Apr 16, 2024     Panned in St. Paul - (1.6 hours) Category: Interior Finish

Measured the lengths required for each planned antenna.
Then went back to seat pan inserts; these were previosly installed by an earlier kit owner, but need additional trimming. However, I found that the seat pans now interfere with the forward cable tunnel closeouts. Now will REALLY need to trim the pans to fit. Manana, as an afternoon meeting with the DAAC...an airport planning group which I've agreed to join.

  Feb 22, 2024     Sloppy but Solid - (3.2 hours)       Category: Interior Finish

Unscrewed the aft cable cover....pita as the screws are low on the side and the curvature of the fuselage bottom makes it difficult to use a screw driver. One of my favorite tools is a small ratchet from Klein Bike Tools with interchangeable bits which works ok. Held my breathe and thankfully the re-resin of the one tab that had broken off was very strong...sloppy (needed to be more like chunky than creamy Pnut Butter consistency to avoid running) but will work fine. Particularly since it's under the aft cable tunnel cover. Safe and Strong is way more important than fragile and pretty.

Did a resort of the "to do's and redo's"...then started finishing up skipped steps. RTV'd the wing wiriring from the cannon plug mid-wing.

  Feb 21, 2024     Sewing - (3.9 hours)       Category: Interior Finish

Finally back to the aft cable covers' laminated tabs, where I'd inadvertently put the nutplates on one (left) side on outboard rather than inboard. While drilling out the 16 rivets, one of the tabs broke loose. So after finishing all the drilling and nutplate re-riveting, decided to route the cables aft to bulkhead A before re-laminating the one loose tab.

Jerry S brought one one of the Glasair gurus Dennis V visiting my hangar last week; he convinced me to use waxed cord to "sew" the cable routing rather than zip ties. Gave it a try, and learned another new skill. Grade was a "C" at best, but as this section will be hidden soon, a good place to try it out.

Mixed up a batch of resin, cabosil (to mayonaisse thickness) and then plus Q-cell to more of a peanut butter thickness. Wax release around the loose tab, and buttered both sides and screwed the cover in place. Will take a look tomorrow at the new bonding.

  Feb 20, 2024     Success - (4.05 hours)       Category: Interior Finish

Final trim for overhead console frame, and then paid attention to the "rotational position" of each standard jack. Managed to clear the width and the pipe as well.

Then moved on to reinstalling the nutplates for the aft cable covers. Due to narrowing of aft fuselage, not possible to get at the AN470 rivets with the squeezer tools. Finally realized I could use AN 1097 rivets (aka "woops" rivets) OR since not structural, use blind rivets..easy peasey.

I'm convinced the reason there is an experience qualifier to get an A&P is NOT that you know what is correct....rather you've had to work your way out of your mis-step or flat out mistakes.

  Feb 19, 2024     Compactor - (3 hours)       Category: Interior Finish

Trimmed (twice up and down) the overhead console frame to max the opening. Then drilled the new (replacement) metal insert plate for the overhead console, and assembled the six audio jacks. This is a very tight fit due to the central cage pipe that runs forward/aft. I now have clearance from the central pipe, but unfortunately the lateral dimension width fights the insert (wiring side) from going into the console. Ran out of time (family commitment) but will resume tomorrow.

  Feb 18, 2024     Misc - (2.5 hours) Category: Interior Finish

Drilled out the last (#8) nutplate installed on the aft cable cover brackets in error.
Then moved on to drilling the new metal insert for the overhead console...spent a crazy amount of time looking for the small air hose that connects to my drill. Found it hiding with the cables inside the plane. :( Then did the insert measuring and prep work, and called it an early day. No sense working on the plane when I'm still irritated/angry at not being able to find the hose.)

  Feb 16, 2024     Top to Bottom - (1.95 hours)       Category: Interior Finish

Overhead console now in place (top)....will insert metal insert with audio jacks tomorrow. Moved on to correcting a mistake from last September; one row (left side) of laminated brackets for the aft cable covers (fuselage bottom) ended up with the nutplates outboard instead of inboard. So drilling out the nutplate rivets to reinstall on the inboard side of the brackets.

