Project: JMillette   -  
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Builder Name:Joseph Millette   -  
Project:   Zenith   -   VIEW REPORTS
Total Hours:1151
Total Flight Time:
Start/Last Date:Jul 30, 2020 - Mar 31, 2022
Engine:Viking 130
Propeller:Whirlwind
Panel:GRT 10.1 Sport
 
Friendly URL: https://eaabuilderslog.org?s=JMillette

Home or Last Project Picture

Mar 08, 2024     CB Wiring - (9 hours)       Category: Avionics
Started wiring the CB for powering the electricals.


 
Mar 07, 2024     Batterys - (6 hours)       Category: Instrument Panel
Connected Contactors and wired battery
Circut breakers and switches next


 
Mar 07, 2024     Farings - (8 hours)       Category: Farings
Made farings and installed Factor Strut faring


 
Feb 25, 2024     Contiued mounting Control horns on Elevator - (8 hours)       Category: Tail Feathers
Installed Elevator control horn and installed Autopilot Trim Tab


 
Feb 18, 2024     Reskinned the Elevator - (8 hours)       Category: Tail Feathers
Since I am installing the iLevel/Aircraft Automation I didnt want to have 2 trim tabs on the elevator, so I had Zenith make me up a elevator skin with out the cut out for the trim tab so that I could instal the trim servo that will operate the autopilit pitch. This also provides auto trim along with the autopilot nfunction. This trip out to the hangar I was able to complete the reskin and mount it to the horizontal stab, Next week I will complte the full rebuild which will include the control horns.


 
Oct 29, 2023     Mounted new panel and more cleaning - (6 hours) Category: Instrument Panel
Today I did a bit more cleaning and also transferred the mounting holes to the new panel. I used less screws this time, but I might add the others still. I will decide this prior to painting it. I have a few more items to look at before starting the wiring again, but in the next 2 weeks, I should be able to get the panel finalized and painted in prep for wiring everything all over again. This project will probably take about 2 weeks. Then I can get the engine running again. This will be good since it has been sitting for about 1 year.
 
Oct 15, 2023     Clean up day - (6 hours) Category: Workshop
Today was a clean-up day. Since It had been a month or 2 since I had been out to the hangar to do any real work, I decided to take the day and do a good cleanup in prep for the coming weeks to really push. I also took a good look at what I needed to get done to move forward.
 
Jun 04, 2023     Panel and Electrical redo - (6 hours)       Category: Avionics
Started to plan out the new panel and layout for terminals and electricals. Installed new switches and took a lot of measurements.


 
May 30, 2023     Panel option redue - (3 hours)       Category: Avionics
Redesigned Panel to accommodate new AP and Trim setup. I am still debating using the GRT EFIS or swapping it to an iPad with the BOM as primary. The AP head unit can act as a PFD.


 
May 28, 2023     Clean Slate - (6 hours)       Category: Avionics
I started pulling Avionic to redo the wiring behind the panel. I was not happy with the current layout of the wiring.
I also purchased an ECOAutopilot from Aircraft Automation. This will use trim tabs to control my aircraft including auto trim and full autopilot modes (GPS and 2D)


 
May 07, 2023     Electrical redo - (6 hours)       Category: Fuselage
Relocated the Batteries to the space under the passenger seat. this will bring the weight aft and also provide easy servicing.


 
Dec 23, 2022     Passenger Door - (8 hours)       Category: Fuselage
Started assembly of the passenger side door.


 
Jan 01, 2023     Wiring from Wing to Panel - (9 hours)       Category: Lighting
Today I routed the wiring from the wings to the panel so that I can start connecting the power and Magnetometer.
Connected Nav and Strobs.


 
Dec 30, 2022     Final Fitting of Windscreen - (16 hours)       Category: Fuselage
Today I completed the final fitting of the windscreen.. Final cutting and cleaning. Man, the glue they used sucks.


 
Dec 28, 2022     Final Assembly of Passenger door - (5 hours)       Category: Fuselage


 
Dec 27, 2022     Pilot Door Final assembly - (5 hours)       Category: Fuselage
Final Assembly of Pilot Door after paint.
Installed on Fuselage


 
Dec 26, 2022     Painted Door frames and Parts - (8 hours)       Category: Fuselage


 
Dec 22, 2022     Decals Installed - (6 hours)       Category: Paint / Decals
ATD made me some more decals to finish off the dress of the plane.


