EAA Builders Log Site

Project: CH750-SR -
Listing for Category : Show all entries

(Please mouse-over any icon to get a description of that function).

Categories


Builder Name:	Skip Rhudy -

Project:	Zenair - CH 750 - VIEW REPORTS
Total Hours:	551
Total Flight Time:
Total Expense:	N/A
Start/Last Date:	Sep 17, 2019 - No Finish Date
Engine:	Corvair
Propeller:	Sensenich W642KL-35GS

Friendly URL:	https://eaabuilderslog.org?s=CH750-SR

Home or Last Project Picture

Apr 25, 2023 Panel Layout - (36 hours)

Category: Instrument Panel

The pictures gathered here show the end stage of the panel design development. It was driven by two primary factors: 1) Requirements of a minimal Corvair engine driven aircraft, 2) Engine control and instrumentation layout similar to C150/152 which I did my primary flight training in and will no doubt fly in from time to time. Development of this panel has gone through multiple iterations and the final version shown here as design drawing is based on analysis of circuit requirements for running the Corvair engine's critical electrical systems (ignition and power generation) and the non-critical electrical systems (lighting and avionics). I decided for traditional panel over software driven multi-display systems, though power and space is provided for COTS devices to run foreflight. I have spent at least 36 hours on the design and accumulation of tools and materials which converge on the panel itself. All electrical is being installed to standards defined in AC 43.13-B

2023-04-25_panel_final_versions_00.jpg

2023-04-25_panel_final_versions_01.jpg

2023-04-25_panel_final_versions_02.jpg

2023-04-25_panel_final_versions_03.jpg

2023-04-25_panel_final_versions_04.jpg

Apr 21, 2023 Forward Fuselage - (1.5 hours)

Category: Fuselage

Prepare forward fuselage floor for buildup and installation.

2022-07-26_front_fuselage_00.jpg

2022-07-26_front_fuselage_01.jpg

Apr 05, 2023 Seat Pan Support Area - (2 hours)

Category: Fuselage

Marked (with a rivet spacer fan) and drilled holes in seat pan support panels / support brackets prior to install. Drilled out all holes to final size and then deburred all holes. Drilled extra attach holes in both vertical support channels on the rear fuselage because lower left / lower right holes have AN nuts so close behind the hole that rivet installation is not possible from outside, and inside the channel the rivet gun head will not fit. The extra hole is in middle of bottom row and make up for the missing outside lower rivet.

2023-04-05_seat_pan_drilling_and_deburring_00.jpg

2023-04-05_seat_pan_drilling_and_deburring_01.jpg

2023-04-05_seat_pan_drilling_and_deburring_02.jpg

Apr 04, 2023 Seat Pan Support - (2.5 hours)

Category: Fuselage

Outboard seat pan supports have to be drilled to fasten the seat pan down. A5 pitch 40 rivets are used. Pilot holes #40, then drilled out to A5 size. Not deburred yet.

Also drilled out the pilot holes for the lower seat belt harness attach point, starboard and port sides.

2023_04_04_outboard_seat_pan_support_00.jpg

2023_04_04_outboard_seat_pan_support_01.jpg

2023_04_04_outboard_seat_pan_support_02.jpg

2023_04_04_outboard_seat_pan_support_03.jpg

2023_04_04_outboard_seat_pan_support_04.jpg

2023_04_04_outboard_seat_pan_support_05.jpg

Apr 01, 2023 Nut Repair - (5 hours)

Category: Fuselage

Minor travails and new access panels to very tight spaces:
When drilling a hole through the side channel upright on my fuselage, down by the landing gear fitment where the holes go to attach the seat pan, I noticed that the drill seemed to not want to go through the sheet-metal -- about like when metal is a bit thicker. So I used a little bit more force. But it turned out it wasn't sheet-metal. On inspection I saw that I had drilled into the nut of the top AN 4 bolt of the rear part of the starboard fitment that connects the front fuselage to the rear fuselage. I couldn't tell how deep I had drilled into the nut or maybe even the bolt. I was unwilling to ignore potential damage to part of the system that connects the rear fuselage to the front (everything might NOT be all right). So began an hours long endeavor to remove the bolt and nut to inspect and replace. It involved getting a 20 ton press, buying a wrench or other tool that I could bend in the press to a U-shape to be able to get back behind the side channel via the narrow area left between baggage floor and seat pan rear support. I knew that I could put an access panel instead and approach it that way. But I started with the "make your own tool way". I managed to remove the nut from the bolt, but had so much trouble getting a new one back on with a washer. Then my custom wrench head got stuck. I was forced to make an access panel. Once the access panel was open it took a whole 2 minutes to remove the stuck tool and reinstall the bolt and torque it correctly.

2023_04_01_nut_repair_complete_00.jpg

2023_04_01_nut_repair_complete_01.jpg

2023_04_01_nut_repair_complete_02.jpg

2023_04_01_nut_repair_complete_04.jpg

2023_04_01_nut_repair_complete_05.jpg

2023_04_01_nut_repair_complete_06.jpg

Mar 01, 2023 Critical Electrical And Panel Area - (15 hours)

Category: Landing Gear

Bought 4x8 sheet of .025 from Airparts. Didn't have metal brake so used rubber mallet method of bending instrumentation wiring support pans between firewall and panel. Bent against grain by accident, however do not believe will be a problem given the non-structural nature and very low weight of service loops of wiring the pans will support. The battery, contactor, and distribution bus is mounted behind the passenger seat. Battery location reinforced with .092 extruded L and wrapped tight with sheet metal to resist high g loads in sudden stop situation. Fabrication and planning of these items took a long time. Acquired a small sheet metal bender for the smaller brackets that the bus and the contactor are mounted on. Used .016 L-angle as "finger" to get appropriate bend radius on those items. Used rubber mallet to create flange that cheap metal brake design doesn't support.

2023-03-01_battery_system_mock_00.jpg

2023-03-01_battery_system_mock_01.jpg

2023-03-01_trays_behind_panel_00.jpg

2023-03-01_trays_behind_panel_01.jpg

2023-03-01_trays_behind_panel_02.jpg

2023-03-01_trays_behind_panel_03.jpg

2023-03-01_trays_behind_panel_04.jpg

2023-03-23_battery_system_installed_00.jpg

2023-03-23_battery_system_installed_01.jpg

Feb 11, 2023 Landing Gear / Wheels / Tires - (3.5 hours)

Category: Landing Gear

Assembled wheels into tires. Ran 1/16 in. bead of Permatex Ultra Grey (82194) high torque gasket maker around the face of one side of the wheel assembly to ensure no leakage between wheel halves. Placed lower wheel on 2x4 wood blocks under tire. Placed upper wheel half onto lower and bolted tight with all six bolts. Then placed the rubber o-ring at the wheel join. Used a lot of watery dish soap as lubricant during tire inflation, used ratchet strap to compress center of tire during inflation to seat bead onto rim.

Gear installation preceded tire / wheel assembly.

2023-02-11_front_gear_00.jpg

2023-02-11_front_gear_01.jpg

2023-02-11_front_gear_02.jpg

2023-02-11_front_gear_03.jpg

2023-02-11_wheels_and_tires_done_00.jpg

2023-02-11_wheels_and_tires_done_02.jpg

2023-02-18_on_gear_00.jpg

2023-02-18_on_gear_01.jpg

2023-02-18_on_gear_02.jpg

2023-02-18_on_gear_03.jpg

Jul 21, 2022 Hangar Move In, Part One - (4 hours)

Category: Workshop

Build rack to hold completed airframe subcomponents. Move engines to hangar.

2022-07-21_hangar_move_in_00.jpg

2022-07-21_hangar_move_in_01.jpg

Jul 15, 2022 Hangar Rented - (2 hours)

Category: Workshop

Found a commericial hangar at KRVS in Tulsa. Rented from Bill Denton, Denton and Associates LLC. Bill is a recipient of the Charles Taylor Mechanic Award.

2022-07-15_hangar_acquisition_00.jpg

2022-07-15_hangar_acquisition_01.jpg

2022-07-15_hangar_acquisition_02.jpg

2022-07-15_hangar_acquisition_03.jpg

Jun 12, 2022 Rear Fuselage - (2.5 hours)

Category: Fuselage

Installing flaperon actuator mount plate (flap function) and control tubes for flaperons (aileron function).

2022-06-12_fuselage_interior_00.jpg

2022-06-12_fuselage_interior_01.jpg

May 03, 2022 Rear Fuselage - (1.5 hours)

Category: Fuselage

Preparing rear fuselage baggage area rear panel for installation.

2022-05-03_fuselage_00.jpg

2022-05-03_fuselage_01.jpg

2022-05-03_fuselage_02.jpg

Feb 21, 2022 Rear Fuselage - (10 hours)

Category: Fuselage

The fuselage pieces, which have been riveted as subcomponents, are here assembled according to Zenith instructions and readied for riveting.

2022-02-04_fuselage_00.jpg

2022-02-04_fuselage_01.jpg

2022-02-04_fuselage_02.jpg

2022-02-04_fuselage_03.jpg

Jan 27, 2022 Fuselage Sides - (3 hours)

Category: Fuselage

Setting up L-angle and longeron on the passenger and pilot fuselage side skins. Also fit the rear fuselage front upright to the front edge of the fuselage. These parts are match drilled but have to be deburred and, on occasion, chased, before riveting.

Also shown is the William Wynne Corvair flight engine in temporary storage before installation. Each day it gets lovingly dusted.

2022-01-27_engine_storage.jpg

2022-01-27_fuselage_side_00.jpg

2022-01-27_fuselage_side_01.jpg

Dec 22, 2021 Fuselage Top - (1.5 hours)

Category: Fuselage

Various L-angle placement and trimming, baggage support. Some holes need to be drilled out to size, deburred.

2021-12-22_fuselage_top_00.jpg

2021-12-22_fuselage_top_01.jpg

Dec 21, 2021 Fuselage Top - (1 hour)

Category: Fuselage

Drilling, deburring. Re-clecoing.

2021-12-21_fuselage_top.jpg

Dec 20, 2021 Fuselage Bottom and Top - (3 hours)

Category: Fuselage

Riveted fuselage bottom pieces together: longerons and z channel around the access hatch. Layout top fuselage skin and longerons. Cleco together.

