Project: dfisher   -  
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Builder Name:David Fisher   -  
Project:   Team Mini-Max - Other   -   VIEW REPORTS
Total Hours:252.3
Total Flight Time:
Total Expense:$1238.85
Start/Last Date:Dec 08, 2019 - Dec 08, 2019
 
Friendly URL: https://eaabuilderslog.org?s=dfisher

Home or Last Project Picture

Dec 27, 2020     Plying the side - (3 hours)       Category: Fuselage
cut and added the plywood strip gussets and tail gusset to the first side. Also cut the firewall to aft of cockpit ply which I will glue up next time.


 
Dec 22, 2020     Gluing in trusses & seat supports - (4 hours)       Category: Fuselage
Glued up all of the corner to corner trusses and seat support components. Also, the piece with the 5 clamps is a laminate made out of excess material to create cross pieces to join the two fuselage sides when they are complete.

Also, I had to put in another wood order... realized I only ordered longerons for one side, which sucks... but then again I also needed more material to join the two sides together so hopefully won't take too long for aircraft spruce to get me the extra material...

Will work on ply pieces and gluing up add'l laminated pieces while I wait...


 
Dec 20, 2020     Gluing up scarfs & vertical cross pieces - (3.1 hours)       Category: Fuselage
Glued up all the scarf joints and vertical pieces of first longeron side. I clamped the hell out of the scarfs to make sure of a great wetting of all the surfaces. The fire extinguisher makes a great weight!


 
Dec 17, 2020     Fitting up truss pieces - (4.2 hours)       Category: Fuselage
Got all of the corner to corner trusses cut and dry fitted.


 
Dec 15, 2020     More scarfing and crosspieces - (3.5 hours)       Category: Fuselage
After more head scratching figured out right scarf joint on the right hand side of bottom longeron piece. Dry fitted the two scarf joints together and held with clamps while I cut cross pieces.


 
Dec 13, 2020     Bottom longeron scarf cuts - (3.8 hours)       Category: Fuselage
The fuselage wood arrived over the last week so I've started building out a side... the bottom scarf joint has been a major thorn in my side... the geometry was a little complex and the plans/directions are very vague at this point in that one has to 'guesstimate' where to start the scarf joint as it doesn't specify in the plans or directions. Plans indicated a minimum 6" scarf so I went with 7.25." I finally got the geometry correct and am just dry fitting the joints to get them as close to perfect as I can... the good news is the second one is just a trace of this one, so should be very fast. Also, this is only the left scarf, there's still a right hand scarf to figure out.


 
Dec 08, 2020     Finishing layout of fuselage - (3.5 hours)       Category: Fuselage
Finished layout out fuselage side on table.

The 'weights' on the side workbench are there to hold a special rib onto the full length plywood gusset.


 
Dec 06, 2020     Aileron nose ribs - (4 hours)       Category: Wings
Glad I kept all of those oddly shaped scraps from the nose ribs, etc. Made ply pattern of aileron nose ribs and started cutting them out.


 
Dec 01, 2020     Special ribs - (3.4 hours)       Category: Wings
Cut out 1/8" ply covers for root & tip ribs and glued up first one. Also, 'decommissioned' rib jig...

Also, I do live edge pieces, so I started on a small live edge shelf for my wife.


 
Nov 25, 2020     Laying out reference line & fuselage - (3 hours)       Category: Fuselage
Drew out reference line datum and built layout strip along line to act as top longeron edge.


 
Nov 22, 2020     Getting ready to start fuselage - (3 hours)       Category: Fuselage
Got the 3 separate build tables together and leveled to build a cohesive unit. Covered in craft paper and began laying out fuselage sides.

Also, my wife got me this awesome custom sign made for my birthday (which was yesterday)...looks awesome above my antique find!


 
Nov 19, 2020     Finished build table       Category: Workshop
Finished up the additional 8' build table in anticipation of wood arrival...

Manhandling 3/4" ply by oneself is awesome,,, esp. trying to get the lower shelf in...


 
Nov 17, 2020     Another build table - (6 hours)       Category: Workshop
While waiting on my fuselage wood to arrive, I needed to build an 8' build table to go with the 2 4' tables (need 14' of flat build table for fuselage) so have been working on that in interim.


 
Nov 10, 2020     Found this       Category: Workshop
Quasi antique metal biplane at an antique store, so onto the hangar wall it goes... quite the find at $15.

I'm waiting on more wood, so just general puttering and getting ready for fuselage build.


