Apr 16, 2022     Fill and Sand Wheel Pants - (1.3 hours) Category: Ext. Finish

Applied lightweight filler to seams in wheel pants. Sanded in preparation for epoxy primer.

  Nov 06, 2021     Port Wing - Finishing - (1.5 hours) Category: Ext. Finish

Carve leading edge drips with new box cutter blade. Sand orange peel areas with 400, 600, & 1200 grit.

Some additional sanding. Cold, snowy winter. No fun for working on finish.

  Oct 17, 2021     Paint Port Wing Top - (2.5 hours) Category: Ext. Finish

Additional hand sanding with medium grit sanding block. Squared spoiler mechanism cutout with flat and bastard files. Clamped spoiler cable slightly open.
Mixed two 18oz cups of Eastwood 3:1 white urethane and medium activator. Air temperature in the mid 60s. Sprayed a wet coat with horizontal and vertical passes. Heavy coat on leading edge leading to a couple long runs.

  Oct 16, 2021     Port wing prep, top - (4.8 hours)       Category: Ext. Finish

Examined urethane finish on bottom, have some orange peal areas that needed a wetter application, but overall pleased with the results. Reconnected aileron pushrod, inspection covers, pushrod fairing. With the assistance of Greg Campbell, flipped the wing to expose the top surface. Sanded epoxy primer with 320 grit and medium grit foam sanding blocks. Extended spoiler, clamping it open. Cleaned the bare metal of the spoiler pocket with Eastwood de-greaser paint prep. Used a can of 2 part spray epoxy to prime the spoiler pocket and to trailing edge that had been sanded to bare metal.
Reattached the long aileron pushrod, covered the pushrod with 3 feet of insulating pipe foam and wrapped it to the spar with film.
Compared white urethane with white epoxy primer on the empennage, color is more of a light gray than brilliant white.

  Oct 11, 2021     Paint Port Wing Bottom - (4.5 hours)       Category: Ext. Finish

Sanded the Eastwood roll-on epoxy primer with 320 grit on cordless orbital sander. Used two batteries to complete. Removed a few roller marks without going to metal. Wiped clean, then sanded leading edge and other curved or between rivet surfaces with a medium grit 3M foam sanding block. Cleared with compressed air and wiped down with Eastwood paint prep. Taped inside aileron pushrod slot from inspection port hole, used 4in plastic map plugs to cover inspection holes, #4 machine screws in nut-plates.
The inexpensive Eastwood gun air pressure regulator would not adjust pressure at the gun. Traveled down the hill to the Sherwin-Williams store and purchased a DeVilbiss gauge/valve reducer for $50.

PPE was disposable full suit, blue latex gloves taped around wrists, face mast with fresh VOC filters (couldn't wear glasses with full-face), Mixed 20 oz Eastwood white urethane 3:1 with medium speed (70-80degF) activator. Loaded paint into 24oz DeVilbiss DeKups disposal cup. Shot patterns against masking paper to adjust gun pattern and flow. Used 1.3mm nozzle and approximately 10-20psi at the gun. Made vertical and horizontal passes, trying to maintain a wet look, but it appeared to flash a bit quicker than anticipated.

Mixed 24oz 3:1 with the slow speed (80-90degF) activator and one part reducer. The second coat lay wetter for a longer period than the first coat. No touches or contact marks (!!). Clean up for 20 minutes then pulled masking tape from the inboard rib. Cleaning the cup was as simple as throwing it away.

  Oct 04, 2021     Port wing prep - (1.2 hours)       Category: Ext. Finish

Hung a plastic sheer to reduce disturbing dust around the hangar wall. Keeping the space open to encourage air flow for reducing isocyanate exposure from urethane. Set the port wing on three saw horses with the assistance of Greg Campbell and Britt Childress.

  Sep 25, 2021     Test Spray Equpment - (3.2 hours) Category: Ext. Finish

Mounted air line closer to compressor, mixed 8oz of Eastwood low VOC epoxy primer. Gun test and adjustment against a strip of masking paper held against the hangar wall. Initially, the gun spit, dripped, and produced a poor spray pattern. Removed the nozzle and cleaned it in lacquer thinner. Cleaned up the gun and tried again. Was able to obtain a good fan pattern down to 7 psi at the gun. Shot a couple sections of the empennage to good effect. Used the Devilbiss DeKups (https://www.eastwood.com/dekups-24-oz-trial-kit.html) disposable cup and lid system, saving a good bit of cleanup time and aggravation. No isocyanates in the primer, PPE use was gloves, eye protection, disposable coat and organic vapor mask.

