May 05, 2024     Skin removal and push rod components - (8 hours)       Category: Wings

Complete drilling the holes to size and removed the skins to be cleaned and primed
Assembled the rocking arms for the aileron push robs.

  Apr 28, 2024     Flap Conveyer Skins - (5 hours)       Category: Wings

Finish forming the flap conveyer skins.and ribs.
I won't be installing these parts until I mount the wings - per the instructions.
Also started to drill the wing skin holes to size - which is a daunting task.
Once I'm done doing this I'll remove, clean, and prime the skins.

  Apr 21, 2024     Skins - (10 hours)       Category: Wings

Completed fitting the leading edge skins and drilling additional holes - looking forward to doing some riveting but I still have a lot of work.
Rotated the wings and fitted a stretch of skin that hangs over the flaps and ailerons.
I need to drill all holes to size, remove the skins - then clean and paint them.
Will work on the internal control rods next..

  Apr 20, 2024     Avionics Inventory - (1 hour)       Category: Avionics

Received the initial shipment of avionics parts from Advance Flight Systems.
I order the complete VFR kit to include building the panel.
I can start installing these components now - it'll be about four months before I receive the panel.

  Apr 07, 2024     Wing leading edge skin - (9 hours)       Category: Wings

Did the initial install of the leading edge skin on the left wing.
This went a lot quicker and easier after have done it on the right wing.
I repeated the same steps.
I'm happy with how it came out - I still have a lot (hundreds) of additional holes to drill in the side skins. Then I'll drill them to size.
I strongly recommend that basic kit builders do the wings last - their much more complicated than the fuselage.
If it was easy it wouldn't be fun.

  Mar 31, 2024     Edging edge skin - (8 hours)       Category: Wings

Complete cleco'ing the forward edge of the right wing
This was one of the harder elements of the build to do - but it got easier once I figure out the best approach
However, I need to get a lot more cleco's to do both wings at the same time.
This has reinforced my view that the wings should be done last - they're much more complicated than the fuselage.

  Mar 24, 2024     Skin - (16 hours)       Category: Wings

Completed drilling the main and rear spar holes into the top and bottom skins.
Decided the that the only way I could install the leading edge skins is to rotate the wings 180 degrees so the leading edges are pointing up.
Had to remove the middle section of the skins in order to have something to grip on to = yes, it would have been easier to do with an extra set of hands.
The leading edge skins aren't pre-drilled - I have to determine the proper placement and match drill the holes that are in the side skins to the leading edge skins. This wasn't easy, but I managed to get the skins cleco'ed on the top of the wing.
I'll work on the bottom holes next.

  Mar 10, 2024     Wing jig and installing skins - (10 hours)       Category: Wings

Went back to plan A and will work on the wings in parallel vice sequential for a few reasons. Allows be to compare how the wings are coming together immediately and address ay deviations and it simplifies the flow of work.
I used my re-purposed fuselage stands to hold the inboard end of the wings and I have a couple of sawhorses that are just the right heights to make the main spar level to the ground.
My golden rule with this kit is if the holes don't align there is an issue how I assembled it - and in a few places the holes in the skins don't align with the holes in the ribs. However, the misalignment was identical on both wings - same locations - and was able to conclude that the flaw was in the manufacturing and I was able to easily adjust.
I doubt this is an problem on the retractable landing gear version - but for LSA version the skin and some ribs are made differently.
Once I got the skins aligned, I began drill out the hole on the spars into the skin which requires removing one side of the skins to access the predrilled holes.
There are a lot of holes and I'll need to get more clecos to finish the job.
I'm planning on rotating the wings 180 degrees IOT align the leading edge skins

  Feb 25, 2024     Internal frame - (8 hours)       Category: Wings

Decided to work on one wing at a time vice in parallel. My repurposed fuselage mounts wouldn't allow me to work on both. If I had a third mount I could do this, but I don't have room in my hanger to do.
Good this though, because my ribs in the section where the retractable landing gear would go don't align with the skins. I mounted s few of the ribs based upon where the holes in the main and rear spars. Apparently, this isn't correct since the because they don't align with the ribs. FL hasn't released a instructions for the LSA wings and best to my knowledge I'm the first the build the basic kit LSA version.
Very minor setback, a technician from FL will call me and walk me through the placement of the ribs.

