May 15, 2024     Blips and Zen Plates - (4.25 hours)       Category: Fuselage

Looking over the left seat pan fitment again, spotted 2 "blips"....I'd run the red pitot line over a frame tube which left it vulnerable to being compressed by the seat pan; only when working on the seat pan did this become obvious. Easy fix, unscrewed at drain junction, re-ran the tube and reconnected. Then a 2nd blip...could not initially figure out why the seatpan no longer fit flush; eventually spotted a zip tie that I'd used to secure tube-wrap was inadvertently around a control cable underneath. Removed and replaced correctly.

Then on to fabricating metal plates to allow each floorboard to be split into two to allow ease of access. The plates will basically "splice" the two segments of each floorboard. 8 holes in each (2) plates, nutplates for each of the 16 holes = another 32 holes, so total 48 holes. Then best practice of up-drilling, #40 to #30 to #19 = 144 drilling operations. Some days it all becomes enjoyable zen, even if not very earthshaking.

  May 14, 2024     Rebending fuel line - (4.3 hours)       Category: Fuselage

Finished trimming left seat pan aft edge; now aligns perfectly with the right aft edge.
Then moved on/back to the fuel line from the union-tee to the on/off valve, which interferes with the left seat pan. Removed it, did various measurements, and rebent the line. Reinstalled and wrapped.

  May 13, 2024     Feet and Butts - (3.25 hours)       Category: Fuselage

Did some final inspection of the right floorboard; the screwholes are spot on, the slow pace paid dividends.
Then moved back to the previoiusly trimmed seat pans; they now interfere with the forward tunnel closeouts. Trimmed, installed, removed, trimmed multiple times. Almost completed; still some fuel line interference/rubbing which I will solve by rebending the fuel line.

  May 11, 2024     Carpentry completed - (4.35 hours)       Category: Fuselage

Got the screwholes drilled for the left and the right floorboards. The "upside-down roofing nail technique in the foamboard template" proved to be a winner. And after locating the holes and updrilling, placing the actual floorboard back in with the roofing nails still in place confirms the screws will go in as expected. One hole in each board required a bit of ovaling, but call it complete.

Now only need to paint; prior kit owner simply varnished his try, but I plan to use an ASA 161 gray. May or may not do so now, but will decide manana.
And some builders complete the floors but then slice each board laterally with a splice underneath, to make it possible to remove the floorboards without removing the seat pans and control sticks. Another aspect to consider tomorrow.

  May 10, 2024     4th time the charm - (1.4 hours)       Category: Fuselage

Finished the cutout of the right floorboard. Can now see where the variation in various prior components has been making this step drag out.

Now back to placing the screwholes which allow the nutplates to be accessed from above. I tried this before with the Glasair method (using paint on the hole tabs underneath and ended up with paint everywhere and no conclusive placements. Then tried the classic "trial and error" (not happy with the result). Puzzling over the way to do this, and finally used sharply pointed roofing nails pointing UP through each nutplate and protruding from the tabs; then carefully lowered the foamboard template and "spiked" each hole location. Easy-peasy. Will verify the locations next time with a clear lexan plate indexed to a side tunnel panel. This makes the 4th attempt to get it right. Then transfer the hole locations from the template to the plywood and drill!

  May 09, 2024     Right Floorboard - (3.6 hours) Category: Fuselage

What more can I say...I'm continuing to redo the redo on the right floorboard. making progress, but slowly. Measure, measure, measure.

  May 08, 2024     Tiny but sweet learning.... - (0.05 hour) Category: Fuselage

I've used a tape measure my entire life. Always noted the tab/hook at the end was not fixed in one place, it moves back and forth.
Finally had the "aha" that this was done on purpose. Why? Nobody could give me a good answer until today.
It move "out" when you want to measure away from the back side of the board. But when you want to measure from the "inside" of the board (think of a drawer's inside dimension), you should move it "in".
Why? The end of the tape tab has a thickness that will give you erroneous measurement unless you push or pull the tab accordingly.
Hey I don't claim to be curing cancer or performing brain surgery...in my (woodworking) defense, I'm an old sparkie.

