Project: wstoelting   -  
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Builder Name:Wade Stoelting   -  
Project:   Just - Highlander   -   VIEW REPORTS
Total Hours:788.9
Total Flight Time:
Total Expense:$68417.69
Start/Last Date:Oct 09, 2019 - No Finish Date
Engine:Yamaha Apex
 
Friendly URL: https://eaabuilderslog.org?s=wstoelting

Home or Last Project Picture

Apr 29, 2024     Travel Struts - (1.5 hours)       Category: Wings
Preparing airplane for trailer transporting to Montana. Removed front leading edge spar pins, and rotated wings back. Fabricated wing travel support/secure struts from 1/2 square tubing. Secured wings for trailering.

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Apr 26, 2024     Cable Pulleys on Wings - (3 hours)       Category: Controls
Located and installed left and right aileron pulleys with cable keepers (4 places). Installed flap control pulleys and cable keepers (2 places). Installed cover/closeout plates.

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Apr 24, 2024     Jury Strut Install - (3 hours)       Category: Wings
Located and drilled jury strut holes in weldment and the bracket straps that attach jury strut to wing struts. Painted brackets. Fastened in place with hardware.

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Feb 26, 2024     Mounted Propeller - (1 hour)       Category: Propeller
Installed propeller. Used hardware torque info from Kyiv Propeller USA website 18 ft-lbs. Set ground adjustable pitch with gauge provided by NR Prop. Installed propeller without nose cone backing plate for initial engine runups and then will retorque the pitch adjustment screws. Then remove hub to install backing plate.

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Feb 05, 2024     Vinyl Wrap Kickpanels and Turtledeck - (4 hours)       Category: Fuselage
Ordered vinyl wrap for kickpanels and turtle deck from Amazon. The orange color and gloss may not match perfectly with airplane paint but adequate. ViVid brand. I am trying to minimize further painting effort due to current Temps, and no more paint booth.

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Jan 24, 2024     Installed Wings - (4 hours)       Category: Wings
Moved plane and wings from garage to hangar. Installed wings after arriving at hangar. Still have a few hardware installation fixes but it sure looks like a plane now.

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Jan 02, 2024     Electrical Supplies       Category: Instrument Panel
PIDG ring connectors, toggle switches, 20ga wire, 22ga wire, 2 conductor and 3 Co ductor shielded wire...

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Jan 01, 2024     Windshield - (6 hours)       Category: Fuselage
Rough cutout the windshield. This is the second attempt as I undercut the first one. Afterwards, made further precision trimming and drilled mounting holes, sanded smooth edges.

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Dec 26, 2023     Engine Cowling - (9 hours)       Category: Fuselage
Fiberglassed inner lower Radiator ducting. Shortened up scoop inlet, clecoed in place, checked fit on airplane, then used epoxy to secure. Next up is finishing with filler then primer.

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Dec 15, 2023     Start your engine!       Category: Engine
Yahoo! Starting after 3 and half years. Video would not save. Saved to YouTube.
https://youtu.be/RITszWDpqu4?feature=shared

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Dec 14, 2023     Battery Charger       Category: Tools
The Lithium Phospate battery requires a charger other than the traditional lead acid type.

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Dec 11, 2023     Panel Finishing - (4 hours)       Category: Instrument Panel
Vinyl wrapped the dash, Dymo labeling. Fit radio chassis, EIS unit, cut holes for vents.

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Dec 03, 2023     Spider of Wires - (3 hours)       Category: Instrument Panel
Continue to make Wire connections and route to panel. These wires are for Master, auto tune, ignition, fuel pumps, start, landing and heater. Still need to route Nav/Strobe and interior light.

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Nov 19, 2023     Battery Cable - (.5 hour)       Category: Instrument Panel
Positive battery cable from battery to main relay. #6 gauge Wire, ring terminals, relay diode. $13 in Wire stuff, rest is shipping cost. Installed cable and diode on relay, routed to battery.

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Oct 31, 2023     Switcheroo       Category: Instrument Panel
Time to get the Instrument Panel switches placed and installed. The cost sure adds up, taxes, shipping and etc.

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Oct 21, 2023     Wires, Connectors, Light, Sleeving...       Category: Instrument Panel
Time to get on with the wiring. Purchased 100 ft of 22 gauge & 20 & 6 ft of 10 gauge, plus Pidg ring terminals, and rubber boots, 100 ft of .25 in Dia sleeving, plus clear heat shrink for labels. Also an interior light having both red and white LED.

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Sep 24, 2023     Battery Contactor & Starter Relay - (1 hour)       Category: Firewall
Found a place to locate the battery contactor and starter solenoid/relay on the cabin side of firewall. Trying to tuck things clear of the rudder pedals. Drilled firewall and installed rivnuts to locate components.

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Sep 23, 2023     Canopy Glass - (4 hours)       Category: Fuselage
Cut, trimmed, drilled Lexan. Aligned and fitted, located Rivet mounting holes. Tried to apply tinting film prior to mounting but learned that was the wrong approach. Scrapped tinting. Riveted overhead "glass" in place.

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Sep 02, 2023     Access Door - (2 hours)       Category: Interior Finish
Decided to install door into aft baggage compartment wall where I can gain access to stowed tool kit.

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Sep 01, 2023     Door Install - (2 hours)       Category: Fuselage
Doors were placed into position and hinge pins installed. Installed gas struts. Door latches were modified by threading ends for turn knots. Much better look and feel than the welded hoop.

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Aug 27, 2023     Exhaust Pipe - (2 hours)       Category: Engine
Needed to fabricate exhaust pipe connection between header collector and mounted muffler. Ordered 2in elbow, 2 inch straight pipe, 2 to 2.5 adapter, band clamp, and sleeve clamp. Had a local guy weld up the 304 stainless pipe.

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Aug 26, 2023     Heater Outlets - (2 hours)       Category: Instrument Panel
Found two Outlets from Miata dash at Pick-a-Part. Used SolidWorks to model spuds for hose connection. Had friend 3d print the parts. Turned out great. Now need to mount in panel.

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Aug 22, 2023     Rock Guard - (.5 hour)       Category: Fuselage
Used Harvey black pipe wrap, 10 mil, on my front gear legs and leading edges of horizontal stabilizer.

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Jul 27, 2023     VHF Radio Purchase       Category: Instrument Panel
Purchased a Garmin GTR 200, used, from AWG International.

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Jun 25, 2023     Propeller Spacer Install - (.5 hour)       Category: Engine
Purchased 10.9 grade 8mm x 1.25 40mm long bolts for spacer to psru installation. Purchased Nordlock washers (25 sets). Torqued down the bolts per in reference to bolt grade.

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Jun 17, 2023     EGT and O2 Sensor Routing - (3 hours)       Category: Engine
Drilled holes through electrical tray, routed wires through tray. Mounted O2 Module, tightened thermal couple's to headers, drilled large hole through firewall, fabricated firewall bundle seal. Wired thermal couple's to connectors and installed.

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May 30, 2023     Throttle Cable - (.5 hour)       Category: Instrument Panel
The previous cable install was with spiral wire cable which is satisfactory for pull, put not pushing. Have you ever pushed a rope? Ordered and installed a solid wire type.

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May 16, 2023     Propeller Spacer       Category: Propeller
Saber mfg 4" spacer and hardware.

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May 07, 2023     Control Stick Collector Covering - (3 hours)       Category: Interior Finish
Redid the decorative interior covering, removing my vinyl fabric covering and used abs plastic sheet instead. Used Heat gun for forming a bend. Made cutouts where appropriate. Overall a better finish and more robust.

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May 06, 2023     Muffler - (3.5 hours)       Category: Engine
Machined a hanger block from HDPE, tapped end of block for 1/4-20 bolt, cross drilled to mount to fuselage at unuesed landing gear bracket. Purchased rubber isolater, and used left over light mounting bracket at the cabane.

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Apr 11, 2023     Engine Cowling - (3 hours)       Category: Fuselage
Trimming Boot Cowl, upper and lower cowling to fit. Lots more to do.

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Apr 09, 2023     Prop spacer Prop - (1 hour)       Category: Propeller
Need to simulate spacer which I have not finished yet in order to fit engine cowling.

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Apr 09, 2023     Heater Installation - (3.5 hours)       Category: Instrument Panel
Found a location on underside of equipment rack. Disassembled heater to locate mounting holes, rotated heater core to point the hose connections where desired. Now I need to figure out routing and fittings through firewall.

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Apr 05, 2023     Heater       Category: Instrument Panel
Thus plane is going to be flown in the snowy winters of eastern Washington and needs cabin heat. T7 Designs builds this compact little Heater setup. Now need to place behind the panel, route coolant hoses through the firewall, and duct warm air to the pilot and passenger.

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Apr 01, 2023     Landing Light Mounted - (.5 hour)       Category: Lighting
Decided on installing just one light on the cabane, and I like the looks. Will find out if adequate.

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Mar 28, 2023     Header       Category: Engine
What a work of art. I decided my fabrication and modification of a Suzuki Sammurai header from Amazon just would not be the most durable and performance way to go. So from a $200 product to a $1800 product seems crazy to me but the right decision for the long run.

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Mar 26, 2023     Decorative Control Stick Covering - (2 hours)       Category: Interior Finish
Had Vinyl material, cut to shape, installed gear shift boots, glued backing material to hold shape. Used contact adhesive.

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Mar 25, 2023     Brakes and Wheels - (2 hours)       Category: Landing Gear
Installed brake flanges, installed calipers, made lines for linking dual calipers. Installed spacers and then wheels.

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Mar 23, 2023     Wheel Spacers - (3.5 hours)       Category: Landing Gear
Needed spacers to mount and align wheel/brake rotor with caliper brake mount. Determined spacer width and so designed up what I desired and machined out of 6061T6 aluminum.

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Mar 11, 2023     Installed Main Gear - (1 hour)       Category: Landing Gear
Installed main gear legs and Shock system. Greased bolts for install, used engine hoist to lift airframe. Discovered I did not have Aluminum axle sleeves to space wheel and brake caliper setup. Also determined the garage is no tall enough for me to install the tundra tires.

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Mar 04, 2023     Battery Mount Installation - (1 hour)       Category: Avionics
Ordered more AN3-4a and AN3-5a hardware for miscellaneous installations like the battery mount. Positioned, located holes, drilled, deburred, mounted battery mount on electronics tray underside.

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Mar 04, 2023     Master Cylinder Brake Lines - (1 hour)       Category: Fuselage
My previous installation had lines too short , moving rudder pedals woul stress the remote master cylinder fittings. Ordered additional brake line material, built longer lines and looped the routing. Operation is improved.

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Mar 04, 2023     Oil Cooler Line - (1 hour) Category: Engine
Received needed AN8 fitting having 90 degree bend. Constructed oil line, included fire sleeve and installed.
 
Feb 26, 2023     Coolant System/Expansion Tank - (10 hours)       Category: Engine
Fittings, silicone coolant lines, clamps, expansion tank. Had a welder weld one aluminum fitting. Mounted tank to firewall, used rivnuts. Lots of time planning routing and etcetera.

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Feb 24, 2023     Battery Mount - (2.5 hours)       Category: Avionics
The battery mount I purchased was sized for EarthX680, the battery I have is a 680C, meaning compact. So fabricated my own mount.

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Feb 02, 2023     Fuel Return Line - (1 hour)       Category: Fuel System
After fabricating the supply fuel line from firewall to engine, it was time to make the return line. Purchased fuel rail adapter fitting and then cut hose to length, installed fittings, blew out line with air hose and installed.

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Jan 27, 2023     Coolant Line Couplers       Category: Engine
1 inch diameter coolant line couplers.