  Feb 14, 2024     OH Console redux - (3.05 hours) Category: Interior Finish

Pulled down/uninstalled the overhead console frame. Dremeled the joggles for the metal inserts to allow for more room to move the jacks outboard on each side. Prepared for the new plate now enroute, marking up a paper template (will match drill the mounting holes). Reinstalled the OH console. Then routed the audio cables to the overhead and zip tied loosely (to be able to pull through for install work on new plate) per the manuals.

  Feb 13, 2024     The Builder Two-Step - (5.25 hours) Category: Interior Finish

Evidently my favorite dance....two steps forward, one (or more) steps back.
Completed the overhead console, sanded smooth several unused rivet holes, mounted the frame to the ceiling, and then screwed in the 6 jacks on the metal insert plate. Then to insert the plate in the frame. GROAN. The plate would not fit...the jacks are hitting the cage pipe right down the middle. Started to try and salvage the piece by "ovaling" the holes, but nah...too visible and just not good enough. Ordered a new insert plate from Zach Chase. Will redo the piece, moving the jack holes as far lateral in each side to minimize hitting the pipe in the middle. Morale of the story....think forward in "3D" as much as possible.

  Feb 12, 2024     Completed the Overhead Console - (3.1 hours) Category: Interior Finish

Cleaned off minor resin overflows on the console.
Tweaked the 2 gauge wire run locations from the aft battery to the firewall and zip tied in place.
Reinstalled the forward tunnel covers.
Mixed up a tiny batch of resin and mill fiber to plug several misdrilled rivet holes on the OH console...will sand smooth tomorrow.
Have not yet purchased an optional overhead "dome light" for the cabin. Easily installed at a later date; maybe after Airventure shopping.

  Feb 11, 2024     Quick stop to turn down heat - (1 hour) Category: Interior Finish

Left the hangar warmer than usual last night to help the resin cure. Stopped by to turn down heat, and also removed the braces. Rookie mistake, I had not used mold release on the screw heads, and resin got into the screw holes. Slow work to chip it out and unscrew the OH console....and also had to also unscrew/remove the metal inserts (Which let me brace the brackets "inside" the console while pressuring the screw heads to turn. Success!

  Feb 10, 2024     Resin batch - (0.75 hour)       Category: Interior Finish

Started the day in Lakeville where there is another Glastar under construction. Fun to look over a "sibling"....the Lakeville Glastar is a bit older...nice to find a big brother locally.
Then to my hangar and mixed a resin batch of promoted resin, cabosil and Qcell. More art than science for the mix (of course the resin and mekp are as precise as I can make it). But added the cabosil to "mayonaisse" texture, and the Qcell to "peanut butter".
Spread the mix on the six brackets, and mounted the overhead console in place with clamps in the front, and board/shims at the rear.

  Feb 09, 2024     Pre-lam of Overhead Console - (3.95 hours)       Category: Interior Finish

Sanded the fuselage ceiling at the bracket points of the overhead console. Then dug out the resin and mixture bags (Cabosil, mill fiber, Q cell); decided to run a test batch of resin, as the promoted resin I have is getting a little old (?). Mixed a batch of resin, mekp, mill fiber, and cabosil. Seemed to kick at 40 minutes or so. Will look at tomorrow and likely bond the console in place.

Also did some document reviews of the left aft baffle which has an unused flange. Found the answer in an old (2006) Glasair document on baffling...it needs a hose to the mechanical fuel pump cooling shroud.

  Feb 08, 2024     Still, still woring on OH Console - (2.45 hours) Category: Interior Finish

Fabricating the fiberglass brackets that will be glued into the ceiling with resin/cabosil/mill fiber blend. False start in visualization of how it all combines, and drilled in error several nutplate rivet holes in the wrong places. Corrected, minor cosmetic issue to catch at final qc. Will try and bond in tomorrow.

