EAA Builders Log Site

Project: nburkholder -
Listing for Category : fuselage

(Please mouse-over any icon to get a description of that function).

Categories

Show All Entries - (334)
Research
Workshop - (5)
Empennage - (49)
Fuselage - (131)
Firewall - (10)
Tail Feathers
Wings - (32)
Controls - (1)
Avionics - (25)
Lighting - (2)
Instrument Panel - (8)
Landing Gear - (8)
Engine - (36)
Propeller - (2)
Fuel System
Interior Finish
Paint / Decals
Inspection - (2)
Tools
Wiring - (23)


Builder Name:	Nancy Burkholder -

Project:	Vans - RV-9 - VIEW REPORTS
Total Hours:	1181.4
Total Flight Time:
Total Expense:	$2.00
Start/Last Date:	May 14, 2022 - No Finish Date

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

Home or Last Project Picture

May 14, 2024 More Canopy Track Attachment - (3 hours)

Category: Fuselage

Fabricate two new spacers to fit under the rear screw holding the canopy rail to the fuselage. The plans call for 1/8" thick shim but 3/16" completely fills the gap nicely. Fabricate two tools to facilitate attaching nuts and washers to the screws that hold the canopy rail to the fuselage. There is a large lip un the underside of the canopy attach stringer that obstructs access to the screw. One tool holds a nut and washer to a fixture that can be inserted into the slot and into position to engage the screw. The second tool provides an offset drive to a socket that allows the socket to engage the nut and the socket drive is offset to pass through the slot. Tried both tools on one screw and they worked acceptably.

Measured and ordered longer rivets and screws to attach the canopy rails and Supertrack rails to the F-705 builkhead assembly.

IMG_0389.jpg

IMG_0390.jpg

May 13, 2024 Rivet F-705 Bullkhead Assembly to Fuselage - (2 hours) Category: Fuselage

Rivet on left fuselage at junction with F-705 Bullkhead Assembly. Some rivets not set by quickbuild: skin to longeron and longeron toF-705 Bullkhead Assembly. Countersink the canopy slide rail and match drill to fuselage at the forward attach screw. Drill some screw attachments for left and right side canopy roller tracks.

May 12, 2024 Rivet F-705 Bullkhead Assembly and Skins to Longeron - (2 hours) Category: Fuselage

Add rivets to right side fuselage at rearF-705 Bullkhead Assembly that were not set by quckbuild: longeron to skin and F-705 Bullkhead Assembly to longeron. Need to order some longer rivets to complete all missing rivets.

May 01, 2024 Fabricate Canopy Slider Track - (2.5 hours)

Category: Fuselage

Drill the canopy track spacer for rivet and attach screws. Cut and bend the canopy track rail to fit the spacer. Match drill the rail to the spacer, machine countersink the rivet locations top and bottom, and rivet the rail to the spacer. Cleco the canopy track to the fuselage and verify fit.

IMG_0349.jpg

IMG_0350.jpg

IMG_0352.jpg

Apr 30, 2024 Bend Canopy Slide Spacer - (1 hour)

Category: Fuselage

Received RV-8 canopy slide spacer from Vans. The forward bend is not correct for the RV-9. Bend the spacer to match the RV-9 spacer using a c clamp as an mandrel.

IMG_0347.jpg

IMG_0348.jpg

Apr 30, 2024 Mount Nutplates to Lower Cowl - (1.5 hours)

Category: Fuselage

Mount the upper and lower cowls. Match drill 6 holes for #10 screws attaching the upper and lower cowls behind the propeller spinner. Drill and machine countersink for floating nutplates. Rivet nutplates.

IMG_0345.jpg

IMG_0346.jpg

Apr 28, 2024 Fasten Aluminum Backing Tabs to Front Lower Cowl - (1 hour)

Category: Fuselage

Match drill the front top and bottom cowl behind the propeller spinner for three screws on the left and right sides. Remove the top cowl and fabricate aluminum tabs to reinforce where nutplates will be mounted for the screws. Epoxy the tabs to left and right side. Remove the lower cowl and set aside to allow the epoxy to cure.

IMG_0334.jpg

IMG_0335.jpg

Apr 27, 2024 Lower Cowl Skybolts and Rivets - (4 hours)

Category: Fuselage

Remove upper and lower cowl. Using a pneumatic riveter with a very narrow jaw. finish riveting the horizontal cowl lower attach plates for rivets that could not be reached with a stock riveter due to the close clearance between the firewall attach point and the engine mount. Rivet Skybolt receptacles to the flanges on the lower cowl at the vertical firewall joint on the right and left sides. Drill the cowl for grommets, attach grommets, and insert studs. Fit cowl lower and upper cowl. Adjust stud depth for a few studs that were not set for the correct depth. Note the clearance between the lower cowl and the filter air box snorkel. I believe this location is ready for installation of rubber baffling.

IMG_0325.jpg

IMG_0326.jpg

IMG_0327.jpg

IMG_0328.jpg

IMG_0329.jpg

IMG_0330.jpg

IMG_0331.jpg

IMG_0332.jpg

Apr 24, 2024 Mount Skybolts at Right Cowl Horizontal Split Line - (2.5 hours)

Category: Fuselage

Rivet flanges to lower cowl. Rivet receptacles to flanges. Mark Skybolt hole locations on upper cowl, drill, and attach grommets and studs. Verify cowl fit and adjust several Skybolts for correct depth.

IMG_0317.jpg

IMG_0318.jpg

Apr 23, 2024 Prepare Skybolt Flanges for Right Cowl Split LIne - (3 hours)

Category: Fuselage

Mount Skybolt flanges to the lower cowl at the right horizontal split line. Match drill the flanges to the cowl. Deburr, machine countersink, and prime the flanges. Machine countersink the lower cowl.

IMG_0310.jpg

IMG_0311.jpg

IMG_0312.jpg

IMG_0313.jpg

Apr 21, 2024 Attach Skybolt Flanges to Lower Cowl Horizontal Split LIne - (3 hours)

Category: Fuselage

Rivet Skybolt flanges to left side of lower cowl at the horizontal split line. Match drill the upper cowl to the Skybolt flanges. Drill upper cowl to accept grommets. Install studs and attach the upper and lower cowl along the left horizontal split line and along the firewall. Pull pins on the receptacles to lock the receptacles in place.

