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Entry #	Created	Title	Category	Hours	# Pictures

187	Apr 09, 2024	Added air filter	Engine	2	2
Removed 90 degree nozzle towards front air inlet Added K&N filter with aluminium tube extension

 

186	Apr 08, 2024	Added baffling to cylinders #1 and #3	Engine	2	0
Added more cover for the #1 and #3 cylinders to bring temperatures HIGHER and bring in line with #2 and #4 ... needs testing

 

185	Apr 06, 2024	Various Little Updates	Paint / Decals	2	0
Fixed cowling nutplate that was bending and falling off Sanded down inside of cowling where rubbing happened Reinstalled tire pressure sensors Refilled brake reservoir

 

184	Apr 06, 2024	Completed Piston/Cylinder Upgrade	Engine	10	2
Finished wiring cleanup Installed baffling Installed plenum Installed cowling Did 1hr test flight CHTs good for cylinders 2,3,4, never above 380 CHT for cylinder 1 too low, never hit 300 ... removed metal tape on front inlet Oil temp went too high at 225 ... removed lower inlet blocks, removed throttle body elbow and increased outlet opening at bottom end of cowling Had lower spark plugs fouled, so removed, cleaned and reinstalled them

 

183	Apr 05, 2024	Continued piston/cylinder upgrade	Engine	12	7
Measured valve lash, all within tolerance, mostly in the 70s Installed valve covers and tidied up loose items Test ran engine for leaks, no leaks found Removed previous CHT sensors Disconnected EGT sensors as bundled together with CHT sensors Resoldered all EGT & CHT connections, with new shrink tubing ... solder joints / sensor readings need monitoring NOTE - right side bundles are #1 EGT & CHT, #3 EGT & CHT, left side mixed up #2 EGT with #4 CHT, #4 EGT with #2 CHT Re-bundled all wires Replaced all spark plugs with new ones Mounted CHT sensor rings on underside underneath the 18 to 14mm adapters Torqued adapters per SDS manual Replaced valve covers with newly cleaned, sand blasted and painted covers

 

182	Apr 04, 2024	Upgraded pistons/cylinders with High Compression	Engine	12	10
Took off cowling, plenum and baffling Took off bottom parts, intake tubes, pushrod tubes and exhausts Removed cylinders and pistons Installed new pistons and cylinders Discovered need for different CHT sensors, no ports for bayonet style sensors ... Ordered 18mm sensors Reinstalled all bottom parts Tried to deflate hydraulic lifters to install rocker arms but inflated again too fast Pushed in valves instead and then installed rocker arms

 

181	Sep 01, 2023	Upgraded Falken FDC to v3	Avionics	20	1
Uninstalled all USB equipment and wiring Rewired everything to serial Installed new GPS Installed new FDC Tested all and installed a bunch of firmware updates

 

180	Aug 27, 2023	Finished paint & decals	Paint / Decals	20	2
Touchups with paint Cowling painted Vinyl applied Decals applied Headrest with embroidery installed

 

179	Jun 22, 2023	Made & installed aluminum baffles	Engine	4	0
Replaced metal tape with metal baffles Baffles are for undersides of cylinders, both front and rear Baffles are held in with safety wire Also added significant metal tape around cyl #4 front

 

178	Jun 22, 2023	Tested EGT & CHT sensors for temp differences	Avionics	1	0
Put all sensors in same hot water and checked for consistent temps ... ALL OK

 

177	Jun 22, 2023	Fixed EGT #2 connection	Avionics	4	0
Had a "Wackelkontakt", a loose connection, at the solder joint for cylinder #2 EGT which also included cylinder #4 CGT probe Re-soldered BOTH connections Redid lots of zip ties

 

176	Jun 20, 2023	Replaced ELEVATOR springs	Controls	2	0
Replaced lighter springs with STRONGER stock springs

 

175	Jun 09, 2023	5 Hour Inspection	Inspection	4	1
Compression - #1 68/80, #3 75/80, #2 76/80, #4 74/80 Top Spark Plugs - Clean; Bottom Spark Plugs - Clean Looked into cylinders with little camera - Looking good from what we can see Torqued spark plugs back to 25-30 outer rings, 18-22 plugs itself Changed oil filter Tempest AA408108-2

 

174	Jun 07, 2023	Added metal tape covers on front cylinders	Engine	1	3
Found significant temp differences between front and pack cylinders Added tape on front to get better flow in back

 

173	Jun 06, 2023	Added sparrow strainers to elevators	Wings	6	1
Had to hold significant back pressure Decided to add carbon sparrow strainers

 

