Apr 16, 2024     Tail light, and the wiring, bonded and riveted the firewall. - (10 hours)       Category: Fuselage

Finished up the tail light fairing and strobe light wiring. Hooked up fuel pump, and associated plumbing. Finished the firewall and bonded and riveted to the fuse. installed the lower exhaust tunnel, placed insulation on the backside of the firewall.

  Apr 12, 2024     Install ELT, build shelf for ELT, Rivet bottom skins - (20 hours)       Category: Fuselage

Built a shelf for the ELT, fabricated a doubler for the ELT antenna, installed the wiring and riveted in the baggage dividers. Also ran the wiring for the rear light/strobe to the cockpit.

  Mar 26, 2024     Wing fairings - (8 hours)       Category: Wings

Measured and layed out the wing faring pieces. This would have been a lot easier if the wing skins had not already been computer drilled. It was a real pain to mark and drill the rear fairings through the skins into the fairings. I'm also going to look for a better rubber trim piece that goes against the fuse as the recommended piece is too flimsy.

  Mar 20, 2024     Trimed Flaps, install belly skin, install auto pilot servos - (8 hours)       Category: Fuselage

Installed flaps, and trimmed the ends to match the fuselage, then cut the flap angle bracket, and riveted the end flanges, and brackets to the flaps. Then installed the belly skin with the polysulfide compound, and rivet to the fuselage. Installed the control box, autopilot servos, and the transponder antenna.

  Mar 17, 2024     Install wings, adjust pins, construct wing farings - (13.00 hours)       Category: Wings

Installed the wings and adjusted the hardware so that the pins moved in and out easily. drilled the rear spar attachments for the rear pins. Installed the side panels so that I could construct the wing fairings. Trimed the flaps and the flap fitting to the control rods. Still need to re-install the flap bulkhead inside flaps and rivet, and need to pull the wings to finish and rivet the fairings.

  Mar 11, 2024     Adjusting wings, Installing fuel tanks, and building aileron pushrods - (15 hours) Category: Wings

Spent a lot of time adjusting the wings so the pins (for the folding wing option) would insert and remove smoothly. I've got them as close as I can for now, but they are still a little tight. Installed the fuel tanks, and riveted them to the wings. Also built the aileron push rods, and installed them in the wings. Then reinstalled the wings so I can build the fairings.

  Mar 05, 2024     Installing wings - (2 hours)       Category: Wings

Moved my cars to the hangar until the wings are complete. This gives me the ability to put both wings on and finish the wing installation. Constructed a new dolly to hold the wing while I need to move it in and out of the fuselage. It's basically just a 2 piece sling I can move under the wing, and it will support it while I move it on and off the fuselage.

  Feb 24, 2024     Installed right wing - (1.5 hours)       Category: Wings

Installed and adjusted the right wing. This will allow me to finish wing root fairings. Will also install the fuel tanks, make the fuel connections to the distribution manifold, and the wiring connectors for the landing, position, and the strobe lights. Then reposition everything and install the left wing, and do the same.

  Feb 20, 2024     Made Circuit Breaker Panel - (6 hours)       Category: Instrument Panel

It took me 3 iterations to finally make this CB panel, but now it just needs to be labeled and assembled to the fuselage.

  Feb 18, 2024     Tested fuel tanks with 100LL - (4 hours) Category: Fuel System

Filled up the right tank with 100LL two weeks ago, and found no leaks, so I drained the right tank and filled the left tank with the fuel, and it sat for a week with no leaks, so drained it today, and now I can attach the fuel tanks to the wings.

  Feb 18, 2024     Main and starter contactors, and cabin heat - (5 hours)       Category: Firewall

Installed the Main and starter contactors and the 60 amp alternator fuse. Also drilled the holes for the gascolator, and the cabin heat diversion box. Mean time, I'm waiting for parts.

  Feb 09, 2024     Auto Pilot Servos; final insstallation - (4 hours) Category: Avionics

Finished up the installation of the pitch and roll servo's. Drilled the floor skins to mount the brackets, and drilled for the rivets in the top braces. photos look similar to last entry, but all screws have been installed, (w/o locknuts for now as the bottom skin is going to be removed for paint, then re-installed) just need to wire the D-subs to the EFIS.

  Feb 08, 2024     Mock-up of Auto Pilot Servos - (6 hours)       Category: Avionics

Built actuation arms for the pitch and roll servos from stock 6061 tubing; drilled and tapped as required and bolted the servos to their brackets. Positioned roll servo. and and hooked up the heim joints to locate a good position. Also did the same thing for the pitch servo. They are now ready to have the floor skin drilled, and mounted permanently. Still have to be wired to the EFIS system.

