Project Log - March, 2001 
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March, 2001

March 13, 2001 - 2 hours
Recieved, inventoried, organized and stored the empennage kit.

It all starts with two cardboard boxes. What will the future bring.

Where am I going to find a place to store all this stuff? There is more in those boxes than I thought. This is going to be great!

March 16, 2001 - 2 hours
Drilled the holes on the web of the rear spar. Started on the rear spar stiffeners.

The HS skins are clecoed to the rear spar channels, so the pilot holes can be drilled out to #40. Love those pre-punched parts.

March 17, 2001 - 4 hours
Finished drilling & deburring the stiffeners on the HS rear spar. Drilled and deburred the elevator hinge brackets. Riveted the bearing to the center elevator hinge bracket. I will have to wait to finish the rear spar until I find some primer.

The stiffeners clecoed to the rear spar channels.

Close-up of the stiffeners clecoed to the rear spar channels.

Bearing riveted to the elevator hinge bracket. First six rivets!!! Only 11,994 more to go.

March 18, 2001 - 2 hours
Fabricate HS-610 and HS-614 forward spar splice angles.

First two cuts in HS-610.

Finished HS-610 and HS-614 HS forward spar splice angle. Notice the undrilled holes. If I hadn't marked them I would have probably drilled them accidentaly.

March 21, 2001 - 1.5 hours
Trimmed the HS-602 forward spar channels, lined them up on the jig with the HS-610 and HS-614 splice angles and drilled the rivet holes.

This shows how I used a string and a plumb to make sure that everything was straight and centered.

Front spar with the splice angles clecoed on.

March 23, 2001 - 1.5 hours
Did some more trimming on HS-602 (front spar) and deburred it. See note.

March 24, 2001 - 1 hours
Bent the front spar and front spar splice angles. Started deburring ribs.

March 25, 2001 - 4 hours
Deburred and fluted ribs.

March 29, 2001 - 2.5 hours
Cleaned, etched and primed all the parts of the HS rear spar.

March 30, 2001 - 1.5 hours
Riveted the rear spar together.

Completed HS rear spar.

Close up of how the center elevator hinge bracket bolts to the rear spar. Note: The bolts are in backwards in this photo. I discoverd this when I mounted the Elevators later in the project. I should really learn to look at the drawings.

March 31, 2001 - 2 hours
Worked on building brackets to fasten the rear spar to the jig.

This shows a close up of how I aligned the brackets to the jig. The dental floss was aligned with the center of the jig using two plumb bobs then all five brackets were aligned with the string as shown.

April 1, 2001 - 6 hours
Mounted the rear spar in the jig and started building up the HS skeleton.

April 2, 2001 - 1.5 hours
Finished drilling all the parts of the HS skeleton, un-clecoed the skeleton and started deburring all the parts in preparation for priming.

HS skeleton assembled and drilled. Ready for primer.

April 3, 2001 - 1.5 hours
Finished deburring, cleaning and treating all the HS skeleton parts.

April 5, 2001 - 1 hours
Primed all the HS skeleton parts

April 7, 2001 - 2 hours
Started assembling the HS skeleton

April 8, 2001 - 3 hours
Finished the HS skeleton and drilled and clecoed the skins to the skeleton.

Completed HS Skeleton. Ready for the skins.

HS skins drilled and clecoed on the skeleton.

This tip rib is not to be riveted until the inside rivets are installed. This is where I will have to stick my arm to get behind those rivets on the tip of the center rib.

April 9, 2001 - 2 hours
Deburring, dimpling HS skeleton and skins.

April 10, 2001 - 1 hours
Built a make-shift table for the C-frame tool, finished dimpling the skins.

April 11, 2001 - 0.5 hours
Sanded cleaned and treated the HS skins.

April 12, 2001 - 0.5 hours
Primed the HS skins.

April 14, 2001 - 2 hours
Started riveting the skins to the skeleton.

April 14, 2001 - 2 hours
Drilled out the pilot holes on the rear spar of the Vertical Stabilizer.

Vertical Stabilizer rear spar clecoed together for drilling out all of the pilot holes.

April 15, 2001 - 3 hours
Finished riveting the skins on the HS skeleton. The horizontal stabilizer is finished

The Horizontal Stabilizer is finished!!!!