  Feb 19, 2024     Initial wing assembly       Category: Wings

Mounted the main spars to my repurposed fuselage end-stands.
The main challenge was figuring out how to mount the wing tip to the stand. I used a set of heavy duty clecos to how the end ribs.
Drilled and temporarily mounted all ribs to the main spars.
This will probably be the first of three times I need to assemble the frame.

  Feb 17, 2024     Ailerons and wing ribs - (4 hours)       Category: Wings

Began assembly of the ailerons and adding parts to the wing ribs - due to the cold weather.
I cleaned and prepped the aileron parts about a month ago.

  Feb 04, 2024     Main Spar - (6 hours)       Category: Wings

Mounted the main spars to the fuselage
Needed to expand the four holes in the main spar pass through bracket - light filing and sanding - finally got the four mounting bolts to fit
Looks like my angles are correct - 2.20 degrees

  Jan 14, 2024     Main Spar - (10 hours)       Category: Wings

Working on configuring the main spars to the correct angle.
To my surprise FL sent me a mounting plate jig - which is a smaller version of the large spar pass through bracket that is part of the central fuselage box.
I mounted the jig to one of the wooden mounts I used to hold both ends of the fuzelage during construction.
I started doing this in my garge - which wasn't long enough - and moved into the basement. It was too cold to do this at the hanger.

  Jan 01, 2024     Main Spar - (8 hours)       Category: Wings

Cleaned and prepped the parts for the main spar.
Drilled and riveted the top and bottom beams on the main spar.
Once I receive the main spar straps I'll temporarily mount the main spars to the fuselage to ensure they are sent and the correct angle - should be challenging.

  Dec 23, 2023     Canopy Latch - (4 hours)       Category: Fuselage

Installed the forward canopy latch.
Added a small sliding panel to the external handle that keeps the opening sealed to the elements.
Also added 3/16" thick spacer between the canopy frame and the latch bracket to provide proper clearance.

  Dec 20, 2023     Wing Parts Prep - (4 hours)       Category: Wings

Received a box with the remaining parts for the wings - minus the man spar straps - the main parts the connect the wing to the fuselage.
I cleaned and Anodyned the aluminum parts.

  Dec 13, 2023     Rear Spar - (10 hours)       Category: Wings

Completed the rear spars.
These were fairly straight forward to assemble. There's ~16 retaining nuts that require #3 solid rivets - which can be a little challenging.

  Nov 26, 2023     Fuel Tank Assembly - (4 hours)       Category: Fuel System

Complete assembly of the second wing tank.
I used the support brackets which made it mush easier to assemble and was less messy.
I pressure test it in a few days.

  Nov 19, 2023     Fuel tanks - (8 hours)       Category: Fuel System

Began assembly of the two wing fuel tanks.
The construction is similar to a flap - but thicker.
However, fuel tank sealant has to be applied during the final assemble - messy task.
Fuel tanks pop rivets are used - something I've never seen before.
Completed the final assembly of one of the tanks. Will need to add more sealant on the outside.
Once the sealant is dry - in a few days - I'll check for leaks.

  Oct 24, 2023     Wing Kit Inventory and Prep - (6 hours)       Category: Wings

Completed the inventory of the wing kit. The missing parts are enroute.
I also started my favorite part - cleaning and prepping the parts - and there's a lot of them. I'm going to Alodine the ribs and smaller parts. The spars and skins I'll paint with grey primer.

  Oct 14, 2023     Wing Kit Delivery - (3 hours)       Category: Wings

Christmas in October - the wing kit was delivered to my hanger this week by the owner of Flying Legend.
He was in country - from Italy - and delivered my wing kit after deliver a quick-build kit north of VA.
Not the fun part of inventorying the kit. He also delivered the Fuel Selector Switch which are about impossible to purchase in the US - supply backlog.
We had a great visit and he liked the wrap on the airframe and my seat cushions.
The engine and parachute will be delivered in the near future.

