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Project: Utah-Jay -
Listing for Category : fuselage

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Categories

Show All Entries - (285)
Boot Cowl - (17)
Workshop - (1)
Empennage - (2)
Fuselage - (69)
Firewall - (4)
Tail Feathers - (9)
Wings - (9)
Controls - (17)
Avionics - (35)
Lighting - (3)
Instrument Panel - (2)
Landing Gear - (16)
Engine - (30)
Propeller - (1)
Fuel System - (8)
Interior Finish - (8)
Paint / Decals - (8)
Inspection
Tools - (1)
Engine Cowl - (31)
Doors - (1)
Baffling - (12)
Cabin Air - (1)


Builder Name:	JAY TOWNSEND -

Project:	Companion - VIEW REPORTS
Total Hours:	1317.5
Total Flight Time:
Total Expense:	N/A
Start/Last Date:	Oct 21, 2021 - No Finish Date
Engine:	Barrow Lycoming O-360
Propeller:	Sensenich 82” GA
Panel:	Dynon

Friendly URL:	https://eaabuilderslog.org?s=Utah-Jay

Home or Last Project Picture

Feb 26, 2023 Data plate installation - (1 hour)

Category: Fuselage

Made backing for the data plate, glued it to the inside of the fabric under the left horizontal, drilled holes for data plate

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Feb 06, 2023 Sky Light - (2 hours) Category: Fuselage

Bolted down the left sky light

Jan 15, 2023 Installed screws on the right center and skylight overhead - (3 hours)

Category: Fuselage

Took hours to install about 25 screws. I used nylon washers, crush washer and acorn nuts

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Jan 12, 2023 Metal Center Overhead IN Placde - (2.5 hours)

Category: Fuselage

Installed (with clecos) the metal center overhead. All weatherstripped and fitted for final screws to be installed

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Jan 11, 2023 Installed Skylights - (4 hours)

Category: Fuselage

I applied weatherstripping on the three sides that fit into the channels, weatherstripping under outside section more for cushion than weather. Had to tap them in with a rubber mallet as the fit was very tight. I used I/16th” nylon washers under the glass and inside the channel to put upward pressure on the glass so the weatherstripping would press against the channel. They will bolted in when the center metal section is installed

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Jan 05, 2023 Reinforcement patch on handle area - (2 hours)

Category: Fuselage

Added reinforcement patch by using a 3” tape to bolster the durability of the handle area on both sides

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Jan 03, 2023 Door Windows and Skins - (5 hours)

Category: Fuselage

Finally finished upsizing the holes in the Lexan windows to 3/16”s, upsized the door skins to 11/64”s. Had to redo a door skin panel as I upsized the WRONG row of holes. Be careful and drill the correct holes.

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Dec 31, 2022 Upsizing window frame and glass holes - (2.5 hours)

Category: Fuselage

Upsized the holes in 4 stages on the window frames from 1/16th to 11/64th, upsized to 11/64th on both upper windows, need to go one more size up to 3/16th

Door skins will be next to match the frames for the #8 screws

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Dec 30, 2022 Window Framing - (6 hours)

Category: Fuselage

Measured all the window framing pieces, marked and punched the hole locations. Drilled holes 1/16”, will upsize tomorrow. Holes in the window will be oversized for the possible changes due to temperature variation. Lots of measuring and math to get the holes evenly spaces for each framing piece

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Dec 28, 2022 Door window frames - (3 hours)

Category: Fuselage

Used flat aluminum 1/16” to create a window frame to sandwich the window. Top swing up doors were fairly easy, bottom door was much more difficult with lots of angles. I did the top two and the bottom left door

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Dec 11, 2022 Windows - (7 hours)

Category: Fuselage

Yesterday I picked up a lower door to begin the framing process of securing the windows in place only to notice one was cracked. Lower doors have a difficult shape and this took a good 4 hours to fit a new one. Luckily I had leftover .125 glass

Then I sanded and sanded and then sanded some more, so all windows all have super smooth edges

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Dec 01, 2022 Inspection covers - (1.5 hours)

Category: Fuselage

Due to a less than idea fit, I redid the forward horizontal stabilizer inspection covers

