Project: N728TC   -  
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Builder Name:Tom Comeau   -  
Project:   Fisher Flying - R-80 Tiger Moth
Total Hours:958
Total Flight Time:
Total Expense:$20783.10
Start/Last Date:Sep 23, 2020 - No Finish Date
 
Friendly URL: https://eaabuilderslog.org?s=N728TC

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May 07, 2024     Skinned the rear panel - (1 hour)       Category: Fuselage
A short session today, I cleaned up and then glued in place the rear instrument panel skin. It will still need a little trimming once it cures.


 
May 06, 2024     Rear panel inserts, finish the rear restraint "T" - (1.5 hours)       Category: Fuselage
I had two inserts back out when I tried to clean the threads, so I pre-checked all the inserts today, rejecting two that were binding. I re-installed fresh inserts, and then installed the rear panel cover inserts. I also installed the two upright pieces of the "T" for the rear restraints.


 
May 05, 2024     Inserts, rear panel cover frame - (4 hours)       Category: Fuselage
I did the inserts for the fuel bay and forward panel covers, epoxied and screwed in place. The spacing on the two covers is the same, but one is skipped because that's where the cabane will go through.

Then I built up the frame for the rear panel cover, using the cover itself (covered in plastic wrap) to hold the frame.


 
May 04, 2024     More panel prep - (2 hours)       Category: Fuselage
The new parts arrived late today, after I did some more work on instrument panel blocks and the bottom blocks for the front restraints.


 
May 03, 2024     Restraint panel prep - (3 hours)       Category: Fuselage
Some preparatory work for the sides, and attaching blocks for the restraints. Waiting on parts expected tomorrow.


 
Apr 29, 2024     Fillers sanded, front end on the mount - (1.5 hours)       Category: Fuselage
I cleaned up all the stuff stuck in place over the past couple days, and then fit the two inner cover plates for the fin post. Then I temporarily set up the engine stand to hold the firewall. I'm planning to do something more elegant, but I need to be able to move the fuselage around, and rotate it, so this is it for now.


 
Apr 28, 2024     Remaining filler strips - (4 hours)       Category: Fuselage
I made up and installed the remaining filler strips, which finished up the right side. I have to decide if I want to put strips on the diagonals, or perhaps just some blocks at the center of the diagonals to help stiffen the panels.


 
Apr 27, 2024     Filler strips, fin installed - (6 hours)       Category: Fuselage
Over the past couple of days, I fit all the panels on the port side to set the final location of filler strips around the gussets on the aft part of the fuselage. I also installed the fin, along with the filler strips and corner blocking to hold it in place. With these details worked out, I can do the starboard filler strips more quickly.


 
Apr 22, 2024     Four more blocks, forward panel bay fit - (1 hour)       Category: Fuselage
I fit, but didn't trim, the forward panel bay. That let me set the length for the reinforcing TF9 between the panel and the fuel bay, and behind the panel under the cabin cover. With that length set, I cut, cleaned, and installed the TF9 and left it to cure.


 
Apr 19, 2024     Fuel tank anchor blocks, cover - (2.5 hours)       Category: Fuselage
I cut blocks to insert below the plywood between the frame members of the fuel bay floor. I'll use those to anchor two straps to secure the fuel tank against the fuel bay floor. This is similar to the setup for the auxiliary fuel tank. I'm still debating whether to run straps below the tank as well. I am leaning against that.

Then I cut a hole for the fuel filler and fit the bay cover with the tank in place. It fits very nicely. I'm thinking about a seal around the neck, to ensure that any spilled fuel doesn't end up on my passenger's ankles.


 
Apr 18, 2024     Fuel Bay - (2 hours)       Category: Fuselage
Much of today was spent on the annual for the Cub, but I did get to shape the TF9s on the side of the fuel bay and then fit, trim, fit, trim, and fit the cover for the fuel bay, and mark the positions for straps to hold the fuel tank in place. I'll drill those holes in the plywood and then put blocks in place below the fuel bay floor to secure the straps with AN3 bolts, using the same kind of setup as for the auxiliary fuel tank.


 
Apr 16, 2024     TF9 bay sides - (1 hour)       Category: Fuselage
I got the last two bits of TF9 glued in place today, then spent time looking through the plans and instructions for details of how to mount the fuel tank. Which I did not find. So I emailed Fisher, and I may ask for help on Facebook.


 
Apr 15, 2024     Firewall - (3.5 hours)       Category: Fuselage
With the lamination cured while I was away, the lower firewall parts got trimmed and now the three pieces are installed on the front of the fuselage. Clamping to the front crossmembers requires some interesting use of clamps.


 
Apr 14, 2024     Learned to paint - (20 hours)       Category: Research
I spent a great weekend with Mark Moser and three other students learning to use Stewart Systems products to cover and paint my airplane. Mark was very good at showing us how to use the products, how to avoid mistakes, and how to fix them when we make them. I came away much more confident that I can get what I want finishing the Moth.

I also go to get close to some very cool airplanes, including a big yellow Stearman!


