Apr 05, 2022     March 20-29, April 3, 4 Sessions - (22 hours)       Category: Workshop

Hundreds of final details before our planned FAA inspection set for May 6! Cleaning up wiring by Harsh. Finishing touches on the canopy fairing and cowling. Securing spinner and pitot tube. started removing all the blue plastic from the skin. "Smoke test" performed last night. R landing light "wig-wags", and Fuel Pump #2 does not run, otherwise A-OK. NO SMOKE!
Starting to run through the Final Checklist from Van's.

  Mar 13, 2022     Sunday session - (3 hours)       Category: Workshop

Propeller mounted by Willem. Cowling scoops fitted, clecoed, and mounted with epoxy by Brady. Spinner pitot fitting installed by Addison. Garrett reviewed process for final inspection, testing.

  Mar 08, 2022     Weekly report - (7 hours)       Category: Workshop

Panel installed by Maggie and avionics bay wiring organized. Wing root trimming completed by Garrett. Pitot mount installed by Logan. Spinner trimmed by Addison. Seat cushion snaps installed by Logan. Richard trimmed and fitted air filter housing.

  Mar 01, 2022     Weekly update - (7 hours)       Category: Workshop

Better progress this week. Wings back on, Flaperon torque arms and tubes final installed. Oil and coolant lines final installed. SCAT tubing for cabin air/heat installed. interior console trim installed. Canopy fiberglas progressing slowly.

  Feb 21, 2022     Feb 14,15,20,21 Sessions - (9 hours)       Category: Workshop

Slow progress due to delay of Flap Actuator decision, canopy fairing, Super Bowl and ice storm. Wings reinstalled and torque arms/tubes drilled per plans after Van's indicated actuator is OK to proceed. They suggested travel of flaps likely to be minimally affected and performance effect nil. Maggie and Garrett used a Vix bit to center the holes on the torque tube and removed and completed the hole drilling. Richard and Willem worked on the oil line placement, learning to safety wire and attache Adel clamps. After numerous tries (learning!) they have accomplished their tasks. Addison, Brady and Adam continued to sand the canopy.
We also reviewed the new Service Bulletin re the tail skin cracking and will be ordering the parts to comply.

  Feb 08, 2022     Sun, Mon, Tues Sessions - (7 hours)       Category: Workshop

Work continues on the canopy fairing, sanding and applying more resin, repeat. Final engine installation included attaching oil and coolant hoses. Richard, Addison and Brady learned how to properly safety wire bolts on the engine. Harsh helped Jim Becker complete installation of the upgraded landing gear on the Cub. The plastic guides in the central fuselage floor were re-installed because they were not tightened correctly the first time. The Flaperon torque tube installation is on hold until Van's confirms our actuator is OK.

  Feb 01, 2022     Sun, Mon, Tues Sessions - (7 hours)       Category: Workshop

This week was spent correcting some errors identified when a metal-metal squeak was noted last week, when moving the sticks. The torque arms and pushrods were removed and it was clear the pushrods were set 1/2' shorter than specified. This explained the low angle between the torque arms and pushrods and the reason the pushrods were rubbing on the ribs. The new torque tubes were received from Van's. The flap actuator was tested and does not fully retract but moves through 1-11/16" travel. We will check with Van's to see that this is acceptable. The pushrods were repainted and set in a jig to get them to the exact length then they were reinstalled. The original torque arms were repainted and reinstalled. Maggie reinstalled the spacers on the torque tubes. The angle at the arms was much greater, and the pushrods don't rub! We're ready to redrill the tubes and set the flaperons.
Richard and Adam spent much time trimming and sanding the canopy fairing and it is nicely taking shape. Addison put nut plates on a cowl scoop, and Brady installed the oil tank, cooler and radiator.
We noted the plastic guides on the floor of the plane were not full secured and these were pulled in order to re-install them properly.

  Jan 25, 2022     Mon and Tuesday Sessions - (4 hours)       Category: Workshop

Productive sessions. Nutplates for cowling hinges by Richard, Successfully re-routed rudder cables through grommets in tail by Garrett. Sanded fairing and removed canopy for further trimming. Richard learned to secure castle nuts with cotter pins. Maggie "the pretzel" Colwell tracked down some squeaking noises when moving the sticks. Turns out the pushrods rub on the bottom of the lightening holes. Larry discussed the issue with Van's and it appears the torque arms are not positioned properly. The cause in unclear. Will need to be sure the flap actuator is not extended at all, and verify the geometry of the torque tubes. New torque tubes, aileron push rods and spacers have been ordered.

