Last 50 Entries
| Entry Date: Thursday, Mar 11, 2010 (details) |
|
|
|
| We're on the GROUND! |
| Fuselage
|
| General
|
| 1 hours
|
Hurrah!
|
|
|
|
|
| Entry Date: Wednesday, Feb 10, 2010 (details) |
|
|
|
| Mount Tubes & Tires on the Main Wheel Assemblies & Mount Wheels |
| Fuselage
|
| General
|
| 2 hours
|
Seperated the wheels (manual calls for 7/16" tools, ours needed 1/2" - We have 8's).
Insert tubes inside tires and put together the wheel halves.
Checked for pinches and inflated the tires.
Attached remaining axle hardware, packed the bearings.
Slid on the wheels and drilled the final outboard cotter pin hole.
|
|
|
|
|
| Entry Date: Wednesday, Feb 03, 2010 (details) |
|
|
|
| Install the Brake Mounting Flanges & Torque Plates on the Axles |
| Fuselage
|
| General
|
| 4 hours
|
Positioned the Brake Mounting Flange on the axle with the proper angle for our taildragger configuration.
Marked and drilled using the step-method.
Installed brackets/flanges/etc.
|
|
|
|
|
| Entry Date: Saturday, Jan 30, 2010 (details) |
|
|
|
| Drill & Bolt the Main Gear Legs |
| Fuselage
|
| General
|
| 4 hours
|
Check final bolt placement before drilling and recheck alignment.
Drill main gear legs using the step method.
Clean and deburr.
|
|
|
|
|
| Entry Date: Wednesday, Jan 27, 2010 (details) |
|
|
|
| Insert & Position the Gear Legs |
| Fuselage
|
| General
|
| 3 hours
|
Test-fit gear legs in sockets to check if honing was needed.
*Left-side fit in perfectly, so this was marked "L" and we moved to the Right*
Used honing tool as necessary, cleaned and regreased between fittings.
Used a steel bar to align gear legs with proper taildragger shims.
|
|
|
|
|
| Entry Date: Monday, Jan 25, 2010 (details) |
|
|
|
| Support & Level the Fuselage |
| Fuselage
|
| General
|
| 1 hours
|
Position fuselage to assist in gear leg insertion.
Level and support.
|
|
|
|
|
| Entry Date: Thursday, Oct 29, 2009 (details) |
|
|
|
| Fuselage Control System Pulleys Installation |
| Fuselage
|
| General
|
| 2 hours
|
(still working on)
Prepared the forward pulley group for installation and made guards.
Installed the following pulleys: Lower Aft Aileron, Center Flap, Lower Outboard Flap, Upper Crossover.
*No cotter pins have been installed yet*
|
|
|
|
|
| Entry Date: Wednesday, Oct 28, 2009 (details) |
|
|
|
| Install the Cable Fairleads |
| Fuselage
|
| General
|
| 0.5 hours
|
Trimmed the four plastic fairleads and installed in the fuselage cage.
|
|
|
|
|
| Entry Date: Monday, Oct 26, 2009 (details) |
|
|
|
| Control Stick Assembly & Installation |
| Fuselage
|
| General
|
| 2 hours
|
Assemble the elevator/aileron control.
Prepare the control yoke bearing blocks.
Install the assembly.
|
|
|
|
|
| Entry Date: Tuesday, Oct 20, 2009 (details) |
|
|
|
| Assemble & Install the Flap Handle |
| Fuselage
|
| General
|
| 0.5 hours
|
Press dowel pin into the flap handle plunger.
Superglue flap button and plunger into the extension.
Gather all pieces, grease moving parts, and assemble.
Install the handle in the fuselage after reaming excess paint from the attach area.
|
|
|
|
|
| Entry Date: Tuesday, Oct 20, 2009 (details) |
|
|
|
| Fabricate the Rudder Pedals |
| Fuselage
|
| General
|
| 1 hours
|
*Purchased Pre-Made!
|
|
|
|
|
| Entry Date: Sunday, Oct 18, 2009 (details) |
|
|
|
| Rudder Control Support Brackets |
| Fuselage
|
| General
|
| 2 hours
|
Drilling - Already completed in the kit.