 
Apr 07, 2024     Firewall lamination, tank install, cleanup and alignment - (4 hours)       Category: Fuselage
After pulling the clamps off yesterday's lamination installs, I cleaned up the edges. I then cut the fuel bay floor and put the tank in place. That let me fine-align the firewall, and trim and align the forward-most lamination, and then glue it in place. It'll have a whole week to cure while I'm away.


 
Apr 06, 2024     Back to the panels. - (5 hours)       Category: Fuselage
I've been trying for weeks to get the airplane on its gear, but I've had a great deal of difficulty getting usable gear legs, and I'm putting that on hold while I think about how to move forward. The drawings aren't very clear, the gear springs didn't come with instructions, and the instructions another builder provided don't match my hardware, and I am terrible at drilling and tapping usable holes. So I will likely get some more tubes and try again from scratch. Or I may outsource it.

So I have flipped the fuselage back over, which puts it upright and on the tailwheel, and supported by the gear angle in front. I put two panels and their reinforcing strips on today, after a lot of trimming, fitting, sanding, and cleaning. I have to do the complicated buildup between the two seats next, which I might start on tomorrow, or might leave until I get back from Toronto and Wooster.


 
Mar 04, 2024     One support leg. - (2 hours)       Category: Landing Gear
It took several rounds of putting it together and taking it apart, checking the correct length, and trying again to get one of the inside legs trimmed and drilled. I'm dithering over whether to put the springs on during assembly.


 
Mar 02, 2024     Six Weeks, two gear legs - (10 hours)       Category: Landing Gear
It's taken six weeks and multiple attempts, but I now have two good gear legs. (And three bad ones.) Getting them even close to aligned has proved very difficult, and I'm now ready to measure and cut the cross tubes and install the doublers.

I was also interrupted by a trip to visit Viking Engines. There are a couple of options to consider, and it was nice to be in Florida in February.


 
Jan 15, 2024     TAG1 & TAG2 installation - (4 hours)       Category: Landing Gear
The garage got a heater, and now the Moth fuse lives in the garage. It is currently upside down getting the gear installed. Once that is complete and the fuse is on the gear there will be excursions to start setting up the wing.

Today I made up the stack for the TAG1. This is a hinge on top of an aluminum strap on top of the floor, with the TAG1 itself on the bottom. I built it upside down with four AN3 bolts - two through each hinge. The hinges will have the front seat rudder pedals attached.

Then I started on the TAG2, using the TAG1 as a guide. The four holes in each TAG2 are in line with the TAG1, so I used the TAG1 as a guide. The bolts are installed head-down, with a big washer and a nut on the inside. The front TAG2 is complete, the rear TAG2 has holes in the aluminum, but not yet in the wood floor, because I ran out of both time and energy. Then I'll be ready to put the first legs of the gear in between the TAG2s and bolt them in place.


 
Jan 11, 2024     Starting the main gear assembly - (6 hours)       Category: Landing Gear
I couldn't find the doublers that go with the TAG3, so I ordered new tube. I also ordered cleco pliers and a small number of clecos, and with those in hand started the main gear assembly. I used Melissa's (larger) vise to insert the round tube in the square tube, and assembled the plates and the DHAG4 into the main legs that will go between the angles. I had to progressively drill and cleco pilot holes, and then swap out the clecos for larger holes and AN3 bolts.
Tolerance is one of the things I'm still learning about. A #12 bit works better than an actual 3/16 bit when making holes for AN3s.

I'm now ready to install those two assemblies between the TAG2s, but first I have to get the TAG2s attached to the floor. And to do that, I think I have to move the fuselage into the garage. For that I'll need help.


 
Jan 07, 2024     Control Stick Assembly - (5.5 hours)       Category: Fuselage
Over the past couple days I've been getting the control stick assembly put together so I could put it in place and drill the final holes in the floor, so I can drill the first pair of holes in the rear TAG2, with the goal of getting started on the main gear.
I am leaving the skins off for now. I plan to put them on when I have it on its gear, which will be temporary anyway because all the hardware has to come off to seal the wood.


 
Dec 30, 2023     Torque Tube, Tailwheel - (3.5 hours)       Category: Fuselage
The replacement tube for the torque tube arrived yesterday, so I cut it off and drilled it, with lots of fitting back and forth. Getting it installed will be ... complicated.

I also set up, drilled, and installed the new tailwheel. Since the plans have the old tailwheel design, I had to make some choices. I may revisit those choices later.


 
Dec 29, 2023     Instrument Panel support lamination - (1 hour)       Category: Fuselage
Did some sanding to clean up the lamination, scuffed the back of the instrument panel, cleaned them both up, and glued the lamination in place.

The new torque tube is out for delivery today, and I got the TH1s in the mail yesterday.


 
Dec 23, 2023     Floor installed - (2 hours)       Category: Fuselage
After some delays unrelated to the project, I have finally installed the lower floor.
I had to do some sanding on the crossmembers and blocks, and scuff the inside of the two floor pieces. Then I cleaned everything off, and glued it in place using a record quantity of glued. I mixed it up 20 +17 grams at a time, and ended up making four batches. I laid down a thin layer on the longerons and crossmembers, and the blocks, then put the floor in place. I pulled the floor back off and used the glue transferred to also put a thin layer on the plywood. I put it back in place, clamped the perimeter, and then used a combination of things to weight down the plywood: Old Aircraft Spruce catalogs, old copies of Communications of the ACM and Naval Institute Proceedings, and my socket set. I'm going to let this cure for a couple days.


