Jan 02, 2024     Phone calls, emails, braces - (4.0 hours)       Category: Fuselage

Call to ABQ FSDO about my test flying area SE of KELP. Talked with Geary Monckton about my proposal and sent email with written plan and diagram on VFR sectional.
Folded wings and secured braces onto wings to support wings during transport. Also drove to far East side to get engraved Data plate done per Frank Sperandeo.
Sent copy of e-mail from ABQ FSDO approving my test flight area and sent photo of data plate for approval.

  Dec 31, 2023     Condition inspection - (1.5 hours) Category: Fuselage

Final assembly inspection and condition inspection completed. Found missing nut for horizontal stabilizer pivot.....oooops!

  Dec 30, 2023     Odds and ends - (3.5 hours) Category: Fuselage

Found some more loose nuts, tightened last of screws in boot cowl, attached tabs on boot cowl/windshiled for glare shield, checked rigging measurements,

  Dec 26, 2023     DAR consult - (1.0 hour) Category: Fuselage

Another hour or so with Frank Sperandeo trying to getting FAA paperwork completed correctly to his specifications. He seems much more confused than I am. Had to resend a lot of paperwork I had already sent but he wanted each document in separate e-mail.
Now that plane is "finished", I was able to send photos of three views: left side, front, right side.

  Dec 26, 2023     Final, finishing details - (4 hours)       Category: Fuselage

Checked for shorts to ground for all GNX and GDU connections and found only pin 43-47????? with slight connectivety, but more inportantly, when i only start GDU under confic settings and NOT GNX, then I get NO red "X's". I'll run with that for now.
Spent several hours using fire proof putty to help seal boot cowl to firewall. Also installed rest of my thin weather stripping used on windshield to help seal boot cowl to airframe aft of fire wall and to front windshield. Installed boot cowl and screwed in 30+ screws to secure it. Tightened up last of nuts I could find.
Red "X's" went away on GDU config screen after my re-wiring.
Sooooo, the plane is essentially FINISHED. Couple more trim items and half dozen cotter pins to install.......oh yeah, already have to do a repair and re-bleed brake lines due to leakage at couple of fittings.
But plane can fly as it is now.

  Dec 25, 2023     Condition inspection - (3 hours) Category: Fuselage

As part of initial condition inspection before airworthiness inspection next month, I started on multiple items: Vacuuming/cleaning cockpit floor, securing multiple nuts/bolts, torque witness paint as needed, lubrication of all moving parts, inspection of inside of fuselage, wings.
Also reconfirmed correct wiring connections for RS 232 between GDU-GEA 24, GNX-375-GSU 25. After panel put back, still shows error connection on GDU port 1 of RS-232. Will check for grounding short tomorrow.

  Dec 21, 2023     W&B - (2.5 hours) Category: Fuselage

Couple of hours measuring arms and weight calculations. Filled standard FAA W&B sheet along with Kitfox balance sheet. Even though plane a little heavy using 2 x170# pilot/passenger, adding 23 gallons gas and 150# luggage in proper location, I'm at max gross and 1 inch forward of aft limits. I'm happy enough with load carrying capacity.

  Dec 11, 2023     Configuration - (3.0 hours) Category: Fuselage

With corrected wiring between GTR200B and GDU460, I now have audio alerts. Also re-set some other limits for sensor read outs.
HOWEVER, I still have issues with RS-232 and ARINC connections. GDU system doesn't "see" GNX375 at all. Another query into G3xpert.

  Dec 10, 2023     Cotter pins and safetry wire - (2.5 hours) Category: Fuselage

Tried to locate all bolts/nuts needing cotter pins and safety. Need to get a slight smaller cotter pin for nuts on nose wheel. Took several tries to safety wire the three bolts on disc brakes.

  Dec 10, 2023     Rewiring of GTR200 - (3.0 hours) Category: Fuselage

eWorking on more panel config, discovered I had lost audio alerts for GDU 460. An answer from G3expert said I had mis-wired. Spent couple of hours and corrected mono audio to connect with GDU and removed Stereo outputs from GDU. That wire that originally went to GTR200B is now stubbed out and behind right panel and can be wired to 3.5mm Jack to provide hard wired external music via cable.

  Dec 05, 2023     tightening nuts and bolts - (3.0 hours) Category: Fuselage

Went through most of airframe parts installed when moved to driveway to tighten nuts bolts and replace some temporary connections with proper bolts.

  Dec 05, 2023     Install windshield and wing tips - (3.0 hours) Category: Fuselage

Spent about 3 hours screwing in about a 100 screws...about half with washers and nuts to final install both wing tips and windscreen. After all screwed in, then I found out about a cement to repair crack in top left corner.

  Dec 04, 2023     Polish windshield scratches - (6.0 hours) Category: Fuselage

Hours and Hours trying to remove some scratches on right side of windshield where I had added some Hysol to get window to fit better. During smoothing of Hysol, I created some scratches on the inside. I worked and worked. Went to store to get more grits of wet sanding paper and buffing compound. Then it dawned on me that the scratches were on the other side of the window. Once those were removed, all quite shiny. Now I won't be bugged by knowing scratches were there.

  Nov 13, 2023     Camlock adjustment - (1.5 hours) Category: Fuselage

Spent an hour or so adjusting camlock receptacles to proper length. Also adjusted numbers on fuel level in tanks to reflect amount left in tank and not including header tank and fuel lines.

  Nov 12, 2023     Fuel level recording - (2.5 hours) Category: Fuselage

Spent couple of hours adding 2 gallons at a time to right (only) fuel tank and marking known levels with labeling tape. I ended up putting 15 gallons into 14 gallon right fuel tank. Seems I didn't account for 1 gallon or so in the header tank. I placed gallon amounts with "arrow" to level noted on site gauge at bottom of meniscus.
Will have to go back and replace numbers to account for 1 gallon in header tank.
I did quickly find reason for massive fuel leak when pumps activated. I had forgotten I had not totally tightened one fuel line connection into large fuel filter after fuel pumps. My intent was that fuel flow requirements would be met before finally tightening.
After filling right tank, I used fuel pumps to empty main tank and determined that fuel pumps put out at least 2/3 gallon per minute. I needed 9 gph and my pumps put out almost 40gph.....more than enough but needed for high pressure for fuel injection.

  Nov 12, 2023     Cowling camlocks - (2.0 hours) Category: Fuselage

Spent couple of hours working on engine cowlings to get all camlocks to work properly. I worked with 4-5 at a time to get proper depth adjusted to allow quick, quarter turn counter-clockwise to release. Then pulled the little pin on female receiver to lock position. Then worked a couple of more receptacles until all completed. Had to install and then remove top cowling each time. Seemed to take forever.

  Oct 30, 2023     Brackets throttle, fuel lines - (4.0 hours)       Category: Fuselage

Several hours to figure out some kind of brace/support for my throttle. After throttle install, it was VERY wiggly when used. I figured out using a couple of cable clamps on the throttle shaft and bracket above it for fuse busses. Clamps connected with tube with smashed ends similar to what I used to brace top of instrument panel. It is 98+% better. Still slight movement but very tolerable and MUCH more secure than previous.
Also used cable clamps to secure fuel lines coming from fuel tanks and secured just below the fuel shut-off valves I installed.
Both jobs took a lot of thought on my part before several tries to check if proper application before final tightening.

  Oct 29, 2023     Avionics config and "stewing" - (8.0 hours) Category: Fuselage

Several hours stewing and researching over what to do about: 1) leaking at brake shoe line fittings 2) floppy throttle 3) How to program GDU, GNX, Radio 4) Whiskey compass need (or not) 5) Trim position indication 6) proper voltage showing up (main and IBBS) 7) low IBBS volt indication 8) Ipad holder interference 9) Discrete button pushes for AP disconnect, radio switching, IDENT,
Also spent hour or so trying to fit strakes between aft, inboard wing and turtle deck.

