Project Log - July, 2005 

 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

July, 2005

July 1, 2005 - 1 hours
Loaded a bunch of small airplane parts into the car and took them to the hangar. Mostly just covers and fiberglass stuff. I'll really get starting moving stuff tomorrow.

July 2, 2005 - 2 hours
Loaded up all the control surfaces, a bunch of tools, and the wings and took them to the airport.

July 2, 2005 - 2 hours
I tested the fuel tanks and found a couple of leaks. The leaks weren't associated with the covers that I just re-did either. That doesn't give me a warm fuzzy feeling. I found one tiny leak in each tank so I did the ProSeal thinned with MEK trick, and pulled a small vacuum on the tanks and let this stuff wick into to the leak for a couple of hours and then put some unthinned ProSeal around that just for good measure.

July 3, 2005 - 3 hours
Moved the fuselage to the hangar. I guess that makes it official. The bird has left the nest. Now all I have to do is bolt all these parts together and go fly. I also managed to get my toolbox loaded up and out there.

Since the gear was just a few inches wider than the trailer we had to take some weight off with the shop crane to get the landing gear to come in.

Now we have to load this thing up and take it with us.

Loaded up and ready to go.

We managed to get this thing to the hangar intact. It feels good to have the road trip behind me. Thanks for the help Gary.

July 4, 2005 - 2 hours
Loaded up a bunch more stuff to take to the hangar. It's gonna take forevever to get all the little tools and pieces-parts that I'll need to the hangar. I also took the plans and started putting the tail together. I got a call from a customer that is having trouble and that put a damper on the tail assembly. Oh well I also got to go sailing and watched the fireworks from a boat anchored in Upper Galveston Bay. Life is good.

July 6, 2005 - 1.5 hours
I finished bolting the Vertical and Horizontal Stabilizers to the fuselage. I had forgotten to put the nutplates on the Horizontal Stab. for the empennage fairing so I had to stop and do that too. It's really fun to be putting these things on permanently.

July 8, 2005 - 2 hours
Installed the Rudder.

July 9, 2005 - 2 hours
Put the elevators on the plane and started installing the trim servo. I'm gonna have to do some more trimming on the elevator to get the trim servo linkage to clear.

July 10, 2005 - 6 hours
Had a hangar warming party today to let people take a look at the plane and help find squaks. I got some good suggestions and a few squaks. Also managed to get the wings on the plane with the NAS bolts and we put the prop on too.

Stabbing the right wing. Thanks for the help guys.

We've got to deal with those wires that need to go through the wing.

Jon helped me get a piece of string through the wing conduit with the old vacuum cleaner trick. I'm taping the string to the wires here.

It seems to be missing something.

Time for the left wing

I had to flare the plastic pitot tube to go on the wing. I hope this works okay because there is just not a lot of room between those wings and the fuselage side.

Now it's starting to look like and airplane.

The cheering section.

How many people does it take to install a prop?

The Prop's on!

July 12, 2005 - 2 hours
Finished installing the trim servo in the left elevator and I managed to get the elevators balanced.

July 14, 2005 - 1 hours
Got the bolts in and torqued for the elevators except for the center bolt that goes through the horns. My hole was a little close to the welds so I may have to put a socket head screw in there instead. I also managed to get the right aileron on.

One aileron installed.

July 18, 2005 - 2 hours
Finished the elevator attach. I wound up putting a washer underneath the bolt head and grinding a little relief on the back side of the washer to clear the weld. I had to use a longer bolt. Installed the big elevator push tube and torqued that all up. Installed the left aileron. Torqued the rear spar attach bolt on the left wing and installed the cotter pin but I couldn't get the nut to line up on the right side and at the correct torque. I need to order some more bolts and nuts so that I can try some different combinations.

The elevators are on for good.

July 19, 2005 - 1.5 hours
Torqued up the 20 bolts that attach the main wing spars to the center section. Now all I lack having the wings on permanent is that rascally little bolt on the right rear spar.

This is the aft side of the wing attach bolts.

Here is the forward side of the wing attach bolts.

July 20, 2005 - 2 hours
Fixed the spinner backplate. Torqued the bolts on the starter. Tightened up the little fuse gusset bolts. Put the little elevator pushtube in and started to install the control sticks.