2021-12-20_fuselage_bottom.jpg

2021-12-20_fuselage_top_00.jpg

2021-12-20_fuselage_top_01.jpg

2021-12-20_fuselage_top_02.jpg

Dec 16, 2021 Fuselage Bottom - (1.7 hours)

Category: Fuselage

Laying out z channel on bottom of fuselage. The note about missing part was wrong.

2021-12-16_fuselage_bottom_00.jpg

2021-12-16_fuselage_bottom_01.jpg

2021-12-16_fuselage_bottom_02.jpg

Dec 14, 2021 Fuselage Bottom - (1.5 hours)

Category: Fuselage

Attaching fuselage bottom to the longerons. Parts in storage. They were soon to be moved to Tulsa, OK in March.

2021-12-14_finished_components.jpg

2021-12-14_fuselage_bottom.jpg

Dec 03, 2021 Pilot Side Wing - (1.5 hours)

Category: Wings

Wing complete.

2021-12-03_pilot_side_wing_complete_00.jpg

2021-12-03_pilot_side_wing_complete_01.jpg

Nov 16, 2021 Pilot Side Wing - (2 hours)

Category: Wings

More wing root work. The sheet metal is now fully in place. It will not be riveted in until final assembly when the wings have been attached to the fuselage, the controls rigged, and all connections tested (including fuel lines).

2021-11-16_wing_root_work_00.jpg

2021-11-16_wing_root_work_01.jpg

Nov 08, 2021 Pilot Side Wing - (1.5 hours)

Category: Wings

Wing root sheet metal work.

2021-11-08_wing_root_work.jpg

Oct 24, 2021 Pilot Side Wing - (2.5 hours)

Category: Wings

Connector to plug into AeroLED wingtip lights.

2021-10-24_wing_wiring_light_connector_00.jpg

2021-10-24_wing_wiring_light_connector_01.jpg

Oct 23, 2021 Fuel Line - (3 hours)

Category: Wings

Used Earl's tooling to fabricate braided steel fuel lines using Earl's AN fittings. Used proper tools (line cutter and fitting clamp). Leak test with 100LL to follow.

2021-10-23_wing_tank_install_01.jpg

2021-10-23_wing_tank_install_02.jpg

2021-10-23_wing_tank_install_03.jpg

2021-10-23_wing_tank_install_05.jpg

2021-10-23_wing_tank_install_06.jpg

2021-10-23_wing_tank_install_07.jpg

2021-10-23_wing_tank_install_08.jpg

2021-10-23_wing_tank_install_09.jpg

Oct 20, 2021 Build and Install Fuel Tank - (4 hours)

Category: Wings

Wing was a lot easier the second time; should be done with this wing soon. The deeper consideration, basic learning, tool and part acquisition was on the first wing. This one is all about refinement and getting better at doing something the second time through.

Installed fuel sender with appropriate aviation grade sealant.

Wired according to plans and crimped according to 43.13-1b.

2021-10-20_build_install_fuel_tank_00.jpg

2021-10-20_build_install_fuel_tank_01.jpg

2021-10-20_build_install_fuel_tank_02.jpg

2021-10-20_build_install_fuel_tank_03.jpg

2021-10-20_build_install_fuel_tank_04.jpg

2021-10-20_build_install_fuel_tank_05.jpg

Oct 06, 2021 Pilot Side Wing - (3 hours)

Category: Wings

Top wing skin work. Including setting up cover for fuel tank.

2021-10-06_pilot_wing_top_skin_00.jpg

2021-10-06_pilot_wing_top_skin_01.jpg

2021-10-06_pilot_wing_top_skin_02.jpg

2021-10-06_pilot_wing_top_skin_03.jpg

Sep 27, 2021 Pilot Side Wing - (2 hours)

Category: Wings

More drilling to final size and deburring.

2021-09-27_leading_edge_skins_00.jpg

2021-09-27_leading_edge_skins_01.jpg

2021-09-27_leading_edge_skins_02.jpg

Sep 25, 2021 Pilot Side Wing - (1.5 hours)

Category: Wings

Leading edge skin work.

2021-09-25_leading_edge_skins_00.jpg

2021-09-25_leading_edge_skins_01.jpg

Sep 10, 2021 Pilot Side Wing - (3 hours)

Category: Wings

Wiring runs along rear spar bolted in with AN hardware and MS21919 clamps. Pitot tubes secured per manufacturer instructions.

2021-09-10_pilot_wing_pitot_00.jpg

2021-09-10_pilot_wing_pitot_01.jpg

2021-09-10_pilot_wing_pitot_02.jpg

2021-09-10_pilot_wing_pitot_03.jpg

2021-09-10_pilot_wing_wiring_and_skins_00.jpg

2021-09-10_pilot_wing_wiring_and_skins_01.jpg

2021-09-10_pilot_wing_wiring_and_skins_02.jpg

2021-09-10_pilot_wing_wiring_and_skins_03.jpg

2021-09-10_pilot_wing_wiring_and_skins_04.jpg

2021-09-10_pilot_wing_wiring_and_skins_05.jpg

Sep 09, 2021 Pilot Side Wing - (15 hours)

Category: Wings

Front skins and trailing edge work.

2021-09-09_pilot_wing_front_skin_trailing_edge.jpg

Aug 24, 2021 Pilot Side Wing - (3 hours)

Category: Wings

Bottom skin and rear channel riveting.

2021-08-24_pilot_wing_work_00.jpg

2021-08-24_pilot_wing_work_01.jpg

2021-08-24_pilot_wing_work_02.jpg

Aug 15, 2021 Pilot Side Wing - (3.5 hours)

Category: Wings

Wing bottom skins.

2021-08-15_pilot_side_wing_bottom_skin_00.jpg

2021-08-15_pilot_side_wing_bottom_skin_01.jpg

2021-08-15_pilot_side_wing_bottom_skin_02.jpg

2021-08-15_pilot_side_wing_bottom_skin_03.jpg

2021-08-15_pilot_side_wing_bottom_skin_04.jpg

Aug 09, 2021 Pilot Side Wing - (3 hours)

Category: Wings

More riveting of pilot side bottom skin.

2021-08-09_pilot_wing_riveting_bottom_skin_00.jpg

2021-08-09_pilot_wing_riveting_bottom_skin_01.jpg

2021-08-09_pilot_wing_riveting_bottom_skin_02.jpg

2021-08-09_pilot_wing_riveting_bottom_skin_03.jpg

Aug 06, 2021 Pilot Wing - (2.5 hours)

Category: Wings

Working on drilling, deburring, and riveting front ribs. In last picture the main spar attachment for the struts is visible. It was attached with AN-4 bolts and nylon lock nuts per instructions.

2021-08-06_pilot_wing_more_drilling_for_front_rib_tips_00.jpg

2021-08-06_pilot_wing_more_drilling_for_front_rib_tips_01.jpg

2021-08-06_pilot_wing_more_drilling_for_front_rib_tips_02.jpg

2021-08-06_pilot_wing_more_drilling_for_front_rib_tips_03.jpg

Aug 04, 2021 Pilot Side Wing - (1.5 hours)

Category: Wings

Initial skeleton of pilot side wing.

2021-08-04_pilot_wing_deburred_for_riveting.jpg

Jul 23, 2021 Pilot Wing Skeleton - (2 hours)

Category: Wings

Cleco together the pilot side wing skeleton, attach both front and rear ribs, attach the rear spar and prepare for riveting.

2021-07-23_pilot_wing_skeleton.jpg

Jul 12, 2021 Pilot Side Wing - (2.5 hours)

Category: Wings

Wing skeleton layout, including nose ribs.

2021-07-12_pilot_wing_skeleton_00.jpg

2021-07-12_pilot_wing_skeleton_01.jpg

2021-07-12_pilot_wing_skeleton_02.jpg

2021-07-12_pilot_wing_skeleton_03.jpg

Jun 22, 2021 Passenger Side Wing - (4.5 hours)

Category: Wings

Wing tip electrical.

2021-06-22_passenger_side_wing_tip_electrical_00.jpg

2021-06-22_passenger_side_wing_tip_electrical_01.jpg

2021-06-22_passenger_side_wing_tip_electrical_02.jpg

2021-06-22_passenger_side_wing_tip_electrical_03.jpg

2021-06-22_passenger_side_wing_tip_electrical_04.jpg

2021-06-22_passenger_side_wing_tip_electrical_05.jpg

2021-06-22_passenger_side_wing_tip_electrical_06.jpg

2021-06-22_passenger_side_wing_tip_electrical_07.jpg

2021-06-22_passenger_side_wing_tip_electrical_08.jpg

Jun 22, 2021 Passenger Wing Tip and Light - (10 hours)

Category: Lighting

Wired and grounded using techniques from AC 43.13-B and instructions from manufacturer AeroLED.

2022-06-22_passenger_side_wing_tip_electrical_00.jpg

2022-06-22_passenger_side_wing_tip_electrical_01.jpg

2022-06-22_passenger_side_wing_tip_electrical_02.jpg

2022-06-22_passenger_side_wing_tip_electrical_03.jpg

2022-06-22_passenger_side_wing_tip_electrical_04.jpg

2022-06-22_passenger_side_wing_tip_electrical_05.jpg

2022-06-22_passenger_side_wing_tip_electrical_06.jpg

2022-06-22_passenger_side_wing_tip_electrical_07.jpg

2022-06-22_passenger_side_wing_tip_electrical_08.jpg

Jun 08, 2021 Passenger Side Wing - (2 hours)

Category: Wings

Fuel tank fittings.

2021-06-08_passenger_wing_fuel_fittings_00.jpg

2021-06-08_passenger_wing_fuel_fittings_01.jpg

2021-06-08_passenger_wing_fuel_fittings_02.jpg

2021-06-08_passenger_wing_fuel_fittings_03.jpg

May 29, 2021 Wing Root - (3 hours)

Category: Wings

Wing root fabrication and sheet metal install. Required using fluting pliers. Clamp root skin into place. Drill #40 pilot holes into fluted support l-angle and cleco.

2021-05-29_passenger_wing_root_00.jpg

2021-05-29_passenger_wing_root_01.jpg

May 13, 2021 Passenger Side Wing - (3 hours)

Category: Wings

Installing the wiring for the fuel sender, as per requirements of 43.13-1b table 11-14.