 
Nov 08, 2020     Finishing nose ribs       Category: Wings
Sanded and cleaned up all the nose ribs... now have nicely countoured and matching set. Into the 'finished parts awaiting future assembly' drawer under the bench.


 
Nov 02, 2020     More nose ribs - (3.3 hours)       Category: Wings
All the nose ribs are now rough cut.


 
Oct 29, 2020     Ribs complete! - (4 hours)       Category: Wings
Finally finished the last of the rib building... still have to add ply to the 4 special, root/tip ribs, but excited to put that behind me... the repetitive nature of building them was getting to me.

Also, moved on to cutting out the hoses... built a pattern out of scrap ply to aid me in getting them all the same.


 
Oct 27, 2020     Almost to the end of rib building - (13 hours)       Category: Wings
almost at the end of rib building. had to order some more capstrip and 1/16 ply to finish

also, end of October and it is chilly here in WA so bought this 'eye of Sauras' space heater to keep the hands and epoxy warm


 
Oct 17, 2020     Ribs - (12.5 hours)       Category: Wings
Just more rib building. Also, finally finished building little box to hold orbital sanding discs.


 
Oct 08, 2020     More ribs & tasty spiders - (19 hours)       Category: Wings
Have just been cranking on wing ribs. I find it amusing that the plans say that building a wing rib can be 'accomplished in about 20 minutes.' I suppose if you had CNC cut parts that fit perfectly, etc. etc. that might be the case to assemble one side, but realistically when you are talking about gluing, stapling, then gluing second side & stapling, then removing about 100 staples per rib, I'm averaging about 2-2.5 hours per finished rib. The joys of plans building fo sho!

The ladies came back and one brave soul decided that my hangar needed to be debugged... she wandered around clucking and chasing spiders (and other insects) around till she was satisfied I was bug free.


 
Sep 27, 2020     Ribs and unexpected guests - (11 hours)       Category: Wings
The stack of finished ribs got so large I now have to have '2 right hooks' to hold them all.

l also had a couple of the local ladies stop by to check out my progress!


 
Sep 22, 2020     Ribs and more ribs - (18 hours)       Category: Wings
Long gap from last entry as have just been focused on wing rib building at present - hence the 18 hours covers multiple build days since last entry. Have settled into 3-4 hours, 3 days a week building... You can find me at the hangar on Sundays, Tuesdays, and Fridays


 
Sep 06, 2020     Finished varnishing rear stabilizer       Category: Tail Feathers
Finished varnishing up the rear stabilizer. Also, did a little personalization of the hangar


 
Sep 04, 2020     Wing Ribs continue apace + more workshop stuff - (3.5 hours)       Category: Wings
more wing ribs being built... I used a 3 tier, left to right org method... on the left are wing ribs with gussets on one side, in the middle, gussets on both sides with staples still in, and on the right, completed wing ribs with staples removed.... looking forward to 24 of those suckers being done!

Also, hung up finished parts on the wall to get them off of the concrete and started building a small box out of scrap to hold orbital sander discs.


 
Aug 23, 2020     Building side workbench - (5 hours)       Category: Workshop
Built a bench against the wall so I have a workbench to layout and cut pieces without using main benches... for now it will be mostly used for building wing ribs...

Also, had a daddy long legs that was trying to hide in the pegboard... Also built a couple of drawers to slide under the benches.


 
Aug 22, 2020     More hangar setup - (3 hours)       Category: Workshop
Got some brackets for peg board and organized tools. Moving in finished pieces and added some varnish to rudder/vertical stab


 
Aug 18, 2020     Hangar! - (8 hours)       Category: Workshop
Well, a hangar became available on Aug 15 at Apex Airport so I jumped all over it as waitlists are 1.5-2+ years at area airports. So, existing 4' x 4' table had to be releveled and I built a second one and leveled it as well. Finally, I built two tables for belt sander and band saw.


 
Aug 01, 2020     Rear stabilizer finishing & wing ribs - (5 hours)       Category: Tail Feathers
Just finishing up some finishing touches on rear stabilizer. Wing ribs starting to accumulate :D The N55 3M mask is now almost a priceless artifact... go figure


 
Jul 29, 2020     More ribs... - (3.5 hours)       Category: Wings
Nowadays, just building ribs... I have to build 24 of them, so getting into the groove... It's a little daunting when you calculate there are over a thousand pieces to cut/make and bevel on sander. So probably won't have a lot of updates for awhile


 
Jul 26, 2020     Things I Realize at this Point in My Build Category: Workshop
In no particular order....