April 15, 2001 - 2 hours
Deburred the ribs and front spar of the VS.

April 22, 2001 - 0.5 hours
Stored away the Horizontal Stabilizer an sanded all of the Vertical Stab parts that need to be primed.

April 26, 2001 - 0.75 hours
Cleaned and treated all of the Vertical Stabilizer parts.

April 27, 2001 - 1 hours
Primed all the Vertical Stabilizer parts

April 28, 2001 - 4 hours
Riveted the VS Rear Spar together and prepared the jig so I could mount the spar.

Finished VS Rear Spar

Detail showing the flush rivets on the forward lower part of the VS rear spar. This is to allow mounting to the fuselage later.

April 29, 2001 - 7 hours
Riveted the ribs onto the rear spar. Mounted the rear spar in the jig. Riveted on the forward spar and the root tip rib. Drilled and clecoed the VS skin.

VS rear spar with the ribs riveted on.

VS rear spar goes onto the jig.

Finished VS skeleton ready to drill the skins.

VS skin drilled and clecoed into place.

My helpers - Curby and Cotton.

May 2, 2001 - 2.25 hours
Riveted the skin to the vertical stabilizer. The Vertical Stabilizer is Finished!!!

Finished Vertical Stabilizer.

May 6, 2001 - 4.5 hours
Trimmed and deburred the Rudder stiffiners. Started deburring the rest of the rudder parts.

May 9, 2001 - 0.75 hours
Finished deburring the rudder parts.

May 10, 2001 - 0.5 hours
Finished sanding the rest of the rudder parts.

There are a lot of parts in the rudder. This is fun!!!

May 11, 2001 - 0.5 hours
Ground off the what was left of the little guide hole on all the stiffeners. The more I looked at it the more it looked like a stress concentration in a fairly high stress place. See note.

May 12, 2001 - 2 hours
Etched, coated and primed all the rudder parts.

May 13, 2001 - 4 hours
Drilled all the rudder stiffeners to the rudder skin. Deburred and dimpled the stiffeners and skin and started back riveting the stiffeners to the skin.

Rudder stiffeners drilled and clecoed to the rudder skin.

Back rivet plate from Avery's that I set into a piece of 3/4" plywood.

May 14, 2001 - 1 hours
Riveted the stiffeners to the rudder

Rudder stiffeners riveted to the skin.

May 16, 2001 - 2.5 hours
Fabricated the little spacer that goes behind the rudder horn. Had to etch and prime it as well. Clamped the spar, reinforcement plates, lower rib and rudder horn together and drilled. Squeezed all the rivets that I could reach with the squeezer. I also built the homemade sheetmetal brake for forming the trailing edge of the control surfaces.

May 17, 2001 - 2 hours
Finished riveting the spar, rudder horn and lower rib together. Formed the trailing edge of the rudder and started setting up the V-block jigs.

Crunching (er. Forming) the trailing edge of the rudder. This works better than I thought it would.

May 28, 2001 - 4.5 hours
Finished drilling the rudder skeleton, set up the V-block jigs for the rudder, drilled and clecoed all of the rudder parts together in the jig.

Rudder in the V-block jigs all drilled and clecoed. Finally ready for some rivets.

May 29, 2001 - 3 hours
Deburred, dimpled and started riveting all of the rudder parts together.

June 1, 2001 - 2 hours
Finished riveting the rudder skin to the skelton. Formed the leading edge of the rudder. Rudder is finished, except for fiberglass and the counterweight.

Detail of the rudder leading edge and one of the rod end bearings that serve to attach the rudder to the vertical stabilizer.

Finished rudder attached to the vertical stabilizer. The funny looking coating is the contact paper that I put on to protect it.

June 3, 2001 - 3.5 hours
Started laying out the stiffeners on the right elevator and cut the stiffeners from the angle provided.

Laying out where the stiffeners will attach to the right elevator. The pre-punched rudder stiffeners were much more fun.

Elevator stiffeners waiting for me to figure out where to drill the holes.

June 4, 2001 - 1.75 hours
Drilled pilot holes in the stiffeners for the bottom right elevator skin and started fabricating the stiffeners for the top.