  Feb 06, 2024     Installed antennas - (4 hours)       Category: Avionics

Installed the COMM, ADS-B, and XPDR antennas. There is a little problem when it comes to mounting the antennas as the comm. must be 3 ft. away from the ads-b, and the xpdr, and the ads-b must be 3ft. away from the xpdr, (and visa versa) but there is not that much room on the bottom of this airplane. So, there had to be some compromises; if there turns out to be any interference from the antennas I'll have to move them later. The Auto Pilot servos are on the way so I'll install them next along with installing the right wing later this week.

  Jan 27, 2024     Auto Pilot Mounts - (5 hours)       Category: Controls

Built the A/P mounts for the A/P servos today. Took the file from SPA to my brothers shop who has a plasma table, and after loading the drawing in the computer we cut the .050" AL sheet for the servo. Brought it home and bent the tabs, and sides with my brake, then sheard the two reinforcements, and bent them in the brake also. Drilled the mounting holes and checked fit in the airplane.

  Jan 13, 2024     Landing, Taxi, Position, Strobe lights install - (15 hours)       Category: Lighting

Finished the installation of the Fly LED's wingtip lights. Spent several more hours than I anticipated getting the PCB's to fit the opening. Fiberglassed the inside of the wingtips for additional strength. drilled mounting holes for the boards, then got the vacuum formed lenses out to trim and install. Placed the lens over each opening orienting them to fit, then began the process of trimming the lens' to fit the channel I made in the wingtip. I spent about 5 hours just trimming each lens carefully so as not to cut too much. They fit very well, and I just have to figure out how I want to attach them. On to the next item!

  Jan 06, 2024     Building Landing, Strobe, and Position Lights - (12 hours)       Category: Lighting

Finished building and soldering the Fly LED's control board. Mocked-up the Fly LED's PCB's, and made a template for the opening. Opening is supposed to be 110 degrees, so the template made it easier to mark the cutout on the inside of the wingtip. Cut the openings, created a lip from the leftovers to hold the lens, then cut the supports from a sheet of 1/8 in. green fiberglass. Temporally installed the supports, then cut out the area where the lights, and heat sinks reside. Now all of the pieces need to be fiberglassed into the wingtips, and reinforced as the landing lights/heat sinks are fairly heavy.

  Jan 02, 2024     Throttle, Mixture cables, avionics, wingtips, and Fly LED's - (15 hours)       Category: Avionics

Whole bunch of small jobs are finished and started in the last week. Includes installing the Throttle and Mixture Cables. I needed to construct a new bracket for the cables as I am using a different throttle quadrant than the factory. Also built new brackets for the Carb Heat, and Cabin Heat cables. Finished installing the L/R wingtips. This became a necessity as my Lab went through the shop last week with her tail waging like a hurricane. I figured I'd rather fix the fiberglass wingtips than repair bent aluminum. They are drilled and countersunk for flush rivets, but not riveted yet as I'm going to install Fly LED's for rec. lights, strobe lights, and landing/taxi lights, and this will entail cutting out the outer portion of the tip to build mounts for the Fly LED's, and building Lexan covers. Started the Fly LED's yesterday, and trimmed the edges, laid out the L/R Strobes, and position LED's. Applied the electrical sealant to the strobes, and soldered them and the position lights to the board. Started the forward facing PCB that holds the Landing/Taxi lights. These come as just a box of parts; lets' call it a kit, if you have a good soldering station they go together easily, just don't drop any of the tiny metric screws on the floor!

  Dec 24, 2023     Panel Layout - (6 hours)       Category: Avionics

Laid out the panel cutouts, cut and filed the openings to fit the Carling switches, and the GRT Horizon EFIS. Worked on positioning the Circuit Breakers by function. I still need to drill for the Engine Primer, Headphones/Mic, Ignition Switch, and Carb Heat control.

  Dec 19, 2023     Built avionics shelf and set up the battery. - (5 hours)       Category: Avionics

Set up the avionics shelf to hold the battery, as well as the battery and starter solenoids, radios, transponder, GPS, etc. I'm using a Braille 11-1/2 # AGM battery that has 904 cranking amps.

  Dec 19, 2023     Hooked up elevator and rudder controls - (5 hours) Category: Controls

Installed the elevator push/pull tube to the control box and elevator, and then hooked up the rudder cables and springs, and adjusted.

  Dec 12, 2023     Control Box, Elevators, Rudder Rigging, Tailwheel. - (11 hours)       Category: Controls

Re-installed the elevator, and rudder, (hopefully for the last time), built the elevator control rod, installed the elevator spring, and drilled the holes to attach. Installed the elevator trim tab control. Had to re-adjust the elevator up angle to the required 25 degrees, somehow it changed. Drilled a larger hole in the tooling holes of rudder and installed a plastic tube to house the wiring for the anti-collision lights, and installed strain reliefs to protect it. Adjusted the control box rod settings to get correct movement. Rigged the rudder controls and adjusted them for even and smooth operation. Also built the shock rod for the tail wheel, and installed.