 
Dec 12, 2022     Passenger side door - (8 hours)       Category: Fuselage
Built passenger side door frame. Next will be drilling for plexiglass and then prep both door frames for paint.


 
Dec 04, 2022     Reconnected fuel lines - (8 hours)       Category: Fuel System
Reconnected fuel lines from wing to fuselage. Made aluminum plates for access panel


 
Dec 03, 2022     Reinstalled Wings after paint - (7 hours)       Category: Wings
Had some friends come over to assist in reinstalling the wings. I also mounted the Flaperons and connected the linkage. I still need to set the throw. Tomorrow I plan to complete the passenger door and then begin rigging the tail controls so I can permanently mount the tail feathers.


 
Nov 27, 2022     Painted both wings - (30 hours)       Category: Paint / Decals
Completed painting the wings and the struts. Install hinge for passenger side door.


 
Nov 07, 2022     Painting Tail feathers - (16 hours)       Category: Paint / Decals
This weekend I bought some 2x4s to build hangers for parts while i paint them. These will also serve to hang the wings when ready to paint next weekend.


 
Oct 29, 2022     Disassembly - (8 hours)       Category: Wings
I removed my wings with some help to begin preparing them for paint. I also removed the tail feathers. I now have a lot of paint prep. While the wings are off i installed all the rivets that I missed (3) during initial build. Added space for easy access to forward wing bolts


 
Oct 30, 2022     Re did fuel channels - (8 hours)       Category: Fuel System
Removed headliner material, cleaned off glue and primed and painted. I wrapped fuel line with silicone heat protection tube for chaff protection. Labeled fuel nipples on fuselage, replace rubber grommets with plastic snap ring and re secured.


 
Oct 23, 2022     Nose Strut Spacer - (4 hours)       Category: Landing Gear
Install the Viking Aircraft nose strut Spacer to bring the nose 2in.up


 
Oct 09, 2022     Installed Flaperons - (8 hours)       Category: Controls
Next step is to disassemble and prep for paint.


 
Oct 02, 2022     Flaperons - (9 hours)       Category: Controls
Completed the construction of Passenger side Outboard and Both inboard flaperons. Next week will begin mounting and preliminary rigging so that I can prepare to disassemble and prep for paint of remaining parts, Wing, Horizontal, Vertical etc…


 
Oct 02, 2022     Stabilizer end cap - (16 hours)       Category: Tail Feathers
I built end caps for the horizontal stabilizers. These are designed using the EAA article. It noted that they should be no more than a 1/4 of the root. The root is 4in so I made the airfoil of the tip 1in. this will allow the airflow to stay over the elevator at low airspeeds and reduce vortices making the elevator more effective.


 
Sep 26, 2022     Building of Flaperon (part1) - (6 hours)       Category: Controls
Started assembling the pilot side O/BFlapperon


 
Sep 10, 2022     Fiberglass Fairing - (8 hours)       Category: Wings
Had to redo my passenger side fairing. I seemed to have missed the resin in the incorrect ratio. The Pilot side came out great. i have trimmed and filled it with a micro glass sphere and epoxy resin to fill the holes. Next will be sanding.


 
Sep 03, 2022     Inner wing skins - (16 hours)       Category: Wings
Completed passenger and pilot side inner wing skins. Made fiberglass fairings for the leading-edge joints.


 
Jul 30, 2022     Radio installed - (8 hours)       Category: Avionics
Installed and tested the Radio system. Installed headset/PTT switch. All works. When the engine is running and Atl Field is on, I get a slight wine sound. will test a filter to see if reduces.


 
 
Aug 27, 2022     Root Wing Skin - (8 hours)       Category: Wings
Started working on inner wing skin on pass. side wing. Will need to complete Pilot side and then make fiberglass fairing.
Also completed wiring on Pilot grip. Added elevator trim control to grip.


 
Jul 28, 2022     Installed Pilot Nav/Strobe - (4 hours)       Category: Lighting
Installed Nav/strobe on pilot side wing. Also completed wiring in Pilot wing, Nav?Strobe, Landing light, and Pitot Heat.


 
Jul 28, 2022     Pilot Wing tip - (4 hours)       Category: Wings
Installed Pilot side Wing Tip.


 
Jul 27, 2022     Parking Brake - (4 hours)       Category: Controls
I have installed parking brake control cable.I am unhappy with the installation and will redo it once a new cable arrives.