 
Dec 05, 2023     Floor prep, firewall lamination - (2.5 hours)       Category: Fuselage
Over the past couple days I've been prepping the bottom of the cabin for the bottom of the floor. The fuselage is inverted, everything is cleaned up and ready to glue the floor on except a little bit of cleanup on the aft end of the floor itself.

I also made up the lamination for the firewall, and I'm thinking about how to do the lamination for the front of the baggage compartment, which has to work around the stringers.


 
Dec 02, 2023     Another lamination - (.5 hour)       Category: Fuselage
I think this is the last of the regular laminations. Still have to do the firewall and the baggage bay.


 
Dec 01, 2023     Inside the floor blocks - (2 hours)       Category: Fuselage
The airplane is now on its side, with six blocks glued in place and curing. These are the under-the-floor blocks for the rudder pedals for the rear seat.



 
Nov 25, 2023     More lamination, working on the controls - (2.5 hours)       Category: Fuselage
I have another lamination curing as I work my way back along the forward fuselage.

Additionally, I have the position for the controls set, and the C2 positions drilled and test fit. I can't find my deburring tool, so another is ordered and on the way so I can assemble the control linkages. I am missing a pair of thrust washers that was omitted from the BOM and the kit, and which I hope are on their way from Ontario. The stop rings won't get drilled until those arrive.

Measuring the location of the forward with both a tape measure and the laser to set the control centerline got surprisingly good agreement!

At some point I need to design and fab a way to remove the front stick and put a cover of some kind over the forward seat so I can put travel baggage up front. That might wait until after Phase 1. :-)


 
Nov 20, 2023     Forward front panel lamination - (.5 hour)       Category: Fuselage
Another one, this one on the back side of the fuel bay closeout, which is the forward end of the forward cabin panel.


 
Nov 18, 2023     Aft fuel bay lamination - (.5 hour)       Category: Fuselage
The first lamination has cured, so I made up the second one the same way, with the addition of some small clamps between the ones that hold it on the fixture.


 
Nov 13, 2023     Fuel Bay lamination - (1 hour)       Category: Fuselage
The upstairs bathroom is now a lamination station. I soak the four pieces for a few minutes in the tub and fit them on the fixture, which was made by screwing down blocks around the TF12. I cut off the ends, and then covered the fixture with plastic wrap. Then I mixed up two cans of T-88, assembled the stack, and clamped it in place.

I want to let the laminations cure for an extended period.


 
Nov 07, 2023     Front of the boot well - (.5 hour)       Category: Fuselage
The final piece of the boot well is in place. It'll need a little trimming once it cures.

Now I have to figure out how to clamp the top and bottom of the firewall.


 
Nov 05, 2023     One little strip all the way up front - (.5 hour)       Category: Fuselage
One strip across the floor all the way at the front to make the floor flat, and then I'll be ready to close up the front.


 
Nov 02, 2023     Most of the front boot bay - (1.5 hours)       Category: Fuselage
Over the past couple days I trimmed the parts, and today I glued up the forward boot bay. I still have to attach the front panel, the side bits of plywood, and then the firewall at the top.


 
Oct 26, 2023     Stack up for horizontal stabilizer, main spar corner blocks - (1.5 hours)       Category: Tail Feathers
The support for the stabilizer is a stack of two pairs of two sticks, plus corner blocks against the TF58. Those are in place now, plus the main spar carry through rear corner blocks. I've now run out of Coke cans, and need to replenish my supply.


 
Oct 25, 2023     Fin gussets - (.5 hour)       Category: Tail Feathers
I trimmed the corner blocks and put gussets over them on the fin. Close to being ready to install the fin.

I did a test fit of the horizontal stabilizer on the top of the tail, and the TF9 stack ends in exactly the right spot. I need to check with FFP about an additional gusset on the bottom of the stabilizer.


 
Oct 24, 2023     Tail, crossmembers glued - (1 hour)       Category: Tail Feathers
I installed the bottom rib in the fin, with some corner blocks that will get cut down and get gussets. I also glued the crossmembers up front.


 
Oct 23, 2023     Quick gluing - (.5 hour)       Category: Fuselage
I scuffed the plywood, then cleaned things and glued them in place. TF11, the front block and gussets for the fin, corner blocks for the lowest fin rib, and one more between-the-gusset spacer.


 
Oct 22, 2023     Lots of fitting, no gluing - (4 hours)       Category: Fuselage
I trimmed all the remaining panels and fit them in place, except for the T1C. I discovered an additional pair of crossmembers to add to the top of the forward fuselage, so I cut and fit those. I started cutting and fitting the TF9 doublers on the top of the longerons, and the last top TF33 that gets feathered into the forward longeron. And I did a bunch of shaping on the tail, trimmed the block and front of the fin, and made up the gussets to hold them together, and the corner blocks but not the gussets for the bottom fin rib.

But nothing glued today. Yesterday's glue looks pretty good.


 
Oct 21, 2023     A whole lot of glue today - (3.5 hours)       Category: Empennage
I had quite a few things cut and fit but not yet installed, so I scuffed the plywood snf cleaned everything on the top of the empennage. Then I glued the bulkheads and stringers in place, then went back and glued on the 1/8th inch strips between gussets on the longerons.