172	Jun 06, 2023	Calibrated fuel sensors	Fuel System	8	1
Found main fuel sendor to be not calibrated Removed sender from tank, rebent slightly to point AFT, not sideways Calibrated on bench with Westach instructions for manual calibration Reinstalled sender Calibrated main sender with V values ... Good values up to 12 gallons Calibrated header sender ... Good values all the way to 5 gallons, room for one more gallon most likely

 

171	Jun 06, 2023	Changed light spring for one side to stronger	Controls	1	0
Experienced stick back pressure needed so added stronger spring Decided to also add sparrow strainers

 

170	Jun 04, 2023	Prop Balance	Propeller	2	0
Done by Jeremy Read 3.6 at start, improved to 1.5-1.6 with one weight taped to inside of flange

 

169	Jun 03, 2023	FIRST FLIGHT	Inspection	1	0
We, well Eric, did the first flight today and most things worked well

 

168	Jun 03, 2023	Swapped tires for better balance & fixed rotor wobble	Landing Gear	4	0
Took out tires and saw significant flat spots Replaced tires with other old tires but in better shape Tightened rotor bolts to achieve best true alignment

 

167	Jun 03, 2023	Swapped tires for better balance & fixed rotor wobble	Landing Gear	4	0
Took out tires and saw significant flat spots Replaced tires with other old tires but in better shape Tightened rotor bolts to achieve best true alignment

 

166	Jun 02, 2023	Installed air vent	Interior Finish	3	0
Connected flex hose to NACA vents on each side ... PIA placing and stuff in the way Drilled and floxed in carbon tube to NACA vent for iPad mount air Connected silicon hose from NACA vent carbon tube to iPad mounts

 

165	Jun 01, 2023	Tested Static & Pitot	Avionics	2	0
With JRs help, tested that both pitot and static ... seems leak free but found significant speed differences between Falken and AV-30

 

164	Jun 01, 2023	Labeled fuel fill	Paint / Decals	1	1

 

163	Jun 01, 2023	Installed, polished and added more screws to spinner	Propeller	6	3

 

162	May 31, 2023	Polished wing, canard and installed VGs	Wings	3	2
Used Marine polish and paint came out amazing VGs look way aft but its according to plan Went with 20 pairs of VGs per side, following Jason Skiby recommendation

 

161	May 30, 2023	Fixed safety wiring on prop	Propeller	1	1

 

160	May 29, 2023	Installed new brake pedals	Controls	8	2
Made new brake pedals out of stronger materials Put a vertical bend on them for extra strength Re-installed new pedals with brake cylinder mounted at the rear of bracket

 

159	May 29, 2023	Label fuel fill	Paint / Decals	1	1
Added label per D.A.R. instructions

 

158	May 28, 2023	Checked travel for all control surfaces	Controls	2	0
Measured against POH numbers Elevator travel more than in POH ... OK Aileron travel a little uneven between up and down Rudder travel OK Compared with Jim P who is less travel than we do

 

157	May 27, 2023	Polished canopy glass	Interior Finish	8	1
What a PIA Used sanding system from ACS first Then used polisher from Harbor Freight with other #3 and #2 polish out of bottle

 

156	May 27, 2023	Moved GPS for better reception	Avionics	2	1
Taxi test showed that under glare shield I loose reception Moved on top of glare shield by drilling hole and glue down with contact cement

 

155	May 27, 2023	Safety wired bolts	Propeller	1	1
Bolts have special nuts but safety wiring just in case Eric re-did mine, in nice 2 bolts at a time pattern

 

154	May 25, 2023	Airworthiness Inspection PASSED	Inspection	2	1
HURRAY!!!

 

153	May 24, 2023	Connected & installed air filter	Engine	3	1
Cut & floxed in a screen Connected throttle body with canopy inlet with baffling material Cut foam filter material and stuffed into air intake

 

152	May 24, 2023	Installed Fobo BT pressure gauges	Landing Gear	2	0
Left one has a bad thread but Chris got it on

 

151	May 24, 2023	Installed N number, Experimental & Data Plate	Paint / Decals	1	2

 

150	May 19, 2023	Wrote POH & Checklists	Inspection	40	0
https://bit.ly/DuckieManuals https://bit.ly/DuckieChecklists https://bit.ly/DuckiePOH

 

149	May 19, 2023	Redid brake lines	Landing Gear	8	3
Redid brake lines with aluminium tubing vs plastic Fixed bend away from wheels

 

148	May 13, 2023	Installed air intake connection to cowling	Engine	1	4

 

147	May 11, 2023	Installed arm padding & glare shield	Interior Finish	4	4

 

146	May 10, 2023	Redoing tailwheel geomotry & cleanup	Inspection	8	11
Reran cables on bell crank Safety wired all cable connections Cleaned fuel filter before fuel pumps ... very little build debris Cleaned up zip ties behind seats and inside cone Plus another taxi test