  Oct 09, 2023     Canopy Installation - (8 hours)       Category: Fuselage

Although I have a large crack in the canopy I went ahead and mounted it to the frame and installed it on the airframe.
The crack is a little behind my left shoulder and doesn't interfere with my field of view.
I'll eventually replace the canopy with the one I ordered.
The canopy is large - but very light weight.
The frame seals nicely to the airframe.

  Oct 08, 2023     Seat harness and cushions - (10 hours)       Category: Fuselage

Received the seat harnesses from Hooker and made the cushions for the seats.
The seat cushions are fairly simple but it took me a couple attempts to get them right. I'll use Velcro to connect the cushions to the seat.
Yes I did the design and sewing - a skill I picked up from my mother. (-:
I also need to come up with a methods to attached the "anti-submarine" crouch strap to the seat.

  Sep 24, 2023     Canopy - (20 hours)       Category: Fuselage

Completed trimming and gluing the canopy to the canopy frame.
Unfortunately this didn't go well on the first attempt - apparently the primer was dry enough and the adhesive didn't set right.
I separated the canopy from the from using skin wedges, but after separating the canopy I accidently cracked the canopy halfway down on the left side - ACKKK.
Needless to say I wasn't happy and I order a replacement which will take a few months to get here.
I decided to repair the canopy and attach to the frame. This time the adhesive set properly.
I used Zlitz polish to buff out a couple scratches from when it was shipped and the crack.
I applied grey wrap to the canopy frame which went easier than expected.
Except for the crack it came out pretty good.

  Aug 20, 2023     Fwd Air Vent and Canopy - (5 hours)       Category: Fuselage

Completed the fabrication of the fwd air vent intakes - I also applied black wrap to the area.
Temporarily installed the hinges to the canopy frame and the external cover plate for the fwd canopy latched.
Placed the canopy on top of the frame - next step is marking the line I need to trim the canopy to.
This should be easy because the canopy fit like a glove on top of the frame.
However, I'll need to enlist help from my oldest son when cutting and adhering the canopy to the frame - it's nearly 8' long and awkward to handle.

  Aug 14, 2023     Seats and Canopy - (8 hours)       Category: Fuselage

Prepared and paints the seats - this involved cutting out holes for the seat belts.
I installed the adjust mounting rails for the seats and installed the front seat. I'll probably need to remove these when I start installing the wiring.
I sat in the front seat for the first time - there's a lot of leg room and there's about 16 positions to adjusts the seats to.
I started working on the canopy and connected the canopy frame to the hinges. The frame fit like a glove and didn't require a lot of trimming.

  Jul 30, 2023     Brake lines and internal panels - (8 hours)       Category: Fuselage

Completed the installation of the brake lines to the parking brake switch and installed the internal cockpit wall panels.
I need to find method for running the brake line from the parking brake switch to the brakes. This involves running the lines down the landing bow. There aren't any instructions for this yet. Apparently, I'm the first the build the basic kit fixed landing gear version and FL is still completing the instructions. This is ok - challenges are fun.

  Jul 16, 2023     Ruder and Rudder Pedals - (8 hours)       Category: Empennage

Wrapped the rudder and added the mount for a tail light. This required cutting a large notch in the aft edge of the rudder and mounted the fiberglass mount. I also wrapped the mount which was a little tricky because of its odd shape.
I install the rudder on the fin and re-installed the rudder pedals. Next I install the cables from the rear pedals to the rudder.
I'll probable has to remove the forward pedals in order to install wiring under the floor board.

  Jul 04, 2023     Installed elevator and fin - (6 hours)       Category: Empennage

Wrapped the elevator and the fin.
Assembled and installed the elevator - which wasn't easy.
I removed the counterbalance weights IOT make it easier to handle. There isn't much room to work with to install the four pivot bolts but I finally got them in place. After I installed the weights, I was concerned because the elevator wasn't balanced. Flying Legend told me that the elevator is only 75% balanced.
The fin was simple to install - starting to look like an airplane.