  Oct 28, 2023     Turtle deck, fuel lines, Wind shield, wing wiring labels - (8.0 hours)       Category: Fuselage

More time on turtle deck smoothing more trimmed edges, redoing some Camlock studs, Pulled pins on camlock receptacles to lock adjustment. Checked trim position sensor actuating tab on horizontal stab and seems to be WNL.
Trimmed more on windshield/front spare junction for more clearance. Sanded and smooth the trimmed areas on windshield.
Fuel and fuel vent lines/hoses installed to header tank.
Put some printed labels on plus connectors coming from the wings before the marker writing totally fades away.
Magnetometer not online...red "X", checked the plug, checked CANbus wiring pulses running up and down, checked voltage and showed almost 12 volts so I guess I killed the magnetometer on one of its drops....i'll have to order another one.
More research into configuration for GNX 375 and GDU 460.

  Oct 27, 2023     Flaperon interference, Turtle deck camlock studs, Cracked windshield - (7.0 hours)       Category: Fuselage

Couple of hours spent filing down flaperon control arm where it interfered with fuselage cross member below the pilot seat. Check to be sure no longer any interference and painted exposed areas with touchup paing
Spent an hour or so working to get Camlock studs just right on Turtle deck. One stud in center at back took well over an hour as I had drilled it off center and stud wouldn't engage properly. I used a file to enlarge hole to be able to line up properly but then stud keeper wouldn't hold it in position. I filled hole with some Hysol and hopefully will work.
Hours filing on push tube for flaperon control that had interference with one of bottom fuselage beams. I though better to remove material only from push rod and not structural fuselage member. Used touch up paint to cover exposed metal.
Started to install more fuel lines. In process, saw where front spar inboard on port wing was rubbing on windshield cutout. I worked on sanding but then saw a CRACK at the corner running about two inches. I did a stop drill hole and used air grinder to really remove interference.
Guess crack occurred when I pulled the aft pin on wing to lube it and wing swung forward, I remember hearing a crack but thought it metal to metal.
Oh well, it cracks more, I'll just have to replace it. I'm getting good at doing that

  Oct 26, 2023     Turtle deck Camlocks - (2.0 hours)       Category: Fuselage

Who would have thought it would take 2 hours to drill 7 holes and trial fit 7 camlock studs?

  Oct 23, 2023     Turtle deck screw up and fix - (2.0 hours)       Category: Fuselage

On turtle deck, I did not cut side at correct angle. Had a narrow slit through flaperon control arm hole but after flperons installed and confirmed that hole cut-out on turtle deck side cleared control arm, I found I could NOT remove the whole turtle deck assembly. Therefore; I had to proceed with cutoff tool to remove 1/2" arc below the hole (as I should have marked and cut along to begin with) to allow deck removal. Oh well....one step forward and two steps back.

  Oct 19, 2023     G3X programming - (2.0 hours) Category: Fuselage

Finished going through configuration screen of G3x. Have to get the magnatometer online to finish do this and also connect up the flaperons to see which way the roll servo needs to move for right and left roll.
Need to still figure out how to put trim position onto G3X. I'm sure one of the discrete coding interfaces. Still need to do the GNX375. I still get error message for transponder function.

  Oct 19, 2023     Turtle deck hinge cutting - (5 hours)       Category: Fuselage

Several hours to cut turtle deck hinge, sand edges, fit hinge, try temp fitted turtle deck hinge onto plane, remove, drill small bolt holes, mess up back drilling aluminum angle stiffener, fix my mess up, install turtle deck, check flaperon temp brackets with broom handle, trim opening in turtle deck side for broom handle, install turtle deck in prep to mount flaperons.

  Oct 18, 2023     Turtle deck hinge cutting - (4.0 hours)       Category: Fuselage

I had obtained some extra flaperon mounting brackets and installed them temporarily to guide broom handle to turtle deck side and marked spot for flaperon torsion spar to penetrate.

  Oct 18, 2023     Parts for plane - (1.5 hours) Category: Fuselage

Had to find some 10/32 screws to secure upper and lower cowls inlet ducts right behind propeller. Also got a sun shade to protect the greenhouse glass window and roof from sun.

  Oct 16, 2023     Door brackets - (2.0 hours)       Category: Fuselage

Spent most of the day recovering from rollout yesterday. Did work on installing both door frame brackets to hold gas piston.supports. Also cleaned garage. Garage looks weird empty.

  Oct 12, 2023     Ground power, lower cowl mod - (3 hours)       Category: Fuselage

I had an extremely difficult time yesterday getting lower cowl installed.....propeller is in the way. Today took a closer look and found I needed to enlarge the cowl cutout for nose gear. Still tight fit but got in back on in about 3-5 minutes instead of 40 minutes yesterday. Nose gear strut paint is still going to be majorly scared in future installing and removing lower cowl. Still have to pry it past back of prop spinner and even scrape blades a little.
Got a ground power supply to run avionics and not kill battery again. Power supply seems to be automatic with no controls other than power switch but it didn't come with any connecting cables. I made up a set with spare parts.

  Oct 11, 2023     Odds and ends - (8.0 hours)       Category: Fuselage

Cleaned up garage, applied anti seize to EGT probes and tightened into exhaust. Installed site tubes for fuel tank level along with split plates to hold fuel level placard. Assembled fuel shut off valves for each tank, cut and installed short section of fuel line between wing and probable area of fuel valve installation. Applied Velcro sticky tape to foot wells for cockpit trim. Cleaned barbs on fuel header tank

  Oct 10, 2023     Camlocks, fuel caps, fuel placards, site tubes - (7.0 hours)       Category: Fuselage

Camlock studs installed top cowl, top four camlocks on turtle deck. oil door installed, fuel caps painted, high temp RTV applied to wiring hole/access through firewall. Got some clips nuts install on forward fuselage just aft of firewall for anchoring boot cowl. Camlocks and looking for parts took ALL day. Didn't get as much done today as desired.

  Oct 09, 2023     Odds and ends - (4 hours)       Category: Fuselage

Cleaned up last of paint job. Put windshield back on. Fitted turtle deck. Drilled foreward 4 holes (in front of hinge locatiofor camlock studs in Turtle deck. Will mount turtle deck with the four camlocks to facilitate marking flaperon access hole and hinge cut when wings mounted.
Checked installed red/white LED lights in the dark. Look quite nice.

  Oct 05, 2023     LED cabin lights - (2.0 hours) Category: Fuselage

Seemed to take forever to stick on LED lights. I kept dropping the spooled LED light string and had to keep winding it back up.

  Oct 03, 2023     Required FAA lables for EXPerimental - (1.5 hours)       Category: Fuselage

Application of required warning labels for Experimental category.

  Sep 24, 2023     Quarter window riveted - (3 hours)       Category: Fuselage

Got quarter windows riveted on. Used some leftover windshield sealant tape to seal the triangle windows. Hope it works.

  Sep 24, 2023     Windshield, LED - (2.0 hours) Category: Fuselage

Finished drilling and sanding holes for wing spar pins. LED strip lighting worked with dimmer. Checked it at night and don't need foot well lighting for either red or white. Door frame white lighting sufficient for cockpit and LED's wrapped around baggage area brace seems for baggage area.

  Sep 23, 2023     LED lights, seat pan, seat belts - (9.0 hours)       Category: Fuselage

Hours and hours trying to figure out what to do with red and whilte LED strips....how to mount them, how to wire them.....do I cut them or just wrap them up.
One of the LED sets came with a power supply and dimmer switch with small plugs which plugged into the LED strips quite easily. I sacrificed the wiring for power supply and dimmer to obtain the quick connect plugs. Have wired the strips to allow using the plugs and short power/ground leads to my dimmer box. Right now, I'm thinking of lining all top of doors and back into luggage area with white strips starting in foot wells. .The red lights will light aft door frames and across turtle deck angle. I was going to put the reds into foot well also but seems the red strip is considerably shorter than white.
Cut slots into seat pan for seat belts with holes and location done per instructions. Almost couldn't insert bolt/nut for outboard co-pilot seat. Header tank in the way.

  Sep 22, 2023     Windshield, pitot mount, stinger exhaust, LED's - (8.0 hours)       Category: Fuselage

Stripped yellow paint from Pitot post and painted gloss black, Worked long time on enlarging holes in windshield for spar bolts with a hand file and sanding drums when I read about using step drill to do holes. Oh well, live and learn...only added a couple of hours to shaping the holes.both
Tried in LED strips behind and above pilot. May be enough LED to line turtle deck angle, top of both doors and down front side of door frame by instrument panel.
Installed exhaust stinger and O2 sensor into bung on exhaust both with anti-seize compound. Connected multiple serial port wires into ECU and just coiled up all wiring in area of ECU......small audio type plug into ECU, with 15 pin serial port connector and serial port to USB adapter for computer use.
Painted both strakes yellow. Wing cuff already painted blue (?). Interesting contrast. Can always repaint.

