Jan 07, 2024     Remove shipping tape/paper from plexiglass - (1.5 hours) Category: Fuselage

Worked on removing tape and residue from exterior of windows. Got all of tape and paper removed from outside. Still need to go back and clean up tape residue.

  Jul 27, 2023     Seat install, sump tank - (4 hours) Category: Fuselage

7-27-23 Sebastian – 4 hours (Last day)
Drill and attach seat rails to seat buckets.
Drill and attach rudder pedal assembly to forward bulkhead.
Fabricate mounting tabs for sump tank.
*(2) bid x (2) each side. Approximately 6”
*Trace shape of tank on bench to locate tabs.
*Apply form release to workbench.
*Lay up 2 bid on bench top each side.
*Set tank, flat side down, onto lay up tabs.
*Lay up (2) bid over first layers and up side of tank +/- 4” to create tabs on either side.
*Left tank on bench for Chad to remove when cured.
*Fabricate front gear retraction limit tabs. (These stop the front wheel from turning in the retracted position and getting stuck in the gear cavity.)

  Jul 26, 2023     Rudder pedals, landing gear, seat install - (12.5 hours) Category: Fuselage

7/26/23 Sebastian – 12.5 hours.
After conferring with Chad, discovered Tyrone had cut the one rudder stem and then welded it back on, making it too short between the hole and tube. Chad asked Tyrone to fix it. Eventually asked Chad if I could just exchange for a different tube assembly and switch my parts over. Chad agreed. Re-painted new piece and swapped parts over.
Finished tapping and drilling front seat pans.
Drilled out holes for rudder push rods at front bulkhead.
Continue front gear install
*Disassemble front fork pivot bolt.
*Install jig for spacing before gear.
*Reinstall aluminum gear stop.
**Locate
**Drill and cleco
**Tap out aluminum with same tap as used on seats. (3/16”)
*remove Jig.
*Cut out copilot access hole in center keel. (Chad moved it to a new location forward of the old one that provides better overall access than the original location as marked on the tunnel.)
*Install spring.
*Install gas shock/piston.
*Install aluminum stop.
*trim & Reinforce sump tank (2) x 4” around perimter of sump tank and back.
*Install front gear stop at back of forward bulkhead.
*Install reinforcing alumin strap on front of front bulkhead per Chad. (This is not in the manual and an improvement that Chad recommended.)
**Fabricate strap from aluminum bar stock.
**Rounded ends and marked centerline of holes to match gear stop.
**Drilled out holes and cleaned up the aluminum.
Front seat Install continues:
*2” down from front edge of front seat bottoms, draw line.
*Hot glue board on line.
*Put seat on rails resting board against front of seat rails.
*Slip 2”x4” between keel and seat pan to space out for upholstery.
*Bondo on 4 corners of rails – set seat on and hold until cured.
*Remove seats.
*Drill 3/16” holes all the way through seat bottoms.
*Trace flat washer over (4) holes in each seat.
**Dig out upper layer and foam, leaving seat bottom intact.
**Figured out how to drill out with ��le saw to cut through top layer and foam, then picked out with screwdriver and chisel.
*Fill hole back in with cabosil and resin to reinforce attachment.
*Let set overnight.
*Re-drill hole and mount seats.
Finished assembly of rudder/brake pedal assembly.

  Jul 25, 2023     Nose gear install, rudder pedals, sump tank - (13 hours) Category: Fuselage

