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Project: mwiseW10 -
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Builder Name:	Matthew Wise -

Project:	Wittman - Tailwind - VIEW REPORTS
Total Hours:	1044
Total Flight Time:
Total Expense:	$12601.00
Start/Last Date:	Nov 20, 2021 - No Finish Date
Engine:	Lycoming O-320 B2B

Friendly URL:	https://eaabuilderslog.org?s=mwiseW10

Home or Last Project Picture

May 10, 2024 Tail feathers - (8 hours)

Category: Tail Feathers

Sand blasted horizontal stabs, elevators, and rudder using a harbor freight gravity feed blast gun and fine black diamond coal slag. Primered with Stits epoxy primer.

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May 05, 2024 Rudder - (6 hours)

Category: Controls

Fabricated forward rudder cable ends, tacked cable fairleads into fuse. Using a combination of 3/8 tubing and store bought fairleads. Decided to use 3/8 tubing in some areas for clearance issues on seat belt attach points. The plan is to insert plastic tubing into the 3/8 tubing to alleviate metal to metal contact.

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Apr 30, 2024 Seat belt attach - (3 hours)

Category: Fuselage

Fabricated and tacked the seat belt attach points.

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Apr 24, 2024 Rudder - (6 hours)

Category: Tail Feathers

Had to buy more piper channel to finish up rudder. Completed ribs, brazed them into structure. Welded stainless steel trailing edge to rudder. Made fabric retention plates for bottom of rudder for a nicer fabric transition around the bottom rudder hinge.

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Apr 11, 2024 Wings - (3 hours)

Category: Wings

Cut holes in bottom of wing plywood to accommodate main spar strut fittings. Finished fabricating main spar strut fittings from 1 1/4 x 1/4 inch thick 2024 t3. Bolted strut fittings to main spars in preparation for wing strut fabrication.

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Apr 07, 2024 Wings - (6 hours)

Category: Wings

Fabricated side plates for each wing fitting and tacked to fuselage with wings in place to minimize movement of metal. Heat formed rear side plates to conform to rear spar carry thru, tacked.

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Apr 04, 2024 Wings - (4 hours)

Category: Wings

Positioned wings up against fuselage, leveled wings and fuse, set correct incidence, and tacked wing fittings to fuselage. Some have interference problems between flap torque tube and upper longeron. I have been keeping an eye on this from the beginnings of laying out the fuselage. Happy to find out that with 0 deg wing incidence, I have 3/8 inch clearance between flap tube and upper longeron.

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Mar 28, 2024 Wings - (4 hours)

Category: Wings

Made fuselage wing fittings to mate with wing attach fittings.

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Mar 22, 2024 Workshop - (4 hours)

Category: Workshop

Made hangers suspended from ceiling to suspend wings for wing mounting.

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Mar 17, 2024 Workshop - (2 hours)

Category: Workshop

Put the wheels back on the bird and wheeled outside to get some sunlight. Rearranged workshop to prep for wing mounting.

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Mar 15, 2024 Expenses Category: Research

Total expenses so far as of Mar 15, 2024:

Airframe: $11625
Welding supplies: $544
Miscellaneous: $431

Mar 12, 2024 Vertical fin - (8 hours)

Category: Tail Feathers

Trimmed and bent top fin rib, brazed in fin ribs. Made rudder top rib and tacked into place. Ran out of channel material, have to order more to finish rudder.

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Mar 07, 2024 Vertical fin - (3 hours)

Category: Tail Feathers

Made patterns for and bent/trimmed middle vertical fin rib.

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Mar 06, 2024 Tailwheel - (6 hours)

Category: Landing Gear

Drilled “RV” tailwheel spring and receiver tube for a 5/16 mounting bolt. Final welded receiver tube into bottom of fuse. Welded nut and .063 washer onto top of receiver tube.

