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Project: phowe -
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Categories

Show All Entries - (408)
Research - (1)
Workshop - (2)
Empennage - (2)
Fuselage - (67)
Firewall - (11)
Tail Feathers - (37)
Wings - (84)
Controls - (11)
Avionics - (30)
Lighting - (13)
Instrument Panel - (6)
Landing Gear - (16)
Engine - (30)
Propeller - (7)
Fuel System - (18)
Interior Finish - (46)
Rigging - (5)
Paint / Decals - (10)
Inspection
Tools
MISC - (12)


Builder Name:	Philip Howe -

Project:	Rans - S-21 Outbound - VIEW REPORTS
Total Hours:	1654.75
Total Flight Time:	6
Total Expense:	N/A
Start/Last Date:	Oct 19, 2020 - No Finish Date
Engine:	Rotax 915is
Propeller:	Whirlwind
Panel:	Dynon

Friendly URL:	https://eaabuilderslog.org?s=phowe

Home or Last Project Picture

May 06, 2024 Wiring - (6 hours)

Category: Engine

Brenden soldered extensions on a couple of the grounds that are part of the wiring bundles that are on the engine provided by Rotax. He also installed a bracket to mount all the wire bundles to and made a holder for the X3 connectors.

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May 06, 2024 Ailerons - (4 hours) Category: Rigging

Taylor and I worked first matching the aileron to the wingtips. After installing the aileron stops on the control sticks we went back and for on the stops to make sure we had adequate deflections in each direction. Then we tightened the turnbuckles to the correct tension. We ended up at about 26lbs of tension on the cables.

May 06, 2024 Hung 1 Flap - (1 hour)

Category: Wings

Taylor and I hung one flap on the right wing. but needed to rig the ailerons before moving on to the flaps.

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May 06, 2024 Temporary Hung Wing Tips - (1 hour)

Category: Wings

We hung both wingtips as they are required for aligning the ailerons for rigging.

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May 06, 2024 Trimmed Brackets Holding Header Tank - (1 hour)

Category: Fuel System

I removed the brackets under the huge hose clamps to trim the bottom sides near the aileron cables and turnbuckle. We were concerned that they might rub on the cables.

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May 03, 2024 Changed Grounds around - (3 hours) Category: Engine

Replaced braided starter ground with an insulated one. Brenden ended up putting 2 ground wires under the engine mount/nose gear mounting bolt.

May 03, 2024 Ailerons - (2.95 hours) Category: Wings

Mounted the ailerons on the wings.

May 02, 2024 Attached Fuel lines to fuel tanks - (1 hour)

Category: Fuel System

Used the fittings and fuel line we attached the main fuel lines. For the vent line, we installed the connector and attached it to the left-wing fuel tank fitting. We are holding off on connecting all the lines to the header tank.

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May 02, 2024 Vents - (1 hour)

Category: Interior Finish

We installed the panel vent and tubing to the cowling exterior air access. We needed to enlarge the panel hole to fit the vent fixtures.

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May 02, 2024 Wire Testing Fixture - (2 hours) Category: Engine

Taylor made a wiring testing fixture for the male and female connectors for HIC A & B

May 02, 2024 Created another Engine Grounding point - (3 hours) Category: Engine

We made a more central grounding point as the lower right point was too far for the battery and starter grounds. We will us the lower right for other grounds.

May 02, 2024 Flap cable - (2.5 hours) Category: Rigging

We had to bend the tang on the flap handle and put 2 large washers on the left side of the handle so the locking nut would clear the handle bracket. We also added standoffs and adele clams to hold the flap cable in place.

May 02, 2024 Connected Aileron Cables Wing to Control Stick Cables - (2.5 hours)

Category: Rigging

I routed the aileron cables through the pulleys on the cage and connected them with the turnbuckles. Working near the header tank was very time-consuming.

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May 01, 2024 Wiring - (5 hours)

Category: Engine

Brenden finished wiring the HIC A & B connectors. This is after he struggled for a long time to remove a miss-pinned wire.

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May 01, 2024 Matched drilled Holes in T-Bone - (1.05 hours)

Category: Wings

We matched drilled the 3 holes in the rear T-Bone wing mount on the left and right wing.

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May 01, 2024 Mounted Wings - (6 hours)

Category: Wings

We noticed that the front spar visible from the cockpit was only partially painted in orange. So we sanded and compromised by spray painting it black. We reviewed the installation procedures with three of us holding the wing Brenden then inserted the bolts, nuts, and washers into the wings and struts. The bolts were then torqued. The bolts were snug but not nearly an issue as last time. High Fives were exchanged.

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Apr 30, 2024 Discussion on how to mount Fuel Pressure Sensor - (2 hours) Category: Engine

LONG discussion on how to mount the fuel pressure sensor. I had ordered an adapter to mount the sensor on the fuel rail just before the pressure regulator from Lockwood. The issue is that both of the sides of the adapter are metric threads. The sensor is a standard threading. After much discussion with Dean and ourselves, the options are to order a metric threaded pressure sensor which would be a one-off for Dynon to support with custom pressure curves. Have a new adapter machined ($$$), we could use a manifold I also bought from Lockwood that the pressure sensor could be screwed in but should be mounted after the small filter. and it needs to have the return fuel routed through it so any air trapped in the line will find its way back to the header tank. Chris has proceeded with the new adapter. and also wants to have me install the manifold. I am torn and it would require new fuel hoses to be made.

Apr 30, 2024 Ailerons, Flaps and Wings - (2 hours)

Category: Wings

Attached the push-pull tubes to the ailerons and flaps in preparation for mounting the wing. We also located all the bolts, washers, and nuts and placed them in the freezer to make them slightly thinner as we had so much trouble when we test-mounted the wing several years ago.

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Apr 30, 2024 Rudder Cables - (2 hours) Category: Rigging

After doing them tighter we got them too tight. We found a cable tension scale. We also noticed we were no longer getting full travel on the rudder. So we changed the holes on the rudder cable, front pully, and the rudder return tangs multiple times to get the right balance.

Apr 29, 2024 Tightened Rudder Cables - (1 hour) Category: Rigging

After visiting Rocky Mountain Kit Planes, and seeng how tight they had made the rudder cables, we made mine tighter. I was at West Desert Aviators doing transition training.

Apr 29, 2024 Ordered New prop Bolts - (.5 hour)

Category: Propeller

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Apr 29, 2024 Installed Return Fuel Fitting - (2 hours)

Category: Wings

We drilled and installed the new fitting in the left fuel tank for the return fuel from the header tank. This is needed for the 915is as it returns unused fuel to the header tank. This requires that there is the ability to return fuel to the fuel tank. We then pressure-tested the tank.

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Apr 24, 2024 Cable Blocks - (4 hours) Category: Controls

We installed he missing cable blocks on the heater and parking brake cables. This allows for increasing/decreasing the force needed to move these cables.

Apr 24, 2024 Additional Ground For Engine - (4 hours) Category: Engine

We didn't like attaching all the wires that needed to be grounded underneath the nut of the motor mount. We had a hole in the firewall on the lower right which we then created a grounding point with a bolt and nut and fitting that covered this hole.

Apr 23, 2024 Sanded Foot of Prop - (6 hours) Category: Propeller

I called Whirlwind and they told me to sand the base of the prop until it fit and could smoothly turn in the hub. Taylor did that and then he and Chris set the initial angle of the prop to 17 degrees. The clamping bolts are not long enough with the larger flange for the 915. I will order the correct bolts on Monday 4/29.

Apr 18, 2024 Rear Fairing - (2 hours)

Category: Fuselage

Now that the elevator pitch is set correctly I discovered that the fairing on station 11 needed to be substantially trimmed so the elevator could travel to its full limit. That meant installing new support strips and nut plates.

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Apr 18, 2024 Fixed the Pitch of the Elevator - (2 hours)

Category: Controls

We used an electronic protractor to set the pitch of the elevator both up and down and riveted the pushrod stops in place. We then had to adjust the length of the small pushrods that were connected to the control stick so they didn't hit the panel or the cage near the seat.

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Apr 18, 2024 Tried to Set the Pitch on the Blades - (1.5 hours)

Category: Propeller

I was able to set the pitch on one of the blades but when only I moved to the second I was only able to twist it about 10 degrees. We took the front cover off and swapped blades but it was the heal of the blade. I called Whirlwind and they said that this is not unusual as they bond the heal onto the blade and occasionally they come off oblong. We need to sand the heal down a bit for easier pivoting. That will happen tomorrow or next week.

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Apr 18, 2024 Patch Hole in bottom Skin - (.75 hour)

Category: Fuselage

We had to move the brake line when we installed the correct header tank for the 915. We finally got around to patching this hole in the skin. This will be under the gear leg fairing.

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Apr 17, 2024 Attached Adelle Clamps on Heater Hoses - (1.5 hours) Category: Engine

Adelle clamps were attached to the heater hoses that I installed yesterday. They were needed to prevent the hoses from rubbing on the engine mounts.

Apr 17, 2024 Wing Fuel Tank Brackets AD-142 - (4 hours)

Category: Wings

We prepared the brackets shipped to me by Rans. We then measured and match-drilled the bottom of the wing and the brackets. The brackets were then riveted in.

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Apr 17, 2024 Rudder Travel - (1 hour) Category: Controls

We measured the rudder travel and calculated the rudder travel angle. We calculated it only traveled 25 degrees. I called Rans and Randy told me to file down the rudder stop, in the tail, down on both sides until we reach the minimum of 28 degrees. We will do that tomorrow.

Apr 17, 2024 Elevator Push/Pull Rod - (.5 hour)

Category: Controls

I bolted the push rod to the elevator horn.

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Apr 17, 2024 Tighten Rudder Cables - (1.5 hours)

Category: Controls

We went back and forth loosening and tightening the front pully and changing the attachment holes on the various tangs. We finally got the front pully cable, rudder cable, and the rudder return cable tight enough to my satisfaction.

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Apr 16, 2024 Engine Wiring - (6 hours)

Category: Engine

We are making headway but it is slow going as we are double checking the wires and Brenden makes the connectors.

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Apr 16, 2024 Cabin Heater Hoses - (1.95 hours)

Category: Engine

:( After going back and forth with Rans trying to figure out what they meant, they sent me a video. There are NO Ts at the firewall. The picture in the parts manual is a bit misleading. The text manual is not clear but after I finally understood what Rans wanted it is clear. All that time was wasted but now it is correct.

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Apr 16, 2024 Antennas - (1 hour)

Category: Avionics

All the antennas are now attached. I must say climbing into the tail to the transponder and ADSB antennas was a challenge I not as limber as I once was.

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Apr 15, 2024 Antennas - (2 hours)

Category: Avionics

I attached the Com, ELT, and transponder antennas to the fuselage. We still need to install the GPS and the ADSB antenna when I get the correct nuts, washers, and bolts.

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Apr 15, 2024 Schematics - (6 hours) Category: MISC

Chris continued to make the schematics for the rest of the wiring ie to the lights pitot tube heater.

Apr 15, 2024 Engine Electrical. - (7 hours)

Category: Engine

Brenden continued working on the wiring of the 915. We had a tech support call to Lockwood Aviation to clarify where to connect the grounds. He also made the starter and solenoid power cables. He worked on assembling the HIC A and HIC B connectors.

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Apr 15, 2024 Wingtip Nav and strobe Lights - (1.5 hours)

Category: Lighting

I installed the connectors on the lights. I had to enlarge the holes in the wingtips as the connectors wouldn't fit. I then attached the lights on the wingtips.

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Apr 15, 2024 Heater Hose connections - (2 hours)

Category: Engine

I verified that Rans wanted me to mount a 1" hose on the 5/8ths" leg at the source and destination coolant hose T's and then mount the hose on the 1" legs on the firewall connections. I was uncomfortable with this as I am concerned that over time the 1" hose on those 5/8th" legs would eventually leak. I instead purchased metal automotive metal cooling system 5/8" T's and installed 5/8" cooling system hoses.

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Apr 12, 2024 Installed Outside Temp Sensor - (1 hour)

Category: Avionics

We installed the outside air temperature sensor under the horizontal stabilizer so it will be out of the sun.

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Apr 12, 2024 Engine Electrical - (8 hours)

Category: Engine

Brenden worked on the electrical connections with the engine. This included a lot of research in the Rotax installation manual and pondering over the Advanced supplied schematics. I helped him retrace wires that the labels had fallen off.

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Apr 12, 2024 Schematics - (6 hours)

Category: MISC

Chris continued to work on the schematics. He worked on adding all the connectors we have added including wire colors and pin numbers.

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Apr 12, 2024 Electrical to the Trim Motot - (1 hour)

Category: Tail Feathers

Taylor routed the cable we had run previously from the passenger side to the pilot's side and zip-tied it to station 10. He then enlarged a hole and ran it out the top of station 11. He then notched the tail cone so the wire could then run up into the elevator.

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Apr 12, 2024 Attached the Elevator - (3.95 hours)

Category: Tail Feathers

While we were attaching the elevator we noticed that the bushings on the elevator had been installed with the incorrect side in. This was one of the first pieces we built and hadn't yet known to look for those things. We were able to reverse them without damaging them. We then bolted them onto the horizontal stabilizer.