 

145	May 06, 2023	2nd Taxi Test	Controls	8	7
Did some longer taxi tests we redone cable/rudder/tailwheel geometry Steering was good, tailwheel broke free when expected Some EFIS bugs, reported to Falken Brake hose leaked in right wheel resulting in redoing brake lines inside wheel pants

 

144	May 06, 2023	Installed canopy gas strut	Interior Finish	4	1
Floxed in 2 attachment points that don't interfere with carbon bar across Went with 40lbs force strut from Amazon

 

143	May 05, 2023	Redesigned, rewelded and reinstalled new rudder pedals	Controls	20	1
Redesigned pedals with full 5/8 torque tubes and U shaped pedals Had Don Houseman weld them for me Reinstalled them, plus special bolt on stops against sideways sliding

 

142	May 02, 2023	Covered all thru holes with silicone	Avionics	1	5
Instead of grommets, put silicon around all wires running through bulkheads

 

141	May 02, 2023	Strengthened tailwheel spring	Landing Gear	16	4
Sanded tail spring for good transition Added 2 layers of UNI and 2 layers of BID, then vacuum bagged Added 2 more layers of BID for cosmetic round look Drilled out tailwheel attachment from 5/8 to 3/4 Floxed tailwheel back onto larger spring

 

140	May 01, 2023	Fixed rudder wobble	Controls	3	1
Changed bold to 5mm Added bushing at top Shortened bottom spacer Widened stop slots

 

139	May 01, 2023	Mounted missing plug hoods	Avionics	1	2

 

138	Apr 28, 2023	Finished brake install	Controls	4	3
Changed spacers from washers to custom CAD spacer Safety wired brake disc bolts Replaced & safety wired brake caliper bolts Replaced all brake caliper bracket to pants bolts, added 3rd bolt on both sides Added FOBO BT pressure sensor

 

137	Apr 28, 2023	Ran static & pitot lines to Falken	Instrument Panel	2	2
Eric climbed into tail to connect to static ports Ran lines forward and connected straight to Falken for now ... missing y splits for AV30 and AP head

 

136	Apr 28, 2023	Redesigned rudder pedals for strength	Controls	3	0
Discussed current pedals with team, Don Houseman (welder) and JR Decided to go with U pedals and 5/8 continous torque tubes

 

135	Apr 27, 2023	Installed canopy lock & safety mechanism	Fuselage	4	1
Used stock design, made CAD drawings and had it cut at Xometry.com

 

134	Apr 27, 2023	Mounted batteries in tail	Instrument Panel	4	2
Made fiberglass walls and fiberglassed in strap holders Taped batteries together Need to still connect trickle charging wires

 

133	Apr 23, 2023	Completed a W&B	Inspection	2	3
Comes out to 699lbs after subtracting 2 gallons of fuel at 12lbs Updated W&B spreadsheet ... https://bit.ly/DuckieWAndB

 

132	Apr 23, 2023	First Taxi	Inspection	4	1
Lots of learnings ... - swap rudder cables to pedals - needed oil to achieve pressure - did w&b - found tailwheel wobble - rudder pedals not strong enough

 

131	Apr 23, 2023	Installed seat belts	Interior Finish	6	1
What a PIA but after cutting extra access hole in center console installed and bolted in all seat belt fittings Ken bent outboard connectors for me I cut them down and drilled smaller 1/4 hole to fit existing attachment points

 

130	Apr 23, 2023	Programmed EFIS values	Instrument Panel	1	0

 

129	Apr 18, 2023	Made bracket & Installed pitch servo	Avionics	8	5
Made servo bracket out of G-10 Sanded inside under header tank Floxed & BID in bracket Installed servo

 

128	Apr 18, 2023	Finished rudder/tailwheel cables	Controls	8	3
After bellcrank and swaging, all fittings on inside were hand crimped ... What a PIA in the tail cone to crimp but its done This includes installation of bungees to spring rudder pedals fwd

 

127	Apr 16, 2023	Changed valve to fix tire leak	Landing Gear	2	0
With Chris help, changed tube valve, now holds pressure and installed Fobo BT sensors

 

126	Apr 16, 2023	Installed aileron servo bracket	Controls	4	2
Made G10 plate from metal bracket as template Floxed abd double BID on both sides

 

125	Apr 16, 2023	Installed all tail aft rudder/tailwheel cables	Controls	16	1
Swaged fittings outside by Ballenger Spars Ran wires and nylon covers inside tail Crimped wires to rudder Crimped wires to tailwheel Shrink tubed endings Connected and tightened to bellcrank

 

124	Apr 15, 2023	Bled brake lines	Controls	4	0
Needed to bleed lines 3 times Bubbles after first time Needed to bleed top screw on calipers as well