  Sep 19, 2023     Triangle window, wings - (5.0 hours) Category: Fuselage

Got some info on how to deal with throttle cable. Have a part coming. Drilled rivet holes for triangle windows. Re-configed shop to hold wings for decal installation. Started on fitting landing lights and covers to wing tips.

  Sep 17, 2023     Painting, screws, wiring - (4.0 hours)       Category: Fuselage

Wired in LED warning lights for main battery, Alt 1 and Alt 2. Painted 2nd coat of yellow on flaperon counterweights. Prepped and cleaned up garage and paint gun. Up-drilled holes between camlocks for boot cowl retention and installed tinnerman nuts.

  Sep 16, 2023     Touch up paint tail and counterweights - (2.5 hours)       Category: Fuselage

Fifteen minutes of touch up yellow paint on tail (due to blue over-spray last year) and repainting flaperon counter weights. Counter weights will need another coat or two but I think the tail will be OK with just one coat to hide the subtle blue over-spray. As usual, not much tme spent on painting but well over 2 hours for prep and cleanup. Still have to re-paint top cowl and lift struts.

  Sep 15, 2023     Quarter windows - (2.0 hours)       Category: Fuselage

Paper pattern then cutting of triangular windows went fairly quick but final fitting took awhile. Haven't decided yet how I'll secure them to frame.

  Sep 14, 2023     Glare shield, flaperon counter weights - (2.0 hours)       Category: Fuselage

Only a few cuts and trimming. Yeah....right... 4 hours of cutting trimming and fitting. Also spent 2 hours cleaning off the messed up paint job on flaperon counter weights using Xylene....my hands felt "wonderful" afterwards.....now ready for repainting.
Got contact to do drilling and welding for O2 sensor for exhaust from ex-patient (Rick Lomeli). Was told to try West side welding in Canutillo on Chanate Rd.

  Sep 13, 2023     Windscreen, lower cowl fitting - (12 hours) Category: Fuselage

Several work sessions over several days fitting windshield to cockpit, Drilling and up drilling all holes for windscreen/skylight. Also drilled and fitted camlocs for lower cowl. Updrilled lower holes on front cockpit pillar for boot cowl and installed clip nuts. Riveted nuts would have been more secure but once installed, I don't intend on removing boot cowl but once a year for annual condition inspection. Did initial fitting of turtle deck by providing clearance for aft cross spar. Can't do much more until wings fitted. Still waiting for decal install. All simple jobs, but like everything else, took forever

  Sep 02, 2023     Test grip doesn't fit either - (2.0 hours)       Category: Fuselage

As stated previously, I had an interference problem between pilot stick grip and G3X panel/knobs. I had spent couple of hours about 10 days ago researching grips and found one from Pioneer Control Grips that looked like it might work. Skylar (owner/builder/maker of grips) was kind enough to send a test grip to try out. I took apart the rest of the broken acrylic panel and shoved all the wires back, mounted panel and G3X unit. Still interference. Packed up the grip and will return next week. Sent a note Gary Phenning in Washingtion asking what grips he used and how avoided interference. About an hour or so later, the thought hit me. I went back to plane. Put my original wired grip back in then adjusted the limit screw for down elevator to prevent the stick from contacting panel. Only had to back out scew maybe 2.5 mm or so. That will change the maximum down elevator I can achieve per instructions in build manual but since I don't have a tail dragger, I don't need strong down elevator to raise the tail. Will see what Gary has to say but think I'll go with my "cheap/cheat" fix.

  Sep 01, 2023     Lift strut fairings - (2.5 hours) Category: Fuselage

Started cutting fairings for left lift strut. I had previously fitted jury strut to mounted wing and marked spots on lift struts for jury strut bracket placement. Also recorded distance to brackets from bottom lift strut attach hole. When comparing measurements the other day between left and right lift struts, there was a significant discrepancy (about an inch) between left and right. After considerable time and even remounting lift strut onto upturned wing on saw horses, I found the issue and corrected a couple of measurements. The differences have to do with different lengths between wing jury strut tabs and the top spar pin holes on left and right side of about 1/2 inch over all and difference between spare hole and aft jury strut tab lengths between two wings about about an inch. I think all good now and jury strut brackets, worse case scenario, wont be off more than 1/2 inch inboard/outboard from "ideal".

  Sep 01, 2023     touch up paint, door lift brackets - (2 hours) Category: Fuselage

Spent some time on odds and ends. Drilled holes for the door gas strut anchors and also brackets to mount on door frames.

  Aug 31, 2023     New pilot control stick - (1.5 hours) Category: Fuselage

Decided to fit my new control stick onto the mixer stub in cockpit with already drill mounting holes......holes hidden when new control stick in place. Took 1.5 hours to figure and accomplish a new through hole for new pilot stick.

  Aug 24, 2023     Cockpit items - (8 hours)       Category: Fuselage

Was reading on Team Kit Fox about lift strut fairing install. I'm suppose to add sheet metal cuff at bottom but a lot of folks just used SuperFill and forewent the sheet metal cuff. OOOPS!! I had already done several cuts in anticipation of using sheet metal cuff.....guess I'll use the sheet metal cuff. I rough fitted leading and trailing lift strut bar fairings and carefully bent the pre-cut (and primed) sheet metal cuff. I think it will work just fine.
Trimmed sanded the repaired windshield edge and re-installed to fuselage.....fits like a glove everywhere it is supposed to. Drilled and clecoed all vertical and boot cowl attach points. I want to mount wings and see how they fit before mounting windshield on top and turtle deck edge. Also still need to fit instrument panel.
I have order a test pilot grip from Pioneer grips to see if it will work in my install. Photos/diagrams sent to me by Skylar seem to show it will fit.....it better.
Scuffed, etched and alodined the panel then used a white primer. For avionics rack, I only cleaned well with alcohol and used a white primer ("sticks to everything"). I mounted avionics rack to panel with flush pop rivets and then used Superfill on the pop rivet heads for avionics rack and glare shield riveted tabs. While I had extra mixed SuperFill, I used it on the boot cowl for holes from air vents and NACA duct defects.
Had started to cut fairings for left lift strut but the measurements are off 1 inch compared to right side. Some of marks on masking tape still on lift strut bars don't match measurements. Before cutting/fitting any more. I want to mount the wings to check/confirm jurty strut position and how first rib fits to butt ribb.
In meantime, will work on sanding.

  Aug 23, 2023     Windscreen, lift struts, panel - (5 hours) Category: Fuselage

Ordered a bunch of tinnerman nuts and sheet metal screws to mount floor boards, console panels and glare shield. Mounted the glare shield tabs to panel. Trimmed the windshield where I add hysol to edge. I'm a little shy in areas and added more Hysol with scrap acrylic to trap proper amount of Hysol for window thickness. Pulled out lift struts and lift strut fairings and laid on table to study all. Quite a job to open the trailing edge snap channel. Worked on right lift strut and tried to determine how to work around jury strut clamps on lift strut. Decided to use measurements previously recorded on lift strut for proper position of jury strut clamps. Then decided to cut separate sections between upper and lower portion of strut split at jury strut clamp.

  Aug 22, 2023     Panel - (2 hours)       Category: Fuselage

Spent time drill holes for instrument panel tabs used to mount glare shield. Also spent time figuring how to mount/secure to these tabs. Researched and ordered basically some Tinnerman nuts. There will not be a lot of on/off with these attachments and strength not necessary. Decided to get similar attachment for the floor boards and panels instead of just screwing into hole in thin metal.

  Aug 22, 2023     Winshield, panel - (1 hour) Category: Fuselage

While on my walk this morning, I came to the conclusion that I could use some Hysol to bond to over-trimmed edge of windshield. I put windshield back in and secure well into place with clamps and added Hysol to the edge. Hope it works.