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Apr 12, 2024 Vertical Stabilizer - (2 hours)

Category: Tail Feathers

We reinstalled the vertical stabilizer and torqued down all the bolts.

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Apr 12, 2024 Installed Horizontal Stabilizer - (4 hours)

Category: Tail Feathers

We set the bushing in the horizontal stabilizer incidence adjustor in the center. This is approximately halfway between the 912 and the Titan setting. This was confirmed by Tony at Rans. Taylor and I need additional washers in the rear to bolt it to station 11. We used 2 thick on the pilot's side and one thick and one thin on the passenger side. We used the nifty washer holder that Taylor made using a scrap aluminum strip and tape. We then torqued down all the bolts.

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Apr 11, 2024 Schematics - (5 hours)

Category: MISC

Chris continues to enhance and add information to CAD files provided by Advanced. He is adding information on the wiring we are doing and adding the connectors that we are installing.

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Apr 11, 2024 Wiring On the Engine - (7 hours)

Category: Engine

Brenden spent most of the day continuing the wiring of the engine. He was able to finish the X3 connector and the grounding straps. He spent a lot of time reviewing the Rotax installation manual and the schematics produced by Advanced.

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Apr 11, 2024 Air Temperature Sensor - (.5 hour)

Category: Instrument Panel

We mounted the temperature sensor to the fuselage, which will be under the horizontal stabilizer.

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Apr 11, 2024 Mounted Vertical Stabilizer - (3 hours)

Category: Tail Feathers

Taylor and I mounted the vertical stabilizer, to discover we needed to install the horizontal stabilizer first :(. Taylor removed the vertical stabilizer.

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Apr 11, 2024 Installed Connector For Light on Tail - (.5 hour)

Category: Lighting

We installed the connector on the top of the fuselage to connect to the vertical stabilizer.

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Apr 11, 2024 Installed The rudder - (1 hour)

Category: Tail Feathers

Taylor and I mounted the rudder to the vertical stabilizer.

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Apr 11, 2024 Finished Installing Vertical Stabilizer Light - (4 hours)

Category: Lighting

We had to enlarge the hole between the light mount and the stabilizer top fairing so the connector would fit behind the light. We then installed the light.

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Apr 10, 2024 Updating Schematics - (3 hours) Category: Lighting

Chirs worked on tracking the drawings manual with wire colors etc. He updated the CAD files to reflect these updates.

Apr 10, 2024 Wiring - (3 hours) Category: Engine

We all spent time looking at where to install the 2 required diodes on the starter solenoids. After reading the Rotax manual I finally emailed Ran's tech support to see if they had any guidance and specs. Brenden started work on making the mate to the X3 connector.

Apr 10, 2024 Light on the Rear of theA Vertical Stabiliser - (4 hours)

Category: Lighting

We drilled a hole through the top of the rear fuselage skin where it will be under the vertical stabilizer. We installed a grommet and passed the wire through. We then created wire mounting points from the bottom of the fuselage to the access hole and zip-tied the wire out of the way so there was no possibility of the wire becoming tangled in the control cables in the rear. Taylor then built a recessed connector bracket for the wire coming from the light down the stabilizer. This will connect with the wire up from the fuselage. We will also install a connector to the light for easy removal.

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Apr 10, 2024 Balanced Rebuilt Aileron - (1 hour) Category: Wings

We balanced the aileron with shot and epoxy and sealed the tube with expanding foam

Apr 10, 2024 Pitot Tube - (1 hour)

Category: Wings

We installed the pitot tube to the mount. We needed to trim the mounting screws shorter so there was no risk of puncturing the tubes. we also confirmed the fit to the wing.

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Apr 10, 2024 AD's and FB post - (1.5 hours) Category: Research

I researched if there was any AD issued that I needed to deal with. There was one. It is the installation of brackets to prevent fuel tank swelling and potentially creating problems with the fuel line. I ordered the no-cost parts from Rans. The FB issue is that there needs to be a fuel return line from the header tank to the left-wing fuel tank. Rotax fuel-injected engines require this. We modified the header tank correctly but not the wing tank. I sent an email to Ran's Tech support asking what the retrofit is and what parts are needed.

Apr 10, 2024 Final Rivets in Firewall - (4 hours) Category: Firewall

I installed the final 8 stainless steel rivets in the firewall. I riveted the firewall to the tabs on the cage. A note to self, do this before you mount all the other items on the firewall :(.

Apr 09, 2024 Electrical Passthrough - (1.5 hours)

Category: Firewall

We installed the electrical passthrough that I purchased from Aircraft Spruce. I didn't want to use the rubber grommet that Ran's supplied. We used stainless steel screws to attach and a sealant.

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Apr 09, 2024 Connection of Cooling System to optional heater - (2 hours)

Category: Engine

I measured and cut the 5/8ths diameter hoses to connect the liquid cooling system to the optional internal heater. This requires a supply hose, a bypass hose, and a return hose. Unfortunately, after cutting the hoses, I discovered the "T's" installed on the firewall for the heater were too large for the 5/8ths hose I had cut. I called Ran's Tech support and talked to Randy S. I sent him pictures so he could figure out what was going on. I hope to hear back tomorrow.

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Apr 09, 2024 Heat shields and Chafing protection - (5 hours)

Category: Engine

We clamped on heat shields to the exhaust pipes to protect nearby hoses. RTV'd hoses together that might chafe. Also installed clamped on various wires and hoses to the engine mounting frame to prevent chafing and contact with exhaust pipes.

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Apr 09, 2024 Pins on the Nav Lights - (.5 hour) Category: Lighting

I put the female pins on the wing tip nav/strobe lights.

Apr 09, 2024 Installed Landing Lights - (8 hours)

Category: Lighting

Mounted the brackets, installed the electrical connectors on the lights, and put the lights in the wing. We also installed electrical connectors on the cables in the wing. After the lights were mounted in the wing, we installed the lenses using clear silicon.

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Apr 08, 2024 Landing lights - (1.5 hours) Category: Lighting

We located the lights and installation brackets. We Spray-painted the brackets black. Chris found his wiring diagram and the connectors and pins he wanted to mount on the lights. Taylor and Chris identified the wires we are using and which need to be terminated. The Wig-Wag function is handled by the ACM, which was provided by Advanced and so doesn't need additional wiring.

Apr 08, 2024 Wing Tip lights - (2 hours)

Category: Lighting

I located the Nav/Strobe wingtip lights. I enlarged the holes that the wires pass through so that a connector will fit. This is so you can remove the light with out removing the tip.

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Apr 08, 2024 Balancing the Right Aileron - (1 hour) Category: Wings

Sprayed foam into the rebuilt aileron so that shot and epoxy can be added.

Apr 08, 2024 Parking Brake - (4 hours)

Category: Controls

I received the parking brake module back from Matco after they repaired the O ring. Taylor reinstalled the brake lines and mounted it to the firewall. We filled the brake line with fluid and looked for leaks. The parking brake cable was cut to length and installed. It works great.

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Apr 08, 2024 Oil Thermostat - (5 hours)

Category: Engine

We received the custom oil hoses from Aircraft Specialty during the break from working on the plane. Today Brenden installed them. It took a while to figure out which hose went where and the orientation.

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Mar 11, 2024 Painted aileron and cowl port. - (2 hours)

Category: Paint / Decals

Jim came in and painted the remanufactured aileron and the cowl air port for the turbocharger installed after it was painted.

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Mar 04, 2024 Remanufactured Right aileron - (5 hours) Category: Wings

Feb 23, 2024 Finished balancing the left aileron - (1 hour) Category: Wings

Finished balancing the left aileron with shot, epoxy and foam

Feb 23, 2024 Engine Oil Thermostat - (3 hours)

Category: Engine

We tried many spots to mount the oil thermostat and finally decided to mount it on the sensor bracket on the side of the engine. We then measured and figured out connections for new oil lines. I ordered the lines and got sticker shock.

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Feb 23, 2024 Rudder Return Kit - (4 hours)

Category: Interior Finish

We ended up drilling out the rivets and moving the back pully. and creating a strap over the back so that we didn't have to drill new holes through the skin. We drilled new holes through the floorboards and riveted those as well. We cut the plastic rudder cable close out so that the cables could pass through. We then measured, cut, and riveted the rudder cable mounts to the floorboards. We matched drilled the tunnel to the mounting rails and then installed the Timmermans.

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Feb 22, 2024 Installed Throttle Cable - (4 hours)

Category: Instrument Panel

We had to enlarge the hole in the panel to fit the cable through. We then routed through the fitting in the firewall and attached it to the throttle body. We had to shorten the cable to fit. We spent time making sure the "throw" of the cable was the correct length. We confirmed that the cable was attached in the correct direction so in the case of a cable break the throttle goes to full power.

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Feb 22, 2024 Balance left Aileron - (3 hours) Category: Wings

We poured a mixture of lead shot and epoxy into the left-wing spar. we then sealed off with expanding foam. We took extra care with this aileron after the right one fell yesterday and damaged it.

Feb 22, 2024 Wiring - (7 hours)

Category: Lighting

Brenden continued wiring. Worked on ELT and created wiring blocks for the left and right wings.

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Feb 22, 2024 Rudder Return Kit - (5 hours)

Category: Interior Finish

Drilled the holes through the skin for the rear rivets - it shifted left 1/2 - 1 " while drilling. I continued drilling then riveted the rear pully assembly as directed. I swapped out the buckle holding the front pully for the one provided with the kit. We started to reinstall the interior closeouts so we could measure where the tunnel is to be mounted.

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Feb 21, 2024 Rudder Return Kit - (5 hours)

Category: Interior Finish

After discovering that Rans Had the Rudder Return kit with the Rudder cable I ordered it last week and It arrived. I primed the parts and assembled the rear cable pully mechanism. I removed the control sticks so that it could be mounted below them and mounted the cables to the rudder pedals.

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Feb 20, 2024 Modified cowl for air intake - (5 hours)

Category: Engine

Cut the hole and attached the air scoop on the right side of the cowl. This allows additional airflow to the air filter into the turbo.

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Nov 17, 2023 Side Seat Closeout - (6 hours)

Category: Interior Finish

Finished the side seat closeouts. Sanded and cut the left closeout and completed the final fitting. Drilled the mounting holes and upsized the bracket hole.

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Nov 17, 2023 Fitting Cowl - (7.5 hours)

Category: Engine

Made good progress with fitting the bottom cowl. Enlarged radiator and exhaust holes. Match drilled to the mounting straps on the boot cowl and then trimmed to fit.

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Nov 16, 2023 Cowl - Exhaust Hole - (0.25 hour)

Category: Engine

Using a hole saw the preliminary exhaust pipe hole was cut in the bottom cowl.

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Nov 16, 2023 Plastic Seat Closeouts - (6 hours)

Category: Interior Finish

Worked on the replacement plastic side closeouts. Trimmed and sanded and the right side is basically done. The left side is rough cut and in the process of being fitted.

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Nov 16, 2023 Completed the Mountings of Intercooler and the Radiatiors - (7 hours)

Category: Engine

Refined the positioning of the intercooler and the radiators. Also mounted the prop gear oil line.

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Nov 16, 2023 Assembled the Oil and Coolant Radiators - (6.95 hours)

Category: Engine

Assembled the Oil and Coolant Radiators and the mounting. This is needed to complete the cowling fitting.

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Nov 16, 2023 Intercooler Scoop and Mount - (7 hours)

Category: Engine

Assembled the intercooler scoop and created the mount. This is needed to complete the cowl fitting.

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Nov 16, 2023 Engine Cowl - (7 hours)

Category: Engine

Cut holes and trimmed the engine cowl.

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Nov 14, 2023 Spinner Cut and Mounted - (6 hours)

Category: Propeller

Cut the spinner for the prop blades and match drilled to mounting disc.

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Nov 10, 2023 Misc Parts were Painted - (40 hours)

Category: Paint / Decals

Flaps, ailerons, wingtips, vertical and horizontal stabilizers, rudder, elevator, trim tabs struts, inspection port covers and fuselage end cap were all prepped and painted.

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Oct 13, 2023 Mounted Prop - (3 hours)

Category: Propeller

We finally received the correct mounting bolts from Whirlwind. The ones they had previously supplied did not take into account the 1 inch spacer that Rans uses on the 915is.

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Oct 11, 2023 Horizontal Stabilizer Fairing - (5 hours)

Category: Tail Feathers

The fairing was mated and bent then match drilled to the stabilizer.

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Oct 10, 2023 Wings - (.5 hour)

Category: Paint / Decals

Wings came out of the paint booth. They turned out nice.

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Oct 10, 2023 Control Cable Closeout - (0.95 hour)

Category: Interior Finish

Closeout was trimmed and fitted.

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Oct 10, 2023 Control Column Closeouts - (3 hours)

Category: Interior Finish

The closeout supports were riveted to the closeouts after match drilling.