2021-05-13_passenger_wing_fuel_electrics_00.jpg

2021-05-13_passenger_wing_fuel_electrics_01.jpg

2021-05-13_passenger_wing_fuel_electrics_02.jpg

2021-05-13_passenger_wing_fuel_electrics_03.jpg

2021-05-13_passenger_wing_fuel_electrics_04.jpg

Apr 19, 2021 Nutplates in Wing Access Panel - (1.5 hours)

Category: Wings

Drilling nutplate holes for fuel tank access panel using standard jig tool.

2021-04-19_fuel_tank_access_panel_nutplates_00.jpg

2021-04-19_fuel_tank_access_panel_nutplates_01.jpg

2021-04-19_fuel_tank_access_panel_nutplates_02.jpg

Mar 14, 2021 Engine on Test Stand - (8 hours)

Category: Engine

At William Wynne's hangar, supervised top-end build and test run. Finished installing: Oil pan, starter bracket / ground bar, starter. Filled with oil. Put on test stand and rotated prop for 30 minutes by hand while running oil pump with drill adapter. Installed distributor at correct test run position.

Test run commenced about 300pm. Engine started within 2 seconds. Ran at varying RPM for 30 minutes.

Adjusted heavy duty oil pump bottom plate to account for slightly stiff rotation to bring it into a level of resistance to rotation that is consistent with other engine builds. Removed from test stand and prepped engine for transport back to Texas.

2021-03-14_engine_on_test_stand_william_wynne_hanger_00.jpg

2021-03-14_engine_on_test_stand_william_wynne_hanger_01.jpg

Mar 13, 2021 Top End / Accessory Attachment - (9 hours)

Category: Engine

Assembled top end of motor at William Wynne's hangar as supervised build. These components assembled as per specification in the SPA Corvair Engine Assembly Manual except when William recommended and showed newer, improved methods.

2021-03-13_top_end_finishing_00.jpg

2021-03-13_top_end_finishing_01.jpg

2021-03-13_top_end_finishing_02.jpg

2021-03-13_top_end_finishing_03.jpg

2021-03-13_top_end_finishing_04.jpg

2021-03-13_top_end_finishing_05.jpg

2021-03-13_top_end_finishing_06.jpg

2021-03-13_top_end_finishing_07.jpg

Feb 27, 2021 Final engine assembly prep - (2 hours)

Category: Engine

Ensure all tools and materials per the final assembly list in the SPA Corvair Engine Assembly Manual and per William Wynne's required tools and materials list put together and made ready to transport to Green Cove Springs, Florida.

2021-02-27_engine_assembly_tools.jpg

Jan 23, 2021 Passenger Wing - (2.5 hours)

Category: Wings

Finish up riveting bottom skin on passenger wing.

2021-01-23_passenger_wing_00.jpg

2021-01-23_passenger_wing_01.jpg

2021-01-23_passenger_wing_02.jpg

Jan 20, 2021 Passenger Wing - (1 hour)

Category: Wings

Preparing to rivet bottom skin of passenger side wing to the skeleton. Beginning the rivet process.

2021-01-20_passenger_wing_00.jpg

2021-01-20_passenger_wing_01.jpg

Jan 09, 2021 Skin on Wing - (3.5 hours)

Category: Wings

Unpack bottom wing skin for installation. Place skin with clecos. Rivet skin into place in all pre-drilled holes.

2021-01-09_wing_00.jpg

2021-01-09_wing_01.jpg

2021-01-09_wing_02.jpg

2021-01-09_wing_03.jpg

2021-01-09_wing_04.jpg

2021-01-09_wing_05.jpg

Jan 08, 2021 Rear Spar Work - (1.7 hours)

Category: Wings

Fastened inboard and outboard rear spar together. A5 rivets in doubler.

2021-01-08_wing_00.jpg

2021-01-08_wing_01.jpg

2021-01-08_wing_02.jpg

Dec 06, 2020 Starboard Wing Skeleton Assembly - (2.5 hours)

Category: Wings

Unpacked the wing skeleton from the crate, organized parts and set them aside in order of assembly.

Clecoed wing ribs to main and trailing spar. Checked for level.

2020-12-06_starboardwing_00.jpg

2020-12-06_starboardwing_01.jpg

2020-12-06_starboardwing_02.jpg

2020-12-06_starboardwing_03.jpg

Dec 05, 2020 Slats and Flaperons - (1.5 hours)

Category: Wings

Installing tips

IMG_20201204_110214.jpg

IMG_20201204_110252.jpg

IMG_20201204_121503.jpg

Dec 03, 2020 Slats and Flaperons - (3 hours)

Category: Wings

Install tips

IMG_20201203_112313.jpg

IMG_20201203_123242.jpg

IMG_20201203_150306.jpg

IMG_20201203_154620.jpg

IMG_20201203_154651.jpg

Nov 21, 2020 Slats - (2 hours)

Category: Wings

IMG_20201121_213342.jpg

IMG_20201121_213345.jpg

IMG_20201121_214238.jpg

Nov 19, 2020 Slats - (3 hours)

Category: Wings

IMG_20201119_123146.jpg

IMG_20201119_123156.jpg

IMG_20201119_140906.jpg

IMG_20201120_112308.jpg

Nov 17, 2020 Slats - (3 hours)

Category: Wings

IMG_20201117_213256.jpg

IMG_20201117_213302.jpg

IMG_20201117_214832.jpg

IMG_20201117_214839.jpg

IMG_20201117_215640.jpg

IMG_20201117_215644.jpg

IMG_20201117_215654.jpg

Nov 16, 2020 Slats - (1 hour)

Category: Wings

IMG_20201116_225307.jpg

Nov 13, 2020 Slats - (6 hours)

Category: Wings

Further assembly of slats. This was a bit trickier than I thought and it didn't come together until I figured out the correct order to attach the clecos.

InboardPass00.jpg

InboardPass01.jpg

InboardPass02.jpg

InboardPass03.jpg

Tips.jpg

IMG_20201113_091334.jpg

IMG_20201113_102355.jpg

IMG_20201113_102400.jpg

IMG_20201113_102409.jpg

IMG_20201113_111644.jpg

IMG_20201113_140422.jpg

Nov 11, 2020 Slats - (2 hours)

Category: Wings

Attaching the doubler to the slat front top / bottom bend.

InboardPass00.jpg

InboardPass01.jpg

InboardPass02.jpg

InboardPass03.jpg

Nov 10, 2020 Slats - (2 hours)

Category: Wings

IMG_20201110_225755.jpg

Nov 06, 2020 Flaperons - (4 hours)

Category: Wings

IMG_20201106_085653.jpg

IMG_20201106_085659.jpg

IMG_20201106_100920.jpg

IMG_20201106_100928.jpg

IMG_20201106_101141.jpg

IMG_20201106_112836.jpg

IMG_20201106_112841.jpg

IMG_20201106_150324.jpg

IMG_20201106_151848.jpg

IMG_20201106_153504.jpg

IMG_20201106_153510.jpg

IMG_20201106_164932.jpg

Nov 04, 2020 Flaperons - (2 hours)

Category: Wings

IMG_20201104_221241.jpg

IMG_20201104_221247.jpg

IMG_20201104_221256.jpg

Nov 01, 2020 Flaperons - (3 hours)

Category: Wings

IMG_20201101_105730.jpg

IMG_20201101_111803.jpg

IMG_20201101_181127.jpg

IMG_20201101_190837.jpg

IMG_20201101_195044.jpg

IMG_20201101_195140.jpg

IMG_20201101_202332.jpg

Oct 30, 2020 Flaperons - (1 hour)

Category: Wings

IMG_20201030_123720.jpg

IMG_20201030_123954.jpg

Oct 29, 2020 Flaperons - (1 hour)

Category: Wings

IMG_20201029_213926.jpg

Oct 28, 2020 Flaperons - (2 hours)

Category: Wings

IMG_20201028_202204.jpg

IMG_20201028_202216.jpg

IMG_20201028_202258.jpg

IMG_20201028_202332.jpg

IMG_20201028_225923.jpg

Oct 26, 2020 Flaperons - (2 hours)

Category: Wings

IMG_20201026_212915.jpg

IMG_20201026_220843.jpg

IMG_20201026_225325.jpg

IMG_20201026_225649.jpg

IMG_20201026_225703.jpg

IMG_20201026_230240.jpg

Oct 24, 2020 Flaperons - (3 hours)

Category: Wings

IMG_20201024_095212.jpg

IMG_20201024_102455.jpg

IMG_20201024_102942.jpg

IMG_20201024_103220.jpg

IMG_20201024_143756.jpg

IMG_20201024_163143.jpg

IMG_20201024_171044.jpg

IMG_20201024_171051.jpg

IMG_20201024_171103.jpg

IMG_20201024_171241.jpg

Oct 21, 2020 Harmonic Balancer Final Install - (.5 hour)

Category: Engine

Note to self: Write SPA a note about their install documentation. 2 inch install bolt does not penetrate far enough into crankshaft to tighten balancer down correctly (at least on my crankshaft). Stripped two inch bolt.