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Nov 06, 2022 Seat Belt attach points - (1 hour)

Category: Fuselage

Had to tap drill the two outside seatbelt attach points and install helicoils for the AN4 bolt as it is not possible to do a pass through

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Nov 06, 2022 Seat Belt attach points - (1 hour)

Category: Fuselage

Had to tap drill the two outside seatbelt attach points and install helicoils for the AN4 bolt as it is not possible to do a pass through

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Nov 06, 2022 Covering is done - (9 hours)

Category: Fuselage

Finished all the seam tapes today. The top of the empennage to vertical to a lot of work, but that is not a surprise with the compound curves

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Nov 03, 2022 Left and Right side covering finished - (6.5 hours)

Category: Fuselage

Finalized the left and right sides which were troublesome due to a compound curve.

Cut the final piece and taped off the top for the glue lines

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Nov 02, 2022 Left side finished - (6 hours)

Category: Fuselage

Left side covering is finished, only thing left is taping the seams which will be all done at the very end

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Oct 31, 2022 Covering the Vertical Stabilizer - (7 hours)

Category: Fuselage

Finally finished the Vertical. I used separate pieces of fabric for both right and left sides to be able to get the fabric to lay down so I could rib stitch the lowest rib.

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Oct 27, 2022 Prepped for Left Side Covering - (3 hours)

Category: Fuselage

Static, AOA and Pitot lines were plumbed, ADSB and Transponder antennas were installed and hooked up to the coaxial cables

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Oct 21, 2022 Right side Fabric - (6 hours)

Category: Fuselage

Made a lot of progress today with tacking and shrinking. I got the window and both inspection holes cut out as well

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Oct 20, 2022 Cut both right and left fabric and attached left - (8 hours)

Category: Fuselage

Both right and left were cut to size and lined for glue. Right side fabric was glued as was the right side fuselage. Tacked the fabric on the side stringers

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Oct 19, 2022 Prep for covering - (4.5 hours)

Category: Fuselage

Riveted in the outer window frames and permanently set the inspection cover backing plates

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Oct 18, 2022 Inspection Covers - (1 hour)

Category: Fuselage

Made the backing and covers for the tail feather attachements, made the covers for the forward horizontal attach location

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Oct 18, 2022 Bottom Covering Complete - (15 hours)

Category: Fuselage

Two days and 15 hours later and the bottom of the fuselage is covered. It was pretty easy, I did need a second pair of hands for an hour or so moving the large fabric piece back and forth several times from the fuselage to the table

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Oct 17, 2022 Prepped for Covering - (2 hours)

Category: Fuselage

Attached 2x4's to the fuselage engine mount holes to be able to rotate for covering. Removed the gear (gear since covered). Inverted to start on the bottom

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Aug 23, 2022 Right side Cargo enclosure - (3 hours)

Category: Fuselage

Installed the right side cargo wall and started taping for the window installation.

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Aug 15, 2022 Left side cargo covering - (4 hours)

Category: Fuselage

I had planned to do both the left cargo wall and left window, but life got in the way. Left cargo wall is now in.

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Aug 12, 2022 Fitting of the skylights - (2.5 hours)

Category: Fuselage

I measured, measured, and measured, then…..

Yep today was skylight day. Right wide was perfect for width, but needed one trimming cut after the initial cut. Left side required two length trims, but both are fitted. It was surprisingly easier than I thought, I was expecting the worst with the compound curve.

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May 12, 2022 Wing Root Panel - (4 hours)

Category: Fuselage

Cardboard, scissors, sharpie and it was template time. They it was transferring to .025 sheet metal, then the cutouts and fitting.

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Apr 06, 2022 Floor boards and cargo area - (2 hours)

Category: Fuselage

Used Scotch Bright to remove scratches and prepare for the carbon fiber wrap. Also re-installed the underfoot floorboard as well the fuel selector. Also brought al the floor boards and cargo closeouts home in preparation for covering

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Apr 05, 2022 Middle section of the roof/sky light - (3 hours)

Category: Fuselage

Drilled the wholes for the GPS and Comm antennas in the metal center section of the roof over the seats. Used scotch bright to prepare the metal for paint/wrap. Upsized the drilled holes for final rivet size.