Press bushings into rudder control support tabs.
Check fuselage level and level the pedal assembly.
Press bushings into rudder control supports.
Install rudder pedal controls into the fuselage.
|
|
|
|
|
| Entry Date: Tuesday, Oct 06, 2009 (details) |
|
|
|
| Set the Dihedral Angle of the Wings, Mark & Drill Struts |
| Wings
|
| General
|
| 2 hours
|
Check lateral-level of fuselage and set each wing at a 1.5 degree dihedral angle.
Checked wings for twist, adjusted as necessary.
Marked the struts for drilling.
Drilled outboard ends of the struts using the Glasair jig.
|
|
|
|
|
| Entry Date: Monday, Oct 05, 2009 (details) |
|
|
|
| Mount the Wings to the Fuselage |
| Wings
|
| General
|
| 5 hours
|
(combining in one post - includes both sides)
Install the inboard wing strut fittings.
Mark the bolt centerlines on the strut attach arm and wing strut.
Triming of attach areas already completed in our quick build.
Mounted wing, inserted pins, fitted the struts for drilling.
|
|
|
|
|
| Entry Date: Thursday, Oct 01, 2009 (details) |
|
|
|
| Wing Riveting - Left |
| Wings
|
| General
|
| 50 hours
|
(Trying to figure out complete hours.)
General Order Follows:
1) Main & cove ribs to the spars.
2) Leading Edges of the nose ribs.
3) Leading Edge assembly to the spar.
|
|
|
|
|
| Entry Date: Friday, Jul 31, 2009 (details) |
|
|
|
| Wing Components - Cleaning/Corrosion Protection Note |
| Wings
|
| General
|
| 1 hours
|
During cleaning and corrosion treatment we implemented a new 'tagging' system.
|
|
|
|
|
| Entry Date: Sunday, Feb 22, 2009 (details) |
|
|
|
| Assemble & Mount the Flap Tracks |
| Wings
|
| General
|
| 1 hours
|
Lay out and set out rivet pattern of the flap tracks. Cleco with the ribs.
Checked clearances and drilled.
Cleaned, deburred, painted and riveted the assembly together (repeated for both inboard and outboard).
Installed flap tracks on the spar.
|
|
|
|
|
| Entry Date: Friday, Jan 30, 2009 (details) |
|
|
|
| Assemble, Rivet and Mount the Flap Bellcrank Assembly and Bracket |
| Wings
|
| General
|
| 8 hours
|
Assemble pieces, lay out rivet pattern per specifications and drill.
Clean, deburr, corrosion protect.
Rivet the assembly together and press the flap bellcrank bearing housing in.
Loctite and press the bearing in.
Assemble, punch, drill and prep the brackets.
Rivet the angles to the brackets, mount the bellcrank assembly, and rivet to the aft spar.
|
|
|
|
|
| Entry Date: Friday, Jan 30, 2009 (details) |
|
|
|
| Assemble the Aileron Hinge |
| Wings
|
| General
|
| 3 hours
|
Assemble the aileron hinges based on manual diagrams.
Align, clamp, drill, deburr and clean.
Rivet pieces together and rivet to spar.
|
|
|
|
|
| Entry Date: Wednesday, Jan 21, 2009 (details) |
|
|
|
| Assemble the Aileron Bellcrank & Mount the Hinges |
| Wings
|
| General
|
| 3 hours
|
Align the pieces of the bellcrank, clamp and drill. Assemble the brackets as well.
Deburr, clean, and corrosion-proof everything except the bearing.
Rivet brackets, assemble and fit to spar.
|
|
|
|
|
| Entry Date: Saturday, Jan 03, 2009 (details) |
|
|
|
| Fabricate & Mount the Outboard Pulley Brackets |
| Wings
|
| General
|
| 1 hours
|
Fabricated the brackets, assembled the pieces and aligned on the spar.
Drilled, cleaned, deburred and painted.
|
|
|
|
|
| Entry Date: Monday, Sep 01, 2008 (details) |
|
|
|
| Finish Drilling the Skins |
| Wings
|
| General
|
| 15 hours
|
Completed drilling on both sides.
Aligned and drilled the nose ribs.
Dimpled skins, countersinking on forward spar and flanges.
