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.

  Apr 22, 2024     Clecoed Covers - (5 hours)       Category: Wings

Spent way too much time trying to buff the perfect circle(s) from the inspection holes I cut out to access the auxilliary fuel tanks in each wing. And trying for perfection of flush-fit covers. Not perfect, not even Airventure show quality...but enough!

  Apr 20, 2024     Double down-down - (3.6 hours)       Category: Wings

Tool maintenance to begin the day; pneumatic squeezer was binding up in terms of gap adjustment. Took apart the yoke and power ram, cleaned and lubricated. All now ok. Then installed K1000-8 nutplates on the doublers, screwed in the covers, and used as a "pass drill template". A bit of buffng wheel trimming tomorrow and it's done

  Apr 19, 2024     Double Down - (1.9 hours) Category: Wings

Installing the nutplates for the cover plates of the new inspection holes. The sequence is important....install the nutplates for the cover first...then screw the cover to the doubler, and then when you fit the insert cover in place, you can through drill the rivet holes for the doubler to the wing skin. Result = exact positioning. If you do it reversed like the manual calls out (through drill doubler to the wing skin first, then the cover nutplates), it's a SWAG/guess to position the cover.

  Apr 18, 2024     A holy day - (5.2 hours)       Category: Wings

Back to the new hole to buff out parts of the circle which are not perfectly circular! Used a die grinder, and improved the circular cutout dramatically.

BUT of course I then realized I'd cut the hole too small. I'd inadvertently used the inside dimension of the doubler, rather than the outside diameter of the cover plate, which inserts flush with the wing skin. Groan. Moved over to the left wing, and cut in that side inspection hole correctly.

Thankfully I'd cut the Right wing hole too small; but not intuitive on how to (over) drill a larger hole without a center index (since the cutoout falls off as you complete the initial circle.) Answer? Gorilla Tape to the rescue. Took a cutout circle, aligned it carefully, and used gorilla tape to secure it in place. That stuff is awesome. Cut in half of the larger circle, moved the tape, and completed the new cut. Easy-peasy.

Then used a die grinder with a small 3M buffing wheel to better round out the hole, and fit the plates in place.

  Apr 17, 2024     Nibbling - (5.05 hours) Category: Wings

I tried using an OLFA knife tool with the hole cutting accessory to scribe-cut an inspection hole just inboard of the aux tank. No joy. So borrowed a "nibbler" cutting tool from the chapter 25 group building their Glastar in Lakeville.Cut in the new inspection hole in the Right wing. Not great (learning curve with a new tool) but reasonable circle. Dress it up with the die cutter tomorrow.

  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.

  Apr 15, 2024     Study Hall - (1 hour) Category: Avionics

Spent most of the day at the hangar reviewing/researching/planning the antennas. (I'd agreed with Aerotronics to wait until the panel was in and the antennas known to decide on coax cable lenghts and routing.) Need antennas for Com #1, Com #2, GTX375 waas, G3X gps, Xm, transponder, etc.

  Apr 13, 2024     Not much - (1.1 hours) Category: Avionics

REviewing cable runs and antennas, Rerouted/reconnected the ELT remote audio warning at the panel.
Researching fuel senders.

  Apr 11, 2024     Owatanah - (1.35 hours) Category: Avionics

Took the morning off...joined with Jerry S and rode along to Owatanah to visit Dennis V's hangar, where his Sportsman was opened up as he finished his annual condition inspection. Man is his work impressive....not just following the manual like I do/did, but also lots of creative "experiemental" touches. And what is it about pilots and sportscars lurking in their hangars. And starting yet another project (starduster biplane in his case). Fun morning with EAA chapter 25 members.

Got back into my own hangar in time to install the other aux tank fuel level sender. Still unsure and thinking about what to do with the main tanks' fuel level senders. Currently have a square hole (flange) and round senders (flange), and round to square adaptors that have a center hole too small to fit the other two Stewart Warner senders I have. Rubrick's cube.

  Apr 10, 2024     Aux Tank Senders. Attenhut! - (2.7 hours)       Category: Avionics

Did a "incoming QC" inspection on the 4 fuel quantity level senders; all four are old style Stewart Warner 385 AB models made in 2018 and 2021. Metered each sender, and confirmed the range is from 31 ohms to 247 ohms. And did the service bulletin on these senders to insure the bend in the arm and the gap with the internal plastic body is sufficient. Then installed one in the left aux tank before running out of time. Will get to right tank tomorrow, with an open question still about using an adaptor for the two main tanks. Originally the Glastar had a mechanical gauge readout only in the wing root.

  Apr 09, 2024     Tubing research and completion - (3.55 hours)       Category: Avionics

While I basically completed the pitot/static lines last time, there was a nagging question as to whether my inherited lines were "Nylo-Seal" or "Nyla-Flow". The difference is in the connections, the Nylo connection is complete as-is, while the Nyla connection requires an insert. Spent time reviewing (ACS has detail pages), the Glastar manual, the parts I had already put in place, and the parts still in my inventory. Concluded I had Nyla and used the inserts before a final trim and tighten.

Next puzzle is the fuel quantity sender for the main fuel tank. Glasair in their wisdom did a running change from a circular flange to a (TWTT driven) square flange, which my existing senders do not fit. I purchased adapters from an owners site member 2 years ago...just can't recall the detail. The puzzle continues. Manana.

  Apr 04, 2024     G5 and GSU 25 Connection - (1.85 hours)       Category: Fuel System

Received a "care package" from Aerotronics with the pitot/static fittings/plumbing ready to go. Aerotronics is my all time favorite vendor....smart, responsive, always exceeding my expectations. Really! Got the G5 and the GSU 25 connected along with the rest of the plumbing. Now just have to run the pitot from the wing, and the static line to a tee from both static ports. Making progress/