Project: WoodysSportsman   -  
            Listing for Category : systems
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Builder Name:John Wood   -  
Project:   Glasair - Sportsman 2+2
Total Hours:873.4
Total Flight Time:
Total Expense:N/A
Start/Last Date:Nov 04, 2017 - No Finish Date
Engine:Lycoming IO390 C3B6
Propeller:Hartzell 80” Trailblazer
Panel:Garmin G3X dual display/GTN650Xi/G5/GNC215
 
Friendly URL: https://eaabuilderslog.org?s=WoodysSportsman

Home or Last Project Picture

Nov 22, 2023     Assemble front gear assy - (1 hour)       Category: Systems
Press pins into fork
Install wear pad onto fork
Assemble fork onto leg

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Nov 21, 2023     Installed bushing in gear fork - (0.3 hour)       Category: Systems

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Oct 21, 2023     Complete install of the valve and lines - (2.5 hours)       Category: Systems

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Oct 20, 2023     Fabricate new left, it was a little short when secured - (1 hour) Category: Systems
 
Oct 17, 2023     Fabricate Left Forward Fuel Line - (2 hours)       Category: Systems
A bit easier than the right from a bending standpoint but figuring out the exit angle from the valve took some time

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Oct 14, 2023     Fabricate Right Fwd Fuel Line - (3 hours)       Category: Systems
Fabricated the right forward fuselage fuel line, lots of fitting and templating to get it right

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Oct 08, 2023     Started building nose gear - (2.5 hours) Category: Systems
Installed bushing in the cage and main leg, basic assembly of the shock bushings
Found the bushings were not pressed into the nose fork. These are factory installed so not in the pick sheet.
Glasair is fabricating a new set and sending them
 
Oct 03, 2023     Epoxy nose gear wear pad - (0.5 hour) Category: Systems
Epoxied the wear pad to the wear plate.
 
Sep 30, 2023     Drilled extended gears, freed fuselage from the caddy - (5 hours)       Category: Systems
Jigged extended gear, used 0 toe, will adjust with shims
Drilled extended gear, hard gear drilling is done!

Lowered the fuselage off the caddy, it served its use but very happy to have the fuselage on its mains

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Sep 29, 2023     Started assembling nose wheel - (2 hours)       Category: Systems
Started assembling nose wheel assembly
Packed nose gear bearings

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Sep 28, 2023     Pack main wheel bearings and install Wheels - (2.5 hours)       Category: Systems
Packed the main wheel bearings
Installed wheels
Drilled holes for cotter pins and installed
Installed brake calipers

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Sep 27, 2023     Installed gear legs and brake flanges - (3 hours)       Category: Systems
Final cleaning/debur and install of main gear legs
Up drilled and reamed brake flanges to 5/16
Debur all holes
Install caliper mounts to brake flanges and install flanges on gear legs

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Sep 26, 2023     Drilled left brake flange - (1 hour)       Category: Systems
Drilled the left brake flange to #10 sized hole

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Sep 25, 2023     Drilled right brake flange - (2 hours)       Category: Systems
Drilled the two mounting holes for the brake flange, on Sunday I created a template to mark the 90 degree lines for drilling and 7then degree rotation.

Started with #30, the up drilled to #10, waiting for bits to drill to 19/64, then ream to 5/16

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Sep 23, 2023     Drilled main gear leg fuselage attach - (2.5 hours)       Category: Systems
Drilled the attach bolts, right side went smooth, left was a bear but they are drilled and reamed to 5/16”

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Sep 21, 2023     Started jigging aft main gear legs - (1 hour)       Category: Systems
Got 8' aluminum angle, started jigging the aft main gear

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Sep 09, 2023     Started assembly of wheels and brakes - (1 hour) Category: Systems
Installed tubes and tires on wheels, discovered that the weldments for the brake calipers are missing.
 
Sep 03, 2023     Complete fitting gear legs - (1.5 hours) Category: Systems
Completed the fitting, all gear legs are in flush. Ready to set toe and drill
 
Sep 02, 2023     Fit main gear legs - (4 hours) Category: Systems
Starting fitting the gear legs, left side went in very well. Trouble fitting the rights
 
Jul 05, 2023     Start gear install - (4 hours)       Category: Systems
Raised the fuselage onto the table.
Drilled 4 holes to 1.5” for main gear legs.

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Jan 15, 2023     Complete Wiring Left Wing Wiring - (2 hours)       Category: Systems
Completed the wiring of the left wing
Replaced the connectors for the pitot tube and the aux pump

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Jan 14, 2023     Complete Left XFER Pump Wire - (1.5 hours)       Category: Systems
Completed updated fuel pump connector setup, rerouted pump power and ground.
Installed 2 PN Molex.