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Mar 05, 2024 Rudder - (6 hours)

Category: Tail Feathers

Made rudder horn out of .100 4130 a bit different from plans. Added additional holes at rear of rudder horn to accommodate a single pushrod or dual springs for Tailwheel steering. Welded horn to 7/8 rudder spar. Flattened and formed bottom rib of rudder from 1/2 inch x .028 4130. Welded to rudder spar. Fitted Tailwheel spring receiver tube, 1 inch x .058, to bottom of fuse.

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Feb 26, 2024 Elevator pushrod - (8 hours)

Category: Controls

Finalized length of elevator pushrod, spliced 5/8 tube to 3/4 pushrod at aft end to allow more clearance on horizontal stab spar. Final welded pushrod. Added support structure for pushrod bushing at midpoint of pushrod. Welded in bushing.

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Feb 23, 2024 Elevator - (8 hours)

Category: Tail Feathers

Fabricated elevator ribs from piper channel. Brazed in all ribs to elevator spar. Welded trailing edge material to ribs using tig machine.

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Feb 13, 2024 Elevator - (8 hours)

Category: Tail Feathers

Fabricated and welded inboard elevator structure. Bent trailing edge material from 26 gauge stainless on friends brake.

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Feb 10, 2024 Elevator - (8 hours)

Category: Tail Feathers

Fabricated elevator horns from 7/8 x .065 square tubing per recommendation from builders manual. Located horn on elevator spars such that a right angle is made between horns and elevator pushrod. Determined length of pushrod and tacked for future welding to get the required elevator throw of 25 deg down and 30 deg up. Fiddled with this quite a bit trying to get control stick neutral with elevator at 0 deg and still get required throw. Had to settle for control stick to be leaning back 2 deg at elevator neutral to get required throw/range of elevator.

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Feb 08, 2024 Elevator - (8 hours)

Category: Tail Feathers

Fabricated and welded elevator counter balances.

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Feb 02, 2024 Vertical fin - (4 hours)

Category: Tail Feathers

Formed and tacked vertical fin ribs to base of fin.

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Feb 01, 2024 Vertical fin - (8 hours)

Category: Tail Feathers

Fabricated and welded vertical fin structure.

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Jan 31, 2024 Rudder - (8 hours)

Category: Tail Feathers

Located and Welded upper rudder hinge bushing onto tail post. Fabricated and welded lower rudder hinge. Cut and fit, welded tail spring support tube .

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Jan 25, 2024 Structure - (6 hours)

Category: Fuselage

Cut and trimmed rear fuse diagonals to complete fuse structure. Tacked and welded into position. Welded in seat support tubes.

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Jan 23, 2024 Structure - (7 hours)

Category: Fuselage

Tacked top of fin tube to tail post to use as alignment fixture. Drilled and bushed bottom of tail post for bottom rudder hinge. Tacked and final welded tail post to fuselage structure.

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Jan 02, 2024 Seats - (3 hours)

Category: Fuselage

Welded forward seat supports and final welded elevator swivel

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Jan 01, 2024 Seats - (8 hours)

Category: Fuselage

Jigged up and tacked seats frames together per tailwind times article, with minor adjustments to address potential clearance issues with aileron pushrod linkage.

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Dec 31, 2023 Vertical Fin - (2 hours)

Category: Tail Feathers

Prepped tail post for vertical fin, reducing from 1 1/4 to 3/4.

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Dec 20, 2023 Structure - (1 hour)

Category: Fuselage

Cut and fit diagonal member at aft part of tail, deconflicting interference with elevator pushrod.

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Dec 19, 2023 Elevator pushrod - (6 hours)

Category: Controls

Mocked up elevator pushrod and control horn to work out travel throws and clearance issues. Had to remake the swivel on the end of the control stick pushrod to elevate the elevator pushrod to correct an interference problem on a bottom diagonal member and the h stab spar. Now have required 30 deg up elevator and 25 deg down elevator without interference.

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Dec 17, 2023 Horizontal stab - (2 hours)

Category: Tail Feathers

Drilled holes at leading edge attach point plate. First top hole represents 0 deg of incidence of the h stab. Each subsequent hole downward drilled on 9/32 centers, which yielded 0.83 deg of negative incidence for each hole.