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Oct 09, 2023 Baggage Area Floor - (5 hours)

Category: Interior Finish

Taylor cut the underfloor supports and then riveted them to the bottom of the floor.

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Oct 09, 2023 Flap Handle Closeouts - (1 hour) Category: Interior Finish

Well after discovering that the epoxy didn't hold, I must have not gotten the ratios incorrect. I bought PVC cement like Rans advised and cleaned and reattached the tabs.

Oct 09, 2023 Side Closeouts - (4 hours) Category: Interior Finish

After cutting down both closeouts so they appeared to fit, I finally found the mounting brackets and riveted them in, I had cut way too much off of them. So I had to order replacements. I really do not like working with the plastic parts.

Oct 06, 2023 Flap Handle Issue - (1 hour)

Category: Interior Finish

I put the flap handle together including the cable ends. Now the cable ends hit the forward mounting point to the cage. It looks like the holes I had to drill were slightly too low. I have emailed Rans asking for replacement brackets.

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Oct 06, 2023 Baggage Area Floor - (8 hours)

Category: Interior Finish

The L bracket supports were sized and cut and riveted to the tabs of the cage for the near area of the baggage compartment. The floor was match-drilled to the supports.

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Oct 06, 2023 Side closeout Next to the Right Door - (5 hours)

Category: Interior Finish

Cut and fit the plastic closeout that fits between the seat and the cage. I was able to fit the right-hand closeout and rough cut the left. I really dislike working with these parts.

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Oct 06, 2023 Mounting Engine ELectrical Components - (8 hours)

Category: Engine

Mounted the fuse box and studied the rotax 915 installation manual to learn what connects to what and why.

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Oct 06, 2023 Wings - (8 hours)

Category: Paint / Decals

The wings got their second coat plus clear coat(don't know if this is what it is called).

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Oct 05, 2023 WIngs - (8 hours)

Category: Paint / Decals

Jim finished prepping the wings and sprayed the first coat of paint. He then started prepping the elevator.

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Oct 05, 2023 Doors - (6 hours)

Category: Fuselage

Attached the handles and latching mechanisms plus the gas strut to help open the doors. The doors were then mounted on the cabin.

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Oct 05, 2023 Connecting Wiring To ACM - (5 hours) Category: Avionics

Brenden finished the "Aircraft Aft" connector with all the wires to the lights, ELT, and pitot heat. He t. hen started work on the wiring for the 915. He fabricated the mount for the circuit breaker etc. and attached it to the engine mount. He also worked on mounting the PCV module.

Oct 05, 2023 Flap Handle - (5 hours)

Category: Controls

I Installed the flap handle. It was made more difficult as the brackets that hold the bottom of the actual handle were each missing a hole to mount it. I had to figure out the best position for the hole. I then put bolts through the holes that were there so that once I drilled the hole they would be match-drilled. I then used a drill press.

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Oct 04, 2023 Doors - (5 hours)

Category: Fuselage

Taylor trimmed all the plastic trim pieces and then riveted them and the plexiglass to the door frames.

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Oct 04, 2023 Wiring to ACM module - (6 hours)

Category: Lighting

Brenden continued the wiring project. He created the connector for all of the lights so that they could be plugged into the ACM.

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Oct 04, 2023 Flap Handle - (6 hours)

Category: Interior Finish

I took over working on the flap handle. I fabricated 2 of the spacers and the "L" brackets ( from raw stock as I couldn't find those supplied by Rans). I fabricated and epoxied the PVC tabs to the flap handle cover.

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Oct 04, 2023 Preparing Wings for Paint - (21 hours)

Category: Paint / Decals

Over the last three days, Jim has been prepping the wings for painting.

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Oct 03, 2023 Doors - (3 hours)

Category: Interior Finish

Taylor picked up working on the doors were we left off over a year ago. He sanded the plexiglass to fit better and worked on the mounting straps.

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Oct 03, 2023 Flap Handle - (2 hours) Category: Interior Finish

Taylor cut out the plastic enclosures and sanded them to fit. Installed the Spring and push button into the handle.

Oct 03, 2023 Wiring - (4 hours) Category: Avionics

Worked on trying to figure out if Rotax sent a connector and wiring harness for the fuel pump - We couldn't locate one so I emailed Rans. Brenden then worked on trying to figure out how to wire the position, strobe, and Nav lights into the ACM module. He is finding Advanced's schematics not very informative.

Oct 03, 2023 Installing Prop Hub - (2 hours) Category: Propeller

We struggled to get the Whirlwind prop hub installed on the engine. We have been confused with the Whirlwind manual that Rans sent with the FWF kit. We then noticed it was for the 912 & 914. I then went on the Whirlwind site and downloaded the 915 manual.
Then we noticed that the bolts were about an inch too short with the spacer installed. I emailed Ran's tech support about this issue.

Oct 03, 2023 Vertical Stab Cap - (5 hours)

Category: Tail Feathers

I finished sanding the fairing tail flush with the rib. I then drilled rivet holes in the fairing and the rib using a rivet fan. I then detached and deburred the new holes. I also drilled a hole through the rib for the tail position light wire and installed a grommet. I then prosealed the fairing to the rib and the vertical stab skins and finally riveted it on.

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Oct 02, 2023 Installing Prop - (3 hours)

Category: Propeller

Started to attach the prop. We got the spacer installed and fitted the spinner mount we figured out how the hub goes together.

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Oct 02, 2023 Tail Station Closeout - (3 hours)

Category: Fuselage

We cut and installed the end cap closeout underneath the horizontal stabilizer and the elevator.

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Oct 02, 2023 End Caps for Horizontal Stabilizer - (1 hour)

Category: Tail Feathers

We glued and riveted the Aerosport manufactured end cap fairings to the horizontal stabilizer.

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Oct 02, 2023 Vertical Stabilizer Cap - (6 hours)

Category: Tail Feathers

I fished the wire for the tail position light up through the grommets in the stabilizer. I sanded the bottom of the fairing so that it cleared the rudder. I matched drilled the fairing to the stabilizer. I positioned and drilled the position light holder and then drilled a hole through the fairing and installed a grommet for the wire to power the light. I then riveted the faring rib to the vertical stabilizer. I needed to move the top grommet in the vertical stabilizer as the rib covered it.

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Sep 29, 2023 Cowl - (5 hours)

Category: Engine

Cut out the sections that needed to be removed. Match drilled the top and bottom halves.

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Sep 28, 2023 Wing to Fuselage Fairings - (2 hours)

Category: Wings

Cut and fit the fairings for the wing root.

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Sep 28, 2023 Mounted Engine - (6 hours)

Category: Engine

We replaced the fabricated spacers for the bottom of the engine mount and firewall with the new ones provided by Rans. There are now 2 spacers on the two bottom firewall to the engine mounts and 1 spacer each between the engine mount and the nose gear mount on the top. The nose gear mount and the engine mount cross members no longer touch. Swapped out the mounting bolts for longer ones that I had purchased from Aircraft Spruce. After that we mounted the engine to the engine mount.

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Sep 28, 2023 Wires for the Lights - (4 hours) Category: Lighting

Created connectors for the wires to the lights so that they can be plugged into the ACM.

Sep 27, 2023 Cowl - (2 hours)

Category: Engine

Mated up the top and bottom cowls and identified what needed to be cut.

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Sep 27, 2023 Installed Aileron Pulleys - (2 hours)

Category: Controls

The pulleys for the aileron cables were installed on the cage.

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Sep 26, 2023 Trim Motor - (3 hours)

Category: Tail Feathers

Final fit and sanding of the trim motor cover. Attached the trim arm to the trim tab. Connected a battery and ran the trim motor. It was sticking a bit so took it apart and put it back together and now runs fine. Attached the cover to the elevator.

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Sep 26, 2023 Belly Fairings - (6 hours)

Category: Fuselage

Cut to fit, sanded, and redrilled fuel drain hole. We finally attached them.

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Sep 26, 2023 Wiring - (7 hours)

Category: Avionics

Continued with wiring up antennas etc.

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Sep 25, 2023 Continued Attaching Wiring - (7 hours)

Category: Avionics

Continued attaching the wires and connectors to various avionics, switches, and control heads (center panel).

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Sep 22, 2023 Avionics Connected to Wiring - (4 hours)

Category: Avionics

After the wires were routed the avionics connections were started to be plugged in and wiring connectors were starting to be installed.

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Sep 22, 2023 Wiring - (3 hours)

Category: Avionics

Brenden worked on routing wires from various sources to behind the panel.

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Sep 21, 2023 Plastic Station 3 Closeout - (1.5 hours)

Category: Interior Finish

The closeouts were marked following the cutout indentations. The left cutout was rough cut and sanded. A preliminary fitting was done.

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Sep 21, 2023 Routing of Wiring. - (4 hours)

Category: Lighting

The wiring was routed and mounted underneath the baggage area. A new hole was made in the closeout behind the passenger seat so the wires can pass through with out blocking the main gear nuts.

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Sep 21, 2023 A Connector GPS Wire - (.5 hour)

Category: Avionics

Brenden installed a connector to the wire to the GPS so that the GPS can be easily removed if that becomes necessary.

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Sep 21, 2023 Left Wing Strut Fairing - (1.95 hours)

Category: Wings

The faring was cut for easy removal and a fiberglass tab was added to support the the cut pieces. One side of the tab is not attached to the fairing. The mounting holes were then drilled through the fairing and the wing skin and then rivnuts were installed.

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Sep 21, 2023 Wing Tips - (3 hours)

Category: Wings

The wing tips were covered with a material to hide the fiberglass and the cut-out indentation marks for landing lights. This was then sanded smooth and test fit to the wings.

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Sep 21, 2023 Belly Fairings - (6 hours)

Category: Fuselage

Chris and I worked at cutting and trimming for the final fit of the belly fairings. On the left side fairing we drilled a hole for the fuel test valve. The parts won't lay flat so after more sanding I tried a heat gun to try and reshape the fairings, This did not work.

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Sep 21, 2023 .Priming - (1.5 hours) Category: Paint / Decals

Chris spent time this afternoon priming the metal parts that came with the 915is firewall wall forward.

Sep 20, 2023 Nose Gear Tire - (3 hours)

Category: Landing Gear

Chris and I refabricated the left spacer to be 1/16" longer and trimmed the right one by a 1/16th for better placement of the wheel. We primed both spacers and put lithium grease on the interiors of each then mounted the tire and installed of the remaining hardware. We torqued all of the nuts and bolts.

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Sep 20, 2023 Interference of Engine and Nose Gear Mounts - (3 hours)

Category: Firewall

To eliminate the interference Ran's tech support advised moving the the engine mount forward about a 1/4". We could use either wide-area washers or spacers. We tried washers first but the welds on the top of the engine mounts didn't allow the washers to lay flat. Brenden the fabricated spacers. The diameter for the top mounts was perfect for the welds. The bottom mounts the diameter of the spacers was too narrow. In a tech support call to Rans, they agreed to ship 2 more spacers with the same part number as the original one and we will double them up. I ordered 4 new bolts to mount both mounts to the firewall that are each 1/4" longer from Aircraft Spruce.

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Sep 20, 2023 Wire Routing Planning - (1 hour) Category: Avionics

Brenden was trying to figure out the best routing of lights, antennas, and AHARS wiring to the back of the panel. We need to avoid the rudder and other cables passing under the seats and along the side finishing panels next to the pilot and passenger feet.

Sep 20, 2023 Doubler For ELT Antenna - (2 hours) Category: Avionics

We fabricated and riveted in a doubler and reinstalled the ELT antenna.

Sep 20, 2023 Wing Tips - (4 hours)

Category: Wings

Sanded the fiberglass and then put body filler

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Sep 20, 2023 Strut Fairing - (2.0 hours)

Category: Wings

The rivnuts were installed in the wing and on the fairing where the split is we put a fiberglass tab on the inside so that we can keep the 2 halves together.

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Sep 19, 2023 Wing to Strut Fairing - (4 hours)

Category: Wings

We trimmed the plastic fairing. We then fit and cut the strut hole and then cut the fairing for ease of removal with out having to remove the strut.

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Sep 19, 2023 Antennas - (6 hours)

Category: Avionics

Brenden mounted the Com, ELT, and GPS antennas. He manufactured and riveted in a doubler for the Com antenna.

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Sep 19, 2023 Aerosport Wing Tips - (3 hours)

Category: Wings

Fitted up wing tips and noticed there was a slight height difference between the tips and the wings. Taylor and Chris layered fiberglass to even out the differences. They will sand tomorrow. They also installed all of the inspection port screw mounts.

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Sep 19, 2023 Nose Gear - Mount Tire and Spacers - (7 hours)

Category: Landing Gear

I mounted the tubeless tundra tire on the MATCO rim after we received the valve kit from MATCO. We discovered the axle had some rust so Chris used Scotchbrite to remove it. we will cover it in lithium grease when we install it on the final assembly. Chris and I mounted the wheel and measured and determined the length of the spacers. We then cut the spacers, deburred, and then primed them.