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Jan 06, 2023     Continue aileron trim installation - (1.5 hours)       Category: Systems
Terminated the new roll trim servo with connector and RTV to body of servo
Terminate the servo end of the aileron cable

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Jan 04, 2023     Continue Trim Wiring       Category: Systems
Came up with a better plan for mounting the connector for the trim,
Terminated the wing connector and RTV/tie in place

Also came up with a new way to terminate the fuel pump

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Jan 03, 2023     Start wiring the aileron trim - (2 hours) Category: Systems
Received the parts to do the trim wiring, did not like the way the connector was wired so will continue to tomorrow
 
Dec 29, 2022     Secure fasteners on right wing - (1 hour)       Category: Systems
Secured all fasteners in the right wing, extended bolts on the flap bell crank and aileron pulley

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Dec 27, 2022     Completed pitot plumbing, rivet pitot doubler - (5 hours)       Category: Systems
Completed installation of pitot supports, riveted the pitot stiffeners and installed hardware
Prepped and primed left outboard top skin
Riveted spar doubler end piece
Torque all hardware, inspect all cotton pins

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Dec 26, 2022     Continue priming, check all spar countersinks - (4 hours)       Category: Systems
Finished countersinking left and right wing spar countersinks, test fit all skins
Continue priming the stiffeners

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Dec 15, 2022     Complete mounting of regulator ( not riveted ) - (1.1 hours)       Category: Systems
Also continued with right wing wiring

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Dec 12, 2022     Add trim wires to main right wing harness - (1.2 hours)       Category: Systems

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Dec 11, 2022     Continue left/right wing laydown - (3 hours)       Category: Systems
Installed connectors on brackets, riveted the end piece for the hole with insufficient edge margin. Stood up the left wing and completed the RTV on the left main fuel wire

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Dec 10, 2022     Continue Left Wing Laydown - (5 hours)       Category: Systems
Continued with the left wing wiring and prep. Primed all brackets and route the vent lines per the plans, RTV the vent lines and outboard wiring through the spar.

Also prepped the bracket for the right wing, and crimped inboard end of the NAV antenna coax

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Dec 04, 2022     Continue the Left Harness Install - (4 hours) Category: Systems
Just about completed the left harness install, all wires routed, still need to secure the main tank fuel QTY, removed tanks and secured wires run outboard, terminated the aux tank lug
 
Dec 03, 2022     Wing Wire - Complete right base harness, start installing left harness - (6 hours)       Category: Systems
Got the materials from Stein Air, completed the based harness for the right wing, Started installing the left wing harness, fabricated bracket for CPC connector, connected aux pump with spade connector, started using spade connectors for the heater to connector hook up but switched this to a 4 CPC, much cleaner and easier to service, going to change the pitot connection to a CPC as well.

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Nov 27, 2022     Wire Wing, Fabricate left / right harness - (4.5 hours) Category: Systems
Started fabricating the main harness for the left and right wing, on left wired up all but the aux tank
On the right, still need to add the ground for nav light, ran out of materials
 
Nov 16, 2022     Completed riveting inspection doubler anchors - (1.3 hours) Category: Systems
 
 
Nov 12, 2022     Prep and prime inspection doublers - (3 hours) Category: Systems
 
 
 
Sep 18, 2022     Trial fit wings and clear cable interference - (4 hours) Category: Systems
Installed wings with Chris, Tom and Ryan. Cleared Aileron crossover interference by sanding burr on crossover guide
 
Sep 10, 2022     Start pitot tube installation - (2 hours)       Category: Systems
Start drilling doubler for pitot tube

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Sep 09, 2022     Complete right fuel plumbing - (3 hours)       Category: Systems
Completed routing the fuel system plumbing in the right wing

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May 07, 2022     Put wings back in jigs for upgrade - (2 hours)       Category: Systems
Removed the wings and put them back in the jigs, started removing rivets for the upgrade

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Apr 30, 2022     Complete prep for wing removal - (9 hours) Category: Systems
Completed drilling holes for cable guides and installed cable guards on aileron wing pulleys.

Setup outboard jig supports for wing finishing.
Removed control surfaces and disconnected wing flight controls. Ready to remove wings.
 
Apr 28, 2022     Prime new pulley guards - (1 hour) Category: Systems
Primed better fitting pulley guards for ailerons in wings
 
Apr 20, 2022     Paint remaining cable guards - (1 hour) Category: Systems
Painted the cable guards for the aileron pulley blocks
 
Apr 15, 2022     Completed flap and aileron cable routing - (10 hours)       Category: Systems
Routed and crimped all flap and aileron cables, secured all permanent nuts with cotter pins less those required to be disassembled, specifically overhead pulley groups.

Need to redo flap and aileron clevis at crimps to add washers.

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Apr 10, 2022     Fabricate fuel lines - (1.5 hours)       Category: Systems
Fabricate copilot side fuel feed line from T.

