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Project: RANS21RB -
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Wing Wiring

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Wingtip and lights

Landing light

Wiring


Builder Name:	Randall Brooks -

Project:	Rans - S-21 Outbound - VIEW REPORTS
Total Hours:	1988
Total Flight Time:
Start/Last Date:	Apr 03, 2021 - No Finish Date
Engine:	Titan IO-340 180HP
Propeller:	Whirlwind

Friendly URL:	https://eaabuilderslog.org?s=RANS21RB

Home or Last Project Picture

May 08, 2024 Airworthiness Inspection - (3 hours)

Category: Inspection

The airplane passed the FAA Airworthiness Inspection today- it's officially an airplane. Our local DAR, Matt Tomsheck conducted the inspection. It was a great learning experience. Now it's time to prepare for Phase 1 testing. I will use the EAA Flight Test Manual and conduct the task-based Phase 1 flight testing.

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May 07, 2024 Prep for Airworthiness Inspection - (2 hours)

Category: Reassembly

Mounted Halon fire extinguisher under the instrument panel, below the engine controls. Went over aircraft a final time to insure all fittings and bolts/nuts/wires are secured. Aircraft is ready for inspection tomorrow at 0900 by our local DAR and his POC at the Cleveland FSDO office.

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May 06, 2024 Cowling - (2 hours) Category: Reassembly

Filled header tank with approx. 5 gal of 100LL today in prep for my FAA Airworthiness Inspection. Finished verifying what cowling fasteners go in each hole of the engine cowling. Next, I'll install the fasteners with the split rings. A Chapter member stopped by and inspected all the airframe and engine hardware for security. You can never have enough eyes look at the plane! I appreciate it very much.

May 05, 2024 Details - (1 hour)

Category: Reassembly

Applied 'Outbound' vinyl decal to upper cowling. Affixed a couple control labels and placards in cockpit. Removed interior trim panels temp installed for W & B yesterday.

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May 04, 2024 W & B - (2 hours)

Category: Reassembly

Weighed aircraft today using our EAA Chapter scales. EW is 1039. Applied N Numbers and data plate.

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May 02, 2024 Fuel Flow test and wing cuffs - (2 hours) Category: Reassembly

Aircraft @ 10 deg nose up: Disconnected output fuel line at gascolator and ran line into graduated gas can. Turned pump on; pumped fuel until can had 1 gallon. Time was 62 seconds. This calculates to 58.06 GPH. Did final trimming and fitting of wing leading edge cuffs. Drilled for 12 attachment screws and applied VHB tape. Fastened cuffs in place and held down with sandbags for pressure on the VHB tape. EAA FTM Test Card 0 is complete.

May 03, 2024 Prep for W & B - (2 hours)

Category: Reassembly

Drained header tank. All fuel is now drained out for W & B tomorrow. Temp installed upper and lower cowling, and spinner. Trimmed silicone baffle in front area for clearance. Tied up a few wire bundles in cockpit that needed additional securing. Laid out N numbers and RANS logo to prep for installation.

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May 01, 2024 Upper Cowling work; Garmin configuration; brake conditioning - (3 hours)

Category: Reassembly

Sealed leading edges of inlet ramps on upper cowling. Located and drilled right wing root cuff for top attachment screw. Will now drill left hand cuff and install both with VHB tape and the upper and lower screws. Leveled airplane in hangar and performed Garmin GSU 25C ADHARS configuration for alignment. Pushed plane out to taxiway and ran engine for vibe test. Ran momentarily to full power for first time as required by the test. Achieved 2210 RPM at full power- exactly what I planned for with 18 Deg. of pitch on prop. All ADHARS tests passed. Then moved plane to end of hangars in open ramp area for GMU 11 Magnatometer calibration. Performed interference tests. Passed. Then aligned with Mag North to start and progressed through compass calibration test as guided on G3X. All tests passed and magnetometer is now calibrated. Started up and taxied airplane to runway and performed Matco brake conditioning runs on runway. Did 3 accelerate/stop runs per the Matco manual. Brakes now hold normally.

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Apr 30, 2024 Rear Windows and engine cables - (2 hours) Category: Reassembly

Sealed and installed rear windows. Worked on punch list from yesterday's Tech Counselor visit. Secured cables and wires in engine compartment. Added washer to right door hinge to lock into place, front to back.

Apr 29, 2024 Tech Counselor Visit - (3 hours) Category: Inspection

Gary Baker, the most experienced of our EAA Chapter 846 Tech Counselors, visited today and inspected the RANS. He spent 3 hours going over the entire airplane. No unairworthy items were found, just a bunch of small stuff like missing torque seal, wires needing more security, etc. We also discussed the Task-Based Phase 1 flight testing and the Additional Pilot Program outlined in AC 90-116. I really appreciate Gary's time and thoroughness. I'll now be more prepared for my 8 May FAA Airworthiness Inspection.

Apr 28, 2024 Doors - (2 hours)

Category: Reassembly

Final fitting of doors. Adjusted latches for snug fit and final drilled for handle hardware install. Used new style handles. Installed lift struts and clear plastic bumpers on bottom of wing for open door buffer. Door fit is very good.

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Apr 27, 2024 Air Intake Seal and doors - (3 hours)

Category: Reassembly

Final trim and installation of the Aerosport Products airbox input sleeve. Used #6 SS screws with brass washers on carbon side and hold-down strip on outside against rubber sleeve. Makes a nice tight seal and super easy to install lower cowling. Hung doors temporarily to align door latches and rear striker plate. Riveted rear striker plate in place with VHB tape on door sill. Tomorrow I'll install forward striker plate and door handle assembly.

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Apr 26, 2024 Punch list - (3 hours)

Category: Reassembly

Unmasked lower cowling after paint. Programmed G3X engine gauge parameters. Tied up a few more hoses and wires in engine compartment. Secured Alt Air cable at airbox. Started engine and taxied for about :05. Brakes and steering normal. Engine ran normally with new ignition coil. Ignition check showed no change in RPM from IGN 1 to IGN 2.

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Apr 25, 2024 Ignition Coil and paint - (3 hours)

Category: Reassembly

Installed replacement ignition coil in 1A position. Original coil was defective and Lightspeed replaced it under warranty. Tested spark per the manual and it fired normally. Will test run engine tomorrow. Masked, prepped and painted silver trim on lower cowling and 4 wing inspection covers. This completes the painting!

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Apr 24, 2024 Doors - (2 hours) Category: Reassembly

Removed all paint masking from doors. Test fit door handle hardware. Tied off a couple more wire bundles in cockpit.

Apr 23, 2024 Paint, Windshield sealant - (3 hours)

Category: Reassembly

Masked and painted entry door upper trim to match interior color. Painted underside of wing root cuff flat black. Tape masked and applied clear silicone sealant to landing light lenses, windshield base fairing, rear hold down strip and skylight joint strip between windshield and skylight. Trimmed hose clamps at firewall wire bundle pass-through.

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Apr 22, 2024 Paint - (2 hours)

Category: Reassembly

Temp installed lower cowling and doors to align and mask for black trim paint. Prepped and painted same. Masked landing light lenses for silicone sealant. Tomorrow's project.

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Apr 21, 2024 Gap seals - (1 hour)

Category: Reassembly

Drilled andd mounted nut plate on eing gap seal for flap gap seals. Applied foam tape and mounted both flap gap seals. Taped 6 wing inspection plates for black trim paint tomorrow.

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Apr 20, 2024 Paint - (2 hours) Category: Reassembly

Masked, prepped and painted cowling and doors blue trim.

Apr 19, 2024 Cowling - (2 hours)

Category: Reassembly

Temp installed cowling and doors for fit and paint trim color masking. Installed seat belts/shoulder harnesses.

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Apr 18, 2024 Wiring - (3 hours) Category: Reassembly

Finished securing cockpit wire bundles and rear door post bundles at Station 3. Secured some wires in engine compartment. Trimmed center console to clear wire bundle. Trimmed intake air box boot. Will rivet after bottom cowl is painted and fitted.

Apr 17, 2024 Paint - (4 hours)

Category: Reassembly

Finished minor bodywork on lower cowling. Scuffed both cowling halves, door trim, spinner, and fairings. Cleaned with Prepsol and setup paint booth.
Sprayed epoxy primer and white on these parts.

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Apr 15, 2024 Paint Prep - (1 hour) Category: Reassembly

Finished masking other door for paint. Scuffed ABS trim. Scuffed spinner for paint.

Apr 14, 2024 Doors - (2 hours)

Category: Reassembly

Mounted doors and trimmed upper leading edge for final fitting. Removed doors and began masking off for painting outer trim.

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Apr 13, 2024 Cowling and Ignition - (3 hours) Category: Reassembly

Finished bodywork on cowling. Finally ready to paint. Continued troubleshooting ignition problem. Found one of the coils is not firing. Swapped it to other ignition box and it still did not fire. OHM reading is 1/3 of other 3 coils. Will return it to Lightspeed for replacement.

Apr 10, 2024 Ignition Troubleshooting and cowling - (2 hours)

Category: Reassembly

Still have the issue of #1 ignition not working. Ran through LSE troubleshooting guide but no resolution. Will contact LSE for suggestions on how to proceed. Finished bodywork on bottom cowling front section. Will scuff sand entire cowling next then prime and paint.

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Apr 08, 2024 Engine run #2 - (1 hour)

Category: Reassembly

Short run today. Only 3 min. #1 ignition box is inop. Engine dies when #2 ignition is turned off. Swapped RG400 leads on ignition #1 control box. A to B. Would not start. Misfires. Swapped leads back to original positions. Engine started and ran normally but IGN #1 is still inop. Tracked prop. Blades match exactly. Checked engine RPM with a TruTach II. RPM verified correct on G3X within 1 RPM.

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Apr 07, 2024 First Engine Run - (2 hours)

Category: Reassembly

Preflight engine and airframe. Filled header tank to 3 gal. Started engine for first time ( other than factory test cell time). All Temps normal. No leaks noted. Ran for approx 7 minutes. 1500 RPM max. Idle at 670. Idle mixture is lean. No rise in rpm at Idle cutoff. Will adjust. Checked ignition operations. Turned off IGN #2 and engine quit. Turned off IGN #1 and engine continued to run normally. Will troubleshoot.

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Apr 06, 2024 Cowling - (2 hours)

Category: Reassembly

Sanded and formed fiberglass build up on front of lower cowling. Filler next then paint.

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Apr 05, 2024 Cowling - (2 hours)

Category: Reassembly

Mixed West Systems epoxy (205 hardner) and applied fiberglass strips to build up right side of inlet area and behind the prop spinner. Will sand and fill when cured.

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Apr 03, 2024 Cowling - (2 hours)

Category: Reassembly

Sanded gel coat in prep for bodywork to correct mis-match at front of cowling on right inlet area. The mold was not even side to side and I have to add some fiberglass and filler to make it match the top cowling. Also, I didn't get the spacing behind the spinner correct for the bottom cowling so I'll add a few layers of fiberglass and filler to that area also.

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Apr 02, 2024 Brakes, Prop, Alternator - (3 hours)

Category: Reassembly

Bled brake system. Used small hand pump to fill 5606 hydraulic fluid from the bleed fittings on each brake assembly. Replaced brake reservoir cap with fitting that had plastic tube attached to allow overflow into a clean container. Pumped both lines full and got rid of air bubbles. Pumped left and right brake pedals to release more air. Brakes were firm and parking brake held also. Brake reservoir level about 3/4" from full. Attached prop hub extension with the six 3/8" bolts provided. Torqued to 30 ft lbs using steps at 10, 20 and 30 in a star pattern. Safety wired bolt heads. Tightened tension on alternator belt and tightened adjusting bolts and mount bolts. Safety wired all bolt heads.

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Apr 01, 2024 Cowling, trim tab - (3 hours)

Category: Reassembly

Safety wired trim tab hinge pins (forgot to do this when I reattached the trim tab after painting). Attached trim motor actuator arm and cover. Fit cowling to check fit of air intake boot and how the baffle seals fit the underside of the top cowling. Also, checked clearance of inlet ramps to front baffling- all ok.

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Mar 31, 2024 Engine - (1 hour) Category: Reassembly

Final fitting and sanding prep for upper cowling inlet ramps. Sanded with 80 grit. Glued inlet ramps in place with ScotchWeld 2216. Used sandbags to hold in place overnite. Removed prop hub, spinner backplate and prop extension in prep for mounting prop tomorrow. Checked header tank filler cap and outlet fitting- no leaks noted.

Mar 30, 2024 Details - (2 hours)

Category: Reassembly

Continued fitting upper cowling air inlet ramps to insure clearance with front baffles. Trimmed front edge of airbox to fit sleeve. Installed and sealed 90 degree wing tank feed fittings in header tank. Filled header tank with 3 gal of 100LL fuel and tightened filler cap. No leaks noted. Attached wing tank fuel lines to 90 Deg. fittings. Next step is to mount prop and test run engine.

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Mar 29, 2024 Details - (2 hours) Category: Reassembly

Tie-wrapped wiring bundles in cockpit. Secured LED strip lighting under glareshield with VHB tape. Drilled header tank cap for safety wire. Installed fuel shutoff valve placard with guard to lower left trim panel. Riveted aft and forward sections of this panel.

Mar 28, 2024 Rigging - (3 hours)

Category: Reassembly

Completed rigging of rudder cables. Took many different combos of cable end bolt locations but finally got the tension to 20# on rudder cables beneath seats. All flight controls are now rigged. Trimmed upper cowl inlet ramps (Aerosport product) to fit. Ready to glue. Adjusted tension on tailwheel steering cables- removed 2 links on each side.

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Mar 27, 2024 Details - (2.5 hours) Category: Reassembly

Secured nav/strobe wires to wing tips. Fit wing root fairings with tinnermans. Adjusted rudder pedal mounts. Tightened adel clamp on rear door frame that secures flap cable and aileron pulley-- keepers are snug on aileron pulley.

Mar 26, 2024 Various details - (2 hours) Category: Reassembly

Secured header tank and safety wired clamps. Final fitting and install of Aerosport vertical stab base fairing. Had to open up some mounting holes. Installed tinnermans for wing root fairings. Test fit flap fap seals. Cleaned up hangar.

Mar 25, 2024 Rudder Cables - (3 hours) Category: Reassembly

Adjusted tension on rudder cables and rudder return cables. Took a lot of trial and error, and moving cable end tangs. Return cables tensioned but not rudder cables. Finally moved rudder cable tang to rear most hole ( course adjustment). Now still have to readjust rudder return cable tangs. Tomorrow's project. Checked rudder travel and it was 4 degrees too low. Removed rudder stop block ( which was a pain!) and trimmed 1/8" off both sides. Reinstalled rudder stop bock and now rudder travel is 28 degrees.

Mar 24, 2024 Rigging and final hardware tightening - (3 hours)

Category: Reassembly

Safety wired 3 turnbuckles on aileron cables. Final tighten of all flap and aileron hardware and jam nuts. Applied torque seal. Set travel limits on elevator per manual. Marked, drilled and riveted stops in torque tube.

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Mar 23, 2024 Rigging - (3 hours) Category: Reassembly

Completed rigging of aileron and flaps. Set cable tension at 20#. Note. When adjusting cable tension, be sure to increase right and left evenly in stages to keep controls centered.

Mar 22, 2024 Wingtips and ailerons - (3 hours) Category: Reassembly

Removed right wingtip and plugged in nav/strobe lights.(forgot to plug in yesterday). Reattached tip along with left wingtip. Plugged in light this time. Fabricated alum spacers for aileron actuator rods. Installed right actuator. Did initial rigging. Adjusted up/down travel with control column stop bolts.

Mar 21, 2024 Flight controls and wingtip - (2 hours)

Category: Reassembly

Mounted right aileron and flap. No helpers today so I used my patented shelf mounting method. Worked great. Did initial rigging of flaps. Installed right wing tip temporarily to check for fit with aileron. Trailing edge lines up great. Removed masking tape from silicone sealant on skylight. Still need to silicone seal the center hold-down strip between windscreen and skylight.

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Mar 20, 2024 Skylight and flight controls - (3 hours)

Category: Reassembly

Sealed outer and rear skylight hold down strips with silicone. Trimmed foam from ends of aileron spars. Mounted left side aileron and flap. Not secured yet.

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Mar 18, 2024 Flight Controls - (3 hours)

Category: Reassembly

Filled aileron spar ends with expanding foam plug to seal off lead shot used for balance. Will trim off after drying, then the ailerons are ready to install. Measured aileron turnbuckle attachment gap for bushing that needs to be fabricated on both ailerons. Tightened all attachment bolts on elevator torque tube in cockpit including attachment to control assembly. Set up and down limits on elevator travel to insure sticks clear base of instrument panel at full forward travel. (Still need to drill torque tube stop sleeves and rivet). Tightened all fittings on control assembly. Applied torque seal to all fittings, bolts and jam nuts on torque tube and control assembly. Tightened male end of rod ends for aileron and flap actuator rods in wing. Applied torque seal. Ensured rod ends had at least 10 thread engagement to begin rigging.

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Mar 16, 2024 Elevator Trim and Aileron Balance - (2.5 hours)

Category: Reassembly

Wired elevator trim motor to lead in fuselage. Crimped d-sub pins on each wire and secured each wire with shrink wrap. Encased the 5 wires with a large piece of shrink wrap and then encased wire in wire loom. Trim motor operates normally using trim switches on stick grips. Checked elevator travel for up and down limits. Installed tail cone stinger. Test fit wing root cuffs from Aerosport Products. These are prototypes that I was given to test the fit. Balanced ailerons-- previously had shot foam into aileron spars about 20" from inboard end. Let it cure for 2 full days at 70 F. (the foam took much longer to setup inside the spar). Clamped small alum angles on edge of work table and inserted bolts into hinge that rode on the angles. Poured in dry lead shot to balance-- took 65oz. (ailerons have been painted). Poured that shot out into cup and mixed West Systems epoxy (2 pumps each from small pumps). After thoroughly mixing, weighed slurry and it came to 66oz. Poured slurry into spar and will let set for day or 2 before sealing end of spar with foam.

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Mar 15, 2024 Elevator and Vertical Stab fairing - (1 hour)

Category: Reassembly

Trimmed rear edges of vertical stab fairing and checked fit. Installed elevator and tightened hinge hardware. Ready to wire trim tab motor and attach elevator push pull tube.

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Mar 14, 2024 Aileron and rudder cables - (2 hours)

Category: Reassembly

Installed cotter pin keepers adjacent to pulleys on the aileron and rudder cables. Temp installed vertical stab to fuselage fairing. Organized hardware for mounting ailerons, flaps and elevator. Tightened elevator Push Pull tube forward attach bolt near forward bearing block. Checked spray foam plug in aileron spars- still not quite setup. Will let dry another day before adding lead shot slurry to balance.

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Mar 13, 2024 Seats and Aileron Balancing - (2 hours)

Category: Reassembly

Riveted seat track guides onto seat frames. Installed seats and sat in my plane for the 1st time since starting the build almost 3 years ago! Very big day for sure.
Started aileron balancing process. Used 1" ID PVC pipe to measure how tall a column of 3# 4oz of lead shot works out. It was just over 15 inches. Converted to 1 1/8" ID aileron spar, that works out to just over 13". I used this measurement to know where to spray the internal plug of expanding foam. I put it at about 20" from the inboard end of the aileron spar to give a lot of leeway when inserting the lead shot and epoxy slurry tomorrow. Will let the foam dry overnight in 70 degree temp as others have recommended. Thanks to SIMDPK and others for the initial 3# 4oz weight for the lead shot. I'll confirm this tomorrow by first balancing the aileron with dry shot, empty it and then will mix up the epoxy slurry for final balancing.

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Mar 12, 2024 Skylight and fairings - (2 hours)

Category: Reassembly

Final riveting of skylight outer hold down strips. Dipped rivets in clear silicone. Removed protective plastic from skylight and windshield. Installed gear leg fairings.

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Mar 11, 2024 Paint and skylight - (3 hours)

Category: Paint / Decals

Primed and painted blue trim color on wingtips, fairings and inspection panels. Installed skylight outer trim hold down strips. Clecoed only. Will rivet next. Each rivet will be dipped in silicone to help seal.

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Mar 08, 2024 Vertical Stab and Rudder cables - (3 hours)

Category: Empennage

Final assembly of vertical stabilizer and rudder cables. Tightened and torqued all 10 mounting bolts on front and rear vertical stab spar attachments. Installed rudder stop block on rear spar attachment. Installed rudder horn on rudder post. Installed rudder cables to rudder horn. Ensured cables were routed properly on all pulleys. Attached tailwheel steering spring, cable and S hooks to tailwheel. This is definitely a 2-person job as the stab mounting bolts and rudder horn are very difficult to access and tighten due to confined space. It's really starting to look like an airplane again.

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Mar 10, 2024 Wing tips and flaps - (2 hours)

Category: Wings

Trimmed trailing edges of wingtips to match aileron trailing edges. Used band saw. Sanded. Tips now ready for paint. Replaced hinge bushings in flaps. Originals had smaller collar.

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Mar 07, 2024 Vertical Stab - (2 hours) Category: Empennage

Installed all mounting bolts for vertical stab. Only able to tighten 3 bolts on my own. Will get help next session. Mounted rudder stop block on rear spar attachment.
Also, fabricated and installed a cover for the electric fuel boost pump. My kit did not come with this cover. Fabricated using a friends cover as a pattern and used .040 6016.

Mar 06, 2024 Horizontal and Vertical Stab Mounting - (1.5 hours)

Category: Empennage

Mounted horizontal stab. First snugged up incidence adjusters on front to lowest setting per manual for the Titan 340. Leveled stab with wings visually. Made slight adjustment to raise right incidence adjuster a very small amount. Tightened socket screws and used blue loctite. Placed 2 AN970-4 large washers between rear spar and rear mounting bolts to take up gap. Drilled and reamed left rear mount bolt and torqued all mount bolts. Horizontal stab is final mounted. Assembled rudder to Vertical Stab using proper hinge bolts which were tightened. Installed vertical stab/rudder combo in fuselage. Temporarily attached Vertical stab using 2 bolts. Will finish installing all bolts next session.

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Mar 04, 2024 Hardware - (1 hour)

Category: Wings

Installed and torqued remainder of wing attach hardware.

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Mar 03, 2024 Hardware - (2 hours) Category: Wings

Installed and torqued permanent hardware in struts. Still need to install permanent wing spar hardware.

Feb 29, 2024 Covers and Fairings - (2 hours) Category: Paint / Decals

Prepped booth, then primed all aluminum covers and fairings. Painted covers and fairings white, where required.

Feb 28, 2024 Wiring and paint prep - (3 hours)

Category: Interior Finish

Applied acid etching to all inspection panels and fairings. Rinsed thoroughly with water. Plan to prime and paint white tomorrow. Continued to wire wing lighting and power/ground wires at Station 3 terminal blocks. Ops checked landing lites and nav/strobe lights. All operating normally. Still need to tidy up wiring . Rerouted flap teleflex cables to final location.

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Feb 27, 2024 Wing Wiring - (2 hours) Category: Lighting

Continued routing and trimming wire wiring. Terminated a couple grounds on the common grounding block at Station 3. Trimmed pitot and AOA tubes for final connection.

Feb 26, 2024 Landing Lights and wiring - (2.5 hours) Category: Lighting

Installed right landing light. Installed landing light lenses in both wings. Still have to silicone around opening. Continued to organize and label wing electrical wiring. Temp installed ailerons to measure trailing edge of Aerosport wingtips for trimming.

Feb 25, 2024 Wing wires and aileron cables - (3 hours)

Category: Interior Finish

Routed and bundled wires, fuel lines and flap control teleflex cables at wing roots to interior. Secured flap teleflex cable to adel clamp on door post. Routed and connected L and R aileron cables thru cockpit pulleys to check for interference with wing root wires and lines. Pinned aileron bellcranks to check centering of control sticks.

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Feb 23, 2024 Wing Mounting - (2 hours)

Category: Wings

Prepped wings and assembled required hardware. Mounted wings for final time. Still need to torque and install all of final hardware-- some fittings are only pinned at this point.

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Feb 22, 2024 Prep - (2 hours) Category: Wings

Assembled all hardware and tools needed for mounting the wings in 2 days. Continued sanding and filling wingtips.

Feb 21, 2024 Antennas and Engine - (1 hour) Category: Fuselage

Reinstalled all antennas on fuselage (removed for painting). Replaced AN fittings for MP and Fuel Pressure lines to pressure transducer manifold on firewall-- installed AN fittings with restricted orifice to provide even pressure for G3X readouts.

Feb 20, 2024 Wing Struts - (2.5 hours)

Category: Paint / Decals

Primed and painted wing struts and landing gear fairings with silver trim paint.

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Feb 19, 2024 Brakes - (2 hours)

Category: Fuselage

Final tightening of wheel nuts per Matco specs. Installed cotter pin. Installed outer brake pads and torqued per Matco specs. Prepped paint booth for prime and paint of wing struts. Will paint tomorrow.