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Jan 24, 2023     Engine Management System - (3 hours)       Category: Engine
Mounted the ECM, Ignition Control Module, Barometric sensor, fuel pump relays to underside of fabricated tray mount.

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Jan 24, 2023     Radiator/oil cooler remount - (2 hours)       Category: Engine
Changed up the mounting of the Radiator and oil cooler to improve routing of coolant and oil lines.

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Jan 20, 2023     Fuel, Oil, Water       Category: Engine
Silicone Coolant line, engine start switch, oil coolant line, fuel fittings.

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Jan 16, 2023     Firesleeve and Fitting       Category: Fuel System
Firesleeve for fuel lines, fitting for coolant expansion tank.

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Jan 15, 2023     Fuel Lines to Firewall - (2 hours)       Category: Fuel System
Built two fuel lines for cabin side connecting tubing lines to firewall bulkhead fitting. Located bulkhead fitting locations. Drilled holes in firewall. Fabricated hoses using Summiy braided hose and Summit Racing fittings.

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Jan 11, 2023     Fuel lines       Category: Engine
Fuel line fittings and hoses for firewall forward . Two oil cooler fittings too. Now will cut to length and assemble.

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Jan 11, 2023     Spinner       Category: Propeller
Carbon Fiber Nose Cone arrived from Kyiv Ukraine.

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Dec 24, 2022     Seat Belt Install - (3 hours)       Category: Interior Finish
Fabricated 4 cable ties for lap belt attachment. Bolt install of Hooker harness seat belts, left and right seat.

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Dec 18, 2022     NR Prop       Category: Propeller
Ordered propeller in August from NR Prop. Kiev, Ukraine. Roman remains in business during the Russian invasion. His family is temporarily in Poland. Intermittent power outages, shelling and etc slowed him down but he managed to get it finished and delivered. Carbon fiber composite, metal leading edges, aluminum hub. Super light.

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Dec 04, 2022     Throttle Control - (5 hours)       Category: Engine
Used some aluminum scrap bar material, and some solid round stock. Purchased some extension springs. Engine throttle cable is pulled to open throttle, pilots push throttle forward to open. The mechanism has a 2 to 4 ratio. Took some effort and a few iterations to make it all work. Will still revise wire rope cable on airplane throttle to music wire.

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Dec 01, 2022     Battery       Category: Engine
ETX680C EarthX LiFePO4 battery for the plane. Lightweight and powerful.

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Nov 24, 2022     Systems Routing - (10 hours)       Category: Engine
Routed engine harness through firewall and made connections on engine. Cut, rotated, welded coolant tubes at head to route to low side. Painted orange. Fabricated electronics rack from .040 5053 AL. ECM and many other electronics will attach here.

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Nov 01, 2022     Elevators - (5 hours)       Category: Tail Feathers
Installed elevator trim piece by riveting hinge piece to trim. Riveted trim cable bracket in place. Spent way too much time installing elevator to horizontal stab. A bushing for push/pull rod was challenging to place and bolting the two elevator halves together.

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Oct 24, 2022     Flying Wires - (1 hour)       Category: Tail Feathers
Installed flying wires to horizontal stabilizer and vertical tail.

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Oct 23, 2022     Tinted Quarter Windows - (3 hours)       Category: Fuselage
Added tinting to the aft quarter windows. I think I got carried away with the number of fasteners to install.

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Oct 19, 2022     Firewall and Engine Install - (6 hours)       Category: Engine
Cut boot cowl shape on firewall stainless steel sheet, located onto fuselage and drilled mounting holes. Riveted in place with CCP42 rivets. I did apply anticipating tape to tubing prior to firewall installation to minimize metal to metal rattle/buzz. Hoisted engine in place and mounted.

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Oct 19, 2022     Paint Landing Gear Legs - (2 hours)       Category: Paint / Decals
Sprayed gear legs with Polybrush and Polyspray on previous days, then sprayed multiple coats of orange. Unlike other parts, I did not first apply one coat of white, curious if I will see a brightness difference in natural light.

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Oct 15, 2022     Painted Fuselage - (8.5 hours)       Category: Paint / Decals
Purchased more reducer and some Dakota Black Polytone. Lots of time with masking. Used fine line tape. Got paint on it before Temps drop. So far I have purchased $1333.23 of Polybrush, Polyspray, Polytone, reducer, epoxy primer, blush remover, surface cleaner and etc. Lots of labor with painting. Pumpkin Orange, Dakota Black, and Insignia White.

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Oct 06, 2022     Polyspray on Fuselage - (3 hours)       Category: Paint / Decals
Applied crosscoats of UV protection to fuselage. Purchased masking tape and filters.

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Oct 01, 2022     Prepping Fuselage for Paint - (4 hours)       Category: Paint / Decals
Took a couple of hours to mask the cockpit and other others I did not want spray on. Then wiped down and tack cloth, then two coats of Polybrush sprayed on. First coat in the morning, second coat late afternoon.

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Sep 11, 2022     Right Wing - (6 hours)       Category: Paint / Decals
Painted Right Wing, now will add pinstripe at orange/white edge. Lots of labor with painting.

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Sep 11, 2022     Paint Booth Filters and MEK       Category: Tools
Purchased more filters, have purchased several now, they clog quickly on the exhaust side of paint booth. MEK works the best for keeping the paint gun clean.

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Sep 11, 2022     Flap Springs       Category: Wings
Plane Fun Aircraft now sells these alternative flap springs which perform better than the tension type provided in the kit.

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Aug 31, 2022     VHF Antenna       Category: Avionics
Comment E series Top Mount VHF antenna.

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Aug 17, 2022     Left Wing Paint - (6 hours)       Category: Paint / Decals
Paint Pumpkin Orange on leading edge to add some character. Wonder if vinyl pinstripe will remain in place.

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Aug 15, 2022     Oil Cooler Mounting Hardware       Category: Engine
AN4-34a bolts and metal stop nuts to mount oil cooler.

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Aug 09, 2022     Left Wing Paint Coats - (4 hours)       Category: Paint / Decals
Applied 2 medium coats and a light coat to get full coverage.

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Aug 09, 2022     More Paint Supplies       Category: Paint / Decals
Another gallon of Insignia White, One gallon of Pumpkin Orange, and a gallon of reducer.

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Aug 05, 2022     Left Wing UV Polyspray - (4.5 hours)       Category: Paint / Decals
Sprayed first coat of Polyspray. Sanded lightly imperfections, smoothed out lifted plinking on fabric tapes with iron. Applied additional coats of UV protectant Polyspray.

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Jul 24, 2022     Left Wing Polybrush Spray Coats - (4.5 hours)       Category: Paint / Decals
Sprayed two coats of Polybrush on left wing. 1st coat on Saturday, then ironed smooth in plinking tapes that peeled up a bit because of solvents in Polybrush.

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Jul 18, 2022     Landing Lights       Category: Lighting
Lights, Fuse Block, Engine Exhaust Gasket, wire harness for lights.

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Jul 02, 2022     Flaps Painted - (4 hours)       Category: Paint / Decals
A couple coats of Insignia White applied. Trim off the fabric identifier ink stamps from fabric before applying, they bleed through the multi coats of Polybrush, Polyspray, Polytone. Dang!

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Jun 26, 2022     Ailerons & Flaps UV Coat - (4 hours)       Category: Paint / Decals
Working through the process of applying 3 crossroads. Iron out air bubbles, picking tape and lightly sanding with 400 grit paper imperfections between coats.

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Jun 19, 2022     Radiator &Oil Cooler Mount - (1.5 hours)       Category: Engine
Fabricated a better mount than my first one, added flanges to stiffen and determining best hardware selection for securing.

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Jun 15, 2022     EGT Bungs - (1 hour)       Category: Engine
Gas welded stainless steel EGT bungs to stainless headers.

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Jun 07, 2022     Insignia White Polytone Paint       Category: Paint / Decals
2 gallons of paint, others suggest 3 gallons are needed, ordered 2 Gallons to keep going. Still need some orange and black paint as well.

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Jun 04, 2022     Polyspray Control Surfaces - (8 hours)       Category: Paint / Decals
Sprayed 3 crossroads on rudder, stabilizers, smoothed picked tape edges with iron on elevators, ailerons, flaps. Applied first crossroad on elevators.

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May 24, 2022     Polybrush Control Surfaces - (6 hours)       Category: Paint / Decals
Sprayed 2 coats of Polybrush on ailerons, flaps, elevators, horizontal stab, rudder. 2 hour rest between coats.

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May 18, 2022     Engine Management System       Category: Engine
Purchased BD Turnkey AEM EFI kit.

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Apr 24, 2022     Flaps- 2 coats of Polybrush - (2.5 hours)       Category: Paint / Decals
Sprayed two coats of Polybrush on flaps. Temps were warm enough. Coats fill the weave of fabric. Waited two hours between coats. Paint booth worked well.

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Apr 11, 2022     Ready to Spray       Category: Paint / Decals
More Polybrush to spray two more coats on everything. Polyspray is the UV protection coating. Plus a quart of surface cleaner and Blush retarded. Still need to buy the Polytone paint.

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Apr 08, 2022     Paint booth - (12 hours)       Category: Tools
Waiting for outside Temps to warm up for too long, built temporary paint booth in garage.

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Mar 30, 2022     Wheel Seals for Tubeless Tires       Category: Landing Gear
Returned inner tubes, ordered Matco tubeless kit.

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Mar 24, 2022     Tundra Tires       Category: Landing Gear
Purchased 27.5 " tall tundra Aero Classic tires that fit the Matco 8 inch wheel. I also purchased inner tubes. The inner tubes were $275. The tires can be run tubeless, uncertain if I will go without tubes.

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Feb 28, 2022     Exhaust Studs - (.5 hour)       Category: Engine
Installed 8 studs into head. Used 8mmX1.25 38mm studs intended for VW air cooled engines.

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Feb 19, 2022     Header - (3.5 hours)       Category: Engine
Modifying Suzuki Sammurai Header. Cutoff flange from header, welded on flanges from APEX engine. $85 header, $115 for acetylene and welding rods.

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Feb 15, 2022     Radiator Mount - (3 hours)       Category: Engine
Radiator from eBay, $171 plus mounting hardware for oil cooler and radiator. Fabricated sheet metal bracket.

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Feb 13, 2022     Oil Tank Fitting Spacer - (3.5 hours)       Category: Engine
Machined an aluminum spacer to make hose clearance.

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Feb 03, 2022     Aircraft Wiring Manual       Category: Research
EAA aircraft wiring guide.

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Feb 03, 2022     Headphone Jacks       Category: Instrument Panel
2 pairs of jacks and insulating washers for installation.

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Jan 29, 2022     Turtle Deck Stiffener - (1.5 hours)       Category: Fuselage
Didn't like how the turtle deck sagged when installed. Add some extra aluminum C channel, so decided to use it as a stiffener. Spaced out rivet holes , drilled 1/16th holes. Countersink. Drilled lightening holes in channel. Installed with solid rivets.

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Jan 29, 2022     Fuel Bulkhead Fittings       Category: Fuel System
Bulkhead fittings for fuel system.

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Jan 23, 2022     Front Quarter Panel Glass - (1 hour)       Category: Fuselage
Cut Lexan, drilled panels, match drilled Lexan.

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Jan 23, 2022     Door Glass - (6 hours)       Category: Fuselage
Cut Lexan for doors, 4 pieces. Drill door frames, match drill Lexan. Painted rivet heads. Finished edges of Lexan. Rivet in place.

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Jan 19, 2022     Door Latch Guards - (.5 hour)       Category: Fuselage
Fabricated two door latch guards that protect the fabric from wear. Then will be secured in place after final paint.

