Project: thelm   -  
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Builder Name:Thomas Helm   -  
Project:   137   -   VIEW REPORTS
Total Hours:1275.7
Total Flight Time:0.7
Total Expense:$31.33
Start/Last Date:Oct 01, 2013 - No Finish Date
Engine:AeroVee
Panel:MGL Xtreme
 
Friendly URL: https://eaabuilderslog.org?s=thelm

Home or Last Project Picture

Feb 10, 2022     Completed       Category: Paint / Decals
Complete reassembly after painting.

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Feb 05, 2022     Paint completed       Category: Paint / Decals
Painting completed, just a couple of trim panels need to be redone due to peeling while removing trim taping.

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Jan 21, 2022     Painting in progress       Category: Paint / Decals
Initial views of exterior painting progress. Blue and yellow lines are tape in preparation for trim lines and color edges.

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Nov 11, 2021     AOA, lift management system - (2 hours)       Category: Instrument Panel
Installed Lift Management system. Indicator in panel and sensor under stub wing on inspection hole cover.

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Aug 18, 2021     Cockpit floor support for ballast - (2 hours)       Category: Controls
Made shelf below and behind pilot seat to support additional ballast for phase one flight tests. Used 3/4x11/2 wood stick to bridge floor and rest on lower longerons. This allowed for antenna hook up under the ballast floor. Fastened .025 sheet to the wood support stick and cockpit cross piece.

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Aug 17, 2021     Half flap position - (1 hour)       Category: Controls
Added 1/2 flap position to flap selector.

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Jul 01, 2021     Pictures - (1 hour)       Category: Completed
First flight June 28, 2021. Flew well, no trim issues. Good engine temperatures. Have slight oil leak, suspect case mating flange at bottom. If so, probably inadequate sealant during assembly, will have to live with it.

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Jun 25, 2021     Secure hydraulic brake lines - (2 hours)       Category: Landing Gear
Secured hyd brake lines to landing gear legs with AN742-D3 clamps. Rather than drill through leg (as per ONX-L04 view B-B) which would have been impossible to counter sync on aircraft, I instead drilled and tapped holes to use AN525-832R6 3/8 machine screws. Clamps needed to be shaped to streamline better with gear leg.

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Jun 17, 2021     Completed       Category: Completed
Completed, waiting for inspection today. Plan painting coming winter.

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Jun 18, 2021     Rear spar folding wing uplock - (2 hours)       Category: Wings
Fabricated rear spar uplock link for each side. Additional support.

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May 24, 2021     Folding wing up lock - (3 hours)       Category: Wings
Fabricated a brace to hold wing upward in folded position. Purpose is to hold wing up while positioning in and out of hanger, preventing wind gusts etc. from causing it to fall. Not intended for trailer travel without additional restraints.
Modified bracket with additional piece to straddle wing folding flange. Also fabricated additional bracket for right wing making a pair. Also added clevis pin.

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Jun 10, 2021     Cover plates for tail spring bolt - (2 hours)       Category: Empennage
After unable to find suitable plugs for tailspring bolt access, I fabricated cover plates for access holes.

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May 27, 2021     Tailwheel fairing - (1 hour) Category: Empennage
Installed tailwheel spring rod fairing.
 
May 27, 2021     Fairings - (3 hours) Category: Wings
Completed installation of aileron and flap fairings.
 
May 27, 2021     Windshield spacer - (1 hour) Category: Canopy
Added a spacer at right rear corner for better windshield fit with canopy.
 
May 25, 2021     Inspection plates and aileron fairing - (1 hour) Category: Wings
Installed plates on both wings. Installed left aileron push rod fairing. Reshaped and buffed both aileron push rod fairings.
 
May 25, 2021     Fairings - (1 hour) Category: Fuselage
Installed rudder cable fairings.
Installed inspection plates on each side of tail.
 
May 25, 2021     Rudder cable fillets - (.5 hour)       Category: Engine
Positioned rudder cable fillets and drilled fuselage for screws. Need to updrill fillets for screws

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May 25, 2021     Power check run Category: Engine
Checked mixture at high idle, mid range, and near full throttle. Noted little need to adjust mixture at this point. Adjusted idle upward to about 1000 rpm.
Full power run showed 3150 or better.
 
May 24, 2021     RPM indication - (2 hours) Category: Engine
Moved rpm sense line from left terminal to right terminal of voltage regulator. Also adjusted RADAC rpm sensitivity to minimum. RPM indication now operates normally. Also tried using P lead with 10K resister which worked but provided irregular and intermittent readings.
 
