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Project: phowe -
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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

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 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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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 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 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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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 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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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.

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

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

Category: Fuselage

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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 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 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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