Project: Patience   -  
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Builder Name:Jeff Orear   -  
Project:   Hatz - Classic   -   VIEW REPORTS
Total Flight Time:
Start/Last Date:Mar 03, 2011 - No Finish Date
Engine:Rotec R3600
Propeller:Culver
 
Friendly URL: https://eaabuilderslog.org?s=Patience

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Jan 19, 2024     Aileron pushrods and slave struts       Category: Wings
Fabricated and installed the aileron pushrods and slave struts. Neat to see the joystick fully operational


 
Jan 12, 2024     Javelins       Category: Wings
In keeping with my doing things the hard way, I'm going to mount my javelins by passing the flying and landing wires through them rather than lashing them in place. I made a jig to cut the required slots to pass the wires through. I took a measurement of the angle made between the landing and flying wires so I could cut the middle slit at the proper angle.


 
Jan 07, 2024     Pitot static tube       Category: Wings
In keeping with wanting this to look like an airplane from the 30's, I made a pitot static tube out of brass. With annealing, it works just a tad stiffer than 3003 aluminum tubing. I'll cut the strap that mounts it when I attach it to a strut


 
Jan 03, 2024     Heat sink       Category: Engine
My fiend and fellow Hatz confidant AC Hutson came for a visit and pointed out that I might have too small of a heat sink for my ignition modules. So I ordered a couple heat sinks like what are used in electronics and fashioned new heat sinks. Should do the trick.


 
Dec 31, 2023     Wing walk       Category: Wings
I wanted to dress up the wing walk, so I made an aluminum frame for it. Got the wing walk stuck down then applied the boarder. I call it wing bling.


 
Dec 23, 2023     Flying/landing wire tensions       Category: Wings
With the aid of a tensiometer loaned to me by AC Hutson, I mounted and tensioned the flying and landing wires. Having that tool took the guesswork out of getting all the tensions uniform. While doing so, I confirmed that dihedrals were equal, and nothing was twisting the wings. All in the process of rigging the wings. From what I see, everything looks good


 
Dec 23, 2023     Strut switch       Category: Wings
To my dismay, I've come to the realization that I had the wing struts on the wrong sides. First indication was how difficult it was to get the right struts on. This should have shut down the wing mounting process, as they were not that difficult to instal prior to covering. Then I noticed that there was more dihedral on the right side than on the left. So I supported each wing with supports and removed the struts. Got it figured out which went where and sure enough, things were good with the world when I remounted them. I had mislabeled the struts. Just another example of me having crainiorectal inversions once in awhile.


 
Dec 16, 2023     New wire lugs       Category: Wings
I had to make a couple new wire lugs to direct the rear landing wire through the two rear flying wires. As it set, they were touching.


 
Dec 02, 2023     Mounted the wings       Category: Wings
I assembled a group of scoundrels and n'air do wells to help out with mounting the wings. Everything went quite smoothly. Total time to complete was about four hours, not including installation of the flying and landing wires. Was a fun day for all.


 
Nov 24, 2023     Center section accessories       Category: Wings
While I wait for help mounting the wings, I installed all the accessories on the underside of the center section, including the fuel line blisters, fuel sight gauge and compass. Also ran the fuel lines down the cabanes


 
Nov 15, 2023     Ready for wings       Category: Wings
The airplane is now leveled and ready to mount the wings


 
Nov 12, 2023     Ailerons mounted       Category: Wings
Got the ailerons mounted. They have simple wire hinges that are secured to the aileron bay with safety wired screws.


 
Nov 11, 2023     Fuel tank repaint       Category: Wings
After getting the fuel tank out to the hangar and seeing it with different lighting, I unfortunately came to the conclusion that it needed to be repainted. Lots of mottling and streaks. I don't like spraying aerothane in the first place, and doing so with a metallic silver adds to my frustrations. So I took it back to the shop and finally, after at least tree coats (I lost count), I am satisfied with the result.


 
Nov 07, 2023     Center section mounted       Category: Wings
Got the center section mounted. I ran two plumb Bob lines down from rack of the root rids down to the floor and marked a centerline on the floor for reference. This assured the center section wasn't tilted one way or the other. Once lined up, the roll wires were tightened.


 
Oct 31, 2023     Mounted empennage       Category: Empennage
Mounted the horizontal stabs, elevators and runner. Looking more like something that will fly.


 
Oct 30, 2023     Fuselage moving day       Category: Fuselage
Day is here to move the fuselage to the airport. Kind of feel like I'm sending one of the kids off to college! I hired a flatbed hauler for the job.


 
Oct 26, 2023     Aileron polish       Category: Wings
I've decided to Polish my ailerons and lave them bare aluminum, like was done in the 30's often.


 
Oct 18, 2023     Prop try       Category: Propeller
I received my prop from Alaina at Culver Props. I think it is one of her best. Just beautiful. I tried it on, only to find I had to sand some of the sealer she used in the bolt hole reliefs. It went on, but then I couldn't get it off! After consulting with AC Hutson, a fellow Hatz builder and award winner, he described a prop puller he made to remove his Culver from his Rotec R3600. I rigged one up, and now the official name of it is the Hutson Prop Puller. 👍🏻


 
Oct 15, 2023     Wing moving day       Category: Wings
Moved the wings and center section to the airport with the help of my long time aviation friend Mark Enderby.


 
Oct 13, 2023     Center section handholds       Category: Wings
I wanted to dress up the handholds on the center section, so I replicated an application I saw at the WAAAM in Hood River Oregon. I wrapped them in chord, then coated them with about 3 coats of epoxy resin.


 
Oct 04, 2023     Logo application       Category: Paint / Decals
Applied the Hatz logo to the vertical fin. Had them made at my local sign shop.


 
Sep 23, 2023     N numbers       Category: Paint / Decals
Prior to buffing and waxing, I painted the N numbers on the top of the top right wing, bottom of the bottom left wing. I had a local sign shop make a couple stencils for me.


 
Sep 20, 2023     Paint buffing       Category: Paint / Decals
Began the process of buffing and waxing the polytone paint.


 
Sep 20, 2023     Wing paint       Category: Paint / Decals
Last panel, last color coat. Finally!


 
Sep 01, 2023     Seam sealer       Category: Paint / Decals
I used seam sealer to fill gaps where the strut fittings exited the wing/covering


 
Aug 17, 2023     Spring covers       Category: Landing Gear
I wanted to cover the spreader bar springs for the landing gear somehow. Originally I thought I would make a leather sleeve, but I assumed that would get oily quite quickly and need replacement periodically, so I opted for aluminum. I made ends that are secured to adel clamps around the gear spreader bars. Then the covers are secured to the ends.


