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.

  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.

  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.

  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.

  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

  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.

  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.