  Dec 05, 2023     Finishing up the canopy - (7 hours)       Category: Canopy

Attached the canopy to the canopy structure, and installed the hydraulic shock to the roll hoop and canopy. Installed the outside latch, and trimmed the fiberglass to spec. Removed canopy, and trimmed the fiberglass a little more as there was an interference when the canopy was up. Re-installed.

  Nov 26, 2023     Finished Flaps - (2 hours)       Category: Wings

Finished the last flap this a.m. and installed it on the wing for safe keeping. With that done I think I've arrived at the end of the "major" construction, everything is done with the exception of wing gap seals to fuselage, landing lights, instruments, wiring, finish canopy, rigging, and engine install. Whew, there's still a lot left!

  Nov 25, 2023     Ailerons and Flaps and Fuel Tank Testing - (12 hours)       Category: Wings

Finished the Ailerons, and installed on the wings. Assembled the Flaps, up-drilled #31/30, drilled #40 for the flange and the hinges, and then up-drilled 30, removed the clecos, dimpled and deburred all surfaces, and it's ready to be riveted tomorrow. Installed the right flap on the wing in the cradle, so it would be out of harms' way.
Then set up my fuel tanks for leak testing. Had a little trouble on the right tank, as I inadvertently inserted a regular rivet in the fuel cap mounting area, and it leaked like an old boat. Replaced the rivet with the proper closed capsuled rivet with new poly-sulfide sealant, waited a week for it to cure and then everything was 100%. Both tanks are leak free at this point, and I'm going to fill then with 100LL and let them sit just to be sure.

  Nov 18, 2023     Aileron Build - (8 hours)       Category: Wings

Started the Right aileron yesterday, built the aileron bell cranks for both L and R ailerons, as well as the L and R counter weight ribs, drilled them #40 and clecoed together in the skin. Up-drilled the aileron #30/31 today and countersunk all flying surface areas. (Protruding rivets on back side and hinge). Started the Left aileron, and I am ready to up-drill #31/30, dimple ,countersink, and rivet tomorrow.

  Nov 15, 2023     Finish Left wing - (7.5 hours)       Category: Wings

Placed all of the skins on the wing frame, drilled the hole for the tie-down. Placed the aileron and flap hinges on the rear spars, clecoed all skins and began riveting the skins. Fuel tank had been previously fitted , but I left out the rivets as if they hadn't been set up. Got everything aligned and riveted, but ran out of the BSC-43 rivets, so I've got them on order, and there are only about 10-15 missing. It's going in the wing cradle this week as I start the ailerons and flaps.

  Nov 12, 2023     Install Pitot and AOA plumbing, deburr and dimple skins - (7 hours)       Category: Wings

Finished deburring and dimpling the bottom skins, realized I forgot to dimple the ribs, so I had to remove the skins, and dimple all of the ribs, then re-hang the bottom panels. Installed the plumbing for the Pitot, and AOA (angle of attack). drilled the ribs and installed ferrules to prevent chafing of the tubing. Shortened up the piping from the Pitot tube, and set up so if I ever have to remove the tube I only have to remove the nut on the clamp then pull the whole assembly out to get to the tubing. Also installed the tube for the folding wing option to ensure there was no interference with the plumbing.

  Nov 10, 2023     Finish drilling left wing - (7.5 hours)       Category: Wings

Finished (up)-drilling the skins. Removed the lower skins and deburred, then dimpled the skins. Removed the top skins, and the rear spar. Counter sunk all of the holes in the spars, and the reinforcements for the skins, and fuel tank. Dimpled the rear spar, reinstalled and riveted the spar stiffener to the spar, then riveted the rear spar to the ribs. Re-aligned the wing in the fixture in preparation of installation of the skins. Will deburr and dimple the top skins tomorrow and start final assembly.

  Nov 08, 2023     Installing Fuel Tank in Left Wing - (4 hours)       Category: Wings

Finished the top skin of left wing, and the nose skin. Up-drilled the nose skin. Installed the fuel tank, but had to trim the nose skin about 3/16" to fit inside the fuel tank. Layed out the drilling pattern for attaching the FT to the spar.

  Nov 07, 2023     Left wing top skin - (8 hours)       Category: Wings

Up drilled the bottom skins, installed the top skins, drilled the ribs, and installed clecos. Cut the aileron hinge and installed in top of wing. Cut the flap hinge and installed in the bottom of wing. Drilled hinge and spar #40 clecoed along the way. Wrapped the nose skin around the nose ribs and tucked it into the top skin for match drilling, and moved into place using ratchet straps, then clecoed the nose skin to the ribs. Just need to drill the spar for the rivets then remove everything, deburr, and dimple.