 

123	Apr 15, 2023	Designed canopy locking mechanism in OnShape	Fuselage	2	1
Took drawings from plans and converted into OnShape CAD ... https://cad.onshape.com/documents/6fe5f2054c0e0da1003c819e/w/532922969c01a880328d39e8/e/0591008fdf0827bafab3f3cf Ordered parts from xometry.com

 

122	Apr 14, 2023	Finished wiring for AP & ELT	Instrument Panel	8	1
Connected reflexor to power & stick Connected roll servo to fwd plugs Connected aileron servo to fwd plugs

 

121	Apr 12, 2023	Installed 3 antennas	Avionics	4	1
Installed new special fiberglass antennas that won't need a metal ground for VHF, ELT and transponder. In picture see the ELT antenna, the transponder antenna is mounted on the left just outside picture and the VHF antenna is the luggage compartment

 

120	Apr 12, 2023	Resin wiped lower cowling	Engine	1	1
Per Jason Skiby, resin wiped lower cowling for better cleaning

 

119	Mar 28, 2023	Mounted oil hatch	Engine	4	0
Riveted in piano hinge for hatch Drilled holes for SkyBolts Riveted in SkyBolts for locking hatch

 

118	Mar 27, 2023	Installed brake calipers & Bled lines	Landing Gear	8	4
Had Ken true my wheel to brake disk mount Adjusted brake caliper mounts for more space for brake lines Installed wheels & loosly brake calipers Cut copper lines and extended with nylon lines Bled fuel lines from calipers

 

117	Mar 26, 2023	Installed Canopy Hinge	Fuselage	8	1
Fit, drilled and mounted bottom hinge on fuselage, needed some Dremel work to make space for nuts Fit, drilled and mounted canopy hinge with some play Then floxed in canopy nuts and took out play ... what a PIA :-)

 

116	Mar 26, 2023	Installed AntiSplat kit	Engine	4	1
Bought kit after recommendation from Jim Patillo Connects to engine blow and goes into exhaust

 

115	Mar 26, 2023	Made ELT tray	Avionics	4	1
Used metal try as form to create fiberglass ELT tray

 

114	Mar 25, 2023	Torqued Spark Plugs	Engine	1	0

 

113	Mar 25, 2023	Installed exhaust heat shields	Engine	4	2
Purchased at ACS after recommendation from Kevin & Ross for heat shielding fuel injectors Installed them and turned around items in the way

 

112	Mar 23, 2023	Installed exhaust heat muff	Engine	1	1
Designed with ACS referred welder from Vegas Installed onto exhaust ... Do I need a bracket to hold it?

 

111	Mar 22, 2023	Finished rough cowling work	Engine	40	2
Made injector bump Primed outside Fit exhaust pipes Installed funnel for intake air Test fit intake rings

 

110	Mar 19, 2023	Torqued & Safety Wired Engine	Engine	4	0
With Kevin's help, went around engine, torqued all bolts and nuts and safety wired everything including prop NO ACCESS to oil pressure nut, next time when engine off!!!

 

109	Mar 16, 2023	Tidied Up Engine Lines & Wires	Engine	4	0
Went around engine and tidied up all lines, wires and put them in place with zip ties and clamps

 

108	Mar 15, 2023	Completed Plenum	Engine	8	5
Added horizontal carbon front plate to stop air from escaping

 

107	Mar 12, 2023	Brake Line Install	Landing Gear	8	3
Installed brake fluid cylinder Installed brake lines from cylinder to top of toe brakes Installed brake lines from each wing to bottom of toe brakes

 

106	Mar 11, 2023	Metal cylinder baffling	Instrument Panel	2	3
Reused James baffling

 

105	Mar 11, 2023	Mounted ADC	Instrument Panel	1	1

 

104	Mar 11, 2023	Cut wheel axles	Empennage	1	1

 

103	Mar 11, 2023	Lots more plenum and cowling work	Engine	40	25
Redid plenum to accommodate spark plugs Made ring holders Faired cowling Made plenum “pimples” Glued carbon sides to plenum top

 

102	Feb 27, 2023	Plenum & Cowling Layed Ip	Engine	40	15
Plenum carbon cured Cowling fiberglass over rings

 

101	Feb 23, 2023	Installed FlightStick	Avionics	3	2
Added plugs for quick connect Found issue with PTT button that needs to be NO … change push button

 

100	Feb 22, 2023	Mounted new prop	Propeller	1	1

 

99	Feb 21, 2023	Installed new FlightStick	Avionics	4	1

 

98	Feb 19, 2023	Adding intakes on cowling	Engine	16	9

 

