Apr 01, 2024     Revision Category: Fuel System

January 2024. I finally saw the errors of my ways regarding the fuel seystem.
I had no “low point drain”
New plan: from each fuel tank the line runs forward just above the door and down the forward windshield post.
The lines are ar teed together just above the surge tank and then a single line drops down the the tank inlet. After that everything stays the same with a main shutoff on the line coming out of the surge tank before going forward and through the firewall to the gascolator.

  Apr 01, 2024     Panel build       Category: Instrument Panel

Back to work in the new year. Forgot to take more pic (but thats not new for me).
I did up a wiring diagram with all the components. After a few variations I finalized the instrument and switch layout.
I will have altimeter, airspeed and vertical speed steam gauges
I purchased a used AV10 engine monitor for pressures, temps, rpm and egt.
I fabbed up a mount system for a mini ipad. It will provide basic navigation with moving map and magenta line.
An Icom radio occupys the center of the panel just below the ipad.

I used some leftover “carbon fibre” vinyl overlay to cover the panel and then started cutting and drilling.

  Dec 01, 2023     Panel       Category: Instrument Panel

To cut the panel I first had to install the boot cowl and make a pattern for the curve of the panel where it fits to the top of the boot cowl. The panel is fastened to the airframe at the lower corners and to the boot cowl with a series of angle brackets attached to the boot cowl. The brackets have nut plates to accept screws to secure the panel.

  Dec 01, 2023     Fuel system       Category: Fuel System

My fuel system consists of 2 11 gallon tanks, one in each wing.
Fuel lines from each tank run to the rear and join behind the baggage area, then a single fuel line runs down and follows the bottom center stringer forward towards the firewall.
I installed a 2 gallon surge tank just aft of the firewall. This was an aluminum race car tank, but was 4 inches too high to fit so I had to modify it to fit. My aluminum welding skills are not great but a pressure leak test didn't show any leaks ( surprise!).
With the tank mounted, the fuel line was plumbed into a lower port. The “out” line goes to a ball valve and a filter before going through the firewall. The valve and filter are hidden under a narrow center console which is easily removable for filter service.
The console will also be the location of the manual master switch for the electrical system.
The surge tank is vented thru a line that is routed up the right forward structure to the wing root.

  Oct 04, 2023     Seats       Category: Fuselage

Started with the original seat base that came with the airframe. I modified it by fabing anew seat back frame that was about 5” taller than the the original. I also enabled the seat back to be tilted forward with a release latch and pivot points.
Next thing was to cut a base from 1/4” plywood and a back from 1/8” plywood.
I cut 4” high density foam for the base and 2” med density foam for the back.
I got some remnant fabric from a fabric shop for a discounted price and covered the seats.
The fabric was attached with contact cement to the underside of the plywood base and back.
Same process used for the back seat.

  Sep 11, 2023     Rear sear       Category: Fuselage

I decided to start on some odd jobs that usually get left until last.
Rear seat is only 2 cross bars and a curved back bar. Time for some innovation.
Sorted through my surplus plywood and found some 1/4” birch big enough to become a seat bottom.

  Aug 23, 2023     delayed Category: Wings

I haven't been making any progress for quite a while. My son and family moved here last fall, however the house they bought doesn't have a garage. He has just as many tools and projects as I have and needed to put them somewhere, and therefore my workspace is severely restricted. Its august of '23 and his garage is nearing completion so with any luck I can get my space back this fall and get going on the wing covering job.

  Feb 19, 2023     Rotax       Category: Engine

I've been watching for an engine for quite some time. Was considering a Yamaha Apex or Rotax 912uls. The Yamaha would add a lot of complication and innovation not to mention the extra hours of flight testing. In the end I located a suitable low hour Rotax 912uls (100 hp) at a price that fit my budget.

  Feb 19, 2023     Aileron covering       Category: Wings

Time to start covering the wings.
Step one is prep the ailerons for covering. Mine are actually original Piper factory built ailerons. While cleaning up I found a signature and date from 1941, presumably from the person that fabricated them.
Wrapping with 2.7 oz dacron fabric was pretty straightforward. I used the Hipec Attach Glue (HAG) to attach the fabric to the aileron and then did the usual 2 step heat shrink.

  Nov 16, 2022     Moved hangars Category: Workshop

We moved from Three Hills to High River in May of 2022.
I was fortunate to purchase a hangar at the Foothils Regional Airport near High River.
It is slightly larger than the one in Three Hills. Also fortunate to sell the Three Hills hangar to a local aviator/builder.
The move process took from September to the middle of November. Not much build progress happening but soon.
Next job is covering the wings.