  Nov 05, 2023     Left wing build, Pitot install - (11 hours)       Category: Wings

Installed the lower skin (inner and outer) on the left wing. Drilled #40 and clecoed the skin to the ribs and spars. Drilled, and attached the flap hinge to the bottom of the wing. Spent about 4 hours installing the Dynon pitot tube, with AOA to the wing using a Van's RV stand-off. Located it at the intersection of rib #8 and #9, as there is an inspection panel here which will make it easier to inspect and maintain the static system. I had to fabricate a backup plate for the tube as the joggle was only about 0.050" and the Panther spar is 0.125" thick. The Van's RV tube is riveted to the spar and the skin, and is very solid. Originally I thought I'd include a right angle brace to the #9 rib, but after drilling and clecoing, it's obvious that it doesn't need any more support.

  Nov 01, 2023     Left wing build - (5 hours)       Category: Wings

Clecoed the ribs to the left spar, attached the rear spar and set the wing level and square, measured the front and rear spar distance and set the rear spar to the front dimension using plumb bobs. Set the rear spar up so no twist is induced. Set up the rib stiffeners and drilled them for rivets.

  Oct 31, 2023     Building Left Wing - (5 hours)       Category: Wings

Started the left wing after finishing the right wing. Leveled the spar and squared up the fixture. Built the bell crank system for rib #8, and the bell crank support on rib #1. Riveted the nylon blocks on rib #4, and #7, and drilled the rib supports for ribs 1 thru 8. Riveted all of the supports and started to install the ribs on the spar. Will finish riveting the ribs tomorrow, and the rotate the spar so the aft spar is on the bottom.

  Oct 20, 2023     Riveting the Right Wing - (7 hours)       Category: Wings

Finished dimpling the nose skin, then installed the outer, inner, and the nose skin on the right wing. Riveted the inspection cover for the aileron bell-crank, outer skin then the inner skin, and finally the nose skin. I'll finish the top skin tomorrow, run a small ridged plastic tube for the wiring of my Fly LEDS through the wing, rivet, and then build a wing cradle so I can start the Left wing.

  Oct 18, 2023     Preparing wing right skins - (5 hours) Category: Wings

Removed all of the skins from the right wing. Deburred and dimpled the skins, rehung the bottom skins and prepared to rivet to the wing ribs and spar.

  Oct 15, 2023     Installing the fuel tanks, finishing Right wing - (12 hours)       Category: Wings

I spent around 6 hours yesterday setting the fuel tank into the wing. It just didn't want to lay down where it joins the outer leading edge skin. After figuring out that it had a lot to do with the amount of Poly-Sulfate tank sealing compound, and that the leading edge was too tight against the end of the tank, I cut the leading edge back 1/4" as suggested in the build manual, and reduced the excess amount of tank sealant on the edges of the tank, and got a good fit. Today I drilled the holes to rivet the tank to the wing. I used my LASER level to layout the lines for the rivets, and it works well; also used it to level the spar before I started building the wing. It took a lot longer than I anticipated to lay out the drill pattern for the tank, as you have to lay out all the holes, and they drill into the spars so you don't want to mess-up here. Tomorrow I'll finish up-drilling the top side of the wing then tear it all apart to de-burr, dimple the skins, and the ribs, countersink the spar, and reassemble to rivet. Will not rivet the fuel tank to the wing at this time, but it's ready to be mounted. Still have to p/u some plastic tubing to run through the wing for the wingtip/landing lights wiring.

  Oct 13, 2023     Install top skin, nose skin and hinges - (6 hours)       Category: Wings

Up-drilled the bottom skin #31 for flush rivets, installed the top skin and clecoed, installed the nose rib skin, and clecoed in place and up-drilled #31. Cut and set up the aileron and flap hinge.

  Oct 10, 2023     First wing skins being installed - (5 hours)       Category: Wings

Clamped and clecoed the outside and inside wing skins. Spent quite a bit of time getting the skins to line up especially the joint between the two skins at rib 8. Once I rechecked the wing for straight and plumb, I also rechecked the twist to be sure everything was correct, then drilled and clecoed first the outer, then the inner skin.

  Oct 09, 2023     Getting ready to skin a cat. (A Panther that is) - (10 hours)       Category: Wings

Set up all of the rib stiffeners, the bell crank ribs, the sliding retract nylon blocks, and the support on the first rib. Then riveted the stiffeners to the ribs, the nylon blocks, and the ribs to the spar. Checked the wing for twist and adjusted before installing and riveting the ribs. Used my LASER level to make sure the spar was perfectly level. Once all of the ribs were installed, I hung the (cat) skin on the bottom of the wing. Just need to drill the alerion and flap hinges to get ready to drill the skin to the ribs.