 
Jul 25, 2022     Steering Linkage - (5 hours)       Category: Controls
installed steering linkage and started to decide on routing of wiring from wing to fuselage. Completed EFIS Mod Per manufacture


 
Jul 25, 2022     Mount for Headsets - (4 hours)       Category: Avionics
Installed headset mounts and installed fuel flow sensors


 
Jul 04, 2022     Static System/BU levil BOM Install - (8 hours)       Category: Avionics
Installed Levil BOM for AHRS BU. Finished installing Static port(S) nees to run static line to front of Aircraft to connect to EFIS and EIS.


 
Apr 04, 2022     EIS Sensor Terminal - (6 hours)       Category: Instrument Panel
Installed terminal block for EIS Sensors. Installed Data Plate.


 
Mar 27, 2022     Fuel tanks and fuel line - (8 hours)       Category: Fuel System
Completed routing fuel line from main wing tanks to the header tank. Few more holes to drill and will be fully set up and ready for testing for leaks.


 
Mar 24, 2022     Finished up the Dorsal - (6 hours)       Category: Tail Feathers
Completed the mount for dorsal on the Vertical fin


 
Mar 25, 2022     Viking Aircraft Fuel Sender - (16 hours)       Category: Fuel System
Installed the fuel sender inserts from Viking Aircraft Co. they are ~1in lower allowing for installation of the fuel senders on the top of the tank.


 
Mar 20, 2022     Dorsal Fin and Access panel - (7 hours)       Category: Tail Feathers
I did more trimming to allow for a better fit of the dorsal fin around the horizontal stabilizer. Also installed an access panel to allow for easy inspection of the elevator pulley.


 
Mar 19, 2022     replaced the nose strut - (6 hours)       Category: Landing Gear
Today I replaced the factory nose strut with a 2in longer one from Zenith Aircraft to allow more prop clearance. Went from 2-3in to 9in.


 
Mar 12, 2022     Fuel Trailer - (3 hours)       Category: Fuel System


 
Mar 06, 2022     Building Fuel Trailer - (8 hours)       Category: Tools
Started assembly of fuel cart for AutoGas for the plane. The trailer is a DIY Kit from Lowes. I added 4x8 3/4in plywood and coated it in Bedliner paint to protect it from water and fuel damage.


 
Jan 16, 2022     Mounted Tail - (16 hours)       Category: Tail Feathers
Over this past weekend i installed the horizontal and vertical stablizer. They are temp. Since i will be painting them while off the aircraft. Incidence of Horizontal is set to -0.9 deg. Which is with in. Tolerences of the plans. The mounting L-Angle is installed to allow mounting of the vertical stab to. The horizontal.


 
Jan 09, 2022     Corrected dihedral - (8 hours)       Category: Wings
Today I fixed the mistake I made on the struts. Here are the steps to correct the issue I created.
1. Level aircraft
2. run string from one wingtip to the other.
3. set wing height to 85mm =/-5mm at inboard rib.
4. Mount struts lose to get correct length.
5. mark holes for weldment and strut.
5. drill holes and then remount.
6. check dihedral (1.3 deg. on both wings)
7. repeat on other wing.


 
Jan 01, 2022     Struts and mounting bolts - (9 hours)       Category: Wings
Mounted struts, Cut ended 1 in short and will need to correct to achieve correct dihedral. Started building fuel cart. Hangar leaks covered plane to prevent damage.


 
Dec 29, 2021     Mounted wings - (8 hours)       Category: Wings
Today I had a few friends come over and help mount the wings to the fuselage. We mocked up the wings in so that i can perform all measurements to get the wings square, set incidence, and then finally dihedral.


 
Dec 20, 2021     Started left wing - (9 hours)       Category: Wings
Riveted the left wing skeleton together


 
Dec 16, 2021     Hobbs meter and Flap switch - (2 hours)       Category: Instrument Panel


 
Dec 16, 2021     Sunroof Install - (8 hours)       Category: Fuselage
Installed the replacement sunroof.


 
Dec 05, 2021     Installed windscreen - (5 hours)       Category: Fuselage
Today I worked on getting the windscreen trimmed and fitted to the fuselage. Went well. Started drilling and fitting the sunroof on. All went well and then the dreaded sound of Lexan cracking. I had to order a new sunroof.