  Jun 25, 2023     wrapping and installing stablizer - (6 hours)       Category: Empennage

Wrapped the stabilizer and installed it on the fuselage.
I added a black trim to the leading edge - this came out really cool
There's four bolts holding the stabilizer - which aren't easy to install - fortunately I don't have fat fingers

  Jun 18, 2023     Control sticks and roll cage - (5 hours)       Category: Fuselage

Bolted the roll cage in place - but didn't install the rivets in case I need to remove it
Installed the control sticks - which wasn't easy.
Wish I had done this when I could rotate the fuselage.
The controls move very smoothly.

  Jun 11, 2023     Control Rod and Air Vents - (6 hours)       Category: Fuselage

Applied a required modification to bulkhead 5. I installed the two brackets on both side of the push rod bushing.
Installed the bell crank below the parachute enclosure and installed the two push rods that connect to the bell crank. Unfortunately the complete instructions weren't available when I installed the parachute enclosure - it would have been a lot easier to install the bell crank when I installed the enclosure. The two push rods fore and alt of the bell crank move very smoothly.
Added the outside air scoops for the rear set air vents and applied the wrap cover. I covered the rivets heads with a small round piece of wrap - this worked out good.

  Jun 04, 2023     Engine mount and air vents - (10 hours)       Category: Fuselage

Began to install the air vents for the rear seat and the engine mount with the front landing gear.
I have the wings, engine, and parachute on order - expect to receive them in a few months.
In the mean time I'll be focused on completing most of the finishing kit and install the empennage.

  May 21, 2023     Main Gear - (4 hours)       Category: Landing Gear

Installed the main landing gear.
I enlisted the help of my oldest son to help me turn the fuselage over after installing the man landing gear. This required lifting up each end another 12" so the landing gear bow could clear the ground.
Next I'll install the engine mount and the front landing gear.

  May 20, 2023     Fuselage Wrap - (4 hours)       Category: Paint / Decals

Continued to apply the wrap to the fuselage.
Getting better at applying the wrap over the many rivets.
Need to apply a few more sections.

  May 07, 2023     Wrapping fuselage - (4 hours)       Category: Paint / Decals

Completed wrapping the bottom of the fuselage.
I really under-established how much wrap is needed to do the fuselage - so I have more on order.
Now that the bottom is done, I'm going to install the engine mount and landing gear - I've reached the point where I don't need to rotate the fuselage.

  Apr 30, 2023     Wrapping the fuselage - (8 hours)       Category: Paint / Decals

I've been researching how to wrap vice paint the airplane.
A lot of builders use wrap to put traim on the aircraft, but few wrap the entire plane.
I decided to take a chance and try to wrap the fuselage. If it doesn't work out, I can always peel it off. However, it not easy to remove a wrap - a lot easier than removing paint.
Instead of trying to wrap large sections at a time, I'm applying smaller section that match the skin sections. This is working very well. Although I need another set of hands for the big pieces.
The biggest challenge is smoothing over the rivet heads - because they're so many of them.

  Apr 29, 2023     Canopy - (6 hours)       Category: Fuselage

Fitted the canopy seal and roll bar to the fuselage.
I positioned the canopy hinges but I couldn't cleco them into place because I couldn't drill holes into the hinge. Not sure what they're made of, but I'll need to drill them like titanium is drilled.
The canopy seal is a strip of plastic that closes the gap between the canopy and the fuselage. I riveted the strips into place, but I have additional work to do on them
I positioned and drilled the holes for the roll bar.

  Apr 02, 2023     Brake and throttle components - (5 hours)       Category: Controls

Installed the brake for the rear seat and the brake system reservoir. The rear brake is optional and looks like a car parking brake. The parking brake is a small switch in the forward seat.
Installing the front and rear throttle quadrants was a challenge. the design was changed but the instructions reflected the old design. I figured it out - I think.
This was also the first time I've worked on the fuselage with it rotated on it side.