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Feb 18, 2024 Assembly - (3 hours)

Category: Fuselage

Raised fuselage with engine hoist and removed transport 'speed' wheels/tires and installed permanent 8.50x22 wheels/tires. Connected brake lines to brake calipers and fuselage thru-fittings. Cleaned wing struts with acid etching compound. Will prime and paint those tomorrow in prep for wing install next weekend.

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Feb 16, 2024 Move fuselage - (2 hours)

Category: Paint / Decals

Unmasked fuselage and moved out of paint booth in my fellow builder's hangar back to my hangar. Will paint wing struts next, mount wheels/brakes and prepare to hang wings next weekend.

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Feb 15, 2024 Fuselage - (4 hours)

Category: Paint / Decals

Applied 3M vinyl line masking tape for the last trim color- silver. Masked off rest of fuselage and scuffed black overspray prior to shooting the silver. I applied the silver in 3 coats- a mist coat, a medium coat and a final wet coat. This allows the metallic to flow out more evenly. I waited about :20 or so between coats to allow it to tack up. I'll let this final coat dry for couple days in the booth, then move the fuselage back to my hangar. Plan is to hang wings in about a week.
Big milestone. Pics to follow when masking is removed.

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Feb 14, 2024 Wingtip prep - (2 hours)

Category: Paint / Decals

Paint prep continues. Scuff sanded carbon wingtips and filled landing light cut line as I'm not installing wingtip landing lights. Removed line masking tape from black trim paint that I painted on Tuesday. Tomorrow I'll mask off for the silver trim color-- the final color on the fuselage.

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Feb 12, 2024 Fuselage - (4 hours)

Category: Paint / Decals

Removed paint line masking tape from blue trim paint. Marked and masked for black trim color. Covered blue painted areas with paper and masking tape. Scuff sanded blue painted overspray areas. Cleaned and dry area with wax and grease remover. Sprayed black trim painted area. Silver trim is the next and final color for the fuselage.

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Feb 09, 2024 Fuselage - (2 hours)

Category: Paint / Decals

Finished masking the white trim paint. Scuffed white overspray to prep for paint. Sprayed blue trim color. Black trim color is next.

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Feb 08, 2024 Masking - (2 hours)

Category: Paint / Decals

Masked off white paint on fuselage to prep for spraying blue trim color which is next .

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Feb 07, 2024 Repaint - (2 hours)

Category: Paint / Decals

Looked over white from Monday's session. I skipped 2nd coat on one section so I had to scuff and mask, then spray 2nd white coat. 2 steps forward, 1 back. Scuff sanded wingtip to prep for paint.

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Feb 05, 2024 Fuselage - (3 hours)

Category: Paint / Decals

Primed fuselage and painted white, the first trim color.

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Feb 03, 2024 Fuselage - (2 hours)

Category: Paint / Decals

Cleaned fuselage with wax/grease remover. Final taping and masking. Paint booth prep.

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Feb 02, 2024 Carbon Fiber prep - (1.5 hours) Category: Paint / Decals

Sanded vertical stab carbon fairing to prep for paint. Started sanding left carbon wingtip to prep. Primed and painted rudder horn.

Jan 31, 2024 Fuselage prep - (1 hour) Category: Paint / Decals

Masked off tailwheel spring assembly and Station 11 openings. Inspected fuselage rivets for stray brush fragments and lint. Re-masked couple spots around doors. Finished paint booth prep.

Jan 30, 2024 Fuselage - (.5 hour)

Category: Paint / Decals

Moved fuselage to paint booth in fellow builder's hangar.

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Jan 29, 2024 Windshield molding and Paintbooth - (3 hours) Category: Paint / Decals

Sanded and filled small imperfections in windshield base molding. Ready for paint. Built 4' extension onto paint booth to accommodate fuselage.

Jan 27, 2024 Fuselage Prep - (2 hours) Category: Paint / Decals

Final prep of fuselage. Masked lower inspection opening, gear leg brake line routed trailing edge and lower engine area.. Sanded and cleaned windshield base molding. Still need to fill some low areas and final sand. Removed excess silicone from rivets on molding.

Jan 26, 2024 Fuselage - (1.5 hours)

Category: Paint / Decals

Final masking of fuselage. Brushed/rolled Bonderite C-IC 33 acid etching solution on entire fuselage. Rinsed thoroughly with water. Will let dry for 2 days before prime and paint.

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Jan 25, 2024 Fuselage prep - (4 hours) Category: Paint / Decals

Scuff sanded fuselage with gray scotchbrite. Wiped down after. Masked brake lines. Ready for acid etching .

Jan 23, 2024 Stab fairing - (3.5 hours)

Category: Tail Feathers

Marked and drilled Aerosport Vertical Stab base fairing per drawing. Transfered to Stab and fuselage for rivnut install. Deburred holes and installed #8 RIVNUTS using red Loctite. Moved right wing from rotator to storage stands.

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Jan 21, 2024 Seats - (1 hour) Category: Interior Finish

Finally able to stretch bottom seat cushion to allow for full velcro attachment. Brut force needed. Used soap solution on bottom frame to help slide. Burned holes in fabric with soldering iron for headrest and slide block attachment. Mounted headrests.

Jan 20, 2024 Fuselage prep - (2 hours)

Category: Paint / Decals

Finished masking off interior and door openings.

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Jan 19, 2024 Fuselage prep - (1.5 hours) Category: Paint / Decals

Continued masking cockpit area in preparation for painting. Unmasked rest of right wing and aileron.

Jan 18, 2024 Moved wing - (.5 hour)

Category: Paint / Decals

Unmasked and moved right wing out of paint booth to my hangar. Still some touch-up needed for a few spots but overall it came out nice. Fuselage is next on the agenda.

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Jan 17, 2024 Fuselage prep - (2 hours)

Category: Paint / Decals

Continued masking cockpit and engine to prep for painting next week. Have to wait for above freezing temps next week so I can acid etch fuselage.

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Jan 15, 2024 Right Wing Paint - (3 hours)

Category: Paint / Decals

Removed masking tape from edge of silver trim paint on right wing and aileron. Applied mask tape line for edge between silver/blue trim. Re-masked silver paint. Scuff sanded silver overspray areas. Cleaned with grease/wax remover and wiped clean. Shot final blue trim paint on wing and aileron. Right wing and aileron are final painted now.

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Jan 13, 2024 Fuselage Prep - (1 hour) Category: Paint / Decals

Continued to mask and tape fuselage for paint. Taped skylight and windshield area.

Jan 12, 2024 Silver Trim - (1.5 hours)

Category: Paint / Decals

Tacked right wing and aileron. Painted silver trim. Blue is next- final color.

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Jan 11, 2024 Prep Right wing - (2 hours) Category: Paint / Decals

Taped, masked, scuff sanded and cleaned right wing and aileron to prep for silver trim paint.

Jan 10, 2024 Masking - (2.0 hours)

Category: Paint / Decals

Removed striping tape from black trim paint line on right wing. Continued masking fuselage. Antenna holes, rear windows and skylight.

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Jan 08, 2024 Right Wing - (2.5 hours) Category: Paint / Decals

Masked and painted Black trim color on right wing and aileron. Silver trim color is next.

Dec 30, 2023 Post painting - (2 hours)

Category: Paint / Decals

Removed all tape and masking from left wing. Installed landing light. Replaced aileron and flap bronze bushings.

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Jan 03, 2024 Paint prep - (2 hours)

Category: Paint / Decals

Finished masking right wing for paint. Scuff sanded right aileron to prep for paint. Moved wing to paint booth.

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Dec 31, 2023 Prep for painting - (1.5 hours)

Category: Paint / Decals

Removed left wing from rotator and placed in storage rack to await assembly. Installed right wing in rotator to prep for priming and painting.

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Jan 02, 2024 Paint prep - (3 hours) Category: Paint / Decals

Finished masking right wing. Finished scuff sanding with scotch brite. Applied Bonderite etching compound and rinsed thoroughly. Will let dry for 2 days before priming and applying white color.

Jan 04, 2024 Prime and paint - (2.0 hours)

Category: Paint / Decals

Cleaned right wingvwith degreaser. Primed and painted 2 coats of white color. Repainted white on right aileron after scuffing.

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Jan 06, 2024 Fuselage - (2 hours) Category: Paint / Decals

Started prep for painting fuselage. Removed all antennas. Started masking skylight. Deburred holes in plexi rear window frame. Painted interior alum window frame to match baggage area splatter paint.

Dec 27, 2023 Fogged cylinders and motored engine; unmasked left wing. - (1.5 hours)

Category: Engine

Dry Motored engine to circulate oil. Got 54psi in 2nd 15 sec start cycle. Confirmed RPM registered on tach (about 150-200rpm indicated during motoring). Put all cylinders at BDC and fogged each with LPS2 since the engine will be idle for at least next 2 months until paint is finished , aircraft is assembled and I'm ready for first start. Installed 14mm desiccant spark plugs in top spark plug holes.

In addition, I repainted the pitot mast on the left wing and removed masking from left wing. Left Wing and aileron are now fully painted.

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Dec 26, 2023 Wing - (4.5 hours)

Category: Paint / Decals

Scuff sanded, taped, masked and cleaned left wing outer section and aileron for blue trim color. Sprayed blue on both . This completes painting of left wing.

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Dec 24, 2023 Masking - (1.5 hours)

Category: Paint / Decals

Masked right wing for paint.

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Dec 23, 2023 Prep Right Wing - (2 hours) Category: Paint / Decals

Started masking prep right wing. Replace smaller flight control bronze bushings with later style larger bushings.

Dec 20, 2023 Silver Trim - (3 hours)

Category: Paint / Decals

Prepped and painted silver trim on left aileron and left wing. Used tack coat and 2 medium coats with about :20 in between to tack up.
On 12/22, I ended up sanding and repainting a portion of the silver on top of the wing. It came out too dry the first time.

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Dec 18, 2023 Masking - (3 hours) Category: Paint / Decals

Masked and scuffed left wing and aileron for silver trim. Lined up mask line on aileron. Unable to spray due to weather- high winds prevented exhaust fans from removing overspray from booth. Filled cleco holes in right wing tip to prep for paint.

Dec 16, 2023 Masking - (1 hour) Category: Paint / Decals

Masked left wing for silver trim color. Need to scuff area prior to painting and mask aileron to match wing.

Dec 13, 2023 Black trim - (3.0 hours)

Category: Paint / Decals

Masked left wing and aileron. Sprayed black trim on both. Silver trim next.

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Dec 11, 2023 Masking - (2 hours) Category: Paint / Decals

Masked left wing and aileron for black trim.

Dec 07, 2023 Paint left wing. - (2.5 hours)

Category: Paint / Decals

Primed left wing and painted 2 coats white on inboard portion of wing. Used friend's IWATA gun that sprays a much more uniform pattern. Will use this gun for rest of painting.

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Dec 06, 2023 Scuff sanding - (2 hours)

Category: Paint / Decals

Scuff sanding ailerons prior to masking and spraying trim colors.

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Dec 04, 2023 Prep for Paint - (1 hour) Category: Paint / Decals

Moved left wing into paint booth to do final prep for priming and paint.

Dec 02, 2023 Left Wing prep - (3 hours)

Category: Paint / Decals

Scuffed and cleaned bottom skin of left wing. Acid etched and rinsed entire wing. Ready to paint after it dries a couple days.

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Dec 01, 2023 Wing Prep - (3 hours)

Category: Paint / Decals

Finished masking left wing. Scuff sanded top skin with Scotchbrite pads. Cleaned with Prep All. Need to scuff bottom skin and etch prior to paint.

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Nov 26, 2023 Wing rotator - (2 hours)

Category: Paint / Decals

Prepped and mounted left wing in wing rotator. Prep for paint is next.

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Nov 29, 2023 Wong prep - (2 hours)

Category: Paint / Decals

Continued prep of left Wong for painting. Filed a few rivet stems, taped inspection openings, secured base of rotator.

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Nov 25, 2023 Wing rotator - (2 hours)

Category: Paint / Decals

Modified wing rotator that I used for my Cub restoration and the RANS fuselage to fit the wings. It will make prep and painting of wing much easier.

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Nov 24, 2023 Elevator balance - (1 hour)

Category: Controls

Balanced elevator after painting. Insured trim tab, trim motor, arm and cover were installed. Used West Systems epoxy and 3lbs. lead shot. Used 3 pumps of resin and hardener per side. Poured 1.5 lbs in left side using funnel then added similar amount to right side until the elevator balanced.

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May 20, 2023 Skylight - (3.5 hours)

Category: Fuselage

Applied foam tape to ribs.( M-D Building Products
Platinum Series 1/2 in. x 1/2 in. x 240 in. Black Expandable Foam Tape Weatherseal for Uneven Gaps)
Opened holes for riveting with awl. Fit skylight in place and clecoed support strips and center hold down strip as well as rear hold down. Skylight is ready to rivet. Next is painting the inside edges of the windshield black where the epoxy glue will be applied. Then windshield will be ready to install.

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Nov 20, 2023 Horizontal Stab - (1.0 hour)

Category: Paint / Decals

Unmasked Horizontal Stab and Elevator. Moved back to my hangar shop for drying and storage. Still a few spots to clean up and buff. Overall very satisfied with the paint colors and scheme.

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Nov 18, 2023 Final Trim color - (2 hours)

Category: Paint / Decals

I received some expert instruction today on shooting silver metallic color from a fellow Chapter member who is a professional painter. Finished masking and shot final trim color of silver metallic on horizontal stab and elevator.

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Nov 17, 2023 Sanding and masking - (2 hours)

Category: Paint / Decals

Final prep of horizontal stab and the elevator.

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Nov 15, 2023 Masking - (2 hours) Category: Paint / Decals

Masked and scuffed Horizontal Stab and Elevator for final silver trim color.

Nov 13, 2023 Parts Rack - (2 hours)

Category: Workshop

Built parts rack to hold painted parts prior to assembly. Used 1/2" steel conduit.

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Nov 10, 2023 Cockpit Light - (1 hour)

Category: Lighting

Installed interior LED cockpit light that mounts to bottom of aileron cable cover panel at station 3. (Available from PilotLights.net)

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Nov 08, 2023 Vertical Stab - (1 hour)

Category: Paint / Decals

Painted top color coat on vertical stab. I used a PVC pipe inserted into stab and clamped to saw horse to support while painting. I attached a piece of safety wire to one of the hinges and used it to rotate part over to paint both sides. Worked well.

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Nov 07, 2023 Rudder - (1.0 hour) Category: Paint / Decals

Top coated rudder with blue color. Vertical stab is next.

Nov 06, 2023 Horizontal Stab - (2.0 hours)

Category: Paint / Decals

Painted Horizontal Stab, Elevator and trim tab blue accent color.

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Nov 05, 2023 Paint and scuff sanding - (2.5 hours) Category: Paint / Decals

Painted right flap after scuff sanding. Finished scuff sanding vertical stab and rudder. Set up horizontal stab and elevator in paint booth in preparation to paint blue color on tomorrow.

Nov 02, 2023 Paint instruction - (2 hours) Category: Paint / Decals

A Chapter member who is a professional painter came by and gave my some great guidance on setting up my HVLP Finish Line gun. He gave me some great instruction and shadowed my as I re-painted the left flap. It came out much better- no orange peel!

Nov 02, 2023 Paint booth maintenance - (4 hours)

Category: Paint / Decals

Removed contaminated plastic floor from paint booth. Installed new sheeting. Vacuumed booth. Changed exhaust filters. Finished scuff sanding vertical stab. I received expert instruction on proper paint gun setup and spraying techniques today. With his guidance, I painted a topcoat on the left flap after scuff sanding. Much better results using his gun setup and spraying methods. ( I should have done this sooner!). I'm using my DeVilbiss Finish Line HVLP gun now.

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Oct 30, 2023 Sanding - (1.5 hours)

Category: Paint / Decals

Scuff sanded Vertical Stab.

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Oct 29, 2023 Scuff sanding - (2 hours)

Category: Paint / Decals

Scuff sanded orange peel on flaps to prep for top coat.

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Oct 26, 2023 Horizontal Stab - (2.5 hours)

Category: Paint / Decals

Finished prep and masking of elevator. Painted black trim color on Horizontal Stab and Elevator. Silver is next color.

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Oct 25, 2023 Horizontal Stab - (1.5 hours) Category: Paint / Decals

Masked off painted white portion to prepare for black trim color. Will spray tomorrow.

Oct 24, 2023 Horizontal Stab/Elevator - (3 hours) Category: Paint / Decals

Finished scuff sanding horizontal stab with 800 grit sanding pad. Cleaned and prepped for paint. Painted white trim color on stab and elevator. Ready for next trim color tomorrow- black.

Oct 23, 2023 Sanding - (2.5 hours)

Category: Paint / Decals

Scuff sanded top of horizontal stab to remove some orange peel and prep for color. Used sanding sheets recommended by a fellow builder. They work great. Smoothed out the roughness.

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Oct 21, 2023 Paint booth setup - (1 hour)

Category: Paint / Decals

Installed 3-stage air line filter for paint booth as I'm switching to my DeVilbiss Finish Line HVLP gun. The turbine gun I was using resulted in some orange peal. I will sand that out and re-shoot those pieces but I plan to use the DeVilbiss gun going forward as it yielded better results with a test spray.

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Oct 22, 2023 Elevator - (2.5 hours)

Category: Paint / Decals

Primed Elevator and trim tab. Touched up ends of horizontal stab where mounting fixture blocked the initial priming.

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Oct 20, 2023 Interior Panels - (2 hours)

Category: Paint / Decals

Touched up interior trim panels near baggage compartment. Moved elevator into paint booth to prep for priming. After my fellow expert builder fabricated new axles, we installed temporary small 8" wheels to move fuselage to paint booth. Will take up much less space in the booth and removes requirement to mask off wheels and brakes before painting.

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Oct 19, 2023 Interior - (2 hours) Category: Paint / Decals

Cleaned and primed sides of baggage compartment floorboard and triangular side trim panels at rear of entry doors. Finished with Gray paint and GM trunk splatter paint to match other interior panels.

Oct 11, 2023 Vertical Stab and rudder - (2 hours)

Category: Paint / Decals

Painted Vertical Stab and rudder with Sherwin Williams Genesis custom blue color.

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Oct 16, 2023 Horizontal Stab - (2.5 hours) Category: Paint / Decals

Prepped and primed Horizontal Stab with Sherwin Williams Genesis DTM primer.

Oct 14, 2023 Horizontal stab - (1 hour)

Category: Paint / Decals

Moved horizontal stab into paint booth. I cleaned, scuffed and etched previously.
Ready to prime and paint. Vertical Stab and rudder completed. Too humid to paint today. Applied 'EXPERIMENTAL' vinyl transfer to upper control cable cover in cockpit.

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Oct 10, 2023 Painting ailerons and etching horizontal stab - (3 hours)

Category: Paint / Decals

Finished spraying white on end ribs of flaps and ailerons. Scrubbed horizontal stab, elevator and trim tab with red scotchbrite pad, wiped down with Prep All, applied Bonderite C 33 acid etching solution and washed with clean water. Parts are ready to prime.

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Oct 09, 2023 Priming - (3 hours)

Category: Paint / Decals

Prepped and primed rudder, vertical stab and ends of ailerons and flaps with Sherwin Williams Genesis DTM primer. (Paint booth was deflated for drying parts overnite at time of pics)

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Oct 07, 2023 Masking - (2 hours) Category: Paint / Decals

Masked ailerons and flaps for priming and painting end ribs as they were blocked from painting when mounted in fixtures. Will prime and paint end ribs next.
Cleaned writing on horizontal stab and elevator; cleaned paint gun; installed bolts in horizontal stab and elevator to protect while painting; removed elevator trim motor prior to painting. (this entry is for 10-7 and 10-8).

Oct 04, 2023 White paint - (5 hours)

Category: Paint / Decals

Painted ailerons and flaps white. Used Sherwin Williams Genesis single stage paint. Color is Toyota Arctic White. Code 040.

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Oct 02, 2023 Priming - (4 hours) Category: Paint / Decals

Prepped and primed 2nd flap and both ailerons today. Used same Sherwin Williams Genesis DTM epoxy primer.

Sep 30, 2023 Priming - (2 hours) Category: Paint / Decals

Mixed first small batch of Sherwin Williams Genesis epoxy primer. Tested gun settings and primed first flap. Will let dry overnight to see results before proceeding with other parts.

Sep 28, 2023 Center console, fabric install and paint booth setup - (3 hours)

Category: Interior Finish

Finished gluing sunbrella fabric to center trim piece ahead of flap lever. Cutout Naugahyde on center console and test fit headset plugs and USB power plug. Installed rubber edging on cockpit trim panels. All interior trim panels are temp installed at this point and will be removed before final assembly. Moved first Flap to our inflatable paint booth to test fit in paint fixture. Holding fixtures are made so you can cleco a part using the tooling holes on the flight controls and tail feathers or you can bolt to the hinges. Ready to prime flight controls.

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Sep 27, 2023 Center Console - (1.5 hours)

Category: Interior Finish

Cleaned and glued black Naugahyde fabric to center console. Still need to cut out holes for headset jacks and USB plug.

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Sep 26, 2023 Cleaning parts - (4 hours)

Category: Paint / Decals

Finished scuffing flaps and cleaning with Prep-All. Applied acid etching to all parts that have been cleaned so far and flushed with water. Will let dry for 2 days prior to priming.

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Sep 25, 2023 Prep - (3 hours)

Category: Paint / Decals

Scuffed Vert Stab, rudder and both ailerons with red scotch Brite. Cleaned with Prep All. Painted rudder cable cover that sits between control sticks. Used SEM paint for plastic. Color is Warm Gray. Moved fuselage into main hangar. I sold my J3. 😩

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Sep 21, 2023 Paint - (2 hours) Category: Interior Finish

Cleaned and prepped under -door ABS panels and flap handle cover for paint. Used red scotchbrite pads to scuff and Prrp All to clean . Painted with SEM paint for plastics- Warm Gray is color.

Sep 18, 2023 Side panels - (4 hours)

Category: Interior Finish

Completed fabric install on forward, side trim panels and control stick base panels.

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Sep 14, 2023 Vertical Stab Tip - (1.5 hours)

Category: Tail Feathers

Final riveting of vertical Stab tip.

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Sep 14, 2023 Vertical Stab tip - (2 hours)

Category: Tail Feathers

Drilled Stab tip for rivets.

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Sep 11, 2023 Prep for paint - (1 hour) Category: Paint / Decals

Cleaned printing off the ailerons and cleaned with Prep All. Plan to clean flaps, and all tail feathers the same way; then etch and alodine prior to priming.

Sep 10, 2023 Interior Trim panels - (3 hours)

Category: Interior Finish

Cut out and glued sunbrella fabric to left and right forward trim panels.

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Aug 30, 2023 Silicone Baffling - (2.5 hours)

Category: Engine

Finished (finally) riveting the silicone baffle seals to the engine baffling. Still need to final trim after fitting the top cowling half.
Also, picked up the paint that I will use for the airframe-- Sherwin Williams Genesis paint system.

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Aug 28, 2023 Wing root ribs - (3 hours)

Category: Paint / Decals

Masked, and cleaned wing root ribs with Prep All using red Scotch Brite pads. Primed with self etching primer. Painted 2 coats Coastal Gray Rust Oleum enamel.

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Aug 25, 2023 Baffling and Paint Prep - (3 hours) Category: Engine

Continued to rivet silicone baffling. Ran out of the longer AVEX rivets. Waiting for AS order. Continued organizing painting supplies to prep for starting paint. Rags, 3M spray cup liners, Etch and Alodine, mixing cups, etc.

Aug 24, 2023 Baffling - (2.5 hours)

Category: Engine

Continued riveting silicone baffling.

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Aug 23, 2023 Baffling - (.5 hour) Category: Engine

Received longer AVEX rivets (1601-0414) for the silicone baffling. They seem to be the perfect length. Riveted first 2 pieces of silicone material on right side of engine. Will continue with these.

Aug 10, 2023 Baffling ans wiring - (.5 hour) Category: Engine

Trimmed fronts of silicone baffles. Covered terminals of ANL fuse with rubber terminal caps.

Aug 09, 2023 Paint Prep - (1 hour)

Category: Paint / Decals

My genius friend and fellow S21 builder designed and fabricated fixtures to hold flight controls and tail feathers whole painting. They are fully adjustable and hold part in any orientation for painting. The parts are clecoed in place .

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Jul 17, 2023 Baffle seals - (1.5 hours)

Category: Engine

Reworked baffle seals. Split rear seal into 2 segments. Should conform better to cowl.

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Jul 15, 2023 Baffle Seals - (2 hours)

Category: Engine

Finished installed baffle seals. Still need final fit of cowling to determine where they need to be trimmed and sealed with RTV.

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Jul 13, 2023 Baffle seals - (2 hours)

Category: Engine

First test fit of main silicone baffle seal.

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Jul 12, 2023 Baffles - (2.5 hours) Category: Engine

Drilled baffle seal capture strips. Test fit. Located and punched holes in silicone baffle material on right side of engine. Clecoed in place.

Jul 10, 2023 Engine Baffle Seals - (2 hours) Category: Engine

Finished trimming and fitting baffle seal capture strips. Deburred and shaped ends. Ready for match drilling to baffles.