  Apr 03, 2023     Doors fitted - (14 hours)       Category: Fuselage

Spent several sessions working on final fitting of poly carbonate door panels to door frame. More door frame fitting, more clear panel trimming, drilling door frame and acrylic panel for mounting screws. Also mounted the hinges I had cut and fitting a couple of years ago. Found some spring pins to fit the hinges so I can pull hinge pin and doors come off. was trying to final fit the gas door struts and attachments but wings have to be on....not there yet.

  Oct 24, 2022     Windshield install practice - (1.0 hour) Category: Fuselage

Went ahead and drilled holes to mount the cracked window.....for practice. I want to be "expert" when I install new one.
I've been fighting a cold/laryngitis for over 5 days. My head still doesn't function well yet but getting better.

  Oct 12, 2022     Windshield cracked - (2.5 hours)       Category: Fuselage

Spent several hours screwing up my windshield. I cracked the top right co-pilots corner....twice. Then trimmed too much off of the vertical post area so when windshield contacts boot cowl, there is not enough to grab when securing vertical sections to the vertical posts. Oh well......only money....a LOT!! for a new one and then have to wait for it..

  Oct 02, 2022     Oil door on upper cowl - (5.0 hours)       Category: Fuselage

Spent most of the day trimming, fitting and sanding oil door to fit into indent. Cut out opening into upper cowl and then trimmed and smoothed edges. More time to trim for hinge to fit. Trimmed hing and drilled holes in cowl and door to fit hinge. Had to do a little body fill to get door to fit better. Day or so later, drilled and fitted Camloc receptacles

  Aug 17, 2022     Hard fuel lines - (5 hours)       Category: Fuselage

One of the things I had been dreading and concerned about was the hard fuel lines from firewall to header tank. I keep putting off and finding other things that "prevented" me from working on it. FINALLY, I decided to work on just one short pipe connection which led to another and another. Got the hard lines put in the cockpit running under console, under knees of co-pilot and down right side cockpit nearly on the floor. Only couple of screw ups.

  Jul 17, 2022     Various task - (5 hours)       Category: Fuselage

Worked on several little items that need to be done before many projects come to completion. Worked on engine mount, firewall, side panels for console, bought paint stripper, assembled battery box, bent mounting band for antifreeze overflow bottle, sanded nose gear piston to allow friction washers to slide, filed nose gear piston bearing to fit into top nylon piston washer, removed powder coat on upper end of nose gear piston to allow fit into nose gear bearing. Using MEK overnight to help remove powder coat from bearing fitting bushing on nose gear and engine mount. Will still need to file down bearings to get them to fit. Removed console to bond fabric covering before final install. Need to do that before I pressurize the brake lines and start installing hard brake lines.

  Jul 14, 2022     Up drilling holes firewall - (2.0 hours)       Category: Fuselage

Up drilled all holes on bottom of firewall rudder assembly nut access with tapered stepped hole drill. Holes ended up close enough to see the nuts but if have to be removed, the holes will need to be enlarged. Had to pull the firewall off because of difficulty drilling the SS.

  Jul 13, 2022     Battery Box - (2.0 hours)       Category: Fuselage

Worked on figuring out battery box assembly, drilled some holes and treated the aluminum for painting. Got some temp bolts for mounting engine mount to firewall and another can of paint for the battery box.

  Jul 13, 2022     Firewall - (2.5 hours)       Category: Fuselage

Spent time on various, scattered projects jumping job to job. Most work time spent on figuring holes to be made into firewall. 1-2 hours to figure out where the holes go then about 30 minutes drilling pilot holes. Holes for fuel lines, holes for battery box, holes on bottom to access rudder pedal assembly mounting nuts.

  Jul 03, 2022     Brake lines and firewall - (6.0 hours)       Category: Fuselage

Worked on running brake lines from parking brake to calipers. Heat formed brake lines as needed to lay flat under seat and also to fit from gear leg to top of brake caliper and allow caliper to be removed easily without disconnecting brake lines. Also redo a couple of lines under rudder pedals and removed all the zip ties I put in. Zip ties created too much stress on the fittings causing passive fittings for several lines to fail. I did use ample vinyl tubing to protect the brake lines from the very limited potential chaffing.
After replacing a couple of brake lines.....I think I'm happy now with all brake lines....I torqued the compression nuts for the 8 fittings under rudder pedals then replaced the firewall. I had the cabin heater coolant connectors and firewall corners held on with clecos. I replaced with pop rivets and sealed with red RTV silicone.

  Jul 02, 2022     Brake lines - (6 hours)       Category: Fuselage

Another "simple" job that took forever. I had done some preliminary fitting of brake lines but wasn't sure how the slack would work with firewall in place.
I re-installed the rudder and connected to rudder pedals and got a more accurate vision of needed slack for brake lines. To minimize tube length and avoid tight bends with the stiff tubing, I used a hint from TeamKitFox per John McBean to put a wire into brake lines then heat carefully to bend to desired shape and remove wire when cool. Wire in tube prevents kinking when heated/bent. I was able to run much shorter tubing and minimize chafing with custom fitted bends on tubing.
Tried mounting brake fluid reservoir but predrilled holes don't match so will have to enlarge holes. I want to charge the brake lines and test them before perm attaching firewall and engine mount. I also want to get all holes drilled into firewall before it is mounted so will need a lot of research for engine install to determine what I need next.
During a break, I went to TeamKitfox again to see how folks ran brake lines under the seat and found good photo of how lines are best connected on master cylinders. Soooo.....I went back into garage and completely re-routed everything I had already done...2-3 times previously...and now for fourth time, I'm much happier with the layout with all lines running along the bottom. I have pictures of "before" and "after" re-routing lines. I believe it was worth the effort, much less strain on some of the connections. I just did a loose fit of tubes into their fittings and worked rudder pedals at extreme limits of movement and now none of the lines pop out of their loose fittings....a sign that nothing is tugging. I found some clear, vinyl tube just big enough for brake lines to fit inside for use as chaffing protectors against some of "pokey" things at base of rudder pedals.

  Jul 01, 2022     Firewall and boot cowl - (6.0 hours)       Category: Fuselage

Worked on initial fitting of boot cowl onto firewall. Also re-mount rudder and re-attached rudder cables to better visualize slack needed for brake lines and clearances with firewall attached. Got the firewall mounted the other day and rough trim on boot cowl (almost too much trimmed off). Also pre-drilled holes in forward door frame for the mounting of boot cowl. Today, i tweaked the bends on the firewall to better match to shape of booth cowl, secured the rough trimmed boot cowl, clipped to fuselage, took my measurements, then back drilled door frame holes into booth cowl. I removed boot cowl and did final trim. Then pulled the firewall and started drilling for through-fittings for cabin heater and for riveting the triangle piece for foot well on firewall.

  Jun 30, 2022     Boot cowl - (4.0 hours)       Category: Fuselage

Worked today and some yesterday to build a simple "hole finder". Simple concept but took almost 2 hours to make the first one....only to be too short. Second one (longer) still took more than an hour (screw up or two along the way). Spent an hour reaming holes for the firewall. Today, worked on drilling holes in door frame to mount the booth cowl. Next step is to mount the boot cowl and adjust firewall flanges to boot cowl.

  Jun 29, 2022     Odds and ends - (5.0 hours)       Category: Fuselage

Found couple of more unpainted parts for cabin heater that I had to paint. Worked on getting brackets drilled for nut plates and holes drilled for mounting brackets. Eight pop rivets to mount bracket and I screwed up one of those. Then needed 4 pop rivets for the nutplates and screwed up 3 of the four. Got them fixed with a hammer and small anvil to smash the pop rivets. Then reamed the five engine mount holes in fuselage to be able to temp mount the firewall to be able to mount/fit the boot cowl
Everything is taking 3-4 x amount of time that it should. Frustrating

  Jun 28, 2022     heater - (3.0 hours)       Category: Fuselage

Pulled out the box with supplies to install the heater. I'm trial fitting several parts in preparation for fitting firewall and boot cowl. I'm missing two long bolts for assembly. The package only had protective sleeves and no bolts. I'm sure I checked off inventory but was only checking off inventory control numbers on bag and not looking and description of what was to be in the bag. I need 2 x 10-32 x 4 inch bolts...none to be found in town....ACSpruce help needed.
Found parts, cut and drilled as needed and then primed/painted with rattle cans.....except for two made mounting brackets I forgot about.