May 21, 2021     First engine run - (2 hours) Category: Engine
Started engine, warmed up and did gradual power increase to full throttle. Ran quite well at all ranges. Even idled smoothly after warm up. Only issue was RPM was not indicating at all. Investigating issue. May consider connecting to magneto P lead instead of alternator output. Had two runs, the first about 7 min and the second about 6 min. Due to no tach reading, Hobbs time not recorded.
 
May 20, 2021     Experimental placard Category: Interior Finish
Installed required EXPERIMENTAL placard on right cockpit wall.
 
May 17, 2021     Weight & Balance - (2 hours) Category: Research
Weighed aircraft with borrowed scales from Sonex. Completed weight and balance calculations. Empty weight is 613 lbs.
 
Dec 31, 2013     F20       Category: Fuselage
Completed

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May 13, 2021     Cotter pined control hinges - (2 hours) Category: Controls
Drilled and installed cotter pins on each end of the aileron and flap hinges. Also secured cotter pin on elevator push rod connection.
Evaluated previously fabricated gussets plates for aileron and elevator push rod exits.
 
May 12, 2021     Wing fold locking indicator - (1 hour) Category: Wings
Painted wing locking indicator on left and right wing to indicate red when in unlocked position.
 
May 12, 2021     Canopy seal - (3 hours)       Category: Canopy
Installed D seal around aft canopy former for better appearance.
Re-fabricated left windshield angle that attaches to longeron for better fit of canopy to windshield.

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May 12, 2021     Registration numbers - (.1 hour)       Category: Paint / Decals
Applied registration numbers to vertical fin.

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May 12, 2021     Trial prop fit - (1 hour) Category: Propeller
Trial fit prop to hub, tight fit on prop flange studs. Checked AN-41 bolt length furnished with kit and found them to long. Ordered AN-40 and AN-37 sizes.
 
May 08, 2021     F01 - (3 hours)       Category: Fuselage
Trial fit p-seal around aft canopy to fuselage joint. Looks good but will have to readjust for easier canopy closure. Also not sure how durable self stick will hold up.
Also added baggage pouch behind seat back. Used wheel chair backpack for pouch (About $30). Fairly sturdy waterproofed fabric. Has Velcro closures and two pockets, one under flap closure, the other flat envelope type. Fastened to seat back cross member with piece of Lexon left over from windshield scraps and four CC machine screws and washers into nut plates. Nut plates were previously there as remote transceiver mount, which was later moved.

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May 07, 2021     D01 - (5 hours)       Category: Canopy
Finished installing canopy. Removed protective film, thankfully, no scratches. Not perfect, maybe next one better.
Also improved locking ability by sanding down phenolic block on rear latch. Then enlarged forward slide opening to allow easier insertion and removal of locking pin.
Applied 1/2” round patch under canopy crack for reinforcement.

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Mar 28, 2020     F03 - (.3 hour)       Category: Fuselage
Sealed NaCA vent with clear silicon caulking

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Feb 10, 2020     G01 - (1 hour)       Category: Fuel System
Mounted fuel shut off valve plate to tank with mounting tape.
Trimmed fuel tank sensor back 2".

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Aug 29, 2020     P02 - (3 hours)       Category: Engine
Completed fitting upper cowling. Needed to extend firewall flange to provide adequate cowling mounting hole from edge of firewall flange.

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Aug 25, 2020     G01 - (2 hours)       Category: Fuel System
Installed gas tank and hooked up and tightened fittings to gas line in prep for fuel flow test. May consider moving fuel filter to fwd of firewall for easier access in future. Did that later and added support to filter.

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Nov 02, 2020     P01 - (2 hours)       Category: Engine
Completed work on baffle seals. Switched to silicone baffle seals later for better fit and seal.

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Sep 10, 2020     G01 - (3 hours)       Category: Fuel System
Accomplished fuel flow test. Level flight with 1.5 gals in tank, 25 gals
/hr, Second test at 16 degree pitch, no fuel flow. Added 2 gals and then got 21.5 gal/hr. Estimated unusable fuel at 3 gals.

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Nov 19, 2020     D02 - (2 hours)       Category: Canopy
Finished mounting windshield.