  Sep 05, 2021     Prep Spray Equipment - (3.1 hours) Category: Ext. Finish

Prepared air compressor with an additional tee and 1/4 turn stop valve, attached desiccant line, cleaned new gun with lacquer thinner, added and adjusted regulator at the gun. Had some difficulty initially with the inexpensive regulator continuously venting.
Sand primer on glare shield and seat back.
Relocated 50 foot air hose/reel.
Gun and epoxy primer expense included in this entry.

  Aug 21, 2021     Starboard Aileron - (0.6 hour) Category: Ext. Finish

Sanded epoxy primer to remove orange peel with foam sanding block. Installed aileron on wing, had to spray on and wipe off WD40 on center pin to get the pin to full insertion..

  Aug 08, 2021     Hang & Cover - (0.5 hour) Category: Ext. Finish

Inspected epoxy coating on starboard side tail. Inspected and cleaned up primed fuselage floor. Stored floor on back hangar wall.

  Aug 07, 2021     Prime Small Parts - (1.4 hours) Category: Ext. Finish

Sanded reverse side of fuselage bottom skin to remove excess Optiflow primer resulting from rolling the opposite side. Cleaned the sheet with with acetone, wiped with tack cloth and sprayed with Eastwood canned two part epoxy primer wearing respirator. Same to starboard ruddervator hinge joint and windscreen strap.
To date, the epoxy primer appears more permanent with better adhesive character than automotive rattle-can self-etching primer.

  Jul 31, 2021     More sanding fairing filler - (1.5 hours) Category: Ext. Finish

Sand in prep for epoxy, concentrating on the fuselage/empennage section, aileron.

  Jul 31, 2021     Last of the Optiflow Primer - (1 hour)       Category: Ext. Finish

Filtered, mixed, and applied the last of the Eastwood epoxy primer to the starboard side fuselage, the faired areas at the fuselage/empennage junction, rear fuselage underside, starboard side cockpit, and bottom of starboard aileron.
Primer and activator seem to have held up through winter temperature cycling. Time will tell.

  Jul 18, 2021     Fill and sand - (1.7 hours) Category: Ext. Finish

Added lightweight filler to underside of ruddervator/fuselage joint.
Sanded previous epoxy primer on fuselage. Removed a few slumps, runs, and dust bits.

  Jun 21, 2021     Sand Fuselage - (2.9 hours)       Category: Ext. Finish

Knocked down slight 'pimpling', orange peel, and roller marks from epoxy primer with 240/320 grit by hand. Applied scratch filler. Wiped down dust.
Found that the fuselage bottom panel, previously sprayed with self-etching rattle can primer several year ago, had areas that lifted from temperature cycling and incomplete bonding. Sanded and wiped down bottom fuselage panel with acetone.

  Jun 18, 2021     Prep and Prime Fuselage - (2.1 hours)       Category: Ext. Finish

Wiped down bare surfaces with acetone and Scotchbright. Sanded prior application to knock down orange peel and 'pimpling' areas with 320/400 grit on 5" cordless orbital sander. Wiped down with tack cloth. Taped holes to reduce flow through.
Wore organic solvent filter. Stirred and strained 6 oz Eastwood OptiFlow epoxy base, added 6 oz catalyst. Twelve oz was just sufficient quantity to apply to entire fuselage, the leading edge and control surfaces of the tail. Started interior priming at high wear (hand and finger prints) surfaces at cockpit bulkhead.

  Jun 13, 2021     Roll Primer on Fuselage - (1.0 hour)       Category: Ext. Finish

Prepared rear fuselage by wiping surface dirt and grease with acetone, knocked down a couple proud rivet shanks. Made up 12 oz. of Optiflow epoxy primer rolling it on to the rear fuselage, recently sanded starboard ruddervator, and seat back. Wore filter mask in heat - better than breathing the ever-present catalyzed fumes.

  Jun 12, 2021     Sand Wing Tip and Ruddervator - (0.9 hour) Category: Ext. Finish

Sanded epoxy primer, removed runs, on starboard wing tip and ruddervator with 5" cordless sander using 400 & 600 grit (depending on the depth of orange peel).

