Project Log - January, 2002 
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January, 2002

October 1, 2002 - 1.3 hours
Finished drilling and fitting all the forward cabin covers.

October 6, 2002 - 5 hours
Finished preping and priming that pile of parts I've had around for months, and riveted together a seat back.

October 7, 2002 - 2 hours
Finished riveting the other seat back and riveted on most of the fuselage / bulkhead gussets.

Finished seat backs installed

The finished tunnel cover

One of the fuselage / bulkhead gussets

October 15, 2002 - 1.4 hours
Finished riveting the forward fuse gussets, installed the rudder cable fairings and started riveting on the aft deck.

Forward fuse gusset that connects the longeron to the firewall

Rudder cable fairing from Avery. I trimmed it a little to make it look more streamlined.

October 16, 2002 - 1.5 hours
Unpacked and inventoried the finish kit.

October 19, 2002 - 3.5 hours
Finished riveting the aft deck. Hung the canopy from the ceiling, finished the details on the baggage compartment bulkhead.

The aft deck is on and the fuse is now rigid.

I had to hang the canopy from the ceiling to get it out of the way. Nothing fancy just some wire and a couple of boards from the shipping crate.

These little platic blocks are where the seat belt anchor cables transfer through the baggage bulkhead.

October 20, 2002 - 5 hours
Installed the flap acutator weldment into the fuse, fabricated all the little angles, brackets and spacers for the flap system and started putting the flap system together

This is the flap acutator weldment installed.

October 21, 2002 - 1.8 hours
Installed some braces to hold the wire conduit that I installed into the fuselage a little better. Piddled with the flap mechanism a little bit.

I installed a little clamp that I made out of some scrap J-channel half way between each fuselage bulkhead to hold the wire conduit.

October 29, 2002 - 1 hours
Got the wife to help me finish a few rivets that still needed to be done on the bottom of the fuse and piddled around with the flap mechanism a little more.

October 30, 2002 - 1.6 hours
Almost finished the flap acutator mechanism and made the two little flap actuator pushrods.

Flap motor assembly detail

November 15, 2002 - 2 hours
Installed the flap actuator mechanism into the fuselage. Installed the static ports and tubing in the rear fuselage.

Flap motor assembly mounted to the fuselage

This is the outside of the Van's static port kit. This is the head of a pretty big blind rivet.

After driving the madrel out of the blind rivet I put the tubing over the back of the rivet.

This Tee ties each side of the static system together with the tubing that runs to the panel.

Finished static system. There is a problem with this... See here

November 17, 2002 - 2 hours
Installed all those bolts in the holes that are left in the spar for main gear mounts on the nose draggers. On the real airplane you just fill the holes with bolts. Also put the little clamps on the little pieces of tubing that hold the rudder cable on the back of the plane. Cleaned the shop up some.

December 2, 2002 - 0.75 hours
Reassembled the flap mechanism with the safety wire that keeps the rod end bearing from twisting.

December 2, 2002 - 0.5 hours
Made a pitot tube out of some thin walled stainless tubing from work and started laying out the placement for it on the wing.

December 4, 2002 - 1.5 hours
Installed the Pitot tube in the left wing and changed the little washers out that go between the bushing halves of the flap center bushing. I also ran the flap motor back and forth several times to make sure that my safety wire installation wouldn't get in a bind.

Pitot tube detail with the aileron bellcrank

Another view of the pitot tube

December 5, 2002 - 0.5 hours
Cut the elevator push rod tubes to length, cleaned and etched them in preparation for priming the inside.

December 5, 2002 - 1 hours
Started trimming the aft end of the fiberglass wing tips. The aft end of the tips stuck out about 3/8" past the the aileron, and both need trimming.

The aft end of the fiberglass wingtips were off by about 1/4-3/8"

It didn't take too long to get them carved down

December 6, 2002 - 0.75 hours
Primed the inside of the elevator push rod tubes.

December 6, 2002 - 0.75 hours
Finished trimming and sanding the wing tip aft edges. That was easier than I thought that it would be.

December 7, 2002 - 1 hours
Drilled both of the elevator push tubes to the end pieces and riveted the end pieces to the big tube. I screwed up the little one by only drilling 4 holes in each end instead of 6. I'll call Van's on Monday and see what they say. I most likely will build another one. This is the elevator after all and it's a cheap mistake.

December 9, 2002 - 1.5 hours
Mounted the Tru Trak autopilot servo in the right wing.

December 11, 2002 - 2 hours
Played with the new NOVA strobe power supply. What a show! Drilled the holes in the wingtips for the strobe head and the position lights and started fitting the lenses for the wing tip.

This is the position and strobe light positioned on the wingtip

I duck taped the lense to the tip to mark the initial cut line.

December 12, 2002 - 1 hours
Finished up the wingtips.

Finished Wingtips

December 12, 2002 - 1 hours
Finished mounting the autopilot servo in the right wing.

Tru-Trak autopilot servo installed in the right wing

Another shot of the Tru-Trak autopilot servo

December 14, 2002 - 7 hours
Finished all the little spacers for all of the aileron push tubes. Installed the AOA Sport probes in the right wing, and put a right angle fitting on the pitot tubing where it exits the wing.

This is the Proprietary Software Systems AOA port on the top of the wing.

This is the PSS AOA port on the bottom of the wing.

I installed a right angle bulkhead fitting on the root end of the wing. The blue RTV is left over from pressure testing the tubing. (Addendum: The fitting needs to point down not aft. It interferes with the aileron pushrod if it points aft and besides the hole where it enters the fuselage is below this point.)

December 14, 2002 - 1 hours
Started making another F-789 elevator push tube. I messed the other one up.

December 15, 2002 - 2 hours
Finished building the F-789 elevator push tube. Primed all the aluminum push tubes. Drilled the hole in the elevator bellcrank for future installation of a pitch servo on the autopilot.

December 22, 2002 - 2 hours
Pressure tested the AOA ports, did a little rewiring on the position lights in the wing tip.

December 28, 2002 - 5 hours
Installed the control sticks and the electric aileron trim.

The electric aileron trim uses two springs and a MAC trim servo for biasing the ailerons.

December 29, 2002 - 4.5 hours
Finished checking the electric aileron trim. Pressure tested the Pitot tubing in the left wing. Mounted the NOVA strobe power supply, and ran the shielded strobe wire down the rear of the fuselage to the tail. I also installed a small aluminum clip to hold the static line under the longeron.

I installed this little aluminum clamp to hold the static line. The little black wire ties are to keep it from moving fore and aft.

I installed the Nova X-Pak 904 powersupply right behind the rear baggage compartment bulkhead.

<<December, 2001  Top  February, 2002>>

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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