I also did a test fit of the TF5s on the right side, to pick a spot for feathering the side strips down to the longerons near where the TF5 and TF5A meet.


 
Oct 20, 2023     Stringer set, not yet glued. - (2.5 hours)       Category: Empennage
I notched the TF57s and then trimmed the TF30B to fit as well as I could. There are little plywood "U"s to hold the ends in place, so it should be fine. I laser-aligned the center one, and did the other two by eye. They're ready to get scuffed and glued in place.


 
Oct 19, 2023     Upper bulkheads - (2.5 hours)       Category: Empennage
I trimmed the back edge of the baggage floor. I was once again standing in just the wrong spot, so there's a rare picture of me.

Then I set up to align the tops of the bulkheads. I got the laser line clipping the tops of the TF56 and TF58, and then inserted the TF57s in series to get the required height to notch out the bottoms. I did the notching of the bottoms and fit them in place. I then started working out the slots for the TF30B, and I have a question out to Fisher about an ambiguity on the plan about where the TF30B stops.

I also spent some time looking at the cabin floor setup, and I think I'm short some TF2, so another Aircraft Spruce order may be in order.


 
Oct 18, 2023     Bottom of the baggage compartment - (1 hour)       Category: Empennage
I had to basically remove part of a gusset over the corner blocks at the back of the bay between bulkheads one and two in order to get the floor of the baggage compartment attached. Once that's cured, it will need to be trimmed to install the TF58 and TF57. Paint cans make decent weights!

I also realized I had made a mistake with the position of the front seat, which I'll have to think about how to address. I'll likely not try to move the seat base, but rather do something to move the seat bottom and back forward.


 
Oct 17, 2023     Small bits of bracing - (1 hour)       Category: Fuselage
The two corner blocks for the front face of the main spar carry through, and some bracing near the tip of the tail were the two small things I was able to do today.

In each case, I had to scuff the plywood (which meant inventing a way to reach between the seat frame and the spar block), then clean everything and glue them in place. The clamping up front was simple and snug, the clamping at the rear is a little more complicated. Very little pressure, just enough to hold things from moving laterally.


 
Oct 15, 2023     Front seat base installed - (2 hours)       Category: Fuselage
Lots of fiddling with getting this in place. The front side of the rear instrument bay is trimmed and fit, but not yet installed. There's a strip of temporary spacer between the spar carry-through and the back of the seat that will come out tomorrow. I think I should varnish the interior of the seat base before I put the top on, and I need to also do something about the front side of the spar carry-through. I still need to cut the hole in that for the control tube.


 
Oct 14, 2023     Front seat assembled - (2 hours)       Category: Fuselage
I finished all the pieces, deciding to add a crosspiece at the top of the front of the seat base to match the one at the back.

Then I scuffed the plywood, cleaned everything, and glued it together. I used a mix of new tech (laser level) to make sure it's plumb, and old tech (framing square) to make sure it's square. I believe this may be a new record for clamp density.


 
Oct 13, 2023     Front seat box set up, but not yet glued. - (1 hour)       Category: Fuselage
I cleaned up the edges of the front seat sides, and started assembling the box, but was called away before I could clean and glue it.


 
Oct 12, 2023     Seat back installed wrong. Fixed now. - (1 hour)       Category: Fuselage
When I unclamped everything, I realized I had installed the frame back TF9 wrong. They came out of the bottom of the seat.

So, I cut them off, sanded the remaining wood off the plywood, cleaned it all up, made new frame backs, and glued those in place, going in the right direction this time.


 
Oct 11, 2023     Front seat sides - (1 hour)       Category: Fuselage
I cut and cleaned all the parts yesterday, and today figured out how to glue them up exactly the same. They're clamped, back-to-back, with a sheet of plastic wrap between them.

I heard back from Fisher about the TF33 - another bug in the plans that I can fix by feathering the front of the TF33 under the TF5A.


 
Oct 07, 2023     Gussets, another mistake - (2.5 hours)       Category: Empennage
I trimmed the large gusset I put across the top against the TF58, which took some extra effort because the router wouldn't reach.

I cut a bunch of gussets, then needed to check where the outside gussets stop, and realized... I used the wrong thickness on the side gussets. They're 1/8th rather than 1/16 in order to match the thickness of the strips that are added to the TF9A on the sides. So I made eight new side gussets, and I'll have to do something about the bottom gussets.

Then I scuffed, cleaned, and glued them in place.


 
Oct 06, 2023     Standard Baggage Compartment After All, TF58 - (1.5 hours)       Category: Empennage
After trying for a while to figure out a design for the top of an extended baggage compartment, I decided it was too much trouble for now. I only have small things to put in there normally when I'm taking somebody with me, and I have a plan for a cargo restraint in the front seat compartment when I'm solo. So I cut, fit, cleaned and glued the diagonal and corner blocks between bulkheads one and two.

I also started making gussets for the top, but I need to redo some at the tail because I also inserted the spacer for the TF58, cleaned up the TF58, made a gusset for the top of the blocks and spacer, scuffed and cleaned that, and put the whole thing together.