  Mar 26, 2023     Main landing gear - (4 hours)       Category: Landing Gear

I temporarily installed the main landing gear. This involved drilling four hours in to the fuselage central box..
The main landing gear and retaining brackets are very heavy duty - and heavy.
I won't be able to install the front landing gear until I first install the engine mount - so I have awhile to go.

  Mar 18, 2023     Control Rods Installation - (6 hours)       Category: Controls

I received the landing gears, fuel system, brake system, and misc parts - still have a few more parts coming from Spruce.
Installed the control rods for the control stick. The left-right rotation of the control rod was very stiff and I had to reduce the thickness of one of the washers by 1/16".
This also involved safety wiring the bolts on the three couplers that connect the three sections of the control rod.

  Mar 11, 2023     Fwd Lower Skins - (6 hours)       Category: Fuselage

Completed the riveting of the forward lower panels.
I held off on doing this until I received the finishing kit and was sure I wouldn't have to access the space under the skins - particularly for the pedels.
everything appears to be GTG - knock wood

  Mar 05, 2023     flaps and pedels - (6 hours)       Category: Controls

installed the actuator for the flaps, rear control pedals, and bulkhead passthroughs for the control rod.

  Feb 19, 2023     Peddles and Flaps - (8 hours)       Category: Controls

Began to install the finishing kit.
I first installed the front peddles to I could finished riveting the forward lower skins.
Fortunately the peddle mounting supports I installed a few months ago were correct.
I then install the guide pulleys for the rudder control wire. Unto themselves this should have been easy, but two of them were place inside the central fuselage box which made installing them a little challenging.
Next I began installing the flap control rod. I'll complete this later.

  Feb 12, 2023     Finishing Kit - (1 hour)       Category: Fuselage

The finishing kit finally arrived - well most of it. The kit contains the large fiberglass/plastic components, landing gears control system, brake system. flap system, fuel system, etc. Flying Legend will ship the remaining parts soon.
I purchased a tool for installing threaded inserts - well worth it - there are a lot of inserts in the fuselage.

  Jan 29, 2023     Elevator construction - (12 hours)       Category: Empennage

Complete most of the assembly of the elevator
I'll move this out to my hanger - and off the dining room table - for completion

  Jan 16, 2023     Stabilizer completion - (10 hours)       Category: Empennage

Completed construction of the stabilizer.
The assembly was relatively simple - but complex.
I used flush rivets on the leading edge like I did on the fin.

  Jan 02, 2023     Stabilizer prep - (6 hours)       Category: Empennage

Cleaned and primed the parts for the stabilizer.
Will begin assembly next

  Dec 18, 2022     completed rudder - (10 hours)       Category: Empennage

completed assembly of the rudder
I moved operations to my garage because of the cold weather
the rudder was relatively and straight forward to assemble

  Dec 05, 2022     Fin Completion - (4 hours)       Category: Empennage

Completed riveting the fin.
I used flush rivet on the leading edge - which isn't required.
I have a bunch of flush cherry rivets and I thought it would a nice appearance - it won't improve air flow

  Nov 13, 2022     Fin assembly - (8 hours)       Category: Empennage

Began to assemble the fin - which is rather easy after completing the fuselage..
The parts fit together very nicely.
I'm going to use flush rivets along the leading edge.

  Nov 13, 2022     Empennage Part Prep - (8 hours)       Category: Empennage

Cleaned and Alodined empennage parts

  Oct 23, 2022     Misc cockpit and parachute bay - (8 hours)       Category: Fuselage

Pretty much completed all I can do at this point to the fuselage. I temporally mount a few parts inside the cockpit and fitted the fiberglass rim around the parachute bay opening.
I really love the green I'm using for the cockpit which will go along with my planned color scheme.
I'll be able to complete the fuselage once I receive the finishing kit - may by Jan 23. I'll start working on the empennage next.

  Oct 10, 2022     Forward Bottom Skin - (2 hours)       Category: Fuselage

Completed the temporary installation of the forward bottom skins.
I'll rivets the skins after I install various control components like the peddles.