  Jun 27, 2022     SS door channel install - (2.5 hours)       Category: Fuselage

Here was another simple job to install SS door channel to protect wear to fabric on bottom and lower back door frames for getting in and out of AC. Only had to fit 4 pieces. SS is VERY tough to cut even with 8,000 rpm air driven cut off wheel. All pieces fit quite well and holding nicely with just friction fit.

  Jun 25, 2022     Fuel tank R&R and paint - (1.0 hour)       Category: Fuselage

Removed and re-installed the header tank to paint the tank. Done amidst other tasks. Not sure tank needed painting but easy to remove and do it now.

  Jun 25, 2022     Several little projects - (5.8 hours)       Category: Fuselage

Figured out parking brake and temp installed. Installed most of brake fittings using Permatex thread sealant. Worked on cutting brake lines and figuring out how much line I needed to have enough for full pedal travel, tested heat bending Nylaflo tubing for 90 degree bend to fit through fabric to gear leg fitting, Also placed doillies for brake line penetration for conventional and tri-gear brake line fittings. Mounted rudder to allow fitting of rudder cables. Threaded rudder cables through fabric penetration port a bottom of tail. Installed the connector plates with the metal eye, fed the cable around the eye and pulled enough on the cables to remove all slack. Crimped on the swedge to hold the "eye" and used cold chisel to remove excess wire rope rudder cable.

  Jun 10, 2022     Paintlng Fuselage - (8 hours)       Category: Fuselage

Several hours over 3 painting sessions to, so far, cover about 1/2 of fuselage with 2 coats of Bahama Blue paint (SW Emerald Urethane enamel) sprays very nicely. Very good coverage. In process, primed and painted the quarter window trim with rattle can enamel, self etching primer and white, satin enamel for white base.

  May 30, 2022     Poly brush spray coats - (6 hours)       Category: Fuselage

Couple of work sessions to move items around in preparation for spray last couple of Poly Brush spray coats. Also fitted trim slat to aft opening of cargo bay. Secured with Hysol, trim filled with micro-fill to smooth margins. Then covered with fabric.
To date, have done first spray coat of poly-brush over about 1/2 of unpainted structures.

  May 26, 2022     Clean up and painting small parts - (12 hours)       Category: Fuselage

Couple of work sessions comprising clean up from months of fabric covering. Cleaning and epoxy priming using Stuart Systems 2 part Epoxy. Used double amount of the expensive paint that I needed....threw away $25+ of paint not needed/used during 4 hour pot life. Paint went on smooth. Then following day, painted the parts with either white, rattle can enamel or the SW Bahama blue paint for parts to be used on fuselage. Multiple inspection covers remain white until I pull out the yellow paint.
Bought some additional tarps to cover parts in garage until their turn to be painted.

  May 25, 2022     Prep for small parts alodine Tx - (4 hours)       Category: Fuselage

Multiple small parts rounded up to paint: Door hinge, Instrument panel tabs, inspection plates, aluminum angles, grove landing gear, gear mounting blocks, tail inspection plates.

  Apr 21, 2022     Filing parts - (4.0 hours)       Category: Fuselage

I went through my box of uninstalled parts and pulled out remainder of metal pieces. Spent a couple of hours and filed smooth sharp edges in prep for primer coat of paint. A couple of days later, I cleaned/etched metal and treated with alodine chemical in preparation for 2 part epoxy primer. Some of these will need to be cut and shaped before use.

  Mar 27, 2022     Finished finishing tapes - (6.0 hours)       Category: Fuselage

Spent about 1.5 hours marking placement for the finishing tapes. Then following day, spent 5 hours applying finishing tapes....went faster than I thought it would. Will allow drying overnight and then iron all tapes.

  Mar 25, 2022     Fuselage covered - (3 hours)       Category: Fuselage

Finished all covering of fuselage on all sides and tapes done on top and both sides leaving bottom covered but no finishing tapes...yet. All seams were ironed and second coat of Poly Brush applied to all tapes. Only bottom still needs finishing tapes. Fuselage was turned from upright to one side. Jeanne is gimp due to her two broken legs so I attempted to turn fuselage onto its tail. Didn't quite make it before tail slipped off of the stool I had the tail resting on for last several months. Jeanne heard commotion of fuselage hitting floor and came running. She steadied the tail as I tipped fuselage the last 90 degrees up onto tip of tail.

  Mar 25, 2022     Razorback curve tape - (3.0 hours)       Category: Fuselage

Decided to work just a small segment of finishing taping in the curve of the razorback on top of fuselage. I had a hell of a time trying to bond and smooth the top fabric in the curve area. I thought that just working with a few inches of the tape right in the curve would make the process easier.....not so. I carefully bonded just the edges of the finishing tape one side at a time and leaving middle 3/4 uncovered with Poly Brush. My thought was I could heat shrink fairly quickly and end up with smooth tape that I would bond to lower layer with wet coat of Poly Brush. I still ended up with a mess!! Spent over an hour serially bonding the small fabric piece then spent well over an hour smoothing the 10" piece of finishing tape. Just like the fabric below, I only got smoothed out about 95%.....not perfect..but functional.

  Mar 20, 2022     Fuselage finish taping - (14 hours)       Category: Fuselage

Multiple hours over several sessions prepping bonded fabric for finish taping. Several hours bonding fabric, then ironing all seams. I rotated the fuselage using the legs bolted to firewall area of frame.

  Mar 17, 2022     Poly brush- brush coat - (7.0 hours)       Category: Fuselage

Multiple hours spent drawing pencil lines around areas where finishing tapes are to be embedded. Thought pencil would mark easier on bare fabric. Only took little over an hour to apply brush coat of Poly-brush.

  Mar 15, 2022     Fabric application - (12 hours)       Category: Fuselage

Several sessions to trim, attach, heat shrink fabric to fuselage and vertical stabilizer. Couple of times with large amount of bunched up fabric after bonding all edges. Left front side near bottom was one such area....able to iron out most all except for some tiny creases that should hide under finishing tapes. The worst was on curve of razor back just in front of vertical stabilizer. Can see from picture the disaster. I knew it would never work but continued to work on ironing. I was able to remove about 95% of wrinkles in the area but not able to get ideal shrinkage/tightness I would like.....but....was it worth ripping off and redoing 5-6 hours of work? Is it perfect?...NO Will I see the error?.....yes. Will other people see the error?......maybe. Will it fly OK?.....YES, definitely

  Mar 08, 2022     Drilling holes antenna and turtle deck - (1.5 hours) Category: Fuselage

Drilled holes for turtle deck mounted comm antenna....a degree or two off of exact midline....but not going to correct it. Read about needing to mount turtle deck plate on after end of baggage opening. Acquired some 8-32 machine screws, washers and nylock nuts. Started to drill holes to begin mounting Cam-locks to hold turtle deck window.

  Mar 07, 2022     Fabric and static port - (6 hours)       Category: Fuselage

Finished ironing out wrinkles on right side. Went quicker since I didn't have so many wrinkles. Went to turn fuselage to up right position and one of the legs on the firewall wooden turning frame split vertically. Had to stop all and figure out repair. Able to replace split board fairly easily....purchase took longer than repair.
Also worked on parts to make the static port. Cut round disc from aluminum stock, filed and back drilled holes. Then cleaned and alodined all aluminum parts. I boogered up the process of installing round plate on static port and had to do a new one. First one took me well over an hour and then another hour to figure out assembly. The re-do only took about 30 mintues total and about 5 minutes to install. Glued assembly to fabric after using Poly Brush on small area. Then after dinner, applied a doily on inside and will place another outside when all other finishing tapes applied.

  Mar 01, 2022     Covering right side - (5.5 hours)       Category: Fuselage

Did much better getting fabric laid out on right side of fuselage and edges cemented down with only very minimal bunching. Only slight amount of ironing needed to correct wrinkles on this application. Got fabric cut, laid out, edges cemented, then overlap cemented, wrinkles ironed out. Tomorrow will work on heat shrinking and making static port attachment.

  Feb 28, 2022     Covering left side - (8 hours)       Category: Fuselage

Two work sessions split by probably last trip for decent skiing at Ski Apache. Covered left side. I messed up getting initial fabric sealed down around door frame and ended with LOTS of wrinkles on left side bottom aft of lift strut attachment. LOTS of 250 degree iron pressure (per Poly Fiber manual) eliminated 98+% of wrinkles. Final heat stretching smoothed everything out. Only wrinkle defects remaining hopefully will be covered by finishing tapes.