 
Nov 28, 2021     Installed Landing Light in Right wing - (8 hours)       Category: Lighting
I cant an access panel to install the landing light to. I will need to add some L-angles to stiffen the panel to reduce flex when flying.


 
Nov 06, 2021     Continued right wing - (16 hours)       Category: Wings
Completed wiring for right wing. Mounted remote magnetometer. Wiring all runs along the trailing edge. Completed sheeting the wing top and bottom. Left inboard skin and trailing edge clecoed until after wings are mounted.


 
Oct 24, 2021     Started skeleton of Right Wing - (8 hours)       Category: Wings
Started assembling the right-wing skeleton.


 
Oct 31, 2021     Right wing continued - (9 hours)       Category: Wings
Completed skinning the bottom of the right-wing, next is wiring.


 
Oct 26, 2021     Color Scheme       Category: Interior Finish


 
Sep 06, 2021     Started wiring the Avionics - (16 hours)       Category: Avionics
For this log entry, I started wiring the avionics in the Cruzer. I mainly wanted to get the EFIS connections with the G175 Garmin, and the the Trig 22 Mode S transponder. I did run into 2 issues. I accidentally connected the Serial out of the ARINC to the EFIS to the In and vise versa. I found the mistake by using a multi meter and checking the pins. I also forgot to wire the Remote on ground wire on the trig 22 transponder. I corrected this issue and all is now correctly working. I continued and installed the RF Cabling for the following antennas, Com radio, Transponder, and GPS Antenna. Attached is my wiring diagram i drew out for future reference.


 
Sep 08, 2021     Chip in prop       Category: Propeller
Today I discovered what looks to be a chip in the whirlwind prop. I have not dropped the prop nor has anything hit the prop. I have reached out to Viking Aircraft Engine and they are going to talk to Whirlwind to determine if it will need to be replaced.


 
Sep 05, 2021     Made Decals for air intake - (3 hours)       Category: Paint / Decals
Today I designed and cut out on my vinyl cutting machine.


 
Aug 29, 2021     Painted and installed Seat frames and Interior - (16 hours)       Category: Interior Finish
Today was a great day, I received my seats from Flightline Interiors LLC. I assembled and painted the frames. Once dry i installed the seats. the interior is made of ultra leather which is light weight and will last longer in the aircraft.


 
Jul 25, 2021     Cowl Continued - (5 hours)       Category: Engine
Since i cut the cowl too short. I had to correct the mistake and remount the lower cowl. The space between the spinner backplate and the cowl is not increased to 20mm. I plan on doing some bodywork to decrease the space. Started upper cowl.

While installing the lower hinge system for the cowling, the rivets need up close to the edge. I measured and determined while close, I was within the minimum of 1.5mm but not within the suggested 10mm from the edge on the skin. I had my friend (A&P Robert McCoy) inspect the issue and he determined that it will be safe.


 
Aug 21, 2021     Primed and Painted Cowling - (16 hours)       Category: Paint / Decals
I completed the priming and painting of the cowling. I added the decals as well.


 
Aug 21, 2021     First Start of Viking Engine - (4 hours) Category: Engine
Today I performed the first start of the Viking 130 engine. This was completed without the prop installed to make sure wiring was installed properly and also to make sure there were no leaks in the cooling system. All went smooth. I followed Viking Aircraft Engines' recommended start checklist.
 
Aug 11, 2021     Brake line covers - (2 hours)       Category: Landing Gear


 
Aug 01, 2021     Electrical of Engine/circuit breakers - (8 hours)       Category: Engine
Completed wiring the circuit breakers for the engine power. Wired switches for engine controls. Installed dual throttle. Installed engine sensor wiring.


 
Aug 07, 2021     Electrical completion for Engine - (8 hours)       Category: Engine
Painted radiator shroud and installed fuel line from the header tank to engine.
I painted the new 2in longer nose strut and completed installing the fuel line from header to Engine.


 
Aug 14, 2021     Cowl Work - (16 hours)       Category: Engine
Completed some bodywork on the cowling to correct the gap between the cowling and the spinner. I also shortened the exhaust pipe to the recommended 2in length.
Pick foam was used to mold the front of the cowling to match the spinner then 2 layers of 2oz fiberglass and epoxy resins were used to bond.


