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Project: MaggieMaeOfKS -
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Builder Name:	Bryce Gorrell -

Project:	Pietenpol - Aircamper - VIEW REPORTS
Total Hours:	394.2
Total Flight Time:
Total Expense:	$7932.61
Start/Last Date:	Feb 01, 2017 - No Finish Date
Engine:	Bryce Gorrell, CorvAIR
Propeller:	Warp Drive

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

Home or Last Project Picture

Mar 01, 2024 Moved into new shop - (3 hours) Category: Workshop

I moved my fuselage and all parts to my shop located at 338 W Sea Ave, Independence, MO 64050.

Jan 04, 2021 Intercom - (1 hour) Category: Avionics

I purchased a 2 place intercom system.

Aug 01, 2020 Packed Up and Moved Out - (4 hours)

Category: Workshop

I moved out of my shop, and stored my tools, equipment, and materials in a trailer, to await the time when I have space to again resume building.

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Jul 07, 2020 Welding - (15 hours)

Category: Controls

I set up a GTAW station, and learned the basics of TIG welding. I welded up one of the elevator control horns.

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Jun 23, 2020 Cut control horns - (2 hours)

Category: Controls

I had the control horns cut out by water jet.

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Jun 16, 2020 Drilled holes for cabane fittings - (3 hours)

Category: Fuselage

I made an aluminum drilling guide and drilled the holes for the vertical cabane fittings.

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Jun 16, 2020 Metal fittings - (2 hours) Category: Wings

I had a lot of metal fittings cut out by water jet.

Jun 15, 2020 Painted Fuel Tank - (2 hours)

Category: Fuel System

I painted the fuel tank with Rustoleum protective enamel.

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Jun 14, 2020 Primed Fuel tank - (1 hour)

Category: Fuel System

I sprayed the tank with zinc chromate primer.

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Jun 14, 2020 Tested Fuel Tank with Water - (4 hours) Category: Fuel System

I filled the tank with water one gallon at a time, and noted a total capacity of 18 gallons. I drained the tank through the fuel outlet until flow stopped. I then drained all remaining water out through the drain sump, collected and measured it. Sitting still on a table in the straight and level flight attitude, the unusable portion measured 15 and one third cups. I will round the unusable portion to one gallon and use that as the basis for calibrating the fuel gauge. I found there to be no leaks.

Jun 10, 2020 Painted Inner Cabane Strut Fittings - (.2 hour) Category: Fuselage

I sprayed the inner cabane strut fittings with Rustoleum gloss white enamel.

Jun 08, 2020 Bent Cabane Strut Fittings - (1 hour)

Category: Fuselage

I bent the inner cabane strut fittings and primed them with zinc chromate primer.

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Jun 07, 2020 Painted Some Metal Fittings - (1 hour) Category: Fuselage

I painted the motor mount fittings, cabane strut fittings, and flying strut fittings with Rustoleum gloss white spray enamel.

Jun 02, 2020 Attached Fuel Quantity Probe, Filler Cap, and Threaded Flanges - (4 hours)

Category: Fuel System

I installed the fuel quantity probe, fuel filler cap, and the two flanges in the sumps in the bottom of the tank. I used Permatex Form-A-Gasket on the threads of the fuel probe fitting, and the flange and flange adapter of the filler cap. The filler cap is attached using 6-32 stainless steel screws with nylock nuts and stainless split lock washers. The flanges in the sumps are fixed using JB Weld as sealant, and are screwed to the sumps using 6 stainless 4-40 screws.

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Jun 01, 2020 Sealed Rivets - (4 hours)

Category: Fuel System

I brushed thinned JB Weld on the outsides of many of the rivets as an extra seal precaution. I also sloshed and brushed thinned JB Weld on some of the rivets on the inside of the tank.

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Jun 01, 2020 Fuel Quantity Probe - (1 hour)

Category: Fuel System

I received my custom length capacitive fuel probe. It has an NPT fitting to screw into the flange on the top of the tank, and is 8.5 inches in length.

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May 30, 2020 Bondo On Outside of Tank - (4 hours)

Category: Fuel System

I sanded the tank to prepare it for painting. I filled the outsides of the top edges with Bondo to create a smoother appearance. I also coated some of the machine screws inside the tank with JB Weld for sealant.