June 5, 2001 - 1.5 hours
Drilled the second set of stiffeners for the right elevator. Started deburring all of the right elevator pieces.

June 7, 2001 - 2 hours
Deburring right elevator parts.

June 9, 2001 - 4.5 hours
Drilled the stiffeners to the right elevator skin. Finished deburring all right elevator parts. Sanded, cleaned, coated and primed all the parts to the right elevator.

Stiffeners drilled and clecoed to the right elevator skin. I used a hollow core door as a table hoping that it would be straighter than the table that I used for the Rudder.

June 10, 2001 - 6 hours
Riveted the stiffeners to the right elevator skin. Formed the trailing edge of the right elevator. Started putting the elevator skeleton together and built the V-Block jig for the elevators.

Stiffeners are back riveted to the right elevator.

Reinforcment plates and platenuts are riveted to the right elevator spar.

June 18, 2001 - 2 hours
Straightened up the V-block jig. I wasn't happy with it. Riveted the tip ribs together. Looked dumbfounded at the manual and the prints for a while until I realized that I was too tired to continue and went to bed.

June 22, 2001 - 2 hours
Finished laying out the Right Elevator skeleton. Started drilling and dimpling holes to attach skin to skeleton.

June 23, 2001 - 6.5 hours
Finished drilling, deburring and dimpling holes. Riveted the right elevator together. Bent the leading edge and mounted to the HS. Drilled the pilot hole for the HS hinge. Right elevator is finished except for fiber glass and bolting on the counter weights.

Close up of how I used a pop rivet dimple die set and a couple pair of Vise Grips to dimple those wicked little holes at the trailing edge of the elevators.

The elevator mounted in the V-block jig.

Close up of the horn attachment. Notice the line that I used to help align it with the centerline of the spar.

I hate this part. Forming the leading edge of the elevator with a piece of 1/2" black pipe.

Right elevator mounted to the horizontal stabilizer.

I used a small quick-clamp to hold the elevator in trail.

Detail showing how I used a small piece of 1/4" stainless tubing as a drill guide bushing to drill the pilot hole of the control horn. Notice that I had to cut notches in the HS spar lower flange so the control horn could move forward.

June 24, 2001 - 9 hours
Started the left elevator. Fabricated and drilled all of the stiffeners. Trimmed the Z brackets for the electric trim servo mount and started deburring all of the parts in preparation for priming.

The stiffeners drilled and clecoed to my holow core door. These stiffeners are not the same as on the right elevator. They are not even located the same. Make sure you look at the plans twice.

June 25, 2001 - 2.5 hours
Deburring, Deburring, Deburring.

June 26, 2001 - 3.5 hours
Received the wing kit today. Shannon and I inventoried all the parts and I stored them away.

Hard to believe that this is going to turn into two wings. This is going to be fun!!!

July 7, 2001 - 1 hours
Deburring, Sanding, Deburring, Sanding

July 8, 2001 - 3 hours
Etching, coating, priming.

July 9, 2001 - 2 hours
Drilled the spar to the left elevator skin and dimpled the holes in the spar. Drilled the rear spar to the skin and dimpled the rear spar (OOPs @#$%& I am supposed to machine countersink those)

July 10, 2001 - 2.5 hours
Undimpled the left elevator rear spar with the Avery squeezer and a flush rivet set. Countersunk the rear spar holes that match with the trim tab hinge. Finished dimpling the elevator skin and all of the stiffeners. Backriveted all the sitffeners to the elevator skin.

July 11, 2001 - 2 hours
Bent the little tabs on the elevator skin where the trim tab is. Started putting the skeleton together.

The elevator goes in the V-block jig and the wedge that was originally cut out is used to secure it for bending the tabs.

Spars clecoed in place and the inboard rib clamped to the assembly almost ready to drill.

July 12, 2001 - 2.2 hours
Mounted the elevator trim servo on the mounting plate. Assembled the reinforcement plate for the elevator trim and riveted it to the skin. Also worked a little on the skeleton.

Detail of the trim server mounting. I really had to stare at those drawings for a while to figure how this went together and now it looks so simple.

The trim tab servo reinforcement plate attached to the left elevator skin.