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Dec 11, 2023 Horizontal stab - (3 hours) Category: Tail Feathers

Final welded all joints of H stab to include doubler on leading edge attach point.

Dec 04, 2023 Horizontal stab - (3 hours) Category: Tail Feathers

Welded frame of h stab while still attached to fuselage. Some areas need final welded that could not be accessed without removing h stab, saved for later date. Started mocking up elevator horn and elevator pushrod to see what clearance issues I may have as this has been a trouble area.

Dec 01, 2023 Horizontal stab - (5 hours)

Category: Tail Feathers

Finished brazing all channel ribs to frame. Tacked elevator hinges to trailing edge of h stab.

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Nov 30, 2023 Horizontal stab - (3 hours)

Category: Tail Feathers

Made a jig to fabricate elevator hinges. Used .016 aluminum spacer to account for fabric thickness. Welded 4 hinges per plans.

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Nov 29, 2023 Horizontal stab - (5 hours)

Category: Tail Feathers

Tacked tab to leading edge of h stab, drilled first hole for 0 degree of incidence. This tab will be used to secure the h stab to fuselage at appropriate angle of incidence, determined after flight testing. Flipped fuselage over and tacked in lower h stab ribs.

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Nov 22, 2023 Horizontal Stab - (5 hours)

Category: Tail Feathers

Used tig welder to tack ribs to fore and aft frame, then brazed channel ribs main h stab spar for upper ribs.

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Nov 20, 2023 Horizontal stab - (20 hours)

Category: Tail Feathers

Clamped angle aluminum under H stab to hold rigid and ensure no twist. Added wood blocks between trailing edge and h stab spar to ensure straightness as the elevator will hinge on this tube. Made patterns for upper ribs. Inboard ribs are 3/8 x .035 tubes and are welded to frame, all other ribs are piper u channel, .020 thickness and brazed to frame to minimize distortion. Tried a few methods to bend piper channel and best method for me was to put a tight fit wood cap strip inside channel and bent using arbor from drill press for bending pressure. Drill press vice applied slight pressure on outside of piper channel to prevent sides of channel from buckling. Picture for reference.

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Nov 11, 2023 Horizontal Stab - (6 hours)

Category: Tail Feathers

Formed basic structure of horizontal stab

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Oct 31, 2023 Horizontal stab spar - (2 hours)

Category: Tail Feathers

After welding the horizontal stab spar to fuse, the ends curled up due to contraction. Used oxy acetylene torch to heat welded joints and straightened spar. Spar is now perfectly straight, square, and level to airframe.

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Oct 26, 2023 Horizontal stabilizer spar - (4 hours)

Category: Tail Feathers

Formed ends of outer horizontal stabilizer spar tubes and final welded.

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Oct 21, 2023 Horizontal stab spar - (5 hours)

Category: Tail Feathers

Fabricated horizontal stabilizer inner spar with reinforcement held in place with one rosette weld, ovaled tube to shape in Bridgeport 6 inch vice. Welded tube into airframe.

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Oct 18, 2023 Flap torque tube - (6 hours)

Category: Controls

Fabricated flap torque tube arms and tacked to torque tube. Final welded flap torque tube bearings and adjusted for freedom of movement.

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Oct 15, 2023 Fuselage - (6 hours)

Category: Fuselage

Put fuse back into rotisserie, final welded master brake cylinder support tube, control stick bearing plates, flap torque tube bearing plates, flap quadrant, and rudder pedal return spring tabs.

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Oct 14, 2023 H stab adjuster plate - (2 hours)

Category: Tail Feathers

Tacked to airframe the horizontal stab adjuster plate. Made flush with side of fuse per plans.

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Oct 13, 2023 Flap torque tube - (8 hours)

Category: Controls

Fabricated and welded flap torque tube, fabricated removable bearings for tube. Tacked bearing plates and bearings.