  Jun 05, 2021     Prep and Prime Control Surfaces - (2.7 hours)       Category: Ext. Finish

Prepared port side aileron and elevon surfaces by sanding orange peal and small bubbles with 320/600 grit on cordless 5" sander. Orange peal and small bubbles were a result of a long (>24 hr) pot life using Eastwood Optiflo roll-on epoxy.
Used extra pieces of hinge to mask control surface hinges from excess epoxy from hinge pin. Used two cans of Eastwood two part epoxy (https://www.eastwood.com/ew-2k-aerosol-epoxy-primer-gray.html) on hinges and channels to coat places that aren't conducive to a thick coating with roll-on primer to bind hinge and pins. Spray epoxy set rather quickly. The the masking hinge pieces were removed and hinge pins cleaned of epoxy residue with acetone.

  May 31, 2021     Sanded filler on wheel pants - (0.9 hour) Category: Ext. Finish

Sanded filler that filled and evened the mating of fiberglass Sonex wheel pants.

  May 28, 2021     Sanding fairing filler - (3.2 hours)       Category: Ext. Finish

Sanded filler around pitot and TE ports, ruddervators.

  May 21, 2021     Fairing Empennage - (1.3 hours) Category: Ext. Finish

Sanded filler around fuselage to ruddervator intersections and around pitot and TE probe sockets.

  May 16, 2021     Paint rack - (0.6 hour)       Category: Ext. Finish

Finished assembling the Eastwood paint rack and mounted several pieces for coating with Eastwood canned two-part spray epoxy.

  May 02, 2021     Sanding fairing filler - (0.7 hour) Category: Ext. Finish

Sanded lightweight polyester filler at pitot and TE probe sockets, stabilator to fuselage areas, and wheel pants.

  Apr 19, 2021     Prep for additional undercoating - (3.1 hours) Category: Ext. Finish

Removed hinge pins, unbolted pushrods and control cable from rudder and removed both ruddervators. Starboard side ruddervator pin was particularly difficult to remove due to excessive length. Long end of pin had been bent to prevent the pin from backing out.
Removed tail tips, applied masking tap to control over spray. Applied lightweight filler to fair between fuselage and root of tail planes. Added filler to wheel pants and tail tips where needed to fill voids or mold marks. Sanded undercoat to removed bumps that developed from rolling on day-old epoxy. Eastwood epoxy undercoat is very difficult to remove from fittings and areas that were inadvertently marked by the roller during application.
Cleaned and taped areas to be coated with spray epoxy around control surface hinges.

  Nov 11, 2020     Touch up primer on wings - (1.6 hours) Category: Ext. Finish

Sanded lightweight filler covering extraneous holes at the outboard end of the port aileron. Sanded edges of fiberglass wingtips. Rolled on Optiflow epoxy primer.
Cleaned the glare shield with Scotchbrite and solvent. Rolled a coat of primer on starboard side stabilizer and ruddervator.

  Nov 08, 2020     Epoxy primer stabilators - (2.7 hours)       Category: Ext. Finish

Cleaned the stabilator top and bottom surfaces and some minimal taping. Mixed 12 oz of Eastwood Optiflow epoxy primer and applied with a wide roller. Used maybe 7 of the 12 ozs. Touched up some areas on the trailer edge of the port wing.

  Nov 04, 2020     Wings in cradle - (0.6 hour) Category: Ext. Finish

With Brendan's help, removed the wings from hanging from the ceiling beams and placed them back on the cradle. Inspected primer from trailing edge, noting several places that will need attention. Overall, the Eastwood Optiflow epoxy primer worked well for conditions, particularly the limited clean space in the hangar and eliminated the need for erecting of a cleanroom. The simplicity of obtaining an acceptable protective finish this far into the build was a relief. Final prep for color may need some additional sanding.