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May 28, 2020 Assembled Fuel Tank - (6 hours)

Category: Fuel System

I built a cover with plugs for the vent tubes to be used on the ground.

I etched with acid the areas of the fuel tank to be sealed, applied proseal to the seams, and riveted the tank together.

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May 25, 2020 Steel Fittings - (3 hours)

Category: Fuselage

I bent the lower motor mount fittings, and cleaned and sprayed zinc chromate primer on the motor mount fittings, cabane strut fittings, and flying strut fittings.

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May 25, 2020 Finished Glove/Helmet Box - (1 hour)

Category: Fuselage

I cut and glued the back of the helmet box in place.

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May 19, 2020 Glove box - (2 hours) Category: Fuselage

I began constructing the glove/helmet box, located behind the rear cockpit's upper seat back.

May 19, 2020 Seat Harnesses - (4 hours)

Category: Fuselage

I created another, independent anchor point for the rear seat's shoulder straps, located at the junction of the tail post and upper longerons. This fitting has a loop of 1/16"" stainless steel cable in addition to that of the first anchor I built. It is secured to itself with 20 aluminum swaged fittings and two cable clamps.

I also set the bolts in place, securing the front seat harness' lap belt. I had previously coated the insides of all four holes in the lap belt attachment blocks with epoxy, and reamed them back out to size.

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May 18, 2020 Vent Tubes, Probe Flange - (1 hour)

Category: Fuel System

I split the ends of the vent tubes, and splayed them out in four directions inside the tank. I riveted them in place, and further set them in place and sealed them with JB Weld. I also sealed the inside of the threaded flange area for the quantity probe with JB Weld.

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May 17, 2020 Fuselage Side Art - (2 hours)

Category: Paint / Decals

I designed the graphics to be placed on the sides of the fuselage.

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May 16, 2020 Fuel Probe Mount - (2 hours)

Category: Fuel System

I made a hole in the top of the fuel tank between the vent and the side, and riveted a threaded flange in the hole, to accept the fuel quantity probe later. I filed a subtle curvature into the flange to make it fit the curve of the tank top.

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May 16, 2020 Turtle Deck, Front Seat Harness Attachments - (3 hours)

Category: Fuselage

I made two ash blocks and glued them to the fuselage to create attachment points for the front seat's lap belt. I also added glue to a few areas in the turtle deck. I trimmed down the bolts, nuts, and washers needed for the forward cockpit's lap belt attachments. These bolt heads will be exposed in the sides of the rear cockpit near the floor, so I rounded off the heads.

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May 12, 2020 Turtle Deck, Seat Belts (5/10/20-5/12/20) - (24 hours)

Category: Fuselage

I built the the turtle deck, and the mounts for the rear seat harness. The bolts and nuts were trimmed down to fit flush with the outer plywood panels on the sides of the fuselage, to be added later.

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May 05, 2020 Turtle Deck - (3 hours)

Category: Fuselage

I made several of the parts for the turtle deck.

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May 04, 2020 Made Gussets for Fuel Tank Sumps - (6 hours)

Category: Fuel System

I made and riveted four small pieces of aluminum that form gussets to strengthen the attachment of the two sumps in the bottom of the fuel tank. These gussets are in addition to the rivets trough the sides and back of the tank. They attach the sumps to the pieces of aluminum angle running across the bottom of the tank. I also made several measurements of the fuselage to aid in designing the turtle deck.

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May 02, 2020 Riveted Top of Tank - (4 hours)

Category: Fuel System

I riveted the top of the tank, the sides, and the angle pieces into a complete assembly, to be joined with the bottom assembly later. I also riveted the mounting bracket to the top of the inside to form the base for the vent tubes.

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Apr 28, 2020 Steel Fittings, and More Fuel Tank - (5 hours)

Category: Fuel System

I got some of my steel fittings cut at a machine shop using a water jet. They are made from 4130 alloy, .090"" thick. I cleaned these up with the belt sander, sprayed them with gun oil, and packed them away in a heavy plastic bag with my engine block. I also finished forming the top of the tank.