Jul 06, 2023 Baffling - (1.5 hours) Category: Engine

Cut all baffling attach strips to fit. Test fit silicone baffle material.

Jun 23, 2023 Wiring - (1.5 hours) Category: Engine

Continued tying and bundling engine wiring.

Jun 22, 2023 Wiring - (2.5 hours) Category: Engine

Tied up and secured engine sensor wire bundles.

Jun 21, 2023 Wing Root Fairing - (1 hour) Category: Wings

Ordered new wing root fairings. I wasn't happy with the original set. I trimmed the new set using tin snips and sanding them to rough size. Still need to drill for spar attach bolt and do final sanding.

Jun 17, 2023 Strut fairings - (2 hours) Category: Wings

Installed Rivnuts on wings for strut fairings. Installed a few cockpit placards.

Jun 15, 2023 EGT Probes, Ignition leads, ducting - (3.5 hours)

Category: Engine

Final hookup of EGT probe wiring. Installed spark plug ignition leads and started to secure leads. Installed SCAT tubing from right muffler shroud to cabin heater box and front, right baffling inlet.

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Jun 16, 2023 Strut fairings - (2.5 hours)

Category: Wings

Set up wing struts in position to locate upper strut to wing fairings. I didn't have the fairings ready to install when we first installed wings so I measured from the lower strut fuselage fitting to the front and rear spat attach fittings. Used this measurement to set position of strut as it would be when installed. Fit fairings and drilled for rivnuts. Also, hung flight controls on wall of hangar until paint.

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Jun 14, 2023 Exhaust - (5 hours)

Category: Engine

Completed install of exhaust system. Torqued flange nuts to 150 lb in. Tightened springs on ball joints to spec and cotter pinned. Fabricated mount braces and installed to mount points. Tightened all bolts and marked with torque seal. Adjusted muffler shroud to line up scat tube takeoffs.

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Jun 12, 2023 Exhaust and securing fuel fittings - (3 hours)

Category: Engine

Initial install of exhaust system per instructions. Used Permatex Zinc anti-seize compound on slip joints. Also, used Nordlocks on exhaust flanges instead of supplied star washer/ washer combo. EGT probes were previously installed. I did the initial fitup of the braces for the exhaust stacks. Also, I sealed and tightened the 90 deg AN fitting on the output of the Red Cube fuel flow unit. Also checked security of all AN fittings on the fuel system and sensor manifold on the firewall.

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Jun 11, 2023 Baffles - (2 hours)

Category: Engine

Completed securing lower cylinder baffling. Used high temp tubing to protect baffling and cylinders.

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Jun 10, 2023 Wingtips - (1 hour) Category: Wings

Cleaned up wingtips after gluing. Test fit completed wingtip on left wing.

Jun 08, 2023 Wingtips - (2.5 hours)

Category: Wings

Prepped Aerosport carbon wingtips for gluing. Sanded rib and tip mating surfaces. Cleaned and glued with 3M 2216 epoxy. Clecoed together using paste wax on clecos to prevent sticking.

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Jun 07, 2023 Tail cone - (2.5 hours)

Category: Fuselage

Fit and installed tailcone on fuselage. Used recommended #8 nutplates and backing strips.

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Jun 05, 2023 Main Gear - (2 hours) Category: Landing Gear

Hoisted front of fuselage to take weight off gear legs. Removed both AN 5 bolts from main gear leg attachments. Straightened plastic rub strip (it was not aligned properly during initial installation- my error). Replaced all 4 AN5 boltsnuts with new and retorqued to build manual values. Applied torque seal to nuts. Retorqued both AN6 main bolts.

May 25, 2023 Wing Tips - (1 hour)

Category: Lighting

Crimped Deutsch connectors to Aveo Strobe/Nav light combo lights that will mount on the wingtips.

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May 26, 2023 Nav/Strobe light install - (2 hours) Category: Lighting

Drilled 2nd wing tip for mounting nav/strobe light. Terminated wiring in wings with Deutsch connector to match connector on light assembly.

May 29, 2023 Wingtip and Landing Light - (1.5 hours) Category: Lighting

Fit left wing wingtip. Mounting rib ready to drill. Wired AeroLed both landing lights with Deutsch connector receptacles.

Jun 02, 2023 Wingtip and lights - (3.5 hours) Category: Lighting

Completed drilling for clecos on right tip. Both tips now ready to glue. Test fit Aero Led landing light in left wing. Installed Deutsch connector on supply wire cable. Trimmed both landing light lenses.

Jun 04, 2023 Landing light - (1.5 hours) Category: Lighting

Installed AeroLed landing light in right wing. Hooked up spare battery to check all wing lighting. All work normally.

Jun 01, 2023 Wingtips - (4 hours)

Category: Wings

Completed install of left wingtip. Match drilled and installed nutplates in right wingtip attach rib. Attached wingtips with clecoes that will hold tips in place while gluing.

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May 30, 2023 Wingtips - (3 hours)

Category: Wings

Fit wingtip rib to outer wing rib on left wing. Match drilled thru the 8 mounting holes and installed nutplates in wing wingtip rib. Drilled top perimeter of wingtip to #40 to prep for gluing. Still need to drill bottom side of wingtip.

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May 27, 2023 AD-142 Fuel Tank Retention Kit - (2 hours) Category: Wings

Installed Fuel Tank Retention Kit per AD-142.

May 24, 2023 Windshield and Skylight Final Install - (5 hours)

Category: Fuselage

Riveted center windshield/skylight hold-down strip. Using 2 #30 drill bits as a guide worked well. Inserted button screws in upper, center windshield hold down strip. Used loctite and clear silicone. Scuff sanded fiberglass windshield hold-down fairing and base of windshield to prep for gluing. Sanded edges to 45 degree bevel as others have done. Masked off windshield and boot cowl. Used 3M 2216 Epoxy glue as recommended. Used the 3M application gun that mixes the 2 parts as it exits the nozzle. Applied directly to windshield base and had to keep cleaning up runs that got on the boot cowl tape. You definitely need to mask off boot cowl very well as the glue runs pretty easily before setting up. Placed fiberglass fairing and clecoed in place. Taped ends to hold in place while glue sets up. Riveted in place with specified rivets. Riveted Z-strips in place also. Dipped all rivets in clear silicone as recommended. Prep is the key. Have everything laid out that you'll need. A paint stir stir worked great to scrape up the excess glue that ran onto the boot cowl masking tape.

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May 23, 2023 Windshield - (2 hours)

Category: Fuselage

Applied foam tape to Z strips and clecoed in place. Clecoed fiberglass base molding in place. Need to sand edges of fiberglass molding then it's ready to glue to windshield.

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May 22, 2023 Skylight and Windshield - (2.5 hours)

Category: Fuselage

Permanently riveted skylight in place. Dipped all rivets in clear silicone. Placed windshield in position for final attachment.

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May 21, 2023 Windshield - (1.5 hours)

Category: Fuselage

Masked and painted inside of windshield behind areas of glue for base molding and wing root cuffs. Used black acrylic enamel.

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May 19, 2023 Cockpit tubing and skylight bows - (4 hours)

Category: Fuselage

Wrapped front cockpit cage tubing with vinyl carbon fiber wrap. Permanently installed skylight and windshield bows. All skylight and windshield trim pieces paint is complete.

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May 18, 2023 Skylight support paint - (2 hours) Category: Fuselage

Applied 2 color coats of gray to the skylight support ribs and hold down strips. Oiled K&N air filter with K&N filter oil. Installed filter and secured alternate air cover to bottom of airbox. Made punch out of alum tubing for black foam tape to punch out for rvet holes in skylight attachments. Will redesign and try again before installing skylight.

May 17, 2023 Skylight supports painting - (3.5 hours) Category: Fuselage

Sorted and marked all skylight support ribs and hold down strips. Cleaned with lacquer thinner and paint prep. Sprayed all components with self-etching primer. Will paint with gray spray paint. Sanded door trim pieces to match. Test fit station 3 upper closeout panel.

May 15, 2023 Air Box - (2 hours)

Category: Engine

Mounted airbox with 1/4 -20 drilled head bolts and nord locks. Saftied bolt heads. Need K&N spray oil for air filter element, then will install alt air door cover plate. Installed engine fuel pump drain hose. Cut bottom of aluminum tube to 45 deg.facing aft.

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Aug 09, 2022 Left Wingtip - (2.5 hours)

Category: Wings

Trimmed and sanded left wingtip support rib. Marked wingtip cutoff line with Sharpie and used dremel to cut wingtip from mold. Did some initial sanding on cut line. NOTE: I subsequently decided to buy the Aerosport carbon fiber wingtips. I like the way they fit and look. Decide for yourself.

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May 10, 2023 Doors - (3 hours) Category: Fuselage

Fit and assembled new style door handles.
Fabricated bushings and roll pins. Trimmed leading edge door trim to match fwd door post.

May 09, 2023 Horizontal Stab fairing - (2.5 hours)

Category: Empennage

Drilled and installed all nutplates in horizontal stab for the stab to fuselage faring. Started install of wingtip strobe/nav lights. Measured tip for drilling.

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May 08, 2023 Main gear - (4 hours)

Category: Fuselage

Removed rear main gear attach bolts and routed brake line in front of bolt. Torqued all main gear bolts. Located, drilled and installed remaining 4 nutplates on rear of tailwheel steering cable fairings on bottom, rear of tailcone. Used single ear type. Polished prop blades with carnuba wax to remove residue from plastic bags used in shipping.

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May 05, 2023 Engine - (2 hours) Category: Engine

Removed spinner and prop for safe keeping until final assembly. Fit airbox and trimmed alt air cable to length.

May 04, 2023 Gear Leg Fairing plus others - (4 hours)

Category: Fuselage

Installed rivnuts for gear fairings. Trimmed and fit wing strut fairings to fit over strut profile. Riveted Coanda fairing to base of firewall. Put bead of RTV behind top edge. Finished replacing rivets on cowling Southco receptacles.

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May 03, 2023 Rivet replacement - (4 hours) Category: Fuselage

Drilled out 1/8 rivets from Southco cowling receptacles and replaced with correct 1/4 rivets (my bad). Primed 'dog bones' on station 1 front spar mount to cover bare metal from trimming. Cut out Station 3 ABS closeout panels. Installed small pulleys for aileron cables on Station 3 uptubes. Cut slot in rear fuselage closeout cone for elevator horn.

May 02, 2023 ELT Antenna Mount and Gear leg fairings - (4 hours) Category: Fuselage

Removed existing ELT mount backing plate and made new plate that will rivet into adjacent top fuselage stringer to add stiffness. Match drilled all holes and riveted new mount backing plate to skin and stringer. This greatly improved stiffness and stability of ELT antenna. Next, placed gear leg fairings in position and marked mount hole locations. Drilled holes in flange of fairing and transfer drilled to fuselage bottom skin, insuring to miss all tubing. Enlarged holes to 17/64" to accept #10 Rivnuts.

Apr 30, 2023 Fairings, wiring - (3 hours) Category: Fuselage

Installed nutplates for flap gap seals. Rewired and re-routed elevator trim wiring in cockpit. Fit gear leg fairing for mount screws. Remounted I pad mount. Removed ELT antenna mount reinforcing plate. Plan to secure with larger plate.

Apr 29, 2023 Wing Removal - (4 hours) Category: Wings

Removed wings for installation of wing tips, tank AD, landing lights, strobe lights-- then painting. Before removing horizontal stab and elevator, I configured the elevator trim indicator on the G3X. Verified up and down travel limits and neutral settings. Trim indicator works perfectly. FYI- you configure this indicator in the G3X aircraft and engine configuration section of the system configuration. Then, removed elevator and horizontal stab and hung on wall for safe storage. Moved parts and work tables around shop.

Apr 28, 2023 Flap gap seals and prep for wing removal - (2.5 hours) Category: Fuselage

Fit and trimmed flap gap seals. Located and drilled for nutplate install. Removed wing tips, ailerons, flaps and doors in prep for wing removal tomorrow. All fairings, gap seals, skylight and windshield have been fit.

Apr 26, 2023 Fairings and wingtips - (5 hours)

Category: Fuselage

Fabricated Horizontal stab to fuselage fairing. Match drilled and drilled for #6 nutplates in stab. Fabricated wing strut fairing. Cut out for strut profile. Drilled and installed nutplates in bottom fuselage inspection plate for tailwheel cable covers. Temp installed wing tip rib to align aileron and set flap trailing edge to match aileron. Fit flap gap seal. Will wait to install when skylight is installed.

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Apr 24, 2023 Windshield and. Skylight - (4 hours) Category: Fuselage

Drilled holes in skylight to #27, deburred. Removed protective plastic at hold down strips. Trimmed rear edge of skylight. Drilled windshield holes to 11/64", deburred. Drilled center bow to #2 and installed rivnuts. Drilled center, top w/s hold down strip to #20. Trimmed top of w/s Z-strips for fit. Riveted center forward cage tube trim pieces to boot cowl.

Apr 22, 2023 Windshield, skylight and flaps - (4.5 hours)

Category: Fuselage

Finish drilling windshield base molding to boot cowl. Opened all holes to #40. Fit leading edge cuff. Trimmed wing root fairing. Removed windshield and skylight. Will enlarge all holes and deburr before installing and riveting. Temp installed flaps and hooked up flap cables to check for correct operation and initial fitting of flap gap seals.

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Apr 21, 2023 Windshield and trim - (3 hours)

Category: Fuselage

Fit, trimmed and match drilled underside wing root fairings. Fit and match drilled windshield fiberglass base trim to boot cowl with #40.

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Apr 20, 2023 Spinner install and first engine motoring - (4 hours)

Category: Fuselage

Removed spinner, prop, hub, spinner back plate. Measured and drilled spinner w/ #40 at required spacing. Match drilled spinner back plate. Opened holes for #11 screws. Drilled and installed nutplates in backplate. Reinstalled all back on engine. .Spinner fits perfectly. Gap around prop blades is good. Filled engine sump with 8qts. Phillips XC 20W50 oil. Removed bottom plugs and hand pulled prop thru about 20 times. Motored engine for 15 sec cycles allowing cool down between cycles. Oil pressure came up on second cycle to 52 psi. Motored 2 more cycles. No leaks noted.

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Apr 19, 2023 Prop and Spinner - (3 hours)

Category: Fuselage

Cut out spinner template and affixed it to spinner. Drew prop cutout outline 3/16" inside cut line to allow for sanding to shape. Found centerline by tracing around circumference on poster paper. Then measured diameter and set radius on compass. Drew several arcs of the radius to find the center of the circle. Drew centerline thru center point and used it to set opposite prop cutout. Unboxed prop for first time-- way cool! Installed prop in hub, snugged down hub. Temp set pitch to 17 deg to see how to use template. Fit spinner to check clearance. Still needs some sanding to final cutout dimensions.

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Apr 17, 2023 Windshield - (4 hours)

Category: Fuselage

Fit, marked and drilled to #40 windshield fiberglass base trim piece. Fit, measured and drilled wing root cuffs. Still need trim on back side. Fit and clecoed Z strips in place at rear edge of windshield. Fit was very close to final with only minor trimming needed on top of Z strip.

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Apr 16, 2023 Fairings, etc - (2 hours) Category: Fuselage

Fit tailwheel steering cable fairings for drilling nutplates. Fit and cut out gear leg fairings. Reworked elevator trim position wires. Updated GNX375 software.

Apr 14, 2023 Baffling and Oil Dip Stick - (4 hours)

Category: Engine

Installed dip stick tube and safetied. I had it out during install of baffles. Safety wired left side baffling on bottom to tie front and rear cylinder baffle sections together. Installed additional cowling fastener receptacle on each side of bottom of boot cowl strip.

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Apr 13, 2023 Wiring - (2 hours) Category: Lighting

Trimmed wing wiring to length for eventual connection at terminal blocks under baggage compartment. Test fit wing strut and gear fairings.

Apr 12, 2023 ABS Fairings - (3.5 hours) Category: Fuselage

Finished rough cutting of all the ABS fairings with a dremel cutoff wheel. Drilled required openings in elevator trim and tailwheel cable fairings. Mounted elevator trim fairing. Printed Figure 06-19 to 1:1 for template for Lift strut fairing. Will cutout tomorrow.

Apr 10, 2023 Trim, tail fitting, fairings - (3 hours) Category: Fuselage

Temporarily mounted horizontal stab and elevator. Hooked up elevator trim motor to test function of trim buttons on control stick. Operated normally. Temp mounted Vertical Stab for fit. Trimmed wing root fairings to initial size.

Apr 07, 2023 Windshield and Skylight - (4 hours)

Category: Fuselage

Aligned skylight bows and match drilled all holes for skylight attachment into bows. Drilled center support strip for windshield using acrylic drill bit for windshield and #30 for bow. Eventually, these holes will be enlarged to accept #8 rivnuts. Measured and drilled rear skylight hold down strip to skylight rear edge and to top of fuselage skin. Test fit doors and windshield Z hold down strips as well as windshield base molding.

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Apr 06, 2023 Windshield and Skylight - (5 hours)

Category: Fuselage

Work continued on fitting windshield and skylight. Bows fit profile of windshield and skylight perfectly. Measured and cut skylight to width. Centered middle mating strip support tube and fixed in place. Fit in place and measured for trimming rear edge of windshield. Cut windshield with dremel cutoff wheel. Refit in place. Trimmed front edge of skylight to final size. Marked and match drilled for rivets on center mating strip. Clecoed mating strip in place. Fit was perfect. Next step is to final trim rear edge of skylight and fabricate hold down strip, and to mark and drill rivet holes in support bows.

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Apr 05, 2023 Skylight - (3.0 hours)

Category: Fuselage

Assembled skylight outer hold down strip parts. Deburred and trimmed bottom hold down strip to length. Clamped all pieces in place on wing root. Located and match drilled through trim strip, spacer and and hold down strip to wing root skin.

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Apr 03, 2023 Skylight - (4 hours)

Category: Fuselage

Reshaped all 3 skylight bows to conform to wing root airfoil. Took a lot of minor adjustments, but finally got them up against all the reference angles.
Drilled and clecoed all three ribs in place. Test fit center mating strip support tube. Match drilled skylight spacer strips to windshield mating strip- ready to install. Marked locations for skylight outer hold downs on wing skins.

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Apr 02, 2023 Windshield and Skylight - (2 hours)

Category: Fuselage

Bent skylight bows to initial fit for wing root profile. Temp installed. Fit windshield to see clearances. Fit windshield base fairing. Fit horizontal and vertical stab for motivation!

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Apr 01, 2023 Mounting wings - (4 hours)

Category: Wings

Mounted wings for first time. Trimmed S1 dog bone to fit front spar. Nerve wracking step for sure. Final fit is very good. Wings will be removed for painting after windshield and skylight are mounted.

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Mar 31, 2023 Wing Attach - (4.5 hours)

Category: Wings

Prepped shop and wings for attaching for first time. Drilled and reamed to final size upper wing strut fittings for AN 7 attach hardware. Moved fuselage and wings into hangar to prep for attaching wings tomorrow.

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Mar 30, 2023 Wing mounting and skylight - (3.0 hours)

Category: Fuselage

Drilled and deburred all skylight trim strips to #30. Measured wing attach dimensions per plans and cut dog bones at station 1 to rough dimensions. Final sizing when I attach wings.

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Mar 29, 2023 Windshield and Skylight - (3.5 hours) Category: Fuselage

Located and inventoried all hold down hardware and trim strips for the windshield and skylight. Cut the trim strips to length, formed corners and laid out the rivet placements. Ready to drill strips for #30.

Mar 27, 2023 Cowling - (4 hours)

Category: Engine

Located and drilled remaining Southco receptacle locations for riveting. Enlarged center holes to 1/4" on cowling and 9/32" on joggle and boot cowl attach strip. Counterbored rivet holes. Riveted receptacles in place. Need 2 more receptacles because I added an additional receptacle on each bottom flange of the lower cowling- plans only showed one at that location.

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Mar 25, 2023 Oil door and cowling fasteners - (3 hours)

Category: Engine

Finished riveting oil access door hinge to door and cowling. Drilled cowling attach strip and cowling to 3/16". Drilled attach strip for Southco fastener retainers.

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Mar 24, 2023 Oil Access Door - (5 hours)

Category: Engine

Sanded oil access door opening in top cowling for final fit. Modified frame to accept Avery hidden hinge. Made spacer/reinforcing plate for hinge mount to cowling. Use 5 rivets for hinge for extra support. Drilled and flush riveted frame to cowling.
Installed Southco fasteners for trial fit. Still not decided whether to use these or Skybolt fasteners as others have done.

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Mar 23, 2023 Cowling - (3.5 hours)

Category: Engine

Sanded side and rear fit lines again for proper gap. Drilled sides of cowling for fasteners. All fastener holes now drilled and clecoed. Cut out oil access door to rough opening. Rolled oil access door and frame to contour of cowling.

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Mar 22, 2023 Cowling - (4 hours)

Category: Engine

Sanded top cowling gaps. Located and installed remaining clecoes in top cowling rear edge. Located fasteners on top/bottom cowl mating line. Laid out oil access door location. Marked for cutting and drilling. I will use the Avery hidden hinge on the oil door instead of the hinge provided in the kit. The Avery hinge in much stronger and is spring loaded. Also, reamed out rear spar mounting location and pre-installed required hardware. Measured for cut line of front spar attach 'dog bone'.

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Mar 20, 2023 Cowling - (4 hours)

Category: Engine

Final cut to fit for top cowling. Drilled and clecoed top rear edge. Final gap sanding and fasteners to go.

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Mar 19, 2023 Fit instrument panel visor trim strip and trimmed top cowling again - (2 hours)

Category: Instrument Panel

Installed padded trim strip on instrument panel visor and did some more trimming of front section of top cowling.

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Mar 18, 2023 Cowling - (1 hour)

Category: Engine

Continued to trim and fit top cowling half.

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Mar 17, 2023 Cowling - (4.5 hours)

Category: Engine

Final trim and drilling of lower cowling for cleco attachment on rear edge. Ready for final sanding for rear edge paint line. Trimmed top cowling again closer to fit line. Sneaking up on it. Cut lower cowl air outlet. Didn't cut to latest text manual cut dimensions. Can open up further if needed after flight testing.

Lower Cowl fit and clecoed. Ready for fasteners and final gap sanding for paint (1).jpg

Lower Cowl fit and clecoed. Ready for fasteners and final gap sanding for paint (3).jpg

Lower cowl mod for air outlet.jpg

Mar 16, 2023 Wiring - (3 hours) Category: Interior Finish

Bundled and secured wiring on copilot side of cockpit floor and sidewall. Trimmed Station 3 closeout panel.

Mar 15, 2023 Finish work - (5 hours) Category: Interior Finish

Final fitting and install of side seat plastic trim pieces per the RANS install video. Used 3 washers under mounting bracket to space back far enough to get the .8" dimension to work out. Bundled wires under copilot seat with lacing cord. Sanded air inlet opening to final size on lower cowling.

Mar 13, 2023 Cowling - (4 hours) Category: Engine

Continued fitting lower cowling. Had to reposition and trim rear edge again. Cut out cooling outflow area on bottom surface.

Mar 11, 2023 Cowling - (2 hours)

Category: Engine

Trimmed rear of bottom cowl. Left 1/8 " sanding line. Temp clecoed rear edge on side and bottom.

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Mar 10, 2023 Cowling - (3 hours)

Category: Engine

Continued fitting upper and lower cowlings. Slowly trimming top cowling to fit. Sneaking up on it!

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Mar 09, 2023 Wiring and trim panels - (3.5 hours) Category: Interior Finish

Tied and bundled cockpit under seat wiring. Trimmed seat-side trim panel according to latest RANS video on same subject.

Mar 08, 2023 Cowling - (4.5 hours)

Category: Engine

Initial trimming and fitting upper and lower cowling halves per Text and Figures manual. Front trimming of bottom cowl is close. Front portion of top cowl needs more trim to fit down over bottom cowl at front. Taking little bites at a time. I trimmed joggle on lower cowling to 1" as per the Figures manual. My text manual says to trim to 3/4" which IMHO is not wide enough for fasteners. Maybe the new text manual has been updated. I used a cordless Milwaukee rotary tool and thin Dremel cutoff wheels. These work great.

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Mar 06, 2023 Boot Cowl and cowling - (4.5 hours)

Category: Fuselage

Final fitting and riveting both boot cowl sides. Connected SCAT tube to fresh air NACA vents. Connected static lines to static ports on both sides. Did initial trimming of front of both engine cowlings.

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Mar 05, 2023 Boot cowl - (5 hours)

Category: Fuselage

Completed install and riveting of upper boot cowl sections. Final gluing of vinyl glareshield cover. Final install of G5 GPS antenna and avionics cooling fan.

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Mar 04, 2023 Boot cowl - (4 hours)

Category: Fuselage

Primed and painted cover grill for avionics cooling fan. Masked boot cowl, instrument panel and engine prior to spraying 3M adhesive for glareshield cover. Glued center section only. Will complete gluing after fan and GPS antenna are installed and the upper, right boot cowl section is riveted.