July 13, 2001 - 4 hours
Finished the left elevator skeleton and started drilling the elevator skin to the skeleton.

Getting ready to assemble the outboard ribs.

I used a 3/16" rod through both of the rod end bearings to help me find center and then set that at the 13/16" distance from the spar that the plans call for.

Complete left elevator skeleton.

Getting ready to hammer on the trim tab to bend those little tabs to close the ends.

July 14, 2001 - 4 hours
Deburred and dimpled the skeleton and skin on the left elevator. Put all the rivets in the left elevator except for where the trim tab hinge is to be attached.

July 15, 2001 - 4 hours
Finished the trim tab and riveted the hinges to both the trim tab and the left elevator. Assembled the tail for a picture and to try and convince myself that all of this stuff will really look like an airplane someday. Stored the tail away and did a little dance because - THE EMPENNAGE IS DONE!!!

I modified one of the bucking bars that I got from Avery's to get in behind the hinges on the trim tab and the elevator.

Completed trim tab

To set the rod end bearings on the rudder I used a couple of pieces of dental floss to mark the face of the spars. I set the top and bottom hinges first and then set the middle one to match.

Completed empennage except for fiberglass.

Another angle of all the tail feathers.

Empennage stored away.

July 15, 2001 - 1 hours
Cleaned up the garage and got the main wing spars out to get started on the wings.

The main spars are just itching to become two wings.

July 20, 2001 - 2.5 hours
Drilled and countersunk all the holes for the tank skin attach platenuts. Started attaching the platenuts and countersinking the screw hole.

July 21, 2001 - 2.5 hours
Finished attaching the tank skin attach platenuts on the main wing spars.

That was a lot of platenuts.

July 22, 2001 - 5 hours
Attached all the platenuts for the wing inspection covers on the main wing spars. Fabricated the little spacers that go behind the tie downs and started working on drilling the tie downs to the wing spar.

July 24, 2001 - 3 hours
Finished the tie down assemblies on the main spars and started deburring the parts of the rear spars.

Tie down assembly bolted to the main wing spar. The platenuts are for bolting the aileron bellcrank brackets to the other side.

Aileron bellcrank brackets on the rear side of the main wing spar.

July 26, 2001 - 2 hours
Deburring the parts of the rear wing spars

July 28, 2001 - 6 hours
Finished deburring the parts for both rear wing spars. Primed the spars and assembled them.

Rear spar with the reinforcement plates attached. The dark color of the spar is the Sherwin Williams P60-G2 primer. I assume that is what it is supposed to look like?

Close up of the inboard reinforcement plates of the rear spar. The missing rivets are where ribs and the flap brace will be attached.

July 30, 2001 - 1.5 hours
Deburring wing ribs

July 31, 2001 - 3 hours
Deburring wing ribs

August 1, 2001 - 1.5 hours
Deburring wing ribs

August 2, 2001 - 1 hours
Deburring wing ribs

August 4, 2001 - 7 hours
Deburring wing ribs

August 5, 2001 - 5 hours
Finished deburring wing ribs and started fluting / straightening wing ribs

August 6, 2001 - 1.5 hours
Fluting and straightening wing ribs

August 7, 2001 - 1.5 hours
Finished fluting and straightening the wing ribs.

August 9, 2001 - 2 hours
Modified the H-Jig for use in holding the wings. Clecoed the main ribs to the main and rear spars of the left wing.

Bracket that will hold the main spar

Main ribs clecoed to the main and rear spar of the left wing. Finally something that looks like it might be part of a wing.

August 11, 2001 - 2 hours
Drilled the ribs and spars of the left wing.

August 12, 2001 - 3 hours
Clecoed and drilled all the ribs and spars of the right wing and then deburred all the ribs and spars. Also started building the little wooden fuel tank craddle.

August 14, 2001 - 1.5 hours
Finished the leading edge / fuel tank craddle. Started drilling the holes in the main ribs for the electrical conduit

This is the cradle where the leading edges and the fuel tanks will be built. It ain't pretty but it don't fly either.

August 15, 2001 - 2.5 hours
Finished drilling all the holes for the conduit. Deburred the holes in the left wing parts and prepared the left wing parts for priming.