97	Feb 19, 2023	Aligned wheel axles	Landing Gear	16	4
Widen inner hole Mark 2” fwd and 3” up for positive camber and toe out following David Gall advice Move outside hole with bore sight

 

96	Feb 17, 2023	Fix avionics connection with new BT hub	Avionics	10	2
Had problems with USB connections to FDC Needed new powered hub

 

95	Feb 12, 2023	Weight check	Inspection	2	1

 

94	Feb 12, 2023	Fit cowling	Engine	16	8
Trim top cowling Fit bottoms cowling Screw into place

 

93	Feb 11, 2023	Installed elevator trim	Controls	10	1
Bought springs & rope Epoxied in roller Connected everything with trim wheel

 

92	Feb 05, 2023	Make wiring harness and connect TXP&RadioCom	Avionics	16	6

 

91	Feb 05, 2023	Installed batteries and powered up panel	Avionics	8	7

 

90	Feb 02, 2023	First engine run … SUCCESS	Engine	8	7
Installed throttle bracket Primed with oil First engine start a little leak on oil filter bracket fixed after tightening Watch engine crank fire leak Alternator not charging

 

89	Jan 30, 2023	Pickup propeller	Propeller	8	4
Picked up prop at Catto, though wrong one and got replaced a few days later

 

88	Jan 27, 2023	Finished panel including decals	Avionics	40	1

 

87	Jan 23, 2023	Installed prop extension	Engine	4	1
Installed pressed fitting lugs Drilled holes in bolt tip for magnets Epoxied magnets into holes and measured gap Tightened bolts to 30 lb ft

 

86	Jan 23, 2023	Hung engine	Engine	8	5
Mounted return fuel line Mounted oil pressure line Mounted oil pressure wiring Hung engine with aircraft grade bolts … NOTE start tightening bottom bolts first!!!

 

85	Jan 22, 2023	Started panel wiring	Instrument Panel	16	3
Started wiring instrument panel Mounted additional items, USB, vents, ELT remote

 

84	Jan 19, 2023	Installed TXP/ RadioCom tray	Avionics	1	1
Mounted tray being seat back

 

83	Jan 19, 2023	Installed headset plug panel	Instrument Panel	1	1
Cut hole in seatback Installed recess panel

 

82	Jan 18, 2023	Panel anodized	Paint / Decals	1	2
Picked up anodized panel at Arnold Metal Finishing in SJ

 

81	Nov 26, 2022	Started behind firewall wiring	Avionics	8	5
Various ground connections Power cables to FDC, EMS, ECU Started connecting sensors to EMS

 

80	Nov 26, 2022	Finished wiring in front of firewall	Firewall	8	1
Connected last few wires, injectors etc

 

79	Nov 23, 2022	Finished alternator wiring	Avionics	3	8
Added 30amp fuse Finished connecting relay Finished connecting warning light/switch wire

 

78	Nov 22, 2022	More engine wiring	Lighting	40	11
Spark plug wires Sensor wires Mounted EMS box Mounted ECU Mounted amp shunt Mounted FDC

 

77	Nov 16, 2022	Fix soft spot on passenger side	Fuel System	16	3
Cut top open and clean Fit in new foam Flox in foam Triple BID Prime over

 

76	Nov 16, 2022	Made glare shield	Interior Finish	16	2
Cut from G10 Mounted with clicos and then flush screws Hard work to get to fit to panel top Made tabs

 

75	Nov 08, 2022	Installed various electrical components	Lighting	8	5
Wing tip lights Alternator parts Fuel tank sensors

 

74	Nov 07, 2022	Installed fuel lines	Fuel System	4	3
Pickup to pump with flex Pump to firewall with hard Firewall to return in header with hard

 

73	Nov 03, 2022	Ran battery / starter wires	Avionics	2	0
Drilled holes in firewall & bulkheads Ran starter + (White) Ran main bus + (Red) Ran ground - (Black) Fit in fuel feed line

 

72	Nov 03, 2022	Glued in zip tie holders	Avionics	1	0
Glued in zip tie holders all around interior

 

71	Nov 03, 2022	Installed various SDS EFI parts	Engine	4	1
Injectors Fuel rail fittings Injector fuel fittings Injector plugs/wires Hall sensor bracket Hall sensor ... needs tightening

 

70	Nov 02, 2022	Installed rudder pedals & toe brakes	Controls	4	1
Installed floor mounts Installed brake cylinders Installed pedals ... pedals need a little adjustment, longer I believe ...