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Mar 03, 2023 Boot cowl - (3.5 hours)

Category: Fuselage

Installed reinforcing angles on bottom of center boot cowl section (glareshield). Fabricated these out of .020 angle and affixed with VHB tape. These greatly stiffened up glareshield and will eliminate any oil canning as well as providing a stable surface for the G5 GPS antenna. Final riveted the visor, center boot cowl and left boot cowl sections. Next, I'll glue the vinyl glareshield cover to the center section, then install the avionics cooling fan and GPS antenna. With the right boot cowl section still off, it gives access to the underside of the boot cowl. Finally, I'll rivet the upper right boot cowl section and glue the right side of the vinyl down. Huge step today to final rivet the boot cowl sections. Onward and upward.

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Mar 02, 2023 Glareshield - (3.5 hours) Category: Fuselage

Attached panel LED strip lighting to underside of panel visor. Clecoed visor and center glareshield section in place. Ready to rivet. Performed phasing check of LASER III Ignition boxes. #2 box needed coil leads reversed to bring in phase. #1 box was in phase. Clecoed support angles in place for side boot cowl skins. Tied up a couple more wires behind panel as a result of a EAA Tech Counselor visit yesterday. Just needed to secure a couple small wires to reduce movement. I'm ready to close up the boot cowl. Scary stuff.

Mar 01, 2023 Boot cowl and Electronic Ignition - (4 hours)

Category: Fuselage

Shot 2nd coat of paint on underside of panel visor. Ready to install. Terminated electronic ignition coil RG400 wires with spade connectors. Plugged wires into respective coils and tightened down mounting bolts with Loctite. Loosened all bottom plugs in prep for removal prior to coil firing test.#4 cylinder plug adaptor came loose with plug to I cleaned the threads and applied anti-seize compound along with a new copper gasket. Installed the adaptor with 40 ft. lbs. torque as required. Cut and fit 2" SCAT tube for fresh air vents. Finally, I gently squeezed the #6 RIVNUTS that will secure the avionics cooling fan to the glareshield..These are also secured with CA glue. I used d-sub pins to terminate the fan wires. They are then covered with shrink wrap. If you need to unplug for any reason in the future, just slit the shrink wrap and unplug. Fan is ready to install. Will use this same technique to terminate the panel visor LED strip lights.

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Feb 27, 2023 Boot cowl - (3 hours) Category: Fuselage

Primed and painted underside of instrument panel visor. Installed rivets in avionics cooling fan housing. Installed d sub pins on cooling fan wires. Checked wiring again behind panel prior to riveting boot cowl. Installed anti chafe wrap on pitot tube line.

Feb 26, 2023 Boot Cowl - (2 hours) Category: Fuselage

Continued to fit center boot cowl. Taped reinforcing angles to underside for test fit. Drilled plastic covers that get riveted to left and right upper boot cowl pieces.

Feb 25, 2023 Boot Cowl - (2.5 hours) Category: Fuselage

Cut out vinyl glareshield cover and test fit. Fabricated stiffner angles for underside of glareshield to reduce oil canning. They will be adhered with VHB tape.

Feb 25, 2023 Boot Cowl - (1 hour) Category: Fuselage

Fit glareshield vinyl template to glareshield to check fitment. Planned how to install avionics fan and GPS antenna after vinyl is glued down.

Feb 22, 2023 Glareshield - (3.5 hours)

Category: Fuselage

Made cardboard template for vinyl glareshield material .

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Feb 20, 2023 Boot cowl - (2.5 hours)

Category: Fuselage

Terminated and secured power and ground wires for avionics cooling fan in top boot cowl. Used d-sub pins secured with shrink wrap. Fit top center center boot cowl section. Determined that reinforcing strips will be needed on underside of this section to prevent oil canning.

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Feb 19, 2023 Wiring - (1 hour) Category: Avionics

Cleaned up routing of a couple wires.

Feb 18, 2023 Throttle and Mixture cables - (3.5 hours)

Category: Engine

Final install of throttle and mixture cables. Drilled mounts for second bolt. Checked travel of controls. Safetied cable to mount. Applied torque seal.
Added 1.5 inches to static line for G5 to give more room to remove G5 if necessary. Re-secured lower tray behind panel that houses control cables and G5 wiring and tubing.

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Feb 16, 2023 Throttle Cable - (2 hours) Category: Engine

Back to work after 3 week vacation and 1 week of being sick as a dog. Installed replacement throttle cable. Original cable supplied with kit was too long. It required a large bend between the instrument panel and the firewall to come close to fitting. This put a substantial bind in the cable and undo pressure on the instrument panel mount location. I ordered a new cable from MacFarlane that is 2.25" shorter. This cable fits perfectly with no bending required to make it fit.
Secured eyeball firewall pass-through with loctite. Still need to drill second #11 hole in mount bracket on throttle body.

Jan 18, 2023 Glareshield LED lights - (3 hours) Category: Avionics

Wired power and ground wires for LED glareshield visor strip lighting to be installed on underside of panel visor. Wired power wire for glareshield avionics fan installed in middle of upper boot cowl glareshield. It will serve as avionics fan and defroster.

Jan 16, 2023 Glare shield GPS and cooling fan - (3 hours)

Category: Avionics

Located and installed GPS antenna for G5 on glareshield. Also drilled and installed avionics cooling fan that will double as windshield defroster.

Glare Shield G5 GPS Antenna and Avionics Cooling fan install (1).jpg

Glare Shield G5 GPS Antenna and Avionics Cooling fan install (2).jpg

Jan 15, 2023 Windshield and skylight - (1.5 hours) Category: Fuselage

Marked forward edge of windshield for glareshield cover. Assembled parts and studied plans for skylight install.

Jan 14, 2023 Baffles and windshield - (3.5 hours)

Category: Engine

Finished installing baffles. Routed ignition leads. Drilled front windshield and skylight bows to mount tabs. Placed windshield for initial fit, which is great. Very little, to no trimming will be needed.

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Jan 13, 2023 Boot cowl and cowling attach strips - (3 hours)

Category: Fuselage

Final fitting and match drilling of cowling attach strips. After final deburring, they are ready to rivet along with the top and side boot cowl skins. I will temp install windshield to mark outline of vinyl material that will be glued to the glare shield area of the boot cowl. Engine cowling fitting and trimming is next task.

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Jan 12, 2023 Engine wiring - (3 hours) Category: Engine

Worked on engine wiring, bundling wires and installing adel clamps. Routed ignition mini-sensor wires on opposite sides of the case secured by adel clamps. Removed top, center boot cowl for final avionics wiring inspection prior to final riveting of boot cowl.

Jan 11, 2023 Boot Cowl and Engine - (4 hours) Category: Fuselage

Finished riveting bottom, forward skin. Enclosed firewall wire pass through with firesleeve. (Note: the location of this pre-dilled wire pass through is right behind the engine mount and it makes it very difficult to encase the wire bundle with firesleeve. Suggest covering the pre-drilled pass through hole and relocating it about 2 inches down and to the center of the firewall for better access). Installed the crankcase breather line to the engine fitting.

Jan 09, 2023 Boot Cowl - (3 hours)

Category: Fuselage

Rolled top, left and right boot cowl skins to better match contour of firewall and instrument panel. Continued to fit boot cowl spacer strips and cowl attach strips. Set up new paint booth to see how it fits in hangar. Bouncy house for old kids!

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Jan 07, 2023 Prop flange and spinner - (3.5 hours)

Category: Engine

Finished fabrication of coanda fairing for base of firewall. Drilled holes and mounted fuel pump overflow and engine breather hoses in fairing with grommets. Temporarily attached prop flange, spinner backplate and prop hub plate for upcoming fitment of cowling. Prop is Whirlwind 80" STOL prop. Retightened all screws on ignition box d-sub connectors.

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Jan 08, 2023 Boot cowl - (2 hours) Category: Fuselage

Deburred cowl strips. Fit cowl strips.

Jan 05, 2023 Boot Cowl - (1.5 hours) Category: Fuselage

Fit top and top side boot cowl section. Clecoed in place. Deburred firewall flange holes.

Jan 04, 2023 Final wiring bundling and boot cowl fitting - (3.5 hours)

Category: Fuselage

Finalized wire bundles securing behind panel. Trimmed forward edge of cockpit lower forward trim panels to make room for wire bundles. Test fit panels. Fit center boot cowl section and glareshield extension. Clecoed in place.

Final fit of top boot cowl and instrument panel glareshield extension (1).jpg

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Final fit of top boot cowl and instrument panel glareshield extension (8).jpg

Final fit of top boot cowl and instrument panel glareshield extension (9).jpg

Jan 03, 2023 Coanda Fairing and wiring - (4 hours)

Category: Engine

Fitup and match drilling of coanda fairing in prep for install. Continued wiring cleanup behind panel. Riveted/screwed remaining firewall to cage tab locations. Task complete.

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Coanda Fairing fitup (2).jpg

Dec 31, 2022 Wiring - (3.5 hours) Category: Avionics

Wired RS-232 d-sub plug for GSU 25C that carries OAT temp info. Ran 3-wire from plug back to station 3 to hookup with 3-wire that is in left wing for the OAT.
Continued to tie up wiring loose ends behind panel.

Dec 30, 2022 Wiring - (2.5 hours)

Category: Avionics

Continued to tie up and secure wire bundles behind instrument panel. Small GPS antenna sitting loose is for G5 and will be installed on top of glareshield. Also, laid out rivet pattern for coanda fairing at base of firewall.

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Dec 28, 2022 Wiring, Etc - (3.5 hours) Category: Avionics

Continued tying up wiring behind instrument panel and the bundles leading down kick panel area to rear cockpit. Fabricated coanda fairing that will rivet to bottom of firewall to improve cowling exit air airflow.

Dec 27, 2022 Wiring Cleanup - (3 hours) Category: Avionics

Continued clean up, re-routing and bundle tying wires behind panel. Drilled out side baffle panels for spark plug lead pass-thru fittings.

Dec 26, 2022 Wiring - (3 hours)

Category: Avionics

Tightened attch screws for d-sub plugs on Laser ignition boxes. Cut out unnecessary wiring behind panel. Routed pitot heat temp sensor wire to station 3 for hook up. Charged IBBS batteries with TCW dedicated charger. Mounted air deflector panels on front baffles with screws so they can be changed if needed.

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Front Baffle Air Defletors (1).jpg

Dec 21, 2022 Wiring - (4 hours) Category: Avionics

Tying and bundling wire behind instrument panel. Wire-laced bundles for avionics and the Laser III ignition boxes.

Dec 19, 2022 Ignition wiring - (5.0 hours)

Category: Engine

Test soldered HT lead scraps to determine best way to solder. Decided to use solder sleeves. Trimmed and stripped high tension ignition leads for soldering 20ga. wire leads. using solder sleeves. Fabricated front cylinder close out plates. Need to be final sized and riveted.

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Dec 15, 2022 EGT Probes and Airbox - (3.5 hours)

Category: Engine

Marked and drilled/deburred exhaust stacks for EGT probes. Needed to drill out to #29 drill size for perfect fit of probes. Clamped probes and trimmed hose clamps. Wired probes to appropriate leads and tested readouts on G3X. All readings normal. Applied heat to stacks with heat gun and all responded correctly. Finished fabricating airbox inlet tabs. Ready to install.

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Dec 14, 2022 CHT Probes and Exhaust System - (3.5 hours)

Category: Engine

Wired all CHT probes. Covered connections with shrink wrap as well as provided mesh sheathing. Checked G3X Engine page and all CHT temps indicate normally. Fit exhaust system to allow for locating and drilling stacks for EGT probe installation. Exhaust stacks fit perfectly.

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Dec 12, 2022 Airbox - (2.5 hours) Category: Engine

Located and drilled holes for silicone baffle seals on front of airbox. Fabricated hold-down strips. Trimmed front of airbox to match factory aluminum airbox pieces.
Airbox is ready to mount to fuel servo.

Dec 11, 2022 Airbox - (3 hours)

Category: Engine

Located and drilled housing for nutplates. Installed nutplares and cable standoff.

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Dec 11, 2022 Airbox and Baffling - (3 hours)

Category: Engine

Removed and drilled all baffling sections for silicone baffles seal attachment. Fit Aerosport Products carbon fiber airbox to fuel servo and assembled air shutter base. Installed cotter pin in pivot bolt!

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Dec 07, 2022 Baffling - (2.5 hours)

Category: Engine

Deburred and riveted front baffles. Located and marked forward, center hole for mounting tab bolt.

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Dec 05, 2022 Baffling - (3 hours) Category: Engine

Finished fabricating attach brackets for front baffles. Match drilled. Ready to rivet. This will complete aluminum portion of the engine baffles. Still need to enlarge side baffles for spark plug wire pass through fittings and do final install of baffles.

Dec 04, 2022 Front baffling - (2.5 hours)

Category: Engine

Fitted and trimmed front, inner baffling . Fabricated mounting tabs to rivet pieces together.

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Dec 02, 2022 Baffles - (3 hours)

Category: Engine

Final riveting of left and right front baffle sections. Started fitting left and right forward baffles that close out behind prop flange.

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Dec 01, 2022 Baffles - (3 hours)

Category: Engine

Worked on front baffles. Match drilled and located cylinder close-out plates. Fabricated and match drilled front, side attach brackets. Ready to rivet.

Front Baffle brackets and cylinder plates (1).jpg

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Front Baffle brackets and cylinder plates (3).jpg

Dec 01, 2022 Baffling - (3 hours)

Category: Engine

Continued work on baffling-- takes time!! Riveted rear baffle units together along with cylinder plates. I added AVEX rivets to the plates where the safety wire will draw the front and rear plates together. Punched out mandrels. This should help reduce wear on the baffles from the safety wire. They fit very well on the engine.

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Nov 28, 2022 Baffling - (3 hours) Category: Engine

Continued work on baffling. Fabricated front angle brackets for inlet floor to outer, front side baffles. Drilled bottom flanges of cylinder plates for safety wire. Inserted avex rivets and removed mandrels to allow safety wire to pass thru. Hopefully, this will reduce wear on baffle flange. Test bent first cylinder plates and checked for fit Riveted rear baffles and rear, side baffles together.

Nov 27, 2022 Baffling - (3.0 hours) Category: Engine

Continued fitting and match drilling of baffling. Drilled rear plates for ignition leads. Fabricated upper center support bracket at ignition mount. Test fit for removal.

Nov 25, 2022 Baffling - (3 hours) Category: Engine

Continued fitting baffling. Started riveting cylinder plates. Secured starter solenoid to firewall after switching starter button solenoid wire to correct post. Tested starter Ops. OK.

Nov 21, 2022 Baffling - (3.5 hours) Category: Engine

Continued work on baffling fitting. Test assembled rear baffling on left and right sides. Had to clean out paint from mounting hole near upper right engine mount for 1/4-20 screw. Finished enlarging and deburring 4" hole in right rear baffle for oil cooler flange. Sealed flange with high temp RTV and riveted flange to right rear baffle.

Nov 20, 2022 Baffling - (4 hours)

Category: Engine

Continued work on baffling. Match drilled front left and right baffles to doublers and support tabs. Installed top front support bracket using existing case bolt. Still have to torque bolt when front halves are joined. Riveted front right flange for cabin heat scat tube. Enlarged oil cooler scat tube opening in right rear baffle to 4 inches per the plans.

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Nov 19, 2022 Baffling - (1.5 hours)

Category: Engine

Sorted baffling parts. Marked oil cooler adapter for trimming of rear baffle. Initial fitting of side baffling pieces to cylinders.

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Nov 18, 2022 Fuel and pressure lines - (3.5 hours)

Category: Engine

Received fire sleeved fuel and pressure manifold lines from TS Flightline. Installed on engine. Installed oil pressure restrictor fitting on engine for OP line.. Installed T fitting in engine fuel pump for fuel pressure line . All fit perfectly. Highly recommend Tom and Steve. Very high quality,, great service. Rerouted #1 LSE ignition mini-sensor lead to left side of engine below cylinders 2,4. Secured starter cable to oil pan screw with Adel clamp. Sorted out baffling pieces in prep for install.

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Nov 16, 2022 Wiring - (3 hours) Category: Engine

Labeled engine compartment wiring. Tied up wire bundles with lacing cord. Trimmed EGT and CHT K leads.

Nov 15, 2022 Wiring - (2.5 hours)

Category: Engine

Routed EGT and CHT wires to respective sides of engine. Terminated LSE manifold pressure line to 'T' fitting that splits line to each LSE ignition box. Re-aligned cylinder #4 fuel injection line and modified adel clamp mount at top of case to allow room for spark plug wires at coil packs.

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Nov 14, 2022 Wiring - (3.5 hours) Category: Engine

Installed connectors on the primary LSE power/ground wires for the Ignition boxes. I used the shield from both wires for the ground and soldered in a pigtail to connect to the Main Battrry negative terminal. Crimped center connector wires together and connected to POS battery terminal. Also, joined Alternator Field wire to main harness field wire .

Nov 12, 2022 Engine accessories - (3.5 hours)

Category: Engine

Fabricated and installed Alternator 'B' lead. Installed Alternator to Starter support arm. Installed MP takeoff fitting in Pressure Transducer manifold for MP line to LSE ignition boxes. Drilled holes in firewall and avionics tray to route MP tube. Removed throttle cable to send to MacFarlane for shortening. Cable length provided in kit is too long and it binds somewhat. Needs to be 3 inches shorter.

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Alternator to starter support arm.jpg

MP line for LSE ignition boxes routnig thru avionics tray.jpg

MP line for LSE ignition boxes.jpg

Nov 10, 2022 Engine Accessories - (4.5 hours)

Category: Engine

Installed starter cable and engine ground wire to starter housing. Installed AN 816-4D fittings in #3 cylinder for MP line and on accessory case above Rt mag closeout plate for oil pressure line. Measured for OP, MP and FP lines to order from TS Flightlines. Installed LSE Mini sensors on mount behind starter ring gear. Installed ring gear and set sensor gap @ .040 (range is .030 to .060). Made gapping tool out of strip of .040 alum and pushed sensor forward in mount so it was snug against gapping tool and sensor ring on rear of ring gear. Snugged mount screws while ring gear still mounted. Removed ring gear and tightened mounting screws with blue Loctite.

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MP Fitting at rear of Cyl 3.jpg

Oil Pressure fitting above Rt Mag closeout plate.jpg

Starter cable and engine ground cable installed.jpg

Nov 09, 2022 Starter ring gear and mini sensors - (3 hours)

Category: Engine

Installed starter ring gear temporarily to fit up LSE mini sensors on mount behind starter ring. Removed top plugs and rotated engine by hand to verify TDC 0 degree marks alignment with centerline of case and on starter mount. Checked good. Alignment checked for mini sensors and alternator belt. Modified alternator field wire plug- removed installed white wire as it will not be used (white wire is for Alt Out lite which I don't have). Routed field and B-lead wires next to crankcase for fit.

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Nov 07, 2022 Engine accessories - (4 hours)

Category: Engine

Installed ignition coil pack mount and coil packs on top of case. Had to slightly re-route 2 injector lines. Installed oil cooler fittings and oil cooler lines permanently. Replaced cooler factory strait fittings with 45 deg fittings as others have done. Allows much better fit of hoses. Temp Installed alternator for fit.

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Nov 06, 2022 Engine accessories - (3.5 hours)

Category: Engine

Wired oil temp bulb to harness. Checked G3X display and it showed oil temp gauge @ 71F. Installed oil cooler lines for fit. Test wired the glareshield LED strip lights. Worked normally with panel dimmer. Fabricated and installed standoffs for LSE coil pack mount.

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Oil Cooler hoses installed for fit (3).jpg

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Oil Temp registers after oil temp bulb install.jpg

Nov 04, 2022 Engine Install - (3 hours)

Category: Engine

Installed engine on mount today. Installed top 2 mounts first, then the bottom right, then the bottom left. The last one required a small amount of tapping on the bolt to go thru far enough to catch the threads. Torqued hardware to 40 ft lbs.

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Nov 03, 2022 LSE Ignition - (5.5 hours) Category: Engine

Wired Input and Output dsub connector wire bundles for both LSE ignition boxes. Remaining tasks for final ignition hookup are mounting coil packs on engine, hooking up RG400 cables to coil packs and mounting mini sensors for ring gear.

Nov 02, 2022 Engine Buildup - (3 hours)

Category: Engine

Installed and torqued CHT probes in all cylinders. Modified new 90 deg. crankcase breather fitting per figures manual. Removed factory straight breather and replaced with elbow. Safetied. Initially torqued alternator bracket mount bolts to 12 ft lbs but waiting to get final torque value as these are not AN5 bolts- they are 5/16-18tpi course thread bolts. Need to get torque value from Lycoming manual.

CHT probes installed and torqued.jpg

Crankcase Breather modified fitting.jpg

Oct 31, 2022 Engine Accessories - (3.5 hours)

Category: Engine

Installed fuel pump drain fitting, alternator mount bracket, fuel servo. Re-clocked throttle arm on fuel servo to align with throttle cable throw. Mixture lever was ok from factory.

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Oct 30, 2022 Engine Accessories - (4 hours)

Category: Engine

Fabricated mount brackets and assembled throttle and mixture cable mount. Replaced engine drain plug with supplied Curtis quick drain plug- safety wired.
Installed supplied engine oil temp bulb and safety wired. Removed and replaced 3 of the 4 fuel servo mounting studs with supplies longer studs on bottom of intake sump. This allows mounting of throttle and mixture cable mount plate.

Oil Sump Quick drain installed and safetied.jpg

Oil Temp Bulb installed and safetied.jpg

Throttle and Mixture cable mount.jpg

Oct 29, 2022 Engine prep - (2.5 hours)

Category: Engine

Removed engine from shipping crate and mounted on engine stand in prep for mounting accessories. Continued to clean up firewall wiring. Installed protective nipples on solenoid connections.

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Oct 26, 2022 Engine Accessories - (4.5 hours)

Category: Engine

Routed LSE ignition RG400 cables and mini sensor input harnesses thru firewall in prep for engine mounting. Labeled LSE harness wires in wire bundle in prep for terminating wires at ignition boxes. Installed nut plates and mounting hardware for LSE ignition coil packs on rear engine mounting plate.

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Oct 25, 2022 Firewall wiring - (3 hours)

Category: Engine

Completed wiring of oil, fuel and manifold pressure transducers as well as the Red Cube fuel flow module.

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Oct 24, 2022 Wiring - (3.5 hours)

Category: Engine

Wired inline fuses for ALT shunt. Wired engine pressure transducers.

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Oct 23, 2022 Firewall Accessories - (3 hours)

Category: Engine

Final install of 60 amp ANL fuse inline with the Alternator 'B' lead. Made copper bus bar to connect ANL fuse to shunt. Fabricated B lead from fuse to alternator.
Secured wire engine sensor wire bundle to engine mount. Fabricated one new lower support for oil cooler. The provided one was too short to mate with tab on engine mount.

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Engine Sensor Wire Bundle.jpg

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Oct 22, 2022 ANL Fuse - (1 hour) Category: Engine

Installed ANL fuse on firewall for Alternator 'B' lead. Will mount with short bus bar to shunt.

Oct 21, 2022 Pressure Manifold - (1 hour) Category: Engine

Sealed the threads on the 3 pressure transducers on the firewall manifold . Sorted wiring for hookup of the transducers. Shrink wrap labeled firewall wires.

Oct 20, 2022 Wiring - (4 hours) Category: Engine

Routed Main Battery positive cable thru firewall and terminated at Battery Solenoid. Terminated Main Bus, Battery contactor and Starter contactor wires at their respective solenoids. Remade bus bar that connects Battery and Starter solenoids with .060 copper bus bar. This will allow the Alternator B lead to connect to the starter solenoid. Sorted out and organized input and output wiring for the Laser Ignition CD boxes.

Oct 19, 2022 Cabin Heat Box and Wiring - (3.5 hours)

Category: Engine

Completed Cabin Heat box. Used rubber edging material to seal flapper valve. Tensioned cable. Began layout and hookup of engine harness. Test soldered wires with solder sleeves. Extended power and ground wires to reach USB charging port in center console.

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Oct 17, 2022 Cabin Heat and Parking Cable - (4.5 hours)

Category: Firewall

Fabricated new hinge arm for the cabin heat cable. Secured cable to firewall with adel clamp. Worked perfectly. This was all due to my locating the cabin heat cable on the right side of the panel which resulted in a reverse cable actuation without using this hinge arm to allow cabin heat to be off with cabin heat knob fully forward. Just took some extra time to engineer a solution. Installed parking brake cable per the plans. Hooked up all brake fluid lines but not torqued yet.

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Oct 15, 2022 Controls - (4.5 hours) Category: Firewall

Rerouted cabin heat cable. Installed oil cooler assembly. Terminated avionics ground wires. Extended USB power and ground wires to center console. Fabricated engine ground wire and installed. Temporarily hooked up battery plus and minus to master solenoid to test master switch and avionics on main battery power. All worked normally.