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Apr 04, 2022 Center roof section - (3 hours)

Category: Fuselage

Cut and fit the .040 2024 T3 middle section of the roof/skylight area. Taped and drilled then upsized the holes in the support rails. Measured to get the metal fit to have equal overhangs on both the right and left, then match drilled from the middle fore and aft alternating left and right to keep everything even

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Mar 28, 2022 Flap Cable Rub Block - (.5 hour)

Category: Fuselage

My left and right flap cables were rubbing on the upper longeron, so I installed rub blocks

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Mar 24, 2022 Right seat bottom webbing installed - (3 hours)

Category: Fuselage

Attached the right seat bottom webbing to the frame, started fitting the right seat bottom cushion

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Mar 23, 2022 Right Rear Window - (2.5 hours)

Category: Fuselage

Used the template to trace out, then rough cut and finally sanded and filed to fit into the window frame,

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Mar 22, 2022 Rear Windows - (1 hour)

Category: Fuselage

Finished the rear window template and transferred the outline to the “glass”

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Mar 22, 2022 Completed Cargo extension/box - (3 hours)

Category: Fuselage

Final fit and attached in 3 places

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Feb 20, 2022 Cargo Closeout and Baggage Door - (15 hours)

Category: Fuselage

Finished the cargo tube, it is all connected via nutplates to the cargo closeout. Cargo closeout baggage door fitted and attached

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Feb 12, 2022 Rear Windows - (3 hours)

Category: Fuselage

Drilled out the factory rivets of the window frames as they were on the wrong way. Drilled and match drilled the frames to the door former. Cut the angle to cover the window frame. Angle is only clamped in at this point

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Feb 12, 2022 Re-did the left side boot cowl - (2 hours)

Category: Fuselage

I was unhappy with the fit of the original, so I re-made the left side

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Feb 06, 2022 Right Lower Door Window - (2 hours)

Category: Fuselage

Cut and fitted the right window for the lower door. Also trimmed the front door skin to clear the boot cowl when fully open

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Feb 05, 2022 Rudder Pedal Spring - (.5 hour)

Category: Fuselage

Changed out the rudder pedal springs to a stronger spring

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Feb 05, 2022 Left Lower Door - (3 hours)

Category: Fuselage

Cut and fitted the acrylic for the lower door. Also trimmed the front of the door skin for clearance on the boot cowl when fully open

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Feb 03, 2022 Rudder Cables - (2 hours)

Category: Fuselage

Finished the cables connecting the rudder pedals to the rudder cable horn

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Jan 13, 2022 Upper and Lower Door - (7 hours)

Category: Fuselage

After an epic fail as cutting acrylic yesterday, today I managed to get the acrylic cut and fitted to the upper doors. I copied a friends BH and cut the skins on the lower doors for a much bigger window.

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Jan 11, 2022 Upper Side Stringer - (1 hour) Category: Fuselage

Fabricated an angle bend of sheet metal to attach the front of the upper side stringer to the rear door former

Jan 11, 2022 Skylight - (1.5 hours)

Category: Fuselage

Permanently riveted the skylight to the fuselage

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Jan 08, 2022 Golf Club cargo tube - (3.5 hours)

Category: Fuselage

I used kydex for the container, and 2024 T-3 for the base of the “tube” to hold it secure to the fuselage.

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Jan 08, 2022 Mouse Trap doors - (5 hours)

Category: Fuselage

Lots of trial and error fitting the piano hinges, took a few attempts to get each one correct. The actual trap doors each took two attempts to get the right fit.

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Jan 05, 2022 Upper Doors - (7.5 hours)

Category: Fuselage

Fitted, drilled and cleco'ed both right and left upper doors. Outside front and rear were cut/mitered to match the top and bottom. Drilling and match drilled to match the inside window brace.

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Jan 05, 2022 Upper D Category: Fuselage

Jan 03, 2022 Upper Door Window Frame - (3 hours)

Category: Fuselage

Cut and fit the frame that holds the acrylic window against the outer frame covering.