IMG_20201021_083734.jpg

IMG_20201021_083841.jpg

IMG_20201021_200710.jpg

Oct 20, 2020 Harmonic Balancer Install - (2 hours)

Category: Engine

IMG_20201015_210539 - Copy.jpg

IMG_20201020_195635~2 - Copy.jpg

IMG_20201020_195650.jpg

IMG_20201020_200600.jpg

IMG_20201020_201413.jpg

IMG_20201020_201421.jpg

IMG_20201020_202902.jpg

IMG_20201020_205344.jpg

IMG_20201020_205420.jpg

Oct 10, 2020 Finish Cylinder Installs - (5 hours)

Category: Engine

IMG_20201010_112524.jpg

IMG_20201010_142451.jpg

IMG_20201010_160634.jpg

IMG_20201010_160645.jpg

IMG_20201010_160714.jpg

Oct 08, 2020 Parts - (.5 hour)

Category: Engine

IMG_20201008_141353.jpg

IMG_20201008_141457.jpg

IMG_20201008_141923.jpg

IMG_20201008_153004.jpg

IMG_20201008_153012.jpg

IMG_20201008_153055.jpg

IMG_20201008_153106.jpg

Oct 05, 2020 Piston / Cylinder #1 Install - (1.5 hours)

Category: Engine

IMG_20201005_211211.jpg

IMG_20201005_211217.jpg

IMG_20201005_214950.jpg

IMG_20201005_225044.jpg

Sep 30, 2020 Piston / Cylinder #1 Install - (1.5 hours)

Category: Engine

IMG_20200930_202841.jpg

IMG_20200930_202859.jpg

IMG_20200930_203138.jpg

IMG_20200930_203142.jpg

IMG_20200930_203145.jpg

IMG_20200930_210128.jpg

IMG_20200930_210143.jpg

IMG_20200930_210830.jpg

IMG_20200930_211316.jpg

IMG_20200930_215349.jpg

IMG_20200930_220108.jpg

Sep 28, 2020 Piston / Cylinder #1 Install - (2 hours)

Category: Engine

IMG_20200928_214723.jpg

IMG_20200928_215128.jpg

IMG_20200928_221343.jpg

$gallery thumbnail$

IMG_20200928_221351.jpg

IMG_20200928_221517.jpg

IMG_20200928_221635.jpg

IMG_20200928_221916.jpg

IMG_20200928_224915.jpg

IMG_20200928_225545.jpg

IMG_20200928_225600.jpg

IMG_20200928_225626.jpg

Sep 27, 2020 Piston / Cylinder Install Prep - (1 hour)

Category: Engine

IMG_20200927_142831.jpg

IMG_20200927_152242.jpg

Sep 22, 2020 Piston / Cylinder Install Prep - (1 hour)

Category: Engine

IMG_20200922_213507.jpg

IMG_20200922_213518.jpg

Sep 19, 2020 Piston / Cylinder Install Prep - (2.5 hours)

Category: Engine

IMG_20200919_145747.jpg

IMG_20200919_145815.jpg

IMG_20200919_145821.jpg

IMG_20200919_150030.jpg

IMG_20200919_155046.jpg

IMG_20200919_155428.jpg

IMG_20200919_160609.jpg

Sep 17, 2020 Piston / Cylinder Install Prep - (1 hour)

Category: Engine

IMG_20200917_220423.jpg

IMG_20200917_220426.jpg

IMG_20200917_220434.jpg

IMG_20200917_220539.jpg

IMG_20200917_220546.jpg

IMG_20200917_220553.jpg

IMG_20200917_221935.jpg

IMG_20200917_222201.jpg

Sep 09, 2020 Inventory - (3 hours)

Category: Fuselage

IMG_20200909_195932.jpg

IMG_20200909_195939.jpg

IMG_20200909_195943.jpg

IMG_20200909_195948.jpg

IMG_20200909_200001.jpg

Aug 31, 2020 Inventory - (3 hours)

Category: Fuselage

IMG_20200831_211030.jpg

IMG_20200831_211030~2.jpg

IMG_20200831_223658.jpg

IMG_20200831_230022.jpg

Aug 30, 2020 Inventory - (4 hours)

Category: Fuselage

IMG_20200830_150234.jpg

IMG_20200830_152824.jpg

IMG_20200830_152842.jpg

IMG_20200830_212424.jpg

IMG_20200830_212429.jpg

IMG_20200830_212450.jpg

IMG_20200830_212455.jpg

IMG_20200830_212501.jpg

IMG_20200830_212506.jpg

IMG_20200830_212510.jpg

IMG_20200830_212514.jpg

Aug 22, 2020 Inventory - (2 hours)

Category: Fuselage

IMG_20200822_220155.jpg

IMG_20200822_220213.jpg

IMG_20200822_220230.jpg

Aug 20, 2020 Inventory - (2 hours)

Category: Fuselage

IMG_20200820_232340.jpg

Aug 18, 2020 Airframe Delivery at Home - (1 hour)

Category: Fuselage

IMG_20200818_005909.jpg

IMG_20200818_071816.jpg

IMG_20200818_071849.jpg

IMG_20200818_083152.jpg

IMG_20200818_083200.jpg

IMG_20200818_100625.jpg

IMG_20200818_101114.jpg

Aug 17, 2020 Pick up rest of airframe at Zenith - (1 hour)

Category: Fuselage

IMG_20200817_073746.jpg

IMG_20200817_073921.jpg

IMG_20200817_073947.jpg

IMG_20200817_074028.jpg

IMG_20200817_074035.jpg

IMG_20200817_084434.jpg

IMG_20200817_092607.jpg

IMG_20200817_104939.jpg

IMG_20200817_105505.jpg

Aug 09, 2020 Parts Storage / Reorg - (1 hour)

Category: Workshop

IMG_20200809_163219.jpg

IMG_20200809_163329.jpg

IMG_20200809_163333.jpg

Aug 01, 2020 Elevator - (2 hours)

Category: Empennage

IMG_20200801_003808.jpg

IMG_20200801_084951.jpg

IMG_20200801_085009.jpg

IMG_20200801_085026.jpg

IMG_20200801_090146.jpg

IMG_20200801_090159.jpg

IMG_20200801_091709.jpg

IMG_20200801_091710.jpg

IMG_20200801_113259.jpg

IMG_20200801_120248.jpg

IMG_20200801_121042.jpg

Aug 01, 2020 Elevator Riveting - (2.5 hours)

Category: Empennage

Riveted the elevator closed. Riveted top and bottom and back center bracket onto elevator. Did a demo video of riveting, but rivet gun was angled badly. So it's a nice video of how to NOT rivet. Decided to drill out, caused hole problems. Was going to do a doubler, but decided not to in the end. A5 seems okay. Would have been better to leave it not seated perfectly. Made note to check this out often during inspections. Will replace if any issue shows up. But it is not a high stress point and nothing will happen if it fails in flight (which it won't). One of 3 minor drilling mistakes on the elevator. And, as usual, it was done in haste not taking enough time to think about what I was doing (that is ALWAYS the root cause of errors so far).

IMG_20200801_003808.jpg

IMG_20200801_090159.jpg

IMG_20200801_091709.jpg

IMG_20200801_121042.jpg

Jul 31, 2020 Elevator - (1 hour)

Category: Empennage

IMG_20200731_232753.jpg

Jul 29, 2020 Elevator - (2 hours)

Category: Empennage

Reassembled for final riveting. Fattened WRONG hole of an L angle tab that connects the spar with the port elevator end rib. Simply drilled another rivet hole enough below to work. Painted elevator hinges to inhibit corrosion. Riveted skeleton. Riveted wire to front spar.

IMG_20200728_214553.jpg

IMG_20200728_215225.jpg

IMG_20200728_233009.jpg

IMG_20200728_233024.jpg

Jul 28, 2020 Elevator

Category: Empennage

IMG_20200728_214553.jpg

IMG_20200728_214604.jpg

IMG_20200728_215225.jpg

IMG_20200728_233009.jpg

IMG_20200728_233013.jpg

IMG_20200728_233024.jpg

Jul 27, 2020 Elevator - (1 hour)

Category: Empennage

IMG_20200727_233736.jpg

IMG_20200727_233743.jpg

Jul 27, 2020 Elevator - (1.5 hours)

Category: Empennage

Place servo into the correct location, set the length of the clevis rod, attach to trim tab, and begin testing and adjustment to get to best travel distance for up and down deflection targeted in the plans. This servo Zenith shipped does not have quite the range specified in the plans though. I'm within 5 degrees up and 8 down. I'll enter exact numbers in a later entry. Run the wire out to the center section of the elevator. Link to test on youtube: https://youtu.be/F_ooA6mKN88

IMG_20200727_233736.jpg

IMG_20200727_233743.jpg

Jul 26, 2020 Servo Mount / Trim Tab Safety Wire - (2 hours)

Category: Empennage

IMG_20200726_082242.jpg

IMG_20200726_083308.jpg

IMG_20200726_083313.jpg

IMG_20200726_103605.jpg

IMG_20200726_103630.jpg

IMG_20200726_105452.jpg

IMG_20200726_105923.jpg

IMG_20200726_124439.jpg

IMG_20200726_134403.jpg

IMG_20200726_151443.jpg

Jul 26, 2020 Elevator - (2 hours)

Category: Empennage

Set up nutplates around access hole. Place and mark. Drill. Rivet (3/32)

IMG_20200726_083308.jpg

IMG_20200726_083313.jpg

IMG_20200726_103605.jpg

IMG_20200726_103630.jpg

IMG_20200726_105452.jpg

Jul 25, 2020 Trim Tab Wiring / Access Nut Plates - (2 hours)

Category: Empennage

IMG_20200725_181016.jpg

IMG_20200725_181211.jpg

IMG_20200725_182152.jpg

IMG_20200725_182157.jpg

IMG_20200725_182245.jpg

IMG_20200725_182809.jpg

IMG_20200725_183148.jpg

IMG_20200725_183204.jpg

IMG_20200725_183342.jpg

IMG_20200725_184050.jpg

Jul 25, 2020 Elevator Servo - (1.5 hours)

Category: Empennage

Put heat shrink tubing onto servo electrical wire connections. Drilled out access cover plate holes to A5 rivet size (5/32), because the nut plate holes are 8-32 size. Safety wire pliers arrived.

IMG_20200725_182152.jpg

IMG_20200725_182157.jpg

IMG_20200725_182245.jpg

IMG_20200725_182809.jpg

IMG_20200725_183342.jpg

IMG_20200725_184050.jpg

Jul 23, 2020 Trim Tab Servo Wiring

Category: Empennage

IMG_20200723_210556.jpg

IMG_20200723_215555.jpg

IMG_20200723_215632.jpg

IMG_20200723_215706.jpg

IMG_20200723_220456.jpg

IMG_20200723_223205.jpg

Jul 23, 2020 Servo Wiring - (1 hour)

Category: Empennage

Use DMC crimper to crimp D-subminiature connectors onto Ray Allen Servo wires. Note colors / markings for future routing of wires up to cockpit!

IMG_20200723_210556.jpg

IMG_20200723_215555.jpg

IMG_20200723_215632.jpg

IMG_20200723_215706.jpg

IMG_20200723_223205.jpg

Jul 18, 2020 Elevator - (1 hour)

Category: Empennage

IMG_20200718_124823.jpg

IMG_20200718_203047.jpg

IMG_20200718_203051.jpg

Jul 18, 2020 Elevator Deburring - (2 hours)

Category: Empennage

Deburring elevator holes. Electrical stuff for Ray Allen Servo wire connecting starting to arrive (after much research).