IMG_0301.jpg

IMG_0303.jpg

IMG_0304.jpg

IMG_0305.jpg

IMG_0306.jpg

Apr 20, 2024 Prepare Skybolts Along Left Horizontal Cowl Split Line - (3 hours)

Category: Fuselage

Mount flanges to the lower cowl along the horizontal split line. Match drill the attaching rivets using a rivet fan. Deburr, machine countersink, and prime flanges. Machine countersink the lower cowl.

IMG_0295.jpg

Apr 20, 2024 Install Skybolts on Upper Cowl at Firewall - (2 hours)

Category: Fuselage

Drill remaining upper cowl at firewall to accept grommets.

IMG_0297.jpg

IMG_0298.jpg

Apr 19, 2024 Trim Lower Cowl Horizontal Split LIne - (3 hours)

Category: Fuselage

Trim lower cowl horizontal split line. The left horizontal split line has sufficient clearance with the upper cowl. The right horizontal split line needs some additional trimming towards the aft and at the nose.

IMG_0289.jpg

IMG_0290.jpg

Apr 18, 2024 Trim Upper Cowl and Install Skybolt - (3 hours)

Category: Fuselage

Install 5 Skybolt receptacles and grommets. Trim the upper cowl horizontal split line.

IMG_0283.jpg

IMG_0291.jpg

Apr 15, 2024 Upper Cowl Oil Door - (2 hours)

Category: Fuselage

Cut out oil door in upper cowl. Attach upper cowl to firewall fuselage with Skybolt cleco adapters. Identify trimming of the upper fuselage and verify vertical placement of the horizontal Skybolt flanges on the right side.

IMG_0275.jpg

Apr 14, 2024 Lower Cowl Attachment - (3 hours)

Category: Fuselage

Rivet lower cowl attachment plates to fuselage and match drill plate nuts to cowl. Not all rivets set due to not having a suitable bucking bar for close clearance with engine mount. Match drill lower cowl right vertical Skybolt cleco adapters to cowl.

IMG_0272.jpg

IMG_0273.jpg

IMG_0274.jpg

Apr 13, 2024 Lower Cowl Fuselage Attachment - (5 hours)

Category: Fuselage

Fabricate two lower cowl bottom attach plates. Apply primer and ready to rivet to fuselage. Rivet the right side lower cowl flanges to the fuselage.

IMG_0266.jpg

IMG_0267.jpg

Apr 12, 2024 Fitting Cowl with Skybolts - (5 hours)

Category: Fuselage

Match drill the remaining upper cowl Skybotts to the bushings in the flanges. Fit the lower cowl and match drill the side Skybolts to the bushings mounted in the flanges.

IMG_0259.jpg

IMG_0261.jpg

IMG_0262.jpg

IMG_0263.jpg

IMG_0264.jpg

Apr 05, 2024 Drill Locating Holes for Cowl Skybolt Studs - (6 hours)

Category: Fuselage

Sand and apply second layer of epoxy with filler to the outside lower cowl exhaust outlet. Mount Skybolt flanges to upper cowl firewall. Tape 10 Skybolt cleco drill bushings to the flanges working from the center flange to the left and right side. Place and level upper cowl. From under the cowl shine a flashlight through each cleco drill bushing hole and mark the light spot seen on the outside of the cowl. Drill #40 and then #30 to align the cowl hole with the hole in the busing. Drill 13 of 17 upper firewall Skybolt flanges.

IMG_0254.jpg

Mar 30, 2024 Prime Skybolt Flanges - (3 hours)

Category: Fuselage

Scuff Skybolt flange surfaces with Scotch Brite pads, wipe with MEK cloth, and apply primer to the flanges. Apply Proseal to the left and right vertical firewall seams with the fuselage skin.

IMG_0242.jpg

IMG_0241.jpg

Mar 24, 2024 Mount Lower Cowl Vertical Skybolt Flanges - (3 hours)

Category: Fuselage

Lay out the location for Skybolt fasteners on the left and right lower cowl vertical firewall attach points, clamp the flanges to the fuselage, and match drill to the vertical firewall rivet locations. Remove the flanges, deburr drilled holes, machine countersink the rivet attach holes and the Skybolt fastener holes, and remount the flanges to the vertical firewall.

IMG_0229.jpg

IMG_0230.jpg

Mar 24, 2024 Supertracks Rear Mount - (2.5 hours)

Category: Fuselage

Fabricate two threaded spacers to support the aft ends of the Supertracks. Fabricate the spacers from 1/2" aluminum bar stock. Use metal lathe to cut spacers slightly long and then face off the ends flat to the desired length. Center drill the spacers and tap for 10-32 threads.

IMG_0212.jpg

IMG_0228.jpg

Mar 23, 2024 Prepare Upper Cowl Skybolt Flanges - (5 hours)

Category: Fuselage

Verify fuselage level orientation. Determine approximate horizontal cowl split line. Lay out Skybolt flange locations on upper firewall. Mount and drill Skybolt flanges to the firewall upper cowl. Remove, deburr, machine countersink, and remount flanges flanges.

IMG_0222.jpg

IMG_0226.jpg

IMG_0227.jpg

Mar 22, 2024 Trim and Fit Upper and Lower Cowl - (4 hours)

Category: Fuselage

Mount lower and upper cowl and trim lower cowl to fit. Mount top cowl, mark spots that need trimming, remove cowl, trim, and remount. Repeat until the cowl fits reasonably well. Begin working through how to mount the Skybolt flanges.

IMG_0214.jpg

IMG_0215.jpg

IMG_0217.jpg

IMG_0218.jpg

IMG_0219.jpg

Mar 19, 2024 Mount Super Tracks, Lower Cowl - (4 hours)

Category: Fuselage

Apply second layer of fiberglass to lower engine cowl exhaust exit. Drill Super Tracks mounting holes and fabricate four shims. Fabricate tool to enable machine countersinking the forward mounting screw. Match drill the Super Tracks to the fuselage.