 

69	Nov 01, 2022	Painted interior with bilge paint	Paint / Decals	8	2
Two coats of white epoxy primer Petit) One coat of light grey epoxy bilge paint ( Total Boar)

 

68	Oct 29, 2022	Primed interior and luggage compartment	Paint / Decals	8	3
Primed forward fuselage with 2 part epoxy white, two coats, including luggage compartment

 

67	Oct 29, 2022	Added finger holes	Instrument Panel	2	1
Cut half holes into ipad holders and panel

 

66	Oct 28, 2022	Primed interior	Paint / Decals	4	3
Used Petitt White Epoxy 2 part Primer Painted luggage compartment Painted outside spots Painted fuel tank repair Painter interior area and foot well

 

65	Oct 27, 2022	Installed firewall fwd comments	Firewall	4	1
Installed various engine compartment items on firewall

 

64	Oct 26, 2022	Painted rudder pedals	Paint / Decals	2	1
Used Rustoleum primer and Industrial Enamel to paint pedals

 

63	Oct 25, 2022	Installed rudder & break mounts	Controls	40	3
Did lots of planning and deciding Opted for Delrin rudder pedals mounts, designed in OnShape, water jetted by Eric Decided to use phenolic to mount with bolts counter sunk and floxed and double BID to floor Used aluminum to create break cylinder mounts, mounted with special bolts floxed and double BID to floor

 

62	Oct 21, 2022	Installed Trim Wheel & Test Fit Panel	Controls	8	2
Installed trim wheel with tapped phenolics Cut slot into panel and mounted with wheel

 

61	Oct 16, 2022	Fixed bolts for throttle body	Engine	3	1
Removed old studs Replaced with new allen bolts

 

60	Oct 15, 2022	Installed arm rest hinge	Interior Finish	2	1

 

59	Oct 14, 2022	Installed bottom tap	Fuel System	1	1
Had to use a step because turns out fitting is smaller than ACS said, might get a larger one eventually

 

58	Oct 12, 2022	Painted firewall	Firewall	4	11
Purchased, tested and painted firewall with Contego paint

 

57	Oct 09, 2022	Worked on CAD design & shopping lists	Instrument Panel	16	5
Updated curves on top ... https://cad.onshape.com/documents/6fe5f2054c0e0da1003c819e/w/532922969c01a880328d39e8/e/28f13d8e3ad3f3d74a9b00cc Increased room for legs by moving instruments up Added switches & fuses Made lists at retailers for parts

 

56	Oct 06, 2022	Test fit panel & rudder placement	Instrument Panel	8	7
Test cut rudder pedal mounts ... need mods, redoing in Delrin Test cut panel, first top, then all of it but without instruments

 

55	Oct 02, 2022	Added bell crank in tail	Controls	4	2
Made phenolic base Floxed phenolic in place Added 2 layers of BID Sat bellcrank on it temporarily

 

54	Oct 01, 2022	Applied 2 extra layers of BID in tail	Fuselage	4	3
Added 2 layers of BID in tail for structural support, per Jim P and Jason S

 

53	Sep 29, 2022	Closing main fuel tank	Fuel System	40	13
Drill 1 1/2 hole for main tank fill Bend 1 1/2 PVC pipe to fit Flox in PVC from header to main Drill fuel pickup from main Bend to fit and flox fuel pickup line Sand & prep border surfaces Flox in inside skin Slurry foam Glue in foam with flox Slurry outside of foam ... after once forgetting and having to redo :-) Apply 3 layers of BID on outside Apply micro & sand ... 3 times to get nice and flat Flip plane over on its wheels

 

52	Sep 18, 2022	Weight fuselage	Inspection	1	2
Added all fuselage parts and weight it ... Total 391 without engine

 

51	Sep 18, 2022	Closed off firewall with boxes	Firewall	6	4
Finished firewall boxes Glued them in with 10 min epoxy Applied thick layer of flox on cockpit side Applied 2 layers of BID on firewall side

 

50	Sep 18, 2022	Fiberglassed in header fitting	Fuel System	3	5
Cut aluminum piece Fiberglassed into header tank Cut fill hole into fiberglass tank

 

49	Jul 28, 2022	Molded new bottom main tank skin, inside fuselage	Fuel System	4	4
Borrowed fuselage from Stan Laid down 3 layers of BID plus peel ply on duct tape

 

48	Jul 27, 2022	Cut out old fuel filler box & pipe	Fuel System	2	4
Cut out box from outside Cut off lid and grind down piano hinge Epoxied door back into place with 1 BID in back ... fixed air bubbles in peel ply after taking picture :-)

 

47	Jul 26, 2022	Cut bottom open for future work	Fuselage	2	1
After talking with Jason, decided to cut bottom open

 

46	Jul 23, 2022	Designed new fuel system	Fuel System	4	1
Looked at what's needed for fuel injection Realized I didn't need a gravity fed header tank feed Redesigned it with fuel coming out of main tank Discussed with various folks Decided to eliminate facet pump and 2 extra fittings Problem of how to fit low point outlet and fill intake by fuel tank leak / redo