IMG_20200715_213041.jpg

IMG_20200715_225708.jpg

IMG_20200717_230901.jpg

IMG_20200718_124823.jpg

Jul 17, 2020 Elevator

Category: Empennage

IMG_20200717_230901.jpg

Jul 15, 2020 Elevator

Category: Empennage

IMG_20200713_120438.jpg

IMG_20200715_205244.jpg

IMG_20200715_205247.jpg

IMG_20200715_205252.jpg

IMG_20200715_213041.jpg

IMG_20200715_225700.jpg

IMG_20200715_225708.jpg

Jul 15, 2020 Elevator - (2 hours)

Category: Empennage

Final drilling to A4 for a few remaing holes. Needed angle drill. Disassemble for deburring. Drilled out nose rib for electrical wire grommet. Cylinder hold down clamps fabricated. Received DMC crimper.

IMG_20200711_225715.jpg

IMG_20200711_235002.jpg

IMG_20200712_213423.jpg

IMG_20200712_221435.jpg

IMG_20200712_231114.jpg

Jul 12, 2020 Elevator - (2.5 hours)

Category: Empennage

IMG_20200712_213415.jpg

IMG_20200712_213423.jpg

IMG_20200712_221435.jpg

IMG_20200712_221442.jpg

IMG_20200712_231114.jpg

Jul 11, 2020 Trim Tab Wiring / Cylinder Hold down fabrication - (2 hours)

Category: Empennage

IMG_20200711_115747.jpg

IMG_20200711_115747~2.jpg

IMG_20200711_225715.jpg

IMG_20200711_235002.jpg

Jul 09, 2020 Elevator - (2.5 hours)

Category: Empennage

I have finished all the drilling, and built the control arm to the correct length to control my trim tab with the Ray Allen servo. This necessitated figuring out the in and out wiring, and measuring distances on the servo actuator arm to make sure I got it just in the middle for installation. A 9V battery runs in in and out. I recorded the polarity for both on the data sheet. Ready for inspection to make sure I didn't miss something, then disassembly and deburring.

IMG_20200709_230403.jpg

IMG_20200709_231958.jpg

IMG_20200709_232339.jpg

IMG_20200709_233025.jpg

IMG_20200709_233513.jpg

Jul 08, 2020 Elevator Servo Placement - (2 hours)

Category: Empennage

I've had the most fun with this servo, where I went off and did a fair bit of learning about aircraft wiring: https://corvair750.com/diary/07-02-2020-aircraft-wiring/

Spent some happy time in the shop drilling the holes for the Ray Allen servo used for trim tab control.

IMG_20200708_225537.jpg

IMG_20200708_225545.jpg

IMG_20200708_232125.jpg

IMG_20200708_232214.jpg

IMG_20200708_233451.jpg

IMG_20200708_233459.jpg

IMG_20200708_233528.jpg

Jun 27, 2020 Cylinders - (1.5 hours)

Category: Engine

IMG_20200627_085211.jpg

IMG_20200627_085227.jpg

IMG_20200627_113202.jpg

IMG_20200627_114114.jpg

IMG_20200627_114124.jpg

IMG_20200627_114240.jpg

IMG_20200627_161321.jpg

IMG_20200627_162701.jpg

Jun 27, 2020 Painting Cylinders and Studs - (1.5 hours)

Category: Engine

Painted some cylinders and painted also the head studs. Head studs can tend to rust so I just painted them over flat black. Same with cylinders, they are prone to rust without paint. High temp engine paint with ceramic -- 500 degree. Note ingenious paint fixture, credit to Billy Kerchner who is building a Corvair powered Sonex (see his posts on WW FlyCorvair facebook group).

IMG_20200627_085211.jpg

IMG_20200627_085227.jpg

IMG_20200627_113202.jpg

IMG_20200627_114114.jpg

IMG_20200627_114240.jpg

IMG_20200627_161321.jpg

Jun 26, 2020 Cylinders - (2 hours)

Category: Engine

IMG_20200626_084730.jpg

IMG_20200626_084919.jpg

IMG_20200626_084934.jpg

IMG_20200626_104434.jpg

IMG_20200626_104445.jpg

IMG_20200626_123904.jpg

IMG_20200626_123922.jpg

IMG_20200626_144057.jpg

IMG_20200626_154317.jpg

IMG_20200626_154319.jpg

IMG_20200626_154327.jpg

IMG_20200626_154342.jpg

IMG_20200626_154735.jpg

Jun 26, 2020 Cylinder cleaning - (2 hours)

Category: Engine

Finished control arm / clevis opening with filing. Then, change of pace: Working on prepping my 3.0L cylinders for installation on my short block Corvair. This is preparation for painting. Was concerned about the step area along the cylinder skirt and asked William Wynne about it. The gasket in that area is RTV green, about a 1/16 bead. No worries there. The areas near the step that are machined out near the stud channels are there so the cylinder does not vibrate against the stud in operation.

IMG_20200626_084730.jpg

IMG_20200626_084919.jpg

IMG_20200626_084934.jpg

IMG_20200626_104434.jpg

IMG_20200626_104445.jpg

IMG_20200626_123904.jpg

IMG_20200626_123922.jpg

IMG_20200626_144057.jpg

IMG_20200626_154317.jpg

IMG_20200626_154319.jpg

IMG_20200626_154327.jpg

IMG_20200626_154342.jpg

IMG_20200626_154735.jpg

Jun 25, 2020 Elevator - (1 hour)

Category: Empennage

IMG_20200625_174723.jpg

IMG_20200625_175019.jpg

IMG_20200625_175022.jpg

Jun 25, 2020 Elevator Trim Tab Control

Category: Empennage

Drilling and forming the trim tab control arm hole on the trim tab spar. Starting to figure out the Ray Allen control servo.

IMG_20200622_214939.jpg

IMG_20200622_214950.jpg

IMG_20200622_221640.jpg

IMG_20200625_174723.jpg

IMG_20200625_175019.jpg

IMG_20200625_175022.jpg

Jun 20, 2020 Elevator - (1.5 hours)

Category: Empennage

More drilling of elevator in tight spots, drilling out to A4 and finished bracket work.

IMG_20200620_165135.jpg

IMG_20200620_165141.jpg

IMG_20200620_165156.jpg

IMG_20200620_165201.jpg

Jun 18, 2020 Elevator work - (2 hours)

Category: Empennage

I had to order an angle drill because it's just not possible to drill out some holes in the elevator without one. Trying to use a regular drill risked dinging up the spars and skins. So part of the delay of getting the elevator put together was researching tools. In this case the nice angle pneumatic drill. Definitely worked as needed once I got all the bits I needed which I hadn't ordered when I originally ordered the drill ...

IMG_20200616_221617.jpg

IMG_20200618_220719.jpg

IMG_20200618_220726.jpg

IMG_20200618_220743.jpg

Jun 14, 2020 Elevator, Trim Tab, and Engine Stand - (2 hours)

Category: Empennage

Worked on the elevator trim tab, and drilling out holes to A4 and A5 and then put together the engine stand. Coffee kept me up late this night.

IMG_20200610_230829.jpg

IMG_20200613_232558.jpg

IMG_20200613_232613.jpg

IMG_20200613_232641.jpg

IMG_20200613_232719.jpg

Jun 13, 2020 Elevator - (1 hour)

Category: Engine

IMG_20200613_232558.jpg

IMG_20200613_232613.jpg

IMG_20200613_232641.jpg

IMG_20200613_232719.jpg

Jun 12, 2020 Elevator Trim Tab - (1.5 hours) Category: Tail Feathers

Drilled out to A4 and clecoed the trim tab into position. youtube:

Jun 10, 2020 Parts Inventory - (1 hour)

Category: Engine

IMG_20200610_160542.jpg

IMG_20200610_160552.jpg

IMG_20200610_160554.jpg

IMG_20200610_160602.jpg

IMG_20200610_230829.jpg

Jun 10, 2020 Parts from Green Cove Springs - (.5 hour)

Category: Engine

Received various engine parts for Corvair powerplant.

IMG_20200610_160602.jpg

Jun 08, 2020 Elevator - (2.5 hours)

Category: Empennage

IMG_20200608_191810.jpg

IMG_20200608_212802.jpg

IMG_20200608_212806.jpg

IMG_20200608_213339.jpg

IMG_20200608_213349.jpg

IMG_20200608_213353.jpg

IMG_20200608_213540.jpg

IMG_20200608_214818.jpg

IMG_20200608_215737.jpg

IMG_20200608_215754.jpg

Jun 08, 2020 Elevator and Engine Parts Inventory - (4 hours)

Category: Tail Feathers

Worked on the passenger side nose skin (in some pics elevator is upside down -- trim tab is pilot side). And the cylinder kit for my 3.0L engine. Once the elevator is done I'm moving on to engine construction, get the cylinders and pistons in. Then also got the trim tab placed and ready for drilling.

IMG_20200605_213416.jpg

IMG_20200605_213436.jpg

IMG_20200605_224728.jpg

IMG_20200605_233714.jpg

IMG_20200608_213353.jpg

IMG_20200608_214818.jpg

IMG_20200608_215754.jpg

Jun 05, 2020 Elevator - (2 hours)

Category: Empennage

IMG_20200605_205758.jpg

IMG_20200605_213416.jpg

IMG_20200605_213436.jpg

IMG_20200605_213447.jpg

IMG_20200605_224728.jpg

IMG_20200605_233042.jpg

IMG_20200605_233714.jpg

Jun 05, 2020 Elevator Nose Skin / Engine Components - (2 hours)

Category: Tail Feathers

More drilling on elevator nose skins (dimple drill first, then remove and drill all the way for proper alignment). Fit perfect, drilled out to A4.

Corvair engine parts arrived from SPA.