IMG_0205.jpg

IMG_0206.jpg

IMG_0207.jpg

IMG_0208.jpg

Mar 17, 2024 Canopy Preparation - (6 hours)

Category: Fuselage

Clamp the sliding canopy track to the longerons and match drill the outer mounting holes. Made a decision to incorporate the Fly Boy's Super Tracks to the canopy build now. Rivet the canopy track extension to the stock track. Notch the canopy tracks at the aft top to allow the canopy rollers to exit the canopy track when sliding the canopy open. Fit the right Super Track in position and bevel the aft end to nestle next to the rear skin.

IMG_0195.jpg

IMG_0196.jpg

IMG_0197.jpg

IMG_0198.jpg

IMG_0199.jpg

IMG_0200.jpg

Mar 17, 2024 Remove Cowl Pipe Mold - (.5 hour)

Category: Fuselage

Remove the mold used to form the exhaust pipe exit on the lower cowl. Trim the stray fibers and excess fiberglass at the exit.

IMG_0188.jpg

Mar 16, 2024 Fiberglass Cowling At Exhaust Pipe Exit - (1.5 hours)

Category: Fuselage

Create a mold from a large can wrapped with packing tape. Fit mold to lower cowling with fiber glass mat in place. Cover mat with epoxy resin.

IMG_0179.jpg

IMG_0180.jpg

IMG_0181.jpg

IMG_0182.jpg

Mar 15, 2024 Final Cowl Trim - (4 hours)

Category: Fuselage

Trim upper and lower cowl to exact firewall clearance. The top cowling ended up with gaps that will need to be filled and shaped. The bottom cowl came out precise with only some light sanding. Cut the clearance relief for the exhaust pipe exit. The cut is ready for fiber glassing the cowling exit channel covering the exhaust pipe.

IMG_0173.jpg

IMG_0172.jpg

IMG_0174.jpg

IMG_0175.jpg

IMG_0176.jpg

IMG_0177.jpg

Mar 14, 2024 Trim Cowl at Firewall - (3 hours)

Category: Fuselage

Trim upper and lower cowl at the firewall. This is an initial trim that still needs to be precisely matched to the firewall. Verify cowls are level.

IMG_0155.jpg

IMG_0156.jpg

IMG_0160.jpg

IMG_0162.jpg

IMG_0163.jpg

IMG_0165.jpg

IMG_0158.jpg

Mar 13, 2024 Canopy Cowl trim lines - (1 hour) Category: Fuselage

Mark firewall trim lines for upper and lower cowling.

Mar 12, 2024 Cleco Cowling to Fuselage - (2 hours)

Category: Fuselage

Add temporary mounting flanges to firewall. Mount cowling, match drill cowling to temporary flanges, and cleco the cowling to the temporary flanges.

IMG_0150.jpg

IMG_0151.jpg

IMG_0152.jpg

Mar 08, 2024 Preliminary Cowling Fit - (3 hours)

Category: Fuselage

Clamp cowling to fuselage and establish the horizontal and vertical placement using a laser level. Mount propeller spinner backplate to propeller and measure distance from propeller mounting flange to rear of spinner.

IMG_0119.jpg

IMG_0124.jpg

IMG_0125.jpg

IMG_0128.jpg

IMG_0129.jpg

Mar 02, 2024 More Cowl to Prop Spinner Clearance Adventures - (2 hours)

Category: Fuselage

Reviewing my prior measurement of the distance from propeller aft mounting/crankshaft flange to the spinner backing plate I mounted the plate backwards. The spinner backing plate has a 5/8" flange around the circumference for mounting nut plate attaching the spinner. This flange extends 7/16" aft from the aft backing plate mounting surface; 5/8" flange - 1/16" spinner back plate thickness - 1/16" spinner backing plate doubler). The location of the cowl relative to the crankshaft mounting is as follows. 1/4" flywheel thickness, 2" from the propeller aft mounting surface to the spinner backing plate minus 7/16" lip. Set Ez Cowl jig for 1 9/16". This distance is less than the supplied spacer that I used to set the clearance distance. Replace the spacer with the four bolts and locking nuts that hold the jig to the flange. The forward bolt head surface sets the clearance distance. The 1-1/4" bolts I have on hand are barely long enough and 1-3/4" bolts on order.

IMG_0093.jpg

Mar 01, 2024 Trim Lower Cowl - (2 hours)

Category: Fuselage

Trim the lower cowl to fit around gear legs.

IMG_0082.jpg

IMG_0083.jpg

IMG_0084.jpg

IMG_0085.jpg

IMG_0086.jpg

IMG_0090.jpg

Feb 29, 2024 Attach Nose Bowl Plate to Cowl - (2 hours)

Category: Fuselage

Determine that the fuselage longerons leveled horizontally are the desired position for mounting the cowl. The engine crank with the attached Ez Cowl Jig is also horizontal. Horizontally center the nose bowl plate on the cowl nose bowl. Vertical center the nose bowl plate and then raise the plate about 1/8" to account for engine mount sag. Match drill and cleco the nose bowl plate to the cowl nose bowl. Place the upper and lower cowl on the Ex Cowl Jig and slide it aft until the lower cowl touches the landing gear legs.

IMG_0078.jpg

Feb 26, 2024 More Cowl Preparaton - (4 hours)

Category: Fuselage

Fabricate a Lexan nose bowl disk to replace the OSB disk. It's thinner and can be clecoed to the cowl. Raise the tail with a longer upright to get the longerons level. This leveled the rear longeron but upon further consideration I probably want to level the forward longeron. Added center lines to the upper and lower cowl. Modified a rubber plug inserted into the crankshaft to block moisture. The plug was initially slightly too small for a tight fit so I expanded it using a 2" socket as a mandrel and a heat gun. Then I trimmer the outer diameter to the same size as the crank OD. Attached the David Howe Ez Cowl Jig to the crank prop flange.