 

45	Jul 23, 2022	Investigated warped floor under fuel tank	Fuselage	8	6
Found warped floor under tank Consulted with Jason Skiby and decided to cut bottom open Took off engine Installed engine mount bracket Flipped plane Cut bottom skin Removed fuel soaked foam Pressure tested tank and found many pin holes in skin Cut openings to look at fabric --> not enough wetted

 

44	Jul 17, 2022	Test hung engine	Engine	2	6
Couldn't use new bolts, not enough clearance Used temp bolts and hung engine

 

43	Jul 14, 2022	Floxed in header tank donut	Fuel System	2	2
Couldn't bend return tube, made a wooden piece to press the donut in Applied epoxy inside, then flox, then donut, then BID, then peel ply

 

42	Jul 14, 2022	Torqued everything according to SDS manual specs	Engine	1	0
Spark plugs 19 ft lbs Spark plug adapters 25 ft lbs ... per service bulletin on April 26/19 http://www.sdsefi.com/cpi.htm 1/2 bolts on engine 180 in lbs (vacuum cover, throttle body) 7/8 bolts on engine 110 in lbs (magneto covers, starter, vacuum pump cover)

 

41	Jul 14, 2022	Made bell crank	Controls	4	1
Designed CAD file Riveted bearing into bellcrank

 

40	Jul 14, 2022	Installed more engine components	Engine	6	3
With new o-rings, bolted on vacuum pump cover and throttle body Made a bracket for the fuel distribution block Mounted fuel distribution block Tightened 1 exhaust nut for all 4 pipes ... needs more work !!! CAN'T TIGHTEN ONE NUT ON THROTTLE BODY !!!

 

39	Jul 13, 2022	Continued engine components install	Engine	8	1
Installed tapped intake elbows Torqued starter, magneto cover, oil screen cover etc according to https://www.csobeech.com/files/TCM-Torque-SB96-7D.pdf Installed intake tubes with new rubber fittings and hose clamps

 

38	Jul 13, 2022	Repaired all aileron fairings	Fuselage	4	2
Left inboard aileron fairings were cracked, on both main fuselage and tail portion Filled inside with micro, after wetting foam with epoxy Sanded down the fairing to give more clearance to aileron avoid future cracking

 

37	Jul 11, 2022	Installed new aileron spacers	Controls	4	2
When cutting corroded aileron tubes out, spacers died with it Ken created new spacers Installed them after repairing fiberglass damage

 

36	Jul 11, 2022	Installed u-joint for ailerons	Controls	8	1
When installing reflexor, realized I needed a joint in aileron tube Added phenolic in seat bulkhead, flox and BID Added u-joint Polished & primed tube

 

35	Jul 08, 2022	Tapped fuel intakes	Engine	2	3
Took off and marked fuel intake elbows Eric tapped them per SDS instructions

 

34	Jul 08, 2022	Installed main tank fuel sender	Fuel System	4	5
Cut hole with two different hole saws Cleaned hole and sanded prep Fluxed donut into place Put down a layer of BID sounds outside Cut hole for header tank ... Fuel return in the way:-(

 

33	Jul 08, 2022	Created arm rest opening	Fuselage	4	4
Cut hole Removed t tail mechanism One layer of BID on backside Filled gaps with micro

 

32	Jun 28, 2022	Made firewall box	Firewall	3	1
Cut out of ply and foam box Fiberglassed outside

 

31	Jun 27, 2022	Installed oil screen cover	Engine	1	1
Bolted down oil screen block cover Insalled oil temp sensor

 

30	Jun 27, 2022	Made & Installed Reflexor	Controls	16	6
Made reflexor parts in CAD Epoxied reflexor donut into space, after cutting first too high Cut aileron torque tube to allow for clearance ... need union joint Installed all connecting rods

 

29	Jun 27, 2022	Cleaned and installed all control surfaces	Controls	8	4
Installed rudder ... Slight up and down slop, maybe a longer spacer Installed elevators ... Just temporarily, with out counter weights, waiting till inside painted Installed ailerons ... Drilled new holes, cleaned all control arms, waiting for universal joint union and need shorter bolts on bottom of arms, spacers need to be cut too

 

28	Jun 25, 2022	Test fit reflexor	Controls	4	4
Sanded parts to fit Cut wrong hole location and reglazed Test fit assembly

 

27	Jun 25, 2022	Installed control surfaces	Controls	4	2
Cleaned all controls from rust Test installed all surfaces

 

26	Jun 25, 2022	Assembled rudder pedals	Fuselage	3	1
Cleaned pedals, removed all rust Assembled parts Primed with Zinc Test fit length