1) You have to make a lot of stuff so you can make airplane stuff. From building work benches to jigs or other tooling... be prepared to spend hours doing something other than making an airplane part.
2) It would be helpful to have someone who can read plans that can double check layouts or dimensions for critical cuts...like those hinge slots... simple mistake and I checked, re-checked, and checked again on my own, but still got it wrong. Kind of like needing an editor when writing. Unfortunately, there aren't very many active builders in my area... even the local EAA chapter has only 3 active builders. In addition, EAA doesn't have a single tech counselor listed for wooden plane builders in the state of Washington.
3) Some very basic power tools make all the difference in the world. Though I would love to have a state of the art workshop with top of the line tools, the simple truth is that I don't have the space or the budget right now. But a $139 Wen belt sander has been an unbelievable productivity booster. After realizing I have 550 3/4" wide gussets to cut to shape and cutting enough for patterns and one rib side (I've been using a utility knife and/or dremel tool with a tiny saw blade on it), it's time to buy an inexpensive table top band saw... I've cut about 60 of the gussets using the utility knife/dremel now and it's a pain!
4) Where a dust mask EVERY time you turn on the sander--I got a little lazy and it's taken me about a month of coughing to give the Simpson DOH! slap to my head on this.
 
Jul 22, 2020     First Rib - (1 hour) Category: Wings
First rib complete (well, one side gusseted anyway)! Only 538 more gussets to cut and 21 ribs to go...
 
Jul 22, 2020     First Rib - (1 hour)       Category: Wings
First rib complete (well, one side gusseted anyway)! Only 538 more gussets to cut and 21 ribs to go...


 
Jul 21, 2020     First Rib - (2 hours)       Category: Wings
Finished laying out the first rib.


 
Jul 20, 2020     Wing Ribs       Category: Wings
Cutting more capstrip to length. Cut gusset patterns and first side of gussets. Began laying out first rib with gussets.


 
Jul 19, 2020     Wing Ribs - (4 hours)       Category: Wings
Well, my capstrip order finally arrived. I received the plywood over 10 days ago. So, today I began building the jig. Once that was finished, I began cutting the capstrip (all 250+ pieces of them) to rough length. The blue tape is to label which is which.


 
Jul 15, 2020     Making Stuff to Make Airplane Stuff - (2 hours)       Category: Tail Feathers
Bit of a delay in wing rib capstrip order, so between my last entry and this one, I've just continued to varnish...lots of dry time (minimum 24 hours between coats). Finally got the shipping date for my capstrip, so i wanted to build a wing rib jig on a stable board that will allow me to work indoors during the winter (the 'garage' that I work in is open on one side and is really just a giant flying buttress to keep the hillside up, so it floods with all of the rain here in Washington and the temp gets cold enough that epoxy doesn't work). so, got some 1/2" ply hobby boards and built a super rigid surface to lay out the jig on.


 
Jul 14, 2020     Rib Jig - (1 hour)       Category: Tail Feathers
Wanted a stable/flat board to build wing rib jig on so got some finished plywood/hobby board and glued up a laminated two-layer board base.


 
Jun 30, 2020     Rudder Prep & Varnishing - (1 hour)       Category: Tail Feathers
While waiting on wood order, I've been continuing to varnish the pieces I've finished so far. Here, I've got the two thinned coats on.


 
Jun 29, 2020     Rear Elevator - (1 hour)       Category: Tail Feathers
Per recommendations of other wood plane builders and further research, began varnishing the rear elevator with 2 coats of marine spar varnish thinned 50/50 with paint thinner, then a final coat of 100% spar varnish. Pictures are after first coats of thinned varnish.


 
Jun 23, 2020     Rear Stabilizer Work - (1 hour)       Category: Tail Feathers
Removing staples from gussets. Began sanding with 320 grit to remove burrs/rough spots left by staples in prep for varnishing.


 
Jun 23, 2020     Printing rib template - (.2 hour) Category: Tail Feathers
Just printed two pages of the plan for the wing ribs.
 
Jun 21, 2020     Uh - oh! - (5 hours)       Category: Tail Feathers
Realized I cut the hinge slots in the wrong place on for the outboard hinges on the back of the rear stabilizer. After panicking and wondering if I would have to replace the rear spar and doublers, plus all of the gussets, I took a deep breath and contacted an EAA tech counselor. We talked through my proposed repair approach and he agreed--said the rear spar would actually be stronger than the original plans. So, I cut two biscuits and expoxied them into the slots. Then, I cut 1.5mm gussets to extend 2 inches past the ends of each of the hinge slots on both sides of the spar. Disaster averted! Thanks Jerry for the quick call, much appreciated.


