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Project: stehee -
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Antenna - (1)
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Elevator - (49)
Flaps - (102)
Firewall - (57)
Fuel System - (28)
Fuselage - (157)
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Builder Name:	Stephen Tehee -

Project:	Glasair - Glasair II - VIEW REPORTS
Total Hours:	1274
Start/Last Date:	Apr 24, 1997 - No Finish Date

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

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Aug 06, 2019 Fuel Tank - (0.25 hour)

Category: Fuel System

I installed the Fuel Bay Access Cover Plate (part number 552-0421-002) and it's gasket, using eight AN73A3 bolts and eight AN960-D10 washers. I will safety wire the bolts at a later date.

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Jul 15, 2019 Nose Gear Trunnion Attach Plates - (1.0 hour)

Category: Landing Gear

I removed the shipping tape from the nose gear trunnion attach plates and removed excess milled fiber that had oozed out from under the plates. I installed the attach plates again using AN-4-15A bolts, AN960-D10 washers, AN970-3 washers, and AN364-1032A nuts. I had to relieve the adjoining edges of the six most forward AN970-4 large washers per Service Bulletin 146.

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Jul 14, 2019 Nose Gear Trunnion Attach Plates - (1.0 hour) Category: Landing Gear

I used shipping tape as a release agent and applied a thin layer of milled fiber to the attach plates. I then temporarily bolted the attach plates to the support rib.

Jul 11, 2019 Nose Gear Trunnion Attach Plates - (1.0 hour)

Category: Landing Gear

I drilled thru the nose gear trunnion attach plates and the support rib. I then put temporary bolts thru all twelve holes.

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Jul 03, 2019 Nose Gear Strut Assembly - (1.5 hours)

Category: Landing Gear

I adjusted the height of the nose gear so that the top of the stop plate on the strut was 23.9” below the attach plate reference line. This resulted in a 45.1 degree angle for the nose gear.

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Jul 01, 2019 Fuselage - (0.5 hour)

Category: Fuselage

I used a six foot level to check for lateral levelness of the fuselage.

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Jun 29, 2019 Nose Gear Strut Assembly - (1.5 hours)

Category: Gear

I fastened the shock truss assemblies to the engine mount. Next, I made sure that the fuselage was level in the lateral and longitudinal directions.

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Jun 21, 2019 Nose Gear Strut Assembly - (.75 hour) Category: Gear

I assembled the nose gear strut assembly to the nose gear trunnion attach plates and pressed in the bushings.

Jun 20, 2019 Engine Mount - (.75 hour)

Category: Engine Mount

I clamped the nose gear trunnion attach plates into place. I checked the fuselage longitudinally and laterally again for level. Next, I bolted the engine mount to the firewall.

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Jun 10, 2019 Fuselage - (.75 hour) Category: Fuselage

I leveled the fuselage both laterally and longitudinally using the waterline 100 reference marks.

Jun 08, 2019 Nose Gear - (3.0 hours)

Category: Gear

I enlarged the above 2-1/2” washers to 1/2” diameter centers. I mounted the rubber shock absorbers, shock truss assembly, and shims to the nose gear strut. I temporary used only four of the 2-1/2” washers. I will use the remaining washers if necessary.

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Jun 07, 2019 Nose Gear - (7.0 hours)

Category: Gear

I made twelve 2-1/2” washers, with 1/4” center holes, for the nose gear. I used a small sheet of 2024T3 aluminum.

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May 29, 2018 Fuel Tank - (0.5 hour)

Category: Fuel System

I installed the main fuel tank cover plate. I will not be using the fuel stand plate.

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Aug 06, 2006 Flaps - (1.5 hours)

Category: Flaps

I made a new aluminum plate, with nutplates, to replace the left slotted flap hardware I had removed yesterday.

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Aug 05, 2006 Flaps - (1.0 hour)

Category: Flaps

While working with the left slotted flap hardware, I noticed threads on one of the nutplates had become stripped. I could not think of a way to fix this problem so I decided to replace the whole thing. I cut a 2 inch hole in the top skin of the wing. This would allow me access to the area.