 

25	Jun 25, 2022	Primed interior	Fuselage	8	3
Sanded, cleaned and then primed interior areas, including foot well and luggage compartments

 

24	Jun 22, 2022	Installed new oil filter adapter	Engine	1	1
New adapter installed Bottom screw not tightened

 

23	Jun 21, 2022	Cleaned, sanded & primed inside cockpit	Fuselage		1
Cleaned & sanded inside cockpit Primed with West Marine Petite Epoxy Primer Need to finish baggage compartment & footwell

 

22	Jun 21, 2022	Removed t-tail bumps	Empennage	8	4
Cut off & sanded flusgh phenolic holes Faired holes on both sides

 

21	Jun 19, 2022	Installed engine mounts	Firewall	8	1
Fluxed in G10 as backing plates Sanded front flush Drilled center holes and held with temp bolt from HD Drilled and bolted down around outside with 3-4 bolts

 

20	Jun 17, 2022	Installed REAL pushrod tubes	Engine	5	1
Installed half of them with Kevins help The rest installed on my own ... need to keep an eye out for leaks

 

19	Jun 17, 2022	Trimmed firewall more	Fuselage	2	1
Needed extra hole for alternator Needed more clearance for starter

 

18	Jun 17, 2022	Made baggage hole covers	Fuselage	4	2
2 BIDs each side Foam inbetween Trimmed to fit

 

17	Jun 16, 2022	Test fitted engine mounts	Fuselage	4	5
Hung engine in front of engine, needed alternator hole Hung engine again, needed more clearance on all holes Location of engine mounts was perfect

 

16	Jun 15, 2022	Removed rudder pedals & tabs	Engine	3	1
Removed a few myself, but also got help from Joe, such a nice kid

 

15	Jun 15, 2022	Removed oil screen housing	Engine	1	1
Turns out oil screen housing interferes with firewall Removed housing, need a block off plate

 

14	Jun 14, 2022	Drilled engine mount center holes	Firewall	3	1
Printed firewall template @ Fedex to scale Mounted paper template & checked leves Drilled center holes for new engine mounts

 

13	Jun 14, 2022	Mounted alternator gear assembly	Engine	1	1
Installed gear assembly ... COTTER PIN NEEDS TO BE CHECKED

 

12	Jun 14, 2022	Microed canopy seam	Fuselage	1	1
Applied micro over foam seam on canopy

 

11	Jun 14, 2022	Installed baggage tray lip	Fuselage	3	1
5min epoxied in lip from foam Applied micro on front and behind to make round Applied BID all around

 

10	Jun 13, 2022	Remounted tail section	Fuselage	2	2
Removed old screws Cleaned & sanded seam Installed new washers & screws

 

9	Jun 12, 2022	Mounted new tailwheel	Landing Gear	3	1
Sanded down tailwheel spring Floxed in new tailwheel attachment Drilled hole & bolted together Tested with a bounce per video ... redo with passengers inside

 

8	Jun 12, 2022	Cut brake opening	Landing Gear	3	0
Took off old brakes Disassembled & cleaned used brakes Cut bigger holes in wheel pants for new floating brake mechanism

 

7	Jun 12, 2022	Installed tires	Landing Gear	3	3
Removed old tires Checked tubes Fixed valve Reinstalled with new tires

 

6	Jun 11, 2022	Installed 2 of 4 new pushrod tubes	Engine	4	2
Removed old pushrod tubes Installed new REAL pushrod tubes Removed intake tubes & cleaned them ... not ready install until injectors arrive and are installed

 

5	Jun 06, 2022	Fiberglass Day	Fuselage	10	7
Cut off tail tbar attachment Cut & fiberglassed baggage tray hole Cut canopy backwall Made left arm rest fiberglass cover Cut starter hole in firewall Floxed shut old holes ... all with the help of Jason Skirby, Mr Fiberglass Jr

 

4	May 08, 2022	Removed elevator & rudder controls	Controls	4	2
Disconnected & removed aileron tubes (not corroded, can be reused) Disconnected & removed rudder pedals (need to take the tabs out because pedals are too far back) Had fun doing this with the help of a new friend from the FB event

 

3	May 08, 2022	Removed corroded ailerons	Controls	4	4
Cut off corroded tubing Disassembled aileron mechanism ... needs to be revised for reflexor anyhow Drilled out corroded tubes (Ken did it, what a hero)

 

2	May 03, 2022	Moved plane inside	Workshop	3	5
Took plane apart Took off tail Cleaned inside Removed Revmaster engine Moved plane into hangar

 

1	May 03, 2022	Bought Duckie	Workshop	1	1
Today was the day and I bought Duckie for $1000, including engine and 6 months hangar use ... HURRAY

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