Project: Cozy4   -  
            Listing for Category : c02 workshop
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Builder Name:Preston Kavanagh   -  
Project:   Cozy - Mark IV   -   VIEW REPORTS
Total Hours:4433.6
Total Flight Time:
Total Expense:$33393.25
Start/Last Date:Sep 01, 2003 - No Finish Date
Engine:IO-360-A3B6D
Propeller:Hertzler Silver Bullet 66 x 78
Panel:Garmin G3X + ipad
 
Friendly URL: https://eaabuilderslog.org?s=Cozy4

Home or Last Project Picture

May 13, 2022     shuffling everything - (20 hours) Category: C02 Workshop
I want to get the wings on so I can work on the cowling and controls. Those wings need a 31" free span, and my garage can just barely do it - if I move everything. I have pretty much everything in the shop on wheels, so it required a lot of putting away, a new storage bay on the ceiling, disassembling a favorite work table.... it's a project that took 2 weeks of nibbling away. The spend was for additional lumber, drywall mud for the cowling work, et al.
 
Aug 22, 2018     more work shop prep post project delivery - (29.5 hours)       Category: C02 Workshop
I kicked off the project by fitting it into the work space. I had to turn a woodworking area into a new space for a family car, install a garage door, build shelves, re-arrange a heck of a lot of accumulated possessions, et c. Everyone reading this will understand the shorthand for weeks and weeks of shop set up time. When the project arrived, I was able to move the wings to the ceiling, canard on a side shelf, miscellaneous in the attic, and fuse front and center.

Friday 8/10/18 Receive Project!
Saturday 8/11/18 8.0 unload, unpack, stow
Sunday 8/12/18 8.0 inventory (missing key, missing bolts
Wednesday 8/1/18 2.0 350.00 lay in basic supplies - laminating & sanding epoxy, BID, peel ply, 4 mil plastic, squeegees, dry wall trowels, sticks, containers, scale, et al
Monday 8/20/18 1.0 65.50 order replacement key
Tuesday 8/21/18 8.0 9.00 design and build device to invert plane (buy bolts), invert
Wednesday 8/22/18 2.5 8.00 build sanding boards
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The last photo shows painted wings and fuse in the workshop. The crowding of benches is the result of multiple open tasks, the result of shipping delays, backing up to redo a prior task, and the urge to get something tangible done in some limited amount of time.


 
Aug 30, 2005     Purchase add'l tools - (6 hours) Category: C02 Workshop
Purchased:
$86.78 - MyPaperMart, 4mil plastic sheeting and 80 ga. stretch wrap
$14.53 - ToolsForLess, decimal-graduated tape measure
$49.99 - AllBrands, Dritz electrical scissors
$63.50 - DryTheAir, Thermo/humidity gauge and heater rods for cloth box
$221.25 - Harbor Freight, Rivet gun, wire stripper, clamps, other misc tools
$49.95 - Aircraft Spruce, Extra set of M drawings
$134.40 - eBay, Oscillating spindle sander
$10.99 - eBay, 40 ft. 22 ga. nichrome wire
$92.99 - eBay, Smart Tool digital level
$64.99 - eBay, Medo vacuum pump

Paying rent on build space is great incentive to experiment with ways to improve productivity - anything that looks like a useful tool is probably worth buying if it's not too expensive. I spent some time browsing other builders' comments and made a list of useful items to have. I probably ended up wasting money on shipping costs by buying from so many vendors, but there were so many odd items to buy I really didn't have much choice. Hopefully this stuff will all end up being useful. The only items I believe I'm still missing at this point are some items related to specific steps in specific chapters. For instance, I may need a few extra drill bits for specific steps. I'll purchase those with the steps they relate to.
 
Aug 22, 2005     Identify New Build Site - (40 hours)       Category: C02 Workshop
Chad's build log....

In 2004, I moved to a new home. While we're very happy where we live now, I made a big sacrifice when it came to the Cozy. There simple is no place to build here - there is no garage at all, and only interior door access to the (small) basement. For various reasons, the back yard is also out. I came very close to giving up my build dreams, and selling the project to a prospective builder.

I could never quite shake the dream, though. I started flying lessons, thinking that would help offset the loss, but they only made me long for the skies even more. I started researching other projects, trying to find things that I could build quickly, and with limited environmental control. I even (gasp!) considered buying a spam can!

What gave me the needed kick in the pants was John Slade, to whom I'll be either eternally grateful (assuming I ever finish the project). John has been considering starting a builder support service, and I asked him if he would be willing to help me out. He was.

The first thing John did was convince me to find a local build site. When it comes down to it, my REAL problem is that my build time needs to come during breaks during my work day (I work from home). Once the work day is done, I'm a daddy and a husband, and don't have time left over to build. I had briefly considered renting a space, then discarded the idea because I didn't think I'd get much done if I had to leave work and drive to the build site. I never considered doing BOTH there.

This is exactly what I'm doing now. I'm renting an industrial space, about 800 sq. ft. for $700 per month, and moving both the plane and my business over to it. In this step I've included the cost for two years' rent. It's pricey, but there are some advantages:
1. It's cheaper than building a garage (not that we have the space anyway).
2. I can write off the rent as a business expense.
3. The space is much larger than most garages - 20' x 40'. I could actually work on the Cozy with both wings attached.
4. The unit is literally 5 minutes from home.

There are also some disadvantages. The two key items are:
1. Two years' rent on this unit adds 30% to my build cost estimates. Fortunately, since it's deductible, the impact is somewhat reduced. If nothing else, this will be incentive to keep me moving if/when I start to get distracted.
2. The garage door is only 8' x 8'. You need 10' or more to push the bird through on its wheels. I've done some modeling and I believe this is possible to do ONCE OR TWICE by removing the gear and pushing it through at an oblique angle, but this definitely needs to be an infrequent event.