Oct 14, 2022 Cabin Heat cable - (3 hours) Category: Firewall

Finished mounting cabin heat cable and attaching to heat box. Cable has too much resistance due to extra curves because of locating it on right side of panel. Cable did not actuate flapper correctly. Also, the flapper door will not close completely due to gasket bending back of box and interfering. Will trim gasket to correct this issue. Plan is to relocate cable to come from starboard side and actuate heater. Frustrating day not making any progress.

Oct 13, 2022 Cabin Heat cable and mount - (4 hours) Category: Firewall

Secured cabin heat cable to firewall with adel clamp. Need one additional clamp. Assembled hardware to secure cable to heater box. Re-clocked actuator arm. Torqued all engine mount to airframe nuts. Used high temp locking nuts. Removed powder coating on mount lug that has engine ground cable. Spent rest of time sorting out and mounting all engine hardware bags to parts board in preparation for engine install next week.

Oct 10, 2022 Control Cables - (4.5 hours)

Category: Firewall

Drilled instrument panel to 3/4" to mount Throttle and Mixture cables. Reamed firewall pass-through fittings to 19/64 to accommodate these cables. Fit Alternate air cable to panel but need to have shoulder washer to mount properly. Fabricated custom firewall pass-through fitting for cabin heat cable. Test mounted main bus onto side of lower instrument panel support.

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Oct 12, 2022 Engine controls and instrument panel support box - (4.5 hours) Category: Engine

Permanently installed Throttle, Mixture and Alt Air control cables. Had to make bushing for Alt Air cable to fit pre-drilled panel opening. Installed throttle brace and fire extinguisher mount plate to instrument panel supports. Used #6 screws and nyloc nuts instead of rivets in case it needs to be removed. Mounted Main Bus Bar to right radio mount/instrument panel support using #8 Rivnuts.

Oct 07, 2022 Firewall components - (4.0 hours) Category: Firewall

Fabricated standoffs then mounted Laser III ignition boxes on firewall. Drilled panel for Cabin Heat and Park Brake cables.

Oct 06, 2022 Firewall components - (5 hours)

Category: Firewall

Relocated main bus that I'd previously installed on the cockpit side of the firewall .Turns out I mounted it where the right hand CD ignition box mounts. I will relocate it to the center panel side support near the main battery. Marked and drilled/deburred mounting holes for both ignition boxes. Still need to fabricate the mounting standoff for the ignition boxes. Fabricated and installed the diodes on the Master and Starter solenoids to prevent backflow of current when de-energizing the solenoids. Routed starter, master solenoid and alternator field wires thru firewall pass-through fitting. Also routed the GEA24 engine harnesses (EGT, CHT, Oil press/temp, man. press, fuel press) through the same firewall pass-through fitting.

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Oct 04, 2022 Wiring and firewall - (5.5 hours)

Category: Avionics

Shortened and terminated all avionics ground wires at firewall ground block. Test fit electronic ignition modules. Installed engine mount. Fabricated positive battery cable and battery ground cable.

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Oct 03, 2022 Pitot Static lines - (2 hours) Category: Avionics

Connected Pitot, Static lines to G3X and G5. Connected AOA line to G3X. Ran static lines to sides or forward cockpit area for eventual hookup to static ports that are mounted just ahead of NACA air vent inlets.

Oct 01, 2022 Wiring - (1 hour) Category: Avionics

Short day- tidied up wire bundle behind panel. Routed pitot and AOA tubing down left side of cockpit. Terminated rear cockpit ground terminal block at main firewall ground block.

Sep 30, 2022 Main Bus - (3 hours)

Category: Avionics

Located and mounted main bus bar onto cockpit side of firewall. Located and drilled hole in firewall for positive battery cable to pass thru to connect to the battery master solenoid. Also mounted control stick assembly to cockpit floor. Relocated main ground block (rotated 180 deg.) on firewall to allow for better alignment to battery negative cable.

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Sep 29, 2022 Wiring - (3.5 hours)

Category: Avionics

Fabricated 12ga. ground wire that will ground the rear cockpit ground block to the main firewall ground block. Routed ground wire on right side of cockpit with other wire bundle. Completed install of main EarthX battery box under avionics tray. Located and installed nutplate to secure the latch to the avionics tray above.

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Sep 28, 2022 wiring - (4 hours)

Category: Avionics

Wired ground wires for stick grip wiring. Used GAD27 dSub pins 28 and 30 (wht/grn) that were originally for the roll trim servo (not installed). Tied the 2 wires together and extended with a third wire using a solder sleeve. This ground wire will be attached to the main firewall grounding block. Discovered error in my wiring of dSub plugs to stick grips. I unpinned and reversed the wires in the male half of the connector to match up with the female connector. (you must be aware that the male and female dSub plugs are mirror images of each other- pay attention to the plug wiring numbers!) Plugged back in and powered up Avionics. After temp installing the headset jacks and headset, I tested the PTT- they work perfectly for both stick grips and both radios transmit from both left and right grips. I also connected the new USB-C power cord to the iPad and it works as expected. The iPad cooling fan also works as expected I also was able to verify voltage on the Avionics IBBS @ 13.8v. In addition, I was able to receive an ADS-B target on the transponder (also appeared on the G3X map display) while still in the shop. Also, I was able to pair my phone to the GMA 245 via Bluetooth and listen to music over the aircraft headset. Way cool! Finally, I verified the V-speeds that I loaded the other day into the G3X. They speed tape has correct speeds and color bands. Testing will continue but I'm very happy with the results of the Avionics testing so far. Again, I'm using a 14V. regulated power supply wired directly to the main bus.

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Sep 26, 2022 Wiring - (5.5 hours) Category: Avionics

Continued cockpit wiring. Connected power/ground wires for the USB C cable Guardian sent to replace the Apple charge cable they supplied originally. I wired in d-Sub connectors for the control stick grip wire bundles for Pilot and Copilot stick grips. This way they can be disconnected if required for removal. I terminated pitot heat power cable and header tank low fuel indicator wires. This pretty well completes the aft cockpit wiring with the exception of the USB charging plug wires. The supplied wires were too short to reach the center console so I'll have to splice in longer wires to reach charging port. Final routing and securing of all aft cockpit wire bundles remains.

Sep 23, 2022 Wiring Testing - (2 hours) Category: Avionics

Temp wired the Aveo combo stobe/nav lights to the cockpit terminal blocks. Strobe and nav lights functioned normally using panel switches. Checked boost pump operation- normal. Checked header tank low fuel light- red light came on with empty tank. Removed cap from tank and carefully lifted switch to simulate fuel in tank- red light on panel extinguished. . Checked ELT operation using remote switch on instrument panel. Remote switch panel functioned normally. All items operate normally

Sep 21, 2022 Wiring - (3.5 hours) Category: Avionics

Soldered trim servo power and position wires. Terminated wing lighting, cockpit lighting and pitot heat power wires to aft cockpit terminal block. Terminated header tank low fuel level switch ground and power wires.

Sep 20, 2022 Wiring - (3 hours) Category: Avionics

Trimmed unnecessary wires from bundles. Routed elevator trim position cable from GEA 24. Stripped and prepared elevator trim power and position wires for soldering.

Sep 18, 2022 Stick Grips - (1.5 hours)

Category: Controls

Installed stick grips after tapping control stick for 4-40 set screw. Used Dawn soapy water to help slide the grips on.

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Sep 17, 2022 Stick Grip Wiring - (5 hours)

Category: Avionics

Wired Pilot and Copilot Ray Allen G-205 stick grips. Wired Elevator trim up and down, PTT and A/P Disc (using right-hand button). Left hand button was not used. Mounted stick grips on control sticks for drilling 4-40 set screw according to the drawings. Ran grip wiring in wire loom.

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Sep 15, 2022 Wiring - (2 hours) Category: Avionics

Trimmed stick grip wires and began soldering stick grips.

Sep 14, 2022 ELT and Stick Grip Wiring - (4 hours)

Category: Avionics

Wired ELT dSub connector with crimp pins. Added ground wire that is soldered to the cable shielding with a solder sleeve. Also, started laying out stick grip wiring.

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Sep 12, 2022 Battery mount, park brake, brake lines - (4 hours)

Category: Instrument Panel

Fabricated standoff for park brake module to prevent interference with cockpit diagonal tube. Attached all cockpit brake lines temporarily for fit. Mounted battery box for EarthX battery under avionics tray on copilot side. This will allow easy access in case of service and a short distance for battery cable to feed thru firewall to Master solenoid. Still need to fabricate the latching mechanism to insure secure mounting.

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Sep 11, 2022 Park Brake. Brake Lines, static ports - (3 hours) Category: Fuselage

Temp installed gear leg brake lines for fit. Attached park brake valve on firewall but need to move 1/2 " due to interference. Installed Show Planes static ports.

Sep 10, 2022 On the gear - (2.5 hours)

Category: Landing Gear

Mounted both tires and wheels. First time fuselage has been on the gear.

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Sep 09, 2022 Gear leg install - (2.5 hours)

Category: Landing Gear

Installed both gear legs- not torqued yet. Will fit axles and brake assemblies tomorrow. Installed new rear cockpit grounding block at station 3.

Gear leg install.jpg

Sep 05, 2022 Wiring - (4.5 hours)

Category: Avionics

Installed CAN Bus terminator in GMU 11 connector. Connected iPad power plugs. Power plug and cooling fan check ok. Started wiring Artex ELT dSub connector. Need solder sleeve. Installed firewall fixtures: Starter and Master solenoids, Engine pressure transducer manifold, Red Cube fuel flow, and Master Grounding terminal block.

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Sep 07, 2022 Wiring - (4.5 hours)

Category: Avionics

Fed wires in sheathing and routed to rear cockpit area. Velcroed wire bundles temporarily to check routing and fitment. Continued to tidy up wiring behind panel with wire lacing. Tested Cockpit, Nav, Landing and Strobe light wiring for continuity. Good test. Switches operate normally.

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Sep 06, 2022 Wiring - (4 hours)

Category: Avionics

Removed iPad power cable from harness- it was supposed to be a USB C cable. Avionics shop is making new dSub plug with correct USB-C power cable. Rerouted antenna cables in order to bundle together. Began installing wire sheathing on copilot stick wiring. Looks like a mess now but it all makes sense-- I hope!

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Sep 03, 2022 Wiring - (4 hours) Category: Avionics

Routed and organized wire bundles from panel to rear cockpit area. Tied some wires with lacing cord. Started install of Can Bus Terminator plug on GMU 11 but mount screws were too short.

Sep 02, 2022 Terminal Blocks - (3 hours)

Category: Instrument Panel

Fabricated mount for power and ground terminal blocks. Installed at Station 3 that will be below baggage compartment floor. All wing lighting, pitot heat and associated ground wires will attach to these blocks. Power wires and one common ground wire will then route forward to instrument panel harness and main grounding terminal block on firewall.

Power and Ground Terminal Blocks at Station 3.jpg

Sep 01, 2022 Lower Forward mount brackets - (4 hours)

Category: Instrument Panel

Completed install of lower, forward support brackets for instrument panel at the lower radio rack. Temp installed terminal block at station 3 just below baggage floor for all power leads from both wings. Positive wires from wings (Nav lights, strobe lights, landing lights, pitot heat ) will terminate at this block. Positive power wires will come out of bottom of block to main/avionics bus. Same for grounds. I will use a terminal block for all ground wires from wings and run one common ground to firewall grounding block.

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Aug 31, 2022 Firewall, wiring, panel - (4 hours) Category: Firewall

Installed firewall and top center panel of boot cowl for instrument panel spacing. Fabricated angles for forward, lower panel supports. Mounted gascolator mount. Located grounding block on firewall. Routed and trimmed elevator trim motor wiring.

Aug 30, 2022 Panel Power Up - (3.5 hours)

Category: Avionics

Powered up panel again with iPad in place. Did some basic programming of G3X. Began to install cooling fan on iPad mount but shroud cracked. Replacement on the way. Began wiring of ELT d sub plug.

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Aug 29, 2022 First Power-Up of Panel - (4 hours)

Category: Avionics

Completed routing and attaching avionics wiring. Checked all plugs and connections. Connected 13.8V power supply to Battery Master board and connected all grounds to (-) side of power supply. Pulled all CB and insured Avionics Master switch was off. Turned on 1 avionics unit at a time to insure wiring was correct. Tested all avionics individually and everything powered up correctly. No smoke!! Finally, I powered up all connected units at once. Still no issues. Continued to routed antenna cables and assorted wiring to rear of cockpit area.

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Aug 28, 2022 Antenna Leads - (1.5 hours) Category: Avionics

Received 5 antenna leads from Shireen, Inc. Temp installed 2 GPS, 2 VHF and 1 transponder antennas. Temp installed all antenna leads in preparation for first power-up of avionics.

Aug 26, 2022 Mounting - (3 hours) Category: Firewall

Temp mounted firewall. Fit firewall wire pass-thru for engine sensor wires. Mounted cabin heater box. Relocated holes for ignition wires. Test fit cabin heater cable for length.

Aug 24, 2022 Wiring - (2 hours) Category: Instrument Panel

Routed some more wires for panel. Measured for GPS, VHF 2 and TX antenna cables. Ordered same from Shireen in Maryland. Great products.

Aug 23, 2022 Panel Wiring - (5.0 hours)

Category: Instrument Panel

Started plugging wiring harness connectors into remote avionics on tray. Routed wiring down side kick panel areas on both sides to rear of cockpit. Installed G3X, Comm 1, G5 and GNX 375.

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Aug 22, 2022 Brake Lines - (1 hour) Category: Interior Finish

Temp installed brake lines to master cylinders. Ran lines to fuselage fitting for gear legs.

Aug 22, 2022 Final Install - (4.5 hours)

Category: Instrument Panel

Marked, drilled and clecoed lower support tray where fire extinguisher will mount. Located and mounted CO detector on avionics tray. Prepped panel for install by tie wrapping wire bundles to secure them for install. Installed panel for final time. Secured overlays onto panel.

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Aug 17, 2022 Panel Supports - (3 hours)

Category: Avionics

Riveted instrument panel supports that will clamp to horizontal cage tube. Had to partially disassemble the panel frame to gain access to riveting from front of panel. Also, tightened and cotter keyed the bolts/nuts at base of brake master cylinders on floorboard.

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Aug 16, 2022 Interior panels and carpet fitting - (4.5 hours)

Category: Interior Finish

Mounted both IBBS batteries on avionics tray. Used single ear nutplates to allow for easier removal if needed. Fit all interior panels and carpeting (front carpet is permanently installed). Removed fuselage from rotator. Prepped instrument panel for install.

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Aug 15, 2022 Floorboard carpet and rudder pedal assy - (2.5 hours)

Category: Interior Finish

Trimmed and installed floorboard carpet. Permanently installed rudder pedal assembly on floorboard.

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Aug 15, 2022 Remote Avionics - (2 hours)

Category: Avionics

Began permanent install of remote avionics units on avionics tray.

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Aug 14, 2022 Tailwheel and Interior - (3.5 hours) Category: Fuselage

Corrected tailwheel spring mount plates. I had the outer plate reversed, so I removed the AN3 mount bolts and reversed it so the curved portion of the mount was facing the tailwheel spring.(check the note in the text manual). I retorqued nuts and marked with torque seal. Tailwheel is permanently mounted. I then re- attached the elevator torque tube under station 3 that was taken apart to allow better access to the tailwheel mount bolts. Next, I removed the rudder pedal assembly so the floorboard carpet can be installed next. The rudder pedal assembly goes over the carpet and I will make cut-outs for the mounting blocks and for the brake master cylinder attach plates.

Aug 13, 2022 Tailwheel - (3 hours) Category: Landing Gear

Removed remainder of masking paper and tape from cockpit after painting baggage compartment. Installed tailwheel spring and tailwheel to fuselage.

Aug 12, 2022 Baggage Compartment - (3 hours)

Category: Paint / Decals

Finished painting baggage compartment. Used AC Delco white/gray trunk splatter paint for finish texture coating. Moved fuselage back to shop to start final install of instrument panel and associated wiring.

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Aug 10, 2022 Painting baggage compartment - (3.5 hours) Category: Paint / Decals

Finished masking fuselage to prep for priming main gear leg contact area and tailwheel spring contact area before bolting both to fuselage. Primed both of those areas. Primed baggage compartment top and sides with self etching primer and painted with gray paint. Plan is to topcoat with a texture paint.

Aug 08, 2022 Left Wing Tip - (2.5 hours)

Category: Wings

Initial layout and trimming of Left Wing Tip support rib. Used a dremel with a thin cutoff wheel. Worked well. Started cutting with tin snips (which worked ok but was slow).

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Aug 07, 2022 Preparing Baggage Compartment - (2.5 hours) Category: Paint / Decals

Finished masking fuselage cockpit area and adjacent fuselage area for painting the sides and top of baggage compartment. Put in paint booth and scuffed surfaces with red scotchbrite and panel prep degreaser. Will clean again with the panel prep just prior to prime and paint. Too humid to paint today.

Aug 06, 2022 Avionics Tray - (2 hours) Category: Avionics

Mounted GAD 27 Data unit to avionics tray. Fit and drilled mounting holes for EarthX battery that will be mounted below the tray directly under the GTR 20 remote radio. It will slide into mounting tray from the cockpit side.

Aug 05, 2022 Avionics Tray Backup Battery Mounting - (3 hours)

Category: Avionics

Completed mounting of second backup battery on standoffs on the underside of the avionics tray. I installed 4 single-ear nutplates on upper backup-battery to allow for removal from underside if needed. This completes the remote avionics initial mounting except for the GAD 27 data box which will be mounted after the panel is mounted permanently.

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Aug 03, 2022 Backup Battery Install - (3 hours) Category: Avionics

Installed nutplates on top backup battery to allow for mounting screws to be inserted from the underside of the avionics tray. Bottom backup battery will mount directly below the top battery using 3/4" standoffs.

Jul 18, 2022 Remote Avionics Tray - (4 hours)

Category: Avionics

Temporarily mounted all but one remote avionics box on avionics tray that will be in front of instrument panel. I made standoff bushings to mount the GMA-245R audio panel box on top of the GTR-20 Comm 2 box. The 2nd backup battery will be mounted directly below the upper backup battery using similar standoff bushings. The main EarthX battery will be mounted on the bottom of the tray to allow for easy removal from the rear, if needed.

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Jul 17, 2022 Remote Avionics Install - (3 hours)

Category: Avionics

Located and attached GTR-20 Comm 2 and GEA 24 Engine Data remote boxes. Used nutplates on forward mount holes to facilitate removal in case needed in the future.

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Jul 16, 2022 Prep - (2 hours) Category: Interior Finish

Prepped paint gun for primer. Installed final attach screws for remote avionics tray.

Jul 15, 2022 Prep for priming interior - (3 hours) Category: Paint / Decals

Prepped test aluminum panels and gun setup for spaying epoxy primer on interior parts.

Jul 13, 2022 Masking Cockpit for painting - (4 hours)

Category: Fuselage

Masked cockpit to prepare for priming and painting baggage compartment sides and roof.

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Jul 10, 2022 Fuselage Rotator Fabrication - (5 hours)

Category: Fuselage

My friend and expert welder made up mounting plates for the rotator assembly. We used an old driveshaft and cut off the u-joints. He welded these to the plates and the station 10 bulkhead mount that I previously fabricated. The station 10 buikhead mount is bolted to the tooling holes on the bulkhead with AN4 hardware. We then mounted the firewall board and the rear mounts on a borrowed fuselage rotator. The design works great as there is no binding when rotating. Also, you can have the ends at different heights if needed. Also, I began attaching the avionics mounting tray to the tubing forward of the instrument panel.

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Jul 09, 2022 Avionics tray and rotator mount - (2.5 hours) Category: Fuselage

Deburred and bent edges of avionics mounting tray. Also, fabricated 2nd version of fuselage rotator mounting hardware. Will use 2 universal joints at mount points to insure no binding during rotation.

Jul 06, 2022 Avionics tray - (3.5 hours)

Category: Avionics

Initial cutting and fitting of avionics tray that will be used to mount the remote avionics. Made from .032 6061-T6.

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Jul 04, 2022 Rotator - (2 hours) Category: Fuselage

Continued to refine the fuselage mounts on the rotator to insure no binding.

Jul 01, 2022 Fuselage rotator - (2 hours)

Category: Paint / Decals

Initial fitting and mounting fuselage in rotator for priming and painting,

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Jun 27, 2022 Center Console - (1 hour) Category: Interior Finish

Modified center console to mount dual USB charging port.

Jun 25, 2022 Rudder Cable Return Kit - (2.5 hours)

Category: Controls

Installed Rear Rudder Cable Return kit. (kit RFK54) Kit was not included in my kit but is now offered as an upgrade.

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Jun 22, 2022 Wheel, Brake and Tires - (3 hours)

Category: Landing Gear

Disassembled one brake assembly and inventoried parts. Reviewed Matco manual. Coated tube with small amount of baby powder ( a little goes a long way!).
Partially inflated tube and assembled wheel halves. Torqued wheel hardware to 100 in lbs. Inflated tube to about 11psi and noticed a leak (or what I thought was a leak) around the base of the valve stem when I deflected it to the side slightly. Didn't know if tube was leaking so I disassembled wheel and installed other tube. Tightened wheel nuts and inflated tube again. Same thing happened-- but it lessened and eventually stopped. I'm sure what happened was the air trapped inside the tire when the tube was inflated was escaping at the base of the valve stem- it's a tight seal around the bead of the tire.. I assembled the brake assembly and axle. Torqued wheel and disc hardware. Ready to assemble on gear leg. I brought first tube home to leak check in water and no leaks were noted.

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Jun 23, 2022 Wheels and Brakes - (2 hours)

Category: Landing Gear

Installed tube in second tire. Packed all wheel bearings with Mobil 28 aircraft grease. Assembled 2nd brake assembly. Torqued wheel and disc hardware.
Both wheels ready to assemble onto gear legs.

Wheel Brearings packed with Mobil 28 Grease.jpg

Jun 20, 2022 Removed avionics boxes and prep for paint - (3 hours)

Category: Avionics

Removed and boxed up remote avionics boxes. Transferred locations of remote boxes to template that will be used to cut aluminum avionics tray. Bundled wire harnesses on panel prior to removal for painting interior panels. Test fit rudder return cable tunnel. Removed all interior trim panels for painting.

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Jun 21, 2022 Rear Rudder Return Spring Kit install - (2.5 hours)

Category: Interior Finish

Riveted nutplates on baggage compartment side panels. Installed rear rudder return pulley and cable from Kit RFK 54 that includes new rear pulley, cable and tunnel cover for rudder cables. Test fitting only.

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Jun 13, 2022 Engine Delivery Day - (1 hour)

Category: Engine

Received Titan XIO-340 engine today. Fedex delivery was great. No issues. Will leave in crate for now and do inventory tomorrow.

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Jun 05, 2022 Avionics mounting - (1.5 hours) Category: Avionics

Planning placement of GMA 245 on avionics tray. Test fit engine wire harness in firewall pass-thru fitting.

Jun 04, 2022 Instrument panel - (2.3 hours)

Category: Avionics

Made cardboard template of avionics mounting shelf that will mount behind the panel on the cage tubing. Placed all remote avionics boxes in locations per the wiring diagram. It appears all boxes will fit as planned. Mounting shelf will be made from .032 6061-T6.

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Jun 01, 2022 Solenoids Pressure Transducer Manifold and Panel Wiring - (4.5 hours)

Category: Firewall

Fabricated and installed copper bus bar between Master and Starter solenoids. This takes the place of the cable. Fit and drilled firewall for engine pressure transducer manifold. Removed boot cowl skins and began organizing instrument panel wiring harness.

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May 31, 2022 Trimmed boot cowl skins - (3 hours)

Category: Firewall

Sanded and trimmed boot cowl side and top skins to match firewall flange. Used small belt sander and hand sanding block. Assembled oil cooler mounts. Installed nut plates in forward, lower mount. Temp installed all necessary mounting hardware.

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May 30, 2022 Firewall and boot cowl - (3 hours) Category: Firewall

Up sized all holes on firewall flange, top boot cowl and instrument panel visor to #30. Removed cowl attach strip and re-clecoed to prep for trimming the skin overlap on the firewall flange.

May 27, 2022 Firewall fixtures - (4 hours) Category: Firewall

Drilled firewall for wire bundle pass through, Alt Air cable, and rudder cable support angle. Assembled rudder cable return pulley that attaches to base of firewall on cockpit side. Started up-sizing cowl attach strips and skins to #30 holes.

May 25, 2022 Firewall Fixtures - (4.5 hours)

Category: Firewall

Located and drilled firewall for Red Cube fuel flow, Ammeter shunt, and rudder cable mount bracket. Installed shunt, mixture and throttle cable eyeball fixtures and Red Cube mount bracket.

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May 24, 2022 Drilled firewall for fixtures - (3.5 hours) Category: Firewall

Located and drilled firewall for ignition cable outlets, master and starter solenoids, oil cooler mount, brake reservoir brake line fitting, throttle and mixture control eyeball fittings.

May 23, 2022 Drilled for firewall fixtures - (3 hours) Category: Firewall

Located and drilled firewall for gascolator, heater box, heater cable outlet, brake reservoir.