IMG_20200602_234002.jpg

IMG_20200605_205758.jpg

Jun 04, 2020 Elevator - (1.5 hours)

Category: Empennage

IMG_20200604_230744.jpg

IMG_20200604_230752.jpg

IMG_20200604_230806.jpg

IMG_20200604_230812.jpg

IMG_20200604_232036.jpg

Jun 03, 2020 Elevator Trim Tab Channel / Nose Skin Placement - (3 hours)

Category: Tail Feathers

Got trim channel drilled out and placed. Started nose skin placement. Came up with a way to get holes on skin drilled perfectly even though removing the clecos on the spar leads to minor (.5 to 1 mil) misalignments of spar and tip rib. Basically: do not drill all the way through the skin with the slightly misaligned skeleton because the skeleton would have possibly misaligned holes with skin. Drilled part way through skin, removed, drilled rest of way. Worked perfect: Absolute alignment of holes in skin and skeleton when clecoed together. (have vid hopefully on youtube someday ...

IMG_20200601_232322.jpg

IMG_20200601_233401.jpg

channelfitmentfixed.jpg

Jun 02, 2020 Elevator - (1 hour)

Category: Empennage

IMG_20200602_231444.jpg

IMG_20200602_234002.jpg

Jun 02, 2020 Trim Tab Channel - (1 hour) Category: Tail Feathers

Cut new block and sanded so I could use mallet on trim tab channel to make it fit outboard tip rib.

Jun 01, 2020 Elevator - (1.5 hours)

Category: Empennage

Resolving issues with a factory made part that doesn't have enough joggle to fit in the end rib.

IMG_20200601_215025.jpg

IMG_20200601_215053.jpg

IMG_20200601_215111.jpg

IMG_20200601_225332.jpg

IMG_20200601_225812.jpg

IMG_20200601_232322.jpg

IMG_20200601_232331.jpg

IMG_20200601_233344.jpg

IMG_20200601_233401.jpg

Jun 01, 2020 Trim Tab Channel Issue - (1 hour)

Category: Tail Feathers

Ran into a problem with the trim tab channel. My solution of whacking on the aluminum a bit to get the "joggle" of the outboard part of the channel smaller to fit into the tip rib correctly was verified by Roger Dubbert at Zenith via email. Measuring, making a form block. The outboard side was about 2 mils to wide ...

trimtabchannelmeasure1.jpg

trimtabchannelmeasure2.jpg

trimtabjoggleblock.jpg

May 28, 2020 Cylinder Assembly Research - (1 hour)

Category: Engine

Cylinder assembly reading, SPA manual pp124 to pp143

ManualFrontCover.jpg

May 25, 2020 Elevator - (3 hours)

Category: Empennage

IMG_20200525_111603.jpg

IMG_20200525_125547.jpg

IMG_20200525_125611.jpg

IMG_20200525_125701.jpg

IMG_20200525_125712.jpg

IMG_20200525_125725.jpg

IMG_20200525_142708.jpg

IMG_20200525_142814.jpg

IMG_20200525_142820.jpg

May 25, 2020 Horizontal Stabilizer - (2 hours)

Category: Empennage

More work on elevator, which is more delicate and complicated than I expected. Ordered a pneumatic angle drill because of tight quarters drilling so I can avoid drilling errors / damage to parts with drills that are too big. Ran into an issue with the CH750 prefab tip ribs not fitting correctly with the trim tab channel ends, which are slightly bent to accommodate fitting inside the tip rib flanges. Aligning the center of the trim tab channel flange properly with the third hole in the tip rib causes the tip rib flange to bulge considerably. So I have a technical question submitted to Zenith about it.

IMG_20200523_003845.jpg

IMG_20200525_111603.jpg

IMG_20200525_125547.jpg

IMG_20200525_125611.jpg

IMG_20200525_125712.jpg

IMG_20200525_125725.jpg

IMG_20200525_142708.jpg

IMG_20200525_125701.jpg

May 23, 2020 Elevator - (2 hours)

Category: Empennage

IMG_20200523_003827.jpg

IMG_20200523_003831.jpg

IMG_20200523_003845.jpg

May 20, 2020 Elevator - (1 hour)

Category: Empennage

IMG_20200520_214042.jpg

IMG_20200520_220825.jpg

IMG_20200520_221154.jpg

IMG_20200520_221241.jpg

IMG_20200520_221402.jpg

IMG_20200520_221602.jpg

IMG_20200520_221628.jpg

IMG_20200520_221827.jpg

IMG_20200520_221859.jpg

May 20, 2020 Horizontal Stabilizer - (1.5 hours)

Category: Empennage

Setting up elevator hinge pins for drilling, cut one too much based on watching the homebuilthelp video. Had to order replacement as I was unwilling to compromise on strength in this area, though honestly I don't think stress tolerances would have changed much. But I didn't do calculations so .... Pictures show difference between cut and uncut. I didn't like that the A5 holes on the end would be so close to the cut end. Even though it's was within acceptable minimum distances for the material.

tipRibHingeCutTooShortForMyTaste.jpg

tipRibHingeCutTooShortForMyTaste01.jpg

tipRibHingeNotCut00.jpg

tipRibLAngle.jpg

May 19, 2020 Elevator Work - (3 hours)

Category: Empennage

IMG_20200519_193834.jpg

IMG_20200519_193837.jpg

IMG_20200519_193849.jpg

IMG_20200519_194851.jpg

IMG_20200519_194854.jpg

IMG_20200519_194903.jpg

IMG_20200519_205817.jpg

IMG_20200519_213628.jpg

May 19, 2020 Horizontal Stabilizer - (3 hours)

Category: Empennage

Skin and skeleton drilling.

IMG_20200506_213802.jpg

IMG_20200509_131711.jpg

IMG_20200509_164412.jpg

IMG_20200511_224503.jpg

IMG_20200515_090508.jpg

IMG_20200519_194903.jpg

May 15, 2020 Elevator Work - (2 hours)

Category: Empennage

IMG_20200515_090508.jpg

IMG_20200515_090514.jpg

May 13, 2020 Assembly Research - (1 hour)

Category: Engine

Studied cylinder assembly procedure. pp103 to pp 124

ManualFrontCover.jpg

May 11, 2020 Corvair 3.0L Cylinder Set - (.5 hour)

Category: Engine

Ordered 3.0L Corvair Cylinder Set for TZero

ConnectingRods.jpg

HiRes_Cylinder.jpg

HiRes_Piston.jpg

May 09, 2020 Elevator

Category: Empennage

IMG_20200509_164412.jpg

IMG_20200509_181136.jpg

May 06, 2020 Elevator Work

Category: Empennage

IMG_20200331_224859.jpg

IMG_20200331_225022.jpg

IMG_20200331_225025.jpg

IMG_20200331_225032.jpg

IMG_20200331_225041.jpg

IMG_20200506_213137.jpg

IMG_20200506_213350.jpg

IMG_20200506_213802.jpg

Apr 30, 2020 Horizontal Stabilizer - (2 hours)

Category: Empennage

Elevator skeleton construction and some skin placement.

IMG_20200506_213137.jpg

IMG_20200506_213350.jpg

Apr 22, 2020 Horizontal Stabilizer - (1 hour)

Category: Empennage

Layout of elevator skeleton and begin cleco-ing together.

IMG_20200505_213459.jpg

Apr 19, 2020 Horizontal Stabilizer - (3 hours)

Category: Empennage

Riveting the top skin onto the stabilizer skeleton. Finished it up!

IMG_20200501_193208.jpg

IMG_20200501_200630.jpg

IMG_20200501_204507.jpg

IMG_20200501_210244.jpg

IMG_20200501_222339.jpg

Apr 19, 2020 Horizontal Stabilizer - (2 hours)

Category: Empennage

Riveting the stabilizer skin on, bottom side first.

IMG_20200429_220422.jpg

IMG_20200429_225935.jpg

IMG_20200429_225954.jpg

IMG_20200429_230854.jpg

IMG_20200429_231025.jpg

IMG_20200501_193148.jpg

IMG_20200501_193158.jpg

Apr 17, 2020 Horizontal Stabilizer - (2 hours)

Category: Empennage

Reassemble for riveting.

IMG_20200427_203430.jpg

IMG_20200427_224036.jpg

IMG_20200428_220556.jpg

Apr 15, 2020 Horizontal Stabilizer - (3 hours)

Category: Empennage

Deburring the pieces.

IMG_20200423_235812.jpg

IMG_20200425_125512.jpg

IMG_20200425_125517.jpg

Apr 13, 2020 Horizontal Stabilizer - (2.5 hours)

Category: Empennage

Drilling skins and clecoing with good straps.

hstablowerskinpilot00.jpg

hstablowerskinpilotfrontview00.jpg

hstablowerskinpilotsideview.jpg

stabstrapgood00.jpg

Apr 12, 2020 Horizontal Stabilizer - (1.5 hours)

Category: Empennage

Straps that don't work. Must have ratchet type.

stabstrapbad00.jpg

stabstrapbad03.jpg

Apr 11, 2020 Horizontal Stabilizer - (2 hours)

Category: Empennage

Bottom skin work, drilling.

bottomskin00.jpg

bottomskin03.jpg

bottomskin04.jpg

Apr 09, 2020 Horizontal stabilizer - (1.5 hours)

Category: Empennage

Working on tip rib angles and skin drilling.

tipriblangle00.jpg

tipriblangle01.jpg

topskinpilot00.jpg

topskinpilot01.jpg

Apr 07, 2020 Corvair 110HP head overhaul - (.5 hour)

Category: Engine

Ordered 110HP head overhaul from Sport Performance Aviation.

spa110Heads.jpg

Apr 07, 2020 Stabilizer - (1 hour)

Category: Empennage

Tip rib placement

StabSkel21.jpg

StabSkel22.jpg

Apr 06, 2020 Horizontal Stabilizer - (2.5 hours)

Category: Empennage

Stabilizer ribs. Nose and center section.

StabSkel15.jpg

StabSkel16.jpg

StabSkel17.jpg

StabSkel18.jpg

StabSkel19.jpg

StabSkel20.jpg

Apr 05, 2020 Horizontal Stabilizer - (1.5 hours)

Category: Empennage

Stabilizer front brackets. Stabilizer tip rib mounting front spar L angle. Fun vid here: https://youtu.be/SeWA7AkL2Ds

StabSkel10.jpg

StabSkel12.jpg

StabSkel13.jpg

StabSkel14.jpg

Apr 04, 2020 Stabilizer - (3 hours)

Category: Empennage

Doublers to A4 size, front and rear spar.