August 17, 2001 - 1 hours
Primed the left wing ribs.

August 18, 2001 - 5 hours
Riveted the main ribs to the main and rear spars. Shannon built the wing storage craddle.

August 19, 2001 - 6 hours
Mounted the left wing skeleton in the stand. Clecoed and drilled all of the main skins. Clecoed the leading edge skin to the ribs and spar.

This is the bracket where the outboard end of the wing sits. Don't copy it! It doesn't work as it looks here. See below.

Wing skeleton mounted to the stand.

Top main skins clecoed to the left wing.

Bottom main skins clecoed to the wing.

Ooops. That ain't gonna work. The rib should be flush with the end of the spar but the skin is extended past the rib for the wing tip mounting and it is interfering with the bracket.

A little drimmel action and the problem is solved. Remember if it don't fly it ain't gotta be pretty.

Wow! It's starting to look like it might be part of an airplane. Now off to read the manual and go to bed.

August 20, 2001 - 1 hours
Installed the W-423 joint plate.

This is the W-423 tank attach piece. This is where the outboard side of the tank skin will attach.

August 20, 2001 - 1 hours
Started marking and drilling the fuel tank attach brackets.

August 21, 2001 - 2 hours
Still drilling and laying out the fuel tank attach brackets.

August 26, 2001 - 2 hours
Countersunk the rivet holes where the platenuts attach to the fuel tank attach brackets. Started deburring the fuel tank ribs.

August 31, 2001 - 1.5 hours
Deburring fuel tank ribs.

September 1, 2001 - 4 hours
Fluted all of the fuel tank ribs, and riveted the platenuts to the left tank attach brackets. Started bolting the attach brackets to the left main spar.

Here are the fuel tank attach brackets bolted to the wing spar.

September 2, 2001 - 6 hours
Lined up and drilled the T-702 baffle to the tank attach brackets and ribs. Mounted the skin on the tank assembly and drilled all of the holes in the tank skin. Drilled and clecoed the stiffeners to the fuel tank skin. Countersunk the holes where the skin attaches to the baffle.

Fuel tank stiffeners drilled and clecoed to the skin.

Trial fit of the skin to the baffle and spar. I put a couple of the ribs in to make this easier.

Here are the fuel tank ribs clecoed to the tank baffle. I had to remove the wing leading edge to get those clecos in on the last outboard rib.

The tank is starting to come together. BTW that craddle doesn't work very well. The 2x4 is in the way.

September 3, 2001 - 5 hours
Fabricated the T-405 tank attach angle and cut out the T-410 reinforcement plates. Predrilled the cpacative fuel sender plates to the ribs and trimed the plates for the proper clearance. Drilled the access plate reinforcement plate to the inboard rib and drilled and clecoed the filler cap and drain flange to the tank skin. Started modifying the number two fuel tank rib for the inverted fuel pickup.

Fuel filler cap drilled and clecoed to the tank skin.

The newly fabricated T-405 tank attach angle with pilot holes drilled.

A very bad picture of the fuel drain flange drilled and clecoed to the tank skin.

September 6, 2001 - 3 hours
Finished the inverted tank mods to the second inboard rib. Countersunk the fuel filler body and deburred the skin and most of the ribs.

Here are the modifications that I made to the second rib of the fuel tank. The little door is there to keep the fuel from flowing backward through the rib, and the big hole is riveted closed for the same reason. This is part of the inverted fuel tank modification.

September 7, 2001 - 2 hours
Finished deburring and dimpling the fuel tank ribs. Deburred the skin.

September 8, 2001 - 4 hours
Finished deburring and dimpling all the tank parts. Modified my leading edge craddle, and built a little 10:1 balance for measuring pro-seal.

Little homemade 10:1 balance that I made from extra stiffener material. The bolt on the right is the balance adjustment. If I were to build it again I would make it a little larger.

September 9, 2001 - 4.5 hours
Pro-Seal session #1. Riveted/sealed the tank stiffeners, the fuel filler cap and the tank drain flange. I also sealed the reinforcement ring that goes inside the inboard rib with the platenuts. (What a mess!)

First session of the fuel tank Pro-sealing nightmare.