  Jan 23, 2022     Sunday Session - (3 hours)       Category: Workshop

Garrett completed the routing and attachment of the AOA, Pitot, Static and OAT lines at the ADAHRS unit in the tail. He began connecting the Stabilator cables and rerouted the rudder cables through the grommets, missed on initial installation. Maggie, Addison and Izzy final drilled the forward holes on the cowling and attached nut plates. Sanding continues on the canopy fairing.

  Jan 18, 2022     Su, M, Tu Sessions - (7 hours)       Category: Workshop

Work continued on the canopy fairing. Sanding and reapplying more epoxy. Final riveting of the canopy hinges. Final riveting of the fuselage skins by Addison and Willem. Garret worked on routing the pitot line from the engine to the ADHARS unit.

  Jan 11, 2022     Jan 9-11 sessions - (7 hours)       Category: Workshop

Maggie "the pretzel" Colwell managed to contort herself in the cockpit for 3 hours and connect the rudder links to the pedals!
Richard and Addison have nearly completed the lower cowling hinges.
Brady finally was able to complete the final skin pieces under the gear after replacing nut plates and removing some rivets
Garrett finished the fuel filler neck and drain line.

  Jan 04, 2022     First 2022 Sessions - (7 hours)       Category: Workshop

Returned to the normal Sun/M/Tu schedule. Fiberglass work progressed with Rick's help, adding layers of resin/microbeads. The rear window, Fuel filler, and turtle deck are progressing. Final attaching the flaperon torque tubes. Steps attached. Exhaust installed preliminarily, needed to get sealant for pipes. Cowling hinge attach holes drilled. It's really starting to look like an airplane.

  Dec 29, 2021     Christmas Break sessions - (8 hours)       Category: Workshop

Over Christmas break we scheduled two 4 hour sessions. We were pleased to see Adam R, Rebecca and Josh back on break from college. Holden also had a chance to view the project. Great progress was made on the cowling and the canopy.

The fiberglass was laid over the forward canopy. Rick supervised this process.

Final tailcone attachment was completed.

  Dec 20, 2021     Tailcone attached for final time - (2 hours)       Category: Workshop

The tailcone was fitted and clecoed in place for the final time! There seemed to be misalignment but by lifting the tail all the holes lined up.

The cowling work is progressing through Richard's diligent work.

The canopy is back on and being prepped for the fiberglass work.

  Dec 19, 2021     Harsh solos today! - (3 hours)       Category: Workshop

Harsh completed his first solo flight in a J3 Cub today, congratulations! We clipped his tail feathers at the hanger.

Work continued on the flaperon torque arms, deburring and reinstalling them.
The cowling is getting close to final fit.
Fiberglass was cut.

  Dec 13, 2021     Good progress - (2 hours)       Category: Workshop

Richard began fitting the lower cowling and drilled the forward attach holes. He then trimmed the lower aft edges.
Garrett final drilled the right flaperon torque tube. We secured the flaperon but it still sags slightly. Rick identified a loose bolt on the center of the bellcrank. Tighten this might have helped a little. The controls seem to have very little play.
Addison and Maggie finished bending the tailcone tabs the put nutplates on some side pieces.

  Dec 12, 2021     Slow progress - (3 hours)       Category: Workshop

Garrett continued to work on the Flaperon torque arms and tubes. Preliminary holes were drilled and he reinstalled the parts. When reinstalled the flaperons were drooping 1/4"-1/2" down slightly more on the R than the L. Not being sure if this was OK we discussed ways of correcting the asymmetry. Larry discussed the issue with Van's Monday morning and it sees this is fine. If we can correct some asymmetry with final hole drilling that would be OK, but final rigging adjustments will be made by lengthening or shortening the long push rods from the sticks.
Adam and Richard worked on the upper cowling, drilling the attachment holes along the aft hinge.
Maggie worked to bend the flanges on the tailbone.
Addison worked on the sideskin pieces, attaching nut plates.
Willem vacuumed the hanger (yeah!) and Logan helped him remove stables from one of the crate plywood covers.

  Dec 07, 2021     Further progress - (2 hours)       Category: Workshop

Further progress on the upper cowling and flaperon controls

  Dec 06, 2021     Cowl fitting - (2 hours)       Category: Workshop

Garrett drilled the holes on the torque tubes.
Richard and Addison continued work on the cowling.
Harsh, Brady, Maggie worked on the panel.

  Dec 05, 2021     Meticulous - (3 hours)       Category: Workshop

Garrett remeasured the flap control rod to verify the proper length (11-29/32”) and verified the torque arms were at the same height (they were within .016”) and then drilled the flaperon torque tube top holes.
Addison cut and finish sanded the remaining holes in the lower cowling.
Adam and Willem worked on the skin pieces for around the landing gear.
Brady found the center panel piece that ALREADY had the autopilot control holes in it! He had been working to cut them and place nut plates for the last week. Chalk it up to experience!
Richard and Harsh worked on their cross country flight plan and Harsh flew from HXF to MSN on the simulator.
We had a brief tutorial on aircraft engines and Larry showed them the C-85 engine entirely disassembled.