 
May 25, 2021     Corrected Radiator plumbing - (2 hours)       Category: Engine
I made the following corrections to the Radiator plumbing.
Mounted overflow is lower than the cap.
Installed clamps.


 
May 23, 2021     Radiator Plumbing - (4 hours)       Category: Engine
Installed radiator hose and mounted ECU. Installed GRT Engine sensors. Coolant Temp, Oil Pressure, Gearbox temp.


 
May 20, 2021     Decals - (1 hour)       Category: Paint / Decals
Had decals made up at ATD of Las Cruces NM. Stars and Bars for Empennage and Nose art for Cowl.


 
 
May 16, 2021     Nose Gear and Brakes - (8 hours)       Category: Landing Gear
Installed brake lines and parking brakes. Installed nose gear to Firewall.


 
May 09, 2021     Prepped for paint and Painted the fuselage - (16 hours)       Category: Paint / Decals
I prepped the fuselage for paint but using scotch-brite pads, soap water to clean and provide a mechanical bond for the epoxy primer used. (Eastwood 1:1 primer system). I then taped all parts that I did not want the paint to get on. I then sprayed the external surface with HotRod Flatz Olive paint. Next week will be detail trim paint (D-Day strips and decals)


 
May 01, 2021     Panel Completed - (32 hours)       Category: Instrument Panel
I completed the panel. I primed and painted it once all holes were drilled and cut out. I cleaned up all the cutouts with a file and sand paper. I called garmin and GRT to check on a few wiring questions, 1: can I feed GPS position from G175 to Trig 21 Mode S transponder to be ADS-B compliant? (Yes) 2: do I need an ARINC and Serial to Panel? (Yes and will need to purchase the ARINC adapter) 3: can i return the FlySafe2020 since I don't need it? (Yes).

I also made my skin doublers and installed all antenna temporarily. Will remove all for paint. Which should be in a few weeks. Built a Avionics tray behind the panel to house all my remote avionics.


 
Apr 22, 2021     Ordered Eng. and Firewall forward kit Category: Engine
Ordered Engine and FWF kit from Viking Aircraft Engines.
 
Apr 18, 2021     New removable panel and Mounted Avionics to panel - (16 hours)       Category: Avionics
I cut the instrument panel and made a new removable panel from .032 aluminum. Cut holes for panel equipment and temporary mounted equipment. Will open all wholes to correct sizes and finish panel next week. This will include nut plates and screws.


 
Apr 15, 2021     Tie downs and Cargo area - (4 hours)       Category: Fuselage
I painted the cargo area with the Krylon bed liner paint and installed tie downs for bungee netting. I also made a Stiffiner plate for the com antenna and test fit onto the Fuselage


 
Apr 11, 2021     Printed decal tests - (2 hours)       Category: Paint / Decals
Test cut N# and Star and Bar decals. Both are cut in Vinyl by a Criket Explorer.


 
Mar 22, 2021     Received GRT Avionics Package - (1 hour)       Category: Avionics
Received and tested on the bench the GRT Sport 10.1in EFIS
Added the Garmin175


 
Mar 27, 2021     New lighting - (6 hours)       Category: Workshop
Installed new lighting and cleaned up garage to get prepped for painting.


 
Apr 04, 2021     Painted the interior - (8 hours)       Category: Paint / Decals
Started getting paint laid down on the interior to prep for the final installing of interior panels.
I used Eastwood Epoxy primer and Hot Rod Flatz Olive drab paint. I also added Krylon Bedliner paint for anti-slip on flooring.
Also started laying out my panel layout.


 
Mar 22, 2021     Prep for A/C install in Working area - (6 hours)       Category: Workshop
Insulated the garage door in preparation for AC install in shop.


 
Mar 22, 2021     installed sliding seats - (8 hours)       Category: Interior Finish
Installed mounting points for sliding seats


 
Mar 22, 2021     Upper front skin - (8 hours)       Category: Fuselage
Test fit and drilled upper front skin.


 
Feb 27, 2021     Mocked up Rudder controls - (8 hours)       Category: Controls
Installed Rudder pedals.


 
Jan 31, 2021     On the Gear - (16 hours)       Category: Landing Gear
Got aircraft on its main gear. Still need to complete the Firewall and nose gear assembly.


 
Feb 06, 2021     Mocked up controls/Final Install - (16 hours)       Category: Controls
Today was setting up the flight controls, mocked everything up to the best that i can with out the surfaces attached. decided to prime the parts and reinstall with grease. Missing one castle nut. Placed order with aircraft spruce.