September 14, 2001 - 1.5 hours
Rebuilt the leading edge craddle and did some last minute preparation for the Pro-seal nightmare that is to begin tomorrow.

I rebuilt the leading edge craddle because the last one didn't work well. There was not enough room to get clecoes in and out of the forward-most holes. This one works much better.

September 14, 2001 - 7 hours
Pro-sealed all of the ribs into place in the fuel tank. Surely 1 hour per rib is a little much but that stuff was curing pretty fast and I had to mix up a batch for each rib. It's still hot in Houston.

September 17, 2001 - 0.75 hours
Installed and wired up the capacative fuel senders in the left tank.

September 19, 2001 - 1 hours
Installed the fuel vent and fuel pickup tubes and fittings as well as the little BNC connector for the fuel sender. Drilled, countersunk or dimpled the holes for the platenuts on the T-423 attach plate.

Inboard bay of the left fuel tank. This tank has the inverted fuel tank modifications.

Capacative fuel sender plate. Notice the purple masking tape, this keeps the Pro-seal away from where the baffle will have to seal.

Outboard bay of the left fuel tank.

September 23, 2001 - 5 hours
Finished closing the left fuel tank. Maybe I'll have time to forget how much I hate Pro-seal before I get to the right tank. Cleaned up the shop getting ready to go back to work on the wing.

Modification that I made to the cheapest rivet puller that I could find. This is to allow me to get into those Z-brackets that attach the tank to the spar.

Finished fuel tank. I haven't pressure tested it yet.

September 24, 2001 - 1.75 hours
Drilled (I thought I already did that) deburred, and dimpled the leading edge skin.

September 25, 2001 - 1.75 hours
Deburring and dimpling wing skins and ribs.

September 30, 2001 - 3 hours
Deburring and dimpling wing skins and ribs.

October 4, 2001 - 1.5 hours
Primed the wing skins and countersunk most of the little holes in the wing spar.

October 6, 2001 - 4 hours
Finished countersinking the spar. Riveted the leading edge skin to the ribs and started installing the Duckworks landing light in the leading edge.

Taped the template on the leading edge to mark the hole cuttout for the Duckworks landing light.

Finished landing light cuttout.

October 7, 2001 - 2 hours
Got the mounting plate built and trimmed the plexi for the Duckworks light in the left wing.

Finished lense mounting plate.

October 9, 2001 - 2.5 hours
Finished the landing light installation in the left leading edge.

Finished Duckworks landing light installation.

Leading edge of the left wing finished and ready to go on the spar.

October 11, 2001 - 1.5 hours
Tapped the tie down bracket and drilled the little hole in the skin for the tie down. Started riveting the leading edge assembly to the spar.

October 13, 2001 - 3 hours
Finished riveting the leading edge assembly to the left wing.

Finished leading edge assembly installed on the left wing.

October 13, 2001 - 1 hours
Pressure tested the fuel tank and fixed the big 'ol leak that I found.

Pressure testing the tank. The top tube goes over the the homemade manometer and the bottom is the tube I used to 'pressurize' the tank.

Here is a picture of my homemade manometer. It is really high tech. Here is a note on how I built it.

October 16, 2001 - 1 hours
Finished leak testing the fuel tank. Decided that the leak was where my test fitting connected to the tank. Couldn't make a single 'Snoop' bubble anywhere else. Installed the tank on the wing.

October 17, 2001 - 1 hours
Started riveting on the top wing skins

October 18, 2001 - 1.5 hours
Still riveting top skins on

October 19, 2001 - 1.3 hours
Finished riveting the top skins and took the left wing out of the jig and into the craddle.

Left wing out of the jig and in the craddle.

This is what the top of the wing looks like. The wing craddle was built by my wife, Shannon. Looks pretty good and it fits like a glove. Build it per the plans from Van and it works great.

October 20, 2001 - 4 hours
Installed the aileron bellcrank in the left wing. Cleaned up the shop and started preparing the ribs for the right wing for priming.

Close up of the aileron bellcrank

October 26, 2001 - 2.5 hours
Primed all the right wing ribs.

October 26, 2001 - 3 hours
Assembled the right wing skeleton and hung it on the jig.