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Apr 27, 2020 Continued Fuel Tank - (5 hours)

Category: Fuel System

I finished the flange adapter, and located it on the top of the tank. I drilled the holes for screws to hold the fuel filler cap, and cut its hole using a router. I located the vent tube mount, and drilled its holes. I also bent and formed the two vent tubes.

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Apr 26, 2020 Fuel Tank - (7 hours)

Category: Fuel System

I reassembled the fuel filler cap, contoured the ring that will form the filler cap flange adapter, and bent the top piece of the fuel tank. I drilled many of the holes required to form the top of the tank.

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Apr 24, 2020 Trimmed Filler Strips - (5 hours)

Category: Fuselage

I tuned up a new block plane, and used it to trim down the filler strips on the sides and bottom of the fuselage. I then sanded all the surfaces and edges smooth, creating a continuous edge along the corners of the fuselage, making a smooth place to form the fabric around the fuselage later.

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Apr 23, 2020 Added Filler Strips - (4 hours)

Category: Fuselage

I cut out and glued filler strips to the sides of the bottom of the fuselage, between the plywood gussets. I then turned the fuselage over, routed the excess gussets on the top of the fuselage, and cut out and glued filler strips in place between the gussets on the sides of the top of the fuselage. This was all done with T-88 epoxy.

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Apr 22, 2020 Glued Gussets, Filler Strips - (6 hours)

Category: Fuselage

I routed the excess gussets off with a flush trim router on the top of the fuselage. I glued the gussets to the top of the fuselage, attaching them with T-88 and small stainless steel brads. I cut out and glued the filler strips to the bottom of the fuselage. I also added a spruce wedge between the top of the floor piece and the diagonal brace that crosses under the rear seat back.

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Apr 21, 2020 Added Gussets - (6 hours)

Category: Fuselage

I cleaned the shop today, then used a router to flush trim the edges of the gussets I added yesterday. I cut out and glued the remaining gussets needed on the bottom of the fuselage, attaching them with T-88 and small stainless steel brads. I cut out the gussets to finish the top of the fuselage, and marked their locations to ready them for gluing.

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Apr 20, 2020 Added Gussets - (3 hours)

Category: Fuselage

I sanded to remove excess glue from the joints where gussets will be added to the top and bottom of the fuselage. I cut out the two long gussets and glued them to the bottom side of the fuselage aft of the rear seat.

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Mar 10, 2020 Started Top of Fuel Tank - (3 hours)

Category: Fuel System

I cut a piece of aluminum sheet to form the top of the fuel tank. I bent one end and prepared to drill holes to begin fitting it to the tank.

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Mar 02, 2020 Built Drain and Outlet Tubes - (5 hours)

Category: Fuel System

I routed the holes in the bottom of the fuel tank through the tabs formed by the side pieces to complete the circles, and assembled the tubes that will form the sumps for the drain and the fuel outlet.

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Feb 26, 2020 Attached Flange Adapter to Fuel Filler Flange - (1 hour)

Category: Fuel System

I made a plywood standoff ring and attached the fuel filler flange to the flange adapter. This will allow me to turn the inside diameter of the flange adapter by gripping the flange in the lathe. I have to do this because the chuck on my father's lathe is too small to grip the flange adapter by the outside.

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Feb 25, 2020 Turned Tubes And Fuel Cap Flange Adapter - (4 hours)

Category: Fuel System

I turned sections of aluminum tubing to length, which will form the sumps in the bottom of the tank, and turned the outside of the adapter to fit under the flange of the fuel filler cap, to allow the flat fuel cap to conform to the curved surface of the top of the tank. I drilled and tapped six holes for 6-32 threads to allow me to attach the flange to the flange adapter for turning.

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Feb 24, 2020 Match Drilled Bottom and Sides of Fuel Tank - (5 hours)

Category: Fuel System

I drilled the rivet holes in the large angle pieces, tapped the ones in the ends for 4-40 threads, assembled the tank and match drilled all the holes, fastening it all up with Clekos.

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Feb 22, 2020 Marked Rivet Hole Locations - (1 hour) Category: Fuel System

I centerpunched the rivet hole locations in the two aluminum angle pieces that will form the base of the fuel tank.