Swage pilot and copilot T and aft mid fittings

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Apr 09, 2022     Fabricate fuel lines in fuselage - (4 hours)       Category: Systems
Fabricated two header fuel lines, installed and swaged fittings for both. Installed T fittings

Fabricate pilot side fuel feed from T to mid fuselage

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Apr 08, 2022     Install cable guide, seal fuel drain holes - (1 hour) Category: Systems
Installed the center cable guide
Mixed up new resin and sealed foam for fuselage drain holes
 
 
Apr 04, 2022     Start fuselage fuel system plumbing - (.5 hour)       Category: Systems
Assembled drain Ts and adapters. Started fitting header tanks, holes didn't line up.

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Apr 03, 2022     Fabricate cable guards and flap primary cable routing - (1 hour) Category: Systems
Fabricated the cable guards for the aileron pulleys

Routed the primary flab cables, not yet terminated
 
Apr 02, 2022     Control Systems Rigging - (10 hours)       Category: Systems
Completed the rudder and elevator rigging, installed horizontal stabilizer and elevator. Crimped rudder and elevator cables.

Cut crossover holes at wing roots.

Routed final flap deployment and retract cables.
Routed and clamped aileron cables.

Trimmed firewall template.

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Apr 01, 2022     Route aileron primary cables - (1.3 hours)       Category: Systems
Route aileron primary cables securing all cotter pins.

Install flap handle tab, secured with cotter pin.

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Mar 30, 2022     Fabricate flap attach tab - (1.0 hour)       Category: Systems
Fabricate the flap handle control attach tab, photo shows painted tab

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Mar 29, 2022     Continue rudder and elevator rigging - (0.8 hour)       Category: Systems
Terminated the empennage wires, including heat shrink and cable ends, temporarily installed clamps, will adjust after empennage is locked down

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Mar 28, 2022     Trim wing cable guide ends - (0.2 hour) Category: Systems
Trimmed the inboard aileron and flap wing cable guide ends. Verified the 18” measurement on the aileron control rod
 
Mar 27, 2022     Install Flaps, Ailerons, and Rudder - (4 hours)       Category: Systems
Removed elevator bellcrank to install elevator stops. Reinstalled bellcrank. Installed rudder and routed elevator and rudder empennage cables forward.

Installed flaps and ailerons, trimmed fuselage for wing fold with flaps.

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Mar 25, 2022     Install rudder and elevator primary cables - (1.5 hours)       Category: Systems
Installed hardware and primary and forward elevator cables

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Mar 24, 2022     Start rigging rudder - (0.2 hour)       Category: Systems
Drilled out cable guides and installed rudder control springs

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Mar 19, 2022     Complete wing fold clearance and pin alignment - (4.5 hours) Category: Systems
Ground fuselage material away where it was interfering with the wing on the wing fold.

Using valve grinding compound adjusted the fit of the forward wing pins, the right was significantly worse than the left. Both are good now.
 
Feb 26, 2022     Install nutplates for wing fold braces - (2 hours) Category: Systems
Drill #10 holes and drilled and countersunk holes for rivets, rivet nutplates

Assisted by Ryan Powers
 
Sep 25, 2021     Mount the wings! - (6.5 hours)       Category: Systems
Mounted wings to the fuselage with the crew. Larry and Brian Gray, Ryan Powers, Dave Cardin, and Tom Chase

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Sep 18, 2021     Trim struts - (3 hours) Category: Systems
 
Jul 11, 2021     Install remaining fuselage pulleys - (0.7 hour)       Category: Systems
Completed installation of the center pulley block, less the cotter pins which will go in after cable installation
Completed installation of the aileron pulleys, need to set cable guards and install cotter pins

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Jul 10, 2021     Painted new parts for the center pulley block - (0.5 hour) Category: Systems
Painted the new parts
 
Jul 09, 2021     Drill hole for Bulkhead a pulley cluster - (0.7 hour) Category: Systems
Drilled new hole and completed assembly of the copilot side pulley block
 
Jul 08, 2021     Match drilled center pulley cluster guards, layup A pulley Block - (1.5 hours) Category: Systems
Match drilled the center pulley cluster guards to the center bar
Small layup to cover original hole for copilot side bulkhead A pulley block
Test bent double pulley guard, much better than Glasair parts
 
Jul 06, 2021     Install strut attach fitting bushings - (0.5 hour)       Category: Systems
Installed the strut attach bushings in all of the strut attach pieces. A total of 16 bushings 2 NAS08-075-16 bushings in each of the lower fittings. Two NAS08-075-18 on each of the upper wing attach fittings and two of the NA08-075-16 in each of the upper strut attach forks