 
Jun 18, 2020     Rear Stabilizer Assembly - (3.5 hours)       Category: Tail Feathers
Beginning to epoxy the real stabilizer gussets.


 
Jun 16, 2020     Rear Stabilizer Work - (2.5 hours) Category: Tail Feathers
Laying out the rear stabilizer and epoxying up one of the stabilizers' leading edges.
 
Jun 16, 2020     Rear Stabilizer Work - (2.5 hours)       Category: Tail Feathers
Laying out the rear stabilizer and epoxying up one of the stabilizers' leading edges.


 
Jun 12, 2020     Gluing up Elevator Cross Pieces - Continued - (3 hours)       Category: Tail Feathers
Continued gluing up remaining cross pieces and gussets on the top side. I left the strips that run the full length of the outboard ribs half free to aid in getting the trailing edge positioned correctly before gluing it on in the next session. Had to re-cut a few cross pieces as I missed factoring the doubler into lengths... fortunately, not too much wastage/scrap. Next session's challenge will be putting on the trailing edge.


 
Jun 11, 2020     Gluing up Elevator Cross Pieces - (2.5 hours)       Category: Tail Feathers
Glued up center line rib and the two major gussets off of the center rib. As usual, soda 12 packs make great weights to keep everything nice and level while drying.


 
Jun 09, 2020     Back to the Elevator - (1.5 hours)       Category: Tail Feathers
Well, the replacement wood arrived today (and I future proofed myself by ordering some extra). So back out to the build. I added the 4th strip to the leading edge of the stabilizer laminate. I also re-cut the doubler and sanded the taper in the proper plane this time (you can see the difference from the first one--the tone on top--vs. the correct plane at the bottom. Finally, glued up the doubler to the spar and brought everything in to dry inside as it was a little chilly outside.


 
May 31, 2020     Cutting Cross Pieces & Tapering Trailing Edge - (4 hours)       Category: Tail Feathers
Today I finished cutting and tapering cross pieces for elevator. I also glued up one leading edge of the stabilizer with the three remaining pieces I had that were the proper length. Come to find out that there were 8 pieces of that length, but I unwittingly used a bunch of them to cut my cross pieces. In addition, after I'd already sanded it (of course) I realized I sanded the taper on the wrong edge for the elevator spar doubler (the doubler is on the plans because I was checking them to make sure I'd actually messed it up... I did). DOH! So, there's a bit of a gap before I can get back to building as I have to order some more wood.


 
May 25, 2020     Building... - (8 hours) Category: Tail Feathers
One of the lessons of building an airplane.... you often spend more time building stuff to allow you to build an airplane...

Added a second 4' x 4' workbench to make an 8' x 4' workbench to start building elevator and rear wing.

I also re-topped my original workbench... the MDF that I used last fall started sagging from moisture as well as the fact I didn't have stiffener stringers. Replaced that top with 1/2" plywood and added 16" on center stringers to workbench to stiffen and support new top. Repurposed MDF for lower shelf to store wood and tools. Amazingly, level all around within 1/8" on first go round.
 
May 25, 2020     Building... - (8 hours) Category: Tail Feathers
One of the lessons of building an airplane.... you often spend more time building stuff to allow you to build an airplane...

Added a second 4' x 4' workbench to make an 8' x 4' workbench to start building elevator and rear wing.

I also re-topped my original workbench... the MDF that I used last fall started sagging from moisture as well as the fact I didn't have stiffener stringers. Replaced that top with 1/2" plywood and added 16" on center stringers to workbench to stiffen and support new top. Repurposed MDF for lower shelf to store wood and tools. Amazingly, level all around within 1/8" on first go round.
 
May 25, 2020     Building... - (8 hours)       Category: Tail Feathers
One of the lessons of building an airplane.... you often spend more time building stuff to allow you to build an airplane...

Added a second 4' x 4' workbench to make an 8' x 4' workbench to start building elevator and rear wing.

I also re-topped my original workbench... the MDF that I used last fall started sagging from moisture as well as the fact I didn't have stiffener stringers. Replaced that top with 1/2" plywood and added 16" on center stringers to workbench to stiffen and support new top. Repurposed MDF for lower shelf to store wood and tools. Amazingly, level all around within 1/8" on first go round.