Feb 19, 2020 Continued Fuel Tank - (4.5 hours)

Category: Fuel System

I deburred the holes in the bottom piece, I cut out the other side piece, removed the paper patterns from both side pieces, routed the holes in the bottom piece, and bent the edges of both side pieces.

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Feb 18, 2020 Continued Fuel Tank - (4 hours)

Category: Fuel System

I finished the edges on one side piece, bent the ends of the bottom piece, and drilled rivet holes in the bottom piece. I used lacquer thinner to remove the paper pattern off the bottom piece. It dissolved the glue very cleanly and allowed the paper to slide off easily.

I routed a radius on the edge of my workbench top to form the bends in the bottom piece.

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Feb 17, 2020 Began Fuel Tank Construction - (5 hours)

Category: Fuel System

I glued full size printouts of my fuel tank parts to sheet aluminum, roughly cut out the parts, drilled many of the necessary holes, and fitted the aluminum angle pieces together that make up the support struts on the bottom of the tank.

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Feb 11, 2020 More Fuel Tank Parts and Supplies - (1 hour) Category: Fuel System

I purchased sheet aluminum, aluminum angle, rivets, cleco fasteners and pliers, screws and washers for my fuel tank.

Nov 27, 2019 More Parts Purchased - (1 hour) Category: Fuel System

I purchased aluminum plates for under the filler cap and under the fuel probe, a piece of aluminum strip to form a base for the vent tubes, and pieces of copper tubing to create vent tubes.

Nov 21, 2019 More Fuel Tank Parts - (1 hour)

Category: Fuel System

I purchased a drain valve, a second threaded flange, and a fuel filler cap.

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Nov 20, 2019 Fuel Tank Design - (6 hours)

Category: Fuel System

I did some CAD design work on my fuel tank, which I plan to rivet together with sealant rather than having it welded.

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Nov 14, 2019 Fuel Tank Parts - (1 hour)

Category: Fuel System

I purchased a threaded flange, a finger strainer, a piece of aluminum tubing and two pieces of aluminum angle to begin constructing the fuel tank.

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Nov 12, 2019 Diagonal Braces - (2 hours)

Category: Fuselage

I cut and glued the diagonal braces for the top and bottom of the fuselage.

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Nov 06, 2019 Cut One Steel Part, Glued Six Cross Struts - (3 hours)

Category: Fuselage

I cut out and trimmed one steel cabane strut attachment fitting, and cut out and glued six horizontal cross struts to the inside of the fuselage.

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Nov 05, 2019 Steel Fittings - (5 hours)

Category: Fuselage

I cut out and trimmed six of the steel parts from the 4130 sheet: Two flying strut attachment fittings, Three cabane strut attachment fittings, and one upper engine mount attachment fitting.

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Nov 03, 2019 Drilled Holes in Sheet for Engine and Wing Fittings - (2 hours)

Category: Fuselage

I centerpunched and drilled the 128 holes in the sheet of steel for the motor mount fittings, the vertical cabane strut fittings, and the flying strut fittings.

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Nov 01, 2019 Laid Out Sheet Metal Parts - (1 hour)

Category: Fuselage

I epoxied paper printouts of CAD drawings of my motor mount fittings, vertical cabane strut fittings, and flying strut fittings to a 12 x 24 inch piece of .090 4130 steel sheet.

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Oct 30, 2019 Glued Some Gussets - (1.5 hours)

Category: Fuselage

I glued the long gussets on the insides of the lower longerons behind the rear seat, the twelve rectangular gussets over the outsides of the fuselage truss joints, and the large gussets on each side of the tail post. I used T-88 epoxy and small stainless steel brads.

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Oct 29, 2019 Gussets - (6 hours)

Category: Fuselage

I readied several gussets for assembly, and marked their locations on the fuselage.

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Oct 23, 2019 Finished Seats - (6 hours)

Category: Fuselage

I made the plywood fronts for under both seats, and glued up the front seat. I also added the plywood to the underside of the rear seat. I used T-88 throughout with small stainless brads in several places.

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Oct 22, 2019 Front Seat - (8 hours)

Category: Fuselage

I made the parts for the front seat back and attached the second boat seat to the plywood base with stainless hardware, doubly locked by way of split lock washers and nylock nuts.