  Feb 22, 2022     Covering bottom of fuselage - (12 hours)       Category: Fuselage

Twelve hours over several days.
Last bit of sanding fill, cleaning before covering. Set up tables. Re-read Poly Fiber manual for covering. Arranged chemicals, Bought more 1" brushes (need more). Only have 1/2 of one can of Poly Tak...will need another can. Spent 30 minutes trying to arrange fabric on bottom then marked for rough trimming. Started by tacking down front portion under rudder pedals and then tried to evenly stretch and tack down fabric around edges. Then went back and trimmed to have about 1.25 inch fabric passed tacked area to wrap around tube. Then spent about 2 hours ironing to 250, removed all wrinkles, then 340 shrink. Came out fairly decent.

  Feb 16, 2022     Pre cover for fuselage phots - (1.0 hour)       Category: Fuselage

Multiple photos of fuselage (upside down) prior to covering showing wiring and routing of wires. Then fabric roughly cut out and clipped to fuselage just before trip to Copperstate Fly-in in Buckeye, AZ to west of Phoenix for 4 day trip.

  Feb 09, 2022     Fuel header tank install - (2 hours)       Category: Fuselage

Installed fuel fittings into fuel header tank. Had to pull out tap set to enlarge threads into header tank to allow at least 3 turns of fitting engaged with fitting bung.
Then installed header tank on fuselage.

  Dec 23, 2021     Txponder antenna holes - (2.0 hours)       Category: Fuselage

Measure twice (no three times) but still drilled too big of a hole in fuselage bottom mounting plate for transponder antenna. Drilled second, correct size hole and patched first one with Hysol and sanded smooth.

  Nov 12, 2021     AP servo for roll installed - (1.0 hour) Category: Fuselage

Use Rust-o-leum self etching primer and Semi-gloss enamel spray (rattle cans) to paint the aluminum bracket to mount the AP servo. Finally placed required rivets after painting and then bolted on the servo. Re-installed roll servo and did preliminary adjustment for AP servo arm limiter. Seems the 2" actuator arm is too short. Need to order the 3" arm to accommodate the required movement of control stick and flaperons.

  Nov 12, 2021     Elevator rod interfence filing - (2.0 hours)       Category: Fuselage

More filing after I turned fuselage upside down.

  Nov 11, 2021     Fuselage turner contraption installed - (1.0 hour)       Category: Fuselage

Installed fuselage frame turning contraption to firewall. Then next day, turned fuselage upside down. Cross bars (side to side) need to be longer to prevent boot ribs from contacting ground when turned.

  Nov 09, 2021     Trim off interference for elevator push rods - (3.0 hours) Category: Fuselage

When adjusting the rod lengths per instruction manual, I determined there was an interference between the front elevator control rod and bracket for center seat belt attachment. Significant filing need on both pieces. Got tired and quit today with about 90% of adjustment filing completed.

  Nov 08, 2021     Adjust push rod length - (3.0 hours)       Category: Fuselage

Spent several hours just adjusting push rod length to obtain proper control stick, rod, elevator and aileron control placement/position with horizontal stabilizer and elevator mounted. I had already spent time reinstalling the trim actuator and re-confirming actuator extension limit and horizontal stab position to proper starting position. I then determined that thin tab bonded to posterior horizontal stabilizer designed to press on trim position sensor was inhibited from moving freely when horizontal stab was placed in full nose down trim. I determined about 4 mm of material on central square tube used to support bearing for horizontal stab needed to be relieved. After control rod adjustment done and tail surfaces removed, I quickly trimmed off small portion of square tube coming from fuselage frame.

  Nov 05, 2021     Trim motor painting and refitting - (3.0 hours)       Category: Fuselage

Trim motor extension rod had rusted from high humidity this summer. I had removed the trim motor with intentions of paining the bare steel extension rod....that was several months ago. Painted the bare metal with self etching primer and white satin finish enamel. Then reinstalled the motor and checked adjustments done almost a year ago. Found that tab on horizon stab that actuated trim indicator rheostat was hanging up on horizontal stab extension. I need to trim several mm's.

  Sep 20, 2021     prep and Poly Brush spraying - (6 hours) Category: Fuselage

Spent couple of hours doing final prep and getting all set up for spraying Poly Brush. Used Poly Brush reducer to remove some of thick Poly Brush and drips.
I agonized doing the spraying but actually went quite well....no visible runs or drips. Did medium coat and heavier coat today and repeating same tomorrow.
Only took about 15-20 minutes to actually spray wing. Used about 2 qts of reduced for each coat of spray for total of about a gallon.

  Sep 18, 2021     Taping and ironing - (10 hours)       Category: Fuselage

Spent about 10 hours over several work sessions to work on place width wise finish tapes on leading, trailing edge and top of spar tapes. Also covered top of wingtip rivets. Then hours smoothing tape edges, lumps and bumps

  Sep 14, 2021     Door hinges - (6.0 hours)       Category: Fuselage

Went over to former patient's house, Niel Gunn, and had him cut the supplied hing material into pieces per the plan then spent hours and hours hand filing to smooth. Got basic holes cut. Was going to mount door hinges and clear door skin but I want to add some "door channel" aluminum to door threshold to prevent wear on fabric covered edge. Not sure if that added thickness will affect the door frame fit I have now or not. Regardless how I go about it, I still have to remove and then re-install temp fit door frame (which I was trying to avoid). So door frames will come off and stored until after fuselage covered.

  Jul 22, 2021     Fitting left door bubble - (3.0 hours) Category: Fuselage

Fitted left bubble door to frame and drilled 3 holes to center again after fabric covering. Won't finish sanding/smoothing edges until final fit after fabric installed and door channel fitted.

  Jul 18, 2021     Door frame fitting - (3.0 hours)       Category: Fuselage

Fitted both door frames by slightly bending to get best fit. Drilled holes in frame for securing bubble door panels. Secured frames into door with hot glue and wood wedges.

  Apr 13, 2021     Side stringer fitting - (2.0 hours)       Category: Fuselage

Fitted right and left side stringers and drilled holes for pop rivets

  Apr 09, 2021     Butt rib and closeout - (7.0 hours)       Category: Fuselage

Spent most of the day working on the right butt rib and butt rib closeouts for L and R. Yesterday I messed up mounting the butt rib, as I finished back drilling the butt rib through the butt rib brackets, I noted that when temp mounting the butt rib to #1 rib that things shifted (dropped) and the rib cap on butt rib was almost 3 mm lower on aft end than it should have been. Only thing to do was pull everything apart and start over for the third (maybe fourth) time. Of course that meant more holes in butt rib that are very close together after adjustment. I'll just fill the holes with epoxy when pop-rivets placed......than all should be good.
I just did all the same on the left side just 2.5 months ago.....a lot of water under the bridge and I had already forgotten how I did things before.
Fitted the butt rib closeouts and cut slots for the butt rib mounting tabs that come off of top of door frame.
No photos.....yet

  Apr 01, 2021     Fuselage cockpit area - (6.0 hours)       Category: Fuselage

Finally started on some projects on the plane. Had seen about interference of seat buckles anchors and header tank on co-pilot side. Spent hour or so sorting out the issue. No picture taken but did bend out the seat belt attach bracket on both lateral sides. Able to see how header tank would mount and seat belt buckle would play together. Adjusted so all would play nicely. Back drilled head tank tabs so tank ready to mount. Still need to place hose fittings and adapt fuel sump drain tubing.....have to find the parts first.
Fitted and set the nut plates to secure the seat pan. Nut plates with pop -rivets went fairly quickly and smoothly after I figured out how it was suppose to work and how to drill for the rivets.
Also bonding side door and window frames/sills for the right side. Left side metal is already fitted from some time ago

  Jan 23, 2021     Autopilot servos - (3.5 hours)       Category: Fuselage

Tried in mounting brackets for auto pilot servos. Mounted and installed pitch servo and adjusted mechanical limit frame to allow full movement of pitch push rod.
Secured servo mounting bracket to frameowork with 5 small screw clamps. One clamp was enough to firmly secure bracket so 5 is overkill. Roll servo mounts to aluminum bracket which needs to be riveted to plate on airframe. Worked to get roll AP servo all set up ready for final mounting after installation of mounting bracket. Have to treat and prime the aluminum bracket before installation.
Each servo and installation hardware weigh just short of 2 pounds. With wiring, total weight will be about 5 pounds.