  Oct 09, 2022     Fuel Lines and fwd structure - (6 hours)       Category: Fuselage

Completed installation of the fuel lines in the forward fuselage and worked on forward bottom structure components and skins.
The fuel lines are only part of the entire fuel line systems, but it easier to install them before the forward bottom skins are installed

  Oct 02, 2022     forward lower skins and fuel lines - (10 hours)       Category: Fuselage

Working on installing part of the fuel lines in the forward fuselage. I needed to order a few tools for the AN fittings and for bending the tubing - fortunately this wasn't expensive.
I also fitting the forward lower skins and structure.

  Sep 18, 2022     bottom Aft Skins - (8 hours)       Category: Fuselage

Completed installation of additional spars aft of the fuselage box. This was a complex task but was made easier by having the fuselage turned over.
I think completed the riveting of the skins aft of the fuselage box. The most challenging part was attaching the skin to the fuselage box - would have been a little easier if I have assistance - which I didn't have.

  Sep 11, 2022     Bottom Aft Skins - (7 hours)       Category: Fuselage

Continued to work on the lower aft skins. I installed a plastic tube (per the instructions) for running wiring to the tail. This is a PVC tube - which I know from working on v-22s is a violation because of toxic fumes when they burn. I also know it can be waivered - I think the fumes will be the least of my worries.
The area where the skin connects to the aft of the central fuselage box was a bit challenging. I figured out that removing the skin after of this section made it a lot easier to align the skins to the brackets.

  Sep 04, 2022     Upper skins Completion - (10 hours)       Category: Fuselage

Completed the installation of the upper skins to include the forward glare shield.
Removed the support block underneath the central fuselage box and the two end supports held the load.
The moment of truth was rotating the fuselage so I could work on the bottom area of the fuselage. I didn't have anyone to help me - so I was a little concerned that the end supports would fail and the fuselage would crash to the floor.
Fortunately the end supports worked as designed. The only challenge was the supports weren't high enough to provide clearance for the upper turtleneck - I had to add 3" of wood underneath the supports' feet.

  Aug 28, 2022     upper skins - (6 hours)       Category: Fuselage

continued to position and rivets the upper turtleneck skins and installed at plastic tube along the right side of the cockpit for future wiring

  Aug 21, 2022     fuselage turtleneck installation - (5 hours)       Category: Fuselage

Started to install the turtleneck skin on the aft fuselage. I also installed the platform for the optional battery aft of the parachute location. I opted to install this in case I decide to use the location for the battery or another electrical component. I also installed the support frames around the five access holes on the side of the fuselage.

  Aug 20, 2022     Fuselage frame brackets - (5 hours)       Category: Fuselage

Permanently installed ten frame brackets inside the cockpit area. These are mounted between the two fuselage spars.

  Aug 14, 2022     mid-fuselage skins installations - (10 hours)       Category: Fuselage

installed two ribs in the parachute bay and installed the mid-fuselage skins. I had to install four pieces on each side. The plans show a specific method for doing this. The skins pull the fuselage frame into tighter alignment.
Once I add a few internal brackets to the skins and the turtleneck skins I'll be able to remove the support under the fuselage box

  Aug 07, 2022     Parachute bay - (8 hours)       Category: Fuselage

Installed the hardware for the parachute bay which sit right behind the luggage storage area. I also fabricated an optional battery storage plate to be located behind the parachute bay. I might not be able to use this for the battery because of CG.

  Jul 31, 2022     Forward Fuselage - (8 hours)       Category: Fuselage

Installed electronics mounting plate and completed the installation of the trim around the cockpit. The trim is for connecting the frame to the skin. This was challenging (in a good way) because of the large number of rivets. Even without the skin stalled the frame is very sturdy.
I also installed the canopy latch.