  Feb 07, 2024     O/H console - (3.05 hours) Category: Interior Finish

Drilled the aft metal insert holes after sanding/ensuring the connectors will fit without interfering with each other. The big even was a visit from 3 EAA Chapter 25 members who are ALSO building a Glastar. What fun. They are certainly welcome anytime to benefit from all my mistakes. Will go by their project this weekend.

(the yellow wire is for a yet-to-be purchased overhead light).

  Feb 06, 2024     Still on Audio in the O/H - (2.25 hours)       Category: Interior Finish

Working with the metal inserts for the overhead console. The audio connections (4 standard jacks) and the 2 bose lemo's need to squeeze into the narrow insert. Lots of measuring, fiberglass tweaking, etc.

  Feb 05, 2024     Overhead nutplates - (2.75 hours)       Category: Interior Finish

Next step installing the nutplates on the console. What a royal pia...they are #6's and -3 rivets. Tiny and/or shows how fat-fingered I am. Was able to use the pneumatic squeezer. Realized the headset jacks go in the narrow aft insert...will be a bit tight to fit in place. The forward insert will allow for future lights/vents/switches/whatever.

  Feb 03, 2024     Responding to Mayday - (2.05 hours) Category: Interior Finish

Went by Bob Collins RV12 build at South St. Paul airport; he'd put out a "mayday" for help getting his stabilizer mounted. Happy to respond, as I can't count the number of times I've asked for and received build help. Stopping enroute to my hangar, I realized I'd forgotten my glasses...back home and then to Bob's. BUT wonderfully, the other 4 "1st responders" had managed to align it enough that Bob could get it bolted in place just before I arrived. Must be a lesson there. But best of all, I met John Schmidt, the president of Chapter 25 who told me of another Glastar being built in Lakeville. GREAT contact.

Kept grinding away on the overhead console once I got back to KSTP.

  Feb 02, 2024     OH trimming and cut outs - (3.95 hours)       Category: Interior Finish

Finished trimming the overhead console. Then drilling and clecoing the metal insert plates. Then cutting out the fiberglass to receive the insert plates with only a Joggle remaining. Also (not included in time entry) visit from the new airport manager Blaine. Fellow alumni of the Moorhead area (next to Fargo)

  Feb 01, 2024     Overhead Console from Zach - (1.25 hours)       Category: Interior Finish

Can't finish installing the wiring until I install the overhead console for the headsets; I purchased an overhead console blank from Zach Chase, guru of gurus. But the O/H requires trimming and fitting to go in place. Up and down, trim, and up and down. Repeat.

Also did a quick trip to South St. Paul at lunchtime to help Bob Collins but he'd gone home already for the day. Returned back to my hangar and continued trimming.

  Oct 18, 2023     Interior Completed, AND, Instrument Panel opened - (4.75 hours)       Category: Interior Finish

Good traction today. Wrestled with completing the forward tunnel cover....it was all together, but lacking the screw on each side of the tunnel cover that keeps it centered between rudder pedals. Unfortunately I've already plumbed the boost pump, which is on top of a center tunnel plate and protrudes through the firwall. I was loathe to disassemble the pump and fuel line and firewall connection which seemed necessary to install the nutplates for those two screw. However, finally mounted them in place using monel blind-rivets. Got it done, but now the gaskets aren't very cosmetic. Oh well, not looking for perfect/show quality.

THEN the big news....finally time to unpack the instrument panel. It's beautiful! Then removed the pfd and mfd for safety and security. It will be easier to install the panel with a lighter load....maybe tomorrow.

  Oct 17, 2023     Fwd Tunnel Cover assembled - (1.5 hours)       Category: Interior Finish

Screwed it all together, less the 2 side locating screws.