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Jul 29, 2006 Flaps - (1.0 hour)

Category: Flaps

I scarfed the upper trailing edge of the wing in the flap area, as shown in FIGURE (J-1, page 51 of 63 in the slotted flap installation manual).

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Jul 09, 2006 Flaps - (1.5 hours) Category: Flaps

I applied six 3” x 4-1/2” bidirectional fiberglass laminates on the outboard side of the copilot's outboard slotted flap wing attach plate. (See step G-5).

Jul 02, 2006 Flaps - (.75 hour) Category: Flaps

I applied six 3” x 4-1/2" bidirectional fiberglass laminates on the inboard side of the copilot's outboard slotted flap wing attach plate. (See step G-5).

Jun 28, 2006 Flaps - (1.0 hour) Category: Flaps

I applied six 3” x 4 ��directional fiberglass laminates on the outboard side of the pilot's outboard slotted flap wing attach plate. (See step G-5).

Jun 26, 2006 Flaps - (1.0 hour) Category: Flaps

I applied six 3” x 4 -1/2” bidirectional fiberglass laminates on the inboard side of the pilot's outboard slotted flap wing attach plate. (See step G-5).

Jun 22, 2006 Flaps - (1.5 hours) Category: Flaps

I applied six 3” x 4-1/2” bidirectional fiberglass laminates on each side of the copilot's inboard slotted flap wing attach plate. (See step G-5).

Jun 18, 2006 Flaps - (1.0 hour)

Category: Flaps

I applied six 3” x 4-1/2” bidirectional fiberglass laminates on each side of the pilot's inboard slotted flap wing attach plate. (See step G-5).

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Oct 24, 2005 Flaps - (3.0 hours) Category: Flaps

I clecoed the pilot's slotted flap aft outboard nutplate into place. I drilled three #40 holes and one 3/16” hole through the nutplate back plate and outboard fiberglass aft rib. I removed the nutplate back plate and drilled two #40 holes. I squeezed two rivets for nutplate to back plate. I clamped the assembly to the rib and squeezed on three rivets for back plate to aft outboard rib.

Oct 23, 2005 Flaps - (0.5 hour)

Category: Flaps

I drilled two 3/16” holes in the above nutplate back plate. I also sanded a 1-1/2” area on the pilot's upper wing trailing edge (See Step J-1). I applied milled fiber to the pilot's slotted flap outboard rib (aft), parallel to the aluminum aft rib.

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Oct 22, 2005 Flaps - (0.5 hour) Category: Flaps

I milled fibered in the co-pilot's outboard slotted flap rib (forward side) nutplate back plate.

Oct 18, 2005 Flaps - (1.5 hours) Category: Flaps

I fine-tuned the nutplate back plate to final shape and fit. I countersunk three rivet holes in the rib, riveted the nutplate back plate, and then riveted the nutplate back plate to the co-pilot's outboard slotted flap rib.

Oct 17, 2005 Flaps - (1.5 hours) Category: Flaps

I drilled three 3/16” holes for the outboard rib and hardware for the pivot plates. I mixed milled fiber and used aluminum foil as a release agent. Lastly, I used modeling clay to form a dam for the milled fiber.

Oct 15, 2005 Flaps - (1.0 hour) Category: Flaps

I roughed out two nut plate back plates for the outboard ribs of the slotted flaps.

Oct 08, 2005 Flaps - (0.75 hour) Category: Flaps

I sanded the shearweb cap, leading edge, trailing edge, joggle, and ends of both slotted flaps. I drilled 1/4” drain holes through the flap shear webs, per paragraph #1. I drilled #20 holes, per paragraph #2 and also drilled through the shearweb, one hole on each side of center. Lastly, I patched two small holes behind the shearweb.