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May 07, 2014     ONX-W06 - (5 hours)       Category: Wings
Completed fabrication

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Jun 12, 2014     ONX-W04 - (4 hours)       Category: Wings
Completed fabrication

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Nov 26, 2013     ONX-W20 - (3 hours)       Category: Wings
Completed fabrication

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Dec 23, 2013     ONX-W16 - (6 hours)       Category: Wings
Completed fabrication

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Mar 21, 2014     F14 - (6 hours)       Category: Fuselage
Completed F14 except for fwd box cover plate.

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Mar 12, 2014     F16 - (2 hours)       Category: Fuselage
Completed

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Jan 08, 2016     W12 - (7.5 hours)       Category: Wings
Left inner wing skinning. Shaved slightly for fit. Drilled ribs to size 40. Noticed interference issue under wing fold assembly for installing pull rivets - checking with Kerry

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Jan 26, 2016     W12 - (5 hours)       Category: Wings
Fitted walk-way skins and shaped inner edge as required. Fitted flap hinges and drilled to #40.

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Feb 01, 2017     T01 - (3 hours)       Category: Empennage
Reinforced Rudder hinge (HH) and horizontal tail aft attachment (AA) with bolts for increased stress of tailwheel spring.

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Dec 13, 2013     W15 Category: Wings
Inboard rear spar details and assembly completed
 
Jun 17, 2014     W14 Category: Wings
Wing fold pin assembly completed
 
Oct 14, 2013     W13 Category: Wings
Unsure of completion date, neglected to log.
 
Aug 05, 2019     W12 - (1 hour) Category: Wings
Fitted new spring latches to wing fold joint handle. Don't like size, will check with Sonex for new hinge pins. Note: Later adapted existing pins and purchased pins to provide good fit.
 
Apr 11, 2016     W12 - (3 hours) Category: Wings
Finished skinning left inner lower wing.
 
Apr 10, 2016     W12 - (2 hours) Category: Wings
Riveted left upper inner wing skin.
 
Apr 08, 2016     W12 - (1 hour) Category: Wings
Installed washer head bolts o aft inner wing spar by hinge point. Still had rivet clearance problem. Plan suggestion, change spacing on skin to straddle bolts.
 
Apr 01, 2016     W12 - (4 hours) Category: Wings
Re-riveted upper inner spar with CCP44 rivets. Waiting for 4 new washer head bolts for rear inner spar hinge mount to allow rivet clearance.
 
Mar 28, 2016     W12 - (7 hours) Category: Wings
Riveted upper surface of right inner wing Discovered washer left on top of main spar and CCP42 used on main spar instead of CCP44. Removed rivets along spar and removed washer. Having trouble with aileron push rod clearance thru main spar. Checked with Sonex prototype and found same problem. I will hook up ailerons and see if problem still exists. If so will radius clearance thru spar for clearance/as per Sonex recommendation.
 
Mar 04, 2016     W12 - (2 hours) Category: Wings
Fitted inner wing skin in prep for riveting. Considered installing flap push rod and bell crank assembly to allow easier access to connections before riveting skin down, Worked on C01 for that.
 
Feb 23, 2016     W12 - (8 hours) Category: Wings
Installed wing fold levers, bolts, and safety wired. Re-made aileron connect paddle due to clearance issue with aileron push rod connector.
 
Feb 18, 2016     W12 - (4 hours) Category: Wings
Finished dimpling on inner wing skins
 
Feb 12, 2016     W12 - (7 hours) Category: Wings
Finished up-drilling leading edge holes with 12" #31. Removed both skins for deburring & dimpling. Dimpled and deburred left inner skins. Aligned & drilled and tapped pitot/static mount. De-burred right wing inner, drilled holes in skin for pitot/static.
 
Feb 03, 2016     W12 - (5.5 hours) Category: Wings
Up-drilled top and bottom left and right inner wing. Waiting on 12 #32 to finish up-drill along fuselage. Enlarged slots for wing folding handle on left wing.
 
Feb 02, 2016     W12 - (4 hours) Category: Wings
Up-drilled top surface of right inner wing. Ordered 12 #32 drills to complete row of rivets next to fuselage. Trimmed slot for aft spar fit.
 
Jan 25, 2016     W12 - (3.5 hours) Category: Wings
Drilled left and right skins to ribs with #40
 
Jan 07, 2016     W12 - (3 hours) Category: Wings
Right inner wing skinning . Shaved inside and outside for fit
 
Feb 10, 2014     W11 - (6 hours) Category: Wings
Fabrication started 2/9/2014, completed 2/10/2014
 
Feb 11, 2014     W10 Category: Wings
Fabrication done 2/11/2014
 
Mar 16, 2015     W08 - (5 hours) Category: Wings
Skinning done. Estimated hours
 
Mar 08, 2017     W08 - (1.5 hours) Category: Wings
De-riveted right wing aileron hinge due to incorrect hinge placement. Re-riveted right aileron hinge to wing .
 
