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Project: MaggieMaeOfKS -
Listing for Category : fuselage

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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

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 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.

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

Category: Fuselage

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

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