  May 08, 2024     Penance and Lessons - (2.2 hours) Category: Fuselage

Only place I've found the 5-ply plywood in the cities is Rockler. (Not marine grade, but not just 2 or 3 ply either). Of course after driving yesterday half an hour to the south store, didn't buy any since they wouldn't rip it for me. Then another hour back to the north store, discovered someone had just come in and cleaned them out of the material. So then back in the car, and another half hour drive to their west store (we'd called ahead)and got the last 2 pieces (30" X 30") Must be a 1/4 inch plywood festival in town. Like I said...penance.

But then today I miscut the piece for the right side. Back in the car again, 20 miles south, and procured the piece.
Penance. (?)

Today in the hangar was more productive. Got the right template fitting, and made the initial sizing cuts to the plywood.

Lessons learned; don't hurry, don't work tired, don't keep working when you haven't eaten lunch, don't assume since your metal working skills are greatly improved that the same is true for your wood working skills (they aren't), really learn the other tools, and so on.
Paul Poberezny called it....educational. Roger that.

  May 07, 2024     Pride goeth before the fall... - (3 hours) Category: Fuselage

Finished a new template for the Right floorboard. On a roll! Was then too casual/in a hurry to finish...and cut the plywood short. :( Now a $25 piece of scrap/sawdust.

This is where it would be easy to say good enough/not structural. But can't tolerate such a visible rookie mistake and will do over. Manana.

  May 06, 2024     Left floorboard template and plywood done - (2.05 hours) Category: Fuselage

Got the template (1/4 inch foamboard) in place. Then cut the 5-ply wood to shape per the template. 3 minutes of sanding,and kerplop...the floorboard dropped in place. Small victories keep you going.

  May 04, 2024     Procurement - (2 hours) Category: Fuselage

One of the benefits for the old TWTT program in Arlington was their procurement function. You assumed all the parts were there, and "built on" everyday. But building a kit at the local airport means you do all your own purchasing/supply chain work. Needed "marine-grade 1/4 inch plywood" for the new floorboards. Easy one, right? Nope....just no local sources, be they one of the big boxes, or a marine supply house. Found one source in Boston who had a product from Europe, but the freight charge was prohiibitive. Finally chose a 5-ply available at Rockler; not the special glues, but I don't plan to leave these out in the rain. Procured the plywood, cut the outlines, and spenty more time on the template. (Time claimed does not include "sourcing" time.)

  May 03, 2024     New left floorboard template - (4 hours)       Category: Fuselage

Cut a totally new template for the left floorboard out of 1/4 inch foamboard, wish I'd tossed the inherited and warped ones right from the start. Also wrapped the diagonal in 3/8th inch clear plastic tube which levels the space with the welded tabs. Straightforward although still had a few slips...the photos show the blue tape putting back in some of the slips. Will now use this template to cut the plywood.

  May 02, 2024     Floorboards Category: Fuselage

Stiiiilllll working on the left floorboard. Tip from another builder to split a clear plastic hose to wrap the diagonal cage tube to equalize the level with the tabs. Tried working with the original clear lexan template I started with, but too brittle to be of much use....also too "floppy". Getting close, but have also decided to split each floorboard laterally to allow ease in future removals. Will also need to test whether the base of the control stick will interfere with the floorboard.

Plan: purchase new 5-ply plywood tomorrow, create new 1/4 inch foam template, and use a piece of clear glass to place the side holes one-by-one at a time. Enough time has been spent on the warped boards.