 
Jul 31, 2023     Wing paint       Category: Paint / Decals
First coat of color top coat


 
Jul 10, 2023     Wing paint prep       Category: Wings
Polybrush and poly spray for the wings continues


 
Jun 29, 2023     Wing finish coats 2       Category: Wings
First wing with 3 cross coats of Polyspray. I'll move on to another wing while this one gasses off for a week prior to applying paint.


 
Jun 23, 2023     Wing finishing coats 1       Category: Wings
Since I had a hiatus over the winter, I needed to reactivate the brushed on coat of Polybrush on the wings. Per instructions, I sprayed a coat of poly brush reduced 50/50, then sprayed two coats with the normal 3:1 ratio.


 
Jun 22, 2023     Empenage in silver       Category: Empennage
Applied 3 cross coats of Polyspray to the empenage. The left elevator was done last fall. Per instructions, I'll either sand it or spray a light coat of reducer on it to reactivate the polyspray prior to paint.


 
Jun 16, 2023     Speed ring paint completed.       Category: Fuselage
Painted the red stripe as well as blue on the speed ring.


 
May 12, 2023     Aluminum and fiberglass painting begins       Category: Fuselage
Painted the boot cowl, and painted red stripe on fuse side skin, as well as the base color of silver on the speed ring


 
Apr 22, 2023     Cockpit coamings       Category: Interior Finish
I laced the cockpit coamings myself. Again, I used naugehide. I probably didn't use the conventional method, as it looks ok from the exterior, but the inside is not as refined. I may do these over using a different technique if I'm so inclined.

I had the upholstery shop sew in a welt bead around the circumference of the material and then cut and slit the material to make it conform around a section of water pipe foam insulation. Using a steam iron and puffing steam in it help to mold it around the foam. I used 3/16” bolt, nuts and washers to temporarily hold things in place I installed antique finished brass grommets and laced with 3/16” leather. I also made naugehide pads for the windshields and installed them.


 
Mar 07, 2023     Seat cushions       Category: Interior Finish
I was going to try my hand at using a sewing machine, but I decided to have an upholstery shop do my cushions for me. Nothing elaborate. I went with boat grade naugehide to keep costs down. If they feel it's durable enough for boats, it should do fine in an airplane.


 
Mar 07, 2023     Seat cushions Category: Interior Finish
I was going to try my hand at using a sewing machine, but I opted to have an upholstery shop make my seat cushions for me. Nothing elaborate. The seat foam is 3” and the back is 1 1/2”. U opted to use genuine naugehide, as it was in season. I wanted to keep cost down, and this material is what is used on boats. Durable enough for me.
 
Mar 02, 2023     Windscreen lexan attachment       Category: Fuselage
My lexan inserts luckily fit nice and snug into the frames when mounted to the fuselage, so I felt th at the use of screws would be redundant. I elected to proseal the lexan to the frames after I painted the lexan black where it contacted the frame. Then I polished the frames, as I'm choosing to not paint them.


 
Feb 13, 2023     Cowl finishing       Category: Fuselage
Began the process of filling and finishing the boot cowl fiberglass. I used 2x heavy fill primer along with glazing putty


 
Jan 24, 2023     Panel labkrs       Category: Instrument Panel
Installed all switch labels/panels. I had them later cut. Then I applied whiteout and then polyurethaned over them.


 
Jan 13, 2023     Backup battery       Category: Engine
I've been concerned about having back up for the engine electronic ignition. I've been accustomed to magneto simplicity and no reliance on an energy source. I decided to install a small EarthX 12v battery that I can switch to in the event of battery/alternator failure. I installed diodes and a switch that allows the battery to be charged by the alternator when not in use, but will isolate the battery to one ignition side from the rest of the electrical system when called on. The battery is mounted on a try just forward of the instrument panel. I plan to instal a connector to all me to periodically check the voltage, as well as connect a trickle charger specific for lithium batteries for winter storage.


 
Jan 07, 2023     Fuel pump shroud       Category: Engine
Since the fuel pump for the Rotec is mounted on the top of the engine, I have been concerned about hear induced vapor lock. I made a small shroud with cold air blast tubes to cool the pump.


 
Dec 21, 2022     Firewall forward       Category: Engine
Completed installation of oil/fuel lines as well as firewall forward wiring. I used lacing in most applications with securing hoses and wiring. I had Aircraft Specialties manufacture all pressure oil lines as well as fuel lines. I had them use the interval fire sleeve type fuel lines and highly recommend them.


 
Nov 10, 2022     Engine install       Category: Fuselage
Mounted engine permanently.


 
Nov 03, 2022     Trim tab cable exit       Category: Fuselage
Established exit for trim cable. Installed rubber grommet. Very happy with it.


 
Oct 22, 2022     Brakes       Category: Fuselage
Installed brakes permanently.


 
Oct 22, 2022     Headrest fairing revisited       Category: Fuselage
Adjusted the fit of the headrest fairing flanges. Also reduced the number of screws required.


 
Oct 20, 2022     Paint       Category: Fuselage
Fuselage on gear permanently


 
Oct 09, 2022     Paint       Category: Fuselage
Painted side skins blue. Inspected by Cooper


 
Oct 06, 2022     Paint       Category: Fuselage
Painted side skins silver


 
Oct 05, 2022     Paint       Category: Fuselage
Epoxy primed fuselage skins


 
Sep 28, 2022     Paint       Category: Fuselage
Painted rudder/n number.


 
Sep 22, 2022     Paint       Category: Fuselage
Painted red accent stripes.


 
Sep 19, 2022     Paint       Category: Fuselage
Painted fuselage blue. Pretty cool.


 
Sep 18, 2022     Paint       Category: Fuselage
Painted Nevada silver on fuse side for stripe. Was hard to tell as it matches the Polyspray almost exactly.


 
Sep 17, 2022     Paint       Category: Fuselage
Painted landing gear


 
Sep 16, 2022     Paint       Category: Fuselage
Polysprayed elevators and rudder


 
Sep 16, 2022     Paint       Category: Fuselage
Painted cabanes


 
Sep 15, 2022     Motor moun paint       Category: Fuselage
Repainted motor mount due to thin spots.


 
Sep 07, 2022     Paint       Category: Fuselage
Polysprayed fuselage


 
Sep 03, 2022     Paint       Category: Fuselage
Polybrushed center section and rudder


 
Sep 01, 2022     Paint       Category: Fuselage
Polybrushed elevators.


 
Aug 31, 2022     Paint       Category: Fuselage
Polybrushed landing gear legs


 
Aug 29, 2022     Paint       Category: Fuselage
Reassembled “hillbilly” paint booth.


 
Aug 27, 2022     Paint       Category: Fuselage
Constructed fixture to paint landing gear legs.


 
Aug 22, 2022     Fuselage covering       Category: Fuselage
Made and installed brake line exit fairings. Mounted landing gear temporarily to establish position.