Jan 06, 2016     W07 - (6 hours) Category: Wings
Fabricated bracket to attach Aircraft Spruce 15144 to horizontal crosspiece fwd of main spar. Will drill & tap bracket to accept machine screws from underside of wing skin.
 
Jan 27, 2018     W05 - (2 hours) Category: Wings
Installed additional -03 wing skin stiffener to trailing edge.
 
Nov 30, 2015     W05 Category: Wings
Waiting to complete skinning inner wing to complet final hook up of wing fold assembly attach. Finished Nov 2015
 
May 23, 2017     W02 - (1.5 hours) Category: Wings
Completed up-drilling . Added several rivets to support retaining strip. Deburred all drilled holes. Riveted wing tips on.
 
May 19, 2017     W02 - (7 hours) Category: Wings
Installed wing tip retaining strips. Refitted wing tips to wings, up-drilled upper surfaces both wings. meed to do lower side next.
 
May 18, 2017     W02 - (3 hours)       Category: Wings
Dennis Frost helped hold tips for positioning. Fitted wing tips to wings . Next remove and install retaining strip.

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May 23, 2017     W01 - (1 hour) Category: Wings
Installed hinge pins. Didn't like how originals were drilled so ordered new ones, stainless steel, and installed.
 
May 23, 2017     W01 - (2 hours) Category: Wings
Trial fitted ailerons, will need to trim counter weight openings/or use shorted bolts. Ordered AN3-16's
 
Oct 09, 2013     T09 Category: Empennage
Completed rudder details.
 
Mar 16, 2020     T08 - (.5 hour)       Category: Empennage
Applied small amount of bon-do to collision light mount to improve finished appearance. Needs sanding to finish.

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Mar 10, 2020     T08 - (3 hours) Category: Empennage
Primed and sanded tail tip several times. Drilled tip for wiring of collision light. Investigated how to run wiring to cockpit.
 
Feb 10, 2020     T08 - (1 hour) Category: Empennage
Epoxied balsa fillets to vertical tail for anti-collision beacon mount. Installed anchors for mounting screws.
 
Oct 22, 2013     T08 Category: Empennage
Completed vertical tail substructure details
 
Oct 23, 2013     T07 Category: Empennage
Completed Vertical tail spar assemblies, 10/22 and 10/23
 
Oct 16, 2013     T04       Category: Empennage
Finished horizontal tail substructure

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Oct 27, 2013     T06 - (6 hours)       Category: Empennage
Completed vertical tail and rudder assembly, started 10/24/2013

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Apr 16, 2017     T05 - (6 hours) Category: Empennage
Replaced and relocated rt elevator hinge. De-riveted left elevator hinge. Replaced and relocated left elev hinge for better match with stabilizer.
 
Dec 31, 1969     T05 - (3 hours) Category: Empennage
De-riveted rt elevator hinge due to elevator mis-match with stabilizer.
 
Oct 15, 2013     T05 Category: Empennage
Completed elevator details
 
Oct 17, 2013     T03 - (6 hours) Category: Empennage
Completed horizontal tail spar assemblies, 10/12, 10/14, 10/17.
 
Oct 29, 2013     T02 - (11.7 hours) Category: Empennage
Finished Elevator assembly.
 
Oct 21, 2013     T02 Category: Empennage
Finished horizontal stab install of tips
 
Oct 19, 2013     T02 Category: Empennage
Finished horizontal tail except for tips.
 
Oct 08, 2017     T02 - (2 hours) Category: Empennage
De-riveted hinge due to improper install. Re-riveted hinge to horizontal stab.
 
Oct 20, 2016     T01 - (2 hours) Category: Empennage
View E-E. After initial fitting found that holes didn't match anchors, re-drilled, then found detail D50 re-drilled again. Anchors now installed 10/20/2016. Removed MS21047-L4 and replaced with MS21059L4
 
May 21, 2018     P04 - (1 hour) Category: Engine
Drille & mounted engine mount. Torqued nuts to 65 in/lb, Torque sealed
 
Dec 31, 1969     P03 - (2.5 hours) Category: Engine
Moved RADAC from left side of firewall to right to make room for future oil breather recovery tank and system. Installed blind nuts to facilitate future removal of RADAC if required. Installed screws in previous RADAC mounting nut plates.
 


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