  Oct 05, 2023     Started the Wings - (6 hours)       Category: Fuel System

Built the structure to support the wings. Placed the Right spar on the fixture and began assembling the parts to make up the wings sans the fuel tanks. It took a little time to sort out all of the pieces and cleco the ribs and bellcrank structure to the ribs. Will updrill all of the parts and reinforcements this weekend.

  Sep 25, 2023     Fuel tank build - (13 hours)       Category: Fuel System

Built both fuel tanks using the Poly Sulfate compound. This stuff is real messy, and as usual the second tank was easier than the first. I ordered an extra pint of the fuel tank sealer so I'd be sure to have enough to finish the back pieces; it should be here by Friday then I'll finish them up, add the fuel gauge senders, make a manometer and test them.

I had enough tank sealant to finish the back of one tank, so I finished it yesterday.

  Sep 20, 2023     Prep and seal fuel tank end plates - (6 hours)       Category: Fuel System

Used a green Scotch-Brite pad on my Milwaukee electric drill to scuff up the end plates so the poly-sulfate sealant would stick to the them. This is a really messy job, as this stuff sticks to everything, and is a pain to clean up. I used acetone as a cleaner for the pieces, and soaked the rivets, and fuel pick-up in it to clean off any oils. Measured the poly-sulfate and its hardener on my gram scale and mixed thoroughly. Then applied to the rib, endplate, and fuel p/u reinforcement. Riveted the assembly together. Then cleaned up the mess! As in most things in life the second one was easier than the first.

  Sep 17, 2023     Dry assembled the wing fuel tanks - (8 hours)       Category: Fuel System

Assembled the Right fuel tank, clecoed the ribs, and attached the stiffeners. Added the fuel pick-up, and associated plumbing. Same build-up on the Left tank. Will dissemble, de-burr, apply the sealant for all the ribs, fuel gauges, vents, and rivets this week.

  Sep 14, 2023     Rivet Spar - (10 hours)       Category: Wings

Set up hydraulic riveter and pressed all 400 (well it was quite a few) rivets in the spars. All went well, it just took a little time for the first spar, but the second one went quite a bit faster.

  Sep 10, 2023     Finished the bonding and bolting of the canopy to skirt. - (3 hours)       Category: Canopy

I let the Bubble and Canopy skirt sit for a week + to be sure the bonding material had set. Installed the screws as per factory for a redundant bonding system.

  Sep 06, 2023     Install spar bushings, Check for riveting - (3 hours)       Category: Wings

Double checked the spars for riveting. Built a long table in preparation of the arrival of the rivet squeezer from SPA. Checked all bolt and rivet locations, torqued the bolts to spec and applied Torque-Seal. Installed the (4) wing bushings. Rivet squeezer should be here Monday or Tuesday.

  Sep 01, 2023     Assembled canopy to the skirt - (4 hours)       Category: Canopy

Prepped the canopy and clecoed the bubble to the skirt, sanded the skirt and the edge of the bubble to be bonded together. Placed the canopy on the fuselage to check fit, adjusted the clecos until I had no gaps between the skirt and the fuselage. Taped the edges so that the bonding agent would only be in the seam between the bubble, and the skirt. Bonded the bubble... what a mess! This is not fun! Took 4 hours just to glue the two together, pull the tape and clean up the excess. Now it has to sit for 3 days to cure.

  Aug 30, 2023     Landing gear install, brakes, wheels and tires install. - (4 hours)       Category: Landing Gear

After sanding and smoothing the landing gear, I installed them in the fuselage. Then installed the wheels, brakes and tire sub assembly to the gear legs. Took the fuselage off of the saw horses and moved it to the other garage. Replaced the saw horses with a low bench to work on the canopy, and am getting ready to glue the "bubble" into the skirt.

  Aug 22, 2023     Landing Gear Prep. & Optional Baggage Close Outs - (5 hours)       Category: Landing Gear

Made a pair of rear baggage close-outs so things don't end up in the tail of the A/P. Received the landing gear legs today, and filed the milling machine marks out, then sanded the surfaces to a smooth surface with no stress risers. Rounded the top of each leg with my grinder, then filed them smooth and sanded them as the rest of the legs. Finally I primed them with a self-etching primer. Landing gear legs were machined really well and there was not as much work here as I expected.

  Aug 18, 2023     Trimming Canopy Bubble - (6 hours)       Category: Canopy

Placed the bubble into the canopy skirt. marked it for trimming, and removed it to cut. Taped up the edge of the bubble 3/4" for the cut. Placed the bubble back into the skirt to check the alignment before the cut. Used my 4" grinder with a 1/16" cut off wheel to cut the bubble. Sanded the edge to the tape line and replaced the bubble. Clecoed the bubble to the canopy skirt. Will finish it when the epoxy gets here.

  Aug 16, 2023     Built structure for Canopy bubble - (3 hours)       Category: Canopy

Built form to install the bubble top canopy. Screwed the canopy to the structure in preparation to mount the bubble.