 
Jan 23, 2021     Painted Landing gear - (16 hours)       Category: Landing Gear
Started to prep for landing gear installation. I painted the main gear, mounted the tires and painted the gear mounts black. I also primed and panted the gear channel in preparation for gear installation next weekend.
To fit the axles on the main gear legs some grinding was necessary to allow freedom of movement of the brake caliper. Once all holes were drilled the surface was primed and painted in urethane flat black.
A few mistakes were made in the construction of the nose gear. The 6 holes on the leg and fork were drill out to an AN5 bolt on accident. All 6 hole were drilled to match and new bolts were ordered to match the holes.
The gear mounts also had a small mistake, the front of the gear mount was to have 4 bolts, i did the moth wrong and ended up with 5 holes. I was unable to get the bolt in the lowest point, so 1 A6 rivet was used and then 4 bolts to the upper section as seen in the pictures. My opinion is that this will still be plenty strong. I plan on having my A&P friend come by and inspect to insure safe and strong.


 
Jan 19, 2021     Fuselage Continued - (23 hours)       Category: Fuselage
This is a culmination of 3 days of work of 8 hrs each day. in the last post, I joined and clecoed the fuselage halves together. This week I commented and riveted them together. I also started assembling the firewall. After the assembly of the firewall was completed I disassembled the parts and primed the aluminum parts with Eastwood 1:1 grey primer and then finally assembled the firewall in preparation for mounting to the aircraft. Once clecoed in place on the front of the aircraft, I began to work on the front stiffeners as seen in the images. I made a mistake and messed up on 2 of the L stiffeners that go on the front skin. I had to order 2 replacements. they should be here by the end of the week and will be installed once received. The next task will be to complete the installation of the gear channel stiffeners and then prep and paint the steel gear mounts. This will be next week. The plan is to have it on its wheels in 1-2 weeks. I also drill out the cabin frame for attachment to the fuselage and clecoed into place.


 
Jan 10, 2021     Joined the Fuselage - (8 hours)       Category: Fuselage
Today I completed a lot. I was able to get the longerons attached to the bottom of the front fuselage. I riveted the front of the Fuselage. I prepped the Fuselage for joining and i was able to cleco the half's together to trail fit. All fit perfectly.


 
Jan 09, 2021     Corrected the mistake - (9 hours)       Category: Fuselage
Today I had to work on the fuselage front section making the corrections to the mistakes that I made last time. I ordered replacement parts to install the seat base and supports. I made all the angles supports and cleco everything in place. Now everything is square and straight and ready to rivets in place. I also went and Fabricated the longeron to fit on the bottom of the fuselage. Tomorrow the plan is to match drill the longerons to the bottom of the fuselage and starts riveting.


 
Jan 04, 2021     Started work on the forward fusealge - (24 hours)       Category: Fuselage
I started working in the forward cabin area. This included the floor, stiffeners, and seat assemblies.
I began to install the sliding seat assemblies and found out the hard way that I should not have started this stage yet due to the sub-assembly not being together and square. The old saying goes, there is always time to do the job a second time, but never enough time to do it right the first time. Well, there it is. I have reordered the parts that I messed up and will continue to move through the build. this time ensuring the front cabin is square and straight. I will then move forward to attaching the cabin sub-assembly to the rear fuselage and then move to install the sliding seats at the appropriate time.


 
Dec 20, 2020     Side Walls and Top - (20 hours)       Category: Empennage
Today was a great accomplishment in my opinion. I got the side walls and the top in place and clecoed. All lined up nicely. I have been priming the parts and where they mate with the skins with rust oleum self etching primer to protect the mating surfaces. I also primed the areas close to the cabin area. Video of the work can be found here: https://youtu.be/-alos3InEQo


 
Dec 14, 2020     Empennage Build started - (16 hours)       Category: Empennage
Started building the empennage, completed the bottom skin and the Right side. I primed between parts using the Rustoleum self-etching primer.


 
Oct 08, 2020     Completion Elevator - (8 hours)       Category: Tail Feathers
Today I completed the elevator and hinged to the stabilizer. I had to drill out 5 rivets that I found out that I used the wrong size. I corrected this and completed the build of the section.