Oct 02, 2005 Flaps - (0.5 hour) Category: Flaps

I applied two layers of 45 degree bias fiberglass to the forward side of each shearweb.

Oct 01, 2005 Flaps - (0.5 hour) Category: Flaps

I applied a q-cell radius to the forward side of the shearweb and the underside of the spar cap of both slotted flaps.

Sep 28, 2005 Flaps - (1.0 hour) Category: Flaps

I trimmed and sanded excess fiberglass cloth from the above two laminates.

Sep 27, 2005 Flaps - (2.0 hours) Category: Flaps

I applied a second layer of 45 degree bias fiberglass to the shearweb aft side of both flaps.

Sep 26, 2005 Flaps - (1.5 hours)

Category: Flaps

I applied a single layer of 45 degree bias fiberglass to the shearweb aft side of both flaps.

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Sep 25, 2005 Flaps - (1.0 hour)

Category: Flaps

I applied a mill fiber mixture to the double wedge trough in the left flap spar shearweb. I then lowered the upper flap panel into place.

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Sep 24, 2005 Flaps - (1.0 hour)

Category: Flaps

I applied a mill fiber mixture to the double wedge trough in the right flap spar shearweb. I then lowered the upper flap panel into place.

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Sep 23, 2005 Flaps - (1.0 hour) Category: Flaps

I applied flour to the top of the left flap shearweb and set the top flap panel into place. I could tell that there were no “low spots” on the shear web using this method.

Sep 22, 2005 Flaps - (5.0 hours)

Category: Flaps

I applied flour to the top of the right flap shearweb and set the top flap panel into place. I could tell that there were no “low spots” on the shear web using this method.

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Sep 19, 2005 Flaps - (3.0 hours) Category: Flaps

I used the Dremel and a small bit to route out a channel in the resin/milled fiber mixture. I cleaned up all excess milled fiber that had flowed onto the shearweb.

Sep 18, 2005 Flaps - (0.75 hour) Category: Flaps

I used a small Dremel bit to “hog out” the shearweb foam (right flap) and removed all foam and Q-cell/resin residue. Next, I mixed up 100 grams of resin/milled fiber and applied it to the shearweb. While setting the panel into place, I noticed that the milled fiber was curing faster than planned. Later, I discovered that the milled fiber did not bond to the 2-layer cap. Thankfully, I was able to remove the two layer cap.

Sep 14, 2005 Flaps - (1.5 hours) Category: Flaps

I made a back plate for the copilot's slotted flap actuator rib and attached MF1000-3 nutplates to it. I also installed pull rivets.

Sep 13, 2005 Flaps - (1.0 hour)

Category: Flaps

I drilled two 3/16” holes through the copilot's slotted flap pivot plate assembly and the pivot late back plate. I fabricated the actuator rib from a pre-cured two layer laminate. I riveted two nut plates to the pivot plate back plate. Lastly, I applied four layers of fiberglass cloth to the actuator rib.

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Sep 11, 2005 Flaps - (2.5 hours)

Category: Flaps

I squeezed two rivets to hold the nutplate onto the pilot's slotted flap actuator rib. Next, I drilled a 3/16” hole in the pivot plate assembly per paragraph 3 on page 45. Then, I removed 3/4” from the leading edge of the flap so that p/n NAS75-3-005 would fit with no interference.

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Sep 05, 2005 Flaps - (1.0 hour) Category: Flaps

I made an aluminum back plate, slightly larger than needed, for the pilot's side flap actuator rib.

Aug 29, 2005 Flaps - (5.0 hours)

Category: Flaps

I fabricated the pilot side slotted flap inboard rib back plate for the nutplates that go forward of the shearweb. Next, I made a two layer procured laminate rib parallel to the pilot's inboard flap rib. It is 3/4" out from the other rib. I temporarily glued it into place with hot glue. Then I applied five layers of bi-directional cloth to the rib.

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Jul 18, 2005 Flaps - (0.5 hour)

Category: Flaps

I fabricated the pilot side slotted flap inboard rib back plate for the nutplate that goes aft of the shearweb. I also fabricated another back plate for the copilot's side.