May 17, 2022 Layout firewall - (2 hours) Category: Firewall

Measured and marked firewall for brake reservoir, heater box, park brake cable bracket and heater cable. Drilled mount holes for park brake cable support bracket and brake reservoir mount.

May 11, 2022 Top and side boot cowl skins - (3 hours)

Category: Fuselage

Fitting and match drilling of top, top/side and side boot cowl skins to firewall with narrow spacer in place.

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May 10, 2022 Top Boot Cowl Skins - (4 hours)

Category: Fuselage

Positioned side, top and top/side boot cowl skins, strapped down and match drilled. Clecoed with #40. Fit side boot cowl skins and match drilled from inside to top/side boot cowl skins. Installed top and side firewall small spacer strips and clamped firewall to forward edge of top skins.

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May 09, 2022 Instrument panel visor and top boot cowl skin install - (4.5 hours)

Category: Instrument Panel

Temp installed top and top-side boot cowl skins to locate instrument panel. Inserted instrument panel visor under boot cowl skins and stabilized panel in proper orientation before match drilling visor. Match drilled all holes to #40 and clecoed.

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May 07, 2022 Fresh Air Vents - (1.5 hours) Category: Interior Finish

Match drilled and riveted fresh air vents to boot cowl side panels. Sealed with silicone.

May 07, 2022 First Panel Install - (5 hours)

Category: Avionics

Partially disassembled panel to locate and install #6 machine screws on sub panel that mount to welded tabs on cage. Mounted panel with help from my friends. Next step is to install firewall and match drill top boot cowl panels that will locate top of panel.

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May 06, 2022 First uncrating of instrument panel - (1 hour)

Category: Avionics

Uncrated and inspected instrument panel and wiring for first time. Studied mounting options.

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May 06, 2022 Completed Interior Panel fabrication - (3 hours)

Category: Interior Finish

Completed fabrication and install of all interior panels.

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May 05, 2022 Flap Handle Closeout - (1 hour) Category: Interior Finish

Cut and glued attach strips to one half of flap handle closeout. Used Oatey General Purpose glue that is made for ABS and PVC.

Apr 23, 2022 Cockpit trim panels - (2 hours) Category: Interior Finish

Fit and match drilled forward baggage area floor, side panels and Station 2B closeout panel.

Apr 25, 2022 Cockpit - (5.0 hours)

Category: Interior Finish

Fitted forward baggage compartment side panels; match drilled and installed nutplates. Fabricated forward baggage compartment floor angle reinforcements. Laid out and drilled for screw attachment holes and riveting to floorboard.

Forward bag compartment floor reinforcement angles.jpg

Apr 26, 2022 Cockpit interior - (5 hours)

Category: Interior Finish

Deburred and riveted forward baggage floor support angles. Cut out for header tank straps. Fabricated rear mount angle for center console. Riveted to St 2b closeout. Drilled and attached center console. Trimmed flap lever cover and test fit.

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Apr 29, 2022 Interior Closeout panels - (5.5 hours)

Category: Interior Finish

Trimmed flap handle closeout sides and front closeout panel, which I drilled and installed with tinnerman nuts. Trimmed, match drilled and installed rudder cable closeout to front seat closeouts using tinnerman nuts.

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May 01, 2022 Interior closeout panels - (3 hours) Category: Interior Finish

Trimmed and fitted seat side ABS closeout panels. Fitted lower, forward side kick panels. Drilled left panel for fuel shutoff valve.

May 03, 2022 Control Stick and Seat side closeouts - (4.5 hours)

Category: Interior Finish

Fabricated, drilled and riveted control stick closeout panel reinforcing angles. Trimmed and drilled out seat side closeout panels for attach screws. Used tinnerman and #8 sheet metal screw with large washer instead of plastic screw rivet called for. Much more substantial attachment.

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May 02, 2022 Interior Closeout Panels - (4 hours)

Category: Interior Finish

Final match drilling and fitting of forward lower kick panels. Fabricated mounting tabs to secure bottom of kick panel to floorboard. This secures seam between the two panels.These will be covered up by the carpet.

Kick Panel mounting tabs to floorboard (1).jpg

May 04, 2022 Closeout panels - (3 hours) Category: Interior Finish

Located and drilled forward screw holes in center console. Trimmed flap handle closeout and cut out ABS glue strips. Located rudder cable exit holes in rudder cable cover.

Apr 22, 2022 Doors and cockpit trim panels - (3.5 hours) Category: Fuselage

Fabricated and installed door latching hardware on both doors. Will do final fitting after interior panels are completed and installed.
Initial fitting of forward baggage compartment side panels and floor panel.

Apr 20, 2022 Doors - (3.5 hours) Category: Fuselage

Disassembled, deburred and prepped Copilot's door for riveting. Clecoed Lexan and trim strips. Riveted perimeter and center bow hold down strip. Used 3M VHB tape on back side of center hold down strip.

Apr 19, 2022 Doors - (3.5 hours)

Category: Fuselage

Removed trim and Lexan from pilot's door. Deburred all holes, trimmed and deburred Lexan edges and drilled holes. Clecoed Lexan and trim to door frame. Riveted all edges. Applied 3M VHB tape to underside of center bow hold down extrusion; clecoed in place and riveted with AAPQ-45 rivets. It helped to punch holes thru the VHB tape prior to riveting on the center bow hold down. Drilled holes in lower Lexan panel for door latch hardware.

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Apr 18, 2022 Doors and Interior - (3 hours)

Category: Fuselage

Fit, drilled and deburred top Lexan window on pilot's door. Trimmed panel and clecoed back to frame. Match drilled center attach extrusion to center frame bow. Fit door to cockpit. Located and test fit cockpit interior trim panels.

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Apr 17, 2022 Doors - (3.0 hours)

Category: Fuselage

Pilot's door. Upsized holes in frame to #30, deburred. Clamped lower Lexan window to frame. Match drilled to frame. Marked and trimmed to size. Sanded cut edges.

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Apr 16, 2022 Doors - (4.0 hours)

Category: Fuselage

Finished drilling, deburring and trimming top Lexan on copilot door. Upsized Lexan rivet holes to #27. Pre drilled center hold down channel and transfer drilled to center bow on frame. Clecoed to frame and test fit door to cockpit.

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Apr 14, 2022 Doors - (3 hours)

Category: Fuselage

Clamped bottom Lexan on Copilot door. Marked and match drilled to #30 with acrylic drill bit. Clecoed. Marked top edge on bow and leading edge for cutting. Trimmed rear edge with tin snips (thanks to another RANS builder for this tip). Works great- clean cut line.

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Apr 13, 2022 Doors - (3.5 hours)

Category: Fuselage

Match drilled and clecoed door trim on copilot door. Sized all holes to #30 and deburred. Removed trim and clamped lower lexan window for initial fit.

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Apr 12, 2022 Doors - (2 hours) Category: Fuselage

Drilled door outer trim pieces and clecoed in place.

Apr 11, 2022 Remote Avionics fit up and door assembly - (4.5 hours)

Category: Avionics

First fit up of remote avionics on template for avionics mounting tray that will be in front of instrument panel. Test fit doors to cage for fit. Straightened on side of copilot door frame. Drilled and riveted both top door frame trim piece.

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Apr 10, 2022 Initial Fitting of Horizontal and Vertical Stab - (3.2 hours)

Category: Tail Feathers

Match drilled and upsized 2 forward and 1 only rear spar holes on horizontal stab for mounting holes. Reamed to .249. Fit up of horizontal stab and elevator and attaching elevator push-pull tube so elevator can be set at neutral-- this will allow control stick assembly to be set at neutral pitch, that will allow AP pitch servo to marked and mounted at neutral position. Also test fit vertical stab rudder for first time. Marked and drilled AP pitch servo and permanently mounted.

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Apr 08, 2022 Aft Fuselage Closeout - (2.5 hours) Category: Fuselage

Removed and deburred all drilled holes. Final riveted remaining holes in aft longeron adjacent to closeout. Final riveted aft fuselage closeout. Installed horizontal stab forward mount bushings and set screws.

Apr 07, 2022 Aft closeout panel - (4.0 hours)

Category: Fuselage

Fit and match drilled aft fuselage closeout panel and S11 doubler. Fabricated S10 mounting bushings. Assembled horizontal stab mounting hardware.

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Apr 05, 2022 GPS Antenna Doubler Mount plates - (3.5 hours)

Category: Avionics

Fabricated and riveted nutplates to both WAAS and G3X/XM GPS antenna doubler mounting plates. Located, drilled and riveted mount plates to top of fuselage above baggage compartment behind Station 3.

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Apr 03, 2022 VHF 2 Antenna Mount doubler - (2.5 hours)

Category: Avionics

Fabricated VHF Comm 2 antenna mount doubler plate and installed on bottom skin below forward baggage area.

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Apr 02, 2022 Antenna Doublers - (2 hours)

Category: Avionics

Fabricated WAAS GPS antenna doubler plate. Installed floating nutplates and drilled out rivet mounting holes.

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WAAS GPS Antenna Doubler Plate.jpg

Apr 01, 2022 Antenna Doubler - (2 hours)

Category: Avionics

Drilled and riveted transponder antenna doubler (.063) to forward, bottom skin. Inventoried Instrument panel and avionics that arrived from SteinAir-- unreal how great the packaging and quality of work that SteinAir provides. HIGHLY RECOMMEND!!! They even laser etch your panel on both sides of the beautiful shipping crate-- how cool is that? I went with the carbon fiber instrument panel that Geoff Combs makes at Aerosport Products. Top quality and looks amazing! Hey, you only live once.

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Mar 30, 2022 Mounts - (2.5 hours) Category: Avionics

Fabricated angle support tab for AP pitch servo mount plate (front right corner that attaches to adel clamp). Drilled GPS mounting doubler plate for rivets. Will mount on upper forward fuselage above STE 3.

Mar 22, 2022 Aileron Servo - (3 hours)

Category: Controls

Final mounting of Garmin GSA 28 Aileron servo mount plate and servo to mount plate. Final connection to aileron cable will be made during rigging of ailerons.
Cleaned shop.

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Mar 21, 2022 HP Fuel Pump Assembly - (4 hours)

Category: Fuel System

Fabricated fuel pump mount. Located mount holes with posterboard template and transferred to pump mount. Located holes for pump housing and installed nutplates. Secured mount plate with AN bolts and loctite. Mounted pump on mount plate with prescribed socket head screws and loctite. Secured filter with hose clamp and AN3 bolt.

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Mar 20, 2022 Header tank - (3.5 hours)

Category: Fuel System

Made new angle brace for mount plate. Countersunk for CCC-42 rivets. Riveted to mount plate. Final install of quick drain valve and fuel outlet fitting. Mounted tank and secured with channels and long hose clamps. Clamps still need to be final tightened and safety wired. Did initial locating of fuel pump assembly with outlet hose attached.

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Mar 19, 2022 Header tank - (2.5 hours) Category: Fuel System

Installed all fuel fittings and low fuel warning sensor in header tank. Repaired rivets in tank mount angle brace.

Mar 18, 2022 Header Tank - (2 hours) Category: Fuel System

Drilled and trimmed access hole in bottom skin for header tank drain fitting. Fit header tank mount plate with mount clamp at left rear. Installed tank drain fitting.

Mar 16, 2022 Header Tank - (2 hours) Category: Fuel System

Match drilled bottom header tank support angle. Trimmed forward tank attach bracket for rudder cable clearance.

Mar 14, 2022 Header Tank - (2 hours) Category: Fuel System

Trimmed and deburred header tank mount plate. Located and drilled rivet mount holes in mount. Test fit tank again. Still need to drill sump drain hole in bottom skin.

Mar 11, 2022 Fuel System - (2 hours)

Category: Fuselage

Measured and drilled openings in header tank for fittings. Temp installed front outlet fitting so boost pump can be located final.

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Mar 10, 2022 Cockpit - (3.5 hours)

Category: Fuselage

Located and mounted Aileron AP servo mounting tray. Installed header tank for fitment. Modified HP boost pump to 'short' configuration per Flyefii. Assembled and mounted Fuel Selector valve on cage mount tabs. Test fit fuel hoses for placement of fuel pump on mounting tray.

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Mar 10, 2022 DAR Inspection - (2 hours) Category: Inspection

Our local DAR visited the hangar and looked over the build up to this point. He had a few minor comments about things to think about later in the build. Overall, he said the work looked great to date and to press on. I spent some time also aligning the aileron AP servo in prep of mounting.

Mar 08, 2022 AP Roll Servo - (2.5 hours)

Category: Avionics

Replaced actuator arm on Garmin GSA 28 servo with Capstan and cable to serve as the aileron servo. Test mounted servo. Still need to make bushings to mount servo to mounting tray and under mounting tray. Cleaned up shop.

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Mar 05, 2022 AP Servos - (3.5 hours)

Category: Avionics

Fitting and placement of Garmin GSA 28 pitch servo. Mounted servo to mount bracket. Had to modify bracket to mount limiting fixture. Measured and drilled servo mount plate to cage mount tabs.

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Feb 26, 2022 Aileron Cables - (4 hours)

Category: Controls

Pinned bottom attach points on brake cylinders. Assembled and installed aileron pulley assemblies in cockpit.

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Feb 23, 2022 Controls - (3 hours) Category: Fuselage

Took rudder pedal mounts off and lubricated bearings. Installed assembly back to floorboard. Tightened brake cylinder mounts- ready to cotter pin. Bolted front of elevator short control tube to control stick assembly. Bolted short tube to long elevator torque tube forward end-- not tightened. Operates normally.

Feb 21, 2022 Cockpit - (3.5 hours)

Category: Fuselage

Installed floorboard. Installed rudder pedal assembly. Greased control stick assembly bearings and tightened assembly. Installed control stick assembly to floorboard. Installed elevator torque tube through fuselage.

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Feb 18, 2022 Park Brake - (2.3 hours) Category: Fuselage

Assembled parking brake AN fittings. Used Loctite 567 as thread sealant. Installed park brake assembly on firewall. Looked at sample of quilt-backed fireproof insulation to install below floorboard for sound deadening. Probably will use this material. Aligned AN fittings on brake cylinders in prep for final install.

Feb 20, 2022 Cockpit - (3.0 hours)

Category: Fuselage

Installed AN fittings in all brake cylinders. Used Loctite 760 as thread sealant. Reinstalled all brake cylinders on rudder pedal assembly and cotter pinned all nuts. Rudder pedal assembly ready to install. Made cardboard templates for under floorboard insulation. Cut out K-Wool quilted, fireproof insulation and fit between tubing below floorboard for sound proofing and some heat dissipation.

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Feb 15, 2022 Cockpit - (2.5 hours) Category: Fuselage

Applied 1/2" wide, 1/8" thick rubber tape to cockpit tubing under the floorboard. Test flt floorboard. Measured nutplate pattern for the aileron servo mount plate and transfered it for drilling. Installed engine mount bolts in Station 1 locations ( be sure to install at least the lower engine mount bolts before final attachment of floorboard= you can't get them in if you wait until floorboard is installed).

Feb 14, 2022 Autopilot - (3 hours)

Category: Fuselage

Finished installing nutplates for AP servo mounts.Layed out and positioned mounts for install. Installed 2 missing rivets on bottom cockpit skin.

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Feb 13, 2022 Cockpit - (3 hours) Category: Fuselage

Removed masking tape from firewall flanges as the bedliner had dried. Removed cockpit doors after initial fitting. Installed nutplates on tabs in cockpit for floorboard and forward baggage compartment floor.

Feb 09, 2022 Firewall - (2.5 hours) Category: Fuselage

Applied 2nd coat of bediner to back of firewall. Test fit cockpit doors.

Feb 08, 2022 Firewall and boot cowl - (3.5 hours)

Category: Fuselage

Prepped and rolled on first coat of bedliner on firewall. Match drilled remaining bottom boot cowl skin stiffeners. Removed rudder pedal assembly after initial fit up.

First coat of bedliner on firewall (1).jpg

Feb 07, 2022 Elevator Push Pull Tube - (3 hours) Category: Controls

Drilled and riveted front doubler and rear fitting to elevator push pull tube. Rear fitting took a lot of sanding and finishing to get it to fit properly.
Insured front and rear fittings were parallel.

Feb 05, 2022 Cockpit - (3.5 hours)

Category: Fuselage

Removed firewall for coating with bedliner. Installed bottom boot cowl skin and stiffners with clecos. Temp installed rudder pedal assy for fitting. Fit AP servo mounts for spacing.

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Feb 02, 2022 Cockpit - (3 hours) Category: Fuselage

Match drilled floorboard to nut plate locations. Installed nutplates.

Feb 01, 2022 Cockpit - (3.5 hours)

Category: Controls

Marked all boot cowl pieces and stiffeners prior to removal. Match drilled cowl attach flanges to #30. Removed instrument panel, all boot cowl skins and cowling attach flanges and spacers. Test fit floorboard. Trimmed where it interfered with cage tube. Match drilled front 4 rivets tabs to #30.

Floorboard fitting.jpg

Jan 31, 2022 Flap Control Assembly - (3 hours)

Category: Controls

Located all parts, fabricated required bushings and assembled flap control handle assembly. Test fit in cockpit. Functions normally.

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Jan 30, 2022 Elevator push pull tube - (2.5 hours)

Category: Controls

Fabricated 35" elevator push pull tube and test mounted in cockpit.

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Jan 29, 2022 Brake cylinders and elevator push pull tube - (4.5 hours)

Category: Controls

Drilled control sticks for PTT and Trim wires. Installed rubber grommets. Assembled brake cylinder assemblies onto rudder pedals. Pre installed all hardware.
Assembled front elevator push-pull tube with all hardware and bearing fabrication.

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Jan 27, 2022 Control assembly - (5 hours)

Category: Controls

Completed inventory of finish kit hardware. Stapled to board. Assembled rudder pedals and rudder pedal control assembly. Assembled control stick torque tube and control rod.

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Jan 26, 2022 Seats - (3 hours)

Category: Fuselage

Completed installing seat back and seat bottom cushions. Very difficult to stretch cushions over frame. Had to tape front corner of seat pan to prevent edge catching on seat bottom when installing. Also had to stretch (widen) base of seat back using long clamp to remove and install seat back support tube when fitting in the bottom pocket of the seat back cushion. Headrest cushions installed and set aside. Also, inventoried and arranged Finish Kit hardware on parts board.

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Jan 25, 2022 Seats - (3 hours) Category: Fuselage

Fabricated spreader bar for headrest frame. Test fit headrest cover. Removed headrest frames from seats and fit seatback cushion to frame. Very tight fit to slide the cushion far enough down to allow the seatback tube to slide through the pocket on the cushion. Will continue to fit.

Jan 22, 2022 Seat Build Up and test install - (6 hours)

Category: Fuselage

Installed seat sliding rails. Located all seat parts. Assembled seat frames per plans. Test installed in cockpit. Fit and operated well.

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Jan 21, 2022 Boot Cowl - (5 hours)

Category: Fuselage

Finished match drilling cowl attach strips and spacers. Clecoed instrument panel in place and fit top middle and top side boot cowl skins. Strapped in place to help skin curve. Flipped fuselage to upright. Installed cage bottom skin stiffeners with 3M VHB double sided tape.

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Jan 20, 2022 Boot Cowl and Firewall Flanges - (3.5 hours)

Category: Fuselage

Match drilled boot cowl side and bottom skins. Drilled cowl attach strips and spacer strips on firewall flange.

Boot Cowl side skin and cowl firewall flanges drill and cleco (10).jpg

Boot Cowl side skin and cowl firewall flanges drill and cleco (6).jpg

Jan 18, 2022 Boot Cowl - (3.5 hours) Category: Fuselage

Continued fitting both side boot cowl skins. Located aft edge with centerline on front door post on cage. Will need to trim at firewall flange, then drill and cleco in place.

Jan 16, 2022 Boot Cowl - (3.5 hours)

Category: Fuselage

Match drilled all boot cowl skin stiffeners to cage tabs. Drilled extra rivet holes at required spacing. Located and match drilled bottom boot cowl skin. Clecoed to firewall flange and cage. Fit up boot cowl side skins.

Bottom and side skin fit up and match drill (1).jpg

Bottom and side skin fit up and match drill (2).jpg

Jan 15, 2022 Cage bottom and side skins - (6 hours)

Category: Fuselage

Final fitting, deburring and riveting cage bottom and side skins. Trimmed and clecoed instrument panel frame to cage.

Cage bottom and side skins riveted (1).jpg

Cage bottom and side skins riveted (2).jpg

Cage bottom and side skins riveted (3).jpg

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Jan 13, 2022 Cage Skins - (4 hours) Category: Fuselage

Primed lower cage side skins where they contact the cage. Deburred the bottom skin rear spacer and skin rivet line. Drilled firewall engine mount holes to 5/16"

Jan 12, 2022 Fuselage and boot cowl - (4 hours) Category: Fuselage

Cleaned, prepped and sprayed self-etching primer on cockpit bottom skiin under cage tubing. Cut and clecoed bottom, inner cowl attach strips. Finished fitting firewall spacers and cowl attach strips. Fabricated boot cowl skin stiffeners.

Jan 11, 2022 Firewall spacer strips and cowl attach strips fitting - (2.5 hours)

Category: Firewall

Initial fitting of firewall spacer strips and cowling attach strips. Clecoed in place and formed spacers for curved sections.

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Jan 05, 2022 Firewall Fitting - (2 hours)

Category: Firewall

Riveted firewall sections together. Test fit on cage.

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Dec 30, 2021 Boot cowl and firewall fitting - (2.5 hours)

Category: Fuselage

Initial fit of boot cowl sides, bottom and firewall.

Firewall fit up (1).jpg

Jan 10, 2022 Firewall and boot cowl - (2.5 hours) Category: Fuselage

Final fitting and drilling of firewall to cage tabs. Fit boot cowl side and bottom skins for alignment.

Jan 04, 2022 Bottom skin - (2.0 hours) Category: Fuselage

Removed bottom skin, cleaned and masked for priming under cage tubes. Cleaned and deburred side skins.

Jan 03, 2022 Bottom Skin - (3.5 hours) Category: Fuselage

Completed match drilling aft edge of bottom skin to bottom spacer strip and cage tabs. Dimpled bottom and side skins for flush rivets that will be under the main gear mounts. Drilled holes in skin for landing gear mount bolts and brake line exit holes. Fabricated stringers for inside of bottom skin. Continued to fit firewall- the cage mounting bushings don't line up with the pre-drilled holes in the firewall when the firewall is square to the cage. Will keep working at this alignment.

Dec 29, 2021 Fuselage bottom and forward side skins - (4.5 hours)

Category: Fuselage

Match drilled side skins to bottom skin.

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Dec 28, 2021 Bottom skin and forward side skins - (4.5 hours) Category: Fuselage

Marked landing gear holes bolt holes to be drilled on bottom skin. Trimmed side skins at various points to fit. Remarked and measured underside of bottom skin for tube clearance. Laid out rivet lines on side skin flanges. Marked and drilled to #40 pilot holes. Reinstalled bottom skin to prep for match drilling side skin flanges to bottom skin.

Dec 27, 2021 Bottom Fuselage Skin - (2 hours)

Category: Fuselage

Fit up and match drilling bottom fuselage skin to cage tabs and rear bottom spacer strip at joint with bottom tailcone skin.

Bottom Fuselage Skin Fit Up (1).jpg

Bottom Fuselage Skin Fit Up (2).jpg

Dec 24, 2021 Left side skin - (1.2 hours) Category: Fuselage

Match drilled left forward side skin to left tailcone side skin thru the spacer strip at S3. Marked location of cage tubes on inside of bottom skin and flanges on side skins for rivet layout.

Dec 23, 2021 Forward Side Skins - (4.5 hours)

Category: Fuselage

Fit, trimmed and match drilled forward, left fuselage side skins. Placed bottom skin on for initial fit and placement. Removed main landing gear after initial fitting.

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Dec 21, 2021 Forward side skins and landing gear - (4 hours)

Category: Fuselage

Finished match drilling and trimming right side forward fuselage skins. Fit and installed main gear legs to check fit. Had to file oblong hole on both gear plates for proper fit of bolts.

Pattern for side skin match drilling.jpg

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Dec 20, 2021 Forward side skin fitting - (3 hours) Category: Fuselage

Initial fit of fuselage forward side skins.

Dec 19, 2021 Fit up of forward side skins and fuselage flip - (3 hours)

Category: Fuselage

Initial fitting of forward side skins and flipped fuselage to fit bottom skin.

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Dec 18, 2021 Seat Adjuster Rails install - (3 hours)

Category: Fuselage

Installed seat rail adjusters.

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Dec 16, 2021 Final Riveting of Tailcone and Top forward skins - (5.9 hours)

Category: Fuselage

Completed riveting of longerons to cage tabs and top forward fuselage skins. Moved fuselage to saw horses to prep for flipping upside down to work on seat rails, side and bottom skins.

Final Riveting of tailcone and top foward skins (12).jpg

Final Riveting of tailcone and top foward skins (13).jpg

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Dec 15, 2021 Landing gear hardware and top forward skins - (3 hours) Category: Fuselage

Assembled landing gear mounting hardware. Reamed main gear spacer bushings. Reamed cage landing gear attach bushings. Trimmed top forward fuselage skins. Drilled 3 new holes in top forward spacer strip due to edge distance problem with original holes.