 
Aug 22, 2022     Fuselage covering       Category: Fuselage
Made and installed pushrod exit holes frames and gussets


 
Aug 18, 2022     Covering fuselage       Category: Fuselage
Applied tapes to stringers.


 
Aug 18, 2022     Covering fuselage       Category: Fuselage
Polybrushrd, again with untinted, all areas where tapes will be applied over stringers.


 
Aug 15, 2022     Covering fuselage       Category: Fuselage
Polybrushed fuselage with untinted polybrush. I felt like I was brushing on skim milk!


 
Aug 11, 2022     Covering fuselage       Category: Fuselage
Covered the right side of the fuselage. Un fortunately, I shrunk the covering to 350 degrees before I laced the covering to the vertical stabilizer ribs. This will make doing so later more challenging. As usual, I make things more difficult on myself at times.


 
Aug 07, 2022     Covering landing gear       Category: Landing Gear
Completed covering landing gear.


 
Jul 16, 2022     Ready to cover fuse       Category: Fuselage
Remounted fuselage on the rotisserie in preparation to cover.


 
Jul 12, 2022     Rubber cable exit       Category: Fuselage
Determined where the rudder cables would exit the fuselage and referenced it on both sides to the vertical stabilizer post. This will be used to eventually slit the covering where the cables exit.


 
Jul 01, 2022     Covering wings       Category: Wings
Completed covering right bottom wing


 
Jun 23, 2022     Covering bottom wings       Category: Wings
Completed covering bottom left wing.


 
Painted the inboard aileron pushrods. Established proper length between heim fittings on inboard and outboard pushrods. Applied polybrush to sheeted areas on bottom left wing.


 
Jun 10, 2022     Top right wing completed       Category: Wings
Top right wing covering completed. Techniques learning from the first wing made the process a bit faster/easier.


 
May 21, 2022     Taping completed for top left wing       Category: Wings
Top left wing covering etc completed.


 
May 17, 2022     Wing tapes and access panels       Category: Wings
Placed the chordwise rib tapes, located and installed the wing access rings and gussets.


 
May 15, 2022     Rib lacing       Category: Wings
Completed the top left wing rib lacing, or as I call it suturing.


 
May 10, 2022     First coat of polybrush.       Category: Wings
Applied the brushed on first coat of polybrush. Rib lacing locations were marked


 
May 08, 2022     Covered bottom of top left wing       Category: Wings
Covered the bottom of the top left wing. The leading edge at the tip required being slit to accommodate the slight taper there. The arc that the leading edge sheet makes at the wingtip was followed with the top and bottom covering.


 
May 07, 2022     Top left wing covering       Category: Wings
Poly brushed the leading edge plywood sheet. Covered the top of the wing first, thus being a top wing. Instead of having the seam between the top and bottom covering, I displaced it aft. The seam is located just forward of the trailing edge of the leading edge sheet. The bottom covering will wrap around the leading edge.


 
May 02, 2022     Prep for wing covering       Category: Wings
As I had to do some sanding on the ribs, I had to reapply some epoxy varnish on the wings prior to covering. First wing up is the top left wing, named Melanie after my oldest daughter.


 
Apr 30, 2022     Tail feathers covering       Category: Tail Feathers
Tail feather covering complete


 
Apr 29, 2022     Rudder tapes       Category: Tail Feathers
Applied tapes for the rudder. The use of bias tape really made the trailing edge taping easy


 
Apr 27, 2022     HS taping       Category: Tail Feathers
Taped the horizontal stabilizers. I cheated on the leading edge radius and used biased tape there.


 
Mar 23, 2022     Lacing       Category: Tail Feathers
Tried my hand at lacing the horizontal stabilizer ribs. I'm using a modified seine knot. Once I got the hang of it, it goes fairly quickly.


 
Mar 17, 2022     Right elevator covered.       Category: Tail Feathers


 
Mar 13, 2022     First horizontal stabilizer covered       Category: Tail Feathers
Moving forward with covering, learning as I go. Very slow process for me at first, but the pace is picking up.


 
Mar 12, 2022     Trim tab covering       Category: Tail Feathers
Began the covering process by starting small, really small, with the trim tab. It has been awhile since I did this procedure, and knowing what I know now, I might redo it. One of the benefits of starting out small I guess


 
Feb 24, 2022     Oil fill neck extension       Category: Engine
I wanted access to the oil filler neck to be as simple as possible, it being located on the top of the fuselage, so I opted to have it extend through the boot cowl. Also adds to the vintage look. I made a hole locator template and then transferred that to the cowl. When I fill the tank, SOP will be to have a rag placed around the neck to prevent spills causing a mess.


 
Feb 22, 2022     Oil tank baffle       Category: Engine
One thing that has bothered me since I had my oil tank welded up is not providing for a way to decrease the chance of oil foaming. It's a problem that is emphasized to prevent when running a radial engine with a remote oil tank. As I had it, oil would return to the tank at the top of the tank, pouring straight down unimpeded. Like pouring a beer straight into a mug, and getting a whopper of a head. Add to that, the level of the oil would be reduced while the engine is running, making the length of drop even higher, causing even more foaming. So a simple solution was searched for before a wholesale revamp of the tank was done. I came up with inserting an angled baffle across the back of the tank positioned under the return fittings that directs the oil toward the back wall of the tank. Again using the pouring a beer along the side of a mug to prevent creating a big head analogy. So I made two slits in the tank and inserted a piece of .050 aluminum. Again, master welder Craig welded it up for me. I'm a bit more comfortable with the result, warranted or not.


 
Feb 08, 2022     Fill neck fillet       Category: Fuel System
Applied a fillet of pro seal at the flange/fill neck junction to prevent the leak I found.


 
Jan 14, 2022     Fuselage/fueling penetration       Category: Fuel System
I wanted to have a nice clean penetration of the fuselage skins for the fuel line instead of following the cabane strut. So I ordered the needed AN fittings. It required a stand-off on the cockpit side of the skin to am.low clearance by the 1/2” square tube located here.


 
Jan 04, 2022     Tank leak test       Category: Fuel System
Finally got around to testing the fuel tank after how many years??! Did the balloon method with soapy water brushed over all rivet lines. Only caught a leak at the fill neck/flange connection. Since the flange was welded with the fill neck screwed in, there was slight distortion that prevents the fill neck from being screwed back out. I'll apply a fillet of pro seal here to eliminate the leak.


 
Jan 04, 2022     Center section underside       Category: Wings
located and installed the tank support stiffeners, fuel line blisters and compass fairing


 
Dec 08, 2021     Center section stiffeners       Category: Wings
Again wanting to recreate a nostalgic look, I'm simulating wood stiffeners located under the fuel tank on the center section. I made 6 stiffeners out of red oak. Picture shows them stained, after which I touched up the spots I missed on some of their tips.