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Jun 30, 2005 Flaps - (0.75 hour)

Category: Flaps

I removed the foam dams and cleaned up the general area. Next, I drilled two 3/16” holes in the left nutplate back plate. I also drilled four #40 holes for the rivets that hold the nutplates in place.

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Jun 25, 2005 Flaps - (1.0 hour)

Category: Flaps

I drilled #30 holes through the inboard and outboard pivot plate assemblies. I installed clecos in each hole. I drilled three #30 holes through the flap panel to hold the right center slotted flap nut plate back plate located aft of the shearweb. I riveted 3 flush AN426AD-9 rivets. I fabricated two nutplate back plates forward of the shearweb. I used a milled fiber and resin mixture to level the plates.

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Jun 19, 2005 Flaps - (3.5 hours)

Category: Flaps

I drilled, countersunk, and riveted the back plate assemblies to the lower flap skin on both flaps.

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Jun 18, 2005 Flaps - (2.5 hours)

Category: Flaps

I made new aluminum back plates for use behind the center rib. I also constructed “foam dams”, behind each center rib, that will hold a milled fiber and resin mixture. This mixture will become a level pad for the nutplate back plates. After the mixture had cured, I installed nutplates on the back plates behind the flap spar center position on both wings.

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Jun 12, 2005 Flaps - (1.0 hour)

Category: Flaps

I trimmed the shearweb and center rib laminates.

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Jun 11, 2005 Flaps - (2.0 hours)

Category: Flaps

I was not satisfied with the placement of the slotted flap shearweb on the pilot's side. Close examination revealed that the aft two 3/16” holes for the center aluminum angles underneath the slotted flap were conflicting with the shearweb. I decided to move the shearweb about 1/2” aft. I removed 8” of the shearweb, centered on the center rib, with a Dremel tool. I prepared the area by sanding with 80-grit sand paper and then cleaned it with acetone. Next, I cut new 1/4" foam to length and q-celled both sides. After the q-cell had cured, I positioned the replacement 8” shearweb and q-celled it into position. I laminated five layers of 45 degree bias fiberglass cloth to both sides of the replacement shearweb, making sure these laminates extended 2” onto the existing shearweb. After two hours of curing time, I laminated three layers of 45 degree bias fiberglass cloth to both sides of the center rib. Lastly, after all laminates had cured, I drilled six new 3/16” holes through the slotted flap bottom panel for the center hinge.

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Jun 08, 2005 Flaps - (1.0 hour) Category: Flaps

I drilled six 3/16” holes through the pilot's side center slotted flap.

Jun 07, 2005 Flaps - (1.0 hour) Category: Flaps

I mixed up 20 grams of Q-cell and resin and formed a 3/16” radius around the left slotted flap center rib.

Jun 05, 2005 Flaps - (0.5 hour) Category: Flaps

I laminated five layers of 45 degree bias fiberglass cloth on inboard side of the outboard right flap rib and to the outboard side of the inboard right flap rib. These laminations were applied to the forward side of the flap spar shearweb. After the laminates reached their green cure state, I trimmed off the excess fiberglass cloth.

Jun 04, 2005 Flaps - (2.0 hours)

Category: Flaps

I was not satisfied with the placement of the inboard and outboard ribs for the pilot's side slotted flaps. I removed the q-cell 3/16” radius and removed both ribs. I clamped both ribs between their pivot assembly and wooden templates to ensure they fit right. Next, I mixed up some q-cell and resin and formed a 3/16” radius around both sides of the inboard and outboard (left) slotted flap ribs. I laminated five layers of 45 degree bias fiberglass cloth on inboard side of the outboard right flap rib and to the outboard side of the inboard right flap rib. These laminations were applied to the aft side of the flap spar shearweb. After the laminates reached their green cure state, I trimmed off the excess fiberglass cloth.