  Aug 12, 2023     Frame for the canopy - (12 hours)       Category: Canopy

Gathered the parts for the canopy system. Measured, drilled and assembled the framework to hold the bubble. Installed the hinges to the frame with much trouble. When they were welded to the fuselage they warped and made it very difficult to operate. This item took a lot more time than I expected, as there is a lot of fabrication here. I'm doing the emergency canopy deployment system. (not that I intend to jump out of a perfectly good airplane).

  Aug 05, 2023     Right and Left spar assembly - (12 hours)       Category: Wings

RIGHT SPAR; Finished filing and sanding the milling marks out of the spar stack. Deburred all holes, countersunk holes for rivets, and c-sunk bolts. Assembled the spar with the required bolts, and used regular nuts until all checks have been made. Will call for the hydraulic rivet tool later this week as I still have to do the left spar and I want to rivet them at the same time.
Update: Left spar deburred, spar stiffeners filed, and sanded to remove all stress risers, bolt holes drilled, and countersunk where required, and correct bolts installed.

  Aug 03, 2023     Spar drilling, and reaming - (4.5 hours) Category: Wings

Drilled the right spar for the bolts, reamed all holes for the bolts, and the rivets. Disassembled the spar stack and started to polish the milling marks and scratches and smooth out the edges. I now know why someone would spend $2000 for the manufacturer to do the spar assembly!

  Aug 01, 2023     Getting ready to start the spars. - (5 hours)       Category: Wings

Started the spars today. Identified the right spar, and with the plans layed out the drill locations for the bolts and rivets. Identified the locations that need to be countersunk. Double checked the locations, (will triple check the locations tomorrow, I don't want to make any mistakes here)

  Aug 01, 2023     Finishing the Fuselage - (8 hours)       Category: Fuselage

Finished dimpling the side skins and the bottom skin for flush rivets. Clecoed the skins and cheeks to the fuse, and when the gear arrives I'll be able to move it to the other garage and start the spars to build the wings.

  Jul 26, 2023     Miscellaneous assembly of fuselage parts - (8 hours)       Category: Fuselage

While I'm waiting for my landing gear and a few other items, I installed the bearings in the wing bell-cranks, assembled the control rod heim joints, and bushings. Cut, drilled, and built the flap handle, then installed the rest of the flap control system. Installed the throttle/mixture control, and the trim lever. Cut the 2" dia. tube that supports the folding wing , and installed the U-joints for the folding wing option, as well as locating the wing tripods on the sides of the fuse. Built the Control Box (still waiting for the 2 main bearings) and assembled the nylon stop, the bearings for the control stick, and attached all of the hardware so that it will be ready when I can install it. Built the tailwheel control, just need to re-mount the rudder to finish it.

  Jul 20, 2023     Install 2 wiring bulkheads in firewall - (6 hours)       Category: Fuselage

Installed the bolts to join the tail cone to the fuselage, which now makes it one piece. Installed two stainless wiring bulkheads in firewall, finished up the trim tab lever, and throttle quadrant. Plumbed the brake master cylinders to the installed reservoir.

  Jul 18, 2023     Tires, tubes, and wheel package assembled - (5 hours)       Category: Landing Gear

Assembled the tires and tubes, to the wheel, fit the gear adapters to the axels, and cut the axles to length. Then drilled the axles and secured them with AN4 bolts.

  Jul 13, 2023     The Tail Cone (TC) meets the Fuselage (F) - (6 hours)       Category: Fuselage

Finished the side air vents, and rearranged the garage to join the TC with the F. Leveled both pieces, joined them, and will drill the holes to bolt the two together.

  Jul 09, 2023     Air Vents Install - (4 hours)       Category: Fuselage

Layed out holes for a set of Van's RV side vents. I was thinking about moving them 4 inches forward of this location, but now that my seat is in it would have been too far forward to operate. These are very reasonably priced and will work quite well I believe.

  Jul 07, 2023     Finished the radio panel cover, and built seat, and installed rudder pedals. - (8 hours)       Category: Fuselage

Applied the former for the top panel on the firewall, and similar on the Instrument panel. Assembled the seat, and installed. I got in and set up the rudder pedals, and brakes to my liking.

  Jul 03, 2023     Install cheeks, Exhaust tunnel, joggle strip - (4 hours)       Category: Fuselage

Finished the cheeks, installed the joggle strip for the cowling, then flipped the fuselage over re-installed the bottom and side skins, and installed the formers for the exhaust tunnel.

  Jul 02, 2023     Fuselage Skins - (8.0 hours)       Category: Fuselage

Attached Left and Right side fuselage skins. Drilled all holes #40, Installed wing, gear and side stiffeners, map box, firewall, and side cheeks. Cheeks still need to be trimmed, and both panels need to be up drilled. Firewall needed quite a bit of massaging to fit properly, I'm not too happy with the way that was designed, as there is no way to make it perfectly flat due to the fuselage construction.