 
Dec 06, 2021     Top forward skin pattern       Category: Fuselage
I refined the top forward fuselage skin by making the roll wire pass through holes smaller.


 
Dec 06, 2021     Pilot control stick grip       Category: Interior Finish
I made the pilot control grip the same as the passenger's, but added a push to talk switch.


 
Dec 04, 2021     Pax control stick grip       Category: Interior Finish
Since I am trying to have a nostalgic look, I wanted to do something along that line for the control stick grips. Fortunately an article in a recent SportAviation outlined how to do them in leather. I modified the technique, mostly due to materials availability. I used a faux vinyl leather that is designed for boats. I also placed a backing using engine baffle material. I made a top out of an oak cowl.


 
Nov 22, 2021     Rear Windscreen Lexan pattern       Category: Fuselage
Made a 1/8” poster board pattern for the rear windscreen. I made one side first, then the other, then joined them to get an accurate fit.


 
Nov 20, 2021     Fuel filter       Category: Fuel System
Installed an Andair fuel filter between the electric fuel pump and gascolator.


 
Nov 18, 2021     Polypropylene sheet bending tool       Category: Tools
I made a bending tool to bend the polypropylene windshields. I followed designs that are found on YouTube. I used a battery charger set on 50 amps to get the nichrome wire hot enough. Works great.


 
Nov 13, 2021     Throttle tensioner knob       Category: Fuselage
I wanted to be able to keep the throttle, mixture and car heat from backing out by being able to tighten the quadrant. I made a knob to be able to do that as well as one from the trim lever.


 
Nov 02, 2021     Fuselage top skin edge refinement       Category: Fuselage
I wanted to dress up the bottom edges of the top fuselage skins. Normally this would be done by using a bead roller. Unfortunately, I do not have one at my disposal, so I set out trying to duplicate a beaded edge. What I came up with was a strip of 6061 aluminum that is folded over and bent out slightly. I had a machine shop shear pieces long enough, then folded over the edge at Balsa USA who has a 48” bending brake. Picture shows a prototype representative sample.


 
Nov 01, 2021     Elevator stops, PTT wire       Category: Controls
I realized that I did not have a full up stop for the elevator planned. I welded a -3 nut on the control torque tube for both the up and down stops, then inserted a -3 bolt with a jam nut. Makes up and down stops adjustable. Also fed the push to talk wires up through the pilot control stick.


 
Oct 31, 2021     Compass pod completion       Category: Avionics
Laid up fiberglass and resin, sanded and primed. I'll position and drill after the center section is off. I plan to place it on the centerline of the center section, and have the face of the compass basically flush with the aft surface of the rear spar.


 
Oct 30, 2021     Compass pod       Category: Avionics
I have been pondering where to mount my compass. Due to several engine instruments being electric, there is not a good spot on my panel that are free of interference. So I have opted to mount it in a pod located in the underside of the center section. Today I made a plug to make a one off part.


 
Oct 25, 2021     Fuel line blisters       Category: Fuel System
Positioned and drilled the fuel line and fuel sight gauge blisters. I'll finish drill and install T-nuts after I remove the center section.


 
Oct 11, 2021     First fuel line fairing out of the mold       Category: Fuel System
Made up the first fuel line fairing by laying in 6 layers of 3oz cloth and epoxy resin. I think I'm coming out a bit too thin for the flange, so I may try to add one or two layers of 9iz cloth at the end of the layup. I tried going with 3 layers of 9oz cloth but got voids right at the edge of the fairing/ flange transition. The 3iz ladies down much nicer.


 
Oct 07, 2021     Fuel line fairing fabrication pt2       Category: Fuel System
After waxing the finished plug and applying PVA separator, I applied a layer of gelcoat. In this case, I had a gelcoat repair kit that included a gelcoat base that was more of a gel than a liquid like I used in the cowl mold. I bushed it on, and it worked fine for this small part. Then I laid up 5 layers of mat fiberglass with polyester resin. This being a small mold, I wasn't too concerned about shrinkage, so I laid up all the layers at one time. Separated just fine. I then trimmed the mold to produce a 3/4” flange on the completed parts and then hot glued it to a spray paint can top as a base.


 
Oct 04, 2021     Fuel line fairing construction 1       Category: Fuel System
Need to make some fairings for where the fuel lines exit the fuel tank/center section. Had a “lightbulb “ idea to use a lightbulb as a plug to make a mold for fiberglass fairings. Made a plywood mount with beveled edges around a hole cut to extend a lightbulb through to the desired depth. Secured the bulb with hot glue, then filled any gaps with bondo. Sealed the bondo with sandable primer


 
Aug 31, 2021     Skin supports and fairing       Category: Fuselage
I wanted to have more support in the rear cockpit skin, so I made 3 angled supports that will be riveted on once the skin and the angles are primed. Also made scalloped fairings for the forward top turtledeck to accommodate the covering.


 
Aug 29, 2021     Fuel line fabrication       Category: Fuel System
Began fabrication of the fuel lines. Moi Ted the tank and had a pleasant surprise that the tension on the upper tank skin when mounted removes 90% of a pucker that was created when welding the fuel cap flange. Made up the line going from the fuel selector valve to e electric fuel pump as well as the lines exiting the tank and following the cabanes to the fuselage.


 
Aug 26, 2021     Empennage support wires       Category: Empennage
Did a quick fitup of the empennage flying wires to assure all is well prior to covering. Fabricated tabs to mount them with.


 
Aug 24, 2021     Top forward skin template       Category: Fuselage
Need to accommodate the roll wires that must pass through the top forward skin, so I made a template to locate the hole.


 
Aug 18, 2021     N struts pt 1       Category: Wings
Began the construction of the N struts. I chose to build them “in place” so I moved the fuse into my larger garage with assurances to my wife that her car's need to be parked outside will be short lived. I used a friend's scaffolding to aid in supporting the upper wing and had a few friends over to help who accept compensation in cold beers.


 
Jun 20, 2021     N struts pt 2       Category: Wings
I began N strut construction by doing the middle strut first. This duplicated the dihedral of the bottom wing at 1.5 degrees. Th3n I made the front and rear struts to fit. I used a method of a tab welded to a bushing that mounts to the wing, then a bolt is passed through the strut and tab to secure the strut to the wing.


 
Jun 19, 2021     Lower wing root fitup pt 4       Category: Wings
After applying the rear most MonoKote, I fit the wine root to the covered fuselage contour. This again was accomplished after assuring the wing was at the proper dihedral. Having the wing resting on two sets of rolling supports allowed me to fool the wing in place, see how much I had to trim, then roll it out of the way. Time consuming, but effective. Once the rear area was completed, I did the same with the front. Same process was repeated on the other wing.