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Sep 18, 2023 Main Gear Fuselage Fairings - (6 hours) Category: Landing Gear

We trimmed and started sanding the plastic parts of the fairing. We still need to trim the holes for the gear legs and probably additional trimming and sanding for fit.

Sep 18, 2023 Electric Fuel Pump - (2 hours)

Category: Fuel System

Mounted the auxiliary electric fuel pump and filter on the tray with the pitch servo.

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Sep 18, 2023 Autopilot Pitch Servo - (2 hours)

Category: Avionics

Remounted the relocated pitch servo.

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Sep 15, 2023 Installed Header Tank - (2 hours)

Category: Fuel System

Installed the header tank and repressure tested it. We did discover an issue. The tank interferes with the left side main gear brake fitting. We will reposition the brake line fitting later.

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Sep 15, 2023 Roll Servo Installed - (6 hours)

Category: Avionics

Mounted and installed the roll autopilot servo.

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Sep 15, 2023 Pitch Autopilot Servo - (4 hours)

Category: Avionics

We had it all mounted then we finally found the the Rotax supplied fuel pumps. Discovered that we needed to move the mount and turn around the servo.

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Sep 15, 2023 Trim Motor Cover - (1 hour)

Category: Tail Feathers

Trimmed the plastic piece that covers the trim motor on the elevator.

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Sep 14, 2023 Header tank - (4 hours)

Category: Fuel System

We had to remove the nipple fittings in the rear to get the header tank to fit. We then drilled and installed the drain plug and drilled the hole in the fuselage. We need to go larger on the fuselage hole. We also bent the strap holders and notched them per instructions.

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Sep 14, 2023 Autopilot servo mount - (3 hours)

Category: Controls

Assembled the combined pitch servo and fuel pump tray and mounted it.

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Sep 14, 2023 Fluid connection to radiant heat - (1 hour)

Category: Interior Finish

Hoses were connected to the firewall pass-through fittings and the heater.

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Sep 14, 2023 Moved transponder - (1 hour)

Category: Avionics

When the cabin heater was installed discovered the transponder was mounted too close for the coax cable. We moved it closer to the panel.

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Sep 13, 2023 Middle Stack - (1 hour)

Category: Instrument Panel

Mounted the middle avionics stack to the panel.

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Sep 13, 2023 Nose Gear Yoke - (2 hours)

Category: Landing Gear

We finished the assembly and mounted the nose gear tundra tire yoke.

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Sep 13, 2023 Cabin Heater - (5 hours)

Category: Interior Finish

We finished assembly of the cabin heater and fans. We mounted it behind the panel. Also finished the fittings on the firewall fluid pass-through for the heater.

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Sep 13, 2023 Engine Mount Nose Gear mount interference - (.5 hour)

Category: MISC

I have been emailing pictures and questions back and forth to Rans' tech support regarding the interference between the 915 engine mount and the tundra tike nose gear mount.

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Sep 13, 2023 Searching - (2 hours) Category: MISC

Chris and I spent time searching for the plastic stabilizer end caps. Also searched for the Aerosport parts I had ordered.

Sep 13, 2023 Attached Rudder - (1.5 hours)

Category: Tail Feathers

I struggled to get the bolts, washers, and nuts through all the bushings and screwed down as it is such a tight fit.

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Sep 12, 2023 Drill bits - (1 hour) Category: MISC

I ran out and bought cobalt drill bits and reams for drilling out the nose gear strut.

Sep 12, 2023 Heater - (4 hours) Category: Interior Finish

Brenden worked on the assembly and mounting of the radiant heater.

Sep 12, 2023 Front Landing Gear - (5 hours)

Category: Landing Gear

Taylor drilled out the holes in the front landing gear strut. He also assembled the wheel mount. Chris and I tried to mount the tire to the rim but discovered there was no valve stem kit provided. I located and ordered one from Matco.

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Sep 12, 2023 Header Tank - (1 hour)

Category: Fuel System

Riveted Header tank tray to the fuselage and put weather stripping tape to protect the tank from rivet heads plus reduce vibration and potential movement. We also pressure tested the tank - it passed.

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Sep 11, 2023 Battery Box and Engine mount - (6 hours)

Category: Firewall

Taylor mounted the EarthX battery box on the firewall. He then worked on getting the engine mount and the nose gear mount installed on the firewall. We have some questions about the spacers at the bottom of the mounts. Rans shipped 3 spacers but plans only mention using one. One of the engine mount bars touches one of the nose gear mount bars. We have a question in to Rans tech-support.

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Sep 11, 2023 Cabin Heater - (2 hours) Category: Interior Finish

Brenden worked on figuring out how to mount the radiant cabin heater on the bottom of the cross support under the boot cowl with the avionics.

Sep 11, 2023 Mounted the Radio - (1 hour) Category: Avionics

Brenden mounted the radio on the opposite side from the transponder.

Sep 11, 2023 Attached the tundra tires - (2 hours)

Category: Landing Gear

We mounted the new tundra tires on the main gear with the repacked bearings.

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Sep 11, 2023 Header Tank - (4.5 hours) Category: Fuel System

Son Chris mounted all of the fittings on the header tank. I worked on mounting the tray I riveted a small plate over the previous header tank's drain hole in the bottom skin.

Sep 01, 2023 Header Tank - (1 hour)

Category: Fuel System

Son Chris located all the remaining parts for the header tank and then watched a YouTube video of a builder assembling one to get a clear understanding of how to install all the fittings.

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Sep 01, 2023 Mounted More Avionics - (8 hours)

Category: Avionics

Brenden created mounts and mounted the EMS, backup battery, transponder, and ADSB in and out.

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Sep 01, 2023 Tundra Tires ready to Mount - (6 hours)

Category: Landing Gear

Son Chris and I mounted the tundra tires on the rims. We also had to clean and repack the wheel bearings as metal flakes had fallen on them.

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Aug 31, 2023 Inserted Innertubes into the Tundra tires - (1 hour)

Category: Landing Gear

Innertubes arrived today so we inserted them into the tires.

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Aug 31, 2023 Prepared the Boot Cowl and the Windshield Front Mount for Painting - (3.5 hours)

Category: Paint / Decals

I sanded the boot cowl so that it can be painted flat black. I spent most of the time sanding and then filling the back of the fiberglass windshield front mount that will be visible from the interior. This also will be painted flat black to reduce glare and reflections.

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Aug 31, 2023 Installation of Avionics - (8 hours)

Category: Instrument Panel

Brenden spent the day creating the mount and then mounting the Advanced Control Module. He also created the mount for the backup battery.

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Aug 31, 2023 Looking for Parts for Header Tank - (2 hours) Category: Fuel System

Even with brother Chris' new inventory/location system son Chris spent 2 hours looking for all the parts for mounting and finishing out the header.

Aug 31, 2023 Looking for Parts for Header Tank - (2.9 hours) Category: Fuel System

Aug 30, 2023 Header tank - (12 hours)

Category: Fuel System

I spent most of the day working on the header tank. I drilled out the support from the smaller header tank and then match drilled the new tray to the support and the fuselage cage tab. I then measured the hole placement on the new header tank then drilled them out. Chris made a metal plate to cover the sump drain hole from the smaller tank. We will rivet it on before we rivet the header tank tray.

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Aug 30, 2023 Worked on Mounting the Instrument Panel - (8 hours)

Category: Instrument Panel

Brenden worked on installing the instrument panel all day. He mounted the throttle location panel, matched drilled all the holes. He also was laying out where to mount the remote instruments behind the panel.

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Aug 30, 2023 Separated Rims from Tires - (1 hour)

Category: Landing Gear

Chris separated the main gear rims from the tires. We are waiting on the inner tubes to arrive from Rans so we can install the tundra tires

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Aug 29, 2023 New Header Tank - (2 hours) Category: Fuselage

Removed the old header tank. The new one is larger and is required for the 915. We primed the new header tray and support.

Aug 29, 2023 Separate the wheels - (3 hours) Category: Landing Gear

Son Chris worked on separating the rims to remove the older tires. to install the tundra tires. We are still waiting on the inner tubes from Rans.

Aug 29, 2023 Additional Items on the Firewall - (4 hours)

Category: Firewall

Taylor worked on the firewall again this AM. Including the parking brake which is located inside.

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Aug 28, 2023 Start to hang components on the firewall - (8 hours)

Category: Firewall

Taylor worked on installing the FWF components on the firewall.

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Aug 25, 2023 Convert to Tundra Gear - (10 hours)

Category: Landing Gear

I decided to upgrade the landing gear to the tundra option. I ordered the parts in the first part of the year. Brother Chris and Taylor inventoried the parts this week, Removed the old main gear removed the brakes and the brake lines, and transferred them to the new main gear. They then attached the new main gear to the fuselage, which is longer.

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Aug 24, 2023 New Wing tips - (8 hours)

Category: Wings

Taylor and brother Chris installed the rib and cut out the tip for the lights on the new Aerosport wing tips. The ones we built previously looked TERRIBLE.

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Aug 24, 2023 Preliminary Work to Install Panel - (8 hours)

Category: Instrument Panel

Brenden found all the components for the instrument panel assembled by Advanced with the carbon fiber panel provided by Aerosport. Brenden convinced Aerosport to provide a CAD drawing of remote instrument placement. One of the owners of Aerosport had built a Rans S21. Brenden also built a tray that is behind the throttle quadrant. We will use this tray to also suspend the fire extinguisher from

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Aug 22, 2023 Inventory FWF Kit - (16 hours) Category: Firewall

Chris and Taylor inventoried the FWF kit for the 915is from Rans that I had ordered earlier in the year.

Aug 21, 2023 Find all the parts - (16 hours) Category: MISC

Brenden, Taylor, and brother Chris spent a good part of the day locating all of the parts that had been stored and delivered in the previous year. They moved them all into the hangar for the build.

Aug 21, 2023 RESTART BUILD AFTER YEAR DELAY Category: MISC

The reason there is such a delay between March 2022 and August 2023 is that I spent 6 months of 2022 in the hospital followed by 3 months of chemotherapy. I then slowly gained my strength back and was able to start up again following my daughter's wedding and a well-deserved family vacation.

Mar 10, 2022 Elevator push/pull rod - (16 hours)

Category: Controls

Brenden and Chris worked on installing the elevator control rod. This included cutting the rod to size and enlarging one of the plastic spacers in the bulkhead pass-throughs so the rod didn't rub. They worked on it on 3/8, 3/9, and 3/10.

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Mar 08, 2022 Install windows in the baggage area - (8 hours)

Category: Fuselage

Chris installed the left and right windows in the baggage area

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Mar 08, 2022 ELT Tray - (4 hours)

Category: Avionics

Brenden created and installed a tray to mount the ELT to the stringers under the baggage floor.

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Feb 18, 2022 Clean up

Category: Workshop

The usual Friday ritual before we head home.

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Feb 18, 2022 ELT - (1 hour)

Category: Avionics

After finding out where others are putting their ELT's (Facebook post) we started working on a mounting tray to sit on the stringers.

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Feb 18, 2022 Reattached the strut attach brackets - (.5 hour)

Category: Wings

Reattached the brackets to the wing trusses.

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Feb 18, 2022 Doors - (8 hours)

Category: Interior Finish

Trimmed and sanded the Lexan for the left-hand door. Drilled the strip for the middle of the door that holds the top and bottom Lexan sheet to the middle of the door. We upsized the holes in the Lexan to the #27 drill size. We then removed the Lexan and the doors and put them back into storage. We will rivet and reinstall later in the build after the interior is completed and the wings are on.

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Feb 17, 2022 Strut Mounting brackets - (6 hours)

Category: Wings

I was extremely cautious (read took way too much time) in enlarging/match drilling the replacement brackets with the brackets that were fine. The brackets attach the struts to the wing trusses. We had elongated some of the holes when we first did the up-sizing drilling on 2 of the brackets on both wings.

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Feb 17, 2022 Doors - (12 hours)

Category: Interior Finish

We worked on cutting, trimming, and sanding the Lexan panels for the right-hand door. Also match-drilled the holes in the Lexan to the door frame. We had previously marked off the positions on the frame and drilled those.
Worked on the trim for the left-hand door. Marked and drilled holes in that door frame

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Feb 16, 2022 Removed Vertical Stab and rudder - (7 hours)

Category: Empennage

We had filed the bushings on the vertical stab to get the rudder to swing better. We rethought this and ordered new bushings. removed the old ones and ordered new ones. We added the rubber bottom strip that we had missed the first time. I don't enjoy putting this on and off. Definitely a 2 person job.

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Feb 16, 2022 Brakes - (3 hours)

Category: Interior Finish

Installed fittings on brake master cylinders and then attached to pedals. We did not attach to floor mounts yet. Will finalize after the firewall is attached.

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Feb 15, 2022 Header tank - (1 hour)

Category: Fuel System

A final pressure test, glued rubber strip around tray and then installed.

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Feb 15, 2022 Doors - (4 hours)

Category: Interior Finish

Worked on the doors - trying to bend so that the middle bar was the correct height off the floor - per manual. Attached doors to the cage. Matched drilled and installed interior top strip on the doors.