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Oct 08, 2023 Flap and aileron horns - (4 hours)

Category: Controls

Fabricated flap and aileron horns. Used 1/8 inch end mill in milling machine to cut slots in clamps.

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Oct 02, 2023 Flap quadrant - (10 hours)

Category: Controls

Fabricated flap handle and flap quadrant. Fit to airframe. Used guidance in Jim Stanton builders manual to make flap handle removable. Took many iterations to make flap handle drag free on the curved quadrant.

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Sep 23, 2023 Aileron bellcranks - (3 hours)

Category: Controls

Fabricated and tacked aileron bellcranks

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Sep 18, 2023 Control stick - (20 hours)

Category: Controls

Control stick fabrication. Being made to be removable from the airframe.

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Sep 09, 2023 Ailerons - (3 hours)

Category: Controls

Made new vice jaws to flatten tubing ends. This idea was pulled from an older eaa book. The idea is to give the tube a nice transition after flattening as opposed to flattening in a vice and leaving a crease in the tube end. Aileron bellcrank tubes and flap control tubes call for flattened ends.

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Sep 08, 2023 Rudder pedals - (20 hours)

Category: Controls

Installed rudder pedal torque tubes/rudder pedals and brake master cylinder support tube. Pedals were made to be removable.

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Aug 29, 2023 Landing gear - (8 hours)

Category: Landing Gear

Jiggled airframe back up in 3 point attitude to drill upper hole in landing gear receivers with correct toe-in. Airplane on wheels! Final numbers were approx 3/32 toe-in, just over 7/16 positive camber, and 8.25 inch sweep of wheels behind firewall.

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Aug 11, 2023 Landing gear - (8 hours)

Category: Landing Gear

Fine tuned geometry of brake mounting flanges/brake calipers. Drilled gear leg axles per plans for single bolt to hold brake flanges. Welded brake mounting flanges.

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Jul 09, 2023 Engine - (8 hours)

Category: Engine

It was time to disassemble this lycoming o-320 b2b to determine what I had before making an engine mount for the airframe. This is a narrow deck, conical mount obtained without any history or logbooks. A local engine builder pointed out several outdated parts due to its age and we discussed a full blown overhaul. Sent out crankshaft, cam and rods to aircraft specialties to start.

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Jul 03, 2023 Landing gear - (3 hours)

Category: Landing Gear

Final welded landing gear mount as much as possible while attached to fuselage then removed to final weld areas not assessable while attached.

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Jun 30, 2023 Landing gear - (6 hours)

Category: Landing Gear

Jigged the welded landing gear truss to firewall with gear legs in place. Cut and fit vertical tubes, tacked in place. Added tubes from upper bushings to top of receiver tubes, tacked in place.

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Jun 24, 2023 Landing gear - (6 hours)

Category: Landing Gear

Jigged up landing gear truss to fuselage for initial fit. Decided to final weld truss first before tacking to mounting bushings to minimize effects of weld shrinkage and prevent risk of bushings not mating up to firewall.

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Jun 21, 2023 Landing gear - (6 hours)

Category: Landing Gear

Cut and fit landing gear truss members in jig, tack welded with mig.

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Jun 14, 2023 Landing gear - (3 hours)

Category: Landing Gear

Jigged up landing gear legs on table. Made plywood template of location of bottom firewall bushings, bolted bushing in template and screwed template to table. Used long straight edge to locate bottom of gear legs and guidance from Clement mod plans for distance of bottom of gear legs to fuselage bottom, camber, etc.

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Jun 04, 2023 Landing gear - (6 hours)

Category: Landing Gear

Turned brake mounting flange on lathe, .090 4130. Added Dutchman type clamping features to landing gear receiver tubes to tighten down on landing gear legs at bottom of legs. Used 1/8 inch end mill to cut slot on receiver tubes. Receiver tubes complete.

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May 29, 2023 Landing gear - (3 hours)

Category: Landing Gear

Welded left and right landing gear receiver tubes.