 
Jun 19, 2021     Lower wing root fitup pt 3       Category: Wings
My plan to get a nice close, even fit between the wing root and the fuselage includes simulating the fuselage covering in the area where the wing mounts. I'm going to use some leftover MonoKote covering from my RC days. A concern I have is the bottom stringer is long between the bulkheads and has a tendency to bow inward. The MonoKote sill not have the same amping of shrink, thus pressure as the cecinite will, so if this stringer bows, the gap will be increased with the final covering. To prevent this bowing, I made a support for the stringer.


 
Jun 17, 2021     Lower wing root fitup pt 2       Category: Wings
I began the process by accommodating the stringers. After assuring the wing had the designated 1.5 degrees of dihedral, In the forward area, I simulated where the lower stringer would penetrate the wing walk plywood. Then I carefully relieved the plywood to allow the wing mount fittings to contact each other.


 
Jun 14, 2021     Lower wing root fitup pt1       Category: Wings
Pulled the fuselage out to begin the process of matching the lower wing root contour to the fuselage.


 
Jun 09, 2021     Speed ring primed       Category: Engine
Primed the speed ring with high fill primer. This required a few coats with glazing putty and sanding between. A long process, but I hate pinholes. Making the speed ring from a mold would have eliminated 90% of the pin holes, but I was burned out making the cowl mold to do another, soba one-off ring was opted for.


 
Jun 01, 2021     Speed ring baffles       Category: Engine
Completed the engine baffle extensions including the flexible baffle, less that at the top of the engine where the lift point is. I'll complete that once the engine is mounted permanently. Pulled the project out of the shop with the cowl and speed ring mounted. Sometimes you have to savor the accomplishments along the journey's path.


 
May 25, 2021     Rudder cables       Category: Controls
Fabricated and installed the rudder cables. Thanks to Don Stewart for lending me his swaging tool


 
May 19, 2021     Rocker valve covers       Category: Engine
I had heard that the current Rotec valve covers have a tendency to leak and that Hans and Sam Gauchi had designed and produced a set that are milled and a bit stiffer, so I went ahead and installed them so I could get a good fit go them with the baffle extensions. I checked to see what clearance I had with the speed ring installed.


 
May 10, 2021     Engine baffles       Category: Engine
Since I have decided to include a speed ring, I started making baffle extensions


 
May 02, 2021     Mounting speed ring       Category: Engine
Made delrin mounts to work with custom rocker cover mounts. Two aluminum angle sets were mounted with bolts between them to squeeze the ring to the rocker cover mounts. Aluminum sleeve was made to cover the joint where the ring comes together.


 
Mar 15, 2021     Speed ring plug continued 2       Category: Engine
Applied a coat of epoxy resin to harden the plaster skim coat


 
Mar 11, 2021     Speed ring plug continued       Category: Engine
Applied foam and joint compound plaster to plug and sanded to shape


 
Mar 10, 2021     Speed ring plug       Category: Engine
Decided to build a speed ring. Began making a plug from masonite and plywood.


 
Feb 18, 2021     Scat tub mounts       Category: Engine
Installed scat tho mounts in two baffles for cold air induction tubes.


 
Feb 16, 2021     Intercylider baffles       Category: Engine
Constructed and installed inter cylinder baffles. Attached at the top with brackets secured with intake and exhaust studs. Secured at the bottom with music wire clamps. Shaped at the back of the cylinders to direct air to the back side of each cylinder.


 
Jan 16, 2021     Riveted ailerons       Category: Wings
Primed the internal surfaces of the skins as well as the ribs and trailing edge with Marhyde primer, then NAPA 7220 when the Marhyde ran out. Started riveting with the lower skin to the spar first. Riveted control horns to ribs prior to ribs being riveted to the skins


 
Jan 14, 2021     Aileron hinge       Category: Wings
Drilled aileron hinge to wing aileron spar


 
Jan 12, 2021     Closing aileron skin corrugations       Category: Wings
Began process of closing the ends of the skin corrugations. I used a slitting tool from Klein Tools to cut a 3/16” deep wedge out of the corrugation ends. Then a homemade tool was made out of a 1/2” bolt that was used to tap the ends closed


 
Jan 04, 2021     Aileron ribs located       Category: Wings
Located and drilled aileron ribs. Temporarily taped them in place prior to drilling


 
Jan 03, 2021     Aileron spar located and drilled       Category: Wings
Marked skin for outboard curve with template. Temporarily taped hinge to skin leading edge, located spar and drilled to aileron skin. Hade a 3/4” mount to raise top skin off of the work table to allow the bottom skin to hang past the trailing edge and later trim to top skin


 
Jan 01, 2021     Ailerons       Category: Fuselage
Began aileron construction by making a template for cutting the skins to shape and bending the trailing edge stock I purchased from Vans


 
Dec 29, 2020     Fuselage       Category: Fuselage
Located and drilled inboard top cowl louvers


 
Nov 21, 2020     Turtle deck stringers       Category: Fuselage
Finalized the contour it the fuselage stringers located at the top longeron to blend into the turtle deck stringers. Used a sheet to simulate the covering in this area


 
Nov 14, 2020     Fuselage stringers       Category: Fuselage
Finalized the fit of the fuselage stringers, varnished and varnished prior to final installation


 
Nov 03, 2020     Wiring started       Category: Avionics
Mounted a corrugated conduit, again left over from my RV build, to pass wires from the rear cockpit to the firewall. I suspended it with plastic adel clamps. Began running wires to switches, radio, intercom etc. no matter how I try, it still looks like a birds nest. At least until I get things wrapped and cleaned up.


 
Oct 28, 2020     Seat back top edge       Category: Interior Finish
In the tradition of Mike Patey, I'm using scraps from my RV build for the Hatz. Here's an example. Edging on the top of the seat backs from McMaster Carr that I used for the glareshield edge in the RV

Scrappy II!


 
Oct 27, 2020     Panel install for wiring       Category: Instrument Panel
Installed panel,and sub panels for wiring. Installed instruments, switches, circuit breakers and warning lights (less oil pressure light)


 
Oct 26, 2020     Stain and varnish panel       Category: Instrument Panel
Veneered panel with walnut. Stained panel and sub panels. Varnished with minwax spar varnish semigloss


 
Oct 25, 2020     Brakeline conduit       Category: Landing Gear
Installed gear leg fairings as well as a 1/2” dia aluminum tube as a conduit for nylon brake lines. Still need to trim the length at the caliper end


 
Oct 07, 2020     Heal protection       Category: Interior Finish
Heal protection for the floorboards with .016 aluminum. I had a stand-in foot see if it was in the right spot


 
Oct 03, 2020     Floor board stain/varnish       Category: Interior Finish
After refining the fit, I stained the floorboards with valspar early American stain, then varnished with valspar oil based exterior polyurethane varnish.