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Feb 15, 2022 Mounted trim servo and trim tab to elevator - (7 hours)

Category: Tail Feathers

Mounted the trim servo to the elevator and then mounted the trim tab. Had to remove one of the piano hinges and install a new one as it was binding and not allowing for the trim tab to freely move.

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Feb 14, 2022 Brake line - (4 hours)

Category: Landing Gear

Mounted fittings on the calipers and drilled holes in the fuselage. Fitting on the fuselage on the right side and attached brake line in the main gear leg. It required removing one of the rear main gear bolts from each leg.

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Feb 14, 2022 Header Tank - (6 hours)

Category: Fuel System

Added sump drain in the tank and mounted tray

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Feb 11, 2022 Header - (5 hours)

Category: Fuel System

Worked on placement so that the connections fit nicely and the placement of the mounting tray.

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Feb 10, 2022 Header Tank - (5 hours)

Category: Fuel System

Worked on installing the connections in the header tank. Did a pressure test.

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Dec 17, 2021 Rudder cables attached to rudder pedals - (4 hours)

Category: Controls

We made and installed all the rudder pulley assemblies, including the pulley attached to the firewall on the bracket on the opposite side of the firewall.

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Dec 17, 2021 Removed wings - (3 hours) Category: Wings

We took the wings back off. This makes it easier to store and move around and work.

Dec 16, 2021 Header tank - (4 hours)

Category: Fuel System

Attached all the fittings to the header tank after working on the tank support needed to trim so that the support would clear one of the stiffeners.

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Dec 16, 2021 Rudder horn and rudder cables - (4 hours)

Category: Tail Feathers

It took 2 of us 2 hours to attach the rudder horn and the rudder cables.....I'm just not as flexible as I used to be.

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Dec 16, 2021 Reinstalled the Vertical Stab with Rudder attached - (6 hours)

Category: Tail Feathers

It took 2 of us 3 hours to reinstall the Vertical Stab and rudder. It took us longer as the hole we had used the first time was now filled with the rudder horn attachment.

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Dec 15, 2021 Attached the rudder to vertical Stabilizer - (1 hour)

Category: Tail Feathers

We attached the rudder using the recommended torque for the AN3 bolt. There is too much friction. I sent an email to Randy S. with pictures asking for guidance.

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Dec 15, 2021 Vertical Stabilizer - (4 hours)

Category: Tail Feathers

Spent ALOT of time attaching the Vertical Stabilizer. It took 2 of us to insert and tighten the bolts. Only to find that we couldn't attach the rudder.....Off came the vertical stabilizer.

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Dec 15, 2021 Horizontal Stabilizer - Drilled final hole - (1.5 hours)

Category: Tail Feathers

After taking way too much time trying to use the laser level to "match the tilt" of the wings. We decided to get about 6 feet behind the tail sit on a small stool and "eyeball" that the stabilizer was parallel to the wings at the struts as the reference. We then drilled the hole, added washers to fill the separation between station 11 and the aft spar and bolted on.

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Dec 15, 2021 Header tank - (1 hour) Category: Fuel System

Worked on the mounts for the header tank. Located on the parts in a sealed plastic bag.

Dec 14, 2021 Header Tank - (1 hour) Category: Fuel System

Drilled holes in the header tank. Started to look for the rest of the header tank parts.

Dec 14, 2021 Tighten all the bolts to the wing. - (1 hour) Category: Wings

Dec 14, 2021 Not a productive day!

Category: MISC

Not a very productive day Icy roads and the downside to putting on the wings.

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Dec 13, 2021 Hung the wings - (2 hours)

Category: Wings

The right-wing went on fairly easy. The left not so much. I was happy we had extra bodies around to hold the wings while we figured everything out.

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Dec 13, 2021 Struts - (4 hours)

Category: Wings

In preparation for attaching the wings, we still needed to up drill the hole to attach the strut to the wing truss brackets. We removed those and drilled them. This didn't go so well, we elongated the holes in 2 of them which will need to be replaced, I have ordered them, they are fine for this test fitting of the wings. We then discovered that we had reversed the lower attach knuckles and put them on the wrong ends of the struts. This came after much trial and error trying to first attach the strut to the fuselage and then trying to attach it to the wing.

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Knuckle on correctly still on the incorrect end

Dec 13, 2021 Took the wing tips back off in prep for wing mounting - (1 hour)

Category: Tail Feathers

Took off the wingtips all the while thinking these are going to be such a pain to get back on.....

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Dec 13, 2021 Horizontal Stabilizer - (2 hours)

Category: Tail Feathers

We fitted the bushings into the incidence adjustors, which required a bit of filing. We then attached the bolts from stations 10 and 11.

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Dec 10, 2021 Replaced incorrect rivet - (.5 hour) Category: Wings

As part of measuring the internal distance of the front spar at the bolt holes, we noticed that a rivet used at the front doubler was too long. We drilled it out and put the correct length one in.

Dec 10, 2021 Trimmed Wing Mounting T-Bone Tubes - (4 hours)

Category: Fuselage

After getting the exact measurements of the distance from the back of the front spar to the middle of the rear mounting hole + 3/8" we filled down the rear T-bone to match this distance with the distance from the T-bone to the rear mount on the fuselage. This took quite a bit of filing. After that was achieved, we then took the exact measurement inside the front spar and cut the front of the T-bone so the distance between the t-bone "arms" was exactly the same as the distance inside the front spar at the bolt holes. LOTS of filing!

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Dec 10, 2021 Attached Rudder to Vertical Stab. - (3 hours)

Category: Tail Feathers

We decided to hang the vertical stabilizer and horizontal stabilize after realizing that to install the rudder pedals and cables we needed to install the rudder which required the rest of the stabilizers installed as well. We worked at installing the rudder. The fit between the bushings was Way too snug. We sanded down the bushing heads to get a better fit. We need to do more as the movement of the rudder is still stiff.

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Dec 09, 2021 Located parts for the rudder cable system - (1 hour) Category: Interior Finish

Located all the parts need to attach the rudder cables to the rudder pedals

Dec 09, 2021 Test fitted/ installed rudder pedals - (2 hours)

Category: Interior Finish

Installed the rudder pedals by screwing them through the floorboard into the nut plates. We had to grind down, ever so slightly, one of the tubes on which the rudder pedals are mounted so we could get the screw in the screw hole.

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Dec 09, 2021 Station 10 and 11 closeout - (4 hours)

Category: Fuselage

Matched drilled the remaining holes from the cover plate to station 10 and station 11 bulkheads adding the additional bracket to station 11. We then deburred and riveted.

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Dec 09, 2021 Reattached the boot cowls skins etc - (2 hours)

Category: Fuselage

Now that all the skins, stiffeners, spacers, cowl attach straps and the panel visor had been deburred yesterday we re-cleccoed them to the firewall, each other, and to the panel mount.

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Dec 08, 2021 Match drilled Floorboard - (2 hours)

Category: Interior Finish

Now that the skins were off for deburring we trimmed the floorboard for the best fit then match drilled where the screws will attach the rudder pedals and the control sticks. We then riveted the nut plates to the tabs.

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Dec 08, 2021 Finished Riveting of the Firewall - (1 hour)

Category: Firewall

With the ordered rivets we completed the riveting, in fact, because this batch left the mandrel in the rivet head we replaced all the other rivets that the mandrel was missing.

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Dec 08, 2021 Added more rivet holes where the bottom skin and the side boot cowl overlap - (.5 hour)

Category: Fuselage

Per Randy S of Ran's recommendation (this was in response to my question about the edge closeness on the side skins), we added more rivet holes where they overlap and through the strengthener.

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Dec 08, 2021 Boot Cowl, Attach Straps, and Instrument visor. - (8 hours)

Category: Fuselage

We match drilled the attach straps and instrument visor to the boot cowl skins. We then up drilled all holes to #30. We then took the skins off and deburred. We also trimmed the front of the skins so they lined up.

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Dec 07, 2021 Picked up Panel from Advanced Avionics

Category: Avionics

Drove up to Canby from Eugene 1.75 hours and picked up the panel - Picture doesn't do it justice.

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Dec 07, 2021 Boot Cowls - (4 hours)

Category: Fuselage

Spent a lot of time with the fit of the boot cowl skins, spacers, and the firewall. The instructions were incorrect all the spacers were precut to the correct length and predrilled. we did have to keep flipping them over to figure out the best fit on these spacers. We match drilled all holes to #40.

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Dec 06, 2021 Inserted spacers between firewall and boot cowl skins - (1.8 hours)

Category: Firewall

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Dec 06, 2021 2 more coats of truck bed liner on floor board - (.5 hour) Category: Fuselage

Dec 06, 2021 Installed Optional Jack Lugs on the main gear - (3 hours)

Category: Landing Gear

Removed both main gear wheels, bearings, and brake discs. Installed the new bolt and jack lug on the lower rear wheel attachment. Then reassembled the wheel/gear.

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Nov 19, 2021 Top Boot Cowl Skins and Panel Frame - (2 hours)

Category: Fuselage

We needed to trim the sides down on the panel frame so that it would fit. We then bent the flanges down a bit on the firewall and up a bit on the panel mount so the top boot cowl skins would lay flush on the tabs. We clecoed the top skins in place.

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Nov 19, 2021 Floorboard - (.5 hour)

Category: Fuselage

Sprayed floorboard with truckbed liner a couple of times.

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Nov 19, 2021 Side Boot Cowls - (4 hours)

Category: Fuselage

Again struggled with the fit of the side boot cowls. The alignment with the firewall, the bottom longeron, and the line on the vertical tube on the aft side were real problems. We decided to make the bottom longeron and the firewall the critical alignments, and if we need to trim the aft portion on the cowl we will do so in conjunction with the mounting of the doors. We then match drilled to the mounting tabs. We cut the stiffeners and match drilled those. On the stiffeners we marked where the additional rivets were going to go. We match drilled those to the sides. As part of the match drilling the right side cowl skin to the bottom cowl skin and the side skin and the mutual stiffeners, we got very close to the edge of the side skin. I have sent a picture to Randy for his review.

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Nov 19, 2021 Floorboard - (1 hour)

Category: Fuselage

Trimmed floorboard around tubes so it would lay flat on the tabs.

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Nov 18, 2021 Bottom Cowl skin - (4 hours)

Category: Fuselage

Another struggle to get the fit where we wanted it. Aligned with the firewall and with enough space on the sides so there was enough metal for the rear tabs and the cowl skin to be revited. After that, we match drilled to the tabs and clecoed. We cut the strentheners to the correct lengths, meassured for the additional rivet holes and matched drilled those and clecoed them in place.

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Nov 18, 2021 Temp Attached and match drilled to mounting tabs - (2 hours)

Category: Firewall

The fit was terrible we ended up using 4 bolts instead of 2 that was suggested we ended having to pound in the bottom bolts. Really concentrated on making sure it was flush against the cage before drilling.

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Nov 18, 2021 More Coats of Truck bed liner - (1 hour)

Category: Firewall

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Nov 18, 2021 Worked on the optional Horizontal Stab grab handle - (1 hour)

Category: Empennage

We went back and worked on this part left over from the early stages. Riveted the doublers in and bought replacement tubes at I wanted longer handles. We will finish later.

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Nov 17, 2021 Firewall - (8 hours)

Category: Fuselage

Located the three pieces of the firewall, rivets (only 1/2), and washers. Cleccoed them together. We reamed the holes as we were unhappy with the alignment. As we riveted the pieces we used Pro Seal to seal around the rivets. We then matched drilled the flange holes to the firewall. We then scuffed the side of the firewall that we sprayed with truck bed liner.

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Nov 17, 2021 Wheels and Mounting - (10 hours)

Category: Landing Gear

Did all the mounting work for the 2nd main tire and the nose gear. Packed the 2nd set of bearings. Mounted the two main gear tires and brakes. Yippie! set fuselage down on the mains.

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Nov 16, 2021 Landing Gear - (12 hours)

Category: Landing Gear

Attached the main landing gear legs to the fuselage. Figured out how to attach the brake calipers to the wheels and how to attach the axles and calipers to the gear legs. Torqued the axes to the legs using the same figures appropriate to the AN bolts. On one of the main gear wheels, Split the Wheel, inserted the tube in the tire (after putting talc powder on the innertube), mounted the tire on the rim, tightened the nuts of the rim to the correct torque. Finally packed the 2 bearings.
We had to call Matco to get install instructions for these wheels and brakes.

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Nov 15, 2021 Started work on the main landing gear - (4 hours)

Category: Landing Gear

Located all of the parts for the main landing gear. We then sanded the gear to remove the light corrosion, then primed it for installation tomorrow.

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Nov 15, 2021 added missing stringers to top skin - (2 hours)

Category: Fuselage

We weren't able to finish the top skin last time as we didn't have long enough stinger pieces left. I had ordered some from Rans and they had arrived in the interim. So we cut, matched drilled, deburred, and riveted them in place.

