Project: RANS21RB   -  
            Listing for Category : fuselage
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Builder Name:Randall Brooks   -  
Project:   Rans - S-21 Outbound   -   VIEW REPORTS
Total Hours:1961
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

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 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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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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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 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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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 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 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 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 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 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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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 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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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 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 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 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.

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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.
 
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.
 
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 04, 2022     Rotator - (2 hours) Category: Fuselage
Continued to refine the fuselage mounts on the rotator to insure no binding.
 
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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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 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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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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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 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 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 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.

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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.
 
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.

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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.

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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.

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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 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 30, 2021     Boot cowl and firewall fitting - (2.5 hours)       Category: Fuselage
Initial fit of boot cowl sides, bottom and firewall.

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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.

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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.

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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.

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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.

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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 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.

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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.

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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.

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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.

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Nov 20, 2021     Window Support Angles - (2 hours)       Category: Fuselage
Fabricated and fit Left and Right Window Support angles. Ready to rivet.

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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.

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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.

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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.

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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.

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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.

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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.

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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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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.

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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.

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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.

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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.

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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.

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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.

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Oct 08, 2021     Fuselage Prep - (1 hour) Category: Fuselage
Located and sorted fuselage parts.
 


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