IMG_0063.jpg

IMG_0064.jpg

IMG_0065.jpg

IMG_0066.jpg

IMG_0067.jpg

IMG_0068.jpg

IMG_0069.jpg

IMG_0070.jpg

Feb 24, 2024 Cowl Preparation - (3 hours)

Category: Fuselage

Complete research and order Skybolt fasteners for the cowling. Cleco the forward top fuselage skin. Add reference line 2" aft of the firewall in preparation for fitting the cowl. Pilot drill #40 the forward cowl attach screws.

IMG_0055.jpg

IMG_0056.jpg

IMG_0057.jpg

IMG_0058.jpg

IMG_0059.jpg

Feb 23, 2024 Fitting Engine Cowl - (3 hours)

Category: Fuselage

Grind and fit the flanges mating the upper and lower cowl at the nose bowl.

IMG_0052.jpg

Oct 29, 2023 Mount Com Antenna - (1 hour)

Category: Fuselage

Mount the Com antenna. I may rivet the doubler plate to the fuselage to facilitate future maintenance.

IMG_9570.jpeg

IMG_9571.jpeg

Oct 28, 2023 Antenna and Cable Infrastructure - (5 hours)

Category: Fuselage

Mount 5 lug terminal strip to the fuselage on the right near the right wing attach point. This strip will splice the CAN bus to the roll servo and the autopilot disconnect wire. Permanently mount the ADS-B receiver mounting brackets to the forward fuselage. Fabricate a doubler plate for mounting the COM antenna to the bottom fuselage aft of the baggage compartment.

IMG_9561.jpeg

IMG_9562.jpeg

IMG_9563.jpeg

IMG_9564.jpeg

IMG_9565.jpeg

Oct 27, 2023 tid bits - (2 hours)

Category: Fuselage

Fabricate a bracket to hold a 5 lug terminal strip. Add zip tie mounts to fuselage to route GPS and ELT antenna cables.

IMG_9557.jpeg

IMG_9558.jpeg

Oct 23, 2023 Add conduit - (2 hours)

Category: Fuselage

Add conduit to route GPS and Com coax cables from center fuselage on right to behind the baggage compartment bulkhead.

IMG_9548.jpeg

IMG_9549.jpeg

Oct 22, 2023 Rivet Doubler Plates to fuselage - (2 hours)

Category: Fuselage

Dimple fuselage at GPS and ELT doubler plates. With assistance rivet doubler plates to fuselage.

IMG_9536.jpeg

IMG_9537.jpeg

Oct 21, 2023 GPS & ELT antenna doubler plates - (5 hours)

Category: Fuselage

Fabricate GPS and ELT antenna doubler plates. Match drill fuselage for both plates.

IMG_9521.jpeg

IMG_9522.jpeg

IMG_9523.jpeg

IMG_9524.jpeg

IMG_9525.jpeg

IMG_9526.jpeg

Oct 13, 2023 Rivet subpanel and instrument panel - (4 hours)

Category: Fuselage

Complete riveting the instrument panel and subpanel to the fuselage.

IMG_9490.jpeg

IMG_9491.jpeg

IMG_9492.jpeg

IMG_9493.jpeg

IMG_9494.jpeg

Oct 01, 2023 Rivet subpanels - (2 hours)

Category: Fuselage

Continue riveting forward fuselage subpanels.

IMG_9445.jpeg

IMG_9446.jpeg

IMG_9447.jpeg

Sep 26, 2023 Complete installing AHRS doubler plate - (2 hours)

Category: Fuselage

Install nut plates and rivet AHRS doubler mounting plate to subpanel

IMG_9439.jpeg

Sep 24, 2023 Fuselage Modifications - (8 hours)

Category: Fuselage

Move left and right wing wiring terminal blocks to inside of rib to allow full access to the outer bay when installing wing attachment bolts. Make doubler plate to attach ADHARS to subpanel. This location facilitates the display screen removal. Move sensor manifold attachment to firewall to a vertical alignment in line with center forward fuselage rib. This location is structurally stronger. Add terminal block to splice sensor wires to the leads from the GEA 24 EMS.

IMG_9430.jpeg

IMG_9431.jpeg

IMG_9432.jpeg

IMG_9433.jpeg

IMG_9436.jpeg

IMG_9437.jpeg

Sep 16, 2023 Subpanel fabrication and current shunt - (6 hours)

Category: Fuselage

Begin riveting the forward fuselage subpanel. Add nutplates for mounting the primary fuse block. Fabricate bracket to hold the primary power shunt and sensor wire fuse blocks.

IMG_9396.jpeg

IMG_9397.jpeg

IMG_9402.jpeg

IMG_9403.jpeg

IMG_9404.jpeg

IMG_9405.jpeg

Jul 19, 2023 Fitting canopy frame - (8 hours) Category: Fuselage

Starting on July 15, worked several hours per day reading the instructions for fitting the canopy side frames to the longerons and fitting the frame. Completed fitting today. Checked rear bow fit with aft turtledeck skin with the bow below the skin by 1/8 to 5/8". Checked front bow with roll bar. Front bow 1/4 to 3/4" higher than roll bar. Will consider trimming the front bows where the rollers attach after fitting the canopy bubble.

Jul 14, 2023 Fit sliding canopy frame to fuselage - (8 hours)

Category: Fuselage

Cut and drill canopy slide rails. Fabricate center canopy guide. Temporarily mount slide rails and canopy guide to fuselage and begin fitting the canopy sliding frame.

IMG_9130.jpeg

IMG_9131.jpeg

IMG_9132.jpeg

IMG_9134.jpeg

IMG_9135.jpeg

IMG_9136.jpeg

Jul 09, 2023 Attach Roll Bar - (8 hours)

Category: Fuselage

Fabricate attachment shims, lay out roll bar attach points. Drill fuselage roll bar attach points and bolt roll bar to fuselage. Trim roll bar brace, match drill, and bolt brace to roll bar and fuselage.