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Jun 30, 2021     Installed rudder pedals and master cylinders - (2 hours)       Category: Systems
Installed the rudder pedals and master cylinders, washers installed to set spacing all cotter pins installed, needs to have lock nuts tightened after final pedal adjustment

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Jun 28, 2021     Touch up paint on bulkhead A pulley guides - (0.5 hour) Category: Systems
 
Jun 27, 2021     Finish opening bulkhead A cable guides - (0.5 hour) Category: Systems
Sanded to final opening size
 
Jun 26, 2021     Continue opening cable guides bulkhead A - (0.5 hour) Category: Systems
 
Jun 25, 2021     Open up bulkhead A cable guides - (0.5 hour)       Category: Systems
After assembling the cable guides, looks like some additional side to side spacing would be usefule

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Jun 03, 2021     Install autopilot tray, assemble rudder pedals with brackets - (0.7 hour)       Category: Systems
Installed the servo mounts to tray and install in fuselage
Assemble the rudder brackets on the rudder pedals

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Jun 01, 2021     Black top coats on rudder pedals and autopilot tray - (1 hour) Category: Systems
Sprayed the black topcoat on internal parts
 
 
May 30, 2021     Prime System and tail components - (4 hours)       Category: Systems
Initial primer application with new paint system, note that discovered the primer needs to incubate to have proper surface

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May 25, 2021     Compete sanding and filling of the rudder pedals - (1 hour) Category: Systems
Fillled unused holes for in the rudder pedals for painting
 
May 24, 2021     Prep rudder pedals - (1 hour) Category: Systems
Disassemble the rudder pedals for preparation
 
May 23, 2021     Prep work and assembly of pulley guards - (4.5 hours) Category: Systems
Completed assembly of the center pulley guards but found out these are not built properly per the latest drawings. Also tried to build the pulley guards for the aileron pulleys
 
May 21, 2021     Complete fabrication of bulkhead A pulley blocks, fairlead installation - (2 hours)       Category: Systems
Completed the fabrication of the second bulkhead A pulley block
Completed installing the fairleads

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May 20, 2021     Continue bulkhead A pulley block fabrication - (1.5 hours)       Category: Systems
Completed fabricating 1 of 2 of the bulkhead A pulley block bracket sets. Made a template for cutting to shape and then drilled the holes. Drilled bottom for corners for the cable slots, trimmed and filed brackets to shape.

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May 16, 2021     Re cut pulley group parts - (2.5 hours)       Category: Systems
Recut the necessary pulley guard parts and reassemble the pulley group

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May 15, 2021     Start assembling the center pulley group - (1.0 hour) Category: Systems
Started to assemble the center pulley group, fabricated the spacers and discovered that there was a revision to the parts that I had cut, need to remake several pieces
 
May 13, 2021     Cut out center pulley brackets - (4 hours)       Category: Systems
Cut out all of the center pulley guard brackets and cut the slit in the square stock

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May 12, 2021     Installed the lower aft flap pulleys and upper crossover pulleys - (1.0 hour)       Category: Systems
Installed the lower aft flap pulleys and upper crossover pulleys

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May 11, 2021     Drill corners for center pulley brackets - (0.5 hour) Category: Systems
Used the uni-bit to drill the inner corners of the center pulley brackets
 
May 10, 2021     Installed the aft center pulleys - (0.5 hour)       Category: Systems
Installed the center aft pulleys, both left and right installed cotter pins for cable guide

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May 09, 2021     Made templates and mark metal for fwd pulley assembly - (1 hour) Category: Systems
Made the templates for all the sheet metal parts for the forward pulley assembly
 
May 08, 2021     Complete installation of Control Yoke and Flap Handle - (1.5 hours)       Category: Systems
Complete assembly and installation of the control yoke
Fit sanded the dowel and completed flap handle assembly and installation

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May 07, 2021     Start fitting control yoke Assy and Flap Handle - (2 hours)       Category: Systems
Started fitting parts for the control yoke assembly.
Started assembly of the flap handle, I got 3/4” dowel for the spacer but this was a little small so did a fiberglass layup to make it the full 3/4

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May 05, 2021     Refit rudder pedal weldments, fab brake linkage - (2.5 hours)       Category: Systems
Refit the pedal weldments to get a better angle. Use large washers to make sure pedals don't move with elongated holes.

Fabricated the last 3 brake pedal linkage pieces to be installed on the cast rudder pedals.

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May 03, 2021     Install master cylinders and rudder pedals, start Assy of control yoke - (1.3 hours)       Category: Systems
Installed the master cylinders, fitted cast brake pedals, need to cut the aluminum tabs

Started assembling the control yoke connecting rod

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Apr 30, 2021     Install Rudder Pedal Brake Weldments - (2.5 hours) Category: Systems
Fit the brake pedal steel weldments, positioned and drilled.
 


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