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May 30, 2005 Flaps - (0.5 hour) Category: Flaps

I riveted the slotted flap center hinge assembly with six rivets.

May 23, 2005 Flaps - (0.5 hour) Category: Flaps

I mixed up 30 grams of q-cell and resin and formed a 3/16” radius around both sides of the inboard and outboard (left) slotted flap ribs.

May 22, 2005 Flaps - (1.0 hour) Category: Flaps

I constructed an extension jig for the pilot's side slotted flap. I drilled the pilot's side wing attach angles to the wing attach plates for the center position.

May 21, 2005 Flaps - (1.5 hours) Category: Flaps

I riveted the flap pivot plate, center position, for the pilot's side. I also riveted the flap pivot plate, center position, for the co-pilot's side. Next, I fabricated the pilot's side wing attach angles for the center position.

May 20, 2005 Flaps - (1.0 hour) Category: Flaps

I riveted a doubler plate between flap pivot template on outboard and outboard end assemblies. I worked on a stand for flap.

May 16, 2005 Flaps - (1.0 hour) Category: Flaps

I fabricated the center rib for the pilot's side slotted flap.

May 15, 2005 Flaps - (1.25 hours) Category: Flaps

I built a wooden extension to the wing jig to hold the slotted flaps in position. I then placed the pilot's side lower slotted flap panel in position onto the extension's surface. I carefully cut the inboard and outboard slots to just clear the pivot plate assemblies.

May 14, 2005 Flaps - (2.0 hours)

Category: Flaps

I drilled six holes through the inboard slotted flap assembly (on the pilot's side) and squeezed on six rivets. Next, I removed the middle slotted flap assembly (attach angles and attach plate) on the pilot's side to check the milled fiber mixture pad. I was not happy with the milled fiber coverage area and apply more milled fiber/resin. I also applied milled fiber/resin mixture to the other two slotted flap assemblies.

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May 13, 2005 Flaps - (1.5 hours) Category: Flaps

I again used the offset drill attachment to drill three additional #30 holes in the middle and outboard wing attach angle/plates. Next, I applied a milled fiber mixture to the underside of the middle wing attach angles to build a pad.

May 12, 2005 Flaps - (0.75 hour)

Category: Flaps

I used an offset drill attachment to drill three #30 holes in the inboard, middle, and outboard wing attach angles/plates.

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May 10, 2005 Flaps - (1.25 hours) Category: Flaps

I fabricated the outboard right wing attach angle and both wing attach angles for the inboard position. I also trimmed the inboard wing attach plate.

May 07, 2005 Flaps - (1.5 hours) Category: Flaps

I trimmed the forward part of both the inboard and outboard left slotted flap wing attach plates to fit. Next, I used hot glue to temporarily place the inboard and outboard ribs.

May 04, 2005 Flaps - (1.0 hour) Category: Flaps

I cut the flap shearweb on both the outboard and inboard ends the prescribed distance. I also laminated two layers of fiberglass cloth to be used for the inboard and outboard flap ribs.

May 03, 2005 Flaps - (0.75 hour) Category: Flaps

I used my drill press, with the jaws fully closed, to press a new hinge bushing (NAS75-3-004) into the pivot hole of part 551-3911-001. I also cut two strips of cloth (1.5” x 75” each) for use in Step E-3.

May 02, 2005 Flaps - (1.0 hour)

Category: Flaps

I applied one layer of fiberglass cloth on the 45 degree bias to the forward side of the left slotted flap shearweb.

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May 01, 2005 Flaps - (3.0 hours)

Category: Flaps

I cut two pieces of 1/4" foam and spliced them together to form a single piece that was 71-3/8” in length. This foam will become the slotted flap shearweb and was 1-3/4" high at the outboard end and 2-1/4" high at the inboard end. Next, I sealed the foam with a resin/Q-cell mixture on each side. While the Q-cell was curing, I marked and sanded the area of the upper slotted flap panel that will receive the shearweb cap. I also constructed a small jig that will hold the shearweb in a vertical position. After the Q-cell had cured, I applied one layer of fiberglass cloth on the 45 degree bias to the aft side of the left slotted flap shearweb.