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Nov 15, 2021 Installed bottom and side skins - (8 hours)

Category: Fuselage

We removed the bottom and side skins and did some additional minor timming and deburred everything. While the bottom skin was off we drilled the holes for the landing gear bolts where we had previously marked. I slowly upsized the drill bit so there wouldn't be a chance of the hole getting off-center. After this was completed we riveted the pieces in place. This took extra time as there were lots of different rivet call-outs. We ended up marking every hole with its call-out.

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Nov 15, 2021 Painted Internal pieces back from painter

Category: Paint / Decals

They came out great, including the big white plastic baggage area closeout.

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Oct 01, 2021 Interior items to be painted - (1 hour) Category: Paint / Decals

located and wrote on all the pieces that need to be painted in the interior. These were then taken over to Jim. the painter to work on between now and next time. Going with a grey that will highlight the cage tubing and will go with the outdoor cloth that I did the baggage area in.

Oct 01, 2021 Rivet call outs - (.8 hour) Category: Fuselage

Wrote on the bottom skin all the rivet call-outs....what a pain in the neck- literally.

Oct 01, 2021 Taped stringers to bottom skin and the side skins - (1 hour)

Category: Fuselage

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Oct 01, 2021 Rivet hole locations on side skins to bottom skin - (3 hours) Category: Fuselage

We used a rivet fan and the standoff distance to create the marks which were then matched drilled to the bottom skin. We were careful to miss the tubing of the cage

Oct 01, 2021 Trimmed the side skins to fit around welds - (1 hour)

Category: Fuselage

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Oct 01, 2021 Fitted, Trimmed and match drilled side skins to cage. - (8 hours)

Category: Fuselage

We fitted up the side skins and match drilled to tabs on the cage. On the difficult ones, we used a hole finder, not a template. This worked really well.

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Sep 30, 2021 Started to fit side skins - (.5 hour)

Category: Fuselage

located and started to look at the placement of the side skins.

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Sep 30, 2021 Flipped the fuselage and match drilled the bottom skin. - (4 hours)

Category: Fuselage

We flipped the fuselage back over and matched drilled the bottom skin to the tabs. We also marked the skin where the landing gear will mount to the cage.

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Sep 30, 2021 Cut the stringers for the interior of the bottom skin - (2 hours) Category: Fuselage

We measured and cut and smoothed the edges of all the required stingers that will be taped to the bottom of the interior of the skin

Sep 30, 2021 Flipped Fuselage and matched up cage bottom skin - (3 hours)

Category: Fuselage

We flipped the fuselage over and fitted the bottom skin to the cage and clamped it. This actually took quite a bit of time to center it left and right and get the correct amount of overhang in the front.

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Sep 30, 2021 FINISH SEAT - (.5 hour) Category: Interior Finish

The needed rivet and washers to finish the headrest arrived in the mail. I enlarged the previously drilled holes and riveted the "buttons". I installed the crossbar, tightened the mounting bolts, and reinstalled the headrest cushion. - DONE

Sep 30, 2021 Finished riveting the top skins - (4 hours)

Category: Fuselage

We riveted the top centerline and the missing ones from the bottom. In fact, we were overzealous and riveted the fronts of the side and bottom skins. We weren't supposed to do this yet....drilled them back out after confirming with Randy S.

Gmail - Re_ Bottom skin question.pdf

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Sep 29, 2021 Rivet top skins to tailcone - (15.7 hours)

Category: Fuselage

Spent the day riveting the top skins to the tailcone. We also deburred the top skins of the baggage area then started riveting them to the fuselage. We also put structural epoxy into the 3 missed drilled holes and filled the remaining slight depressions with filler. We did not have enough stringer/stiffener raw stock to add the required 2 additional ones. Ordered more from Rans and noted with tape on the top. we Will finish next time.

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Sep 28, 2021 Tailcone skins - (6 hours)

Category: Fuselage

Matched drilled the top skin strings as well as the spacers. Clecoed the baggage window lexan spacers after cutting it and up drilling them. Checked for twist once again.

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Sep 28, 2021 Assembly of control sticks. - (3 hours)

Category: Interior Finish

Finished up assembling the control sticks and mechanism.

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Sep 28, 2021 Baggage Area skins - (3 hours)

Category: Interior Finish

Trimmed and fitted the fabric over to the backside to "lock" the fabric in place. Glued and rolled. Had to trim the fabric off where the sides are wedged under the window supports. I think turned out pretty well.

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Sep 28, 2021 Seats - (1 hour)

Category: Interior Finish

All but finished the remaining seat. Remelted the holes for the screws and attached the headrest. Only waiting for the rivets and washers to reinstall the crossbar on the headrest.

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Sep 27, 2021 Seat - (8 hours)

Category: Interior Finish

Removed the damaged back and headrest from the seat. Cut, Drilled, and installed the rivet nuts on the replacement seat back and headrest. Thought I was done but discovered that I had attached the back to the bottom backward. I also had not ordered the replacement rivet and washers for the internal support bar. Should arrive this week, then the seats will FINALLY be done.

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Sep 27, 2021 Assembly of control sticks. - (6 hours)

Category: Interior Finish

worked on assembling the control sticks and mounting structure.

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Sep 27, 2021 Tailcone stringers and skins - (6 hours)

Category: Fuselage

The top skin stingers were bent to the correct angles. Skins over the baggage area were match drilled and clecoed.

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Aug 18, 2021 Front Top Skins

Category: Fuselage

I heard back from Randy at Rans on the miss drilling of the holes on the forward top skin. These are cosmetic - phew. See below for the email response.

Gmail - Re_ Issue with match drilling top forward top skin to Station 4 bulkhead.pdf

Aug 13, 2021 Front Tailcone Top Skins - (4 hours)

Category: Fuselage

We matched drilled the forward top skins to the cage, window support, and number 4 bulkhead. During the match drilling of the top part the bulkhead moved. This caused the misalignment on the front and back top skins. On the back top skin, the holes are at the very edge of the skin and likely not to hold a rivet. We redrilled which created a second hole in the correct position. This was only 3 holes but we reached out to Rans to make sure this was not structural and just cosementic.

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Aug 13, 2021 Cloth on baggage area skins - (4 hours)

Category: Interior Finish

We cut out pieces of the fabric that were slightly larger than the skins. I first started with the baggage area floor. After struggling to get the fabric glued over most of the skin, the fabric had shifted and was angled so that it wouldn't cover a corner of the skin. Pulled the fabric off, cut another one started at the middle, and worked to the edges. This time it fit. We also covered the small side panels. Figures crossed when we check them in September they will be firmly attached to the skins.

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Aug 13, 2021 Second Seat - (1 hour) Category: Interior Finish

Ahhh We tried to attach the headrest again this morning and we broke the rivet nut. The screw holes that we had drilled in the seat back are just not lined up good enough with the headrest holes, they are angled so much it is almost impossible to attach the headrest.....solution is we ordered a replacement seatback and headrest frame.

Aug 12, 2021 Fitting top skins over baggage area. - (3.5 hours)

Category: Fuselage

We started the fit-up of the top skins over the baggage area. When we clecoed the aft portion to the other top skins we noticed that they were sitting lower in the front tops over the window supports than the Rans build photos on their website. We were concerned that the tailcone and cage weren't mounted together correctly. We sent an email to Rans tech support which doesn't open until 2 Kansas time (3 hours later). We finally received a response from Randy saying our pictures matched one that they were building in the shop so all was good , see attached photo from Randy and email. We resumed the fit up.

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Randy email on the junction.pdf

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Aug 12, 2021 2nd Seat - (4 hours)

Category: Interior Finish

The replacement seat bottom frame arrived by UPS late this morning. So we worked on finishing up the 2nd seat. Drilled holes, attached to the back, riveted the seat pan, and put on the cushions. The only thing left is attached the headrest.

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Aug 12, 2021 Interior - Baggage area fabric - (2 hours)

Category: Fuselage

Check the test article this morning, one side was good the other not so. So decided to cut up the fabric to fit the 3 pieces. Tried on half of the largest piece. Peeled it off as I was not happy with how it was sticking. Did a small piece - do think it is going to work. I bought a roller and will spray the fabric instead of the aluminum tomorrow and press the fabric with the roller.

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Aug 11, 2021 Test glued a piece of the material for the baggage area - (0.3 hour) Category: Fuselage

We cut a 6" square piece of the fabric I want to use in the baggage area and test glued it to a scrap piece of aluminum. We will see how it held in the morning.

Aug 11, 2021 Edged the bottom of Baggage area top skins - (0.5 hour)

Category: Fuselage

We edged the bottoms of the baggage top skins. Tomorrow we will work on fitting them.

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Aug 11, 2021 S4 Closeout - (13 hours)

Category: Fuselage

Continued working on the s4 close-out all day. We cut, drilled, and glued the spacer onto the back of the S4 closeout, continued fitting the plastic. Near the end of the day we drilled the S4 on the bottom side and top through it and the aluminum behind/below. We then attached the nut plates to those aluminum pieces, so the s4 cutout can be screwed into place.

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Aug 10, 2021 S4 Closeout - (2 hours)

Category: Fuselage

Trimmed the plastic piece that forms the S4 closeout. It required an angled cut to fit over the window supports. This left a large space in the plastic above the spacer. We are brainstorming ideas to covering it but still allowing it to be removable. Chris and I searched high and low for the stock material for the fabrication of the spacers to be glued to the back. Still haven't found them. I posted on Facebook on the Rans builder site for help.

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Aug 10, 2021 Finished tailcone wiring - (4 hours)

Category: Avionics

Finished attaching the wiring and tubing to the bulkheads and other surfaces. Almost forgot to run the OAT sensor to the area that will be shielded from the sun under the horizontal stabilizer. It required splicing additional wire.

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Aug 10, 2021 Clecoed top skins to tailcone - (0.5 hour)

Category: Fuselage

Clecoed the top skins onto the tailcone, excluding the center, but including the piece to the space between S10 and S11.

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Aug 10, 2021 Edged the Top skins - (0.5 hour)

Category: Fuselage

Edged/creased the edge on the middle longeron. Creased the top and bottom edge of the left skin.

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Aug 10, 2021 Window Supports (S3 to S4) - (8 hours)

Category: Fuselage

Chris and I finished fitting the window supports. We then matched drilled, deburred, and then riveted the tang of the window support to the middle longerons.

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Aug 09, 2021 Fabricating window supports between tailcone and cage - (8 hours)

Category: Fuselage

Took us a while to find the material from which to fabricate the window supports, to discover that we didn't have enough. Luckily Synergy had a spare angle bar with the same dimensions, and bonus it was already primed. So we cut the required lengths and created the angled tang. We now need to finish the "fitting" to the top of the cage. We are grinding material off of the sides and top to fit around the welds.

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Aug 09, 2021 Wiring - (8 hours)

Category: Avionics

Brenden spent all day running wires/coax cable for all the antennas and rear light and the trim motor. He also fabricated all of the pitot and static tubes that will connect to the ADAHRS.

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Aug 09, 2021 Seats - (3 hours)

Category: Interior Finish

Finished 1 seat !!!!! We also replaced 2 broken rivet nuts. One was under the rightmost seat rail (threads were somehow stripped), the other was in the seatback frame of the 2nd seat (rivet head ripped off when we took the headrest frame off). I riveted the seat pan on, struggled to put the cushions on, melted the required holes, riveted the seat guides under, and bolted on the headrest.

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Aug 06, 2021 Seats - (4 hours)

Category: Interior Finish

Continued to work on the one seat as we need to wait for the replacement bottom frame from RANS. The top and bottom were attached to each other per diagram from the parts manual. The seat internal supports were cut to 13.75" and inserted as well as the Builder Alert supports and the attachments were tightened. The bottom seat pan was match drilled and deburred.

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Aug 06, 2021 Seat rails - (4 hours)

Category: Interior Finish

The seat stops were fabricated and rivet nuts were installed for the bottom track. One of the nuts was pushed in during the bolting process. We will deal with that Monday - I ordered more rivet nuts. The top track was match drilled and countersunk.

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Aug 06, 2021 Static ports were mounted on opposite sides near the ADAHRS

Category: Avionics

Holes were drilled for the right-hand side one, both were prepped and pro-sealed to the lft and rht sides.

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Aug 06, 2021 ADAHRS - (2 hours)

Category: Avionics

ADAHRS was mounted with bolts on the horizontal supports.

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Aug 06, 2021 ADSB and Transponder Antenna Mounts - (2 hours)

Category: Avionics

After deciding where to mount these the holes were drilled into the bottom skin just behind the baggage area on opposite sides from each other.

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Aug 06, 2021 Planning and Ordering - (1 hour) Category: Avionics

Spent time figuring out where to mount all the antennas. I have a com, ADSB, transponder, GPS, and ELT. All need to be the minimum distance from the ADHARS and each other. I then ordered 50' of coax cable and connectors for B&C electronics.....WOW the cost was not what I was thinking. Obviously from the price they are NOT the same quality as your TV Coax. Mandy of Synergy is going to order all the additional wire we need to run everything back to the panel and power etc. We also decided to mount the OAT sensor under the horizontal stabilizer.

Aug 05, 2021 Created the ADHARS mounting - (5 hours)

Category: Avionics

Fabricated a mounting for the ADHARS between stations 6 and 7. Also, drilled holes for the static ports on the bottom side skins near the mounting.