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Jan 19, 2022     Airborne Bracket - (.5 hour)       Category: Engine
Made a new supoort bracket for air intake that is more rigid and secure than first fabricated part.

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Jan 16, 2022     Oil Kit       Category: Engine
Synthetic oil, filter, plug gaskets.

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Jan 13, 2022     Thermostat Oil Bypass - (4.5 hours)       Category: Engine
Removed oil/engine coolant heat exchanger. Machined from 6061 3 in round bar a housing for thermostat bypass. Purchased oil thermostat bypass, machined spacer. Installed onto engine. Ordered 8AN x 22mm fittings. Used bench top lathe/mill to make the parts.

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Jan 09, 2022     3/8" VHB Tape       Category: Fuselage
Very High Bond Tape for door Lexan, and front kick panel Lexan glass installations.

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Jan 09, 2022     Door Window Strut Mounts - (3.5 hours)       Category: Fuselage
Built mounting brackets for gas struts for hinged windows on doors. Fabricated from split steel tubes and welded flanges. Brackets painted and riveted to door and window frames. Installed gas struts.

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Jan 02, 2022     Butt Rib to Fuselage Closeout - (3 hours)       Category: Fuselage
Made a pattern template with poster board. Purchased .025" aluminum sheet. Cutout sheet metal. Formed bends. Marked and drilled rivet holes. Match drilled fuselage and butt rib. Painted sheet metal. Installed and rivet in place.

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Jan 01, 2022     Door Gas Strut Install - (1.5 hours)       Category: Fuselage
Located lower gas strut mount to fuselage, temporarily installed door gas strut mount with hose clamps, secured. Adjusted both brackets till door opened to nearly underside of wing. Drilled door mount bracket, painted bracket, rivet in place. Repeat for other side.

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Dec 30, 2021     Throttle Cable       Category: Engine
Quite an expensive a nice cable that I will cut up to fabricate what I need. I did not find a friction lock type for less.

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Dec 23, 2021     Finished Air Intake - (4.5 hours)       Category: Engine
Cut 4 inch PVC pipe to length, shortened flange on end cap, located and drilled holes for throttle body tubes, made supporting brackets, painted end cap, applied carbon vinyl wrap to tube. Installed filter.

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Dec 19, 2021     Oil Cooler, Fittings       Category: Engine
Engine oil cooler, 2 fuel line bulkhead fittings, 2 fuel line connection fittings.

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Dec 19, 2021     Airborne Materials       Category: Engine
4 inch PVC for air box and end cap, plus air filter.

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Dec 06, 2021     Mount Doors to Airframe - (2 hours)       Category: Fuselage
Cut larger piano hinge material to length. Mark out and drill holes into hinge. Locate hinge to door frame and match drill, use clecos along the way. Center door to fuselage, mark location. Center hinge half to fuselage door opening and match drill. Rivet hinge half to door and other hinge half to fuselage. Mate door to fuselage install hinge rod to locate and install door X2.

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Dec 04, 2021     Doors - (3 hours)       Category: Fuselage
Installed hinged windows in doors. Cut piano hinge to length. Mark out mounting holes into hinge. Drill #30 holes. Place hinge on window frame, drill. Center hinge on door and drill mounting holes. Rivet hinge to window and door. Repeat for other door.

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Nov 30, 2021     PSRU and Head Cover Install - (4 hours)       Category: Engine
Cleaned head cover of corrosion and grime (magnesium), removed engine cover, cleaned gasket surfaces. Painted head cover with black wrinkle paint. Installed head cover and SkyTrax PSRU.

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Nov 30, 2021     Head Cover Gasket       Category: Engine
New gasket for head cover for Apex Engine, torque seal for fasteners, retaining compound for PSRU drive gear installation.

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Nov 23, 2021     contacted. Washers       Category: Fuselage
Nylon washers for mounting of forward side panels and rear quarter windows.

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Nov 23, 2021     Starter and Continous Relays       Category: Avionics
Starter solenoid and power relay/contacters.

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Nov 23, 2021     Gear Leg to Fuselage Bolts       Category: Landing Gear

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Nov 20, 2021     Spark Plugs       Category: Engine
New spark plugs for Apex engine.

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Nov 20, 2021     Left Main Gear Leg Covered - (4 hours)       Category: Landing Gear
Covered left gear legs with fabric and applied first coat of Polybrush.

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Nov 15, 2021     Rivnuts in Elevator Access Flange - (.5 hour)       Category: Fuselage
Installed #6 rivnuts in flange mount for elevator access panel mounting. 14 places.

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Nov 13, 2021     Right Gear Leg Fabric Covering - (4.5 hours)       Category: Landing Gear
Covered right gear legs using Polyfiber process. Could have gone without but like the final look of airplane with gear legs covered.

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Nov 06, 2021     Left Elevator - (6 hours)       Category: Tail Feathers
Applied fabric to the last control surface requiring it. The left elevator has some additional shape features for trim tab which results in more corners to deal with. Applied finish tapes and one coat of Polybrush. Two more spray coats, then UV coating then final paint required yet.

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Oct 31, 2021     Fabric Tapes and Things - (16 hours)       Category: Fuselage
After applying fabric and using iron to shrink, applied tapes anywhere metal was behing fabric and seams. Added rudder cable penetratration fairings and elevator access plates. Applied one coat of Polybrush over all surfaces afterwards.

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Oct 11, 2021     Fuel Line Reroute       Category: Fuel System
More Fuel line, needed to reroute so it does not rub on fabric covering. $7 for line, $14+ for shipping.

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Oct 10, 2021     Fabric Covering - (14 hours)       Category: Fuselage
Continued covering fuselage, applying to sides.

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Oct 04, 2021     Aileron Fabric - (6.5 hours)       Category: Wings
Applied covering to remaining aileron.

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Oct 02, 2021     Right Side Elevator - (6 hours)       Category: Wings
Covered starboard elevator.

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Sep 30, 2021     Rudder Fabric - (9 hours)       Category: Wings
Applied fabric and tapes to rudder. Used Polyfiber system as with everything else.

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Sep 24, 2021     Horizontal Stabilizer Fabric - (3.5 hours)       Category: Wings
Finished Left Stabilizer by adding fabric and tapes to unfinished side.

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Sep 20, 2021     Elevator Inspection Plate Kiy       Category: Fuselage
Purchased Elevator Inspection plate to mount in fabric on fuselage from Just Aircraft.

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Sep 07, 2021     Control Cable Fairings       Category: Fuselage
Control Cable fairings for rudder cable penetrations in aft fuselage fabric.

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Aug 31, 2021     Fabric Covering - (6 hours)       Category: Fuselage
First piece of fabric on fuselage. Rolled out fabric on underside. Cut and trimmed extra off. Applied Polytak to lower longreons. Trimmed around landing gear attach points and other fittings. Applied Polytak to fabric and glued in place. Did an initial 225 degree heat shrink to tighten the fabric a bit.

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Aug 28, 2021     Fuselage Rottiserie Stand - (4 hours)       Category: Tools
Built after stand and mounted airplane. Ready to apply the fabric.

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Aug 26, 2021     Left Stabilizer Fabric - (4 hours)       Category: Tail Feathers
Had enough left over wing fabric to cover one side of stabilizer.

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Aug 23, 2021     Muffler       Category: Engine
KTM dual sport bike muffler. Heavy but quiet.

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Aug 18, 2021     Fuselage rotisserie stand - (3 hours)       Category: Tools
Used scrap steel tubing from kit shipping container to fabricate stand for front of fuselage.

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Aug 18, 2021     Right Horizontol Stabilizer - (4.5 hours)       Category: Tail Feathers
Covering horizontal stab with left over fabric from wing. Used two pieces, underside first, then top side. Adding tape.

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Aug 14, 2021     Left Aileron - (8.5 hours)       Category: Wings
Purchased more MEK. Completed fabric application to left aileron.

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Aug 08, 2021     Left Flap - (9.5 hours)       Category: Wings
Added fabric to left flap. Process same as right flap work. Takes a lot of time to do properly. Skill gets better with each time.

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Aug 05, 2021     Landing Gear Fit Up - (1.5 hours)       Category: Landing Gear
Reamed fuselage/gear mounting holes. Reamed gear leg holes, V cabane holes and shock connect holes. Mounted legs to fuselage, cabane to fuselage, installed shocks. Bolts provided for gear legs are to short.

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Aug 04, 2021     Right Flap - (4.5 hours)       Category: Wings
Added leading edge tapes. Finished trailing edge tape on bottom side. Applied Polybrush to all surfaces.

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Aug 01, 2021     Left Flap - (4 hours)       Category: Wings
Applied fabric to flap. Used one piece. Applied adhesive to trailing edge. Wrapped, First applied Polytak to leading edge, and ribs. Drilled ribs for rivets. Used adhesive to bond the fabric. Did low temp shrink to work out the wrinkles on leading edge. Bonded to tip and root ribs. Used thinned Polytak t I bond leading edge. Trimmed fabric, overlapped tip and root ribs. Shrunk fabric at 250F, 300F and 350F.

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Jul 30, 2021     Elevator Trim Tab - (3.5 hours)       Category: Wings
Applied fabric to elevator trim tab. Used one piece. Used Polytak along leading edge, wrapped and overlapped, applied adhesive between fabric pieces. Trimmed. Bonded edges. Shrunk. Applied polybrush to all surfaces. Applied tapes to all edges.

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Jul 27, 2021     Right Wing Fabric - (3.5 hours)       Category: Wings
Used 6 inch tape for leading edge and two 3 inch tapes for trailing edge.

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Jul 25, 2021     Right Wing Fabric - (4.0 hours)       Category: Wings
Added Chordwise tapes over ribs top side and bottom side. Added tapes to false ribs and span wise over rear spar on underside. All were first marked out with #2 pencil and straight edge to get bond lines straight. Precoated fabric where tape was to be applied with Polybrush. Then applied wet, brushed over then dried then second coat over tapes.

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Jul 22, 2021     Right Wing Fabric - (3.5 hours)       Category: Wings
Finished fabric edges at trailing and leading edge butt rib and tip rib. Smooth fabric along leading edge. Bonded to gussets around strut fittings and control pulley areas. Installed reinforcement tape on under side ribs and secured fabric with large head rivets before final shrinking because of under camber wing. Used iron shrunk at 250F upper and lower sides. Next will shrink at final 325F or so.

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Jul 19, 2021     Right Wing Top side Fabric - (3.0 hours)       Category: Wings
Unrolled fabric across top side of wing. Cut off roll. Used Polytak to apply to trailing edge. Bonded leading edge. Bonded to wing tip rib and rib two. Trimmed leading edge fabric to chalk line for two inch overlap. Used iron at 225 to shrink top side, then rotated to shrink bottom side.

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Jul 18, 2021     Right Wing Fabric - (3 hours)       Category: Wings
Installed/applied fabric to lower side of wing. Process is going more smoothly after learning from process on left wing.

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Jul 18, 2021     Magnetometer - (.7 hour)       Category: Wings
Fabricated a mount for GRT magnetometer to be installed on/in right wing wing tip rib.

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Jul 03, 2021     Polyfiber SuperFil       Category: Wings
Purchased more Polyfiber Superfil to smooth out rib to trailing edge joints, welded joints and etc to improve overall fit and finish of fabric applications. Expensive with shipping when comparing to autobody filler.

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Jul 02, 2021     Landing Gear - (1 hour)       Category: Landing Gear
Tk1 Shock Monster Gear arrives. Expensive but awesome.