Dec 14, 2021 Tailcone skins - (3.5 hours)

Category: Fuselage

Prepared and riveted tailcone skins to bulkheads and stringers. Trimmed and cleaned top front skins and clecoed in place. Some adjusting needed before riveting.

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Dec 13, 2021 Tailcone top skins - (5 hours)

Category: Fuselage

Trimmed top right skin for fit at VHF 1 Comm antenna mount. Deburred and prepped for riveting. Riveted top right skin to bulkheads and mid longeron (not completed).

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Dec 12, 2021 Tailcone skins - (3.5 hours) Category: Fuselage

Final riveting of VHF 1 antenna doubler. Routed antenna cable to baggage compartment area. Riveted window angle supports to mid longerons. Fit top right tailcone skin. More fitting required as well as match drilling top center seam.

Dec 09, 2021 Skin Prep for riveting - (4.7 hours)

Category: Fuselage

Deburred and edge formed left tailcone skin and upper fuselage skins. Riveted right mid longeron stiffner. Installed countersunk #8 nutplates in VHF 1 and 2 antenna doublers. Riveted VHF 1 antenna doubler to left tailcone skin at S5. Clecoed left tailcone skin in prep for final riveting.

VHF 1 Doubler Plate Rivnut install (1).jpg

VHF 1 Doubler Plate Rivnut install (2).jpg

Dec 08, 2021 Fuselage skins - (4.5 hours) Category: Fuselage

Removed forward and rear fuselage skins. Cleaned, deburred. Trimmed top forward skins for fit. Primed window support angles where they attached to upper cage tabs. Re-primed spacer strips after deburring. Enlarged window attach holes to #27. Edge formed bottom of tailcone skins and forward top skins at middle longeron overlap.

Dec 07, 2021 ELT and VHF #1 antenna Mounting - (4 hours)

Category: Avionics

Completed fabrication of ELT mount plate. Cleaned and deburred. Located, drilled, dimpled and flush riveted nutplates (10-32 screws) to mount plate. Drilled rivet mounting holes in stringers and S4 bulkhead, then riveted using AAPQ-42 rivets to stringers and AAPQ-41 rivets to S4. Mounted ELT mount tray to ELT mount plate w/ 10-32 stainless screws (used Blue threadlock). Mounted ELT with provided strap. Removed right top tailcone skin and located VHF #1 antenna mount doubler to check location and clearances. Measured length of RG400 cable required for VHF #1 antenna cable and ordered same.

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Dec 05, 2021 ELT and VHF mounting - (3 hours)

Category: Fuselage

Fabricated ELT mounting plate to be riveted in below aft baggage floor. Clecoed VHF antenna doubler just aft of St. 5 on top of tailcone for fitment.

ELT mounting plate.jpg

Dec 04, 2021 Cage to tailcone attachment - (3.5 hours) Category: Fuselage

Match drilled upper sides and top spacer strips to top forward skins. Riveted bottom and side skins to lower longeron (forward section). Started fabrication of mounting doubler plate for ELT.

Dec 02, 2021 Top Forward Stringers - (3.5 hours)

Category: Fuselage

Trimmed center top stringer to length. Match drilled all top stringers to top forward skin. Side skin spacers match drilled to final size.

Top Forward Skin Stringers match drilled top skin (1).jpg

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Nov 30, 2021 Top Fuselage Skins - (5.5 hours)

Category: Fuselage

Rear edge of top fwd fuselage skins match drilled to S4 and tailcone skins. Upper stringers (except center) marked, trimmed to length and bent to follow fwd skin profile. Match drilled lower side edges of fwd fuselage skins to middle longeron. Upper side spacer strips match drilled to cage tabs.

Forward Fuselage Skin Install (1).jpg

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Forward Fuselage Skin Install (7).jpg

Nov 29, 2021 Window Support Angle - (3.5 hours)

Category: Fuselage

Trimmed right window support angle and top forwards skins at cage for fit. Match drilled both window support angles to upper cage tabs. Match drilled both window support angles to top forward skins. Changed out rivnut tool insert to 10-32 fixture for seat mount plates.

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Nov 27, 2021 Top Forward Skins - (3.5 hours)

Category: Fuselage

Top forward skin initial fitting. Temp installed top stringers for marking bend and cut lines. Riveted stringer in right side tailcone skin. Fit spacer strips for top forward skins.

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Nov 26, 2021 Aft Baggage - (3.5 hours) Category: Fuselage

Relocated 3 nutplates for better fitment of rear baggage floor and side skins. Fit , trimmed and drilled window support angles. Clecoed to middle longeron behind S4. Fit top tailcone skins and started clecoing.

Nov 24, 2021 Rear Baggage - (3.5 hours) Category: Fuselage

Installed nutplates in floor and bag compartment sides. Drilled S4 closeout for screws. Glued spacer blocks to upper corners of S4 closeout. Fit window supports.

Nov 23, 2021 S4 Closeout - (4.3 hours) Category: Fuselage

Finished trimming and fitting S4 Closeout panel. Cut openings for top stringers. Located and started install of nutplates for closeout to floor and side panels as well as the upper corner AN3 bolts and rear spacer blocks.

Nov 22, 2021 S4 Closeout - (4 hours) Category: Fuselage

Continued fitting and trimming S4 closeout panel. Installed nutplates in baggage floor supports. Located nutplates for baggage side walls.

Nov 21, 2021 Rear Baggage Compartment - (2.7 hours)

Category: Fuselage

Initial trimming and fitting of S4 closeout panel. Final fitting and riveting of floor left and right panels to each other. Marked and drilled for 6 floor to cage nutplates as well as floor to floor support nutplate locations.

S4 Closeout initial fitting (1).jpg

S4 Closeout initial fitting (2).jpg

Nov 20, 2021 Window Support Angles - (2 hours)

Category: Fuselage

Fabricated and fit Left and Right Window Support angles. Ready to rivet.

Window Supports Fabrication (1).jpg

Window Supports Fabrication (2).jpg

Nov 18, 2021 Rear Baggage Compartment - (3.7 hours)

Category: Fuselage

Removed all clecoes on lower longerons and removed baggage floor supports. Deburred supports, longerons and longerons doublers. Reassembled all parts. Riveted aft end of baggage floor supports to S4. Fit baggage floor and sides. Eased top edge of baggage floor pieces at overlap to sides.

Final Fitting Aft Baggage Compartment prior to drilling (1).jpg

Final Fitting Aft Baggage Compartment prior to drilling (2).jpg

Nov 17, 2021 Rear Baggage Compartment - (2.5 hours) Category: Fuselage

Continued to fit rear baggage sides and floor. Clecoed top skins in place at S4 and S5 for fit.

Nov 14, 2021 Rear Baggage Compartment - (3.5 hours)

Category: Fuselage

Initial fit up of rear baggage floor and sides. Transfer drilled sides to middle longeron. Riveted floor stiffeners to floor panels.

Rear Baggage Comp Initial Fitting (1).jpg

Rear Baggage Comp Initial Fitting (2).jpg

Rear Baggage Comp Initial Fitting (3).jpg

Nov 11, 2021 Baggage floor supports and tailcone spacer strips - (3.5 hours)

Category: Fuselage

Match drilled S3 S4 baggage floor supports to lower longerons. Drilled and clecoed bottom and lower side tailcone spacer strips to cage tabs and stringers.

S3 S4 Floor Supports (1).jpg

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S3 S4 Floor Supports (5).jpg

Nov 10, 2021 Longeron supports - (2.3 hours) Category: Fuselage

Completed match drilling of lower left longeron support using .020 spacers. Fit bottom and side skin spacer strips.

Nov 09, 2021 Longeron supports install - (3.5 hours)

Category: Fuselage

Drilled and installed mid longeron support on both L and R sides. Drilled and installed lower longeron support on right side. I chose to sandwich the cage gusset between the longeron and the support as the bottom skin holes and side skin spacing lined up perfectly that way.

Tailcone to Cage longeron supports (2).jpg

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Tailcone to Cage longeron supports (5).jpg

Nov 06, 2021 Cage to Tailcone final mating, drilling and cleco - (1.5 hours)

Category: Fuselage

Final measurements, alignment and clamping of cockpit cage to tailcone. Drilled mid and lower longerons to cage tang attachment points. Clecoed same.

Cockpit Cage to Fuselage Tailcone final drilling and mating (5).jpg

Cockpit Cage to Fuselage Tailcone final drilling and mating (6).jpg

Cockpit Cage to Fuselage Tailcone final drilling and mating (7).jpg

Nov 04, 2021 Cage Fit Up - (2.5 hours) Category: Fuselage

Continued cage fit up to tailcone.

Nov 03, 2021 Cockpit Cage Fit Up - (4.7 hours)

Category: Fuselage

Primed tailcone and spacer strips with self-etching primer. Unpacked cockpit cage and brought into workshop for initial fitting. Will need to trim forward edge of bottom skin stringers as they slightly interfere with the rear, lower tube on the cage.

Cockpit Cage fitup (1).jpg

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Nov 02, 2021 Fuselage skin and wiring - (4 hours)

Category: Fuselage

Encased electric pitch trim wire bundle in sheathing. Secured wire bundles on left and right side of fuselage with clip-on cable ties. Fabricated spacer for S-11 to right side skin. Riveted stringer on right side skin and riveted right side skin to bulkheads and lower longeron.

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Right Side Skin and wiring install (8).jpg

Nov 01, 2021 Side skin - (3.0 hours)

Category: Fuselage

Installed cable ties for elevator trim wire bundle. Gathered bag comp. Skins and supports. Fabricated tailcone longeron support angles and tailcone spacer strips. Clecoed right side skin to tailcone.

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Oct 31, 2021 VHF Comm 1 Install - (4 hours)

Category: Fuselage

Drilled, deburred VHF Comm 1 antenna doubler at Sta. 5 top. Drilled skin and fit antenna. Riveted left side skin at Sta. 11. Needed .020 spacer. Fabricated lower and mid longeron stiffeners. Clecoed lower and mid longerons at every hole Sta 3 to Sta. 4. Install of Com antenna at this point, with right side skin not yet riveted gave good access.

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Oct 30, 2021 Antenna doubler - (3 hours)

Category: Fuselage

Measured and fabricated doubler plate (.032 6061-T6) for VHF Com 1 antenna to be mounted on top of fuselage at Sta.5.

VHF COM 1 antenna doubler (1).jpg

Oct 28, 2021 Riveting stringers - (3 hours)

Category: Fuselage

Riveted stringers and lower longeron on left side of fuselage. Removed top stringers and labeled for future install.

Left Side stringers and lower longeron riveted.jpg

Oct 27, 2021 Fuselage stringers - (2 hours) Category: Fuselage

Cut and trimmed remaining fuselage stringers for top skins. Clecoed top left skin in place for fit.

Oct 26, 2021 Antenna fitting and Stringers - (4.5 hours)

Category: Fuselage

Fabricated transponder antenna doubler plate. Cut upper fuselage stringers to size and clecoed in position. Clecoed upper left skin in place for fitment.

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Oct 24, 2021 GMU 11 and Rudder Cable Install - (3.7 hours)

Category: Fuselage

Located and riveted Garmin GMU 11 Magnatometer per plans. Mounted GMU with stainless steel machine screws and lock nuts. Installed rudder cables and tailwheel steering cables. Still need to final tighten all rudder cable pulley hardware.

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Oct 23, 2021 Fuselage build up - (3.5 hours)

Category: Fuselage

Riveted bulkheads to bottom skin. Installed GMU-11 wire harness in fuselage. Clecoed left side skin on bottom skin. Flipped fuselage and set on build table.

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Oct 21, 2021 Fuselage side skins - (2.7 hours)

Category: Fuselage

Cleaned and prepped fuselage side skins. Trimmed stringers. Clecoed in place. Marked middle longeron for trimming. Riveted tailwheel steering cable pulley mounts to S9 before riveting bulkheads. Be sure to do this prior to riveting S9, S10 to bottom skin or you won't be able to get rivet gun in afterwards. I had already match drilled the rear portion of these mounts to S9.

Side skin prep cleaned and stringers clecoed (1).jpg

Side skin prep cleaned and stringers clecoed (2).jpg

Oct 20, 2021 Bottom Skin Stringer install - (5.6 hours)

Category: Fuselage

Clecoed all stringers, longerons and inspection cover rings. Riveted same. Installed nutplates in inspection cover rings. Hung bulkheads from bottom skin for initial fitting.

Bottom Skin Riveting and clecoing bulkheads for fit (1).jpg

Bottom Skin Riveting and clecoing bulkheads for fit (2).jpg

Bottom Skin Riveting and clecoing bulkheads for fit (3).jpg

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Bottom Skin Riveting and clecoing bulkheads for fit (7).jpg

Bottom Skin Riveting and clecoing bulkheads for fit (8).jpg

Bottom Skin Riveting and clecoing bulkheads for fit (9).jpg

Oct 19, 2021 Bottom Skin Fab - (5.1 hours)

Category: Fuselage

Cut, trimmed all stringers to size. Primed inspection panel mount rings with self etching primer. Temp mounted S9, S10 and S11. Drilled mount holes for tailwheel steering cables at S9. Located and drilled tailwheel spring mount holes. Flipped skin upside down and clecoed all stringers, longerons and inspection panel mount rings.

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Oct 18, 2021 Bottom Skin layout - (5.6 hours)

Category: Fuselage

Finished fabrication of bulkheads 9,10 and 11. Deburred and cleaned all fuselage stringers and longerons. Put bottom skin on bench and laid out stringers, longerons, and inspection hole reinforcing rings.

Initial Layout of bottom skin with stringers and longerons (4).jpg

Initial Layout of bottom skin with stringers and longerons (6).jpg

Initial Layout of bottom skin with stringers and longerons (7).jpg

Oct 17, 2021 Bulkheads - (4.1 hours)

Category: Fuselage

Fabbled Rudder Cable Pulley assemblies and fabricated alum bushings for mounting to S-8. Riveted doubler on S-8. Cleaned, deburred and clecoed doubler to S-9 and prepped lower attach fitting for install. NOTE: If you are building a taildragger version, be sure to see note on S-8, S-9 parts page to substitute and install the 4 tangs in place of the washers in the main rudder cable pulley mount. These will connect to the tailwheel steering cables. They are located in the landing gear hardware parts bag (the one with the tailwheel spring in it). It took some searching to find them-- thought I'd save you some time.

S8 and S9 Bulkheads with Rudder Cable pulley assembly (1).jpg

S8 and S9 Bulkheads with Rudder Cable pulley assembly (2).jpg

S8 and S9 Bulkheads with Rudder Cable pulley assembly (3).jpg

Oct 16, 2021 Bulkheads - (4 hours)

Category: Fuselage

Continued work on S5, S6, S7 and S8 Fuselage bulkheads. Be sure to check parts drawings on which side rivets are driven.

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Oct 12, 2021 Fuselage Bulkheads - (3 hours)

Category: Fuselage

Located and laid out all fuselage bulkheads and associated parts. Fit doublers to S-4 bulkhead but had to bend doubler top tab to match angle on bulkhead. Clecoed and match drilled doublers. Cleaned and deburred then riveted doublers to S-4. Drilled out holes for rubber grommets in bottom doubler.

Layout and initial riveting fuselage bulkheads (1).jpg

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Layout and initial riveting fuselage bulkheads (3).jpg

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Oct 12, 2021 Wing Struts - (3 hours)

Category: Wings

Final upsizing of mounting bolt holes. Drilled with drill press- started with 3/8" bit, then 27/64" then reamed to .4365 (.001 undersize). AN7 mounting bolt fit perfectly. Sanded face of mounting fitting and installed hardware in both ends of each struts temporarily.

Wing Sturt Final Upsizing of mounting bolt hole.jpg

Oct 09, 2021 Wing Struts - (2 hours) Category: Wings

Match drilled lift strut doublers to #30. Deburred and clecoed in prep for final sizing to #11 and riveting.

Oct 11, 2021 Wing Struts - (3.5 hours)

Category: Wings

Laid out and match drilled wing strut ftting doublers to #11. Deburred and cleaned struts and doublers. Clecoed, clamped and riveted doublers.

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Oct 08, 2021 Fuselage Prep - (1 hour) Category: Fuselage

Located and sorted fuselage parts.

Oct 07, 2021 Right Aileron - (3 hours)

Category: Controls

Cleaned/deburred right aileron skin and spar. Clecoed and riveting skin on right aileron.

Rt Aileron (2).jpg

Rt Aileron Fitting.jpg

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Oct 06, 2021 Right Aileron - (2 hours) Category: Controls

Finished clecoing Rt Aileron. Match drilled bottom skin to ribs and leading edge of top skin to spar. Removed clecos for deburring and cleaning.

Oct 04, 2021 Left Aileron - (4.0 hours) Category: Controls

Match drilled skins to rib flanges and spar. Disassembled aileron and deburred skins, spar and rib flanges. Repaired small damaged spot in skin. Reclecoed skins and riveted bottom skin to ribs and spar.

Oct 03, 2021 Flaps/Ailerons - (3.0 hours)

Category: Controls

Widened hinge slots in both aileron skins. Bent L Aileron skin. Clecoed skins to ribs and bottom of spar.

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Oct 01, 2021 Flaps/Ailerons - (3.5 hours)

Category: Controls

Prepped aileron skins for bending and riveted inspection plate rings.
Removed clecos from Rt flap. Cleaned/,deburred skins, rib flanges and spar. Clecoed skins and riveted top skin on Rt flap.

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Oct 03, 2021 Flaps and Ailerons - (2 hours)

Category: Controls

Completed riveting skins on Right Flap.

Right Flap Completed.jpg

Sep 29, 2021 Flaps - (4.0 hours)

Category: Controls

Prepared Rt flap and aileron skins. Removed and filed bend tabs. Marked centerline on all bottom rib flanges. Bent top skin with 2" PVC pipe. Clecoed top of skin to ribs and spar.

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Sep 28, 2021 Flaps - (4.2 hours)

Category: Controls

Matched drilled bottom skin to ribs and spar. Removed all clecos. Deburred bottom skin, ribs and spar interior. Clecoed skins. Riveted top and bottom skins.

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Sep 27, 2021 Flaps - (3.8 hours)

Category: Controls

Moved Rt wing to cradle. Deburred inside of spar.. Clecoed L. Flap skin to PVC pipe. Rolled top skin 270 (needed 3 people to hold proper pressure on table). Marked bottom rib flange centerline. Clecoed ribs to top skin. (Left first 3 rows of clecoes out to make it easier to insert spar). Inserted spar. Finished clecos. Turned flap over and checked for twist.

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Sep 26, 2021 Flaps/Ailerons - (3.5 hours) Category: Wings

Drilled/reamed hinges. Pressed in bronze bushings. Reamed to 3/16". Riveted hinges to appropriate ribs on flaps and ailerons.

Sep 25, 2021 Flaps/Ailerons - (3.5 hours)

Category: Wings

Prepped ribs and hinges. Grouped in order.
Cut to length and match drilled 2"PVC pipe for bending flaps and aileron top skins.

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Sep 25, 2021 Flaps/Ailerons - (3.5 hours)

Category: Wings

Prepped ribs and hinges. Grouped in order.
Cut to length and match drilled 2"PVC pipe for bending flaps and aileron top skins.

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Sep 23, 2021 Right wing build up - (4.7 hours)

Category: Wings

Riveted root rib. Assured tank supports were under rib flange. Prosealed cap to wing gap. Inventoried aileron and flap parts.

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Sep 22, 2021 Right Wing Build-Up Fuel Tank - (3 hours) Category: Wings

Attached remainder of fuel tank fittings with EZ Turn Fuel Lube. Removed screws from cap flange and reinstalled with EZ Turn. Vacuumed out tank. Pressure tested with balloon. Installed tank in wing. Clecoed root rib.

Sep 21, 2021 Right Wing Build-Up Fuel Tank - (5 hours)

Category: Wings

With tank in wing, I measured fuel cap opening, marked center and screwed in template for drilling 3" hole for cap. Marked location of fuel tank quantity fittings with template. Measured for rear pickup fitting. Drilled all holes and deburred. Vacuumed tank out. Installed fuel tank pickup and fuel quantity fittings. Used blue loctite on nuts. Measured and marked top of tank for fuel cap flange. Drilled screw holes and deburred. (On this tank, I drilled the 3/8" hole for the vent at this point. On the left tank, I drilled out this hole for the vent after attaching and prosealing the cap and pressure testing the tank. Doing it this way, the way the plans suggest, I found it difficult to drill the tank and not damage the threads in the inner flange. I had to tap those threads as the bit damaged the first few threads. This time, I drilled the 3/8" hole in the tank first and installed the vent along with the other screws. I will seal this vent hole when I pressure test the tank.) Vacuumed tank again. Installed fuel tank support and inner cap flange with temp bolt. I prosealed underside of cap flange and installed with screws and the vent. Will let setup overnight. (Just a note: I used disposable 10cc syringes to mix and apply the proseal. Seemed to work well and was not too messy).

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Sep 20, 2021 Right wing build up - (2.5 hours)

Category: Wings

Riveted inspection tab rings and remainder of fuel tank supports. Turned wing right side up and made initial fit of fuel tank.

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Sep 19, 2021 Right Wing Build-Up - (4.3 hours)

Category: Wings

Removed clecos from TE and last 5 rows of skin holes. Deburred TE skin and rear spar where it was match drilled. Vacuumed chips out of wing. Clecoed wing skin and finished riveting skin field rivets and TE row of -42 rivets. Prepped inspection holes tab rings for riveting. Drilled out and replaced a few 'oops' rivets that were not set level to skin.

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Sep 17, 2021 Right wing build up - (5.6 hours)

Category: Wings

Bottom skin, right wing.. Completed riveting stringers. Completed riveting LE flush rivets. Riveted rib rivets (1/2 complete). Match drilled bottom skin to rear spar. Still need to deburr.

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Sep 16, 2021 Right Wing Build-Up - (5 hours) Category: Wings

Clecoed LE and first 5 rows of rivets as well as tank supports. Skin was not sitting flush with spar, so I removed all the clecoes to reposition skin for LE fit and clearance around hinge arms on TE. Re-clecoed skin, stringers and fuel tank supports. Riveted half of stringers and middle 10 rivets on LE. Will continue riveting tomorrow.

Sep 15, 2021 Right Wing Build-Up - (2.5 hours)

Category: Wings

Removed clecoes from LE. Deburred skin and LE of spar. Countersunk LE of spar and dimpled LE of skin with 120 degree dies for c/s rivets.
Vacuumed inside of wing of shavings.

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Sep 14, 2021 Right Wing Build-Up - (3.5 hours)

Category: Wings

Trimmed/enlarged one aileron hinge cutout. Clecoed tank supports. Rechecked wing for twist. OK. Clecoed leading edge of bottom skin from LE to first stringer.
Match drilled LE of bottom skin to spar. #30. Clecoed all holes. Ready to dimple skin and c/s spar.

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Sep 13, 2021 Right wing build up - (3.5 hours)

Category: Wings

Trimmed stringers to length and clearanced aft stringer for truss clearance. Rechecked for twist. Clamped wing in jig. Clecoed inspection rings. Clecoed stringers to check fit. Clecoed skin for initial fit. Need to widen one slot for an aileron hinge arm.

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Sep 12, 2021 Right Wing Build-Up - (2 hours)

Category: Wings

Moved right wing to cradle. Placed bottom skin on worktable. Cleaned printing off and formed LE with delrin block. Placed wing on worktable in jig. Leveled wing to remove twist and placed bottom skin on wing for initial fit.

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Sep 11, 2021 Right Wing Build-Up - (2.5 hours)

Category: Wings

Completed riveting of top skin, gap seals and tank supports. Ready to flip and work on bottom skin.

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Sep 10, 2021 Right Wing Build-Up - (4.5 hours)

Category: Wings

Removed gap seals and deburred and cleaned gap seals, skin and rear spar. Modified gap seals, cutting the pieces out from below the aileron and flap actuator arms. Clecoed entire skin and began riveting from front to rear, one row at a time. Got about half the wing completed. Riveted forward fuel tank supports

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Sep 09, 2021 Right Wing Build-Up - (4.1 hours)

Category: Wings

Riveted top skin stringers. Riveted 3 of 4 tank supports. Riveted first 3 rows of skin rivets. Trimmed and fit gap seal. Aligned with top skin so it's parallel. Ready to match drill next session.

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Sep 08, 2021 Right Wing Build-Up - (3 hours) Category: Wings

Riveted flush rivets on LE of top skin to front spar. Clecoed top skin back to second stringer. Trimmed gap seals.

Sep 07, 2021 Right Wing Build-Up - (4.5 hours)

Category: Wings

Cleaned and deburring LE holes in skin and front spar. Dimpled and countersunk scrap pieces to set rivet squeezer and micro stop. Dimpled LE of top skin and counter sunk LE of front spar. Clecoed wing and pulled 3 rivets in middle to check fit. OK to finish riveting LE.