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Aug 05, 2021 seats - (12 hours)

Category: Interior Finish

Worked on the seats today, primarily the optional headrest. We drilled all the holes to attach the headrest. Had a major oops, somehow when up drilling one of the matched drilled attachment holes with the drill press it was WAY off from the prior holes. I decide to redrill and go with the new holes. I did this based on it is just one of the attachment holes and it is for the headrest only.
We also fabricated the bar to be inserted into the headrests.

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Aug 04, 2021 Started to work on Seats - (8 hours)

Category: Interior Finish

Assembled the seatbacks by trimming off the excess, and loosely attaching the side seat brackets. This was after drilling through the doubler and countersinking the outside seat brackets. Next worked on the seat bottom support by drilling the required holes. One of them was done incorrectly and so a replacement was ordered. on the other one attached the flanges after up drilling. Ended the day by starting on the optional headrests. Located the parts and marked the position for holes to be drilled tomorrow. Too hot to do anything else

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Aug 04, 2021 Drilled the locking rails for the seats - (2 hours)

Category: Fuselage

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Aug 04, 2021 Assembled Rudder pedals - (1 hour)

Category: Fuselage

Attached the pedals to the supports.

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Aug 04, 2021 Baggage Area - (5 hours)

Category: Fuselage

Matched drilled the installed nut plates and screws to the bottom and side skins.

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Aug 03, 2021 Constructing seats - (5 hours)

Category: Interior Finish

After locating the parts.......which took forever as we were looking for parts on the parts list not included with our seats. Worked on the backs trimmed and drilled per instructions. Worked on installing the bottom tracks that attach to the fuselage cage.

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Aug 03, 2021 Worked on the aft baggage area - (5 hours)

Category: Fuselage

fitted and riveted the bottom skin of the aft baggage area.....sweated over the fit near station 4 and the top skin. Cut additional amounts off the top piece where it meets the bulkhead (Station 4) to relieve the pressure and the bow of the aluminum. Called Rans tech support on how hard we need to push the bottom against station 4 the reply was enough so that the back plastic end cap can fit.

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Aug 03, 2021 Rudder pedals - (.5 hour)

Category: Fuselage

Put 5 coats of bed liner. Drilled out plastic brackets

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Aug 02, 2021 Worked on assembling the rudder pedals - (3 hours)

Category: Fuselage

Riveted the rudder pedals together matched drilled the bushings to the pedal. Will continue working on them tomorrow.

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Aug 02, 2021 Work on the Baggage area - (5 hours)

Category: Fuselage

Worked on installing siding and bottom supports of the baggage area. To make sure the station was locked in we clecoed the top skins of the tailcone on.

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Aug 02, 2021 Attached Wing Tips - (3 hours)

Category: Wings

It was difficult to get the bolts to thread...but finally were able to mount and tighten the bolts.

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Jul 15, 2021 Wing tips - Project that won't end - Navigation light - (1 hour)

Category: Wings

The navigation/strobe light attachment was riveted to the wing tips.

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Jul 15, 2021 Wing tips - Project that won't end - (8 hours)

Category: Wings

We repeated the process of match drilling the right wing tip and rib. Got almost all the way done.....we had forgotten the nut plate supports. We drilled out the rivets on both, luckily found the correct size rivets in the finishing kit (ordered replacements) and re-attached the nut plates to both wing tips with the supports.

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Jul 15, 2021 Wing tips - Project that won't end - (5 hours)

Category: Wings

Left wingtip, we first tried match drilling the holes to attach to the wing......too difficult. After looking at the Rans video we marked the holes with a marker then after taking the tip off of the wing, drilled the holes. We then attached the nut plates.

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Jul 14, 2021 Rudder cables - (3 hours)

Category: Fuselage

After much struggling to get the pulleys that attach on S8 to work correctly, bolt short enough to allow the pully to turn freely but long enough to keep the cable from coming off of the pully.

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Jul 13, 2021 Wing tips - Project that won't end - (2 hours) Category: Wings

Refined the Jig and the spacer for the wingtip glued the right rib and tip.

Jul 13, 2021 Wing tips - Project that won't end - (1 hour)

Category: Wings

Checked the re-glued left wing tip. It was MUCH better. I sanded off a lot of the excess adhesive.

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Jul 13, 2021 Tailcone to Fuselage cage - (6 hours)

Category: Fuselage

We had to redo everything but middle longeron strengtheners.....Needed to match drill the BOTTOM Longerons FIRST. Nothing lined up that we had previously match drilled. We needed to scrap all of the side skin strengtheners as they were the wrong length. The biggest problem is that before we figured out that the skins were out of alignment we had match drilled the lower right S3 to S4 support for the floor of the baggage area. We drilled the holes too close to the edge, which meant we needed to order a new part. This stopped all work on the fuselage until that part arrives in time for our next visit. We were able to find identical material for the bottom and side strengtheners that were to be used later in the build...I ordered replacements for this as well. We were able to match drill the lower left longerons and the S3-S4 support.

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Jul 12, 2021 Cage to tail-cone work - (6 hours)

Category: Fuselage

After struggling with the text, parts, and figures manuals (all the related parts etc are in multiple sections). We cut and all the related strengtheners, Top, bottom, and sides. Match drilled with the tabs on the cage. We cut the middle and bottom longeron strengthners and match drilled the middle longeron and clecoed in place. Ended the day trying to figure out the best way to attach the bottom strengthener.

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Jul 12, 2021 Wing tips - Project that won't end - (.5 hour)

Category: Wings

Decided to attempt to re-glue the left wing-tip using the new jig and different glue. We will know tomorrow.

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Jul 09, 2021 Mounting cage to the tail cone - (12 hours)

Category: Fuselage

Chris, Chris, and Brenden spent most of the day leveling the cage and the tail cone. They tried may iterations of shims and tables. They were finally able to get it to the good enough state regarding pitch and twist. They were able to finally drill and cleco the mounting bracket to the tail cone at the very end of the day.

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Jul 09, 2021 Wing tip - part from ...... - (7 hours)

Category: Wings

Looked at the glued left-wing tip. Rib had slid back and not very glued to the rib. We pulled it apart causing slight damage to the tip (very small crack). I sanded off the adhesive. Rather than work on that tip again I decided to work on the right. I spent the rest of the day making the jig for the right wing. I am taking EXTREME care on the fit of the jig.

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Jul 08, 2021 Wing Struts - (6 hours)

Category: Wings

Son Chris and I worked on the Wing struts, after locating the parts. We match drilled and upsized the strut and the doublers. Deburred and then riveted the doublers on.

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Jul 08, 2021 Wing tips - Project that won't end - (7 hours)

Category: Wings

Chris and Chris worked on the wing tip jig with a sander. Finally got it good enough to use. Some areas needed shims. Bro Chris when and picked up .05 aluminium to use as the shim between the tabletop and the rib and also bought ABS adhesive. Bro Chris worked on cutting out the aluminium shim. At the end of the day, we took the bold step and glued the rib and tip together weighing down the rib and the rip with sand bags......will know how it looks tomorrow.

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Jul 08, 2021 Pro Sealed fuel cap right wing - (2 hours)

Category: Wings

The fuel cap was Pro Sealed to wing skin on the right-wing.

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Jul 08, 2021 Rivet Left wing final rib - (1 hour)

Category: Wings

First thing this AM I finished riveting the rib that holds the fuel tank in on the left wing.

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Jul 07, 2021 Installed fuel tanks in the right wing - (2 hours)

Category: Wings

Right-wing fuel tank was installed. We decided to junk the grommets provided by Rans for the fuel sight gauge and found ones that fit better, did this on both wings. Riveted the end rib in place after struggling to get the rib positioned between the skin and the support strut for the fuel tank. Pro Sealed around the fuel cap assembly.

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Jul 07, 2021 Wing tips - Project that won't end - (6 hours)

Category: Wings

Finished trimming the tip to fit. Then started the jig to glue the tip to the plastic rib....took forever to get it to fit.

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Jul 06, 2021 Fuel Tank - (6 hours)

Category: Wings

Pro sealed the screws of the fuel cap, pressure tested tanks then drilled the vent hole. We struggled with getting the wing rib back in after putting the tanks in the wing finally clecoed. Fuel sight gauges, decals, and grommets installed.

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Jul 06, 2021 Continued working on the wing tips - (6 hours)

Category: Wings

Continued with the trimming and the fitting process.

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Jun 28, 2021 Header Tank - (1 hour) Category: MISC

After going back and forth with Rans on which header tank to order....decided on the 2.7-gallon header tank and added the electric fuel pump as well.

Jun 28, 2021 Shot for balancing the ailerons and elvator - (1 hour) Category: MISC

scoured the web to find reasonably priced shot, found a site and ordered 25lbs

Jun 11, 2021 Fuel Tanks - (4 hours)

Category: Wings

Installed the fuel tank internal support and attached the fuel cap and pro sealed. Pro Sealed all the tank fittings.

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Jun 11, 2021 Wing tips - (8 hours)

Category: Wings

Last Day of our sprint so we decided to work on the wing tips. We taped and started the trimming process on the plastic tip and the plastic mounting rib.

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Jun 10, 2021 Fuel Tanks - (5 hours)

Category: Wings

Worked on the left and right fuel tanks. Difficult to follow how tight wants the fittings to be on the tanks. Ended up buying an allen wrench on a socket to help tighten the smaller fittings. We finished the right tank fittings and started to work on the left tank. It was then noticed that on the right tank the rear hole was drilled at just over 3" from the measuring point VS 1 3/16". Checked with Rans and said this was OK.

Gmail - Re_ Messed up again This time Right fuel tank.pdf

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Jun 10, 2021 Recreated Pitot tube Mount - (2 hours)

Category: Wings

After miss drilling the match holes to screw into the inspection port mounting ring. we measured precisely to a) make sure the mounting bracket would clear all the tabs of the inspection ring, B) would be facing perfectly forward. The hole for the pitot mount was created with a drill, grinder, and files. It was matched drilled and riveted to the plate.

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Jun 09, 2021 Right Fuel Tank - (4 hours)

Category: Wings

Brenden made the tools for cutting out the required holes in the fuel tanks. He also worked on how best to do the fittings on the tank. What was tight enough but not too tight per the instructions.

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Jun 09, 2021 Pitot Support - (2 hours)

Category: Wings

After carefully measuring where to position the pitot support to the port, I missed drilled one of the holes to the mounting bracket below ruining the base. So took the mount off the scrap base and started again. I had to cut the base two times. The first one was more oval than round. The second one was rough cut with a band saw and then refined with a sander. It was much better.

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Jun 09, 2021 Finished off left wing bottom skin - (12 hours)

Category: Wings

Finished off all the riveting on the left bottom skin, including the fuel tank support which had arrived from Rans.

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Jun 08, 2021 Finished Skins Right Wing Started Bottom Skin Left Wing - (8 hours)

Category: Wings

I was not at 100% so Chris did most of the work. Finished the right-wing bottom by match drilling and riveting rear spar and the inspection covers. We swapped out wings and checked for twist on the right wing. Then matched drilled front spar, dimpled, countersunk, deburred, and then riveted. Then riveted most of the rest of the skin. Chris ended damaging one of the corners of the fuel tank supports, talked to Rans and it was decided to replace and have it next day air for aesthetics vs redrilling inboard.

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Jun 07, 2021 Attaching skin to bottom of the right wing - (12 hours)

Category: Wings

Positioned the bottom skin on the right wing. There was a slight interference between the skin and flap/aileron attaching bracket. It was filed to enlarge. After the skin and the inspection port brackets were clecoed the skin and the front spar were matched drilled, dimpled, countersunk, deburred and finally riveted. The rest of the rivets were installed leaving the last 4 near the rear spar only clecoed. This is done so that the skin and rear spar can be matched drilled. Note: I was not at 100% so Chris did most of the work.

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Jun 04, 2021 Transferred right wing to jig and notched stringer for strut support - (1 hour)

Category: Wings

We flipped the right wing over on to the jig, clamped everything down, and then checked for twist. We were ecstatic that there was no shimming required. we partially clecoed the bottom skin on to locate the exact spot on the stringer were it needed to be notched for the strut support. Then notched it.

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Jun 04, 2021 Assembled wing jig - (3 hours)

Category: Wings

While Chris and I worked on the gap seal on the right wing, Brenden assembled the wing jig. We bought 2 more 2x2 extruded aluminum pieces cut to length. We discovered that we attached the front one in the wrong direction - easily fixed, we didn't notice until we tried to put the wing on it. Notice in the pictures the front piece is in the wrong direction.

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Jun 04, 2021 Gap seal installation - Right wing - (10 hours)

Category: Wings

Installed the right-wing gap seal. This time we made sure the aileron and flap gap seals were at a consistent separation between the piece that fits under the wing skin and the angled part that attaches to the rear spar. We used a hand seamer on both gap seals to make sure they were equidistant (squeezed it gently at the crease) This time it was a lot easier to make sure that they matched the angle of the wing skin. We matched drilled, disassembled, deburred, and then riveted the remaining wing skin rivets (all but the root rib) and the gap seal to the wing. We then checked the range of motion of the aileron and flap. 4 Rivets needed to be redone to on the flap, so it didn't rub. This went so much easier than the left. Were the two meet in the middle was almost perfect, not like the left.