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Jul 01, 2021     Left Wing Fabric - (3 hours)       Category: Landing Gear
Applied last span wise fabric tapes. The Leading edge and trailing edge. Used 6 inch wide tape on leading, and two 3 inch tapes for trailing. Marked out straight tape lines with pencil. Applied Polybrush, dried. Then applied wet polybrush when laying down the tape. Finally add a second coat of polybrush over the tape. Ironed out any bubbles, wrinkles.

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Jun 25, 2021     Gear Legs and Shocks       Category: Landing Gear
Purchased TK1 Monster Gear Legs and Struts.

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Jun 22, 2021     Left Wing Fabric - (7.0 hours)       Category: Wings
Bonded lower side ribs, shrunk fabric at 250F, applied reinforcement tapes,, installed rivets, securing fabric to ribs, shrunk at 300F, Applied gussets and fabric dollies over bracket areas, chordwise tapes over ribs top and bottom sides using the polyfiber system instruction.

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Jun 05, 2021     Left wing Fabric - (6 hours)       Category: Wings
Continue to work on wing as time permits. Learned plenty along the way, next wing will go better. Had to iron out several wrinkles in fabric, will cut holes for wing strut mounts prior to attaching lower side fabric next time. Applied upper fabric with 2 inch bond line on leading edge, 1 in trailing edge. Did initial 250 degree heat shrink with iron, continued to trim for jury strut and control pulleys. Used soldering iron to burn holes through fabric for rivets in lieu of lacing. Applied reinforcing tape, burnt holes, installed rivets. Next is to shrink at 300 and final 350 prior to applying Polybrush and tapes.

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May 14, 2021     Lower Side Fabric-Left Wing - (4 hours)       Category: Wings
First piece of fabric being applied. Still have a few wrinkles to iron out prior to applying top fabric. So much more to do just to finish this wing.

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Apr 28, 2021     Fabric Supplies       Category: Wings
Anti-chafe tape, rib lacing, needle. $20 for tape, $50 for thread, $20 for needle, $20 for shipping. Crikey things add up.

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Apr 25, 2021     Polybrush on Leading/Trailing Edges - (1.5 hours)       Category: Wings
Mixed Polybrush with Reducer and applied two coats to leading edge, and trailing edge and fabric plates.

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Apr 25, 2021     MEK Substitute       Category: Tools
Solvent for cleaning brushes and mixing cups.

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Apr 25, 2021     Dry Iron       Category: Tools
Purchased an old style dry iron because the heat should be more consistent than steam type for installing fabric with Polyfiber system.

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Apr 15, 2021     Polyfiber Materials       Category: Paint / Decals
3 gallons of Polybrush, 3 yards of lightweight fabric for doilies, 1 gallon of 65-75 Reducer.

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Apr 15, 2021     Engine Stand Engine Mount - (3 hours)       Category: Engine
Fabricated engine mount so it could be hung on stand.

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Apr 12, 2021     SkyTrax PSRU Arrives       Category: Engine
$3500 + PayPal fees, shipping and insurance. Yikes.

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Apr 08, 2021     Removal From Snowmobile - (3 hours)       Category: Engine
Removed Yamaha Apex Engine for 2007 Yamaha MTX.

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Apr 05, 2021     Support for Fuel Shutoff Actuator - (1.5 hours)       Category: Fuel System
Fabricated support plate to stabilize long actuator for fuel shutoff.

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Mar 31, 2021     Tech Counselor Inspect Prior to Covering - (3 hours)       Category: Inspection
Jeff Bongard inspected fuselage, control surfaces and wing assemblies prior to fabric covering step.




 
Mar 29, 2021     Wire Support Track - (1.5 hours)       Category: Interior Finish
Purchased household type wire track, lightened it by drilling out material. Mounted in airplane via Adel clamps.

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Mar 28, 2021     Center Cargo Floor Panel - (2 hours)       Category: Interior Finish
Modified aluminum floor panel to make cutout relief for fuel lines. Applied vinyl film have 3d carbon fiber look.

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Mar 27, 2021     Fuel Shutoff - (3 hours)       Category: Fuel System
Fabricated a fuel shutoff switch extension to work with preferred fuel shutoff location.

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Mar 21, 2021     Prep for Covering Wings & Control Surfaces - (15 hours)       Category: Wings
Applying Superfil, sanding, and etc. Tedious effort to blend leading and trailing edges with spars and ribs. Still not perfect, but might say good enough.

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Mar 02, 2021     ACK E-04 ELT Install - (1 hour)       Category: Avionics
Received ELT in mail, positioned on mounting plate in aft section of fuselage. Located holes for mounting plate, and ELT brackets and antenna. Installed. Remote switch, audible alert, cabling to be installed later.

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Feb 28, 2021     Control Area Cover - (3 hours)       Category: Interior Finish
Purchased floor covering. Cut to fit. Purchased universal shift boots. Fabricated flanges, Mounted shift boots.

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Feb 28, 2021     Pitot and Static Tube Routing - (1 hour)       Category: Wings
Routed two tubes from Pitot and static location, into rear spar at rib 2 and extend tubing out the end of spar at root.

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Feb 27, 2021     Floor Panel Covering - (2 hours)       Category: Fuselage
Improved fit of forward floor panel for ease of removal, cleaned surface. Applied carbon fiber look vinyl to surface. Similarly did the floor panel aft of seats.

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Feb 18, 2021     Left Aileron Fabric Plates - (3 hours)       Category: Wings
Added joggle to fabric plates to install on underside of custom leading edge. Trimmed to fit. Applied chromate primer to underside. Drilled mounting holes, countersunk, applied epoxy to mating surfaces, located in place, installed rivets.

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Feb 12, 2021     Vent Line, Filter, Elbow Fittings       Category: Fuel System
1/4" fuel vent line, header tank drain and fittings for pitot hose.

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Feb 07, 2021     Metal Fuel Routing, Filter Install - (4 hours)       Category: Fuel System
Bend and route aluminum tube fuel lines, install fittings, clamp in place, secure.

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Feb 02, 2021     Pitot Tube Mount - (4 hours)       Category: Avionics
Made a bracket mount for pitot and static tube assembly. Designed so I could later replace with pitot/aoa is desired later.

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Jan 26, 2021     Fuel Line Mounting Hardware       Category: Fuel System

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Jan 24, 2021     Installed Fuel Line Shutoffs - (1 hour)       Category: Fuel System
Routed fuel line along fuselage welded members to wing root ribs. Cut fuel line where shutoff were to be located. Installed and secured with worm clamps.

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Jan 24, 2021     Fuel Line, Thread Sealer, Silicone Tape       Category: Fuel System
Purchased additional fuel line, Permatex PTFE liquid thread sealer, Rescue Tape.

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Jan 23, 2021     Fuel Fittings and Header Tank Install - (3 hours)       Category: Fuel System
Applied thread sealer to header tank fittings and installed. Located tank in fuselage and mounted in place with Adel clamps. Began fuel line routing.

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Jan 22, 2021     Filled Leading Edge Cuff Joint - (4 hours)       Category: Wings
Scuffed and solvent cleaned spar surface along bonded cuff. Marked flush surface line on spar. Applied tape along line to limit area for filler application. Mixed up super light filler from Polyfiber. Applied to upper and lower mating cuff edge to spar area. Allowed overnight curing and then sanded.

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Jan 22, 2021     Filled Leading Edge Cuff Joint - (4 hours) Category: Wings
Scuffed and solvent cleaned spar surface along bonded cuff. Marked flush surface line on spar. Applied tape along line to limit area for filler application. Mixed up super light filler from Polyfiber. Applied to upper and lower mating cuff edge to spar area. Allowed overnight curing and then sanded.
 
Jan 21, 2021     Painted Header Tank - (3 hours)       Category: Fuel System
Scuffed surfaces with Scotchbrite. Solvent cleaned surfaces. Warmed up the part and paint and spray area. Applied paint to 5 of the 6 surfaces, dried. Painted remaining surface. Applied Wild West Aircraft decal to Header tank.

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Jan 21, 2021     Fuel Fittings/Filter       Category: Fuel System
Purchased various AN fuel fittings and filter for metal fuel lines from header tank to engine.

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Jan 17, 2021     Rear Quarter Window - (.5 hour)       Category: Fuselage
Cut from Lexan sheet, rear quarter window. Temporary install to straighten sheet metal for epoxy application.

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Jan 17, 2021     Fuel Line, Return - (1.0 hour)       Category: Fuel System
Straightened coiled aluminum tubing, routed from firewall to header tank, made 90�end to route from lower fuselage to tank.

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Jan 17, 2021     Fuel Pump - (1.5 hours)       Category: Fuel System
Mounted fuel pump. Fabricated two aluminum straps, used four cushioned clamps.

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Jan 16, 2021     Fuel Line       Category: Fuel System
Purchased 8ft of rubber fuel line. 4ft of line worked for right wing to header tank. Should have measured twice for left wing, too short.

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Jan 08, 2021     Header Tank - (1.0 hour)       Category: Fuel System
$750 + shipping. Seems exorbitant, but I practiced TIG welding and fabricating my own. The effort was taking too long and the results would not be satisfactory. Received tank, located and marked mounting points for Adel clamps. Drilled, demurred, mounted.

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Jan 04, 2021     Aileron Cables - (1.5 hours)       Category: Controls
Made up aileron cables that run from control mixer to aft of door. Installed nico sleeve, thimble, clevis on 3/16th" wire rope, swaged nico sleeve in place. Routed cable to determine length, cut cable and installed nico sleeve, thimble with turnbuckle. Swaged. Two cable assemblies.

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Jan 04, 2021     Aluminum Fuel Line and Clamps       Category: Fuel System
3/8th inch fuel line -25ft, size 10 adel clamp qty=6, size 8 adel clamp qty=8. And 10 #8 nutplates.

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Jan 02, 2021     Pitot with Static Port       Category: Avionics
Pitot and Static Port for Wing

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Jan 02, 2021     Sandpaper 180 grit Category: Tools
 
Jan 02, 2021     Acetone Category: Tools
 
Dec 30, 2020     Rudder Cable Installation - (3 hours)       Category: Controls
Fabricated cables. Clamped rudder and pedals in neutral position. Installed turnbuckles at pedals. Sized cables and swaged ends.

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Dec 29, 2020     Smoothing Out Imperfections - (3.5 hours)       Category: Wings
Mixed up light weight filler and applied to left wing at rib/trailing edge interface. False rib to front spar joints. Applied to wing tip/strobe light mounts.

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Dec 28, 2020     Serial# Plate - (.5 hour)       Category: Fuselage
Located, drilled, riveted serial number plate in place.

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Dec 27, 2020     Varnish False Ribs, Rear Spars, Bracing - (3.5 hours)       Category: Wings
Mixed up varnish, brushed on false ribs, rear spars, flaps and aileron false ribs and ribs.

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Dec 27, 2020     Wing Tip &Strobe Light Mounts - (2 hours)       Category: Wings
Epoxied light mounts. Fabricated wood closeouts for wingtip at aileron area.

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Dec 26, 2020     Nav Light Mounting To Wing Tips - (4 hours)       Category: Wings
Fabricated aluminum brackets for mounting nav/strobe/position lights. Pressed treaded inserts into brackets. Bonded to inside of fiberglass strobe mounts.

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Dec 26, 2020     Nutplates, Adel Clamps, Fuel Line Category: Wings
Parts for fabric plates, and mounting fuel system.
 
Dec 21, 2020     Left Wing Control Pulley Mounts - (6 hours)       Category: Wings
Position flap pulley mount near rib#2. Trimmed rib cap. Aligned with flap control horn. Drilled, cleco in place. Abraded mating surfaces, applied epoxy, riveted in place. Did the same with aileron pulley mounts. Slotted trailing edge for flap spring. Positioned trailing edge, drilled and countersunk rivet mounting holes, abraded mating surfaces. Epoxy and rivet in place.

