Apr 29, 2024     Skybolt Flanges - (4 hours)       Category: Firewall

Spent the day putting the Skybolt flanges onto the firewall. They had to be bent a certain amount (some of them, not all). I put a spacer underneath them - .032". I was able to mount the Skybolt fastener on all but two of them - I used two more than planned on the belly - 3 per side, rather than 2, so I was short two on the upper firewall. They are all clecoed in place except for the lowest two on each side. I riveted the bottom one in completely and the one above it is half riveted in ( I have to wait for the upper fuselage skin before I can do the other rivets).
Now I think I can put the engine mount back on - I had to take it off in order to attach the lower flanges.
Oh yeah, the reamer came in the mail today - except it is a #15 reamer and not a 5/16" reamer. Had to send it back.

  Apr 28, 2024     Skybolt Flanges - (2 hours)       Category: Firewall

I spaced out the flanges for the Skybolt fasteners that will go from the left side of the firewall up and over to the right side. I will use hinges for the rest of the cowling fasteners - for the left and right side lower cowling and going forward between the upper and lower cowlings. It just seemed like the Skybolts was a really good choice for the upper firewall. I drilled all of the holes in the flanges and the .032 spacer beneath them. I will need to deburr and countersink all of them and I will be able to rivet the lowest one on each side in place. I hope I didn't jump the gun in drilling all of those flanges but I think I am fine.
Kind of in a "can't do this until I do this" setup. Waiting for a carbide reamer so I can clean up the holes in the landing gear, then I can mount the engine mount. Once the aircraft is on it's feet, I can mount the antennas (couldn't do that with it on it's belly). The engine can be mounted and connections made. Once all of the wires are connected, I can test the electronics and avionics. Once they are good, I can rivet on the upper fuselage skin and the Skybolt flanges. Lots of dependencies.

  Apr 27, 2024     Trying to put her on her feet - (3 hours)       Category: Landing Gear

Worked on figuring out the Skybolt and how to take it apart. That took a little while. Once I did that, I prepped the bottom flanges for the fasteners. I put the locator magnets in place on the bottom flanges.
Next, I started spacing out the flanges for the upper cowl. I need to order a few more (miscounted).

  Apr 05, 2024     Trying to put her on her feet - (3 hours)       Category: Landing Gear

After drilling the hole through the tail spring, I was able to fit it and a quick pass with the drill made it so the mounting bolt fit.
The I lifted the airplane up high enough so I could mount the landing gear. I have to ream out the bolt holes that the AN5 bolt goes through to hold the landing gear in place. The holes in the engine mount are good but the holes in the steel spring landing gear are just slightly undersize for an AN5 bolt.

  Apr 04, 2024     Tailwheel - (3 hours)       Category: Landing Gear

I am about to mount the landing gear and realized that I really needed to mount the tailwheel first. So I mounted the tailwheel to the tail spring. Then I had to drill a hole from the bottom of the tail spring through the hole that is already in the tail spring mount (WD-409). I put it in position and started drilling upward through the hole in the tail spring mount. Once I had the hole started, I took out the tail spring and finished drilling the hole through it using the drill press. I would have never been able to drill the hole up from the bottom - it was hard enough on the drill press. Now the hole is in but I haven't had the chance to see if the holes line up.

  Apr 02, 2024     Throttle quadrant - (3 hours)       Category: Instrument Panel

I had to drill a hole through the firewall for cable access. Through this hole passes the throttle/propeller/mixture/oil cooler control/alternate air/and cabin heat control cables. Once that hole was ready, I was able to mount the throttle quadrant to the instrument panel and run the cables through the hole.
Additionally, I mounted the engine mount. Soon comes the engine.

  Apr 01, 2024     Got it together - (3 hours)       Category: Instrument Panel

Finished up the connections. Got the parking brake reconnected. Then I got all of the avionics and put them in the panel for a look at how the finished product will look. No engraving but I am really happy with the results. I should get the parts I need from Van's anyday now and then I will be able to run the cables through the firewall and will consequently will be able to mount the throttle/prop/mixture/etc.

  Mar 31, 2024     Putting back together - (2 hours)       Category: Instrument Panel

Yeah. So much for waiting a week or so for the clear coat to cure. Started putting all of the switches and other items back on the instrument panel and re-hooking up the wiring. I think it came out really good - not engraved, but still durn good.

  Mar 30, 2024     Instrument Panel and flaps - (3 hours)       Category: Instrument Panel

Removed all of the switches that I had put on the instrument panel. Once that was done, I clearcoated the panel a few coats. Now I need to let it cure for a week or so before putting anything back together.
I connected up all of the flap hardware and torqued it properly.

  Mar 28, 2024     Labels - (3 hours) Category: Instrument Panel

Now that the panel is painted, I am starting to put switches back in place and labeling those switches. After I had a few of them installed, I realized that I didn't clear coat the panel. Once all of the labels are on, I will have to mask off some of the switches and then spray the clear coat.