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May 24, 2023 Landing gear - (3 hours)

Category: Landing Gear

Cutting pieces for landing gear receiver tubes. Making preps to put fuselage on wheels. Machined a stack of washers to insert into receiver tubes prior to welding to minimize distortion.

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May 17, 2023 Structure - (4 hours) Category: Fuselage

Welded in the permanent diagonal at firewall.

May 16, 2023 Structure - (6 hours)

Category: Fuselage

Welded engine mount bushings into the corners of the firewall.

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May 10, 2023 Structure - (10 hours)

Category: Fuselage

Welded in seat support tube and bottom door frame. Removed fuse from rotisserie and fashioned temporary seat to sit in fuse to determine location of rudder pedals. Cut piece of plywood and clamped to firewall to enable engine mount spools to be tacked into firewall corners and be in the same plane.

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May 01, 2023 Control stick - (6 hours)

Category: Controls

Made spools for engine mount, bushings for removable control stick base, elevator yoke, and forward end of control stick pushrod.

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Apr 16, 2023 Structure - (80 hours)

Category: Fuselage

Over the past month, worked on final welding all cluster joints in basic fuselage. Basic fuselage welding now complete. Trimmed lower longerons flush with firewall plane.

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Mar 17, 2023 Structure - (8 hours)

Category: Fuselage

Added X boards to fuselage structure to push out upper and lower longerons prior to final welding. The longerons were pushed out approximately 1/4 inch with these X boards. This is to ensure the fuselage longerons maintains their natural curves after welding is complete.

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Mar 06, 2023 Rudder pedals - (2 hours)

Category: Fuselage

Welded rudder cable control horns for rudder pedals.

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Mar 05, 2023 Structure - (4 hours)

Category: Fuselage

Added temporary box channel to tail with welded on bolt to enable fuselage structure to be rotated for final welding. Adapted previously made rotisserie to front of fuselage structure.

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Mar 04, 2023 Structure - (8 hours)

Category: Fuselage

Added seat back structure members. Tacked members into place.

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Mar 02, 2023 Structure - (8 hours)

Category: Fuselage

Added over head structure to fuselage. Tacked in members.

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Feb 26, 2023 Structure - (2 hours)

Category: Fuselage

Added windshield diagonal members. Tacked into place.

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Feb 25, 2023 Structure - (8 hours)

Category: Fuselage

Trimmed and fit more diagonals in aft fuselage, top and bottom. Tacked in members.

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Feb 19, 2023 Structure - (8 hours)

Category: Fuselage

Used turnbuckles and wire to square fuselage structure. Using plum bob from centerlines of top crossmembers to bottom crossmember and lined up on centerline of fuselage, established on tabletop. Started trimming diagonals back through tail.

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Feb 17, 2023 Structure - (6 hours)

Category: Fuselage

Trimmed and fit crossmembers back through tail section. Established center lines on cross members to be used later for squaring fuselage tail to center line on tabletop. Tach welded into position.

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Feb 16, 2023 Structure - (6 hours)

Category: Fuselage

Trimmed and fit diagonals in bottom forward fuse, and firewall crossmembers. Tach welded into position using miller mig welder.

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Feb 15, 2023 Structure - (3 hours)

Category: Fuselage

Fine tuned squareness of fuse in seat area. Used plum bob from center marks on upper cross members to centerline on table. Tach welded cross members in place.

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Feb 10, 2023 Structure - (8 hours)

Category: Fuselage

Made jig with blocks for rear spar carry though crossmember in accordance with Jim Clement mod drawing. Welded rear spar crossmember. Trimmed and fit bottom crossmembers at station 18 and 48. Trimmed and fit front and rear spar carry though crossmembers. Used cargo straps to square up fuselage sides before tach welding cross members in place.

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Feb 08, 2023 Fuselage sides - (4 hours)

Category: Fuselage

Stacked the fuselage sides on top of one another, clamped together then tach welded the tail at the very end. Laid out the profile of the bottom fuselage on tabletop, with centerline from firewall to tail. Stood up fuselage sides and blocked at bottom at stations 0, 18, and 48.