 
Oct 05, 2023     Top diagonals, tail issues - (5 hours)       Category: Empennage
Over the past several days I've been making up corner blocks and the diagonals for the top of the empennage, plus working out the alignment of the tail and the back of the turtledeck. The TF58 I got was just a rectangle of plywood I had to cut to the correct shape, and once I got that done I discovered a stackup of errors that put bulkhead 5 about 3/4 of an inch further forward than it was supposed to be. I measured to the wrong side, failed to correct for shrinkage, and I think there's a cosine error between the TMF1 and TMF2 views of the tail position, because the sides constructed in TMF1 angle in towards the tail. But I believe I now have a correction in place.

The corner blocks took a very long time to cut and fit, and today I spent a little over an hour gluing them all in place. That took three batches of T-88.


 
Sep 29, 2023     Gussets trimmed and cleaned, started aligning the tail - (2.5 hours)       Category: Empennage
I trimmed and cleaned up the gussets on the empennage, then started trimming the tail. Once I had an initial cut, I flipped the fuselage on it's belly and broke out the laser to get the centerline, and made some measurements. Then I trimmed the tailpost and clamped it in place to start working out the details of how to attach the fin.

I also tried to get out all the pieces for the front seat frame, and discovered by TF29 is the wrong size -- it's supposed to be 1/2 by 1/2 but it's 1/2 by 3/4. I have an email out to Fisher to see if I need to rip it down or can just use it as-is.


 
Sep 27, 2023     More gussets installed - (2 hours)       Category: Empennage
I made up two more gussets and then installed four.

After a break to do some work, I verified that I had all the corner blocks for the bottom, installed those, and installed the remaining four gussets over them.

This completes the bottom gusset and blocks installation. The top gussets will wait until the fuse is flipped and the remaining diagonals are installed.

I also trimmed, cleaned, made corner blocks, and installed the tail-most diagonals, which go onto the tail plywood. That's the last pair of diagonals before flipping the fuselage.


 
Sep 26, 2023     Corner blocks, gussets again - (.5 hour)       Category: Empennage
I glued two more corner blocks and four more gussets in place.


 
Sep 25, 2023     Made corner blocks and gusset, only installed them two places - (1.5 hours)       Category: Fuselage
I think I still have one pair of corner blocks to make for Bulkhead 5, but I have all the bottom gussets cut.

I started gluing them in place and made a mistake, and it was late, so I decided it was time to stop. So just two sets of gussets and one set of corner blocks got installed.


 
Sep 24, 2023     Seat base, gussets trimmed - (1.5 hours)       Category: Fuselage
I trimmed the gussets installed yesterday, assembled the seat bottom, scuffed and cleaned the plywood, cleaned the TF9 and TF10, and glued it together.

I started making the exterior gussets for the empennage, but ran out to time (no pics).


 
Sep 23, 2023     Seat gussets, Tail plywood - (1.5 hours)       Category: Empennage
I made up some gussets for the seat support, scuffed and cleaned them, and then installed them.

I also made up the replacement for the TF23B and TF23C, scuffed and cleaned the replacement and the TF23A, and cleaned off the TF23 block previously installed, and glued them in place.

And that runs me out of clamps.


 
Sep 23, 2023     Corner blocks, tail plans - (2.5 hours)       Category: Empennage
I got some guidance from Fisher on how to set the updated tailwheel mount. It means discarding two bits of plywood and one of aluminum and replacing the two offset 1/8th inch plywood with one piece of 1/4 inch.

The new T-88 arrived last night, so I glued all the corner blocks previously made in place. These should all be ready for gussets tomorrow.

I have the diagonals for the very last bay, which lands on the inner bottom plywood, cut and fit but don't want to install them until I have all the parts assembled.


 
Sep 19, 2023     Cut all these corner blocks, tail mockup - (2 hours)       Category: Empennage
I cut, fit, and cleaned a large number of corner blocks, but I'm afraid my T-88 has gone bad again. So I ordered more, and now I have to wait until some time (probably late) on Thursday to get my order.

So I did a test assembly of the bottom of the tail pieces, where the tailwheel will attach. Three more pieces of wood and two of aluminum. I can (once I have adhesive) assemble the wood but I need to get the tailwheel out and see how that's going to attach. I have the upgrade, so I know it will be slightly different than the original steel spring.


 
Sep 18, 2023     Corner blocks, second tail post - (2.5 hours)       Category: Empennage
Today was one post and a bunch of corner blocks. I realized I missed four corner blocks - two on each side, and of course, I still have the corner blocks for bulkheads 2-5.


 
Sep 17, 2023     Seat support, two diagonals, tail alignment - (3.5 hours)       Category: Fuselage
Many things today.

The last two bottom diagonals were cut, trimmed, cleaned and installed. That completes the bottom diagonals.

The seat support are four TF10 pieces with corner blocks, and the TF10 pieces have to be the right length to avoid putting a bow on the TF7. The corner blocks are also difficult to clamp, and I used a big clamp to stabilize the TF7 while it cures.