IMG_9112.jpeg

IMG_9113.jpeg

IMG_9114.jpeg

IMG_9120.jpeg

Jul 07, 2023 Add subpanel supports for avionics and control cables - (4 hours)

Category: Fuselage

Created subpanel supports for the avionics stack and control cables. The control cables will be attached with Adel clamps.

IMG_9096.jpeg

IMG_9097.jpeg

Jul 02, 2023 Attach stick grips - (2 hours)

Category: Fuselage

Attach pilot and copilot stick grips to control sticks. Trim both sticks to eliminate interference with instrument panel controls.

IMG_9089.jpeg

IMG_9090.jpeg

Jul 01, 2023 Test fit panel - (4 hours)

Category: Fuselage

Cleco upper deck spars and subpanels,and mount panel in fuselage to test fit wiring with cutout hole in subpanel. Organize wiring routed from aft into two bundles that will route to the panel along the floor to the forward uprights, one on the left and the other on the right

IMG_9067.jpeg

IMG_9068.jpeg

IMG_9069.jpeg

May 28, 2023 Mount Alternate Air Door cable pass through - (2 hours)

Category: Fuselage

Drill firewall for alternate air door firewall pass through fitting. Tight space between mounted throttle fitting and vertical angle brace. Trim edge of throttle firewall pass through fitting and starter solenoid mounting bracket reinforcement plate to accommodate pass through fixture.

IMG_8837.jpeg

IMG_8839.jpeg

May 28, 2023 Fabricate secondary battery hold down strap - (3.5 hours)

Category: Fuselage

Fabricate hold down strap for secondary battery. Scuff and prime strap. Removable by pulling hinge pins.

IMG_8833.jpeg

IMG_8834.jpeg

IMG_8835.jpeg

IMG_8836.jpeg

IMG_8840.jpeg

IMG_8841.jpeg

May 21, 2023 Complete match drilling forward top skin - (4 hours)

Category: Fuselage

Clamp forward upper fuselage skin to workbench and roll form it around a pipe to add bend. Cleco and match drill the forward upper fuselage skins to fuselage and firewall..

IMG_8794.jpeg

IMG_8795.jpeg

IMG_8797.jpeg

May 19, 2023 Test fit forward upper fuselage skin - (1 hour)

Category: Fuselage

Cleco forward upper fuselage skin to fuselage in preparation for match drilling and dimpling to airframe and identify precise instrument panel location prior to drilling holes for panel to fuselage mounting angles.

IMG_8786.jpeg

IMG_8787.jpeg

IMG_8788.jpeg

May 18, 2023 Replace right wing vent line - (2 hours)

Category: Fuselage

Right wing fuel tank vent line interfered with subpanel. Fabricate new vent line fitted to avoid interference.

$gallery thumbnail$

IMG_8783.jpeg

May 14, 2023 Replace left wing tank vent line - (2 hours)

Category: Fuselage

Original left wing vent line interfered with subpanel. Fabricate and install new vent line.

IMG_8742.jpeg

IMG_8743.jpeg

May 01, 2023 Prepare flap and aileron gap seals - (4 hours) Category: Fuselage

Match drill, dimple, and prime right wing aileron and flap gap seals.

Apr 28, 2023 Complete aft top skin riveting - (2 hours)

Category: Fuselage

Complete riveting the aft top skin at and forward from the baggage compartment bulkhead.

IMG_8648.jpeg

IMG_8649.jpeg

Apr 27, 2023 Rivet aft top fuselage skin - (4 hours)

Category: Fuselage

Cleco aft top skin to fuselage and rivet to fuselage except for rivets at and forward from the baggage compartment bulkhead.

IMG_8642.jpeg

IMG_8643.jpeg

Apr 25, 2023 Horizontal Stabilizer trim pieces - (3 hours)

Category: Fuselage

Fit horizontal stabilizer trim pieces to fuselage. Match drill and dimple trim to fuselage holes. Trim about 1/16" to create a gap between the trim piece and HS.

IMG_8637.jpeg

IMG_8638.jpeg

Apr 23, 2023 Rudder pedal brake lines - (2 hours)

Category: Fuselage

Install fittings to brake cylinders. Cut for fit the left and right brake lines. Check for fit in fuselage.

IMG_8627.jpeg

IMG_8628.jpeg

Apr 22, 2023 Fabricate battery box and drill firewall penetrations - (8 hours)

Category: Fuselage

Started on 4/21 and finishing today. Fabricate battery box and install on firewall. Create steel template for drilling fire wall penetrations for DoubleTee firewall fittings. Locate and drill throttle, mixture, and propeller governor fittings and install on firewall.

IMG_8611.jpeg

IMG_8620.jpeg

IMG_8621.jpeg

IMG_8622.jpeg

IMG_8624.jpeg

IMG_8625.jpeg

IMG_8626.jpeg

Apr 16, 2023 Paint fuselage interiorq - (2 hours)

Category: Fuselage

Mask and cover fuselage in preparation for painting. Wipe all surfaces to be painted with coarse Scotch Brite pad and wipe with tack cloth. Hired painter to paint the fuselage interior. Jeff did a fabulous job.

IMG_8595.jpeg

IMG_8599.jpeg

IMG_8601.jpeg

IMG_8604.jpeg

IMG_8605.jpeg

$gallery thumbnail$

IMG_8606.jpeg

Apr 11, 2023 Pick up removable interior panels from paint shop - (2 hours)

Category: Fuselage

Inventory and transport 30 removable panels, flooring, and seat backs to paint shop. Pick up painted parts.

IMG_8584.jpeg

IMG_8585.jpeg

Apr 08, 2023 Attach fuel senders to mounting plate - (6 hours)

Category: Fuselage

Attach fuel senders with cork gaskets to fuel line mounting plates. Kit inventory provided two left tank sending units 385B. Install the right sending unit upside down. Bend float rods and install on senders. Attach right sender to left tank and left sender to right tank with floats facing outside. Verify float travel from minimum to maximum travel.

IMG_8570.jpeg

IMG_8571.jpeg

IMG_8572.jpeg

IMG_8573.jpeg

IMG_8574.jpeg

Apr 08, 2023 Mount light control board - (6 hours)

Category: Fuselage

Fabricate mounting bracket for FlyLEDS "works" control circuit board. Attach bracket to fuselage.

