and holding the wing while I worked on installing the attach pins and bolt. The wing pretty much slid right in! Had to tap the pin a few times but it went in fine.

Now I need to wait for the wing strut drill jug to arrive...hopefully Monday or Tuesday.

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Jul 11, 2020     Step #27 - Trim openings in wing root area - (.5 hour) Category: Fuselage (VIII)
Used Dremel..had to make a few new passes when setting the wing
 
Jun 20, 2020     Steps #49 - 94 - (5 hours)       Category: Fuselage (VIII)
Completed audit of each step and finished a few steps that needed completed. Audit did not reveal any issues and I was able to better understand the assembly thus far. The SB-74A was completed by the previous builder and the tailcone is reinforced for TW install.

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Jun 20, 2020     Steps #47 - 48 - Factory QB - (.5 hour) Category: Fuselage (VIII)
Verified installation is correct
 
Jun 20, 2020     Steps #39 - 46 - mounting rudder assembly - (1 hour)       Category: Fuselage (VIII)
Verified installation is correct

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Jun 20, 2020     Step #74 - 82 - Various steps install shearweb & HS FWD attach bracket - (.5 hour)       Category: Fuselage (VIII)
Verified all steps completed correctly and installed HS FWD Attach bracket

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Jun 19, 2020     Step #38 - install bulkheads completed by factory Category: Fuselage (VIII)
Verified correct installation
 
Jun 19, 2020     Step #37 - Align and cleco Vertical fin half - (.5 hour)       Category: Fuselage (VIII)
Verified work completed correctly. Used Plumb line to check vertical fin alignment and it's near perfect!

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Jun 19, 2020     Step #36 - completed by factory Category: Fuselage (VIII)
bulkheads already installed. Inspected for proper installation and not signs of cracks or issues.
 
Jun 19, 2020     Step #35 - Level fuselage longitudinaly Category: Fuselage (VIII)
Verified correct via waterline marks
 
Jun 19, 2020     Step #32 - 34 - Various steps completed by factory Category: Fuselage (VIII)
Verified correct as per assy. Manual and QB instructions.
 
Jun 19, 2020     Step #31 - cut-out vertical fin rib Category: Fuselage (VIII)
Verified complete - the rudder has been installed therefore, the vertical fin rib was already installed.
 
Jun 19, 2020     Step #30 - Mark the fuselage Waterline - (.5 hour) Category: Fuselage (VIII)
I found the marking on the fuselage on the LH side of the Fuselage (fwd & aft). But did not see any fwd markings on the RH side. I'll need to investigate this a little closer to verify that its correct. I will check with Jory to see how he set the waterline.
 
Jun 19, 2020     Step #29 - Install FWD shell attach fittings - (.2 hour) Category: Fuselage (VIII)
Verified correct installation and checked for proper torque
 
 
Jun 19, 2020     Step #27 - Position and drill AFT shell attach fittings - (.5 hour) Category: Fuselage (VIII)
Verified step completed correctly. There is one nut that cannot be tightened due to the support wood that is supporting the fuselage. This needs to be fixed when the fuselage is put on the gear.
 
Jun 19, 2020     Step #26 - Position and drill the LWR shell attach fittings Category: Fuselage (VIII)
Verified work completed correctly and checked torque of screws / nuts
 
Jun 19, 2020     Step #25 - Position and drill the upper shell attach fittings - (.5 hour) Category: Fuselage (VIII)
Verified installation was correct. Also verified that I have the 'new��yle doors that do not require the bushing as noted in this step. It was not installed and noted within the build manual but I also confirmed this to be true.
 
Jun 19, 2020     Steps 13 - 24 - Various steps completed at factory Category: Fuselage (VIII)
Reviewed Assy. Manual and verified work completed correctly.

Tightened all cage attach screws and installed one lock nut that was missing.

I am so glad I did not have to buy a slow build kit and do all of this work myself.
 
Jun 19, 2020     Step #12 - install wing pivots - (.5 hour)       Category: Fuselage (VIII)
Yeah! My first parts installed on the fuselage. Went as planned. Greased and set castle nut propoerly.

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Jun 19, 2020     Step #11 - Press bushings into wing pivot joints Category: Fuselage (VIII)
Reviewed Assy. Manual and verified work completed correctly.
 
Jun 19, 2020     Step 7 - 10 - Various attach fitting fabrications Category: Fuselage (VIII)
Reviewed Assy. Manual and verified work completed correctly.
 
Jun 19, 2020     Step #6 - Cut angle stock for shell attach fittings Category: Fuselage (VIII)
Reviewed Assy. Manual and verified work completed correctly.
 
Jun 19, 2020     Step #5 - Prep & Prime steel parts Category: Fuselage (VIII)
Reviewed Assy. Manual and verified work completed correctly.
 
Jun 19, 2020     Steps 1 - 4 - Prebuild completed at factory Category: Fuselage (VIII)
Reviewed Assy. Manual and verified work completed correctly.
 
Jun 19, 2020     Cage Serial Number Category: Fuselage (VIII)
Cage Serial Number = 80121
 
Jun 18, 2020     Reviewed Assy. Manual for section VIII - (2 hours) Category: Fuselage (VIII)
As much as I want to start working on Systems (Section IX) I need to audit everything the factory has done, Service bulletins, and what the previous owner has completed. This will be time well spent. I also built a small sawhorse for the tail and worked on a raising the front of the fuselage up and keeping the roller dollies secure.
 
Jun 17, 2020     Moved Fuselage to Workshop - (3 hours)       Category: Fuselage (VIII)
Rearranged workshop to make room for Fuselage. Organized parts

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