  Nov 30, 2021     Major Visual Progress (MVP)! - (2 hours)       Category: Workshop

Final torqued the flaperon bolts.
Adam cut the rudder links to size.
We attached both wings in preparation for final drilling the flaperon torque tubes.
Addison cut the lower cowling holes.
Logan had the honor of being the first to sit in the plane and make airplane sounds!

  Nov 29, 2021     Productive week - (9 hours)       Category: Workshop

Larry was out with Covid but the team labored on without him this week!
The cowling top was fitted preliminarily. The lower cowling HS been rough trimmed.
Final check of the cockpit revealed a bottomed-out nut on the stabilator pulleys. The bolt was cut out and appropriate washers were used in the reinstall.
Fuel tank wiring was completed.
Tonight the tailcone was attached with clecos and the rudder cables were pulled back and attached. Brady set the forward attach links so that the pedals are even and there is adequate tension.
Harsh continues to work on the avionics bay.

  Nov 15, 2021     Monday session - (2 hours)       Category: Workshop

Amber placed snap bushings and learned how how to tie wrap wire bundles. We triple checked wire routing and secured loose wires. We used RTV to secure the right stick wire as it emerges at the bottom so that it doesn't stretch when the stick is full forward. Harsh finished the dome light attachment.

  Nov 14, 2021     Sunday Session - (3 hours)       Category: Workshop

Garrett re-routed elevator cables around the pulleys in the cockpit which had been incorrectly routed. He installed the ADSB unit on the rear bulkhead and antenna on the tailcone. Adam temporarily attached the rudder cables at the pedals for fitting, and he helped with the cowlings. Addison and Richard rough cut the cowling and began finish sanding the edges. Harsh routed the dome light wires through the roll bar. Willem helped Dan and Wayne disassemble the C65 Cub engine which is now ready for removal. Logan finished zip tying the ELT wires.

Steve Krog provided ground school for Willem, Logan, Addison and Taylor. He provided simulator missions for Adam, Richard and Harsh to practice.

  Nov 09, 2021     Tuesday session - (2 hours)       Category: Workshop

Garrett secured and torque sealed all fuselage controls. He wired the flap motor.
Logan installed the ELT batteries and mounted it. He secured the wires with zip ties and snap bushings.
Addison and Richard began trimming the upper and lower cowling.

  Nov 08, 2021     Monday session - (2 hours)       Category: Workshop

Brady worked on panel holes for A/P controls. Addison worked on cowl hinges and Amber started to disassemble the Cub engine for removal. We rearranged the planes with the Cub in position to change the engine to an 86 and upgrade the landing gear.

  Nov 07, 2021     Sunday ses - (3 hours)       Category: Workshop

Good session. Garrett reattached the flapperon torque arms after they were repaired by Dan Forsberg. Washers were welded on both sides of the rod end bearings to correct the misalignment. Addison finished assembling the seat belts and work was started on the cowling attach hinges. Brady began cutting the openings for thr autopilot control panels. Harsh continued to work the common electrical section.

We confirmed the presence of the lock washer per SB-00045, Rotax SB-912i-012is.

  Nov 02, 2021     Tuesday session - (2 hours)       Category: Workshop

Logan deburred shoulder harness attach straps. Addison collected seat belt hardware. Garrett worked on the flapperon torque arm and A/P servo attachment. Unfortunately it appears the torque arms are not exactly the same length so the will need to be removed and adjusted.

  Nov 01, 2021     11-1-2021 Build Session - (2 hours)       Category: Workshop

Brady installed the auto pilot servos and cut out the panel for the dash.
Garrett installed the autopilot pitch servo and torque all bolts in forward control area.
Addison final installed the canopy handle and is worked on the foam for the fiberglass.

  Oct 31, 2021     10/31/21 - (3 hours)       Category: Workshop

Flight controls were installed by Garrett, including the flapperon control arms as well as the elevator wheel cables. Harsh and Willem set up flight simulator and fixed their mistake where he did not cut the slit in an electrical grommet. Mentors continued organization. Addison encountered problems installing the canopy handle, but eventually got the handle primed and painted and ready for install. Brady worked on installing the servos necessary for the autopilot, he installed it on the left flapperon torque arms. Richard began installing the radiator but encountered issues locating the appropriate hardware in order to install. Maggie worked on fabricating hardware in order to attach the upper/lower cowling.