October 28, 2001 - 6 hours
Clecoed and drilled all of the main wing skins top and bottom as well as the leading edge skin. Time to start on the other tank. :-(

October 29, 2001 - 2 hours
Fabricated the right tank attach brackets and drilled them to match the main spar.

October 30, 2001 - 2.5 hours
Finished the right tank attach brackets and bolted them to the spar. Cut out and deburred the tank stiffeners.

October 31, 2001 - 1.5 hours
Drilled the stiffeners to the right fuel tank skin and started getting the baffle lined up on the tank attach brackets.

November 1, 2001 - 2 hours
Drilled baffle to the attach brackets, drilled the skin to the ribs and the baffle.

November 2, 2001 - 1.5 hours
Prepared the capacitive fuel sender plates and drilled them to the proper ribs.

November 3, 2001 - 3 hours
Fabricated the tank attach angle (difficult with the bandsaw out of commission) Drilled the attach angle and doubler plates to the ribs. Drilled the fuel filler and drain to the skin.

November 4, 2001 - 3 hours
Cut the big hole in the inboard rib, fit and drilled the tank access reinforcement plate. Prepared the tank access plate for the fuel pickup and fabricated the anti-rotation bracket and drilled it to the tank attach plate.

November 5, 2001 - 2 hours
Fabricated the fuel pickup tube. Also made the little cover to fit over the tooling hole in the outboard rib. Started deburring and dimpling all the parts of the right tank.

Fuel pickup tube for the right fuel tank. (OOpps it is shown inside out in this picture. But don't worry nothing is tight.)

November 6, 2001 - 1.75 hours
Deburring and dimpling right fuel tank parts.

November 10, 2001 - 3 hours
Finished dimpling and deburring all of the right tank parts. Now I am ready for the Pro-seal.

November 11, 2001 - 7 hours
Sealed and back riveted all the right tank stiffeners, fuel tank filler, drain flange and six of the seven ribs. It goes faster the second time and it helps that it wasn't so hot this time so the Pro Seal cures slower.

November 13, 2001 - 1.5 hours
Installed the capacative senders in the right tank. Also cut and flared the the vent line. These things are much easier with the inboard rib off.

November 17, 2001 - 3 hours
Finished the capacative fuel sender installation, installed the inboard rib with the reinforcing ring and installed both of the reinforcement plates and the attach angle to the leading edges.

November 18, 2001 - 3.5 hours
Installed the baffle in the right tank. TANKS ARE FINISHED!!!! Now if it will just not leak then I can be done with Pro-seal.

November 19, 2001 - 2 hours
Cleaned up a little bit and worked on the leading edge parts.

November 20, 2001 - 2.5 hours
Removed the top skins from the skeleton and deburred both of them as well as the leading edge skin. Riveted the platenuts to the tank attach plate.

November 21, 2001 - 2.5 hours
Dimpled the leading edge skin and both top skins, and got everything ready to prime.

November 23, 2001 - 9 hours
Primed all the right wing skins, deburred the main ribs, riveted the leading edge together and almost finished installing the Duck Works landing/taxi light into the leading edge.

November 24, 2001 - 6 hours
Finished the Duck Works light installation and countersunk all the little holes in the spar where the skin dimples sit. Also rivted the leading edge skin to the spar.

November 25, 2001 - 0.75 hours
Pressure tested the right fuel tank, and cleaned up the shop a bit.

November 25, 2001 - 6 hours
Started the ailerons by knocking off the edges of all the ribs and stiffeners. Got the old door out and drilled all the stiffeners to the skins and started deburring the stiffeners.

Here's a shot of the aileron stiffeners drilled and clecoed to one side of one of the ailerons.

November 26, 2001 - 2 hours
Finished deburring and dimpling the aileron stiffeners. Started getting all the aileron parts ready to prime.

November 27, 2001 - 1.5 hours
Got the rest of the aileron parts deburred, dimpled and ready to prime.

November 29, 2001 - 1.75 hours
Finished installing the leading edge to the right wing by riveting the ribs to the spar (it took until tonight because I waited for John to give me a hand). Installed the fuel tank on the wing as well.