 
Oct 01, 2020     Turtle deck stringers       Category: Fuselage
Installed turtle deck hat stringers with pulled rivets. Inspected by Cooper


 
Sep 30, 2020     Brake pedal setup       Category: Controls
Installed the master cylinders for the brakes and determined the position of the heel brakes relative to the rudder pedals. I decided to rake them slightly forward.


 
Sep 22, 2020     Fuselage tubing painted       Category: Paint / Decals
Completed painting the fuselage tubing with poly fiber aerothane. I'm pleased with how the paint sprayed. I used a touch up gun to make access to certain areas easier.


 
Sep 10, 2020     Set up poorman's spraybooth       Category: Paint / Decals
Needed to setup a spraybooth to paint the fuselage tubing framework. I'm working out of a single stall garage, so I decided to set the booth up just outside the garage. I bought a Harbor Freight 10'x20' carport on sale for $99.00. I built gables for the ends out of 1 1/2 x 1 wood and 4mil plastic. Then I made curtains out of 4mil plastic by folding over the last 12” 3 times to make a doubled area strong enough to support grommets again purchased at HF. I zip tied these to the support rods for the carport. I made a frame to hold two box fans as well. These have filters to catch overspray before air is exited out the booth. One gable has filters that allow air to be sucked into the booth high, and exited out low. A down draft, sorta. When I'm not using it, all the curtains are rolled up and wood clamped to the support rods. I put some red absorbent paper on the floor. Nice thing about this setup is that since the weather is starting to change here in NE Wisconsin, read that getting colder, the booth kind of acts like a green house to warm things up.


 
Aug 06, 2020     cowl fiberglass layup       Category: Fuselage
After spraying the mold with PVA, laid up 1 layer of 3 oz and 4 layers of 7oz glass cloth with Fiberglast 3000 epoxy resin. I chose this resin because it is a high temp resin, resistant to 270 degrees without heat treating, up to 300 if it is treated. I was concerned about the proximity to the collector ring and possible deformation of lower temp resin such as West System. Again, was a nice sound to hear it come out of the mold


 
Jul 29, 2020     cowl mold7       Category: Fuselage
Separated the mold from the plug. Nothing better than hearing that sound it makes when it lets loose. Time for a T&T


 
Jul 10, 2020     cowl mold5       Category: Fuselage
Sprayed gelcoat on the top portion of the plug. I used Evercoat thinned down and used a modified $10 Harbor Freight HVLP gun that I drilled out the nozzle to 1.8mm. Worked great. Mixed a slurry of polyester resin, flox and carb o sil and applied to the corners made by the plug and forms for rear flange and mold split dam. Then began the process of laying up 5 layers of fiberglass matt and polyester resin. Each layer was allowed to cure overnight before the next layer was applied to prevent shrinkage


 
Jun 29, 2020     cowl mold4       Category: Fuselage
Sprayed PVA on the top portion of the cowl as a separator


 
Jun 16, 2020     cowl mold3       Category: Fuselage
Since I am going with a split mold, I needed to make a damn in the center of the mold. This is a piece of 1/8" masonite finished on one side. Again, glued on with some supports under one side with hot glue, modelers clay to fill gaps and waxed.


 
Jun 13, 2020     cowl mold2       Category: Fuselage
Made a form for the aft flange from 1/16" ply hot glued to the aluminum tabs. Gap with the fuselage was filled with modelers clay. I varnished over it to make sure the polyester resin didn't react with it. Applied packaging tape and waxed over it to aid as a separator


 
Jun 03, 2020     Began process of making a fiberglass mold       Category: Fuselage
I need to make a flange on the aft edge of the cowl. I made aluminum angles that I hot glued in place to support a form to make a flange on the aft edge of the mold. Waxed the mold with several coats of wax...20 to be exact.


 
May 24, 2020     boot cowl plug construction continues6       Category: Fuselage
Final coat of primer. Began process of sanding with fine grit wet dry to establish smooth surface. Got it baby smooth


 
May 23, 2020     boot cowl plug construction continues5       Category: Fuselage
Sprayed high build primer on the plug, sanded, applied spot putty, sanded. Basically came up with a spotted cowl


 
May 18, 2020     boot cowl plug construction continues4       Category: Fuselage
Layers of mount compound applied to further refine the contour. Once satisfied, I applied a couple coats of epoxy resin. If I had it to do over, I would add a layer of fiberglass, as even with the resin, the plug was prone to denting if not careful


 
May 16, 2020     boot cowl plug construction continues3       Category: Fuselage
Added bondo to the area where the side foam meets up with the front ring. Added plater joint compound to refine the contour


 
May 10, 2020     Boot cowl plug construction continues       Category: Fuselage
Had to move the masonite ring to the front of the cowl forward ring so it could be bolted to the engine mount. Mounted it to the cowl and then made forms from the fuselage to the cowl ring. Used flexible piece of wood to establish the contour, then duplicated for the other side at the same location on the cowl.


 
Apr 30, 2020     Boot cowl plug construction       Category: Fuselage
Began construction of boot cowl plug. Disk was cut from 1/8" masonite. 1/4 round forms were glued equally spaced and then blue foam hot glued between them. Foam was then contoured to shape of forms. This establishes the curved forward edge of the cowl just behind the exhaust collector ring.


 
Apr 22, 2020     Throttle cables       Category: Engine
Preliminary installation of throttle, mixture, carbheat and primer cables. Mounted primer knob on left sub panel


 
Apr 22, 2020     TBI throttle linkage       Category: Engine
Constructed linkage for TBI for better leverage and direction of travel


 
Apr 22, 2020     TBI throttle linkage Category: Engine
Constructed linkage for TBI for better leverage and direction of travel
 
Apr 04, 2020     Bottom forward skin       Category: Fuselage
Installed the forward bottom skin, after hitting my head on the exhaust stacks several times before getting the Packers hard hat out!


 
Apr 01, 2020     Bottom stringers       Category: Fuselage
I made the bottom stringer supports out of 3/8"" aluminum tubing, mounted them to tabs I had welded to the fuselage prior, and fitted and drilled the aluminum hat section stringers in place


 
Mar 25, 2020     Fuse box       Category: Fuselage
having built an RV using the Nuchols' philosophy of using fuses vs circuit breakers and having great success with it, I have decided to follow suit with the Hatz. I built a fuse box to mount a blade fuse block and have access to it from the cockpit. Best place I could find to mount it was on the right side just forward of the fuel valve.