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Apr 30, 2005 Flaps - (0.25 hour)

Category: Flaps

I sanded the inside surface of the left flap.

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Apr 28, 2005 Flaps - (1.0 hour)

Category: Flaps

I cut off approximately 3-1/4” from the left (pilot's side) top slotted flap panel on the outboard edge. Next, I marked the slotted flap shearweb centerline and the 2-1/2” wide strip that is centered on the centerline. I sanded this area and cleaned it with acetone.

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Apr 25, 2005 Flaps - (0.5 hour) Category: Flaps

I ordered part 551-3911-001 Slotted Flap Attach Plate (inboard) from New Glasair.

Apr 24, 2005 Flaps - (2.25 hours) Category: Flaps

While attempting to cut the pilot's inboard slotted flap wing attach plate, the piece slipped and I put a large gouge in it. I determined that the plate was unusable and will order another from New Glasair. I also worked on pages 9, 13, and 14.

Apr 19, 2005 Flaps - (0.75 hour) Category: Flaps

I used the plexiglass template that I had previously made to drill both inboard slotted flap attach angles on the pilot's side.

Apr 18, 2005 Flaps - (0.75 hour) Category: Flaps

I used the plexiglass template that I had previously made to drill both middle slotted flap attach angles on the pilot's side.

Apr 17, 2005 Flaps - (0.75 hour)

Category: Flaps

I used the plexiglass template that I had previously made to drill both outboard slotted flap attach angles on the pilot's side.

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Apr 11, 2005 Flaps - (0.5 hour)

Category: Flaps

I drilled through the plexiglass, at the three locations on the pilot's side, with a 3/16” bit. Next, I removed the plexiglass templates for use in drill the 3/16” holes through the aluminum slotted flap attach plates.

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Apr 10, 2005 Flaps - (0.75 hour) Category: Flaps

I cut numerous 3” x 4” pieces of 1/8” plexiglass to use as templates to mark the holes for the pilot's side flap attach angles. Next, I clamped the plexiglass to the underside of the wing on the pilot's side. Once the plexiglass was in place, I very carefully drilled pilot holes, for the outboard flap attach plates, through the plexiglass using a Dremel.

Apr 03, 2005 Flaps - (0.5 hour)

Category: Flaps

I used my table saw, with a metal cutting blade, to cut six slotted flap attach angles. These will go onto the pilot's side of the main wing.

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Mar 13, 2005 Flaps - (0.75 hour)

Category: Flaps

I used my drill press, with the jaws fully closed, to press bushings onto each outboard flap pivot plate on the pilot's side. Next, I used a #30 drill bit to drill holes in the two flap pivot plates and also in the doubler plate. These holes will have rivets installed in them to hold the pilot's side flap pivot plates and flap doubler plate together.

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Oct 11, 2004 Flaps - (0.75 hour) Category: Flaps

I mixed up a batch of Q-cell/milled fiber/resin and fabricated a bed under the forward nut plate back plate for the center rib.

Oct 10, 2004 Flaps - (2.5 hours)

Category: Flaps

I riveted MF-5000-3 nut plates onto all of the nut plate back plates for the center rib of the right slotted flap panel. Next, I used a mixture of Q-cell/milled fiber/resin to fabricate a bed under the aft nut plate back plate for the center rib. I kept the mounting screws from sticking by coating their threads with wax.

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Oct 05, 2004 Flaps - (1.0 hour) Category: Flaps

I discovered that I had fabricated the right inboard slotted flap assembly about 1/2" too long. I completely removed the assembly from the wing and flap. Next, I drilled out the six rivets that hold the assembly together. I used a hacksaw to cut off the excess material and dressed up the ends with a small file. I then squeezed on the six rivets. Lastly, I mounted the assembly to the right wing and check the final length.