  May 01, 2024     Floorboards Forever - (4.5 hours) Category: Fuselage

Yet again working on the left floorboard. Seemingly infinite amount of measuring. Getting closer but no joy.
Rereading the assembly manual, I realize by context that the boards have to sit on top of the cage pipes, and not just the tabs as I previously concluded in error. In fact, the manual notes the accompanying drawinge overemphasizes the fitment detail. And the diagonal frame pipe under the floorboards is NOT level to the side pipes/tabs. But now clear what needs to be done. The existing inherited boards are indeed warped, too wide (for the space with the closeouts in place first), and were not cut long enough to give a good closeout under/aft of the rudder pedals.

  Apr 30, 2024     Floorboards continue still - (3.9 hours) Category: Fuselage

Got the right floorboard trimmed, in place, holes drilled, and actually screwed down. Not pretty. Will redo this one regardless. Also, the 3/8th length screws just do not have the reach..used 5/8th lengths. Then returned to trying to make the warped Left side floorboard work. Patience grasshopper.

I continue to try and get both left and right floorboards in place, even though quite chewed up with attempts to get the holes to line up...I will redo both, but want to have a good "template" when I do so.

  Apr 29, 2024     Floorboards Continue - (5 hours) Category: Fuselage

Started working again on the left floorboard. Lots of measuring. Then right floorboard again. Just not able to get them to fit in place and locate the holes in the underlying tabs. Frustrating. Also did a fair amount of (on-line) searching for local source of "marine-grade plywood". The existing floorboards I inherited are warped (commecial 3-ply wood). ALSO I realize that the existing floorboards were done before I did the forward cable closeouts = narrower width to work with between the closeout edge and the fuselage wall across.. No joy.

  Apr 27, 2024     Easy? Then it's wrong - (1.85 hours) Category: Fuselage

I was alll too happy the prior kit owner had fabricated the floorboards. Used the lexan template I arranged yesterday; drilled the attach holes, and installed the nutclips on the frame tabs. BUT holes/floorboard does not line up. And/or they line up, but 1/2 inch length screws do not reach the nutplates. Upon review I can see the error in the currently fabricated floorboards....the dimensions have the boards sittng on the frame pipes, rather than the tabs "inside" the pipes. Will now need to rework the floorboards inherited, or completly fab a new set. Will sleep on this and make a decision next Monday.

  Apr 26, 2024     Floorboard mounting - (3.7 hours)       Category: Fuselage

The 1/4 inch thick floorboards were completed by a previous kit owner; likely not the "marine grade" plywood mentioned in the manual, as the pilot's side floorboard is warping. (Will consider a redo later). Both floorboards mount to tabs underneath; the trick is locating those tabs and the holes already drilled in place by the factory. Hobby Lobby sells plastic laminate sheets, 2' X 3' for $4.00 each. Used the existing wooden floorboards as templates, cut out a laminate "floorboard", and then put it in place instead of the wooden piece. Easy to trace tabs and holes on the laminate, which now will be the template on top of the wood to drill the mounting holes.

  Jul 15, 2022     Firewall Template - (2.2 hours)       Category: Fuselage

Outlined the whiteboard, and spent time trimming the inside dimensions.
Will trace on the stainless steel sheet next time, and start the metal trimming.

  Jul 15, 2022     Christmas in July - (2.5 hours) Category: Fuselage

Received a box from Glasair, and spent the morning checking in the kits and items:
Oil Cooler and mounting; induction kit; FWF Hoses (lots of parts); mag cooling kit; cables for throttle, prop, mix; boost pump and mounting plate. Now in pretty good shape for when the engine shows up.

  Jul 13, 2022     Copilot Rudder Pedals and Rough version of firewall template - (3.2 hours)       Category: Fuselage

Simple is best relative to keeping the copilot rudder pedals vertical (without brakes). Used 2mm steel wire with plastic.

Whiteboard sourced for firewall template. Rough cut it, and taped. Will do internal trim tomorrow.