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Dec 21, 2020     Shutoff Valves       Category: Fuel System
Wing tank shutoff valves 6AN male fittings.

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Dec 21, 2020     Left Wing Control Surfaces - (1 hour)       Category: Wings
Mixed epoxy adhesive, solvent cleaned mating surfaces, applied epoxy to hinge plates and riveted in place.

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Dec 21, 2020     Left Wing Control Surface Hinges - (2 hours)       Category: Wings
Located supports from top of wing contour. Placed flap and aileron in position with spacers to offset from wing trailing edge. Located hinges, clamp in place, drill through hinge mounting plate holes through rib webs. 6 hinge pairs.

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Dec 21, 2020     EAA Certification Guide Step by Step       Category: Tools
EAA Certification Kit

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Dec 21, 2020     Zinc Chromate Primer       Category: Paint / Decals
One rattle can of Zinc Chromate primer.

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Dec 16, 2020     Flap Hinges- Left Wing - (1.5 hours)       Category: Wings
Temp installed trailing edge. Clamped straight edges to ribs on top side of wing, and 1/8 spacer to position flap. Match drilled hinge mounting holes,, reamed 3/16th hinge bushing hole x6. Positioned hinges and clamped in place.

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Dec 14, 2020     Left Wing Aileron Leading Edge - (2 hours)       Category: Wings
Fitted leading edge to aileron. Drilled rivet holes, countersink each one. Abraded and solvent cleaned spar and metal leading edge. Applied epoxy to 14 ribs, positioned, applied epoxy to main ribs, placed leading edge in place, installed rivets.

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Dec 10, 2020     Leading Edge Cuffs - (3 hours)       Category: Wings
Cut relief cuts in leading edge cuffs for lift strut bracket and jury strut bracket. Sanded mating surface, solvent cleaned surfaces applied Dynaflex 260 sealant to mating surface. Taped into place, positioned per template.

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Dec 07, 2020     Leading Edge materials Category: Wings
One tube of Dynaflex 230 sealant to affix leading edge to front wing spars. 1/16ths thick basswood straps for aileron leading edge.
 
Dec 07, 2020     Tailwheel Fuselage Closeout Plate - (1 hour)       Category: Fuselage
Fabricated access panel to closeout tailwheel area in fuselage.

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Dec 07, 2020     Left Flap Leading Edge - (1 hour)       Category: Wings
Cut leading edge clearance cutouts around hinges and bellcrank.

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Dec 06, 2020     Left Wing False Ribs & Cable Guided - (2 hours)       Category: Wings
Marked out locations of 14 false leading edge ribs. Abraded wing stringer and leading edge. Solvent cleaned, applied epoxy to ribs and installed. Used templates to locate control cable holes through main ribs near trailing edge. Drilled pilot hole then opened hole for nylon cable guides. Cut tubing, swaged one end of each, 16 pieces. Installed into ribs, swaged other end. Used heat gun and pressed ends with metal strip to swage.

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Dec 03, 2020     Left Aileron Hinges&Bell Crank - (1.5 hours)       Category: Wings
Abraded hinges and bell crank mating surfaces, abraded spar at mounting locations. Solvent cleaned surfaces. Mixed up and applied epoxy to mating surfaces, installed hinges and bell crank with CCP44 rivets. Located leading edge and marked locations of hinges and bell crank. Cut 5/8 inch slots at those locations.

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Dec 02, 2020     Left Wing Trailing Edge - (1 hour)       Category: Wings
Lightly abraded inside surface of trailing edge. Masked wing main rib locations. Applied chromate primer.

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Nov 28, 2020     Left Wing Flap - (2 hours)       Category: Wings
Trimmed fiberglass flap leading edge to fit. Marked locations for leading edge ribs. Mixed epoxy and applied to false rib edges. Installed and used tape to keep square, applied epoxy to flap ribs and positioned flap leading edge. Taped in place.

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Nov 24, 2020     100 pack of CCP45 rivets Category: Wings
Rivets to install brakes on ailerons.
 
Nov 24, 2020     Loctite EA 9460 Adhesive       Category: Tools
Two tunes of epoxy adhesives.

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Nov 24, 2020     Left Wing Flap - (1.5 hours)       Category: Wings
Clamped left flap and aileron together with 1/4 inch spacer. Centered both surfaces with wing, marked centerline of wing ribs 1,2,4,5,7,9 onto front spars. Centered and clamped hinges and bell crank on flap with markings. Secured with hose clamps. Set position of hinge points with measurements from trailing edge. Located flap to wing to confirm alignment. Transfer drilled #30 holes from brackets to spar. Removed hose clamps to access other holes to transfer. Cleco in place and drilled remaining holes. Mixed up epoxy, solvent cleaned surfaces, applied epoxy and riveted flap hinges and bell crank in place.

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Nov 20, 2020     Right Wing Tip - (1.5 hours)       Category: Wings
Taped along molded in scribe mark. Trimmed off fiberglass at scribe line. Hung aileron on wing, marked notch area for aileron travel, cut notch in wing tip. Installed wing tip onto wing, transferred drill holes in fiberglass for mounting.

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Nov 18, 2020     False Rib Install, Right Wing - (1 hour)       Category: Wings
Selected 14 false ribs. Spaced and marked positions on front spar and stringer two false rib locations evenly spaced between main ribs. Abraded surface, silent cleaned. Mixed and applied epoxy to false rib mating edges, squarely placed and applied fillers of epoxy. 14 places.

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Nov 17, 2020     Right Flap Fabric Plates - (1 hour)       Category: Wings
Drilled matching rivet holes in aileron leading edge with fabric plates. Sanded mating surfaces of aileron leading edge around hinges and flap control bracket. Sanded sheetmetal fabric plates. Solvent cleaned surfaces. Mixed epoxy and applied to mating surfaces, riveted plates to edge of leading edge.

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Nov 15, 2020     Fitting Fabric Plates- Right Wing - (2 hours)       Category: Wings
Prepared fabric plates for control surface hinges, trimming to fit, adding joggle to aileron hinge fabric plates to work with metal leading edges. Applied epoxy to wing fabric plates, installed in place on ribs with rivets.

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Nov 13, 2020     Fabric Plates - Strut Brackets, Control Surfaces - (1.5 hours)       Category: Wings
Located and matched drilled fabric plates with strut brackets. Riveted in place. Fit fabric plates for aileron and flap control brackets. Drill plates, match holes into leading edge of control surfaces.

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Nov 12, 2020     Fabric plates Right Wing - (1.5 hours)       Category: Wings
Fitted fabric plates for aileron and flap control pulleys. Clearanced opening, installed nutplates to fabric plates and trailing edge of right wing.

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Nov 11, 2020     Right Wing Trailing Edge - (1 hour)       Category: Wings
Countersunk rivet holes in trailing edge, Abraded mating surfaces, applied epoxy and riveted trailing edge to rivets in place.

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Nov 10, 2020     Wing Control Cable Guides - (1 hour)       Category: Wings
Cut nylon tubing in 2 inch pieces, 16 pieces for right wing. Heated one ened of each piece and presses end to create a bulb. Installed pieces into previously drilled wing rib holes. Heated and pressed remaining end of tube pieces to lock in place in ribs.

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Nov 08, 2020     Aileron Hinge Brackets, Cable Rib Holes - (2 hours)       Category: Wings
Lightly sand, clean right wing aileron hinge brackets. Painted. Printed out rib templates for control cable locations. Placed templates to ribs and drilled with 1/8" drill. Then drilled holes with 5/16th drill. Cut cable bushings.

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Nov 06, 2020     Engine Mount Powder Coat       Category: Wings

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Nov 03, 2020     Flap Hinges Right Wing - (2 hours)       Category: Wings
Located flap to hinge brackets, position flap flat with top contour and 1/8 inch gap. Clamp brackets in place, drilled through bracket holes through rib web. Removed flap, epoxied and riveted hinge brackets in place.

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Nov 03, 2020     Flap Hinges Right Wing - (2 hours) Category: Wings
Located flap to hinge brackets, position flap flat with top contour and 1/8 inch gap. Clamp brackets in place, drilled through bracket holes through rib web. Removed flap, epoxied and riveted hinge brackets in place.
 
Oct 20, 2020     Engine Mount       Category: Engine

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Oct 18, 2020     Right Wing Trailing Edge Mounting - (1 hour)       Category: Wings
Position Trailing Edge, drill #40 holes into each rib thru trailing edge. Counter sink holes in metal trailing edge.

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Sep 14, 2020     Left Aileron Leading Edge Bonding - (2 hours)       Category: Wings
Drilled Aileron Leading edge for rivets into rib caps. Abraided mating surfaces, solvent cleaned, epoxied in place.

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Sep 07, 2020     Aileron Pulley Blocks Right Wing - (3 hours)       Category: Wings
Position pulley blocks on rear spar, clearance rib cap. Drill, and cleco in place. Abrade and clean mating surfaces, apply epoxy to mating surfaces, install rivets.

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Sep 06, 2020     Control cable pulley install - (1 hour)       Category: Fuselage
Position and locate 8 pulleys.

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Sep 06, 2020     Turtle Deck Install - (3 hours)       Category: Fuselage
Make pattern with poster board for trimming clearance for control cables and head rack, trim both sides of turtle deck. Position and locate camlock locations, drill and install Camlocs

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Sep 01, 2020     Flap Pulley Block -Right Wing - (2 hours) Category: Wings
Position Pulley Block to inboard side of rib 2, trim rib cap, align with control bracket on flap, mark location, drill and locate with clecos, abrade and clean rear spar and block. Apply epoxy and rivet in place.
 
Aug 31, 2020     Aluminum Header Tank - (1 hour)       Category: Fuel System
Practice TIG welding, in prep for tank welding.

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Aug 31, 2020     Left Aileron Leading Edge Splice - (.5 hour)       Category: Wings
Completed joining the two leading edge pieces with splice. Used 3/32nd solid rivets.

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Aug 31, 2020     Nav/Position/Strobe Lights Category: Fuel System
Purchased Aveo Nav/Position/Strobe Light and AN4-16A bolts.
 
Aug 28, 2020     Fuel Pumps       Category: Fuel System
Purchased Edge Performance fuel pumps setup.

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Aug 20, 2020     Epoxy Left Quarter Window - (1 hour)       Category: Wings
Masked and applied epoxy at rear quarter window to fuselage.

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Aug 20, 2020     Epoxy Left Quarter Window - (1 hour)       Category: Wings
Masked and applied epoxy at rear quarter window to fuselage.

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Aug 19, 2020     Right Wing Return Spring - (1 hour)       Category: Wings
Aligned and attached flap spring bracket to flap spar. Slotted leading edge for flap spring.

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Aug 15, 2020     Left Aileron Leading Edge - (2.5 hours)       Category: Wings
Mr. Naoya Kishimoto assisted with modifying aileron rib leading edges for custom leading edge. Marked cut line on ribs, and 14 false ribs. Trimmed away material for fitting metal leading edge. Installed leading edge splice to one of two pieces. Marked rivet location, drilled #40 holes, countersunk for flush rivets. Installed rivets with squeeze and impact gun.

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Aug 15, 2020     Right Wing Flap Pulley Block - (2 hours)       Category: Wings
Temp installed flap, positioned pulley block, cut rib cap for clearance, clamped pulley block with pulley in place. Marked trailing edge for flap return spring slot. Drilled out 2 -3/4" holes and then removed material in between.