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Feb 07, 2023 Fuselage sides - (8 hours)

Category: Fuselage

Completed right side of fuse in table jig. Tach welded together using miller mig welder.

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Feb 05, 2023 Fuselage sides - (8 hours)

Category: Fuselage

Fitting structural members for right side of fuselage.

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Feb 04, 2023 Fuselage sides - (6 hours)

Category: Fuselage

Tach welded left fuse side and hung up on wall so right side could be started. Used tig welder for tachs. Very tedious and time consuming. Going to borrow a mig welder from friend to tach other side.

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Feb 03, 2023 Fuselage sides - (8 hours)

Category: Fuselage

Completed left side of fuselage. Ready for tach welding.

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Jan 28, 2023 Fuselage sides - (8 hours)

Category: Fuselage

Spliced and welded upper and lower longerons at proper spot. Started coping tubing and adding blocks to table to stabilize structural members.

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Jan 25, 2023 Fuselage sides - (6 hours)

Category: Fuselage

Longer material arrived. Putting bends in upper and lower longerons using tube bending mandrel. Heated tube with torch and bent using blocks and mandrel.

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Jan 23, 2023 Rudder pedals - (6 hours)

Category: Fuselage

Still waiting on longer material for longerons. Decided to start making rudder pedals. Ran out of material for brake pedal.

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Jan 17, 2023 Fuselage sides - (6 hours)

Category: Fuselage

Started mitering joints for fuselage side structure. Ordered longer tubing for longeron splices after realizing 8 ft lengths were not long enough for the w10 fuse, would require more splices that I wanted. Took a break from the fuselage sides to play on the metal lathe. Turned a piece for the flap handle.

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Jan 13, 2023 Layout - (3 hours)

Category: Fuselage

Completed tabletops for fuselage side layouts. 4x16 ft. Laid out entire fuselage side on tabletop in preparation for cutting tubes.

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Jan 09, 2023 Workbench - (3 hours)

Category: Fuselage

Made hangers for left and right wing to start prepping for fuselage construction. Moved work bench to other garage bay. Started building another 4x8 table to attach to current workbench.

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Jan 05, 2023 Left wing - (3 hours)

Category: Wings

Glued washers to wood structure where aileron and flap hinges will seat. Glued in corner blocks for wingtip ribs.

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Dec 30, 2022 Ailerons - (4 hours)

Category: Wings

Riveted right aileron skin to aileron spar.

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Dec 29, 2022 Ailerons - (6 hours)

Category: Wings

Primered aileron and flap hinges, and wing attach fittings. Riveted left aileron skin to spar using long bucking bar inside aileron spar. Flush rivets.

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Dec 27, 2022 Ailerons - (3 hours)

Category: Wings

Finished welding aileron counterweights, cut bushings to correct length. Preliminary balancing of the ailerons.

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Dec 20, 2022 Ailerons - (3 hours)

Category: Wings

Used metal brake at Gsell HVAC shop to put creases in aileron skins to lay flat on backside of aileron spar. Welded right aileron counterweight to bushing tube.

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Dec 19, 2022 Ailerons - (5 hours)

Category: Wings

Deburred all holes in aileron skins, countersunk holes in aileron spars to accept flush rivets. Dimpled holes in skins for flush rivets. Made end rib for right aileron and drilled. Welded wing attach fittings.

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Dec 18, 2022 Ailerons - (5 hours) Category: Wings

Continued shaping aileron counterweights on belt sander. Drilled holes in aileron spars for counterweight and bushing on flap end.

Dec 11, 2022 Ailerons - (5 hours)

Category: Wings

Trimmed left aileron skin for aileron hinge. Made wooden form block for end rib in aileron and flap. Formed end rib for left aileron. Bored holes for aileron counter weights on Bridgeport mill, rough cut out counterweights. Trimmed flap skin for left wing.

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