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Dec 28, 2021 Lower doors - (3 hours)

Category: Fuselage

Drilled and cut the patroller window on the right lower door as well as trimmed the top of the side skin at the front and back for both the right and the left doors so allow the doors to fully shut. Drilled the door latch holes in the door frame for both left and right doors.

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Dec 24, 2021 Lower door - (9.0 hours)

Category: Fuselage

Drilled holes in the door frame, match drilled in the skins, drilled and set the top angle for the door. Cut the hole for the patroller window and was then trimmed and all edges smoothed. I rolled the skin to fit on the window. Window frames were glued together and the acrylic was set into the frame

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Dec 22, 2021 Lower Door top fitting - (.5 hour)

Category: Fuselage

Cut aluminum angle to fit on top of the lower door

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Dec 22, 2021 Lower Door Windows - (6.5 hours)

Category: Fuselage

Cut frame for window/acrylic. Cut and fitted the acrylic to fit inside the frame, then cut and fitted the backing to hold the acrylic in the frame and to the door skin.

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Dec 16, 2021 Rear Window frames - (.5 hour)

Category: Fuselage

Re-installed the window frames and started to bend the supports to make a clean line to work with the covering.

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Dec 16, 2021 Door Skin - (3.5 hours)

Category: Fuselage

Mounted the skins on each door, this took some cutting and filing to get the proper clearance for the door hinges. Spent a good 2 hours exploring a way to have a patroller window in the door.

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Dec 15, 2021 Hung Doors and Windows - (1.5 hours)

Category: Fuselage

Had to ream the holes and then flatten one side of the pin head for clearance

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Dec 14, 2021 Sky Light and Window Former Painting - (2.5 hours)

Category: Fuselage

Had to drill out the rivets on the front window retainer to remove. Used two coats of etching primer and then two coats of black satin paint on the sky light and front window former.

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Dec 14, 2021 Stringers - (1.5 hours)

Category: Fuselage

Riveted in the left and right side stringers, all stringers are now riveted in. Required some upsized drilling to fit the pull rivets.

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Dec 12, 2021 Ski/Golf Club compartment - (1 hour)

Category: Fuselage

Got started on the specialized baggage compartment for skis and golf clubs. I am using Kydex and forming it with a heat gun.

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Dec 02, 2021 Sky Light and windshield attach area

Category: Fuselage

Had to drill out the temporary rivets for the skylight frame and the windshield attach at the front. Everything was then drilled to size, match drilled and the skylight frame cleco'ed back in. I did rivet in the top windshield attach area, but it will be coming back out as I decided to paint all of these pieces black

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Dec 02, 2021 Door Formers - (5 hours)

Category: Fuselage

Drilled out the temporary rivets and removed the door formers. Drilled the tabs and them match drilled the tab holes to the formers. Countersunk the holes for flush riveting. Installed the formers with clecos and then riveted them in. There were some tight fits for the bucking bar, but I managed to get them all in. There were some that were drilled out and re-riveted to make them perfectly flush

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Dec 02, 2021 Bottom Stringers - (4 hours)

Category: Fuselage

The bottom stringers require bending so as to allow the fabric to transition to the tail without an edge.

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Dec 02, 2021 Stringers Pt. 1 - (4 hours)

Category: Fuselage

Rough cut to lengths then fit and trimmed to perfect length. Lots of filing and sanding of the ends to make sure nothing has a chart edge. No holes drilled yet, just all fitting and then clamping in place

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Dec 02, 2021 Seat Adjustment mechanism - (5 hours)

Category: Fuselage

This was a long arduous process of drilling the holes for the seat adjustment. There was a lot of measuring and re-measuring in the seat frame bottoms. The actuating arm which holds the seats required a bit of fitting as well

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Dec 02, 2021 Window - (3 hours)

Category: Fuselage

The window frames came nicely drilled for the attach points, Drilled the tabs and cleco'ed in the windows temporarily. October 1

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Dec 02, 2021 Delivery - (5 hours)

Category: Fuselage

Taking delivery required a few people out offload things and get everything Stowe din the hanger. Fuselage was put on sawhorses to protect the bottom stringer attach points. Several hours were spent removing plastic and bubble wrap

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