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Aug 15, 2020     Pulley Blocks - (1 hour)       Category: Wings
Marked and drilled #30 holes in 6 pulley block mounts for wings. Sanded mating surfaces free of paint.

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Aug 12, 2020     Varnished Left Wing - (2 hours)       Category: Wings
Applied Poly Fiber epoxy varnish to wood ribs of left wing.

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Aug 05, 2020     Left Wing Root Rib Lightening - (2 hours)       Category: Wings
Marked out cutout pattern similar to right wing. Completed cutouts, bonded and riveted stiffener to underside rib cap.

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Aug 04, 2020     Flap Leading Edge-Right Wing - (1 hour)       Category: Wings
Abraded spar of flap where false ribs were to be bonded. Applied epoxy to false ribs and to ribs. Mated leading edge and secured in place.

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Aug 03, 2020     Left Wing Tank Cover - (2.5 hours)       Category: Wings
Aligned sheetmetal over ribs one and two. Located holes aligning with nutplates in ribs. Drilled. Installed tank and aligned sheetmetal to locate hole for tank filler spout. Marked and cutout hole.

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Aug 02, 2020     Butt Ribs and Trailing Edge Finish - (2 hours)       Category: Wings
Installed reinforcement to butt ribs, epoxy and riveted in place. Applied paint to butt ribs. Applied Zinc Chromate primer to inboard surface to right wing trailing edge.

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Jul 30, 2020     Epoxy Varnish Butt Ribs and Aileron - (2 hours)       Category: Fuselage
Applied Varnish to Butt ribs, right wing aileron and flap ribs. Applied varnish to false ribs in leading edge of aileron and flap for right wing.

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Jul 30, 2020     Loctite EA9460 Epoxy Adhesive Category: Tools
Purchased additional epoxy adhesive.
 
Jul 27, 2020     Aileron Hinge and Bellcrank Mounting - (1.5 hours)       Category: Wings
Abraded mounting surfaces of hinges, bell rank and front spar. Solvent cleaned, applied epoxy and riveted in place.

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Jul 22, 2020     Aileron Leading Edge Right Wing - (2 hours)       Category: Wings
Cut relief clearance cuts around hinge and bell crank locations for hinge brackets from main wing.

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Jul 16, 2020     Aileron Leading Edge Fillers - (1 hour)       Category: Wings
Purchased 1" x 24" x 1/16" basswood to use as filler to close gaps between false ribs and leading edge preventing distortion when fabric covering is shrunk.

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Jul 16, 2020     Panel Placement - (1 hour)       Category: Instrument Panel
Placed Instrument Panel, marked fastener locations, drilled and positioned panel, cleco'd in place for control stick adjustment. Shortened control sticks for adequate clearance.

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Jul 15, 2020     Flap Leading Edge - (1 hour)       Category: Wings
Cut and sanded leading edge hinge and bell crank relief cutouts so flap can be installed.

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Jul 14, 2020     Right Flap Hinges and Bracket Attach - (.5 hour)       Category: Wings
Abraded mating surfaces of hinges and control bracket and flap spar. Cleaned surfaces with acetone. Applied epoxy adhesive to matting surfaces. Cleco'd in place. Installed CCP-44 rivets.

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Jul 13, 2020     Varnish and Aileron False Ribs - (2 hours)       Category: Wings
Applied second coat of epoxy varnish to tight wing ribs. Applied epoxy adhesive to aileron false ribs and installed into right wing aileron. Cleco'd aileron leading edge in place to secure false ribs in place for adhesive to cure.

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Jul 12, 2020     Right wing root rib stiffener - (.8 hour)       Category: Wings
Placed metal stiffener. Marked for holes, drilled #30. Transferred holes to lower rib cap. Abraded mating surfaces and applied epoxy, riveted in place.

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Jul 12, 2020     Root Rib Web Out - (3 hours)       Category: Wings
Decided to remove material from rib #1 right wing similar to patterns on other ribs. Drew out pattern, marked center points for radius. Used hole cutter at locations then used small, reciprocal saw to remove material. Sanded cutouts. Installed fuel tank for verification.

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Jul 11, 2020     Quarter Windows in Kick Panels - (1.5 hours)       Category: Fuselage
Cutout desired window profile in aluminum sheet material which are located on forward part of fuselage. Temporary install of rear quarter window features too.

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Jul 10, 2020     Epoxy Varnish to Right Wing - (2.5 hours)       Category: Wings
Applied by brush epoxy varnish to wood ribs and gussets of right wing.

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Jul 09, 2020     Epoxy Prime Parts - (1.5 hours)       Category: Paint / Decals
Primed more control surface hinges and front kick panels and access plate.

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Jul 08, 2020     Priming of Small Parts - (1.5 hours)       Category: Paint / Decals
Applied epoxy primer with spray gun to aileron/flap hinges and control brackets as well as windshield mounting brackets.

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Jul 08, 2020     3/32nd Clecos and #8 Anchors Category: Fuselage
 
Jul 08, 2020     Paint and Sheetmetal Category: Fuselage
 
Jun 28, 2020     Sheetmetal and Paint Category: Fuselage
Purchased .025 aluminum sheet and orange spray paint.
 
Jun 28, 2020     False Rib Install In Right Aileron Leading Edge - (2.5 hours)       Category: Wings
Positioned leading edge, marked centerline for Control bracket and hinges. Marked offsets and measured. For other false rib locations. Sanded fiberglass leading edge bonding areas. Applied epoxy to ribs and installed. 24 hour cure.

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Jun 27, 2020     Fuel Tank Cover Leading Edge Mouny - (1.5 hours)       Category: Wings
Located piece in place on front spar and marked with Sharpie. Drilled for rivets on rib 1 and 2 rib caps. Scuffed mating surfaces, solvent cleaned. Mixed up epoxy and applied to mating surfaces. Positioned, clamped in place with straight edge, installed rivets and allowed 24 hour cure.

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Jun 23, 2020     Camlocs for Turtledeck and Cowling - (2 hours)       Category: Fuselage
Drilled and located CAMLOCS for turtle deck 7 places. Squeezed rivets to install. Located and drilled for CAMLOCS for engine cowling 12 places.

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Jun 22, 2020     Rear Quarter Windows - (2 hours)       Category: Fuselage
Cut out windows in sheetmetal, cut from sheetmetal the frame to trap and secure window. Primed and painted the inside. Drilled holes for securing window.

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Jun 15, 2020     Rear Windshield Bracket - (.5 hour)       Category: Fuselage
Aligned Rear Bracket with butt rib caps using straight edge. Trimmed lower edge to clear fuselage tubing. Marked and drilled mounting holes.

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Jun 14, 2020     Slotted Trailing Edge Left Wing - (1 hour)       Category: Wings
Slotted trailing edge for aileron and flap hinges at ribs 5, 7 and 9.

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Jun 13, 2020     Flap and Aileron Rt Wing Brackets - (1 hour)       Category: Wings
Drilled rivet holes into front spar of aileron and flap for hinge brackets and bellcranks for right wing.

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Jun 12, 2020     Flap and Aileron Leading Edges - (3 hours)       Category: Wings
Cut fiberglass leading edge for flap to length. Trimmed long edges so edges mated with rib caps. Cut metal aileron leading edge to length. Cut slots to clear hinges.

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Jun 10, 2020     Left Wing Trailing Edge - (2.5 hours)       Category: Wings
Marked, set punch drilled for nutplates in trailing edge for fuel tank cover mount. Cut trailing edge pieces to length to meet at rib web.

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Jun 07, 2020     Right wing trailing edge. - (2.5 hours)       Category: Wings
Cut trailing edge pieces to length for right wing. Chained drilled and filed slots for aileron and flap hinges.

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Jun 02, 2020     Aileron and Flap Install-Right Wing - (2 hours)       Category: Wings
Placed wing underside up. Clamp straight edges on wing ribs to support aileron &flap. Cleaned up epoxy around flap spar and rib so hinge can be placed.

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May 31, 2020     Butt Rib Left - (2 hours) Category: Wings
Clamped root rib to butt rib with 1/8 inch spacer. Measured distance to fuselage mounting bosses. Measured and cut standoffs. Drilled mounting to butt rib. Riveted standoffs to butt rib. Drilled and cut features into web for clearance of fitting s and fuel lines.
 
May 31, 2020     Aileron Leading Edge Splice - (1 hour)       Category: Wings
Aligned leading edge pieces, marked out spacing, drilled for 3/32nd holes. Matched drill splice doubler.. Countersunk for flush solid rivets. Installed rivets.

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May 31, 2020     Filler Rib Left Wing - (1 hour)       Category: Wings
Trimmed Filler rib caps flush with web aft edge. Taped wing trailing edge in place for filler rib alignment. Scuffed rear spar for bonding. Cleaned surface. Installed rib and confirmed position and squareness. Applied epoxy, let sit for 24 hours.

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May 30, 2020     Right Aileron Leading Edge Mod - (1 hour)       Category: Wings
Modified shape of leading edges of aileron ribs to fit custom shaped Steve Henry aileron leading edge.

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May 30, 2020     Butt Rib Fuel Tank Fuel Fitting Holes - (1.5 hours)       Category: Wings
Marked fitting locations to rib, drilled holes in rib to allow installation of fuel line fittings.

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May 30, 2020     Left Wing Fuel Tank Install - (3.5 hours)       Category: Fuel System
Temporary installed root rib, clamped supports between ribs 1& 2 to support tank. Clamped tank mounting brackets in place, marked positions, removed tank. Drilled 4 brackets, match drilled front and rear spar. Riveted brackets. Applied epoxy at bracket joints. Match drilled tank to bracket mounting. Installed nutplates.

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May 29, 2020     Left Wing Root Rib - (2 hours)       Category: Wings
Fitted rib to spar, positioned similar to right wing. Abraded spars. Solvent cleaned. Epoxies in place.

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May 27, 2020     Fuel Tank Install Left Tank - (2 hours)       Category: Wings
Positioned butt rib so 1/8 inch gap with tank at ribs 1 and 2. Clamped 2 straight edges on underside. Positioned tank, clamped mounting brackets to tank and marked positions for attaching brackets to front and rear spars. Marked, drilled brackets, positioned and transferred drilled spars, riveted in place, applied epoxy at bracket spar joints.

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May 12, 2020     Right Wing Fuel Tank Cover - (2 hours)       Category: Wings
Drilled and located nutplates in trailing edge. Used strap duplicator to locate fuel tank cover mounting holes. Marked out and located fuel inlet.

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May 11, 2020     Right Wing Wing Tip Nutplates - (2 hours)       Category: Wings
Measured out, marked, drilled 1/8 center holes, checked, transferred drilled 3/32nd mounting holes, opened up center holes with #18, counter sunk 3/32nd holes. Riveted nut plates in place.

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May 10, 2020     Installed Left Wing - (1 hour) Category: Wings
Reamed fuselage mounts. Rearranged shop and located fuselage in other garage bay to make room for installing left wing.
 
Apr 28, 2020     Left Wing Tip Trimming - (1 hour)       Category: Wings
Applied tape along scribe line, used angle grinder with cutting wheel to trim part. Finished edge with hand sander. Sanders flash off at parting line as well.

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Apr 27, 2020     Paint Scheme Concept       Category: Paint / Decals
Nitsuj Designs provided a conceptual paint scheme. Paint Theme name is "Brush Cutter".

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Apr 26, 2020     Right Wing Butt Rib - (3 hours)       Category: Wings
Pivoted wing back to place butt rib. Reamed tubing mounts on fuselage. Cut to length rib T-fittings. Clamped Butt rib to root rib, marked and located fuel fitting holes and sight gauge holes.