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Oct 21, 2019 Rear Seat - (8 hours)

Category: Fuselage

I cut out the floor under the rear seat, made the rear seat back, and glued the rear seat in place. I attached the molded plastic boat seat to the seat bottom using stainless steel hardware, doubly locked with split lock washers and nylock nuts.

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Oct 16, 2019 Built Seat Bottoms - (4 hours)

Category: Fuselage

I sanded the excess epoxy around the tail post, and built the seat bottoms.

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Oct 15, 2019 Girls Checked Out Floor Fit

Category: Inspection

The girls visited the shop to inspect the new floor. They gave their approval.

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Oct 15, 2019 Trimmed Floor, Finished Tail Post - (5 hours)

Category: Fuselage

I trimmed the excess floor extending past the longerons with a router, and finished the tail post by sawing, sanding, and joining the tail with T-88.

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Oct 14, 2019 Began Forming Tail Post, Glued Floor - (7 hours)

Category: Fuselage

I began to sand and cut the tail post(s) to shape, and attached the floor using T-88 and small stainless brads.

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Oct 08, 2019 Glued First Cross Struts - (3 hours)

Category: Fuselage

I glued the first few cross struts in place between the fuselage trusses.

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Oct 07, 2019 Set Up Fuselage Trusses - (2 hours)

Category: Fuselage

I sanded the joints smooth once again, and marked my workbench as a guide for assembling the fuselage side trusses. I set the trusses up on edge and began fitting the horizontal struts in place.

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Oct 02, 2019 Added Gussets to Insides of Trusses - (3 hours)

Category: Fuselage

I added the gussets to the insides of the fuselage trusses using T-88 epoxy and small stainless steel brads.

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Oct 01, 2019 Added Wedges, Made Gussets - (6 hours) Category: Fuselage

I sanded the joints on the other truss to return them to flatness. I cut out the plywood gussets needed to complete the trusses, and added wedges to the joints above the forward landing gear attachment points.

Sep 24, 2019 Dismantled Truss Jig - (5 hours)

Category: Fuselage

I dismantled the fuselage truss jig and sanded the joints on one of the trusses to eliminate excess epoxy and return the joints to flatness to prep them for plywood gussets.

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Sep 20, 2019 Zenith Homecoming & Corvair College #44 - (20 hours) Category: Research

Attended Zenith Aircraft Company Homecoming in Mexico, MO. Expenses include food, fuel, lodging, and CorvAIR maintenance, operations, and procedures manual and Pietenpol weight & balance manual from William Wynne.

Sep 18, 2019 Second Fuselage Truss - (2 hours)

Category: Fuselage

I glued up the other fuselage side truss using T-88 throughout.

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Sep 17, 2019 Second Truss - (4 hours)

Category: Fuselage

I cut out the wedge pieces and laid out the truss as it will be held together for gluing.

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Sep 10, 2019 Second Side Truss - (1 hour)

Category: Fuselage

I laid out the pieces for the other fuselage truss and cut the longerons to their final lengths for assembly.

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Sep 09, 2019 Glued First Truss - (3 hours)

Category: Fuselage

I glued up one fuselage truss using T-88 epoxy throughout.

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Aug 29, 2019 Bought Spruce Wood for Vert. Stab. & Rudder - (1 hour) Category: Engine

Bought new wood ""kits"" after I decided to rebuild them. I am not completely satisfied with the workmanship of my first stab and rudder.

Aug 26, 2019 Built Fuselage Jig - (10 hours)

Category: Fuselage

I cut the upper and lower longerons for one side of the fuselage truss to shape, constructed a jig to hold the truss in place on the workbench, and test fitted the pieces to ready them for final assembly.

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Aug 01, 2019 Moved Into Pleasant Valley Basement - (6 hours) Category: Workshop

I moved my shop to the basement located at 6901 N Chas Dr, Pleasant Valley, MO, and resumed construction.

Nov 15, 2018 Moved Out of Lawrence Hangar - (8 hours) Category: Workshop

U-Haul from Lawrence to Gladstone/North Kansas City. I moved out of the hangar due to the expense, and stored my supplies and tools at a friend's garage.