  Oct 16, 2023     Completion of forward tunnel cover - (7.5 hours)       Category: Interior Finish

Finished trimming side panel bolt relief holes. Shimmed and ziptied the aft end of the FTC. Then ziptied the forwared end of the boost pump plate. Installed nutplates (drilled, dimpled, riveted).

  Oct 14, 2023     Nearing the Forward Tunnel Cover finish-line - (3.25 hours) Category: Interior Finish

Still working on Forward Tunnel Cover pieces. Drilled locator holes to anchor to cage tunnel. Drilled in face plate flanges. Drilled lower side panels to upper tunnel cover with #30, then updrilled to #19. Cut in tricycle gear collar bolt relief in the upper tunnel cover. Now only nutplates remain.

  Oct 13, 2023     Slow progress on forward tunnel cover - (3.6 hours) Category: Interior Finish

Just like the title says. Working on fitment of forward tunnel. It's a grind....glastar vs sportsman dimension deltas; original option did not expect nose wheel which has protruding collar bolt/nut; for whatever reason I'd used a 3/8th red-gasket shim for mounting the boost pump = higher mounting dimensions all around for the covers; did not use the 3-way fuel valve = different faceplate holes = custom cutout for on-off valve; etc, and so on. This is really quite the bespoke interior. But making progress. Also realized that the UPPER forward tunnel cover will need the missing holes on each side for the collar nut/bolt that was on the lower panel, but the upper overlaps enough to also require. Manana.

  Oct 11, 2023     Go slow to go fast - (3.5 hours)       Category: Interior Finish

Continuing to work on forward covers. Very cautious/slow as the interior finish and fitment will be visible. And the Glasair forward tunnel cover option assumed a three way fuel valve (ie on a Sportsman) which my Glastar will not use.....so trimming in a different position for the on/off fuel valve. Also used a 3/8th shim when I mounted the boost pump (again, a small delta dimension Glastar to Glasair), which means everything in the tunnel cover must have a 3/8th trim adjust. I plan to use a simple cover plate on the aft end of the cover to hide the unused valve holes.

  Oct 10, 2023     Forward Covers - (4.15 hours)       Category: Interior Finish

Making progress on the forward console covers. Actually fit and drilled both left and right side panels.
Also a bit of "repositioning" of several factory drilled holes, as the Glastar dimensions are a bit off from the Sportsman dimensions.
Now a bit of a mongrel...the latest sheetmetal came (only) in black, which was the latest "initiative" at Glasair before they pulled up stakes.

  Oct 09, 2023     Forward Cover Panels - (2.9 hours) Category: Interior Finish

Started woriking on the forward console (pulleys/fuel boost pump/etc) covers. Lots of measuring to drill holes to allow bolts to stick out. Measure many times, cut once.

  Sep 29, 2023     Battery Ground. Seat Pans - (3.05 hours)       Category: Interior Finish

Realized that while I'd ground off the paint for the battery to cage ground on the inside of the fittings, I'd missed doing so to the outside. Did so.

Removed the seats and frames, and then put the seat pans in and out many times for trimming. Making progress.

  Sep 28, 2023     Seats, Pans, Floorboards - (6.15 hours)       Category: Interior Finish

Installed left cover nutplates; not pretty but will suffice. Replaced ground tab cage attachment to longer bolt. Installed seat pans trimmed by a previous owner. (Some interference with fuel lines; revisit later). Installed seat frames and seat upholstery done by Billie of Northcountry Interiors.

Made airplane noises.

  Sep 27, 2023     Got you covered - (3.45 hours)       Category: Interior Finish

Finished sanding the left tabs for the aft cable cover. Drilled the nutplates. Tailored a small patch of BDM to relaminate the one tab which had the material pull away from the tab, and laminated it in place. Cleaned and permanently assembled the left and right cable covers. Was able to use the pneumatic squeezer for the end pairs, but had to go old-school to rivet the others. Definitely a RElearning process. Took me several rivets and two dings/slips to finally recall the technique, then easey-peasey.