7-25-23 Sebastian – 13 hours
Continue nose gear installation
*Have Tyrone shave +/- 1/32” more off of copilot side bushing.
Continue work on sump tank
*Cut excess material off
*Rough up inside of tank gently.
*Tape over holes
*Rough up back of tank.
*Do coat of Jeffco on inside of tank and back plate.
*Wait +/- 1 hour for it to start to set up.
*Check Jeffco thickness w/ light. Work on re-coating and filling in pin holes for close to an hour.
*Recoat whole tank when first coat is starting to set, but before it is dry.
*Stick halves together and weight down. Let sit overnight.
Assemble seats
*Align aluminum bracket w/ bottom of pans.
*Handle goes on door side.
*Leave �� bottom pan from edge of pan to aluminum.
*Clamp bracket to seat pan and back.
*Leave “2”x4” of space between back and bottom pan for cushion and upholstery.
*Use laser level to get back of seat straight along axis of fuselage.
*When satisfied with fit, drill and tap holes in brackets and seat pans.
Rudder Pedals
*Paint rudder assembly with Rustoleum Hammered Grey paint.
*Ream out all 3/16” holes all over.
*Put aluminum block on end piece.
*Aluminum blocks go to front, one has larger hole and they only fit on tube one way.
*Sand paint off end of tube and/or aluminum blocks to get good tight fit.
*Bolt pedals on stems.
*Master cylinders – start even with top of rod, then tighten down 5 turns so threads are higher in clevis. This leaves room for adjustment later.
*Put 3 washers on nut side of bolts and master cylinder to space away from extrusions.
*Washer and nut on each one.
*Per Chad, don't follow book, this was the old way. (Figure 10-9) Big holes and center hole.
*Discovered one of the stems was fabricated incorrectly and the clevis would not without hitting the hinge tube.
*Front bulkhead – Center horizontally and vertically.
**Up ��aw horizontal line.
**Over 2 ��ch way, drill 1” hole at each point.

  Jul 24, 2023     Seat Install, sump tank, landing grear install - (13 hours) Category: Fuselage

7-24-23 Sebastian – 13 hours
Finished (2) bid 2” x 48” layups to reinforce bench seat to support front and back.
Installed sump tank drain and low fuel warning sensor hard points.
*Roughed up area
*Aluminum tape over openings on hard points between tank and hard points.
*Cabo adhere hard points to tank.
*Cabo ramp around hard point.
*(2) bid 5” x 5” around hard points.
Begin installation of front landing gear
*Level fuselage side to side.
*Open up and level ��le in keel.
*Drill through keel with 1” hole saw, keeping level with 1” bushing through far hole and very long drill bit.
*Had Tyrone shave down front gear bushings to match duct sidewall thickness.
*Gear should sit at 83 degree past vertical.
*Chad provided drilling jig for gear top holes. Used this to verify angles needed to go past 83 degrees to get jig to fit.
Cut notches at top of rear gear over center receivers
*Rough up all surfaces to prep for glassing.

  Jul 23, 2023     Seat Install, Sump tank fabrication - (12 hours) Category: Fuselage

7-23-23 Sebastian – 12 hours
Continue work on bench seat.
*Lay up (2) bid and cabo ramp around tube to reinforce hinge tube, let sit overnight.
*Vaseline on tube to allow removal.
*Wet out bid on plastic and cut to size.
*Cabo/ramp around tube.
*Lay up bid.
*Added (2) bid 1 ��4” at each intersection of pipe/flange (4) for extra reinforcing.
Cut and shaped support for bench seat
*Drill tiny pilot hole through door “trace line” to find point of carbon fiber rib. This is going to be installed later on my plane, this establishes the measuring point from manual.
*Measure 14 ��ck from carbon beam to vertical support for back seat.
*Measure 1” line back on bottom – front of bench seat. Draw line across seat.
*Trim bench seat support to fit floor, duct, keel, and side walls.
**Leave ��p around tunnel and sides for interior.
*(2) bid front and back at bench bulkhead and seat bottom
*Hot glued into place temporarily.
*Roughed up surfaces, cleaned with alcohol
*Structural adhesive seat pan to support
Drilled and tapped sump tank
*Shaped sump tank to fit against flat back piece.
*Prepped drain and low warning sensor connections.

  Jul 22, 2023     Seat install, keel reinforcing - (12 hours) Category: Fuselage

7-22-23 Sebastian – 12 hours
Wet out fiberglass for front seat hard points and inside tunnel reinforcing.
Finished placement of co-pilot hard points.
Roughed up all surfaces and wiped down with alcohol.