Aug 04, 2018 Cut Struts and Braces - (4 hours)

Category: Fuselage

I cut the vertical and diagonal members of the two trusses that comprise the sides of the fuselage to their final shapes and sizes.

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May 01, 2018 Moved to Lawrence - (8 hours) Category: Workshop

U-Haul from Storage locker in Overland Park to hangar at Lawrence Municipal Airport.

Sep 29, 2017 Corvair College #40 - (20 hours) Category: Research

Attended Corvair College in Mineola, TX. Costs include food, fuel, car rental, lodging.

Jun 01, 2017 Bought Wood for Fuselage - (1 hour)

Category: Fuselage

Bought wood ""kit"" from AS&S.

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May 01, 2017 Workbenches - (2 hours) Category: Workshop

I bought and assembled two workbenches, each two by eight feet, giving me two by sixteen feet of flat work surface on which to build.

Mar 05, 2017 Bought Distributor, Rear Oil Case, Other Parts - (1 hour) Category: Engine

Distributor, rear oil case assembly (high volume oil pump), pushrod tubes, oil pan installation kit (hardware and oil pickup), sheet metal baffling, valve covers, oil dipstick and tube, set of pushrods.

Mar 01, 2017 Bought Spruce Wood for Empennage - (1 hour) Category: Empennage

Bought spruce wood ""kits"" from Aircraft Spruce & Specialty.

Mar 01, 2017 Bought Engine Mount - (1 hour) Category: Engine

Bought ""high thrust line"" CorvAIR engine mount from flycorvair.com and had it shipped to my home.

Feb 24, 2017 Received Another Core Crankcase - (1 hour) Category: Engine

Received crankcase from 140 hp engine and began cleaning it. One stud broken, two with damaged threads. Case looks pretty good.

Feb 23, 2017 Continued Cleaning Engine Parts - (2 hours) Category: Engine

Continued cleaning. Scrubbed rockers, pushrods, etc. Cleaned rear oil accessory case.

Feb 22, 2017 Continued Cleaning Engine Parts - (1 hour) Category: Engine

Continued cleaning. Placed rockers, tubes, pushrods, other hardware in gasoline to soak.

Feb 21, 2017 Continued Cleaning Engine Parts Category: Engine

Continued cleaning. Brushed heads with gasoline.

Feb 18, 2017 Began Cleaning Engine Parts - (3 hours) Category: Engine

Lightly washed crank, cam and case halves.

Feb 16, 2017 Continued Core Engine Disassembly - (5 hours) Category: Engine

Completed disassembly. Removed remaining upper cylinder studs (threads rusted away past nuts), cylinders, pistons, crankshaft, camshaft. Split case halves apart.

Feb 15, 2017 Continued Core Engine Disassembly - (3 hours) Category: Engine

Continued disassembly. Removed a few cylinder studs. Removed oil pan, oil pickup and dipstick tube.

Feb 11, 2017 Continued Core Engine Disassembly - (3 hours) Category: Engine

Removed more shrouding, heads, harmonic balancer and rear oil accessory case. Placed pushrods, rockers and tubes in plastic containers to clean later.

Feb 04, 2017 Began Core Engine Disassembly - (6 hours)

Category: Engine

Began disassembly of Corvair engine. Removed shrouding, top cover, oil filter housing. Placed Marvel Mystery Oil in cylinders and on crank.

Corvair Disassembly 2-4-17.JPG

Feb 01, 2017 Bought Plans from Pietenpol Family - (1 hour) Category: Research

Bought complete set of original plans.

Feb 01, 2017 Bought First Core Engine - (1 hour)

Category: Engine

I bought an engine from a 1966 Corvair from a salvage yard in Ohio and had it shipped to my home.

Corvair Tag from Junkyard.JPG

Jan 29, 2017 Decided to Build an Airplane - (1 hour)

Category: Research

I discovered a video on YouTube from the FliteTest channel: ""My Homebuilt Airplane."" I decided I would begin building a Pietenpol Air Camper. I decided to convert a Corvair engine to have the most interactive building experience among the engine options I saw.

Capture.JPG