  Sep 26, 2023     Aft Cover Snake - (2.5 hours)       Category: Interior Finish

Photo of rear cable cover tabs laminated in place also shows the control cables wrapped in paper for protection from cover work. Looks like a snake. :)

Reinstalled the LEFT cover half yesterday before laminating the tabs in place. Today they're fairly rigid, so drilled the #19 holes through the cover and the individual tabs. Trimmed same (dremel and diamond cutting wheel), and then began sanding them smooth. One tab had the laminate pull away....cut it out, and will relaminate one layer of BDM cloth for the one tab tomorrow.

Also did one trip to Wipaire for some missing bolts, and Menards for a fresh cutting wheel.

  Sep 25, 2023     Guilty of a Cover-Up - (5.35 hours) Category: Interior Finish

Removed the cage to belly attach bolt to sand the paint off the OUTSIDE of the cage attach brackets. (For surety of the electrical ground connection). Also located the battery ground cable attachment tab and fit it in place...will require a longer bolt...order an AN4-8A and upsize the AN4-6A. Put off the fabrication of the actual cable itself to focus on cover completion.

Then finished installing the nutplates on the right side of the aft cable cover.

Then reinstalled the LEFT side aft cable cover, taped in place and catalyzed resin. Set up faster than I wanted (a recurring theme) so had to do a second batch half way through the 8 tabs for the left side. Used more "peanut butter" of cabosil and Qcell to set the tabs in place. as there is less "level" area on the left compared to the right.

Reviewed the process steps for the FORWARD covers....missing some of the panels....I have only those for the O-360...and will need to fabricate or buy (?) the upper closure panels for the boost pump.

  Sep 23, 2023     Belly screws and Battery ground - (4.45 hours)       Category: Interior Finish

Realized that when I laminate the mounting tabs for the Left side of the aft cable cover, it will make accessing the aft center CAGE attach brackets awkward. And remembering that for an aft battery installation, I need to run a ground from the battery behind Bulkhead A to the cage. BUT as compared to newer kits, my cage does NOT have a convenient mounting tab on the cage; it's ok to terminate the ground at the lower cage attach tab BUT it's imperative to remove the brackets and remove all paint from the cage and bracket contact points.

This is a mandatory 2-person job...one outside and underneath the belly, and one inside at the center aft cage. Not hard, just need 2 people to do it.
My friend Owen is a trooper, and drove over from Flying Cloud within the hour of texting him!! What a great guy.
We made quick work of it relatively speaking. Also discovered a missing screw/nut, and a partially installed nut on the brackets, which was a factory step.

Also managed to install nutplates on half of the right cover tabs. Awkward to get at these nutplates with a pneumatic squeezer. Used 1097 (oops) rivets to avoid the countersinking.

  Sep 21, 2023     Laminated tabs - (2.8 hours)       Category: Interior Finish

Laminated one side/row of metal tabs to the fuselage belly yesterday. Removed the side cover today (the mold-release I applied worked just fine). Looks good, but of course now needs to be trimmed and drilled for nutplates.

Each metal tab gets "seated" in a 50/50 mix of Cagosil and Qcell, then two layers of BDM cloth that are wetted out with resin. Example shown loose.

  Sep 20, 2023     Too Warm - (2 hours) Category: Interior Finish

A key variable in working with resin is the ambient temperature. Surprise...it got to 80's in the hangar....translation, the resin "kicked" faster than yesterday. Only got through 6 tabs on the right side of the aft control cable cover before the catalyzed resin gelled. Did a fast 2nd batch on the fly, and ended up sloppy but adequate. Will see tomorrow how it all set up when I remove the defacto-form of the side cover. Then will put in place the Left cover and do it all over again. No photos...embarassingly sloppy. Oh well.

  Sep 19, 2023     Mr. Wizard - (1.6 hours)       Category: Interior Finish

Did a test run. Felt like Mr. Wizard, testing and relearning resin; taking promoted resin and catalyzing same. Then tried mixing Cagosil plus Qcell plus resin to make a "peanut butter" to seat the aluminum tabs in place. Also "wetted out" several pieces of DBM cloth. Will do the actual 16 tabs tomorrow.