  Oct 26, 2021     Tuesday session - (2 hours)       Category: Workshop

Brady reinstalled the flaperon and stick push rods after they were primed. We tried to connect the flaperon torque arms but the bolt would not go through the slightly offset holes with the rod end bearing in place. We removed the torque arms and drilled through with a rod end in place, then reinstalled. We are preparing the A/P servos for installation. Nash assisted Brady. Addison finished riveting the canopy forward bar.

  Oct 25, 2021     Monday session - (2 hours)       Category: Workshop

Rebuilt flaperon push rods, fit to final size. Reinstalled stick push rods. Riveted side skirt on canopy frame.
Installed new simulator table and moved simulator to hanger

  Oct 24, 2021     Canopy and controls - (3 hours)       Category: Workshop

The canopy was screwed to the rear and side frame.
The flapperon and control stick pushrods were sanded, prepped and primed. We need to reinstall the rod ends with FOUR rivets rather than two at each end.
The engine wires and safety wiring was completed. It took 6 tries but we learned the proper technique from reviewing AC-43.
Harsh completed the wing root electrical connector attachment.

  Oct 19, 2021     Back to the canopy - (2 hours)       Category: Workshop

Because our flaperon torque arms have unaligned holes we can't proceed with the controls.

We removed the torque tubes for priming and noted they need two more rivets on each end.

We reinstalled the avions bay cover and canopy in anticipation of Fiberglas fairing work.

  Oct 12, 2021     Frustrating night - (2 hours)       Category: Workshop

We mounted the transponder mounting plate and re attached the fuse box, and Garret machined control stick to correct size and mounted it into control column. Had difficulty locating correct bolts and rudder attachment parts.

  Oct 11, 2021     Build Session 10-11-2021 - (2 hours)       Category: Workshop

Mentors & Izzy worked on organizing the paper plans using clothing hangers and a shelf attached to the whiteboard.
Maggie sanded corners of back window and installed the EMS unit.
Richard & Addison cushion clamped and routed the ECU cables. Larry and Dan sacrificed their fingers
Garrett attached six cushion clamps over rudder cables.

  Oct 10, 2021     Sunday Session - (3 hours) Category: Workshop

Garrett and Maggie and Logan finished shaping the rear window and final drilled the holes to #27.
Addison and Richard mounted the ECU and began to route the main cables from the engine to the ECU in the avionics bay.
Securing three Adel clamps on one bolt is proving to be a challenge.
Maggie attached the replacement canopy latch closure switch. Over the weekend, Larry reprepped and primed the cockpit and roll bar.

  Oct 04, 2021     Engine mounted! - (2 hours)       Category: Workshop

Richard helped attach the engine mount to the engine then four of us lifted the engine and placed it on the airplane. Engine mount bolts snugged and ready to torque. Izzy, Brady and Logan worked to attach the control column.

  Oct 03, 2021     Plane on Landing Gear - (3 hours)       Category: Workshop

Plane put on landing gear
Ready to put on engine
Mentor Adams last day

  Sep 27, 2021     Monday session - (2 hours)       Category: Workshop

Mounted wear plates above left/right landing gear, noticed a roughly 30/1000 lip on the main landing gear support structure, decided to stop work on mounting landing gears until confirmation from Van's.

Deburred holes in rear window and the aft section of the roll bar, prepared for final trim of rear window

Also configured the brake lines into both landing gears, without actually attaching the landing gear.

  Sep 26, 2021     Sunday Work Summary - (3 hours)       Category: Workshop

The landing gear was completed and is ready for installation, and the cowling vents were completed. The rear canopy was drilled and tapped and some misc electrical work was completed

  Sep 21, 2021     Monday and Tues session summary - (4 hours)       Category: Workshop

Finished drilling attach holes for rear canopy. Will need to final size them before final assembly. Using the Dremel tool and files, Nash finished the cowl opening for the Oil access door.

  Sep 19, 2021     Summary of 9/19/21 - (3 hours)       Category: Workshop

Canopy- drilled enlarged holes
Canopy latch switch screw missing
Checked wire harness and put in an attachment for the fuse box.
Upper cowl- put in oil access panel still needs to rivet. Dremeled one vent.

  Sep 14, 2021     Canopy holes and oil access door - (2 hours)       Category: Workshop

We heated the canopy by putting a space heater inside the fuselage. Logan got inside the sauna and held a wood backing block while Garret and Maggie drilled in the holes for the bolts. Adam and Adam drilled the holes for the cam locks on the oil access door. They completed the installation of the cam locks

  Sep 13, 2021     Photos       Category: Workshop

Here are photos from tonight

  Sep 13, 2021     Monday workshop summary - (2 hours) Category: Workshop

Richard and Nash bend tubes for the break lines and installed them. We metal prepped a part that holds the windshield dome, sanded it with 100 grit, metal prepped it again and then painted it. Installed microphone and headphone jacks. Started installing the rear window.