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Apr 26, 2020     Tapped Sight Gauge Fittings - (.5 hour)       Category: Fuel System
Located, marked, drilled and tapped 1/8NPT threads for sight gauge fittings in right wing tank.

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Apr 25, 2020     Rib 9 Nutplates for Wing Tips - (2.5 hours)       Category: Wings
Located, marked, drilled, countersinked, riveted 23 nutplates into last rib of left wing.

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Apr 25, 2020     Duplicator Strap Category: Tools
Hole duplicate. Will use for locating mounting holes in wing tips.
 
Apr 25, 2020     Epoxy Varnish Category: Wings
Ev-400 Epoxy Varnish kit Qt.
 
Apr 24, 2020     Right Wing Tank Nutplate Mounted - (1 hour)       Category: Wings
Located Nutplates with clecos to 4 drilled mounting holes. Transferred drill 3/32nd holes. Countersinked. Mounted nutplates with rivets, 4 places.

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Apr 24, 2020     Tank Cover Front Mount Nutplates - (2 hours)       Category: Wings
Installed nutplates to the two wing tank front mounts. Used 3 inch spacing. Drilled 1/8 holes on centers. Cleco'd nutplates to locate mounting holes, drill 3/32nd holes. Opened up 1/8 holes with #18 drill for thru holes. Riveted in place with solid rivets.

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Apr 23, 2020     Left Root Rib Nutplate Install - (1 hour)       Category: Wings
Marked Out Three Inch spacing. Drilled 1/8 inch holes on center. Cleco'd nutplates to locate 3/32nd holes. Drilled out 1/8th holes with #18 hole. Countersink rivet holes. Located rivets and squeezed to locate nut plates.

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Apr 21, 2020     Butt Rib Reinforcement - (2 hours)       Category: Wings
Steve Henry recommended improvement-adding reinforcement to the butt rib rib cap. The cap is stapled and glued to the web. The windshield is mounted to this rib. Fabricated aluminum angle extrusion to follow contour of upper rib cap. Will be epoxies and riveted in place.

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Apr 20, 2020     Left Wing-Installed Wing Joint Doublers - (1 hour)       Category: Wings
Match drilled doublers to spars. Abraded mating surfaces, cleaned surfaces with acetone. Epoxied, bolted and riveted in place. Cleaned surfaces of excess.

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Apr 19, 2020     Left Wing-Strut Brackets - (1.5 hours)       Category: Wings
Bonded previously drilled spar/lift strut brackets, interface front and rear spars. Installed Jury strut brackets. Cleaned and abraded surfaces, applied epoxy to both sides and rivet in place.

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Apr 18, 2020     Flight Test Manual and check cards Category: Wings
Ordered EAA's Flight Test manual and test check cards.
 
Apr 18, 2020     Lift Strut Brackets- Left Wing. - (1.5 hours)       Category: Wings
Drilled front and rear spar of left wing for lift strut brackets.

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Apr 18, 2020     Left Side Kickpanel Nutserts - (2 hours)       Category: Fuselage
Drilled out mounting holes to install 8-32nd nutserts. Used nursery puller to complete installation.

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Apr 16, 2020     Fuel Tank Cover Nutplates - (3 hours)       Category: Wings
Chalked lined on upper rib caps. Drilled 1/8 inch holes on ribs 1 & 2 every 3 inches. Cleco'd nutplates in place to locate 3/32nd mounting holes. Drilled holes. Cleaned surfaces. Countersink 3/32nd rivet holes. Cleco'd nutplates into position, installed flush solid rivets, used rivet squeezer to compress rivets to secure nutplates.

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Apr 15, 2020     Right Wing Tank Rib - (1 hour)       Category: Wings
Cut rib caps flush for trailing edge. Marked location on rear spar. Abraded spar surface, solvent cleaned. Applied epoxy, positioned end rib behind fuel tank. Used trailing edge to secure in place.

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Apr 15, 2020     Left Wing Stringer Install - (1 hour)       Category: Wings
Install stringer through ribs 2 to 9, mark where to cut to length. Abrade stringer for bonding to each rib. Clean surface with acetone. Position stringer. Apply epoxy.

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Apr 14, 2020     End Rib Drag Links - (2 hours)       Category: Wings
Fabricated drag links from leftover stringer material. Cut to length, pinched ends, bent angles, drilled mounting holes, transferred holes to rib and spar, drilled holes, abraded metal mating surfaces, applied epoxy and rivet in place.

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Apr 12, 2020     Left Wing Gussets - (1.5 hours)       Category: Wings
Positioned wing to work. Sanded mating surfaces. Applied epoxy to gussets, positioned. Applied epoxy fillets to both sides of 8 gussets between spars and drag links.

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Apr 12, 2020     Bonding Root Rib - (1 hour)       Category: Wings
Abraded spars, used acetone to clean up surfaces. Assured proper place and position of root rib. Epoxy rib in place.

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Apr 12, 2020     Root Rib Cutouts - (1 hour)       Category: Wings
Marked locations for fuel tank fittings locations onto root rib. Used hole saw to make holes.

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Apr 11, 2020     Front Kick Panels - (1 hour)       Category: Fuselage
Installed 8-32 nutserts 13 places for locating right side footwell side panel. Drilled out panel mounting holes to accept 8-32 screws. Marked out window cutout.

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Apr 11, 2020     Ailerons Trailing Edge - (2 hours)       Category: Wings
Prepared trailing edge pieces for flaps. Cut to length, abrade mating areas, temp install for drilling mounting holes,#40, through rib caps, both sides. Countersink for 3/32 rivets. Mix up epoxy, apply to rib caps, install trailing edge, install rivets, wipe off squeeze out epoxy. Cure for 24 hours.

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Apr 10, 2020     Flaps - (2 hours)       Category: Wings
Prepared trailing edge pieces for flaps. Cut to length, abrade mating areas, temp install for drilling mounting holes,#40, through rib caps, both sides. Countersink for 3/32 rivets. Mix up epoxy, apply to rib caps, install trailing edge, install rivets, wipe off squeeze out epoxy. Cure for 24 hours.

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Apr 08, 2020     Rear Side Windows - (2 hours)       Category: Fuselage
Made window frame pattern made with poster board from fuselage. Cut frame from .025 aluminum sheet. Located onto fuselage to size window. Marked out window on sheet. Cut window out and dressed edges with file.

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Apr 07, 2020     Fuel Tank Install - (1 hour)       Category: Wings
After brackets were installed, placed tank and drilled mounting holes in each of the four brackets. Shimmed with thick tape where needed to eliminate and play at mating surfaces.

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Apr 06, 2020     Fuel tank support brackets - (2 hours)       Category: Wings
Right Wing: Placed temp supports across underside of ribs #1 & #2. Positioned tank, clamped mounting brackets to mounts on fuel tank. Marked positions on front and rear spars. Removed tank, marked out 4 hole positions on each bracket, drilled #30 holes. Relocated brackets and drilled holes into spars. Riveted in place and backfilled with epoxy.

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Apr 05, 2020     Flap Trailing Edges - (2 hours) Category: Wings
Cut trailing edge material to length. Filed edges smooth. Installed onto flap ribs, marked on edge width of rib caps, both sides. Center punch for drilling #40 hole on trailing edge on each rib cap. Drilled. Ordered 3/32nd countersink.
 
Apr 05, 2020     Countersinks Category: Tools
#30 & #40 Countersink cutters needed for Micro adjust countersink tool. $12.85 a piece
 
Apr 05, 2020     Camloc Pliers Category: Tools
Camloc Pliers Tool needed to locate CamLoc Receptacles
 
Apr 02, 2020     Installed Right Wing - (.5 hour)       Category: Wings
Temporarily installed right wing to locate fuel tank and root rib.

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Apr 02, 2020     Trim Trailing Edge Rib Cap Strips - (1 hour)       Category: Wings
Trim and sand upper and lower cap strips at trailing edge flush with ribs. Radius edges so trailing edge installs flush.

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Apr 01, 2020     Lift Strut Wing Brackets - (2.5 hours)       Category: Wings
Lift Strut locations preset by factory. Aligned and match drilled bracket hole locations into front and rear spar of right wing. Cleco'd has holes were drilled. Removed, cleaned holes, painted brackets, abraded mating surfaces, mixed up epoxy, applied to mating surfaces, riveted in place and cleaned up epoxy squeeze out.

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Mar 30, 2020     Jury Strut Brackets, Right Wing - (1 hour)       Category: Wings
Measured and positioned jury brackets 90 degrees normal to bottom of front and rear spars. Drilled 1/8 holes in brackets teamed 3/16ths holes in tabs, abraded mating surfaces applied epoxy. Riveted in place. Cleaned excess squeeze out.

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Mar 29, 2020     Header Tank Fabricate - (2 hours)       Category: Fuel System
Folded sheetmetal flat patterns to make a header tank. Had no sheetmetal brake. After forming, radiused edges, and did final fitting.

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Mar 28, 2020     Header Tank Fabrication - (2 hours)       Category: Fuel System
Used prototype mockup to layout flat patterns on 3003-H14 .063" sheet aluminum. Cut out flat patterns.

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Mar 28, 2020     Wing Tip Rib Drag Links - (1.5 hours)       Category: Wings
Fabricated drag links from leftover stringer material. Drilled for rivets. Abraded mating surfaces. Mixed up Hysol and applied to cleaned mating surfaces. Installed rivets. Cure for 24 hours.

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Mar 28, 2020     Attachment Doubler - (2 hours)       Category: Wings
Installed upper and lower doubles to forward and aft spar fuselage attachment points for right wing. Located, drilled #30 holes 4 places per doubler. Mixed up Hysol epoxy, abraded mating surfaces. Cleaned, applied Hysol to mating surfaces. Installed rivets and fastener. Let cure 24 hours.

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Mar 25, 2020     Gussets - (2 hours)       Category: Wings
Installed gussets between drag links and spars on right wing. Shaped gussets to fit. Roughed up surfaces on drag links and spars where gussets install. Applied Hysol to edges of gussets and installed eight places. Then applied Hysol fillets to all sides of install.

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Mar 21, 2020     Brake Line Routing - (1.5 hours)       Category: Landing Gear
Routed Matco brake lines between cylinders and parking brake valves.

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Mar 21, 2020     Systems support tray - (1.5 hours) Category: Fuselage
Used an extra aluminum channel piece and modified for a system routing and supporting feature underneath floor board.
 
Mar 19, 2020     Brake master cylinder installation - (2 hours)       Category: Landing Gear
Reamed mounting holes in fuselage and rudder pedal assembly. Fitted pedal brake mounts. Installed cylinders and marked drill points in pedal mounts. Drilled 5/16ths holes. Painted pedal mounts. Reinstalled master cylinder assemblies and connected pedals to cylinders using the appropriate hardware.

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Mar 18, 2020     Parking brake control unit - (1.5 hours)       Category: Landing Gear
Located mounting plate below control mixer with Adel clamps. Mounted brake fluid flow control unit. Cut pull cable to length and installed.

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Mar 18, 2020     Switch Plate - (1.5 hours)       Category: Fuselage
Fabricated plate to install forward of control mixer for mounting parking brake pull cable and tailwheel locking lever. Shaped aluminium plate, drilled mounting holes, drilled holes for parking brake pull cable and tailwheel locking lever. Installed.

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Mar 17, 2020     Tailwheel - (1 hour)       Category: Landing Gear
Received Tundra Lite tailwheel in mail. Mounted it to Superstol tailwheel suspension by aligning and drilling for 1/4" securing bolts.

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Mar 16, 2020     Header Tank Pattern - (2 hours)       Category: Fuel System
Made a mockup header tank with foam board. Measured, made first pattern from cardboard, fitted, made adjustments to make final pattern. Will now transfer to .063 aluminum sheet. Foam board assembled with hot glue gun.