  Sep 18, 2023     Study Hall - (3.5 hours) Category: Interior Finish

Sanded the fuselage in spots where the aluminum tabs will be laminated in place. Applied mold-release to the other half of the cover (left).

Then studied all my resin/lamination/technical information to come back up to speed on fiberglass.

  Sep 14, 2023     Pre-lamination of covers - (2 hours)       Category: Interior Finish

Getting covers ready to laminate aluminum tabs previously fabricated. Consulted with guru Zach Chase.

  Sep 13, 2023     Pre-lamination of aft cable cover tabs - (4.5 hours)       Category: Interior Finish

Riveted back tabs of aft cable cover. Cut 32 bi-directional fiberglass patches to laminate the brackets to the fuselage floor.
My new favorite tool is the Fisk rotary cutter wheel.
Aft cable cover in and out multiple times for trim/fitment/etc.

  Sep 11, 2023     Short day - (1 hour) Category: Interior Finish

Removed aft cable cover for fitment.

  Sep 08, 2023     Aft Cable Cover still... - (3.6 hours) Category: Interior Finish

Puzzled over the 4 tabs connecting to the Bulkhead A. #40 rivet holes on one side, #19 to a K1000-8 on the other side. Inadvertently used the #19 on both sides; upon review, simply redrill holes in the tabs....not structural. Then installed the nutplates behind the bulkhead; got the top two with the pneumatic squeezer, but had to dig out the rivet gun to get the other (lower) two. Thnk this means I'm multilingual or somesuch.

  Sep 07, 2023     Tab-fab and drilling - (3.55 hours) Category: Interior Finish

Took the 20 blanks I'd cut out for aft control cover tabs; Polished the edges, marked and bent. Then taped 4 on the rear bulkhead and drilled the tabs in place on the cover. Busy work, but not unpleasant.

  Sep 06, 2023     Aft Control Cable Cover Tabs - (2.55 hours)       Category: Interior Finish

Returning to interior finish work. Trimmed the bottom of the aft cover although not really much required. Then fabricated 20 mounting tabs from the scraps cut off from the length of the covers in a prior step. Seems like busy work to me.

  Aug 21, 2023     Aft Cable Cover - (2.5 hours)       Category: Interior Finish

Fabricated the aft cable covers. Simple/fun/lots of drilling an clecoing. Yet to trim the bottom edges to the curvature of the fuselage bottom.

  Aug 19, 2023     Completed the BH A Closeout - (4.75 hours) Category: Interior Finish

Close-out for bulkhead A. Now that the close-out was finished yesterday, onward to installing the nutplates on the bulkhead. Countersunk all rivets, figured out the best way to enter and lay back into the fuselage, and installed the nutplates. Biggest issues included discovering the thickness of the interior fuselage and bulkhead varies based on number of reinforcing fabric layers = different rivet length required. Also "flinched" at inopportune times, mis-setting rivets and nuplates. A real test to be drilling out bad rivets on your back and while basically in the dark. Who said homebuilding was fun? But got it done.

  Aug 18, 2023     Bulkead A Closeout - (4 hours)       Category: Interior Finish

Started on the interior while waiting for Glasair to return my exhaust pipes.The close out for the rear cabin (bulkhead A) starts with .020 flat stock, gets shaped, then drilled into the fuselage. Good progress. Simple step, but the gyrations to get into the rear area are challenging.

  Apr 14, 2023     Seats! - (2 hours)       Category: Interior Finish

Finished cutting aft edge of lower cowl.
Best news...10 months later my seats arrived! Yeahhhh!!

  May 24, 2022     Ordered North Country Seats & removed seat back frames - (2.1 hours)       Category: Interior Finish

Took apart the seat to rail assembly. Need to send the back frames to Billie in North Country Upholstery (Arlington, WA) to do the seats.