 
May 20, 2020     Removed staples and cut hinge slots - (2.5 hours)       Category: Tail Feathers
After much measuring, measuring again, and stressing, cut the slots for the rudder hinges... Also, removed staples from vertical stab gussets. Beveled gusset edges.


 
May 19, 2020     Cut and epoxyed lower left gussets on vertical stab... - (2 hours)       Category: Tail Feathers
Cut and glued up the gussets for the lower left of the vertical stabilizer. Also, took the vertical stabilizer to the bench sander and sanded down the portion of the upper trailing edge of vertical stabilizer to get the vertical stabilizer ready for a protective coat.


 
May 18, 2020     Cutting gussets for vertical stabilizer and expoyxing them on - (1 hour)       Category: Tail Feathers
First lower right gusset i cut for vertical stab, my jigsaw mangled the long angle... after looking at it for awhile, decided that better to 'waste' the materials and cut a new one rather than have my a$$ hanging in the wind with a flapping vertical stab at 1000' AGL.


 
May 18, 2020     Cutting gussets for vertical stabilizer and expoyxing them on - (1 hour) Category: Tail Feathers
 
May 14, 2020     Glued up a cross piece - (.2 hour)       Category: Tail Feathers
just gluing up a crosspiece today.


 
May 12, 2020     Pulling Staples - (.3 hour) Category: Tail Feathers
Pulled staples off of glued gussets. New gusset plywood arriving Friday, so more progress after that... for now, pretty much in a holding pattern.
 
May 12, 2020     Pulling Staples - (.3 hour) Category: Tail Feathers
Pulled staples off of glued gussets. New gusset plywood arriving Friday, so more progress after that... for now, pretty much in a holding pattern.
 
May 11, 2020     Not much today.... - (.5 hour) Category: Tail Feathers
Just pulled out staples used to hold gussets in place yesterday.
 
May 10, 2020     More Gussets - (1 hour)       Category: Tail Feathers
Today was just doing more gussets. I had to order more 1.5mm Birch plywood today as all of the re-work has left me without much material left. Will probably have to suspend more work until delivery next Friday (or perhaps sooner, depends on Amazon), when I get the new plywood. Was happy to add gussets to the triple joint on the rudder to prevent breakage. I ended up cutting off one rib as it was misaligned which I will probably add back tomorrow on a butt joint glue job to hold in place until gusset material arrives.


 
Apr 29, 2020     Gluing up Rudder - (2 hours)       Category: Tail Feathers
Today was just about gluing up the butt joints on the cross pieces to the front rudder spar.


 
Apr 27, 2020     Tool for taper to rudder trailing edge - (2.5 hours)       Category: Tail Feathers
Today I used some scrap wood to create a jig tooling to have a consistent trace on trailing edge taper. Rough cut all of the tapers.


 
Apr 21, 2020     More gussets on the vertical stabilizer - (1 hour)       Category: Tail Feathers
Flipped vertical stab over and added small gussets to backside.


 
Apr 12, 2020     Rework of Vertical Stabilizer - (4 hours)       Category: Tail Feathers
Today, made good progress on fixing vertical stabilizer. Glued up all the butt joints and added some gussets back. Will need to order more gusset material as can only do the smaller gussets at this time to add some strength. Also cut cross pieces to fit on rudder.


 
Apr 02, 2020     Jig for trailing edge - (1 hour)       Category: Tail Feathers
Tried various ways of setting up a jig for gluing the trailing edge of the rudder onto the ribs. Ended up abandoning this and instead, shifted to attaching after gluing up the straight pieces and sanding down the cross pieces to the curve in the pattern.


 
Mar 30, 2020     Redo of rudder - (3 hours)       Category: Tail Feathers
More sanding off gussets and cutting out of cross pieces. Was able to salvage the front laminated spar and many cross pieces. Started cutting and laying out the rudder pieces.


 
Mar 29, 2020     Redo of rudder - (3 hours)       Category: Tail Feathers
After a several year hiatus wherein the beginning of my project, building the tail feathers, was pulled out of storage so I could complete the rudder, I discovered I made a mistake on the original build... the angle at the top was incorrect due to me not having the space to lay out the full tail feathers side by side. Big sigh, but I hit reset and redrew on the craft paper covering my new workbench and stripped down the incorrect pieces in anticipation of the reset. Lots of sanding off of gussets and the like.


 


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