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Mar 14, 2020     Forward Skin Panels - (2 hours)       Category: Fuselage
Used poster board for pattern. Cut left and right skin panels from. 025 aluminum sheet. Drilled pilot holes and used clecos to secure panels for final fitting. Used body hammer to shape panel edge to door frame edge. Cut pattern for windows in forward skin panels.

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Mar 12, 2020     Header Tank Category: Fuel System
Purchased 48 inch x 48 inch X 0.063 inch 3003H14 material to fabricate a header tank.
 
Mar 08, 2020     Windshield A Post Mount - (1.3 hours)       Category: Fuselage
Drilled out windshield post mounting holes with #30 bit. Fitted formed sheetmetal pieces to fuselage. Trimmed where needed. Back drilled through mounting tabs. Ready for primer.

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Mar 07, 2020     Side Floor Panel Closeouts - (1.5 hours)       Category: Interior Finish
Because I am choosing not to apply fabric covering on interior sides of fuselage I fabricated side of seat closeouts that extend beyond structure to close gaps with applied exterior covering. Provided AL sheetmetal strips are not used. Made poster board templates, cut sheetmetal, drilled mounting holes, zinc Chromate primer, and painted.

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Mar 06, 2020     Stick Grip Install - (1 hour)       Category: Controls
Determine where the PTT wires should exit the sticks. Found some grommets for the routing wiring through sticks. Drilled sticks, routed wires, installed grip with tube diameter adapter, mounted PTT cap, fixing it to stick with rivet.

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Feb 28, 2020     Control Stick Grips.       Category: Controls
Purchased RAC Stick Grips. $46.55 each, tax and shipping

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Feb 24, 2020     Bottom Stringer - (1.5 hours)       Category: Fuselage
Cut standoffs to a length that provides a nice stringer profile. Drill fuselage bushings, align stringer standoffs and match drill. Bushings had to be reamed. Primed standoffs with chromate primer. Rivet Standoffs. Align stringer and mark standoff locations. Drill stringer. Prepare epoxy adhesive. Apply adhesive to standoffs, install stringer. Secure stringer in place with bungees. Cure overnight.

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Feb 21, 2020     Tundra Lite Tailwheel Purchase       Category: Landing Gear
Ordered 8" SuperSTOL Tundra Lite Taillwheel from Pekola Enterprises- Jim Pekola $957+$Tax+$22 shipping.

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Feb 13, 2020     Control stick shaping - (2 hours) Category: Controls
Added bends to the control sticks to jiggle and improve position of stick handle in relation to reach from seated position.
 
Feb 09, 2020     Elevator Push/Pull Rod Install with Control Mixer - (4 hours)       Category: Controls
Installed Control Mixer, Positioned control sticks and drilled for mounting. Formed bends into long elevator push/pull rod for alternate routing below floor. Installed push/pull rods to bell crank.

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Feb 08, 2020     Paint Category: Tools
Purchased black & safety orange enamel paint in rattle cans, and 3 feet of non-skid tape.
 
Feb 08, 2020     Assembly- Seats, Rudder Pedals, Control Mixer - (3.0 hours)       Category: Fuselage
Riveted Seat back & base aluminum panels to seat frames, assembled seat backs to seat frames with hardware, installed seat adjuster spring pins. Installed rudder pedal assembly to fuselage. Assembled control mixer, control stick pivots, and tie rod.

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Feb 05, 2020     Paint Parts - (1.0 hour) Category: Fuselage
Painted miscellaneous parts, push/pull elevator control rods, touch-ups on rudder pedal assembly.
 
Feb 03, 2020     Paint Parts - (1.5 hours) Category: Fuselage
Paint Seat Frames, Control Mixer and other miscellaneous parts.
 
Jan 26, 2020     Finishes for Metal Parts - (4 hours)       Category: Fuselage
Prep Chrome moly/steel parts for paint. Scotch brite all surfaces and etc. Hang from fixture.

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Jan 25, 2020     Elevator Install - (2.5 hours)       Category: Fuselage
Installed elevators to horizontal stabilizers. Clamped leading edges. Applied welding clamp to elevator horns to secure alignment. Removed leading edge clamps and positioned elevators so 5/16th" hole could be drilled through horns for elevator push/pull rod clevis installation. Drilled and reamed. Removed elevators from plane, cleaned finished hole, placed elevators on flat surface, clamped horns and removed material to fit clevis. Reinstalled elevators to plane.

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Jan 24, 2020     Manual Trim Control Assembly. - (2 hours)       Category: Fuselage
Trimmed flat aluminum sheet to fit manual trim cable mount on elevator. Located mounting holes, drilled with #30 drill, installed blind rivets. Aligned elevator trim with elevator, sized piano hinge, cut to length and notched, drilled for mounting piano hinge between elevator and elevator trim part. Located assembly with clecos. Fabricated more robust angle for cable mount in lieu of provided L-bracket. Drilled for rivets, aligned with elevator trim actuator arm, located angle to plate mounted in elevator and drilled #30 holes for rivets. To be mounted at final assembly after fabric installed to control surfaces.

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Jan 18, 2020     Fly Wires - (6 hours)       Category: Fuselage
Built wood frames to hole the Horizontal stabilizers at horizontal, and the vertical fin vertical. Used Swage-it Tool to make up the Flying wires- upper and lower.

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Jan 13, 2020     Seat Adjustment Rail Installation - (0.6 hour)       Category: Fuselage
Located and drilled the seat adjustment positions in the left and right seat adjustment rails.

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Jan 12, 2020     Seat Adjustment Rail Installation - (1.5 hours)       Category: Fuselage
Located seat adjustment rails, drilled & reamed 1/4" mounting bolt holes in rail, temporary install of flap pulleys, located seat adjustment stops for aft position.

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Jan 12, 2020     Fly Wires - (1 hour)       Category: Fuselage
Ream 1/4" bushings in Horizontal Stabs and Vertical Fin for mounting of Fly Wire Tabs. Gathered appropriate bolt/washers/nut hardware and located tabs.

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Jan 09, 2020     Seat Backs - (2 hours)       Category: Fuselage
Trim .040 Aluminum sheet to fit seat frames-Seat backs (2), Seat Bases (2). Drill for rivet installation.

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Jan 06, 2020     Flap Handle Assembly and Install - (1.5 hours)       Category: Fuselage
Drilled Push button rod, assembled plates with flap handle with spring detent and appropriate hardware. Tested actuation. Located into fuselage, drilled mounting holes, reamed fuselage mounting bushings. Handle and pushbutton detent rod will be painted.

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Jan 05, 2020     Manual Trim Control Assembly. - (1.5 hours)       Category: Fuselage
Dressed up the manual trim handle with lightening holes, drilled pilot holes in plate for pre-assembly.

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Jan 04, 2020     Seat Runners - (2 hours)       Category: Fuselage
Installed 4 seat runners (PTFE) Strips. Drilled, countersinked, and riveted in place.

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Jan 02, 2020     Horizontal Stabilizers - (1 hour)       Category: Fuselage
Shorten front stabilizer bushing .060" for flush fitment of stabilizers, confirmed zero degree angle of incidence, drilled 3/16ths holes in front stabilizer mounts.

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Dec 31, 2019     Swage-It #2 Tool, Nico Gauge, & EP-420 Primer Category: Tools
Ordered Nicopress (Swage-it #2) for cable making. Ordered EP-420 Epoxy Primer, with catalyst and reducer. All purchased through Aircraft Spruce.
 
Dec 31, 2019     Top, Side Aluminum Stringer Install - (1.5 hours)       Category: Fuselage
Sanded all fuselage spigots, Vertical Fin and aluminum stringers in vicinity of structural epoxy application with 180 grit, cleaned all sanded surfaces with acetone. Applied epoxy, completed installation, seized all installation positions with bungees. After epoxy drying for 2 hours, smoothed transition areas where fabric covering would telltale through. Riveted top stringer to vertical fin during epoxy application, used CP44 rivet.

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Dec 31, 2019     Hysol Epoxy Plunger - (.5 hour)       Category: Tools
Made a dual plunger tool for pushing out the Hysol Epoxy Structural adhesive from tubes. Epoxy was squirted into zip lock bag for mixing and dispensing.

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Dec 30, 2019     Finishes for Metal Parts - (.5 hour) Category: Research
Reviewing Poly-fiber Aero-Thane information. Checking on prices. Sent inquiry of which orange color option best matches the Cardinal Color safety orange.
 
Dec 30, 2019     Fitted Aluminum Stringers - (1 hour)       Category: Fuselage
Removed temporary installed aluminum stringers, added corrosion finish to ends of all the welded spigots that were cut to define fabric covering shape. fabricated an additional support for upper aluminum stringer. Top and side stringers are now ready to be bonded in place.

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Dec 30, 2019     Revise forward Fuselage Stand - (0.5 hour)       Category: Fuselage
Removed cross support for my fuselage stand, welded 45�races instead. Fix allows me to install Bottom fuselage stringer.

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Dec 24, 2019     Rudder Pedal Assembly Prior to Painting - (1.5 hours)       Category: Fuselage
Scotch brite the metal pieces, shaped and drilled the plastic spacers,assembled, aligned mounting brackets and assembly in fuselage, drilled bottom bracket of assembly through the oil holes to rivet mounting brackets. Now the assembly is ready for paint, later the rivets will be drilled out.

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Dec 21, 2019     Fitted Aluminum Stringers - (3 hours)       Category: Fuselage
Fitted Top Aluminum Stringer to fuselage, welded spigots had to be trimmed for proper installation of top stringer, had to install Horizontal Stabilizer Front attach bracket to finalize fitment of Top stringer.

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Dec 17, 2019     Ordered Reamers and Clecos from Aircraft Spruce Category: Workshop
Ordered 10 1/8" Clecos, 3/16", 1/4", 5/15", 3/8" Reamers.
 
Dec 16, 2019     Footwell, baggage Floor Panels - (1 hour) Category: Fuselage
Fitted Aft Baggage Panel
 
Dec 14, 2019     Footwell, baggage Floor Panels - (1.5 hours)       Category: Fuselage
Fitted Baggage Floor Panels

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Dec 13, 2019     Footwell, baggage Floor Panels - (2.5 hours)       Category: Fuselage
Fit Aluminum Footwell Floor Panel.

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Dec 10, 2019     Picked up Parts from Powder Coater - (1 hour) Category: Fuselage
Returned powder coated parts to shop.
 
Nov 29, 2019     Scotch brite fuelage -prep for powder coat. - (6 hours)       Category: Fuselage
Prep Fuselage, Vertical Fin, Horizontal stabilizers(2), elevators(2), Jury struts (2), welded door assys (2), wing struts (2)

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Oct 24, 2019     Picked up Parts from Powder Coater - (1 hour) Category: Landing Gear
Picked up Matco Wheels after powder coating black.
 
Oct 15, 2019     Dissembled Matco Wheels for Powder Coating - (1 hour)       Category: Landing Gear
Split Matco Wheels to prepare for Powder Coating

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Oct 11, 2019     Inventory Kit - (4 hours) Category: Inspection
Uncrate, inventory parts, read through the 14 pages of Bill of Materials.
 
Oct 09, 2019     Airplane Kit Arrives - (1.5 hours)       Category: Workshop
My Just Aircraft Highlander quick build kit arrives via Semi-Tractor trailer. Unload to trailer, then transport to garage and unload and slide crate in garage. Shipping charges shown.

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May 04, 2019     Order Highlander from Steve Henry - (1 hour) Category: Research
Ordered Quick Build kit
 


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