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Jun 03, 2021 Installed gap seal left wing - (11 hours)

Category: Wings

Installed the gap seal on the left wing. This included match drilling after trying to make it have the same angle as the wing skin. we had a heck of a time. We used the hand seamer to crimp it. I was a little overzealous on flap seal and dented the bottom a bit. where the 2 meet in the middle didn't line up like we wanted. When we disassembled to debur Brenden a dimple remover tool to get some of my dents out. After we reassembled we riveted the remaining wing skin rivets and the gap seal under the wing skin and also to the rear spar. We then checked for clearance. Brenden used a ball peen hammer, per the instructions, and creased the underside so the flap would clear. He was no happy on how hat looked, but the flap cleared.

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Jun 03, 2021 Finished ailerons and flaps - (2 hours)

Category: Wings

We finished riveting the ailerons and flaps.

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Jun 02, 2021 Visited Advanced Flight Systems - (1 hour) Category: Avionics

On Tues afternoon Chris and I drove up to Advanced to see their facilities and talk about the avionics and panel (I have already purchased the carbon fiber one from Aerosport). We discussed how we can accommodate all the required switches for the Rotax 915 that I am planning to install. I also picked up the Dynon ADAHRS so we can install in the fuselage. In talking with them, and based on what other S21 builders are finding, I eliminated the separate magnetometer.

Jun 02, 2021 Ailerons and flaps - (10 hours)

Category: Wings

Again, a very time-consuming day working on the flaps and ailerons. lots of remeasuring as we riveted, we were slowed by sharing the 1 smart level. EXTREMELY focused on not having any twist. We ended early at 2PM

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Jun 01, 2021 Aileron and Flaps - (20 hours)

Category: Wings

Today was totally focused on the ailerons and flaps. We completed match drilling to the bottoms of ribs, after attaching the needed attachment brackets. On the left aileron match drilled and deburred to the spar. One of the most time-consuming things was to make sure there was no twist. Lots of measurements and shimming. Thankfully, we had the sandbags from before + I had brought another down. We transferred sand to gallon zip-lock bags so they were lighter.

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May 14, 2021 Wings - (80 hours)

Category: Wings

Brother Chris and Brenden worked on the wings. Brenden installed wiring and pitot tube. Chris worked on the wing I couldn't get to. Running the aileron cables etc. They were able to rivet the top skins on both. Left it there as the aileron and flaps need to be completed to check fit. Brenden also made the Pitot tube mount.

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May 07, 2021 Attached bellcranks to Right wing - (1 hour) Category: Wings

I was able to attach and safety wire both the aileron and flap bellcranks to the right-wing.

May 07, 2021 Work on left wing - (10 hours)

Category: Wings

Mainly focused on the left-wing. Bellcranks for aileron and flap were attached, including safety wire and lock tight. We ended up drilling holes in the rib flanges for the safety wires, after reviewing what others had done on the Rans S21 builder Facebook page. The plans were silent on where to attach the safety wire. The aileron cable and the flap cable were also attached. The electrical wire holes were drilled and grommeted on ribs 3-10 and the serrated grommets were attached on ribs 1 and 2 on both the left and right wing. After reviewing the Rans pitot tube attachment suggestion, it was decided to fabricated and riviet a plate through which the pitot and the AOA tube will be passed through grommets on the affected ribs. I asked Rans about how close the aileron cables are to rubbing on the strut attachment mount and whether this should be a condition inspection item. Here is the reply "Yes, add that to the list, we inspect that every annual, so far no issues, we do place anti-chafe tape in the area of possible contact."

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May 06, 2021 Riveted Ribs to Spars - (8 hours)

Category: Wings

After we had clecoed the ribs to both spars, we bolted the strut support to rear spars. We then riveted the front and rear spars to the ribs, except rib 1. Completed both wings.

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May 06, 2021 Riveted Hinge brackets and bell crank attachments to left and right wings - (8 hours)

Category: Wings

We riveted the hinge brackets and bell crack attachments to the ribs, after match drilling and deburring. We had drilled and deburred the be bell crank attachment holes.

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May 05, 2021 Cut out wing shaping tool - (.5 hour)

Category: Wings

I had laid out the tools on a 1" cutting board at home using a protractor and a ruler. Cut it here as they have a band saw.

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May 05, 2021 laid out ribs and numbered for both left and right - (.5 hour)

Category: Wings

Laid out the ribs in order and confirmed they were level. Had to swap some around as the end ribs are slightly different, I clecoed the angle mounts to the hinges and clecoed to the correct ribs.

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May 05, 2021 Left wing strut mounting bracket issues - (.5 hour)

Category: Wings

After enlarging the bolt holes one was oblong and one of the mounting holes was too short. Emailed Rans and got this response - this is ok as long as the bolts pass through, and shimming to get an even footprint is a good idea.
We used a thin washer to shim. finished mounting the bracket.

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May 05, 2021 Installed strut support to the front spar and torqued the nuts - Rht wing - (.5 hour)

Category: Wings

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May 05, 2021 Installed strut mount brackets to the strut support Rht wing - (.5 hour) Category: Wings

After enlarging the holes in the bracket and the support attached it to the support - not tightening the nuts.

May 05, 2021 Drilled and installed bushings in the aileron and flap hinges - (3 hours)

Category: Wings

used the drill press to enlarge bushing holes and then hammered in the bushings

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May 04, 2021 Sick as a dog Category: MISC

All I can figure out is that I had some sort of reaction to my second Vaccination....Horrible abdominal pain Monday night and Tues. leaving Brenden to focus on the optional wing lights.

May 04, 2021 Optional landing lights - (8 hours)

Category: Wings

Brenden spent the day measuring, cutting and drilling the brackets for the left and right-wing for the landing lights. He also cut the plastic for the lenses and test fit them.

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May 03, 2021 Locating wing ribs and parts for tomorrow - (1 hour) Category: Wings

Emptied most of the crate to locate all of the ribs for the wings

May 03, 2021 Optional Landing openings - (4 hours)

Category: Wings

We spent about 45 min looking for the template first in the manuals, then in the crate. Finally found it and after marking the front spars the openings were cut with a grinder. The rest of the time was filing the openings so they were even.

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May 03, 2021 Bell Crank - (2 hours)

Category: Wings

Completed the bell cranks. Added connecting parts to all four. I attached the safety wire to one of the aileron cranks after being shown by Brenden on the first one. I ended using about 5 feet of wire on the many multiple tries to get the one acceptable one.

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May 03, 2021 Getting Organized and figuring out where we left off - (1 hour) Category: Workshop

We unpacked the crate and looked at the manuals to figure out where we left off. Still ended up spending more time finding parts than we would have liked.

May 03, 2021 Finished Riveting of doublers on Spars - (1 hour)

Category: Wings

After a long break for COVID, I started by finishing riveting the remaining doublers on the remaining wing spars. I also drilled out the required holes

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Dec 29, 2020 Right wing spars - (1 hour) Category: Wings

I deburred the right-wing front spar (inside). I clecoed the doublers to the front and rear right spars.

Dec 29, 2020 Aileron and Flap bellcrank - (2 hours) Category: Wings

After buying a lock ring pliers brother Chris was able to finish both the left and right aileron and flap bellcrank assmblies

Dec 28, 2020 Began Work on Aileron and Flap Bell Crank - (1 hour)

Category: Wings

Located aileron and flap bell crank parts. Wedged the bearings into the aileron pulley and the flap bell crank.

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Dec 28, 2020 Front and Back Spar. - (4 hours)

Category: Wings

Located all the parts for the left-wing spars. Then riveted the doublers to each. Did not rivet the holes that were supposed to not yet be riveted. Drilled out the bolt holes in the front spar and the doubler.

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Dec 28, 2020 Elevator - Finished Riveting - (2 hours)

Category: Tail Feathers

Picked up where we left off in Oct. We riveted the end ribs and the front skins.

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Dec 28, 2020 Riveted Missing Rivet Horizontal Stabilzer - (.5 hour)

Category: Tail Feathers

After receiving a spare rivet from RANS I riveted the missing rivet.

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Oct 30, 2020 Elevator - (6 hours)

Category: Tail Feathers

Riveted the skins to the elevator after match drilling the pieces that are on either side of the trim tab. Incorrectly riveted the ends of the elevator which were then drilled out to allow for the installation and match drilling of elevator tip skin. We were only able to cleco this on.

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Oct 30, 2020 Shaped the flaps and ailerons - (4 hours)

Category: Wings

A 2" aluminum pipe was used to form the curve on the top portion of the skins for the flaps and ailerons. Holes were matched drilled to the holes in the skins. Skins were then clecoed to the pipe and rolled until the clecos rounded and touched the bottom of the skins. It took 3 of us to roll.

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Oct 29, 2020 Cut the tabs off of the Flaps and ailerons. - (1 hour)

Category: Wings

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Oct 29, 2020 Pulled and identified parts for the flaps - (1 hour) Category: Wings

Chris and Phil pulled all the parts for the flaps.

Oct 29, 2020 Continued work on trim tab hinges. - (3 hours) Category: Tail Feathers

Oct 29, 2020 Tailcone - riveted side skins to bulkhead - (2 hours)

Category: Fuselage

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Oct 28, 2020 Trim tab hinges - (3 hours) Category: Tail Feathers

Brenden worked on installing the hinges - methodically making sure there were flush and no twist.

Oct 28, 2020 Bent and installed top skins of elevator - (2 hours)

Category: Tail Feathers

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Oct 28, 2020 Side and top tailcone skins - (4 hours)

Category: Fuselage

Chris and Chris measured, clecoed and riveted the stingers to the top and side skins. Clecoed side skins to bulkheads.

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Oct 28, 2020 Attached the station bulkheads to the bottom skin - (2 hours)

Category: Fuselage

Clecoed and then riveted the bulkheads to the bottom skin.

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Oct 27, 2020 Tailcone - riveted longeron, stingers to bottom skin - (4 hours)

Category: Fuselage

Chris and Chris riveted the longerons and stingers to the bottom skin.

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Oct 27, 2020 Elevator - (1 hour)

Category: Tail Feathers

The Installed the elevator horn after the missing rivets arrived, and the horn was completed.

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Oct 26, 2020 Horizontal Stabilizer - (3 hours)

Category: Tail Feathers

Installed Skin on the horizontal stabilizer

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Oct 26, 2020 Tailcone - Bottom skin stringers and inspection plates - (4 hours)

Category: Fuselage

Chris, Chris, and Phil Measured and cut all the stingers and riveted the inspection covers and the nut plates to the bottom skin (later realized skin was upside down) Tuesday the inspection cover mounts were drilled out and flipped.

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Oct 26, 2020 Rans Fix for over countersunk rivet hole - (3 hours)

Category: Tail Feathers

Rans got back to us Mon AM. Brenden created a doubler that stretched 2 rivets on either side. Rivets are flush but longer to take into account the size of the doubler

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Oct 24, 2020 Horizontal Stabilizer - (4 hours)

Category: Tail Feathers

We worked on skinning the stabilizer. Clecoed, leveled and match drilled the spars. I over countersunk one of the holes in the spare - waiting for Rans to respond if it acceptable or need to order new spar before riveting

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Oct 24, 2020 Horizontal Stabilizer - (4 hours)

Category: Tail Feathers

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Oct 21, 2020 Trim Tab - (2 hours)

Category: Tail Feathers

Chris and I finished riveting the bottom portion of the trim tab skin to the spar. Brendan spent a significant amount of time leveling and match drilling the top portion of the skin to spar of the trim tab

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Oct 21, 2020 Fuselage Stations - (6 hours)

Category: Fuselage

Completed Station 4,5,6 and 8. Worked on and almost finished Station 10

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Oct 20, 2020 Elevator and Trim Tab Skin Vertical Stab - (8 hours)

Category: Tail Feathers

Chris, the elder, and Brendan worked on the Vertical stab. They matched drilled and riveted the skin on to it. Son Chris and I worked on the elevator riveting the ribs onto the spars and riveted the horn, We couldn't complete the horn as we are missing 3 AAPQ-46 rivets, which I ordered yesterday.
We found all the parts and started the trip tab. Riveting the ribs to the spar and clecoed the skin on. we will finish tomorrow.

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Oct 19, 2020 Vertical Stab and Horizontal Stabilizer - (8 hours)

Category: Tail Feathers

worked on the vertical and horizontal stabilizers. Riveted ribs to spars of both today with the help fo my son Chris and Brother Chris as well as Brendan of Synergy Air.

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Jul 23, 2019 Rudder - OSH - (2 hours)

Category: Tail Feathers

Built the Rudder in the Rans booth at AirVenture 2019 under the guidance of Eddie Gill and other great attendees. The attendees were full of helpful suggestions and even lending an extra hand when I needed it.

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