  Jun 23, 2022     triage - (5 hours) Category: Fuselage

Researched drilling out blind-rivets...the issue is that the methods are based on punching out the stem/mandril.... I do not want to do this as it will punch holes in my outer laminate fuselage. Got input from Glasair. finally decided to drill one more hole in the doubler and install another rivet for security. Basically the Glasair specified rivet is TOO long/tall. Went to an AAPQ-42 and that just fit. And next I'll "pot" the gap between the large head and the doubler plate that was the result of the original blind-riveting. Non-structural.

Worked on the fuel line segment that interferes with the flap cables.

  Jun 22, 2022     Seats and Static Port Drain - (1.2 hours)       Category: Fuselage

Considered seating color selection. Using North Country in Arlington WA to do the seats. Selected a non-leather fabric in gray.
Drilled and blind-riveted the pitot drain into the fuselage belly. Only after riveting did I realize the rivets specified were too LONG. Groan. Sleep on it.
Removed the fuel line fabricated by Dan K. that hits the flap cables. Will have to redo.
Hot & humid in the hangar...good day to quit early.

  Jan 24, 2022     Waterline leveling and Wings' repositioning - (2.9 hours)       Category: Fuselage

Moved right wing off the jig table to rolling stand. Asked the police outside the door to help move it. :) Then asked St. Paul Flight Center (Pete) to help me get the fuselage on the wing jig table to work on the main gear. Previously had been on Tailwheel gear, now going to put on Tricycle gear.

  Dec 01, 2021     Pivot interconnect - (4.9 hours) Category: Fuselage

Finally figured out the interconnect/how to shorten/adjust. Aileron travels are good.

  Nov 19, 2021     Nico pressing flap cables - (5 hours)       Category: Fuselage

Swaged the sleeves. Flap system works smoothly.
Photo shows clamps pre-noco-press.

  Nov 14, 2021     Flap cable attach tab - (2.2 hours) Category: Fuselage

Put in a new bench vise. Used to finish bending the fap cable attach points.

  Nov 13, 2021     Corrosion Treatment flap cable attachment tabs - (1.6 hours) Category: Fuselage

Used Aluma and Alodine for the tabs

  Nov 10, 2021     Flap cables - (1.7 hours) Category: Fuselage

Did the attachments to the control lever. #11 clevis

  Nov 09, 2021     Corrosion treatment of flap attach tabs - (1 hour) Category: Fuselage

Back from California last night. Treated attach tabs

  Nov 03, 2021     Cable Spaghetti - (2.2 hours) Category: Fuselage

Cleaned up the cable runs to minimize crossovers.

  Nov 02, 2021     Flap Cables and Corrosion Treating - (4.2 hours) Category: Fuselage

Fun day.....spliced the flap primary cables to lever both sides. Al clean and alodined MS turn barrels. Also corrosion treated the flap slot brackets.

  Nov 01, 2021     Flap deployment cables - (2.8 hours) Category: Fuselage

Routed the left and right flap deployment cables

  Oct 30, 2021     Tail shearweb - (4.1 hours) Category: Fuselage

Trimmed the shear web to fit without so much flex going in. Guest visitors...Chris & Bob (FCM) and Stephanie & Tom.
Started flap cable installation.

  Oct 21, 2021     Drain Holes - (1.2 hours) Category: Fuselage

Noted that already have drain access between bulkheads D, E. Inspection holes between D and C provide the same....no benefit to another hole per manual.

  Oct 19, 2021     Levelling - (1.5 hours) Category: Fuselage

Smart Tool battery replace, working to sandbag the fuselage for level to waterline for next steps.

  Oct 17, 2021     Aligning - (1 hour) Category: Fuselage

Working with Smart Tool...battery going dead.

  Aug 28, 2021     Continuing waterline work - (3.5 hours) Category: Fuselage

Continued analysis of waterline, aligning to neutral.

Drilled brace holes at both doors to install waterline angle bracket.

  Aug 27, 2021     Waterline! - (5 hours) Category: Fuselage

Aligning the fuselage and using digital level and also trying the old fashioned water-level.