 
Mar 22, 2020     Airbox mounting       Category: Engine
Mounted the airbox. I made a couple modifications to the airbox prior to installation. First, I made an aluminum support ring to sandwich the fiberglass box between the TBI and the ring. Didn't like relying on the fiberglass to be strong enough. Then I made an alternate air/carbheat door. Happily the box just fits between the TBI and the firewall. I installed a small tab at the outboard edge of the airbox for more support. I plan to isolate that with some neoprene rubber for vibration isolation. Otherwise it could fracture from the engine moving around.


 
Mar 21, 2020     Remounted engine       Category: Engine
Remounted the engine to provide reference for airbox mounting. Mounted master solenoid


 
Mar 19, 2020     batter box mount       Category: Engine
As the battery, in this case an Odyssey PC 680, is quite heavy, I also wanted it to have good support as well. I located the battery box and welded 4130 sheet to the fuselage tubular structure to support the battery


 
Mar 16, 2020     Oil tank mount       Category: Engine
Mounted the oil tank. I am using a method recommended to me by an experienced builder where no tabs are welded to the tank that could fatigue and fracture. The tank is supported on the motor mount by a sheet of plywood. This sheet is attached to the motor mount with two clips. The tank is then strapped down onto this plywood mount with a stainless steel strap that is attached to the motor mount via two bushings with two bolts that are welded to steel plates that are in turn riveted to the stainless steel straps. Rubber bumpers stand the tank off from the firewall, and two angles with rubber bumpers keep the tank from sliding side to side that are located along side the lower part of the tank that extends through the plywood mount. It is quite secure.


 
Mar 09, 2020     Electric scavenge pump mount       Category: Engine
As I am going with an engine that has a dry sump, a separate oil tank is used. Oil needs to get back to the main tank from a small sump on the engine via an engine driven scavenge pump. An auxiliary pump is recommended which I have purchased from Radial Conversions. The pump itself is quite hefty, so relying on the stainless steel firewall to support it is not a good idea. I fabricated a 4130 steel plate and welded it to the fuselage tubular structure for adequate support. Not a good demonstration of my welding skills. I was a bit rusty. Also mounted the gascolator and oil filter block


 
Mar 02, 2020     Secured headrest fairing       Category: Fuselage
Finally got around to attaching the fiberglass headrest fairing to the fuselage


 
Feb 29, 2020     Storage box       Category: Fuselage
I wanted to have a place to store a handheld and an iPad so I made a box to fit behind the throttle quadrant in the rear cockpit. I made it out of scrap 3003 from the windshield construction.


 
Feb 25, 2020     fuel valve extension       Category: Fuel System
Made a support for the fuel valve extension and installed the valve lever


 
Feb 20, 2020     Windscreen frame construction       Category: Fuselage
Windscreen construction continues with bending the flanges at the base to fit to the fuselage. I used a modified
joggle tool to act sort of a mobile english wheel. I rolled it along the edge while simultaneously bending the flange. I used a piece of steel purchased at the hardware store as a straight edge while making the cutouts for the windscreen material


 
Feb 18, 2020     Frame construction       Category: Fuselage
Bent the edges of the windshield frames that retain the windshield material.


 
Feb 17, 2020     Windscreen frame construction       Category: Fuselage
Cut out the windscreen blanks from 3003 .025 aluminum. I didn't want a sharp bend line at the corners of the frames so I made a bending brake out of particle board with a larger radius to use with my harbor freight bender. It also made bending flanges in later steps easier. I made a template to gauge the bend angles and bent the blank prior to making the cutouts for the clear windshield material.


 
Jan 31, 2020     windscreen patterns       Category: Fuselage
plotted out and drew the patterns for the windshield frames


 
Jan 22, 2020     Secured aft end of fuselage stringers       Category: Fuselage
Finally got around to securing the fuselage stringers to the vertical stabilizer post. As I was doing so, one stringer in particular kept on breaking at the scarf joint, so I decided to double up all the stringer scarf joints with 1/16"" ply top and bottom.

All stringers were secured with .063 aluminum plates holding opposite sides together using 3/16"" bolts. I used 3/32"" plywood on the top of the stringers at the locations of the aluminum plates and large washer on the bottom to make sure the mahogany
stringers weren't damaged. Some of them were fabricated out of rather hard mahogany which requires quite a bit of persuasion pulling them to the tail post.


 
Jan 17, 2020     Headrest fairing layup       Category: Fuselage
Layed up 3 layers of 6oz fliberglass cloth for the headrest cover. Not my favorite material to work with, but I muddled through it. I used a pregreg technique where I laid down a sheet of 4 mil plastic sheet, then a piece of fiberglass cloth over that. I then squeegeed resin into the cloth. I cut out the shape of cloth I needed, including the plastic sheet underneath. I picked up his pre resined cloth/plastic and placed it on the headrest plug. After it was generally in place, I pealed off the plastic and then adapted the fiberglass cloth to the shape of the plug. Repeated for each layer. Worked quite well, despite me being five thumbed when it comes to fiberglass.


 
Jan 10, 2020     Headrest fairing plug finishing       Category: Fuselage
Completed finishing the headrest fairing plug. I plan to do a one-off construction and not use a mold technique


 
Jan 03, 2020     Cockpit edge support       Category: Fuselage
Constructed the edge support for the cockpits by using 1/2"" aluminum tube from menards. I annealed it, and bent it to duplicate the shape of the cockpit edges. As I bent it to fit, I slit it with a diegrinder and slipped it over the edge of the fuselage skin. Where the tubes butted up to each other (bending a piece long enough to make it all the way around the opening would have been a bear) I inserted a piece of tubing that was made to fit inside the bent tubing. Gave a bit more support there and hopefully will eliminate a stress riser and potential site of a crack. I then drilled 1/8"" holes for rivets. Before riveting, I injected JB Weld on both sides of the skin through the rivet holes, and then inserted the rivets. I allowed this to set, and then set the rivets with a rivet squeezer. This gave the rivets some support on the inside of the tube as they were squeezed to produce an adequate shop head. This procedure really stiffens up the skin at the cockpits. I plan to river angles of aluminum to further stiffen things up here.


 
Dec 05, 2019     panel bezel       Category: Instrument Panel
Finally decided on the location of instruments on the panel. It was quite the ordeal, with several options being considered. I made a plywood bezel to highlight the main instruments, and will veneer this in maple.


 
Nov 12, 2019     forward top fuse skins       Category: Instrument Panel
Made the cutouts for the cabanas to pass through the forward top fuselage skins. I made a poster board template that allowed me to locate the holes properly and to transfer that to the aluminum skins.


 
Nov 01, 2019     Front cockpit skin       Category: Fuselage
Fitted and clecoed the forward fuselage skin. I recommend not cutting out the cockpit opening until the skin is in place to prevent distortion of the skin. Don't ask me how I figured that one out.....