IMG_8567.jpeg

IMG_8568.jpeg

Mar 30, 2023 Fuel selector valve and lines - (4 hours)

Category: Fuselage

Mount fuel selector valve to valve mounting plate. Fit left and right fuel tank lines from the valve to outboard the fuselage. Temporary installation without flare fittings which will be added at final installation after installing the fuel filter and boost pump.

IMG_8540.jpeg

IMG_8541.jpeg

Mar 25, 2023 Collect panels for painter - (2 hours)

Category: Fuselage

Collect all removable panels and cabin artifacts needing painting, label and catalog them prior to sending to the painter. Thirty items total.

IMG_8517.jpeg

Mar 25, 2023 Fabricate stick boot rings - (2 hours)

Category: Fuselage

Fabricate two stick boot rings.

IMG_8516.jpeg

Mar 25, 2023 Fabricate and install left fuel tank vent line - (3 hours)

Category: Fuselage

Fabricate and install left fuel tank vent line

IMG_8515.jpeg

Mar 24, 2023 Right Fuel Tank Vent Line - (4 hours)

Category: Fuselage

Fabricate and install the right fuel tank vent line.

IMG_8490.jpeg

Mar 19, 2023 Wiring for ELT and Pitch Servo - (4 hours)

Category: Fuselage

Route wiring from the empennage forward towards the pitch servo. Connect pitch servo wiring and route the wiring forward through the center tunnel. Wire the ELT except for the antenna, and run wiring forward through the center tunnel.

IMG_8486.jpeg

Mar 18, 2023 ELT and Mag Sensor - (10 hours)

Category: Fuselage

Complete wiring the magnetometer connector. Fabricate a mounting plate for the ELT. Mount ELT to fuselage.

IMG_8461.jpeg

IMG_8462.jpeg

IMG_8463.jpeg

IMG_8464.jpeg

Mar 17, 2023 Wiring to Tail Light and Conduit to empennage - (8 hours)

Category: Fuselage

Install conduit to carry wiring from the empennage forward to behind the baggage comparment. Install wiring tail light forward to the fuselage behind the baggage compartment. Rivet the rudder fairing.

IMG_8459.jpeg

IMG_8460.jpeg

Mar 15, 2023 Tail light wiring - (4 hours)

Category: Fuselage

Add conduit to bottom of rudder tip. Drill hole through vertical stabilizer for tail light wire. Attach rudder to vertical stabilizer. Route tail light wire from empennage to tail light.

IMG_8450.jpeg

IMG_8451.jpeg

IMG_8452.jpeg

Mar 13, 2023 Routing static line - (4 hours)

Category: Fuselage

Routed conduit along left side under the baggage floor and seat floor. Add cable ties to support static line leading to the conduit.

IMG_8446.jpeg

IMG_8447.jpeg

IMG_8448.jpeg

Mar 11, 2023 Flaps and Static Port - (10 hours)

Category: Fuselage

Assembled flap mounting, added nut plates, and fit the side skirts. Mounted two static ports and routed line to the lower fuselage.

IMG_8434.jpeg

IMG_8436.jpeg

IMG_8437.jpeg

IMG_8438.jpeg

Mar 10, 2023 Flap attach bracket - (6.7 hours)

Category: Fuselage

Make angles and plates for flap assembly. Fit bracket to fuselage and match drill. Attach flap motor to bracket and actuator. Rivet all flap bracket parts and nut plates. Attach nut plates to forward elevator push tube tunnel.

IMG_8427.jpeg

Mar 06, 2023 Install flap actuator - (4 hours)

Category: Fuselage

Cut and drill 3 flap bearing blocks and install flap actuator in fuselage. Drill safety wire hole in the end of flap motor shaft.

IMG_8422.jpeg

IMG_8423.jpeg

Mar 05, 2023 Create carboard templates - (3 hours)

Category: Fuselage

Create cardboard templates for fuselage floor and side walls.

cardboard templates.jpeg

Mar 04, 2023 Begin empennage wiring - (5 hours) Category: Fuselage

Install electric trim servo and wiring in elevator. Route wiring to rear bulkhead. Run rear tail light and strobe through empennage. Reinstall vertical stabilizer.

Mar 04, 2023 Install heat vent valve - (5 hours)

Category: Fuselage

Drill two 2" holes in firewall for heat valve. Use 2" hole saw and a piece of wood with 2" hole to prevent the hole saw center from wandering. Use slow speed, plenty of cutting oil, and constant pressure. Bend center cover air louvers. Clamp a stiff straight edge to the bend line and a wide putty knife inserted under the louver as a metal brake.

IMG_8408.jpeg

IMG_8409.jpeg

IMG_8413.jpeg

IMG_8414.jpeg

IMG_8407.jpeg

Feb 24, 2023 Instrument panel layout - (10 hours)

Category: Fuselage

Working with UpNorth Aviation for the past month laying out the instrument panel. The panel is ready to cut out.

IMG_8378.jpeg

Feb 19, 2023 Install control sticks - (4 hours)

Category: Fuselage

Install left and right control sticks.

IMG_8363.jpeg

Feb 12, 2023 Aileron Trim - (5 hours)

Category: Fuselage

Fabricate aileron trim control and mount.

IMG_8350.jpeg

Feb 11, 2023 Attach fresh air intakes - (4 hours)

Category: Fuselage

Install fresh air intakes to fuselage

IMG_8343.jpeg

IMG_8344.jpeg

IMG_8345.jpeg

IMG_8346.jpeg

Feb 04, 2023 Steps and Brake Reservior - (3 hours)

Category: Fuselage

Drill firewall, attach nut plates, and brake reservoir to firewall. Rivet left and right steps with help from Xander.

IMG_8291.jpeg

IMG_8292.jpeg

IMG_8289.jpeg

IMG_8293.jpeg

Jan 23, 2023 Install Pitch Servo - (2 hours)

Category: Fuselage

Rivet pitch servo mount to center skin brace. Attach pitch servo to elevator bell crank.