Front seat hard points
*Faired out points w/cabosil.
*Taped over anchor holes to keep resin out of hard points.
*Layed glass over co-pilot side and then pilot side hard points.
*Glass oner (3) layers bid. (Used strips to cover front and back attach points on each side.)

Front of keel reinforcing
*Laid (2) x (2) bid 23” x 4” on tunnel floor/wall and up front bulkhead.
*Laid up 9” x 13” triax along bulkhead and sidewalls.
*Laid (6) bid 3” x 11” strip 6” above pilot hole as marked previously.

  Jul 21, 2023     Seat Install, Install battery tray - (12.5 hours)       Category: Fuselage

7-21-23 Sebastian – 12.5 hours
Finished drilling seat top rails for seat buckets.
Installed triax on outside of tunnel at front bulkhead.
Begin bench seat prep
*Align bench seat halves front and back then clamp together.
*Measure 3 1/2:” up and drill hole for hinge/tube.
Install battery tray
*5 �� front bulkhead to corner of tray.
*Cleco tray in place.
*Sand down surfaces.
*Glue down w/ structural epoxy + cabosil + flox and rivet in place.

  Jul 20, 2023     Rudder cable pulleys, - (13 hours)       Category: Fuselage

7-20-23 Sebastian – 13 hours
Assemble rear main gear pully assembly
*Cut reinforcing aluminum strip per pattern in manual.
Bracket (Use “Jetnut”)
(2) AN3-21A Bolt
(4) ANM970-3 Washer
(4) MS21042-3 Lock Nut
Pulley Axle (2)
(1) AN4-11A Bolt
(1) MS210183N4 Nut
Added 3/16” “normal” thickness washers between pully block and plate as well as to angle per Chad [Not in manual?]
Fair out and glass canard tips
*rough up surfaces
*Cut 3”x20” (2) bid doubled
*Cut diagonal on front corner of canard to better fit shape of tip being pushed back.
*Fair out joints and tip with Cabo.
Lay Bid up on joint from weight pocket around to joint at elevator.
Install center keel
*Put in place.
*Centerline of keel at centerline of front bulkhead.
*Bottom of keel at front inside dimension must be 2 ��rline, ie, 5” clear.
*Drill and cleco into place. (Drill only through inside skin, not through outside skin)
*Lay out cleco/rivets every 6” down length of keel.
*Trace keel all around on floor to help with placement when installing.
*Sand floor under flange.
*Cabo/seal under floor under flange to help keep oil out of floor if hydraulics leak.
**Small amount of cabo in resin to help with adhesion.
*Mix structural adhesive
*Apply bead to bottom flange using bag cut and used like pastry bag.
*Install rivets in flange down to fuselage
*Clean up excess adhesive
Drill bottom of front seat rails for anchor points.
*2” in from each corner.
*1/4” holes centerd in rail.
*(4) per seat.

Drill top rails of seat reals
*3/16” holes 1 ��nds (4) per seat.

Front tunnel reinforcements.
*Cut front tunnel reinforcements.
*Measure 6” up from gear pivot holes in tunnel, draw line.
*Trim front bottom corner of keel to allow front gear doors to close completely.
*Aluminum tape back side of front gear doors apply wax.
*Cut triax reinforcements for front of tunnel/gear attachments per manual.
**Inside
***(2) 9” x 13” – strong axis along the 13”
***(6) 3” x 11” – strong axis along the 11”
**Outside
***Make 2” larger than the template (from manual, but Chad had a wood one to use)
***(4) criss cross fibers each layer. (2) per side.
**(2) x (2) bid from near ball joint up to front bulkhead 6”. (23” long x 4” wide)

Install front seat hardpoints.
*Bolt (4) hard points onto seats, use washer to space out.
*Roughed up surface of seat hard points.
*Temporary bolted hard points to seats using (2) washers to keep bolts short of bottom.
*Align inside edge of seat rail to tunnel. Leave 4 ��ide of keel to side of silver tube on seat slide mechanism. (Make sure it's parallel or the seat cushion may rub against keel.)
*Level seat rail side to side.
**remove inside skin and some floor as necessary on outside.
**Shim up rail as necessary on inside points.
**Mix up some bondo to create level point of anchors. Let set up.
**Remove bolts and take out seat rails.
**Build up cabo ramp around hard points.