StabSkel03.jpg

StabSkel05.jpg

StabSkel06.jpg

StabSkel07.jpg

StabSkel09.jpg

Apr 01, 2020 Stabilizer Skeleton - (3 hours)

Category: Empennage

Initial work putting together the horizontal stabilizer skeleton. Upper and lower doublers on rear spar.

StabSkel00.jpg

StabSkel01.jpg

StabSkel02.jpg

Mar 29, 2020 Stabilizer - (.5 hour)

Category: Empennage

IMG_20200329_162523.jpg

Mar 29, 2020 Parts Inventory - (1.5 hours)

Category: Empennage

Unpack, inspect, check inventory. All present and accounted for.

PartsA4.jpg

PartsElevatorSpar.jpg

PartsFlapSkins.jpg

PartsSpars.jpg

Mar 27, 2020 Pick Up At Estes - (2 hours)

Category: Tail Feathers

Went to Estes in SA to bring Tail kit, Slats / Flaperons kits back to shop. Unloaded parts.

AtShop01.jpg

Estes00.jpg

Estes04.jpg

PartsUnloaded00.jpg

Mar 26, 2020 ACF-50 Crankshaft - (.5 hour)

Category: Engine

To protect the crankshaft while waiting further build out I slathered on ACF-50 and got it in the journal areas too.

tzeroACF-50_00.jpg

tzeroACF-50_02.jpg

Mar 25, 2020 110 HP Head Search - (2 hours) Category: Engine

Found a possible source for 110 Head. Contacted Mike's Corvair Parts. Since I have one head at William's hanger, casting #3856759, Mike is going to look to see if he has one around his main store.

Mar 07, 2020 Parts Rack - (3 hours)

Category: Workshop

High tech finished parts rack made of 2x4. Shop organization.

See this link: https://corvair750.com/personal-blog/finished-parts-rack/

RudderOnWall00.jpg

RudderOnWall01.jpg

Mar 06, 2020 Sky Ranch Engine Manual - (2 hours) Category: Research

Introduction. Start Chapter 1: Fatigue Analysis

Mar 02, 2020 Zenith Order - (1 hour) Category: Tail Feathers

Ordered Zenit Tail / Slats / Flaperons from Zenith. 2 week lead time. Shipping to Estes in San Antonio.

Feb 29, 2020 Rudder Final Rivet - (3 hours)

Category: Empennage

Final riveting of the rudder after returning from Green Cove Springs where I built the Corvair short block.

rivet00.jpg

rivet01.jpg

rivet02.jpg

rivet03.jpg

rivet04.jpg

Feb 24, 2020 Short Block - (1 hour)

Category: Engine

Drive from Green Cove Springs Florida to Seguin Texas. 16 hours starting Sunday at 130pm arriving Seguin Monday about 11am. Move TZero into shop.

wwh_tzeroreturnstobase.jpg

wwh_tzeroserialnumber00.jpg

Feb 23, 2020 Short Block - (3 hours)

Category: Engine

Rear oil housing install. Oil pickup install. Gold top and gold oil pan.

wwh_oilpickup.jpg

wwh_rearoilhousing00.jpg

wwh_rearoilhousing01.jpg

wwh_tzeroshortblockcomplete.jpg

wwh_skipreadswilliamworks.jpg

wwh_williamtastetests00.jpg

Feb 22, 2020 Short Block - (12 hours)

Category: Engine

Installed oil gallery plugs. Put TZero in engine build stand. Put in crankshaft, camshaft, and aligned them. Lubed the cam lobes. Closed the case and torqued correctly. Put on 5th bearing case. Drilled and pinned 5th bearing. Put on gasket material and torqued 5th bearing housing correctly. Put on 5th bearing oil seal. Installed safety shaft and prop studs.

wwh_5thbearinganaerobicgasket01.jpg

wwh_5thbearingsealbox00.jpg

wwh_camlobeslubricated00.jpg

wwh_casebolttighteningpattern00.jpg

wwh_safetyshaftinstallcollett.jpg

wwh_safetyshaftinstallcranklock.jpg

wwh_tzeroleftcaseinstand.jpg

wwh_tzerooilgalleryplug00.jpg

wwh_hanger.jpg

wwh_wiliamdansheridancarbtestrun00.jpg

wwh_camcrankalignedcorrect00.jpg

wwh_camlobeslubricated01.jpg

wwh_crankshaftincase.jpg

wwh_mainbearing10undersize00.jpg

wwh_paintstartergear01.jpg

wwh_safetyshaftinstallcollett.jpg

wwh_tzerocamshafttestfit.jpg

wwh_tzeroshortblockbefor5th01.jpg

wwh_tzeroshortblockbefore5th00.jpg

wwh_tzeroshortblockcomplete.jpg

wwh_tzeroshortblockcomplete.jpg

wwh_spa5thidmarkings01.jpg

Feb 21, 2020 Case Inspection - (3 hours)

Category: Engine

At William Wynne's hangar inspected TZero case for cleanliness. Restored all threads. William removed a case dowl pin from an older case because processing at SPA had lost the dowel pin in mine. Noted my original case bolts / nuts not returned. Other bolts instead.

wwh_threadrestorerkit.jpg

wwh_tzerocasehalves.jpg

wwh_tzerocaselefthalf.jpg

wwh_tzerothreadrestoring00.jpg

wwh_williamremovessparecasepin.jpg

Feb 16, 2020 Rudder Parts Trimming / Deburring - (2.6 hours)

Category: Empennage

Trim nose skin. Tried to use Homebuilt Help technique of cutting with blade -- I didn't have the right blade. This turned into a PITA because of the excess filing I had to do. When cut with shears, line was straighter in the end and much faster to file. Can't do each hole deburr on skins -- will take too long. Need to give in and do the flat file technique to knock burrs off. Can buff out minor scratches with Scotch-Brite. Still have to deburr skeleton ribs and spar and second side of rear skin.

rudder_deburr_00.jpg

Feb 15, 2020 Rudder Rear Skin / Nose Skin - (3.6 hours)

Category: Empennage

Drill out all holes to final size, in rear skin and nose skin. Separate parts for deburring. Mark up the nose skin for final cutting.

rudderskin_drill_06.jpg

rudderskin_drill_07.jpg

rudderskin_drill_08.jpg

rudderskin_drill_09.jpg

rudderskin_drill_10.jpg

Feb 13, 2020 Rudder Rear Skin / Nose Skin - (1.5 hours)

Category: Empennage

Put nose skin in place. Drill more holes.

rudderskin_drill_04.jpg

rudderskin_drill_05.jpg

Feb 10, 2020 Rudder Rear Skin - (1.5 hours)

Category: Empennage

Work on rudder rear skin, placement and drilling out pilot holes and A4 holes.

rudderskin_drill_00.jpg

rudderskin_drill_01.jpg

rudderskin_drill_02.jpg

rudderskin_drill_03.jpg

Feb 08, 2020 Rudder Skeleton Riveting - (2.4 hours)

Category: Empennage

Rivet rudder skeleton.

rivetskeleton_00.jpg

rivetskeleton_01.jpg

rivetskeleton_02.jpg

rivetskeleton_03.jpg

rivetskeleton_04.jpg

Feb 02, 2020 Plans analysis / HomebuiltHelp Video - (2 hours) Category: Research

Reviewed the sheet metal materials requirements for scratch building the horizontal stabilizer. Also viewed homebuilthelp video for scratch building metal aircraft. Ordered two more videos, one on tail section, one on rudder. Will review Rudder before riveting skeleton and working on the skins.

Jan 28, 2020 Rudder work - (2.5 hours)

Category: Empennage

Had a problem with drilling too deep on the rudder bottom spar and was unsure of fit for rudder horn against rudder spar. Conferred with Zenith. Horn fits spar perfectly, decided to replace bottom rib instead of using a doubler.

rudderhornsparfit.jpg

rudderhorntospar.jpg

Jan 27, 2020 Rudder Assembly - (2.7 hours)

Category: Empennage

Began drilling rudder spar doublers to spar, marked out locations of ribs.

assmbly_00.jpg

assmbly_01.jpg

assmbly_02.jpg

assmbly_03.jpg

Jan 25, 2020 Rudder - (1 hour)

Category: Empennage

Uncrate Rudder Kit. Inventory all parts.

IMG_20200124_135135.jpg

IMG_20200124_135233.jpg

PartsList.jpg

parts_00.jpg

parts_01.jpg

parts_02.jpg

Jan 24, 2020 Unpack Tools - (1 hour)

Category: Tools

Unpack and inspect Zenith toolkit. Inventory all quantities.

tools.jpg

Jan 24, 2020 Unpack Tools - (1 hour) Category: Tools

Unpack and inspect Zenith toolkit. Inventory all quantities.

Jan 18, 2020 Aircraft Fabrication Bench - (8 hours)

Category: Workshop

Build aircraft fabrication bench.

shop01.jpg

shop02.jpg

shop03.jpg

shop04.jpg

Jan 14, 2020 Toolkit Category: Tools

Ordered complete toolkit from Zenith for CH 750.

Jan 14, 2020 Rudder - (.5 hour) Category: Empennage

Ordered Rudder Kit

Jan 13, 2020 Ordered Options Plans - (.2 hour) Category: Research

Ordered Options Plans from Zenith, since I want wing lights, dual stick, folding wings, etc

Jan 12, 2020 Engine Cleaning - (1.7 hours) Category: Engine

More tube, hardware, and valve cover cleaning.

Jan 10, 2020 Engine Cleaning - (3.6 hours)

Category: Engine

Cleaned all kinds of parts including pushrod tubes, head clamps, clamp bolts, baffles, baffle hardware, valve cover. Some pushrod tubes may not be useable because of internal pitting which I don't approve of and find not acceptable. Plan to have William Wynne review.

rg090.jpg

rg092.jpg

rg093.jpg

Jan 10, 2020 Engine Shipping - (2 hours)

Category: Engine

Crated and shipped engine case to Sport Performance Aviation LLC to have it bored to be a 3.0L engine.

rg088.jpg

rg089.jpg

Jan 09, 2020 Engine Cleanup - (1 hour) Category: Engine

Cleaned up case bolts and nuts to fasten case together to ship to Sport Performance Aviation LLC.