  Jan 23, 2021     Tail access covers - (2.0 hours)       Category: Fuselage

Initial fitting of tail access covers. Instructions are not clear and somewhat contradictory. Not totally clear exactly where/how to cut and rivet after portion. Trying to figure out how many cuts needed in covers to allow easy application and removal. Only did cuts I am sure about and riveted support patches....exactly the same on both panels.....oops...should have been mirror images. Drilled out most of wrong rivets. Left one to hold patch in place so not lost. Have to re-order the small aluminum rivets to do a repair....3 minute job. Will do final fitting after horizontal stabilizer back on plane for final assembly.

  Jan 22, 2021     Fitting of console side panels - (2.5 hours)       Category: Fuselage

Trimming and fitting of side panels. Adjusted the panels for bottom edge to fit between wood flooring and fuselage mounting tabs.

  Jan 21, 2021     Pitot fitting - (1.5 hours)       Category: Fuselage

Fitted Garmin pitot into pitot extension. Fitted extension through wood fitting. Found where on wing for Pitot fitting to go and removed neighboring Hysol to allow good fit in proper position.

  Jan 21, 2021     Trying in seat pads and interior trim - (1.5 hours)       Category: Fuselage

Spent some time after initial fitting of console side panels placing carpet, side panels and seat cushions to try them out. Found that seat cushion too thick and puts my head near aft carry through spar. Will need a thinner cushion.

  Jan 19, 2021     Brake master cylinders - (1.5 hours)       Category: Fuselage

Simple enough install of brake master cylinders on all rudder pedals.

  Jan 07, 2021     MIsc small jobs - (3.0 hours)       Category: Fuselage

Door latch block, re-drilled Jury-lift strut brackets, drew cut lines for door hinges,

  Jan 06, 2021     Door frames - (4.0 hours)       Category: Fuselage

Finished fitting door frames. Not perfect fitting around welds but Super Fil will cover all defects.

  Jan 05, 2021     Door frame trim - (3.0 hours) Category: Fuselage

Finishing trim fitting on right side and started fitting on left side. Did some cleaning, organizing to get restarted on build after 2 months off for Thanksgiving visit, Falcon Virgo with scanner/observer training beforehand to have enough crew and Wreaths across America.

  Nov 09, 2020     trim motor - (6.0 hours)       Category: Fuselage

Simple job. Only four bolts and multiple washers. Well......wasn't that simple. Took awhile to get my head wrapped around the mounting and ALL the washers. Had to clean, sand and paint some scissors hing parts. Some tabs had some holes (that I missed early on) that needed reaming to bolt size....easy enough.....had I reamed them BEFORE bonding in horizontal stab ribs. Now limited (actually, NO access). Two special trips to Lowe's (first drill wouldn't cut), second drill wouldn't reach one hole. After 2-3 hours, I resorted to Amazon order to get a 12" drill to drill ONE hole. My left fore finger points to offending hole.
Got the trim motor installed. Very tricky trying to get bolt, holes, and washers all lined up at same time. Pulled out a battery charger and got the trim motor to run up and down......YEAH!!

  Nov 09, 2020     Rudder pedal assembly install - (2.5 hours)       Category: Fuselage

Rudder pedal assembly has been finished for several weeks. Decided to install the assembly because it already "fit" and would only take 10-15 minutes to install and check off......NOT!!!. One of the brackets, master brake cylinder bracket, had too much lateral pressure when all nuts for assembly snugged up. Lateral pressure torqued the rudder pedal assembly to point that NONE of the rudder pedals, left nor right, would move hardly at all. Had to remove most of nuts to loosen bolts and remove the brake cylinder bracket in middle of assembly on each side and file to fit, file to fit, file to fit, file to fit.........2.0 hours later, they fit and bolts just dropped into holes. Rudder pedal assembly installed. Fifteen minute job only took 2.5 hours.

  Nov 08, 2020     Rudder cable - (10 hours)       Category: Fuselage

About 10 hours of work over couple of days. Rudder cable runs through several fittings welded to frame. Nylon tubing inserted into the fittings to re-direct cable path under seats and luggage back to tail. Tubing was shipped all coiled up and even cutting into small pieces left all pieces with curves that didn't fit into fittings. I used a hair dryer to warm the tubing and then pressured tubes to become more straight. Finished bonding false ribs onto last wing and used left over epoxy to bond in the tubing to fittings.
Next was to cut the wire rope (cable) into four pieces, manufacture terminating eyes that attach to adjustable rudder levers, then route cables through guide fittings to the tail. It was pretty but manual said could use a cold chisel and couple of hammer whacks to cut the cable. I had a piece of RR rail in side yard that Scott brought home many years ago that I occasionally use as an anvil. First practice cable cut worked perfect, but each additional "real" cut was worse and worse. Finally looked at the tip of the cold chisel and realized that the temper on the RR rail was much higher than for cold chisel. I was trying to "cut" the cable with a cold chisel with flat tip. Got out my hand file and re-sharpened the cold chisel and found a large rock to use as cutting anvil. Worked pretty well.

  Nov 03, 2020     Rudder pedal assembly install - (3.5 hours)       Category: Fuselage

Now that I have the console finished, I looked to complete the cockpit area completion of install. I didn't know if I would need to remove things or not so I have used temp nuts or not torqued down real ones as yet. I started with the rudder pedals which I thought would take 5-10 minutes to install and torque nuts. It did only take few minutes but then pedals wouldn't move well. I determined a master brake cylinder bracket was the issue and had to loosen assembly to remove the small brackets and file to fit and file and fit and file and fit and file and fit....you get the idea. By golly, 3 hours later, they did fit and rudder pedals work great.

  Nov 02, 2020     Console riveting of flaps, rudder adjustment - (2.0 hours)       Category: Fuselage

Finally took delivery of a 100 degree counter sink drill.....very hard to find. Did the counter sink on top of console and riveted into place. Thought I had lost two screws and corresponding spacers for the brackets. Very carefully cut down an aluminum spacer I found at Lowe's and got it perfect. When assembly parts for try-in, all of a sudden I had extra parts. Thought I needed 8 screws and spacers but only needed 6.

  Oct 02, 2020     Rudder pedals assembly, pulleys, LIft strut brackets - (12 hours)       Category: Fuselage

$105 for odds and ends. Hydraulic pop rivet puller. Paint cup, paint strainer, counter sink drill, IR laser thermometer (finally back in stock after COVID run).
ABout 12 hours over several days finishing Rudder assembly install. Alodine, Stewart system EcoPOxy primer on console, rudder and flap adjust ratchet brackets, hold down brackets for rudder assembly. EcoPoxy went on very blotchy with foam brush. Did top coat with Rustoleum white enamel which made it look better. Placed rudder pedal assembly and drilled holes. Then back drilled through floor board. Temp mounted assembly and placed screws to verify fit and function. Removed and stored parts under final assembly.
Rudder cable pulleys under back of front seat installed. Vertical stabilizer forward wood bulkhead fitted and metal angles for access panel fitted but not yet drilled.
I had neglected to varnish the tail bulkhead earlier so now done along with small stringers used to stiffen ribs. Now all wood varnished and ready to glue and bond to vertical stab and rudder.
While waiting for varnish to cure, I pulled down a wing and fitted lift strut brackets. Had to drill a LOT of holes but with new, sharp drill, drilling went quickly. Have to pull SS pop rivets, 160 plus. My hand were tired after pulling 9 rivets on the rudder tubes so got a hydraulic rivet puller. Harbor freight had one for about $45. Brought it home and attempted to activate it. Had to put in some hydraulic fluid. Didn't know I needed it. Had some old brake fluid so used that. I mis-understood directions about where and how much fluid to put in. I thought it needed about 6-8 oz. only needed about an oz. the other 5-7 oz of fluid ended up all over the floor. Brake fluid attacked the garage floor paint. Wing strut brackets for left wing are ready to install.