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Sep 05, 2021 Right Wing Build-Up - (4.5 hours)

Category: Wings

Completed install of serated grommets on ribs 1 and 2. Glued with superglue. Checked wing for twist and racking and verified root and tip were equal angles. Clamped wing. Laid stringers in position. Clecoed top skin and match drilled all holes in skin to front spar. Sanded long surface scratch in skin near LE.

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Sep 02, 2021 Right wing build up - (3.0 hours)

Category: Wings

Secured wire bundle with lacing cord. Moved wing to cradle and put top skin on worktable. Cleaned bottom side with MEK.
Trimmed stringers to length and deburred. Placed wing back on worktable and laid top skin in place. Secured with a few clecos for fitting and alignment of wing.

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Sep 01, 2021 Right Wing Build-Up - (1.5 hours) Category: Wings

Replaced one rib rivet. Ran ground wires for nav/strobe light and landing light. After wires are tied and secured, wing is ready for top skin.

Aug 31, 2021 Right Wing Build-Up - (5 hours)

Category: Wings

Torqued and safety wired bellcrank mount bolts. Safety wired aileron cable and flap teleflex cable in place. Riveted front and rear ribs flanges to spars. Ran wires for landing light and nav/strobe light.

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Aug 30, 2021 Right Wing Build-Up - (4.5 hours)

Category: Wings

Bolted rear mount of wing truss. Riveted hinges, bellcrank doublers to ribs. Clecoed ribs to spars. Initially squared and leveled spars. Bolted flap and aileron bellcranks in place. Need to final torque and safety bolts on bellcranks.

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Aug 29, 2021 Right Wing Build-Up - (4 hours)

Category: Wings

Right Wing. Installed main truss to front spar. Cleaned front and rear spars w/ MEK. Laid out ribs in order (they were previously fluted). Clecoed aileron and flap hinges, bellcrank supports and rear attach angles. Match-drilled hinges to ribs. Next is to remove clecoes and deburr.

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Aug 28, 2021 Right Wing Build-Up - (1.7 hours)

Category: Wings

Verified proseal setup around fuel cap. Removed wing from worktable to wing stand. Setup worktables for right wing spars. Collected truss and mounting hardware. (Front and rear spar on right wing were previously prepped with doublers and spar attach fittings installed. Also, I previously drilled and mounted the strut attach fittings and mounted them to the truss).

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Aug 26, 2021 Left Wing Build-Up - (4.5 hours)

Category: Wings

I installed the fuel tank in the left wing. I connected the fuel line to the rear pickup fitting prior to install. Riveted root rib including the AN3-5A bolt on the top hole of the rear flange. I installed the fuel sight gauge with hose clamps provided. Finally, I applied proseal around cap assembly to form fillet as written in the plans. Left wing construction is complete except for wing tip install. I've decided to wait for Aerosport to offer their new carbon fiber wingtip to make final decision on which tip to install.

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Aug 25, 2021 Left Wing Build-Up - (2.0 hours)

Category: Wings

Removed screws in cap and reinstalled (one by one) with Fuel Lube thread sealant. Blew up balloon and attached to rear fuel fitting for pressure testing. Sprayed soapy water on fittings- no leaks noted and it appeared to hold pressure after about 2 hrs. Drilled out fuel vent fitting.

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Aug 23, 2021 Left Wing Build-Up - (1.4 hours)

Category: Wings

Prepped fuel cap, installed inner ring and tank support. Applied Proseal to underside of outer cap and fastened with final screws. Will let setup overnight.

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Aug 18, 2021 Left Wing Build-Up - (1.5 hours) Category: Wings

Vacuumed tank. Mixed test mix of Proseal using syringes. Drilled out 2 bad rivets in fuel tank supports.

Aug 16, 2021 Left Wing Build-Up - (1.5 hours) Category: Wings

Measured and drilled left fuel tank for gas cap flange. Tightened fuel sight gauge and fuel pickup fittings- used blue Loctite.
Drying overnight before installing remainder of those fittings.

Aug 15, 2021 Left Wing Build-Up - (2.6 hours)

Category: Wings

Measured and drilled required holes for tank fittings left wing fuel tank. Cut cap opening with 3" hole saw (not a fly cutter). Fished fittings in tank with safety wire as suggested in the plans and RANS video on same subject.

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Aug 14, 2021 Left Wing Build-Up - (3 hours) Category: Wings

Flipped wing over onto bottom skin. Removed tank. Slid para cord under fuel tank supports and reinserted tank. Made wood dowel locator for sight gauges and plate for drilling fuel cap opening. Temp installed root rib (very difficult to insert under tank support ends- took a lot of time to fit properly). Tank is ready to mark and drill for cap and sight gauges.

Aug 12, 2021 Left Wing Build-Up - (2.2 hours) Category: Wings

Pre-assembled fuel tank fittings for both fuel tanks. Made drill guide for filler cap hole drilling.

Aug 11, 2021 Left Wing Build-Up - (2.5 hours)

Category: Wings

Completed bottom skin riveting of fuel tank supports, installed tinnerman nuts on inspection rings and temp installed inspection plates. Fit fuel tank for first time.

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Aug 10, 2021 Left Wing Build-Up - (3.5 hours)

Category: Wings

Completed riveting bottom skin and stringers on left wing. Still need to rivet fuel tank supports to bottom skin.

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Aug 07, 2021 Left Wing Build-Up - (2.3 hours)

Category: Wings

Trimmed pitot mast opening in skin. Reattached pitot with screws and blue thread lock. Riveted leading edge flush rivets and front portions of 3 ribs.

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Aug 06, 2021 Left Wing Build-Up - (2.5 hours)

Category: Wings

Hooked up pitot and AOA lines with quick-connect fittings. Made all electrical connections on pitot heat controller box. Secured wires. Mounted pitot tube mast to wing (still needs some final trimming of opening). Clecoed leading edge (middle, out) and half of ribs.

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Aug 05, 2021 Left Wing Build-Up - (2 hours) Category: Wings

Moved wing from cradle to workbench. Fit lower skin. Clecoed inspection cover rings. Fit pitot mast and OAT probe. Prepped wing for riveting.

Aug 04, 2021 Wing Build-Up - (2 hours) Category: Wings

Deburred all holes drilled in front and rear spars and skins. Finished deburring and smoothing holes cut for pitot and OAT probe. Primed pitot mast with self etching primer. Drilled out and replaced 2 bad rivets on 2 ribs at forward spar attach flanges.

Aug 03, 2021 Wing Build-Up - (2.5 hours)

Category: Wings

Cut out opening for pitot mast and OAT probe in left wing, lower wing skin. Used spoon and light hammer dolly to remove smile crease in skin. Sanded and deburred rear spar holes. Vacuumed shavings out of wing.

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Aug 02, 2021 Wing Build-Up - (0.7 hour) Category: Wings

With 2 other helpers, placed left wing in wing stand with bottom skin clecoed in place. Removed clecos, removed skin and placed skin on work table to drill out pitot mast and OAT probe holes in previously marked locations.

Jul 20, 2021 Wing Build-Up - (4.5 hours)

Category: Wings

Match drilled TE of bottom skin on left wing. Dimpled LE of bottom skin. Counter sunk LE of front spar. Dimpled skin for pitot mast mount.

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Jul 19, 2021 Wing Build-Up - (3 hours) Category: Wings

Prepped bottom wing skin for match drilling LE. Checked that wing was square. Match drilled and clecoed skin LE to front spar. Drilled with #31 and reamed to #30 size.

Jul 17, 2021 Wing Build-Up - (2 hours)

Category: Wings

Match drilled pitot mast mounting reinforcing plate from inside of bottom wing skin. Located and marked opening for pitot mast and OAT probe for drilling after skin removal and deburring.

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Jul 15, 2021 Wing Build-Up - (2.5 hours)

Category: Wings

Initial fit of bottom wing skin on left wing. Checked for clearance on hinges and tie down ring. Clecoed every other hole in ribs.

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Jul 13, 2021 Wing Build-Up - (4 hours)

Category: Wings

Terminated wires for pitot heat. Routed wires and secured in wing. Mounted pitot heat control box on fwd. inspection plate

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Jul 10, 2021 Wing Build-Up - (2.5 hours)

Category: Wings

Fabricated mounting bracket for OAT probe. Riveted to rib. Test mounted probe. Finished fab for pitot tube mount bracket- drilled for reinforcing rivets thru skin.
Riveted bracket to rib test fit pitot mast to mount. (Note; I ended up removing this mounting bracket as I countersunk the bracket too deep and the rivets would not hold-- Experimental!!)

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Jul 12, 2021 Wing Build-Up - (2.5 hours)

Category: Wings

Fabricated new pitot mount bracket from .032 aluminum. Mounted pitot mast and added 4 rivet hole locations to rivet to skin when installed. (I drilled/countersunk original .062 bracket too deep- rivets would not set).

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Jul 08, 2021 Wing Build-Up - (2.5 hours) Category: Wings

Fabricated pitot mounting bracket and test fit.

Jul 06, 2021 Wing Build-Up - (2 hours) Category: Wings

Trimmed and deburred bottom skin stringers. Filed out to clear truss.

Jul 05, 2021 Wing Build-Up - (1 hour) Category: Wings

Riveted nutplates to Gretz pitot mount. Refined plan for mounting angle to rib.

Jul 03, 2021 Wing Build-Up - (1 hour) Category: Wings

Worked on pitot tube mounting plate; trimmed plate to fit pitot tube mount.

Jun 30, 2021 Wing Build-Up - (5.5 hours)

Category: Wings

Match drilled gap seals left wing. Removed gap seals, deburred seals, skin and spar. Clecoed gap seals back on. Trimmed seal at pushrod exits. Finished riveting wing skin at ribs, then riveted gap seals. Completed riveting of top fuel tank supports

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Jul 01, 2021 Wing Build-Up - (2 hours)

Category: Wings

Built wing jig fixtures to support wing while working on bottom side. Flipped wing over and leveled in fixture. Test fit Garmin GAP 26 Pitot mounting plate and planned install location.

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Jun 28, 2021 Wing Build-Up - (2.6 hours)

Category: Wings

Finished riveting stringers on left wing, top skin. Trimmed tags off gap seals and trimmed ends flush. Clecoed gap seals and set top parallel with top of wing skin.
Ready to match drill.

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Jun 27, 2021 Wing Build-Up - (0.5 hour) Category: Wings

Continued riveting stringers on left wing, top skin.

Jun 26, 2021 Wing Build-Up - (0.7 hour) Category: Wings

Riveted stringers on left wing, top skin

Jun 19, 2021 Wing Build-Up - (0.7 hour) Category: Wings

Continued riveting left wing top skin. Short session today.

Jun 16, 2021 Wing buildup - (5.7 hours)

Category: Wings

Removed all top skin clecos. Re drilled countersink depth. Eased skin leading edge again to restore curve. Clecoed skin. Pulled leading edge c/s rivets. Clecoed tank supports.

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Jun 15, 2021 Wing Build-Up - (4 hours) Category: Wings

Left wing. Clecoed stringers and fuel tank supports to upper skin. Dimpled leading edge of skin and countersunk spar to prep for flush riveting.

Jun 14, 2021 Wing Build-Up - (5 hours)

Category: Wings

Temp cleco fuel tank supports in top skin for left wing. Fit skin to leading edge. Numerous adjustments to clecos. Finally clecoed entire wing. Skin then fit very well to leading edge joggle. Dave M and Ron L helped pull skin down while I match drilled spar with #30 drill. Clecoed every hole in leading edge. Tested scrap leading edge piece for proper countersink depth and dimpling of skin to prep for final dimpling and countersinking.

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Jun 13, 2021 Wing Build-Up - (2.5 hours) Category: Wings

Prepped top wing skins. Cleaned, inspected and eased leading edge with delrin tool. Brought wing back to shop leveled on work table.
Started to cleco top skin on left wing.

Jun 12, 2021 Wing Build-Up - (1 hour)

Category: Wings

Moved left wing to cradle. Brought wing top skins into shop to clean and prep for forming leading edges.

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Jun 10, 2021 Wing Build-Up - (1.5 hours) Category: Wings

Temp installed Garmin GTP59 OAT probe in approx mounting location in left wing. Ran wires back to wing root. Tied up wire bundle runs with lacing cord.

Jun 09, 2021 Wing Build-Up - (2.5 hours) Category: Wings

Installed 12ga wire for pitot heat power and ground as well as 22ga wire for pitot heat controller discrete channel. Leveled wing build table to prep for top skin install.

Jun 08, 2021 Wing Build-Up - (2.2 hours) Category: Wings

Removed top skin from wing and rearrange crate for wing skin storage. Installed wires for nav/strobe light, landing light and pitot heat. Temporarily terminated until permanent install.

Jun 07, 2021 Wing Build-Up - (2.5 hours)

Category: Wings

Cut top skin stringers to length, deburred and place on top ribs. Test fit top skin on wing structure. Modified shipping crate with supports for wing and fuselage skin storage.

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Jun 04, 2021 Wing Build-Up - (3.8 hours)

Category: Wings

Installed serrated liner in ribs 1-3. Installed aileron cables and flap teleflex cable. Safety wired both cables. Installed rubber grommets for wire runs. Ran pitot and AOA tubing to pitot location. Riveted ribs to front and rear spars. Left out middle rivets in rear spar that will be used for gap seals.

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Jun 02, 2021 Wing Build-Up - (4.2 hours)

Category: Wings

Left wing aileron and flap bellcrank assemblies installed and safety wired. Front and rear truss mount bolts torqued and safety wired. Clecoed tie down ring at Rib 7.

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Jun 01, 2021 Wing Build-Up - (6 hours)

Category: Wings

Match drilled aileron and flap hinge arms for attachment to ribs and for bellcrank mounting. Fabbed rear rib attach brackets. Riveted hinge arms and bellcrank doubler plates to ribs. Bolted truss to front and rear spars (not torqued yet). Clecoed ribs to front and rear spars.

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May 31, 2021 Wing Build-Up - (3 hours) Category: Wings

Fluted ribs for both wings to attempt to straighten. Pressed in bronze bushings for aileron and flap hinges for both wings. (reamed hinge openings to .3115 and pressed bushings with vice. Worked fine). Clecoed hinges, flap teleflex cable support and aileron/flap bellcrank mounts to ribs. Cut out and cleaned up rib rear reinforcing brackets.

May 30, 2021 Wing Build-Up - (1.5 hours) Category: Wings

Organized wing parts. Numbered ribs according to plans. Began fluting ribs.

May 29, 2021 Wing Build-Up - (4.2 hours)

Category: Wings

Reamed mounting holes in wing trusses. Match drilled and reamed lift strut mount brackets and match drilled to wing trusses. Sorted parts for wing rib build-up.

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May 28, 2021 Wing Build-Up - (5.7 hours)

Category: Wings

Completed fitting of left wing landing light assembly. Marked right wing leading edge with template and cut out leading edge for landing light opening. Filed and cleaned up opening. Measured and drilled for landing light attach brackets. Riveted landing light brackets. Drilled out front spars attach fittings. Drilled hole thru leading edge to rear face of spar with 1/4" bit, then drilled up-size to 23/64"; then reamed with .374 (.001) undersize reamer. 3/8" mounting bolt fit perfectly. Cleaned up holes and temp installed 3/8" mounting bolt and hardware.

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May 27, 2021 Spars - (4.1 hours)

Category: Wings

Deburred and riveted doublers to rear spar. Match drilled truss attachment bolt holes. Laid out and cut landing light opening in left wing. Not for the faint of heart!

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May 26, 2021 Spars - (5.2 hours)

Category: Wings

Completed assembly of aileron and flap bellcrank assemblies. Re-safetied one aileron bellcrank bolt. Filed front spar forward spar attach doubler to fit contour inside of leading edge. Laid out all doublers. Riveted doublers onto both front spars and marked rear spars for doubler layout.

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May 25, 2021 Wing Build-Up - (5.5 hours) Category: Wings

Cleaned and deburred wing spars. Washed and degreased spars. Assembled aileron bellcrank assembly- pressed in bearings, assembled and safety wired. Pressed in bearings in flap bellcranks and started assembly. Laid out spar doublers in prep for assembly.

May 23, 2021 Elevator - (4.3 hours)

Category: Empennage

Completed riveting elevator tips. Fit trim servo motor and trim tab. Stored elevator. Gathered wing spars, bellcranks and wing ribs to begin left wing construction.

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May 23, 2021 Elevator - (2.2 hours) Category: Empennage

Sealed tip rib with silicone for future epoxy/lead balancing. Riveted bottom of tip skins to tip frame.

May 21, 2021 Elevator - (4.5 hours)

Category: Empennage

Finished riveting top elevator skins. Riveted tip rib to elevator. Clecoed and fit tip skins. Match drilled tip skin.

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May 19, 2021 Elevator - (5.5 hours)

Category: Empennage

Took bottom skin off frame to re-bend the leading edge. It did not match up to allow riveting after the initial 90 deg. bend. Bent both top and bottom leading edges slightly more and then re-clecoed the skins back on the frame. This allowed leading edges to match up for riveting. Riveted the bottom skin and leading edge. Cut bend tabs off tip skins and cleaned up. Riveted bulkhead rib to tip rib. Match drilled tip rib to elevator end ribs.

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May 18, 2021 Elevator - (4.7 hours) Category: Empennage

Trimmed hinges on trim tab for better fit. Match drilled trailing edge skins. Took skins off to deburr and clean. Clecoed skins back on and began to rivet.

May 18, 2021 Elevator - (2.3 hours) Category: Empennage

Riveted hinges to elevator and trim tab. Test mounted Ray Allen Trim motor and tested operation. All OK.

May 16, 2021 Elevator - (6.7 hours)

Category: Empennage

Match drilled and clecoed trim tab. Riveted trim tab together. Clecoed bottom skin on elevator. Aligned and measured trim tab hinges. Drilled and clecoed to elevator and tab.

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May 14, 2021 Elevator - (3 hours)

Category: Empennage

Formed leading edge of elevator skins using PVC pipe per the plans. Laid out and riveted ribs to trim tab and clecoed skin in prep for riveting. Cut hinge stock in prep for measuring and mounting hinges on trim tab/elevator.

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May 15, 2021 Elevator - (1 hour) Category: Empennage

Clecoed top elevator skin to prep for trim tab fitting.

May 12, 2021 Elevator - (4 hours) Category: Empennage

Deburred ribs and spars; riveted elevator horn; clecoed and riiveted frame; test fit tab to elevator.

May 08, 2021 Elevator - (0.9 hour)

Category: Empennage

Drilled out screw holes in trim servo ribs and installed nut plates for servo mounting. Up-drilled servo mounting holes to #20 per plans. Test mounted servo for fit and tested operation with 9V battery. Works normally.

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May 08, 2021 Elevator - (1.8 hours)

Category: Empennage

Riveted horizontal stab tips. Initial assembly of elevator frame to check for fit and do inventory of parts needed for elevator and trim tab.

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May 04, 2021 Horizontal Stabilizer - (0.6 hour) Category: Empennage

Final drilled horizontal tips for install. Glued 1/8" backing washers prior to riveting.

May 03, 2021 Horizontal Stabilizer - (5.7 hours)

Category: Empennage

Final riveting both skins of horizontal stab. Fit and drilled stab tips for riveting.

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May 03, 2021 Horizontal Stabilizer - (2.6 hours)

Category: Empennage

Dimpled nose ribs with pop rivet puller. Had to grind die to modify so it fit into flange of nose rib for dimpling. Clecoed top and bottom skins and started to rivet.

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Apr 30, 2021 Horizontal Stabilizer - (5.6 hours)

Category: Empennage

Riveted Ribs and nose ribs to front and rear spar, dimpled skins in center section and countersunk front spar on top and bottom flange in center section.

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Apr 28, 2021 Horizontal Stabilizer - (5.4 hours)

Category: Empennage

Completed disassembly of spars, doublers and ribs. Finished deburring spar match drilled holes. Riveted doublers to front and rear spars. Riveted inspection plate reinforcement rings in place. Test dimpled scrap aluminum and set countersink depth in prep for riveting center section of skins with countersunk rivets.

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Apr 27, 2021 Horizontal Stabilizer - (4.3 hours) Category: Empennage

Removed all clecos and deburred spar holes that were match drilled. Drilled stab tips for install. Clecoed inspection covers reinforcement rings.

Apr 26, 2021 Horizontal Stabilizer - (3.5 hours)

Category: Empennage

Completed match drilling and up-sizing skin to spar holes to #30. Trimmed bend tabs from skin. Trial fit Aerosport tip fairings-- which are a prefect fit with no trimming required.

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Apr 25, 2021 Horizontal Stabilizer - (2.2 hours) Category: Empennage

Match drilled bottom skin front and rear spar flanges.

Apr 24, 2021 Horizontal Stabilizer - (1.6 hours)

Category: Empennage

Clecoed bottom skin. Ready for match drilling spars.

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Apr 23, 2021 Horizontal Stabilizer - (1.5 hours) Category: Empennage

Clecoed top skin in place.

Apr 23, 2021 Horizontal Stabilizer - (5.6 hours)

Category: Empennage

Cleaned and deburred spars, doublers and ribs. Clecoed assembly today. Fit skins initially.

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Apr 21, 2021 Horizontal Stabilizer - (3.5 hours) Category: Empennage

Modified Wing cradle to hold vertical stab and rudder temporarily. Leveled and clamped my 6ft and 8ft work table together for the horizontal stab assembly.
Inventoried and laid out all parts for the horizontal stab and aligned spars and doublers in correct orientation.

Apr 19, 2021 Vertical Stab Top Fairing and Pull Handle - (2.2 hours)

Category: Empennage

Completed assembly and install of tail pull handle. Test fit rudder and Vertical Stab tip fairing.

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Apr 18, 2021 Vertical Stab Top Fairing and Pull Handle - (2.6 hours) Category: Empennage

Finish fabricating tail pull handle per the plans. Used JB weld to glue the handle doublers together. Started fitting top tail cone fairing. Fairing is aftermarket from Aerosport Products which fit perfectly the first time- no trimming required.

Apr 17, 2021 Vertical Stab and Pull Handle - (3.2 hours)

Category: Empennage

Completed riveting of side skins and leading edge skins. Began install of pull handle. Drilled out initial 3/4" hole in skins.

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Apr 16, 2021 Vertical Stab - (3.2 hours)

Category: Empennage

Continued riveting skins. Completed left side skin and leading edge skin.

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Apr 15, 2021 Vertical Stab - (2.5 hours) Category: Empennage

Removed clecos, cleaned and deburred the match-drilled holes in the front spar, leading edge skin and side skins. Clecoed skins back on, aligned surface and began pulling rivets on side skin.

Apr 14, 2021 Vertical Stab - (3.5 hours)

Category: Empennage

Leveled and secured assembly. Removed leading edge skin and edge-formed the trailing edges for overlap of side skins. Clecoed back in place and match drilled leading edge skin, side skins and front spar. Clecoed in place. Initial fitment of tail pull handle doubler plates.

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Apr 13, 2021 Vertical Stab - (2 hours)

Category: Empennage

Fit side and leading edge skins to frame.

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Apr 12, 2021 Vertical Stab - (5.5 hours)

Category: Empennage

Inventoried all vertical stab parts. Flutted ribs to straighten, then clecoed all parts together. Pressed in bushings in rudder hinges. Riveted front spar doublers first, then the rear spar doublers, then all the ribs. Finally, riveted hinges to rear spar taking care to install an AN3 bolts in the hinges prior to riveting. Reamed hinges bushings to 3/16".

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Apr 09, 2021 Parts Board - (3 hours)

Category: Workshop

Constructed parts board from large crate top. Used 2 Harbor Freight furniture dollies for the base. Cheaper than buying 8 castors and wood for a frame. Screwed boards directly to dollies on bottom. Used screws from the crate!

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Mar 19, 2021 Rudder Build - (4.5 hours)

Category: Empennage

Attended RANS Rudder Build Workshop. Constructed Rudder under Eddie's supervision. Great class. Great people at RANS.

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Apr 08, 2021 Organizing - (2.5 hours) Category: Workshop

Organized hardware on plywood top from large crate. Plan to mount on casters. Stapled hardware bags to plywood.

Apr 07, 2021 Inventory - (5 hours)

Category: Inventory

Completed kit inventory today. Grateful to my wife who helped out throughout the inventory process.

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Apr 06, 2021 Inventory - (3 hours)

Category: Inventory

Continued kit inventory. Opened large, VERY heavy hardware box to begin categorizing all the hardware and fittings.

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Apr 05, 2021 Inventory - (6 hours)

Category: Inventory

Broke down crates and continued inventory of kit contents. Carefully removed end panel of large crate, as suggested by other builders, to allow removal of large aluminum sheets for wings and fuselage. It's critical to remove all the 2x2 framing from the end of the large crate so you can slide the large sheets out.

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Apr 03, 2021 Delivery Day - (2 hours)

Category: Kit Delivery

Kit delivered 347 days after ordering. Great delivery by Stewart Transport. Kits are loaded on at the factory and not offloaded until they come to you. Trailer has custom overhead track and boom system that was designed originally for Factory Five Racing kit car crate delivery. Driver was great about calling and keeping me updated with his schedule so I knew exactly when he would arrive. Very smooth offload of kits.

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