The spinner backplate is now on correctly. I had too many washers in front of it when we bolted it up the other day so I had to remove it and redo it. Now the spinner fits well.

A little safety wire on front spinner bulkhead.

This is the little fuse gusset that goes in the tailwheel versions. This area would be full of main gear mount weldments on the nosedraggers.

July 23, 2005 - 1.5 hours
Installed a small heat sheild on the exhaust where to keep some heat off the fuel line. Ran the two little air tubes for the AOA up to the AOA CPU. I also started connecting the autopilot wires that I had stubbed out under the floor pan of the passenger side. I had a couple of wires that had lost their labels along the way so I had to remove the servo from the wing to get to the little D-sub connector so that I could identify those wires. It wasn't as bad as I thought and I'm glad I did it because I'd forgotten to put any loctite on the bolts holding the servo.

Jon suggested that I put a heat sheild here where the fuel line goes up to the flow divider. I just happened to have a spare heat sheild.

July 24, 2005 - 5 hours
Finished hooking up those wires to the autopilot and reinstalled the servo into the wing. There are two wires that can be interchanged on the servo that determine the direction that it works. I wanted to make sure that I had these right before I buttoned it all up so I turned on the autopilot and wiggled the wings and tail to make sure that it would try to move the aileron in the right direction. It did! That was way too much fun! Then I finished all the wiring on the lights. I did both wingtips and the tail, dug out the right fuses and started flipping switches. I had one small problem with the left position light. The factory connector had been put on too tight and pinched the ground wire. Fixed that right fast. I turned on the position lights and they worked then I flashed the landing/taki lights and they worked and then I tried the strobes. That was a lot of fun too. So while I had all the wiring tools out I decided to finish up any wiring that I could find and the only thing around was the capacative fuel sender adapters for the EI Fuel Gauge. So I put those on. Unless I'm forgetting something that should be the last of the wiring.

I managed to get all the lights in the wingtips wired up. I still need to get in there and secure the wires a little better so there are just clecoed on for now.

Tail position / strobe light installed in the rudder bottom.

Right wingtip wiring.

Left wingip wiring

July 25, 2005 - 2.1 hours
I got a new bolt for the right rear spar today so I installed that one. It still took a couple of iterations to get it torqued and lined up but I had plenty of washers, bolts and nuts to play with. I installed the flaps and hooked up the control rods to them. I also managed to get the tailwheel springs on but I'm not sure that I like them very much.

I used some safety wire and some holes drilled through the flap brace to secure the flap hinge pins.

The flaps are on.

This is a real close up of the flap push rod.

I am sure that this is too much slack but it was gettin late so I snapped this picture on my way out.

The chain interferes with the rudder bottom when the rudder is at full deflection. It's not bad because by this point the tail wheel has broken loose and is free castoring but it seems like it shouldn't do this.

July 26, 2005 - 2 hours
I put the tanks on and hooked up the tubing. It's gonna take longer than I thought to get all those bolts and screws tight. I need a smaller ratchet.

July 29, 2005 - 2 hours
Fiddled with the tanks some more. I managed to get one on and the other one started.

The right fuel tank is attached, the vent line, the fuel pickup and the EI capacative fuel level adapter are all hooked up.

July 30, 2005 - 5 hours
Managed to get the left tank on. There were a few bolts that were trying to be difficult but I managed to get them in. I tightened up the tail wheel chains and that made the rudder interference problem worse. I think I'll have to try that Rocket Steering Link. I also started rigging the ailerons.

It looks like a wing with the fuel tank on it.

July 31, 2005 - 6 hours
Started rigging the ailerons and installing all the control stick stuff. I discovered a little interference with the bellcrank and the short aileron push tube. I rechecked everything, from finding the neutral position with the aileron jig. I decided that the way to fix it was with the "optional" aileron stops. This pretty much took the rest of the day. Oh and I put a little adel clamp on the ELT antenna so that it wouldn't be flopping around back there tearing up something important.

Since I had to take the wingtip off again to check the neutral position of the aileron I put this split corrugated tubing around the wires that I can't really secure.

The sticks are in.

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 February 3, 2021