 
Oct 27, 2019     Front baggage       Category: Fuselage
I'm using the area in front of the front cockpit area as a forward baggage area. I made a 3/16��floor, with aluminum angles on the edges that will support the fuselage skins as well.


 
Oct 27, 2019     Rear instrument panel fabrication       Category: Instrument Panel
Fabricated the rear cockpit instrument panel from .063 Aluminum. I first made a plywood template that was just short of the fuselage skin. Try to keep this to less than 1/4. I clamped this template in position, and noted the area where the panel will eventually make contact with the fuselage skin. I removed the skin and applied clear packaging tape in this area to act as a releasing agent.

The skin was replaced and automotive body filler, AKA Bondo was mixed up and then squeegeed into the space between the template and the skin. If the gap is too big, the Bondo will slump too much. It this is the case, pieces of pasteboard can be taped to the back side of the template the give the Bondo some support.

After the Bondo sets, the skin is removed as well as the template. I sanded down the Bondo to be flush with the surface of the plywood template, and then used the Bondo-modified template the trace out the shape of the instrument panel on a sheet of .063 aluminum, in this case 2024 T3.

This method makes the panel fit like a glove in relation to the fuselage skin. Repeat for the front cockpit


 
Oct 26, 2019     Front side skin       Category: Fuselage
Installed the front side skins.


 
Oct 09, 2019     Rear cockpit skin       Category: Fuselage
Fit the rear cockpit skin and clecoed in place.


 
Oct 05, 2019     Oil tank       Category: Engine
As my engine is a dry sump, a separate oil tank is required. The engine needs 2.64 gallons of oil, plus an airspace . I designed the tank to reside over the top of the engine mount. It's made out of .08 6061 aluminum.


 
Sep 17, 2019     Engine hung       Category: Engine
Big day today, as the engine was hung.

I'm using a Rotec R3600. I realize many will recoil at that prospect due to negative reports about the engine that are found on the internet. While I acknowledge these reports, I am also making note of those that have the engine and are quite pleased with it. I appreciate those that have reported problems, as well as their solutions. I also appreciate Brian Kelly of Radial Conversions who supplies add on components that improve the functionality of the engine.

My main takeaway from all the research I have done on the engine is to make sure it is treated as the round engine that it is. There are care and maintenance issues that must be adhered to. I am not saying that those that have had problems did not do so, but I have come to realize you just can't operate this engine as though it were a flat four.


 
Aug 31, 2019     Primed fuselade       Category: Fuselage
Primed the fuselage in stits epoxy. Painting is not my forte, and painting tubing was a bear for me.


 
Aug 08, 2019     Fuel valve       Category: Fuselage
Mounted the fuel valve


 
Aug 02, 2019     Lift handle       Category: Fuselage
Decided to add a fuselage lift handle.


 
Jun 29, 2019     Lower wing mounted       Category: Fuselage
Positioned the lower wings to locate and weld the rear wing mounts.


 
Jun 19, 2019     Throttle quadrant pushrods       Category: Controls
Started to fabricate the inter-quadrant pushrods. I needed to notch the lever arms to properly clear the rod ends.


 
Jun 08, 2019     Floor boards       Category: Fuselage
Using templates previously made from poster board, the floorboards were fabricated from 3/16��ply and installed.


 
May 04, 2019     Throttle quadrants       Category: Controls
Completed fabrication of the throttle quadrants. I'll designated the levers more by color on the lever arms later.


 
Apr 02, 2019     Mounted firewall to fuselage       Category: Firewall
Got the firewall in position and mounted to the fuselage. Took a very little bit of coaxing, but it slid on pretty nicely.


 
Mar 19, 2019     Firewall flange       Category: Fuselage
Fabricating aluminum flange for the firewall. I'm facing my flanges forward to make access to cowl attachment easier. A holdover from building an RV. The Harbour Freight stretcher/shrinker worked great.


 
Mar 01, 2019     Motor mount       Category: Firewall
Started construction of the motor mount. Luckily, I was able to use a mount duplication fabricated by Ed White, who is using the same engine as I am. A square tube frame, basically ����shaped, that held the duplicate out in front of the fuselage in the position the engine needs to be. The mounting cups were secured to the duplicate, made out of aluminum, and all the tubing supporting the engine was then welded to them. Worked really well, and at the end of the day, the engine mount actually fit the fuselage! A big win for this hack welder.


 
Feb 12, 2019     Aileron skins       Category: Wings
Stamped out all my aileron skins out of 1/16��aluminum using a press that my buddy Rick Shultz rigged up.


 
Jan 30, 2019     Rear baggage area       Category: Fuselage
I'm utilizing the area behind the rear cockpit as a baggage area. Built the area out of 3/16��ply, and 3/64��ply for the top. The front face, which will have th3 access door, is separate from the main unit and will be screwed to it. All sealed in clear polyurethane


 
Jan 29, 2019     Trim lever       Category: Fuselage
Installed trim lever mount and trim lever. Still need to trim the trim lever length


 
Jan 24, 2019     bottom stringer supports       Category: Fuselage
Fabricated and installed the bottom stringer supports. They are .025 4130 bows that were formed with my trusty Harbor Freight shrinker/stretcher. 4130 mounts were made to support the aluminum stringers and welded to the bows prior to welding the bows to the fuselage.


 
Jan 16, 2019     Top rear stringers       Category: Fuselage
Installed top rear stringers. I have left them long at the aft end at this time and will trim to proper lengths later.


 
Jan 08, 2019     mounts for top rear stinger supports       Category: Fuselage
fabricated and welded mounts for the top rear stringer supports. The plans call out welding a small length of rod that the tubular mounts would slip over. I decided to weld tabs, flatten the tubes and then rivet the supports to the tabs.


 
Jan 06, 2019     front side stringer mount       Category: Fuselage
Fabricated and welded front side stringer mount. L shaped tabs were welded to the mount for attaching stringers prior to welding to the fuselage.


 
Jan 02, 2019     side fuselage bulkheads       Category: Fuselage
Mounted plywood side fuselage bulkheads. I used a string to make sure all the stringer mount slots lined up so the stringers wouldn't look like noodles when they are installed.


 
Dec 21, 2018     forward support for turtledeck       Category: Fuselage
Fabricated and welded forward support of the turtledeck. Made from .025 4130, shrunk to form the arc required. V shaped mounts were fabricated from .025 and welded to the support prior to being welded to the fuselage.


 
Dec 04, 2018     forward vertical stab support       Category: Fuselage
installed and welded forward vertical stabilizer support using 1/2"" 4130 tube


 
Dec 02, 2018     forward turtledeck support       Category: Fuselage
Fabricated the forward turtledeck support from .025 using my Harbor Freight shrinker.


 


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