  Jul 17, 2022     Addition of skins and misc work - (6 hours)       Category: Fuselage

Completed a few misc tasks - primarily riveting the luggage deck and frame brackets.
I began riveting the first set of skins which run along the central sides of the fuselage.
The holes of the skins line up well with holes in the frame - this starts pulling the fuselage into shape.
I also started to use an edge forming tool from Cleveland AC tools to put a slight 1/4" bend on the skin edge where it overlapped with another skin - great tool.

  Jul 16, 2022     Preparing fuselage skins - (10 hours)       Category: Fuselage

Alodine'd the fuselage skins - not an easy task because of the length of the parts.
I ended up merging my two pans into one large pan. Which still wasn't long enough for several parts, but make the task a lot easier.

  Jul 10, 2022     Fuselage frame assembly - (10 hours)       Category: Fuselage

Spent the weekend completing the assembling of the fuselage frame and most of the riveting.
As more parts are added the frame pulls into position/form.
Everything is coming together nicely.
Next I need to prep the fuselage skins.

  Jul 04, 2022     Fuselage bulkheads and spars assembly - (8 hours)       Category: Fuselage

Began to re-assemble the fuselage bulkheads and spars. I built a new jig for the central box using the same level feet I use on the two end support jigs.
This make leveling the central box lot easier. I first positioned the central box at the right angle (1.5 degrees tilted back) and then attached the four spars to the central box. The two end bulks were then attached along with all the other bulkheads.
I found a green primer for the cockpit area that I like.

  Jul 02, 2022     Fuselage Spars - (6 hours)       Category: Fuselage

Completed assembly of the fuselage spars. There are four unique spars, but the assembly is identical. Each spar has ~80 solid and pull rivets.

  Jun 26, 2022     parts prep - (2 hours)       Category: Fuselage

cleaned, prep, and primed a lot of small fuselage brackets.
I found a green primer I like and will use it to paint the cockpit - to go along with airplane paint scene.
I'm only going to use the primer in the cockpit area. It's expensive and the Alodine is just as good - and cheaper.

  Jun 25, 2022     Initial assembly - (6 hours)       Category: Fuselage

Temporarily assembled the fuselage armature.
I used a platform level to support the central box and added sims to get the correct angle. Although this worked, I going to make a platform using the same type of adjustable feet I used on the two end support.
Connecting the lower spars to the central box was a little challenging but I figured it out.
Next I'll take it apart, assemble the spars, and re-assemble the fuselage - good times.

  Jun 20, 2022     Setting up fuselage end stands - (1 hour)       Category: Fuselage

Set up the fuselage end stands in my hanger. The stands work well. I'm using a laser level to align the center of the two stands. I'm sure I'll need to fine tune the stands as I begin to assemble the fuselage.

  Jun 19, 2022     preparing fuselage spars - (12 hours)       Category: Fuselage

Cleaned and Alodine coated the fuselage spars. The spars are up to 10' long. We used a 10' long plastic rain gutter to soak the parts in the alum prep and Alodine. This was a simple and inexpensive solution.

  Jun 17, 2022     Fuselage end support stands - (12 hours)       Category: Fuselage

Designed and built fuselage end support stands. Flying Legend instructions requires the use of end supports for the fuselage assembly and support for the central fuselage assembly. The supports I created have a rotating support for the end bulkheads - the support can also be adjusted up and down. The stands have leveling feet to compensate for unlevel floor in my hanger.
Engines stands are heavier duty, but they can't be adjusted.

  Jun 05, 2022     Fuselage Central Box Final Assembly - (16 hours)       Category: Fuselage

Complete the assembly of the fuselage central box.
This is a lot of work, challenging, but not hard. The central box assembly is relatively straight forward.
A few parts are fitted but not permanently attached - this will be done later the fuselage assembly

  May 27, 2022     Fuselage central box Bulkhead 5 - (6 hours)       Category: Fuselage

Completed initial assembly of bulkhead 5 - which is the aft bulkhead of the fuselage central box.
This included preparing the two side heavy brackets that connect to the bulkheads 5 and 4 in the fuselage central box

  May 24, 2022     Fuselage Central Box bulk head 4 assembly - (8 hours)       Category: Fuselage

Completed the partial assembly of bulk head 4 - which is the forward bulk head in the cental box.
This bulk head contains the spar pass through bracket
The bulk head is made up of layers of metal.
However, no solid rivets are used in the assembly - just stainless steel 04 pull rivets.
This is a partial assembly, I taped off the holes that will be riveted later.