The tail alignment is critical because the stabilizers have to be square. I've installed one of the trailing edge TF9A posts to help with alignment, and using the TF23 triangular block to set the exact position of the bottom longerons. I'll put the other TF9A on when this is cured. Currently, the tailpost is square in both directions, and is exactly aligned with the centerline markings on bulkhead 1 and the rear instrument panel floor.


 
Sep 16, 2023     Two diagnonals, rear seat front support - (1 hour)       Category: Fuselage
I cut, fit, cleaned and installed two bottom diagonals, between bulkheads 1-2 and 2-3. I also did a fine alignment of the leading edge of the rear seat support with the rear spar. It's TF7, so it has a non-square shape, and is aligned with the rear plane of the rear spar. Doing it with the line level gives me submillimeter alignment. I don't get fringes because the edge isn't a knife edge, so I can't do much better.


 
Sep 15, 2023     Remaining bulkhead diagnonals, more seat work - (2.5 hours)       Category: Empennage
I cut, fit, cleaned, and installed the remaining diagonals for bulkheads 2-5. Once they are cured they get corner blocks as well.

I also cleaned and installed the side struts for the seat support. I started fitting the additional parts for the seat, including an initial trim of TF7, which will be positioned directly over the rear spar carry-through. The TF27 is clamped in place for reference - it will eventually be bolted in place to carry part of the elevator control.


 
Sep 13, 2023     Bulkhead 5 horizontals, bulkhead 1-2 side diagnonals - (1 hour)       Category: Empennage
The side diagonals between bulkheads 1 and 2 have to be installed after the tail is joined, so I did that. I also did the top and bottom cross members for bulkhead 5.


 
Sep 12, 2023     One diagonal, two gussets - (2 hours)       Category: Fuselage
I'm still moving slowly from my overstressed back, but this was always going to go slowly.

I made the diagonal for bulkhead 2 and installed it. Then I cut slots in the rear cross-member for the rear instrument panel and made gussets for the junction of side members there. I had to go slowly because I wanted the slot to be just wide enough for the gusset to slide in. Then I scuffed the plywood, cleaned everything, and glued and clamped them in place.


 
Sep 11, 2023     Second session: Seat start and bulkheads - (2.5 hours)       Category: Fuselage
I started working out the rear seat braces and installed the first blocks for that on the side.

I then made and installed the top and bottom pieces for bulkheads 2, 3, and 4. I have to check that every bulkhead is square when I install the diagonals.


 
Sep 11, 2023     Rear spar braces - (1 hour)       Category: Fuselage
I pulled the clamps off the rear spar carrythrough and installed the diagonal braces with their corner blocks.

Observant followers will note the error in the installation of the cross-member for the rear instrument panel floor. I'll have to cut a slot to allow the inside gusset to go where it belongs.


 
Sep 10, 2023     Rear spar carry through installed - (1.5 hours)       Category: Fuselage
I tweaked my back moving things around yesterday, so today was a light day.

I installed the rear spar carry through and the matching below-the-floor cross-member. The tail is unblocked for that.

The rear spar is slightly wider than the floor, so it will get trimmed after it cures.


 
Sep 09, 2023     Flipped and blocked, set up to join the tail - (2.5 hours)       Category: Fuselage
I flipped the fuse end-for-end and actually brought a wing down and clamped all the hardware in order to measure the best location for the rear spar carrythrough. (With help from Peg and Melissa!) Then I got the next print on the table and installed the fuselage upside down and blocked it in place to start joining the tail and installing the remaining bulkheads. I also trimmed the big gusset on the back of bulkhead #1.

No pictures of the test fit, sadly. My helpers were between errands and I didn't take time to get pics.


 
Sep 07, 2023     Main spar bracing glued in place. - (2 hours)       Category: Fuselage
Turns out I had two more corner blocks to cut on each side, at the top of the aft brace. I cut and fit those, then scuffed the plywood pieces, cleaned everything off, and glued it all in place.

Edit. I was looking at the photo of the block on top of the spar on the starboard side, and I saw a gap. So I pulled that block off, trimmed it a tiny bit, and reglued it.


 
Sep 06, 2023     Cut and fit main spar braces - (1.5 hours)       Category: Fuselage
I had time to cut and fit the braces for the main spar, but didn't get to glue them in place. These have big gussets and a big block that will eventually support the cabanes.


 
Sep 03, 2023     Bulkhead 1 gussets and blocks, main spar carry through - (2.5 hours)       Category: Fuselage
I cleaned up the aft side of the bulkhead center corner blocks from yesterday and cut a slightly-oversize gusset for it. I had already made the other corner block, but I ran out of gloves. Today I got new gloves, and glued the gusset and blocks in place.

Then I glued the main spar carry through in place. I have the ends clamped, and a PVC 1x2 clamped across the middle.


 
Sep 02, 2023     Another top component, bulkhead blocks - (4.5 hours)       Category: Fuselage
I installed the TF16 across the top of two crossmembers, and the corner blocks at the bottom on top of the floor. The TF16 will be the bottom of the instrument panel, which got me thinking again about what size display I want for my avionics. I'm getting close to having a seat to actually try looking at it.

The big four blocks at the center of bulkhead #1 were actually easy to do. I'm still working on the corner blocks for the bulkhead - they have very strange shapes.