December 2, 2001 - 5 hours
Riveted the top skins on. I didn't back rivet these and they seemed to turn out better. I had trouble keeping the rivets straight with the backrivetter. I also took the wing out of the jig! Now I can take down these two posts.

Two wings out of the jig and into the craddle!

December 2, 2001 - 4.5 hours
Primed all the aileron parts. Backriveted the stiffeners to the aileron skins, formed the trailing edge bend and started assembling the skeletons.

Stiffeners riveted to an aileron skin.

December 3, 2001 - 2.2 hours
I took down the emp/wing jig and cleaned up a little. Worked on the forward aileron skeletons some more.

December 6, 2001 - 2.2 hours
Attached the aileron hinges and aileron gap seal to the left wing, started on the flap brace.

December 8, 2001 - 4 hours
Finished installing both sets of aileron hinges, aileron gap seals and flap braces.

Outboard aileron hinge of the right wing.

Another view of the outboard aileron hinge.

Inboard aileron hinge

Aileron gap seal installed on the right wing.

Flap brace riveted to the rear spar of the right wing.

December 9, 2001 - 1 hours
Installed the aileron belcrank in the right wing.

December 9, 2001 - 6 hours
Drilled the ribs and spars of the right aileron, drilled and countersunk the counterbalance pipe, dimpled and countersunk all the holes and assembled the aileron. Also bolted on the hinge brackets.

Close up of the aileron counterbalance pipe riveted to one of the leading edge ribs.

Aileron spar, rib and counterbalance assembly.

Once all the clecoes are in I had to build up under the aileron to hold it straight while I finished drilling.

Riveting the top of the aileron was much easier once I clamped the spar down to some blocks to hold it steady.

Inboard side of the aileron. Notice the hole that had to be cut in the rib to access the nut that bolts the hinge bracket on.

Right aileron finished.

December 10, 2001 - 2 hours
Installed the right aileron on the wing and started drilling out the reinforcement plates on the left aileron.

December 11, 2001 - 1.5 hours
Finished putting the reinforcement plates on the aileron spar, riveted the leading egde ribs to the spar and riveted the counterbalance pipe to the ribs.

I clamped the aileron to the table as I drilled and riveted the counterbalance pipe to the ribs to help keep it from twisting.

December 12, 2001 - 2.1 hours
Finished Drilling all the holes in the left aileron and started deburring, dimpling and countersinking everything.

December 15, 2001 - 4.5 hours
Finished deburring and countersinking all the parts for the left aileron, and finished riveting it together.

December 16, 2001 - 2.5 hours
Mounted the left aileron to the wing. Cut, primed and assembled both aileron control rods. Installed and adjusted the control rods to the ailerons.

Close up of the Rod End assembly of the aileron push rod.

Completed aileron push rod.

Detail of the inboard hinge/push rod connection.

This shows the bellcrank and the push rod assembly with the bellcrank jig (the blue thing). The jig holds the bellcrank in the neutral position while the length of the push rod is set.

December 16, 2001 - 1 hours
Installed the nylon corrugated wiring conduit in the wings.

Both wiring conduits installed in the left wing. I put two in to separate RF signals from lighting signals.

This shows what the conduit look like protruding through the outboard rib.

I simply enlarged the aft tooling holes to locate the wiring conduit. It's hard to tell from this photo but there is about an inch of clearance between the conduit and the push rod.

December 17, 2001 - 1.3 hours
Cleaned up a little, got all the Flap parts out of storage and started fabricating the little reinforcement brackets.

December 18, 2001 - 1.5 hours
Finished fabricating the reinforcement bracket and started deburring all the edges of the flap parts.

This is the reinfocement bracket that rivets to the front of the flap spar on the inboard side.

December 19, 2001 - 1.5 hours
More deburring of flap parts

December 30, 2001 - 1.4 hours
Deburred the edges of the flap skins

  Top  April, 2001>>

Disclaimer:
This web site and the infomation contained within it are for entertainment purposes only. The opinions expressed on construction techniques are my opinions only and should not be confused with proper construction techniques. There is undoubtedly more than one way to build an airplane and some methods that I use may or may not work in any given circumstance. If there is any question please call the kit manufacturer. I love to help but I am not responsible for the misuse of any information contained on this web site.

 January 20, 2021
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