  Jun 29, 2023     Started the skin application on the fuselage       Category: Fuselage

Centered and clamped the bottom skin to the fuse, drilled #40, installed the bottom stiffeners, fuel box, and a few other misc. parts. Placed the side skin on the fuse to get ready to drill #40.

  Jun 29, 2023     Cut tail faring to better fit the H/V-tail - (3 hours)       Category: Empennage

Cut and smoothed out the faring, re-fiber glassed it to fit the tail

  Jun 10, 2023     Installed Magnetos and timed to engine, added oil filter component - (2 hours)       Category: Engine

Installed new mechanical fuel pump, and fittings. Installed rebuilt mags, and timed mags to engine. Installed oil filter adapter and filter.

  Jun 06, 2023     Installed Static Ports - (2 hours)       Category: Empennage

Drilled holes for Dynon Pitot/Static system, countersink holes, and flush rivet.

  Jun 02, 2023     Reconfiguring the accessory case for a mech. fuel pump, and new seals. - (2 hours)       Category: Engine

Installed new gear with fuel pump eccentric, adding pump rod, changed out oil pump, removed vacuum pump, cleaned oil pan for new paint.

  Apr 30, 2023     Finishing the Tail Cone (Horiz. Stabilizer, and Rudder Install) - (4 hours)       Category: Empennage

Located the HT supports, made sure the HT was square with the TC. Drilled, and reamed the mounts for tight fit bolts. Removed rudder from VT and mounted it on the TC. Still have some work left to finish the install.

  Apr 12, 2023     Finished the Tail Cone - (4.5 hours)       Category: Empennage

Re-clecoed and finished dimpling a couple of pieces I forgot to do. Started riveting yesterday, and finished up with everything else today. Nothing to do now but wait for the next installment. Still waiting for the tail wheel spring,and a couple of back ordered items needed to finish.

Also set the Horizontal Tail and the elevators on the TC to see how it's going to look.

  Apr 10, 2023     Corrosion proofing - (2 hours)       Category: Empennage

Disassembled the Tail Cone, and etched the skins with Bonderite C-IC 33 AERO, rinsed, and then applied Bonderite M-CR 1001 AERO, dried and moved back to garage to re assemble. Bonderite M-CR 1001 is a clear Alodine, and does not stain the aluminum that gold color.

  Apr 05, 2023     Dimple Tail Cone skins, and re-cleco - (6 hours)       Category: Empennage

Disassembled and deburred the TC skins, dimpled the skins and countersunk the longerons for flush rivets. Reassembled the TC, clecoed, and riveted the bulkheads, strengtheners and formers for the turtle deck skin.

  Apr 01, 2023     Former #1 attached - (8.0 hours)       Category: Empennage

Attached the front skins to the Tail Cone. This turned out to be more frustrating than I thought it was going to be, I had a hard time lining up the skin to the TC. Once I got everything lined up I was able to cleco the skin to bulkhead #2 then attach the #1 Former to the front skin, drill and cleco. I then drilled the skin to the upper longerons. Once I was happy with the install, I up-drilled all of the holes that were #40 to #31, and I'm now on to the tailwheel reinforcement on bulkhead #4 and #5.

Tail wheel mount was welded incorrectly, so it's on the way back to SPA, mean time I've finished up-drilling everything and disassembled everything to start the dimpling sequence. 3 more hours.

  Mar 31, 2023     Turtle Deck install - (4.5 hours)       Category: Empennage

Clecoed the #2, #3, #4 formers, and rear deck. Stretched the upper skin over the formers and clecoed to the upper longeron, and down the other side. Then installed the skins for the front above the baggage compartment.

  Mar 29, 2023     Build of the Tail Cone - (8.0 hours)       Category: Empennage

Received my Tail Cone section on 3/28, laid out the parts, orientated the upper and lower longerons, as per the plans. Drilled #40 and clecoed the skin to the lower longerons, then the upper longerons. Built the #1 thru #3 bulkhead structures, and clecoed everything together. Updrilled #31 the lower longerons. Turned the fuse over, and drilled #40 for the bottom skin. Put in the stiffeners for the side and bottom skins. Updrilled #31 the bottom skin to the lower longerons, and clecoed.

  Mar 20, 2023     Fit elevator end fairings - (2.0 hours)       Category: Empennage

I'm waiting for the next installment of my kit, so I spent a couple of hours fitting the end fairings on the elevators. Set them up for flush rivets and riveted the closing rib to the fairing. I didn't final rivet the fairing to the wing but it's all ready with dimpled skin and c'sunk fiberglass.