 
Sep 01, 2023     Bulkhead 1 crossmembers - (4.5 hours)       Category: Fuselage
It took three days to cut and install three sticks. One long one and two shorter ones. Now I have a dozen corner blocks to cut, and gussets to go over them.


 
Aug 27, 2023     Last three crossmembers installed - (2.5 hours)       Category: Fuselage
There's actually one more crossmember which will be right at the back of the floor, but I decided to place it after I get the exact position of the rear spar.

The other three crossmembers are in place and curing, again on the plane's belly with magazine weights to assure good contact with the floor.

The last thing to do in this orientation is the corner blocks that go over the floor, at which point I'm ready for another table change - to TMF2 - which may mean taking it outside to flip it the long way, in addition to putting it bottom-up.

After a break I also cut and set the corner blocks for the forward struts that go on top of the floor.


 
Aug 26, 2023     Crossmembers and floor - (4.5 hours)       Category: Fuselage
I got six of the nine crossmembers installed, and the forward part of the floor (forward of the splice) glued in place.

The fuselage is now on it's belly so I can weight the floor to get good adhesion all the way across the floor. I spent some time thinking about how to make sandbags of some sort without getting sand all over my basement, and suddenly realized I had a better option: Magazines. Old copies of Communications of the ACM, the Naval Institute Proceedings, and Sport Aviation.


 
Aug 25, 2023     Forward crossmember - (.5 hour)       Category: Fuselage
The forward-most crossmember is the only thing that got installed today, but I did spend some time planning to glue several more crossmembers and the floor tomorrow.


 
Aug 24, 2023     Two more crossmembers - (1 hour)       Category: Fuselage
Pulled the clamps off the fuel tank floor.

I installed two more cross members that will be the top and bottom of bulkhead #1. The top of the bulkhead is TF7, which is shaped to match the angle of the seat back, and is offset to accommodate the TF58 plywood.


 
Aug 23, 2023     Fuel tank floor installed - (1 hour)       Category: Fuselage
I pulled the clamps off, marked the location to cut the floor out, and cleaned up the assembly and the front ends of the longeron. I removed the firewall so I could set up a crossbrace to hold the alignment while I glued the floor in place on the front uprights and the upper longeron.

The quarter-inch difference between the top and the bottom of the box was dealt with by the simple expedient of sticking a 1/8th inch shim under the bottom of the right side.


 
Aug 22, 2023     Fuel tank floor - (.5 hour)       Category: Fuselage
I test-fit the frame (it's good) and then cleaned up the frame, scuffed and cleaned the plywood, and glued it in place.

While the floor is curing, I did a coarse align with a line level. I was already pretty close. The box is quarter of an inch wider at the top than at the bottom, so I need to adjust for that when I do bulkhead 1. I'm not planning to install the firewall yet, so the very front will be floppy. I'll clamp the firewall in place upside down without gluing it to limit floppiness.


 
Aug 21, 2023     Fuel Tank Floor Frame - (.5 hour)       Category: Fuselage
I managed one thing today: Cleaning and gluing the fuel tank floor frame. Tomorrow I'll add the plywood for the floor itself.


 
Aug 20, 2023     Crossmembers - (3.5 hours)       Category: Fuselage
Lots of crossmember fitting, along with some analysis of the plans to understand where things go.

I've decided to build the floor of the fuel bay on the table, so that I'm sure it's perfectly square, and use that to help align the top of the fuselage.


 
Aug 19, 2023     Started joining the sides` - (1 hour)       Category: Fuselage
I lined up the left side, and had time to cut one crossmember. I'm going to wait to attach the firewall, so there will only be a couple of sticks going across when I get it on it's top.


 
Aug 18, 2023     Front firewall attach doubler, floor prep - (2.5 hours)       Category: Fuselage
I was all set to start levitating the left side and was looking at how it would go together, and decided that would be easier if the TF2 doubler at the front of the fuselage side was already attached. I should have done it when I did the gussets, but I didn't so now I have.

I also laid out and cut the notches for the forward inner floor. I incorrectly cut an extra pair of notches that I should have skipped, which I'll have to do something about later. For now, the floor is ready to be fit in place once the TF2 has cured.


 
Aug 16, 2023     Four big inside gussets - (1 hour)       Category: Fuselage
I cleaned up the excess T-88 on both sides, labeled the left and right inner and outer sides, and then scuffed, cleaned up, and glued the four big interior gussets.


 
Aug 15, 2023     Last two side bays - (2 hours)       Category: Fuselage
Last night, and then late this morning, I finished cleaning and gluing and clamping the last two bays.


 
Aug 13, 2023     Another bay - (2 hours)       Category: Fuselage
I checked my usual stick-vs-can-pulloff test first, and got gratifyingly good fibers on the can side.

Then I did the bay between bulkheads 2 and 3. I had to get some glue off the back of the seat belt anchor block, which meant I needed to re-clean everything before I started gluing. Then I glued the sticks and blocks in place and assembled the big mess of clamps. At this rate, I'm two days from being done with sides.


 
Aug 12, 2023     Two more uprights - (1 hour)       Category: Fuselage
Limited time today, so I unclamped the forward bay and moved on the the next two sections. Most of the sticks in these sections don't get installed until the spar carry through parts are in place, so only two were added to each side, plus the large block that will carry the seat belt anchor pins.