Jan 08, 2020 Engine Parts - (2 hours) Category: Engine

Ordered following components for rebuild from Sport Performance Aviation: Case bore service, case cleaning service, 5th Bearing Crankshaft Service w/New gear, crank core charge (refundable), 5th Bearing Journal - 2nd Gen, 5th Bearing Housing Kit, CV1100 Cam and Lifters, CV200-HV Rear Assembly, CV3301 - E/P distributor, Gold Billet oil pan, Oil pan installation kit, Starter kit

Jan 05, 2020 Workshop Reorg - (5 hours) Category: Workshop

More stuff, making more space. Need to get rid of a wood lathe, maybe in trade for an orbital spindle sander.

Jan 04, 2020 Workshop Reorg - (5 hours) Category: Workshop

Removing things I just don't want to be in the way. Like what? Well, like a Kubota T1880, tools to be sold on EBAY (forget facebook marketplace it's useless), and goat feeding supplies (goats donated to another person's cause. Next up will be selling a 2005 Sportster 883 - 1200 conversion. It's got go, and that's what I want it to do (though it was good to me).

Dec 31, 2019 Engine Cleaning - (1.2 hours)

Category: Engine

Clean head attachment hardware. Inspect rocker arms. Not considered useable according to William Wynne's specs. Will have to find replacement. ACF-50 all head attachment components, useable or unuseable. Threw away pushrods.

rg085.jpg

rg086.jpg

rg087.jpg

Dec 30, 2019 Engine Cleaning - (.9 hour)

Category: Engine

Clean 6 pushrod tubes.

rg084.jpg

Dec 29, 2019 Engine Cleaning - (3.5 hours)

Category: Engine

Removed gasket material from rear oil case housing. Wire brushed oil pump housing bolts and cover plate. Cleaned oil pump gears.

rg081.jpg

rg082.jpg

rg083.jpg

Dec 17, 2019 CH750 Plans / Drawings - (2 hours) Category: Research

Begin evaluating material needs for Rudder, Horizontal Stabilizer, Elevator, slats, and flaperons. Find material suppliers. Begin looking at tool acquisition sources / costs. Begin reading Zenair Construction Standards.

Dec 15, 2019 Workshop organizing - (1 hour) Category: Workshop

Beginning to remove unneeded items. Plan for changes to allow successful build.

Dec 14, 2019 Engine Cleaning - (3 hours)

Category: Engine

Finished cleaning left case and prep for sending to Florida. Began cleaning heads. Evaluation of head quality. Pictures sent to FlyWithSPA / FlyCorvair for a review. Two cylinders may be too damaged for reconditioning.

rg072.jpg

rg073.jpg

rg074.jpg

rg075.jpg

rg076.jpg

Dec 12, 2019 Engine Cleaning - (2 hours) Category: Engine

Remove rust and scale from case studs.

Dec 09, 2019 Engine Cleaning - (1.5 hours) Category: Engine

Engine internal, external, and lifter bores. Also a few more screw holes in base of case half. Removed gasket material. Ready to clean the case studs.

Dec 08, 2019 Engine Case Cleaning - (2 hours)

Category: Engine

Left case cleaning. External. Internal. Oil galleries and all screw / dowl holes. Flush oil passageways. Remove scum and varnish.

rg066elf.jpg

rg067.jpg

rg068.jpg

Dec 06, 2019 Engine Assembly Instruction - (2 hours)

Category: Research

Corvair engine assembly, DVD 1 by William Wynne. Covered putting crank and cam back into engine, placing case halves together, tightening.

AssemblyDVD1_00.jpg

AssemblyDVD1_01.jpg

AssemblyDVD1_02.jpg

Dec 06, 2019 Case / Cam - (1.5 hours)

Category: Engine

Left case half cleaning. Exterior and interior. Oil galleries. Lifter bores. Clean cam, treat with ACF-50, wrap in plastic, ready to take to Florida.

rg064.jpg

rg065.jpg

Dec 01, 2019 Sheetmetal Scratch Technique review - (2 hours) Category: Research

Reviewed creation of form blanks from plans for aircraft parts using common woodshop tools, methods for cutting sheet metal, bending metal to form parts. First couple of chapters of Homebuilt Help's "Scratch Building Basics for Metal Aircraft".

Nov 29, 2019 Engine cleaning - (3 hours)

Category: Engine

Finished cleaning right case half. Removed rust / scale from case studs. Cleaned stud threads. Treated all studs with ACF-50 and wrapped in plastic for temp storage before taking to Floriday. Cleaned but camshaft and cam gear. Restored rear oil case attachment hardware to near orginal condition. Restored old head nuts (but will not reuse due to minor munging). All treated with ACF-50 and stored.

rg061.jpg

rg062.jpg

rg063.jpg

Nov 24, 2019 Engine crankshaft - (2 hours)

Category: Engine

Finished cleaning engine crankshaft. All passages flushed with solvent. Main bearing and connecting rod throw journals cleaned with light application of scotch brite 7447. Slathered in ACF-50 and wrapped for storage until delivery to Florida for processing into flight engine crankshaft.

rg058.jpg

rg060.jpg

Nov 22, 2019 Engine Case and Crankshaft - (2 hours)

Category: Engine

Almost finished cleaning R(ight) case half. All holes cleaned. Oil gallery cleaned. Surfaces cleaned and dowl holes cleaned. Still needs to have studs de-rusted / de-scaled. Minor pitting on some gasket surface areas that is not significant. No pitting on case mating surface. Internal surfaces clean enough for assembly.

rg054.jpg

rg055.jpg

rg056.jpg

rg057.jpg

Nov 17, 2019 Case and Crankshaft cleaning - (1.8 hours)

Category: Engine

Gasket removal. Discovered that gasket remover does a great job of getting stubborn varnish out of internal areas that are hard to get at. Crankshaft cleaning / minor polishing. Flushed all the crankcase oil passages thoroughly with solvent. Note that in first crankshaft pic the first two throws have very mild surface corrosion. In second picture it is gone -- just a bit of light rubbing with Scotch-Brite 7447.

case.jpg

crank00.jpg

rg051.jpg

Nov 15, 2019 Case cleaning - (1 hour) Category: Engine

Case detailing, removing dirt on outside, varnish on inside. Removed oil gallery plug for later cleaning.

Nov 13, 2019 AC 43.13-1B Engine - (.5 hour) Category: Research

Chapter 8 Engines, Fuel, Exhaust, and Propellers 8.1 to 8.13

Nov 09, 2019 Detail cleaning - (2.5 hours)

Category: Engine

Parts cleaner / lots of Scotch-Brite 7447

rg048.jpg

rg049.jpg

Nov 06, 2019 AC 43.13-1B Wiring - (.7 hour) Category: Research

9 Environmental Protection and Inspection, 10 Service Loop Harnesses, 11 Clamping, 12 Wire Insulation and Lacing String Tie, 13 Splicing

Nov 02, 2019 Case Cleaning / Crankshaft inspection - (2 hours)

Category: Engine

More case cleaning. Crankshaft inspection and attempt removal of woodruff key. Wouldn't come out. Taking to William Wynne / Dan Weseman.

rg042.jpg

rg043.jpg

rg046.jpg

Oct 30, 2019 AC 43.13-1B - (1 hour) Category: Research

6 Aircraft Electrical Wire Selection, 7 Table of Acceptable Wires, 8 Wiring Installation INspection Requirements

Oct 28, 2019 Engine Cleaning - (2 hours)

Category: Engine

Cleaning case halves.

rg039.jpg

rg040.jpg

rg041.jpg

Oct 25, 2019 AC 43.13-1B - (.7 hour) Category: Research

11.5 Electrical Wire Rating -- read it but still need to work through the examples.

Oct 21, 2019 Engine Core Teardown - (4.5 hours)

Category: Engine

Remove stuck cylinders by whatever means necessary without damaging case. Result: Success. Crank looks serviceable as well as heads, case, and the oil routing end case.

rg035.jpg

rg036.jpg

rg037.jpg

rg038.jpg

Oct 17, 2019 Engine Core Teardown - (2.5 hours)

Category: Engine

Remove front of case / bell housing. Split case by unding case bolts. Remove cylinder 5 by pounding on underside of piston stuck in cylinder. Same technique pounded piston out of cylinder 3. William Wynne recommended cutting slots (weak spots) on interior of cylinder wall to help break cylinder out of case.

rg030.jpg

rg031.jpg

rg032.jpg

Oct 14, 2019 AC43.13-1B 11.1 - 11.4 - (1.5 hours) Category: Research

11.1 Inspection and Care of Electrical Systems
11.2 Storage Batteries
11.3 Inspection of Equipment Installation
11.4 Inspection of Circuit-Protection Devices

Oct 11, 2019 Engine Core Teardown - (3 hours)

Category: Engine

Remove fan housing. Unable to get crank to rotate, so had to cut through rods (recommended by William Wynne). Cut through rods to be able to remove cylinders. After cutting through 4, began to be able to rotate crank while cylinders 1 & 2 still attached by rod. Undid rod bolts. Unable to remove rod cap. Sawed through both remaining rods. Tapped rod bolts out using previously removed rod with bolts set on the rod bolts not coming off and tapping lightly.

rg028.jpg

rg029.jpg

Oct 07, 2019 Engine Core Teardown - (2.5 hours)

Category: Engine

Remove pushrod tubes and pushrods. Remove head stud bolts and rocker retainers. Remove cylinder bottom cooling baffle. Remove cylinder heads.

rg018.jpg

rg020.jpg

rg024.jpg

rg025.jpg

rg026.jpg

rg027.jpg

Sep 25, 2019 Engine Core Teardown - (1.5 hours)

Category: Engine

Remove exhaust logs, engine cooling baffles (end pieces). Remove harmonic balancer. Remove distributor retaining screws. Left distributor in until understanding if it can be just pulled out. Videos can be found here: https://corvair750.blogspot.com/2019/09/steady-progress.html

balancer.jpg

discard00.jpg

discard01.jpg

rg016.jpg

rg017.jpg

Sep 18, 2019 Engine Core Teardown - (1.5 hours)

Category: Engine

Began tearing down core engine for flight engine conversion rebuild. Engine serial No: T04I3RG, Heads S/N: 3856743. This identifies as a 1965-1969 95 HP Corvair engine core.

Power washed. Removed sheet metal and accessories including carburetor and some vacuum lines.

rg003.jpg

rg005.jpg

rg007.jpg

rg012.jpg

rg31.jpg