IMG_8272.jpeg

Jan 21, 2023 Install Roll servo, HS tips - (4 hours)

Category: Fuselage

Rivet the horizontal stabilizer fiberglass tips. Install the roll servo in the right wing.

IMG_1439.jpg

IMG_1440.jpg

IMG_1441.jpg

Jan 11, 2023 Inventory Finishing Kit - (3 hours) Category: Fuselage

Received finishing kit yesterday. Inventory complete except for back ordered items.

Jan 01, 2023 Match drill panel angles - (4 hours)

Category: Fuselage

Add nut plates and cleco attach angles between panel and fuselage. This is a temporary setup before committing to using the supplied panel. Cleco the angle joining the center rib with the middle subpanel.

IMG_1429.jpg

IMG_1431.jpg

IMG_1432.jpg

IMG_1433.jpg

IMG_1434.jpg

IMG_1435.jpg

Dec 31, 2022 Attach rudder pedals to rudder pedal assembly - (1 hour) Category: Fuselage

Attach 4 rudder pedals to the rudder pedal assembly.

Dec 31, 2022 Fit front deck - (6 hours)

Category: Fuselage

Make attach angles, plate, and stiffening angle. Drill center rib to firewall. Deburr and fit left, center, and right ribs, left and right outboard subpanels, and center subpanel to fuselage. Check partial fit of forward top skin to verify fit with center rib.

IMG_1424.jpg

IMG_1425.jpg

IMG_1426.jpg

IMG_1427.jpg

IMG_1428.jpg

Dec 18, 2022 Mainly Crotch Straps and VS tip - (7 hours)

Category: Fuselage

Drill to fuselage, deburr, install nut plates, and primer right and left crotch straps. Ready for riveting. Create a fiberglass 4 ply layup sheet to enclose the aft end of the vertical stabilizer tip. Cut and shape to fit inside tip. Trim rudder lower fiberglass tip to fit around rudder cable attach brackets. Drill rivet holes tip to lower rudder. Drill mounting hole for rear marker light/strobe.

IMG_1420.jpg

IMG_1421.jpg

IMG_1422.jpg

Dec 11, 2022 Mount Rudder to VS, install tail cone stiffeners - (6 hours)

Category: Fuselage

Mount Rudder to Vertical Stabilizer. File rudder stops to ensure 35 degree rudder deflection. Measured 46 1/8" from rudder trailing edge to outboard elevator trailing edge. Unbolt HS and VS from fuselage and deburr all mounting holes. Install left and right rear tail cone stiffeners F-00773A: Look up installation on Van's website because drawings did not show, layout on fuselage, drill, dimple, and rivet stiffeners to fuselage.

IMG_1410.jpg

IMG_1412.jpg

IMG_1413.jpg

Dec 11, 2022 Mount steps to fuselage - (1.3 hours)

Category: Fuselage

Cleco left and right steps to fuselage and bolts support blocks and steps to fuselage. Ready to rivet steps.

IMG_8103.jpeg

IMG_8104.jpeg

IMG_8105.jpeg

IMG_8106.jpeg

IMG_8096.jpeg

Dec 10, 2022 Drill Rear VS Spar to bulkhead - (2 hours) Category: Fuselage

Drill vertical stabilizer rear spar to rear bulkhead F-712.

Dec 08, 2022 Drill horizontal and vertical stabilizer to fuselage - (2 hours)

Category: Fuselage

Drill vertical stabilizer front spar to F-981 attach plate. Drill horizontal stabilizer rear spar to Up elevator stop F-912C.

IMG_8109.jpeg

IMG_8110.jpeg

Dec 07, 2022 Mount horizontal and vertical stabilizer to fuselage - (2 hours) Category: Fuselage

Fabricate and mount Up Elevator Stop F-912. Mount attach plate F-981 to horizontal stabilizer forward spar. Trim vertical stabilizer forward spar Clamp the vertical stabilizer rear spar to to the back of builkhead F-912. Adjust vertical stabilizer such that the hinge line is colinear.

Dec 05, 2022 Steps and Vertical Stabilizeer - (4 hours) Category: Fuselage

Drill left step support block and deburr step. Prime left and right step. Restore the F-750R,L rear baggage cover plate nuts to the bulkhead. Both steps ready for permanent installation.

Bolt F-981 attach plate to horizontal stabilizer forward spar. Trim VS-702 vertical stabilizer forward spar as depicted in DWG 27A. Fabricate elevator stop F-912D.

Dec 03, 2022 Mount Left Step - (8 hours)

Category: Fuselage

Complete drilling left step support block to floor rib. Drill 1 1/2" diameter holes through skin and two ribs, and trim two flanges to situate the step to the left fuselage. Remove F-650 rear side baggage cover; drilled out QB installed nutplates, to expose F-624 rib that will support riveting the step to the fuselage. Drill left step rivet and support blocks. Left and right step ready for priming and riveting.

IMG_8086.jpeg

IMG_8088.jpeg

Dec 02, 2022 Start Right Step Mount - (3.3 hours)

Category: Fuselage

Drill 1 1/2" diameter holes through skin and two ribs, and trim two flanges to situate the step to the right fuselage. Remove F-650 rear side baggage cover; drilled out QB installed nutplates, to expose F-624 rib that will support riveting the step to the fuselage.

IMG_8083.jpeg

IMG_8082.jpeg

Nov 12, 2022 Rivet rear bulkhead and rudder stops - (7 hours)

Category: Fuselage

Rivet rear bulkhead F-712 to fuselage except for lower, inside rivets. Need pull rivets. Rivet rudder stops to fuselage. Add lightening holes to rudder pedal brace F-6118. Drill 3rd rudder position position. Split side rudder pedal bearing blocks. Since steps and flap parts are on back order, the next step appears to temporarily mount the wings and set the wing incidence.