  Nov 01, 2020     Second coat port wing & stabilator - (2 hours)       Category: Ext. Finish

Clean and prepared the underside of the port stabilator. Mixed 12 oz of Eastwood epoxy primer and rolled the top side of the port wing. Second use of pan liner, third use of mixing cup. New foam rollers. Rolled primer on the underside of the port stabilator and the top of the port ruddervator. Used a small foam roller to prim the inside of the ruddervator and the inside of the starboard aileron.
Easy cleanup, discarded the pan liner and mixing cup. Foam rollers after they set up.
Fairly pleased with the ease of application and clean up compared with possible spray application. The objective is to establish a reliable primer surface for future color application and to combat the observed corrosion. Corrosion of the 6061 T6 seems accelerated in places that were used in early polishing trials and edges that were exposed to atmospheric moister condensation, and places touched or pushed with hands.
Color coat will probably be white, with color application using vinyl.

  Oct 31, 2020     Clean, prep, prime - (2.3 hours)       Category: Ext. Finish

Cleaned port wing top side with acetone and Scotchbrite pad, wiping residue with shop towel. A second cleaning pass with Eastwood paint prep to both sides of the wing. Mixed 12 oz of Eastwood Optiflow epoxy primer & activator was just enough to roll on a second coat on the bottom and a first coat to the top of the port wing. Held the spoiler open by clamping the spoiler control wire.
Drilled out and replaced a wingtip rivet on the starboard wing top side.
Will likely remove wing tip, fill the leading interior with epoxy, and sand the leading edge to match the aluminum.

  Oct 17, 2020     Clean, prep, prime - (3.5 hours)       Category: Ext. Finish

Disconcerting to find the spoiler was glued shut while inspecting the primed top of the port wing. Used three or four box cutter blades inserted under the lip of the spoiler to find and gently break the epoxy seal. Inserted a plastic spacer to hold the spoiler open during application of the second coat.
Scrubbed underside starboard wing surface with Scotchbrite & acetone, wiped residue with paint prep solvents. Lightly brushed the previously primed top surface of the port wing with a Scotchbrite pad.
Installed three missed rivets in the port side wing tip.
Mixed 12 oz of Optiflow epoxy primer & activator to finish the first coat on the bottom of the starboard and and apply a second coat to the top of the port wings.
Shot a yellow color coat to six inspection covers.
Trimmed foam board anti-rodent cover close to the shape to use as a template to cut an aluminum sheet. Plan is to create a more durable anti-rodent wing end cover to block any critter capable of creating a nest inside the wings.

  Oct 12, 2020     Clean, prep, prime - (3 hours)       Category: Ext. Finish

As described previously, filled mandrel nubs from the top side of the port wing, scrubbed surface with Scotchbrite & acetone, wiped residue with paint prep solvents. Lightly brushed the previously primed surface with Scotchbrite to remove several gnats stuck to the surface.
Used 5 oz of epoxy primer left from the previous day on the outboard end of the wing. Noticeably less viscous, the primer became tacky quickly after application. So tacky that bits of the foam on the end of the roller tore and had to be picked off the surface. Mixed and applied an additional 15 oz of Optiflow primer & activator to finish the first coat on the top and apply a second coat to the bottom.

  Oct 11, 2020     Clean, prep, prime - (3.4 hours)       Category: Ext. Finish

Prepared port wing underside for application of Eastwood Optiflow epoxy primer. Initial preparation consisted of removing inspection covers, aileron pushrod fairing and pushrod. Inspected each rivet for protruding sharp nubs from the mandrel. Filed sharp ends flush. Wearing vinyl gloves, used a Scotchbrite pad occasionally wet with acetone and a clean acetylene soaked rag to scrub oxidized spots, tape adhesive, and surface oxidation. A second pass with Eastwood prep (xylene + acetone) spray and several clean shop rags to ready the area for primer. Masking tape across the reverse side of the leading edge of the wing to catch primer.
Mixed 10 oz (5+5) Eastwood Optiflow epoxy primer 1:1 with catalyst. Used half (5 oz) to coat the underside of the one wing.
The thin epoxy primer was rolled on to the vertical, leading edge up, wing. Initial rollout of the primer resulted in a lightly mottled finish, but subsequent application blends into adjoining sections. The primer seemed to adhere more readily with additional pot time. Eastwood's instructions indicate 20 minutes pot time as a maximum, but the 5 oz left in the mixing cup looked usable.
Cleanup is a simple matter of throwing out the used foam roller and tray liner.

  Oct 10, 2020     Hang wings for priming work - (2 hours)       Category: Ext. Finish

Suspended the wings from the hangar ceiling through the main spar and hold down fitting. Began cleaning tape residue and dirt in preparation for epoxy primer.