  Sep 24, 2020     Rudder and Flap adjustment bracket - (10 hours)       Category: Fuselage

Long layoff from construction due to work on instrument rating. Failed first check ride and barely passed second try. Did better on flight on my own couple of days later.

Spent about 10 hours over 3-4 partial days of work to adapt adjustment brackets for rudder length and flap setting. Also treated pre-fabricated aluminum parts for rudder pedal assembly and flap/rudder adjustment with cleaner and alodine solution. Have fitted parts and dis-assembled to allow painting with Stewarts system of 2 part, water base epoxy primer.

IR thermometer finally back in stock after COVID-19 caused a run on thermometers. Acquired IR thermometer to calibrate iron for fabric heat shrinking while in stock for now.

  Jul 28, 2020     Rudder pedal assembly - (6.0 hours)       Category: Fuselage

Bought some "C" clamps for portable vise and other uses. Also got 7/16 clevis pin and wood dowel to try to use to wet sand brake pivot tubes. Glued some used 400 grit paper glued to 7/16 wood dowel. Worked well to smooth inside of brake tube pivots after spending almost 2.5 hours filing the inside with a rat tail file to reduce enough for the rubber/plastic tubes that will be pivot and bearing for brake pedals.
Drilled and pop-riveted the outside pedals onto torque tube. Before pop-rivet, I used white grease to well lube all bearings for concentric rudder tubes and for brake pivots. Then placed blue masking tape to keep from losing plastic bearings until unit is installed.
Worked about 6 hours over two days to finish basic rudder torque tube assemly

  Jul 24, 2020     Rudder pedals - (12 hours)       Category: Fuselage

Hours listed for this period were done over several days/sessions.
Picked up a right angle drill as I could not find a suitable Dremel tool. It worked quite well. Spent MANY hours sanding off powder coat off of metal tube exterior and interior, sanding down outside plastic bearing. Not much visible progress but a LOT of work to get concentric rudder tubes and bearings to operate smoothly. Other builders post said this is critical to get right for rudders to function properly down the road.
Someone suggested a brake cylinder reamer to remove powder coat inside tubes, but didn't work well. The right angle drill worked better than the old Dremel tool I got from Bill LIvely. Used coarse arbor bands on mandrel to clean inside of tubes. Used sand paper strips for belt sander by hand to reduce diameter of outside bearings and paint removal from tube exteriors starting with very coarse grit. Use of gloves allowed more pressure to be placed on sanding strips without hurting hands and prevent overheating of bearing. Got all parts to move smoothly working over several days.
Spent about $45.00 for right angle drill from harbor freight and some 1.0" wide sanding belts in coarse and medium grits to remove powder coat.

Not much progress as I have been focusing most on flight training for my instrument rating. Also Jeanne recently with hand surgery for ruptured tendon and not able to cook. So not only learning to fly on instruments but also learning to cook again. Once Jeanne is healed and I've done my instrument check ride, then can work full time on plane.

Recently watched EAA webinar on painting plane with house latex paint. As crazy as it sounds, think I'll do it. No fumes, no spraying, no paint booth, $2-3000 cheaper than "official" paint for plane.

  Jul 07, 2020     Floor boards - (1.5 hours) Category: Fuselage

Spent some time final fitting floor boards and back drilling holes. Also varnished (poly-urethane) what I had to grind to fit.

  Jul 05, 2020     Rudder pedals - (2.0 hours) Category: Fuselage

Revarnished some of vertical stab ribs that didn't look well covered/protected. Will recoat again tomorrow. Primed and painted the safety straps for rudder cable pulleys....not sure why other than protect metal....possible that the strap material is stainless steel and painting not needed. Four little pieces of metal strap to fit onto the rudder cable pulleys. Took 1.5+ hours to fabricate the first part to a successful fitting....only took 10 minutes to fabricate last of the four parts.
Have all the parts out for the rudder pedal assembly with instructions laid out. Trying to get my head wrapped around how all this fits together. Seems to be a LOT of powder coat to clean off and pieces to fit.

  Jul 04, 2020     started on rudder pedals - (4.0 hours) Category: Fuselage

Worked two sessions about 4.0 on rudder pedals. Finished rudder cable safety strap for adjustable rudder pedals. First strap took be about 1.5 hours to figure out how and what to bend strap over. Pounded strap flat to start over 2-3 times. Last of four straps took 10 minutes TOTAL. Started by rounding up all parts and pieces.

  Jun 22, 2020     Varnish for wood parts - (15.0 hours)       Category: Fuselage

Got about $10 worth of pain brushes. Spent 3 days and 15.0 hours mixing and applying two coats of varnish to all wood parts: flooring, wing ribs, tail feather ribs. Finished late this afternoon.
For past couple of weeks, Have been going to Donna Anna county airport for IFR training on Redbird Sim with Shane Lipson as instructor.....I'm struggling

  Jun 16, 2020     control column and mixers - (15 hours)       Category: Fuselage

Spent several sessions working on fitting and installation of control column and mixers for ailerons and flaps. Total of at least 15 hours over 3-4 days Control column was pain to get controls loose and smooth but not too loose. Installed and removed several times to get reaming and trimming of plastic bearing with metal bearings on right side of control column to work smoothly. Installed bearings for aileron/flaps mixer but neglected to install the pivot bolt during bearing gluing. Had to ream out the glued bearings to get the mixer to pivot freely.
Just as I finished installation, I had a COVID-19 CAP flight to San Angelo (in bed by 0200) then Bob and Arlee Emmott stopped by for 3 days to visit.....good time.

  Jun 12, 2020     control column and mixers - (15 hours)       Category: Fuselage

Spent almost 1.5 hours drilling two holes for pop river in elevator limit block. Ready to mount to fuselage.
Also received seat cushions and trim fabric. Received two part epoxy, and several other items for treating and protecting multiple aluminum parts with cleaner, alodine and epoxy.
One box from aircraft spruce had been cut open and contents inspect but I guess the thief didn't want paint.
We're gone for weekend when packages arrived

  Jun 04, 2020     Control tube and others - (9.0 hours) Category: Fuselage

Worked on control tube more. Tired of waiting for epoxy painted and sprayed 4-5 parts with rattle can self etching primer and riveted elevator stop bracket. For that part, had to use some well lubricated ����clamps to press in steel tubes into aluminum block. I calculated couple of hundred pounds of force using the screw clamp to seat the pins, suppose to drill through aluminum and steel tube and place pop rivet but drill wouldn't penetrate steel and slipped off. I don't thing the steel pin is going to come out. Had to relieve several bushing to accept the bronze bearing and flue them in. Then had to relieve inside of bearings to allow bolt and thin steel sleeve to pass through. Several small parts ready for final install on control tube. Nylon type bearing, lamp, anchor trimmed to fit and close to fitting control tube onto fuselage frame.
Started to fit some bearing into bosses 9n fuselage then left town to Ruidoso for several days. I believe paint mask came in along with epoxy paint. Now hope to spray and wipe varnish on a
L wood parts before assembly.

  Jun 02, 2020     Assembly and prep - (1.5 hours) Category: Fuselage

Picked up some files....round and half round for trimming. Used one of new files as soon as got home. Able to put all parts together for control yoke first part assembly. File allowed right control arm connector to "twist" into place. Bearings glued and bolts, washers and nuts loosely into place. Also round up parts bags for next several pages.
WAiting for epoxy primer and paint respirator to varnish all wood parts and prime aluminum parts for next many steps.

  Jun 01, 2020     More reaming - (10.0 hours) Category: Fuselage

More and more and more reaming for controls. Trying to get control links to fit. Ground the shit out of right control boss to make from for control link. Took an hour or so but finally got it early the next day. Tried glue in washers on control arm to simplify the fitting of rod end. Reglued 3-4 times. finally got all put together. Parts picture today and finished product in tomorrow's post.

  May 31, 2020     More reaming - (1.5 hours) Category: Fuselage

More reaming of horizontal stab. Used some 3in1 oil.....worked much quicker and smoother.

  May 29, 2020     Floor - (3.5 hours)       Category: Fuselage

Trimmed, fitted and sanded flooring for front. Haven't yet drilled holes. Also did bus de for baggage area which seems to be some kind of fiberglass covered chipboard. Only going to varnish edges of chipboard as no one will see it