 
Sep 27, 2020     Started assembly of the Elevator - (6 hours)       Category: Tail Feathers
With the horizontal stab completed up to the point of installing on the fuselage, I decided to move on to the elevator assembly. So far all went smoothly. I did have some issues when it came to installing the L angle brackets on the center channel and the middle ribs. It is a tight fit and getting a drill in there to match drill was difficult. I ended up riveting it together as a sub-assembly and then installing it under the skin as one piece. At this point, all of the elevator is clecoed together. The elevator is also hinged to the Horizontal stab and moving freely. I will need to make final adjustments to the tips once the elevator is riveted together. The final steps of the assembly will be to install the counter balance and control horns. Then I will install the trim tab and servo for the pitch trim.

https://youtu.be/lf6Qq6Zzj5U


 
Sep 20, 2020     Completion on the Horizontal Stab - (7 hours)       Category: Tail Feathers
Today I completed the assembly of the Horizontal Stab. Main goal was to correct a bad rivet on the L bracket holding the end rib on the tip. I then finished riveting the skin to the skeleton frame. I made a mistake while cleaning up a hole on the stab tip. The drill grabbed and pulled thru causing the hole to be bigger then needed. I repaired the hole by mixing 30min epoxy and micro balloons to fill the whole and then added 2oz fiberglass on top and bottom of the hole to regain the strength. I also ordered the remaining parts of the kit and I will be picking it up on Nov 30th 2020.
https://youtu.be/Mcp7gsajVho


 
Sep 13, 2020     Horizontal Stabilizer Part 2 - (4 hours)       Category: Tail Feathers
Today I continued work on assembly of the horizontal stabilizer. I completed the riveting of the skins to the bottom of the skeletal structure. Installed the stab tip ribs. Clecoed the skin to the top of the stabilizer. I drilled and test fit the elevator hinge. Once completed, I determined that the hinge is about 2in too long total and will need to be trimmed to fit properly to allow freedom of movement of the elevator when the tips are installed. Next steps will be trimming and mounting the stabalizer tips.


 
Sep 09, 2020     Horizontal Stabilizer Part 1 - (5 hours)       Category: Tail Feathers
Today I started building the Horizontal Stab for my Cruzer. I started off with deburring all the parts needed. I then removed the label stickers on the parts prior to assembly. I ended my day with a test fitting the skin to the bottom. Video of progress is below and also linked.
https://youtu.be/Rhrq_suPvj8


 
Aug 28, 2020     Tail Kit Arrived and Inventory - (1 hour)       Category: Tail Feathers
The Tail kit arrived from Zenith Aircraft. I took a careful inventory of the contents of the kit and found that 1 part was missing from the kit. (the L angle). with that Ialso determined that the new kit included another rudder kit. Should start the process of building the kit in the following weekend.


 
Aug 13, 2020     Purchase of Tail Kit - (1 hour) Category: Research
Purchased the Tail kit from Zenith Aircraft and the Drawings and Manuals for my build.
 
Aug 09, 2020     Completion of rudder assembly - (5 hours)       Category: Tail Feathers
Today I completed the rudder assembly. I followed the directions to the letter. All parts were de-burred and test fitted for proper fitting prior to cleco and then finally riveted. I started at 10:30AM and completed at 3:30PM (5Hrs). The rudder was set aside awaiting the next parts to be sent out from the factory. The next order will have the Horizontal Stab and Elevator assemblies.


 
Aug 08, 2020     Rudder Trial Fit - (2 hours)       Category: Tail Feathers
Today I deburred all the parts for the rudder. I then trial fit all the parts and cleco all together to see how it fit together. I put in an order for #20 and #30 drill bits so that I can drill the spar doublers and cleco together. Next week will start putting the rudder completely together and complete the assembly.


 
Jul 30, 2020     The journey begins... - (1 hour)       Category: Research
I received the first component of my new project on Tuesday the 28th of July 2020. I am excited to get started and looking forward to the experience of building my first plane. I have built many RC Models over the years and I am very interested in how much of this experience transfers. I will be putting using video documentation on this build as well and will be posted on my youtube channel (www.youtube.com/joesrccorner). I started this build by reading the manual in-depth to get a good understanding of the construction techniques. I have one other project in the way and once completed, I will be cleaning my workspace in preparation for the build. If anyone out there is building the same plane, I would love to hear from you so that I can get tips and tricks along the way.


 


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