Project Log - May, 2003 

 Project News
 February 3, 2021

 Project Log

  Horizontal Stabilizer
  Vertical Stabilizer
  Rudder II

 Wing Kit
  Fuel Tanks

 Fuselage Kit
  Aft Section
  Foreward Section
  Top Fuselage


 Firewall Forward
  Fuel System

  Finishing Up!

 Project Notes
 Project Summary
 Other Stuff

May, 2003

May 1, 2003 - 0.5 hours
Put some more Super-Fil on the emp fairing and re-fit it to the tail. This should be the last time.

May 1, 2003 - 1 hours
Drilled some of the forward top skin holes.

May 4, 2003 - 3 hours
Reattached the elevators and the rudder, fabricated and installed the rudder stops.

I used a plumb bob hanging from the trailing edge of the rudder to help get the angle set.

The finished rudder stop. I'll put the last two rivets in after the VS comes off.

May 4, 2003 - 1 hours
Finished drilling the top forward skin holes out and started fitting the panel.

May 4, 2003 - 0.5 hours
Sanded the Super Fil on the emp fairing and took off the rest of the Saran wrap. It fit's pretty good.

The emp fairing fits pretty good. Now I just need to countersink the screw holes and attach the nutplates after the VS and HS come back off.

May 6, 2003 - 1.5 hours
Finished fitting the panel into the forward fuselage, drilled the little angles that go around the forward canopy deck to fasten the panel and started fitting the eye-ball vents to the bottom of the panel.

May 7, 2003 - 1 hours
Finished the eyebal vents. Did some last minute adjustments on the Rudder Pedals. They seemed to stick more than I would like so I spent some time fine tuning them.

Eyball vent asseblies. I still need to drill them to the side of the fuselage but that can wait until the panel is mounted.

May 11, 2003 - 5.4 hours
Finally finished fabricating all the parts for the top forward fuselage. Finished drilling all the holes and took it all apart, deburred, dimpled and countersunk all the holes and just nearly got it all ready to prime.

Forward fuselage structure and panel all drilled and clecoed into place.

May 12, 2003 - 1.5 hours
Deburred all the holes in the fuselage where the top forward structure will go. Re-installed (hopefully for the last time) the fuel vent lines. Played around with rudder pedal location until I was comfortable.

May 13, 2003 - 2 hours
Installed the brake fluid reservoir. Built and installed a doubler plate for the parking brake valve. Installed all the fittings into the brake master cylinders.

This is the brake fluid reservoir.

This is where the brake fluid reservoir comes through the firewall. I used a little Pro-seal to help keep the fumes out.

I used one wrap of 1/4" Teflon tape on the 1/4" NPT threads for the brake line fittings.

Tubing fittings installed on the parking brake valve.

Parking brake valve mounted to the doulber plate and firewall.

This is what the firewall side of the parking brake mount looks like.

May 14, 2003 - 1.6 hours
Tubed up the parking brake valve to the firewall bulkhead fittings. Re-installed the rudder pedals (hopefully for the last time). Fabricated the little plates that attach the rudder pedals to the rudder cables, and started tubing up the brakes.

I used 1/4" aluminum tubing to tie the parking brake valve to the firewall bulkhead fittings. Note: Don't mount the valve like this. I found out later that it interferes with the rudder pedal travel.

May 17, 2003 - 1.5 hours
Moved the parking brake valve to the new location, and tubed it up.

The old position of the parking brake valve interfered with the brake pedals. This is how I wound up mounting it.

Another view of the parking brake valve.

May 18, 2003 - 2 hours
Retubed the parking brake valve. I didn't like the way the flares came out the first time and was afraid it wouldn't seal. It's much easier to fix it now than to crawl under the panel later so I decided to play it safe. I also went ahead and tightened up on all the plastic/brass fittings on the brake system.

These are the little spacers that go under the aft deck to hold the roll bar. They are needed because the bolt goes in very close to the longeron and these spacers give the bolts a nice flat spot to grip.

May 18, 2003 - 2 hours
Pilot drilled the aft decks for the roll bar attach bolts. Trimmed and primed the little spacer blocks that go under the aft deck and started trying to bend the roll bar to the right width.

May 19, 2003 - 1 hours
Cleaned and primed all the parts of the forward fuselage structure.

The rudder pedals are in and the brakes are tubed up.

May 23, 2003 - 2 hours
Riveted all the structure together for the forward fuselage.

The forward fuselage structure is all riveted in. The top skin will have to wait until I'm done with the panel.

May 26, 2003 - 5.1 hours
Finished bending the roll bar, clamped and drilled the roll bar to the forward fuselage. Spent way too much time putting the little spacers and nuts up under the aft decks, and bolted the roll bar to the fuselage. I had to make a couple of shims to get it perpendicular to the fuse. Then I cut and fit the roll bar brace and drilled the holes to bolt it to the fuselage and the roll bar. I cut the slider rails to length and drilled the little nylon guide that goes on the back of the canopy frame. Started building the canopy guide track, but I didn't get very far.

I clamped the roll bar to the table, wrapped some rope around it and used a wrench to make a turnbuckle to bend it.

The roll bar and the roll bar brace.

This is the little roller assembly that attach to the canopy frame and allow it to roll in the rails.

May 27, 2003 - 1.6 hours
Finished building the slider track and taped the track to the fuselage. I started trying to figure out how to fit the slider frame to the fuselage. This is going to be a patience testing exercise.

The canopy slider rail is duct taped to the top of the fuselage for initial fitting.

May 28, 2003 - 1.25 hours
Today I worked on bending the canopy frame. Cussed a little, bent a little, cussed some more, unbent a little, measured, cussed, bent, cussed.....

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 February 3, 2021