The almost-exactly-vertical one was easy to clamp. The other one, which has the block attached, was less simple.


 
Aug 11, 2023     Pulled apart and cleaned, glued the forward bay - (2.5 hours)       Category: Fuselage
After so carefully aligning and cutting and trimming and fitting corner blocks... I pulled it all apart.

And spent about an hour cleaning everything off to get ready for T-88. Now I have to decide whether to glue them in one layer or two. The two sides are very close to identical right now, so I'm inclined to glue them at the same time to keep them that way.

And I went back and started on that. I have the first bay glued and clamped. Some of the clamps have very little force on them - they just hold the piece in place. Top-to-bottom there's a little more to keep everything in contact.


 
Aug 10, 2023     Remaining blocks - (1 hour)       Category: Fuselage
I made up the corner blocks for the last two bulkheads. At this point these all need to get cleaned up and glued in place and the left side picked up before I can do any more.


 
Aug 09, 2023     Corner blocks - (1 hour)       Category: Fuselage
I cut 12 corner blocks today. Tiny bits of wood are almost as much work as big bits of wood.


 
Aug 08, 2023     Corner blocks. Lots of corner blocks. - (1.5 hours)       Category: Fuselage
A few of the corner blocks aren't installed until after the floor. I think I've made all the ones forward of the seat that I can. Aft of bulkhead 1 I think I can make them all.


 
Aug 07, 2023     Lower longeron cleanup, forward struts - (2.5 hours)       Category: Fuselage
I trimmer off the excess wood and then cleaned up the excess T-88 on the lower longeron joints.

Then I made the three forward-most struts for both sides. There's also a short piece from the forward blocks (that will become the spot to receive the engine mount) to the front struts, but I made it too short and then decided I need to understand exactly where they need to go.

I came back and did the short front struts, and the one strut between the seats. Everything else will wait on the connection between the sides. Corner blocks are next.


 
Aug 06, 2023     Bays between bulkheads 1 and 5 cut - (3.5 hours)       Category: Fuselage
I cleaned the extra T-88 off the upper longeron splices.

The sides for each bulkhead from five forward to 1 are joined by a diagonal. Apparently it takes 20 minutes per stick to make them. I need to study a different print to understand the tail, and I think I need to wait until I join the sides at the fin post to really assemble it anyway.

Forward of bulkhead 1 are a lot of struts marked "do not install until blah blah blah" so they'll wait. I'm also working around a big knot in one TF9 stick. At least a foot that's unusable!


 
Aug 05, 2023     Lower longerons joined - (1.5 hours)       Category: Fuselage
The upper longeron splice is curing - I decided to let it go 40+ hours like a lamination. I spent the morning on the Zodiac, which is still waiting for parts from the annual, and spent the afternoon on the Moth.

The lower longeron is three pieces: A forward section below the fuel tank, a rear section that runs from under the seats all the way to the tail, and a short center section that serves to also splice the front and rear segments together. I built another splice-cutting jig and cut the front sections with very good results. Then I altered it to do the rear section and that did not go well. I didn't get the right angle from dragging it through the table saw. So I marked it and sanded it with my flat random sander. I then basically washed it off to get all the sawdust out.

I glued up both sets, again separating them with plastic wrap, clamped everything in place, and left it to cure. It'll get a long cure, too.


 
Aug 04, 2023     Upper longerons spliced. - (3 hours)       Category: Fuselage
I made a jig to cut longerons at an exactly 12:1 slope with my table saw. I wanted to do it with the bandsaw, but I couldn't get satisfactory results. So I switched to the table saw, and got very good results. My jig loads onto the table saw "backwards", so that I'm pulling the long part of the stick off the back of the table. To make that slightly safer, I reinstalled some of the safety guards on the table.

I cut the first pair, and then decided to pull down the rest of the sticks and cut the second pair as well. I have like a mile of thin-film plastic (literally: I got a 6000 foot roll from a wholesale club a couple years ago) so I can cover each joint on what will be the right side, and build the left right on top of the right.

So I glued up the two longerons, and glued some trimmed off excess as a test article.


 
Aug 02, 2023     Started longeron layout - (1.5 hours)       Category: Fuselage
I started the process of laying out the fuselage with the longerons. I have the blocks for the full length, and started marking where the splices will go.

I also reorganized the plywood sheets. They're now all in numerical order, except for a couple of odd ones that are separate. I spent a little time looking at the two different Dynon panel sizes, too. A 7 inch would would be a good size for the panel, but the 10 inch would be a good size for my eyes. I'll keep thinking about it.

I found the first thing I want to change, too. The baggage compartment is rather shallow, and needs a "trap door" so I can put the ADAHRS on or near the floor underneath it.


 
Aug 01, 2023     TF1 on the table - (1 hour)       Category: Fuselage
The table had to get bigger. It needed to be six inches wider and three feet longer, so I got two sheets of half-inch plywood with a foot ripped off the side and screwed them onto the existing table. TF1 is actually two rolls, approximately half a mile long, and slightly offset from each other. There's a line that goes nearly the full length, so I used the laser to get it lined up.

The next step is to put plastic over it and start laying out TF9 and TF9A.


 


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