JPEG image 17.jpeg

Nov 10, 2022 Forward covers - (5 hours)

Category: Fuselage

Fit center floor F-982C, access plate F-982E, and heat baffle F-982C, and install nut plates and rivet. Rivet nut plates to fuel valve plate V-983A and screw to bulkhead F-904. Fit F-982C between center floor reinforcement angles and adjust to fit fuel valve cover F-983C. Drill F-982C to floor stiffener angles and firewall recess F-601K-1. Install all remaining nut plates. Do not trim fuel valve cover yet.

JPEG image 13.jpg

Nov 09, 2022 Seat backs and rests - (4 hours)

Category: Fuselage

Rivet right and left seat backs and seat back braces. Add lightening holes to seat back braces. Match drill and dimple F-982E access plate and F-982 heat baffle to F-982C center cabin cover. Cleco nut plates to F-982C.

JPEG image 11.jpg

JPEG image 12.jpg

Nov 08, 2022 Seat backs and rests - (4 hours) Category: Fuselage

Rivet right and left seat backs. Fabricate two seat back rests; ready for riveting and lightening holes.

Nov 07, 2022 Build right seat back - (3 hours) Category: Fuselage

Drill, deburr, and prime right seat back assembly. Ready for riveting.

Nov 06, 2022 Tunnel cover & seat backs - (10 hours)

Category: Fuselage

Riveted tunnel cover to side flanges and drilled to forward floor and attached nut plate. Completed preparing left seat; material cut, drilled, and deburred. Started right seat.

JPEG image 10.jpg

Nov 03, 2022 Harness cable wear blocks - (4 hours) Category: Fuselage

Fabricate parts and install F-6114B&C cable wear blocks.

Nov 02, 2022 Baggage Compartment - (3.5 hours) Category: Fuselage

Drill in place the forward top skin F-774 to bulkheads and stringers. Skip steps installing the steps which are back ordered. Install nutplates on F-706

Oct 30, 2022 Fitting forward top skin and F-6111 ribs - (5 hours)

Category: Fuselage

Fit the F-7112 forward top skin to F-706 and F-707 bulkheads. Fit F-788 gusset. Ready to drill skin to bulkheads, stringers, and gussets. Trim and match drill F-6111 ribs to F-7112 skin.

JPEG image 6.jpeg

JPEG image 7.jpeg

JPEG image 8.jpeg

JPEG image 9.jpeg

Oct 30, 2022 Fabricate and fit elevator bell crank - (2.5 hours) Category: Fuselage

Trim F-757 gussets per plan Assemble and install elevator bell crank. Remove and store for use later. Quick build verify bell crank support, fitting aft top skin, and installing F-565L and R gusset plates.

Oct 29, 2022 Mount Rudder pedals in fuselage - (5 hours)

Category: Fuselage

Drill mounting holes in rudder pedal end blocks and center support block. Cut center support block per drawing. Mount rudder pedals in fuselage and drill mounting holes 3" from firewall. Cut and drill rudder pedal support bracket and match drill for mounting to firewall. Drill support bracket to fit center support block. Inspect quick build fuselage steps: install floor stiffeners, framing baggage area, riveting forward side skins, finishing forward fuselage and longeron details, installing forward fuselage gussets, and installing should harness anchors. Mark side gussets F-757 to trim for cutout per drawing.

JPEG image 3.jpeg

JPEG image 4.jpeg

JPEG image 5.jpeg

Oct 25, 2022 Rivet rudder pedals - (4 hours) Category: Fuselage

Machine counter sink and rivet left seat right and left rudder pedals.

Oct 23, 2022 Fuselage - (8 hours)

Category: Fuselage

Fabricate left and right F-792 rudder stops. Paint WD-409 tail spring bracket; ready to install. Fabricate left rudder pedal; ready to rivet. Inspected fuselage related to preparing and assembling the center fuselage and note instructions for preparing the step for installation (steps are back ordered), joining rear and center fuselage assemblies, adding the forward fuselage, installing auxiliary longerons and forward bulkheads.

IMG_7945.jpg

IMG_7946.jpg

Oct 22, 2022 Rivet Seat Adjustment Parts - (2 hours) Category: Fuselage

Bend seat adjustment plates with 4 degree bend per drawing. Rivet F-705J angle, F-705K plate, and F-705L seat adjustment supports to F-705F channel for right and left seats.

Oct 15, 2022 Drill WD-409 keeper rivet holes - (3 hours) Category: Fuselage

Fit F-712 bulkhead and drill two rivet keeper holes through F-712 and WD-409

Oct 14, 2022 Begin WD-409 installation - (4.5 hours) Category: Fuselage

Relieve F-779 skin to make room for tail wheel spring mount tube. Match drill WD-409 to F-711

Oct 13, 2022 Inspect Bulkheads - (3 hours) Category: Fuselage

Deburr, machine countersink, and prime seat adjustment parts. Need to bend F-705K with 4 degree angle prior to riveting to fuselage. Inspect quick build bulkheads F706, F-707, F-708, F-709, F-710, F-711, and F-712. Remove F-712 bulkhead and review WD-409 tail wheel spring mount installation.

Oct 12, 2022 Seatback fabrication - (4 hours) Category: Fuselage

Fabricate two each F-705J, F705K, and F-705-l seat adjustment supports Inspect F-705 bulkhead construction.

Oct 10, 2022 Assembling F-904 Bulkhead - (1.5 hours) Category: Fuselage

Verify quick build assembly: F-904A,B,C,D snap bushing holes 5/8", F-904C-L&R bulkhead assembly, rivet F-904C, F-904D, and F-904G. Fit WD-610, WD-611, and WD-612; filed WD-610, W-D612, and both brass bearings to fit WD-611,

Oct 09, 2022 Assemble F-601 Firewall - (6.5 hours) Category: Fuselage

Step through F-601 firewall assembly instructions to verify quick build construction and familiarize with parts, and drawings, Fabricate F-601 TD brake line bracket, match drill, machine countersink, prime, and rivet to firewall. Drill two 7/16" holes through bracket and firewall for brake line fittings, Match drill and dimple firewall recess F-601K-1.

Oct 07, 2022 Inventory Fuselage and Wings - (5 hours) Category: Fuselage

Receive quick build wings and fuselage, Store parts in hangar and begin inventory,