  Mar 14, 2023     Finished Tail Section - (8.0 hours)       Category: Empennage

Finished riveting rear spar in the Horiz. Tail, installed R skin, and hinge, clecoed all, riveted the skin. Move on to the Vertical Tail, installed rivets for the spar, re installed skin, clecoed, installed hinge, and riveted skin to structure. Installed the elevators to the Horiz. Tail to install the control mechanism, and riveted it to the HT end rib.

  Mar 10, 2023     Build-up of the Vertical Stabilizer - (5.0 hours)       Category: Empennage

Made a set of legs to elevate the rudder while working on it, and laid them out in the middle of the spars. Deburred, pre-drilled spars and stiffeners, assembled the ribs, nose pcs. and spars. drilled and clecoed the R side, turned over and drilled and clecoed the L side. Drilled the hinge and clecoed to the end of the VT and then laid out the drilling for the lower portion of the hinge.

  Mar 05, 2023     Elevator skins ready for updrilling - (3.50 hours)       Category: Empennage

Finished the R elevator bottom,& clecoed, started the L elevator, clamped skin and adjusted, drilled, and clecoed the top skin, flipped the assy. and used ratchet straps to pull the skin to the rear spar. Aligned the ribs, drilled #40, and clecoed the skin. Elevator is now ready to updrill #31, drill for the hinge, dissasemble & debur.

  Mar 04, 2023     Elevator skin install - (4.50 hours)       Category: Empennage

Drilled the R elevator skin #40, clecoed, updrilled #31, re-clecoed. Flipped the elevator over and used a few blocks and ratchet straps to contour the skin to rib structure so the skin was tight to the ribs and spars. Aligned the skin, drilled #40 and clecoed as I went untill all of the ribs and spars were clecoed. The skin is nice and tight to the structure. Just have the hinge to drill, and then it gets riveted.

  Mar 03, 2023     Preparing the Horiz. Tail spars & start Horiz.Tail - (4.50 hours)       Category: Empennage

Riveted the FWD spar to the stiffener, clecoed the AFT spar to the stiffener as I'm using flush rivets, I'll mock it up, up drill etc, dissasemble the AFT spar, then dimple, rivet, and rivet the whole skin. (there is not enough room to dimple the AFT spar if it's already riveted therefor the need to remove the spar from the stiffener)

  Mar 02, 2023     Rudder - (6 hours)       Category: Empennage

While waiting for a couple of items I forgot to order, I started the rudder. Trimmed the stiffeners, clecoed, installed the ribs per plans. Attached rib #3 fixture to eliminate twist in the control surface, trimmed, drilled, and installed the hinge, and finally the rudder horn. Then up-drilled, and clecoed for 1/8" rivets.

  Mar 01, 2023     Rudder - (5 hours)       Category: Empennage

Finished riveting the elevator this a.m., and started the Horiz. Tail spars. Clecoed the spars to the spar supports, reamed holes, dimpled the center rivets, and C-sunk the spar supports. Removed, deburred all holes and prepped for riveting.

  Feb 27, 2023     Riveted elevator skins - (7.00 hours)       Category: Empennage

Up drilled, Deburred the R/L elevators, and trim tab, dimpled the top and bottom skins, countersunk holes for the trim tab in the hinge. Riveted the R elevator and prepared the L elevator for tomorrow.
BEST TIP OF THE WEEK… I bought a set of “Deburr” tools that are used in a drill; I had to get them from the UK as no one here had any. These will probably save me over 50 hours for the build. I highly recommend over the “hand deburring tool”.

2/28/23 (3 Hrs.)Finished Left elevator and trim tab, started rudder by disassembling and deburring, re-clecoed, and prepared to rivet.

  Feb 23, 2023     Started rudder - (4 hours)       Category: Empennage

Started to dimple the elevators, but found that my nail dimpler is missing, so I started the rudder. Drilled the rudder horn to the lower support. Put in the stiffening strips, all ribs, and clecoed the whole assembly.

  Feb 20, 2023     Elevators - (7.0 hours)       Category: Empennage

(4.0 hrs.) Started Left elevator, same as yesterday, except this control surface has the trim tab to deal with. Accomplished the same amount today as I did yesterday in 6 hrs.

2/21/23 (3.0 hrs.) Finished up the trim tab spar and stiffener. Trim tab hinge installed. Found that the trim tab bracket has been bent incorrectly so I notified the MFG, and they are sending me a new one.

  Feb 19, 2023     The Project Starts - (6.00 hours)       Category: Empennage

2/19/23 Unwrapped the empennage kit, and laid out the right horizontal tail section. Reviewed the plans and Build Manual for the Panther. Assembled right elevator; the ribs, drilled #40, and clecoed the skin to the ribs. Laid out the elevator hinge, drilled #40, and clecoed.

  Jan 27, 2023     This is what I'm building       Category: Research

Received my tail kit today, will start in a couple of weeks.