  May 20, 2022     Fuselage Central Box Prep - (8 hours)       Category: Fuselage

Prepared and Alodined the parts for the fuselage central box. A few pieces were a little too big for the trays, and I had to soak half of the part and then flip it and soak the other half.
The central box contains more parts than the other bulk heads combined.
Apparently, I'm the first basic kit builder to make the fixed landing gear version which makes the central box more complex.

  May 15, 2022     Firewall and misc bulkhead - (8 hours)       Category: Fuselage

Completed the firewall, installed the bell crank on bulkhead 11, complete bulkhead 3, and installed the pass throughs on bulkhead 2.
I'm very happy with the kit. The instructions make the assembly very straight forward.
I received the remaining fuselage parts from Flying Legend. I'm adding the parachute option which changes the standard fuselage configuration.
I've completed all the bulkheads and will start the fuselage central box - which is more complicated than all the other bulkheads combined - I can't wait.

  May 08, 2022     Bulkheads 9, 8, 7, 6, 3, and 2 assembly - (8 hours)       Category: Fuselage

Bulkheads 9, 8, 7, 6, 3, and 2 assembly.
Assembly involved pull and solid rivets. I still need to add smaller parts to a few of the bulkheads (pass-throughs).
Assembly was relatively simple.

  May 07, 2022     Bulkheads 9, 8, 7, 6, 3, and 2 Application of Alodine Coating - (6 hours)       Category: Fuselage

Applying Alodine coating to parts. I found 30" square plastic pans at Home Depot that were perfect for the aluminum preparation and Alodine application - washing machine floor pans.
I soaked the parts in each tray ~ 6 minutes and rinsed them off with water in between the trays and after the Alodine application.

  May 02, 2022     Bulkheads 9, 8, 7, 6, 3, and 2 prep and temp assembly - (8 hours)       Category: Fuselage

Preparation and temporary assembly of bulkheads 9, 8, 7, 6, 3, and 2

  Apr 28, 2022     Bulkheads 12, 11, and 10 - (8 hours)       Category: Fuselage

Fly Legend provides a detailed set of instruments to follow - kind of like building a model airplane - vice a set of plans.
I decided to start with the fuselage vice the empennage. I'll work on the empennage while I'm waiting for the finishing kit to be shipped from Sicily. I'll save the wings for last.
Per the instructions I started with bulkhead 12, 11, and 10.
All the parts are pretty clean and didn't require a lot of prep work.
I'm going to Alodine all the parts - if possible. This is the most challenging and time consuming step - but well worth the effort.
Assembly involved pull and solid rivets.

  Apr 28, 2022     Hanger       Category: Workshop

My hanger - workshop and future home

  Apr 27, 2022     Fuselage and Empennage Kit Inventory - (8 hours)       Category: Inventory

Completed the inventory of the fuselage and empennage kits using the inventory provided on the Flying Legend web site.
Unfortunately, the inventory was a PDF that was broken down into small groups which made it difficult to inventory because the kit wasn't packed by group - with some exceptions.
I transfer the inventory into an Excel Spread Sheet which allow me to sort by part number - this greatly streamlined the process.
A few minor parts and one major part were missing - these parts weren't available when the kit was shipped from Sicily Italy.
I ordered the parachute variant which wasn't reflected in the inventory - so I add several extra parts.
We had a video conference and Flying Legend will be sending the missing parts soon.
Overall, I'm happy with the kit inventory process.

  Apr 12, 2022     Tucano - love at first sight       Category: Research

Pic of me sitting my sales rep's Tucano-R,
I fell in love with this kit in 2016 - I ordered the fuselage and empennage a couple weeks before seeing and sitting in one
No guts - no air medal