Ultimately, I believe this is the right decision for my project. Time to get the space set up.


 
Jan 22, 2004     Epoxy hot box - (1 hour)       Category: C02 Workshop
My epoxy hot box is quite simple - just a simple frame of rigid foam insulation screwed together with LONG screws. (The front cover is not shown in the picture below.) There is absolutely no strength in this structure but that's fine because I don't move it around and it bears no weight. I installled one light bulb as a heat source for now - later this will be two bulbs and a thermostat. Currently I must monitor the temperature of the box and make sure it doesn't get too hot - I just only turn on the bulb an hour before I plan to use it.

You must be VERY safety-conscious if you follow in my footsteps. The aluminum foil is conductive, so the light bulb is actually mounted to a junction box that contains the wiring, and there are no sharp edges for wires to catch on. Don't let it get too hot, either. This type of insulation is flammable if exposed to flame or extensive heat (somewhat more than wood). Finally, note that one side is more reflective than the other (a stamping on the board indicates which) and should face INTO the box.

I have a very accurate digital scale for measuring my epoxy, and I plan to work by weight rather than by volume. I purchased the set of cheap-o West Systems epoxy pumps (I am using MGS 335) with the intention of doing as other builders had done and keeping the epoxy in Hefty gallon-size freezer containers (see Jeff Wilson's site, et. al.). However, I could not find suitable containers, and in the end discovered that the pumps fit the MGS bottles just fine if you don't mind the resin pump not actually screwing on. I also intended to work by volume and make the modifications to the pumps' depth controls discussed by others, but discovered that measuring by weight is so much easier (and more accurate) that it's not worth the effort and risk (of making a mistake).

Larry Wimble has created an excellent spreadsheet for MGS 335 that shows you precisely how much of each component to mix for a desired target quantity. I have cached a copy here in case he (re)moves the file - it's only 6K. Hope you don't mine, Larry

Building this project required:
1. One sheet of 1-7/8 rigid foam insulation ($23.25)
2. One junction box ($1.25)
3. One box-mount light bulb socket ($1.06)
4. Cut-off cord from a trash-bound device ($0)
5. Screws and masking tape ($0.75)
6. Four (for future replacements) 40W light bulbs ($.96)


 
Jan 20, 2004     Fabric Cupboard - (2.5 hours)       Category: C02 Workshop
I planned to make my cloth box wall-mountable, but for the time being I will be working out of my new office, and I didn't want to mar the walls (as you can see I'm still taping - I didn't have the heart to put four NEW screws into it!) I opted for a solution similar to that of some other builders (Dean May, Jeff Wilson, et. al.) and just made a few minor modifications.

First, I only have one leg at the moment - this is a temporary support while I figure out where I'll ACTUALLY be building the next few years, at which time I will be designing the table to drop down and hook onto a work table, giving me a bigger surface to cut fabric on. The sawhorses are also temporary.

Second, my front lid is mounted slightly offset from the bottom of the box. This allows it to fold down flat on the sawhorses I currently have it on, or whatever shelf/table it may sit on in the future. This prevents me from having to have the box flush with the front lip of a shelf.

Finally, my latches are two chest latches on the top of the box to help keep the cheap-a** utilitygrade plywood from warping and exposing the cloth to dust. I cut notches into the top of the lid that the latches hook onto.

I intend to eventually install a paper tape measure along the edge of the lid to make measuring things out faster, or simply install a self-healing cutting mat for rotary cutters, as these have markings on them already.


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Last time I went all out making a huge cloth box, and even though I used 1/2" plywood, it was heavy and also clumsy to use. The lid dropped down to make a cutting area, which seems like a nice touch until you have to cut large pieces. It was rough, and annoying to use. This time I applied the KISS principle (Keep It Simple, Stupid). I just need something to get the job done, and the setup you see below does this with standard closet shelving brackets. This produces a dual-use storage area - the cloth is mounted on closet rods, and the shelves can hold extra rolls of cloth, scissors, measuring tools, and etc. I'll mount another pair above the current two to provide storage for peel ply and plastic, and I can pull the plastic down to keep dust off the cloth.

For the cutting table I reused a work surface I had built a year ago. I initially planned to use this for the plane, but since I built new jig tables I didn't need it any longer. This is just a sheet of hardboard on a sheet of plywood, and like the jig tables, the base is built from 2x4 lumber (the only cost of this step). I'll marked cutting lines on the table at some point. Note that this produces a HUGE cutting surface, and can serve double-duty as a utility workbench when it comes time for chores such as wiring.


 
Aug 04, 2018     shop fixtures - (42 hours) Category: C02 Workshop
Tuesday 7/31/18 12.0 - clear workbench, re-do pegboard, fix wiring, move shop tools to garage
Wednesday 8/1/18 12.0 - clear workbench, re-do pegboard, fix wiring, move shop tools to garage
Thursday 8/2/18 6.0 - consolidate shelving units, moving two to hangar (home to Cub)
Friday 8/3/18 6.0 - consolidate shelving units, moving two to hangar (home to Cub)
Saturday 8/4/18 6.0 130.00 - build rolling fixtures
Saturday - build ceiling storage rack
 
Jun 30, 2018     New FL home - (92 hours) Category: C02 Workshop
Saturday 6/30/18 60.0 900.00 - in shop, removed wall and installed garage door, allowing wife's car to move to air conditioned splendor while I take over the 2- car garage.

Wednesday 7/18/18 24.0 85.00 - install 8 feet of additional shelving in new garage, shift and sort from construction space

Monday 7/30/18 8.0 - relocate stained glass workbench + approx 1000 lbs colored glass

 


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