  Jul 19, 2023     Canard work, gear leg tubes - (8 hours)       Category: Fuselage

7-19-23 Sebastian – 8 hours
Continue with fitting of canard tips
*Cleco tips into position. (3) top and (3) bottom.
*Pack foam at end of canard w/ cabo to seal up pores.
Insert tips.
*Insert tips making sure it is fully filled.
*Clamp elevator flat to aluminum channels.
*Cleco tips in place, clamp back of top to elevator.
*Clean up joints, fill in end.
*Clean up tips with alcohol.
Adhered brake line “duct” tubing to gear legs
*Sanded gear legs (2) sides each to accept bid cover for tubing.
*Adhered vinyl tubing to each leg +/-1” from trailing edge w/ hot glue.
*Prepared (2) layers bid 32” x 4” x (2)
*Faired out vinyl tubing on gear leg to prep for glassing.
*Laid up bid over tubing.

  Jul 18, 2023     Rudder cable install, torque tube - (12 hours)       Category: Fuselage

7-18-23 Sebastian – 12 hours
Drilled fiberglass out of holes in main gear bulkhead
Cleaned up fiberglass around canard bulkhead
Installed rudder cable tubes
*Drilled rear and main gear bulkheads to accept tubing.
*Reamed out holes to create a smooth path.
*Installed ��ng along path. Temporarily affix to duct with hot glue.
*Laid up (2) bid 4” wide on plastic.
*Faired out tubing with cabosil.
Installed (2) bid strip over tubing on both sides.
Installed elevator torque tube and weights
Began fitting of canard tips
Marked aileron cut lines on main wings

  Jul 17, 2023     Fuselage reinforcement, canard work - (12.5 hours) Category: Fuselage

7-17-23 Sebastian – 12.5 hours
Prepared underside of rear “ramps” for reinforcement
**Sanded as needed
**Wiped with alcohol
**Cut bid 9” x 22” x (4)
*Prepared all corners with fairing (Resin + cabosil). Coated all surfaces with cabo to assist w/ adhesion.
*Wet out (2) plies bid each on plastic. Let cure until sticky.
*Installed bid to underside and rolled out bubbles.
Install elevator on canard
*Final fit hinges to elevator/canard.
*Cut notch in elevator to fit actuator assembly.
*Assemble hinges for install
*Abrade hinges where they anchor into canard
*Fill mounting holes with cabosil + resin. Work into hole until full.
*Insert elevator and hinges into cabosil
*Assemble elevators, hinges, actuator. Clamp elevator to aluminum channel to keep straight.
*True up elevator aligning torque tube length of canard.
*Align hinges with back of slots. Fill with cabosil
*Clean up all surfaces.
Install (2) layer bid at Canard bulkhead and fuselage sides.

  Jul 16, 2023     Elevator, spar reinforcement - (11 hours)       Category: Fuselage

7-16-23 Sebastian – 11hours
Elevator hinge screws
*Drill and countersink (1) screw hole in each hinge. 5/8” up from rivet, 3/8” over from vertical tab.
*Invent miracle wedge! to hold wrench and nut to secure hinge screw.
*Fasten nuts from back side w/ extended wrench.
Bid reinforce lower spar to back bulkhead.

  Jul 15, 2023     Kit purchase - Part 2 Category: Fuselage

  Jul 15, 2023     Kit purchase - Part 1 Category: Fuselage

First half of kit purchase entry