Deburr.
*Added 5 hours for cleaning, corrosion-proofing, and painting of all wing-bits. (estimated) Completed in stages through 8/1/09.
|
|
|
|
|
| Entry Date: Saturday, Aug 16, 2008 (details) |
|
|
|
| Position & Drill the Upper Skin Stringer Channels |
| Wings
|
| General
|
| 1 hours
|
Since the channels were already in place the skins didn't have to be moved again for this step.
Re-positioned the channels with the lower skins off, supported and drilled.
|
|
|
|
|
| Entry Date: Saturday, Aug 09, 2008 (details) |
|
|
|
| Position & Drill the Upper Hat Stiffeners |
| Wings
|
| General
|
| 4 hours
|
Remounted upper skins, removed lower. Repeated procedures to prepare the hat sections.
Position and drill.
Enlarge all rivet holes through spars and where the skin splices to #30.
|
|
|
|
|
| Entry Date: Thursday, Jul 24, 2008 (details) |
|
|
|
| Position & Drill the Lower Skin Stiffener Channels |
| Wings
|
| General
|
| 1 hours
|
Fit the skin stringer channels underneath the lower skins.
Centered as well as possible and drilled.
(We changed the order from the manual and did this before the upper hat sections. Seemed to make sense not to waste time removing skins inbetween tasks)
|
|
|
|
|
| Entry Date: Sunday, Jun 01, 2008 (details) |
|
|
|
| Install Hat Sections Stiffeners & Lower Wing Stiffeners |
| Wings
|
| General
|
| 5 hours
|
Checked each hat section for straightness. Corrected any issues.
Smoothed edges and rounded the ends on the grinder.
Marked rivet lines.
Position and drill.
|
|
|
|
|
| Entry Date: Thursday, May 01, 2008 (details) |
|
|
|
| Position & Drill the Lower Inboard Main Skin |
| Wings
|
| General
|
| 2 hours
|
Same procedure as for all skins.
|
|
|
|
|
| Entry Date: Tuesday, Nov 13, 2007 (details) |
|
|
|
| *Cough* |
| Fuselage
|
| General
|
| 0 hours
|
Poor, poor neglected airplane! We have abandoned it these past few months. But we promise we have a good excuse....
We're building a hangar!
(see, not too bad of an excuse eh?)
|
|
|
|
|
| Entry Date: Friday, Jul 06, 2007 (details) |
|
|
|
| Position and Drill the Lower Outboard and Center Main Skins |
| Wings
|
| General
|
| 0.75 hours
|
Used the same method as attaching the upper skins and attached the lower outboard and lower center skins.
|
|
|
|
|
| Entry Date: Sunday, Jul 01, 2007 (details) |
|
|
|
| Finish Drilling the Upper Main Skins |
| Wings
|
| General
|
| 7.5 hours
|
Attached all upper skins and rechecked the alignment.
Drilled all rivet holes: spars and ribs, forward spar flanges, main ribs, aft spar, and finally the flap and aileron cove ribs.
|
|
|
|
|
| Entry Date: Thursday, Jun 14, 2007 (details) |
|
|
|
| Mark and Trim the Leading Edge Skins |
| Wings
|
| General
|
| 3 hours
|
With the upper skins in place and secured, marked anywhere the skins overlapped.
Removed the excess material with a file.
|
|
|
|
|
| Entry Date: Friday, May 11, 2007 (details) |
|
|
|
| Where have Shawn & Aimee gone??? |
| Fuselage
|
| General
|
| 0 hours
|
Sorry folks but we've left you high and dry for a loooong time.
Good excuse though... we moved! Yes, we took apart that lovely wing in it's nice jig and packed everything up in boxes. The move went well (thanks to our intrepid friends who had to move something more interesting than a couch). No damage to any parts! Whew.
We've got the jig mostly back in place. Our new garage configuration is a lot different so we've had to change/build tables and jigs.
We're trying to get a hangar built and having to rebuild the engine in 04F so we're a tad busy. No worries builder-folk, we'll plug away as time pops up! Maybe i'll even try to get some fresh pictures in here.
|
|
|
|
|
| Entry Date: Saturday, Jan 13, 2007 (details) |
|
|
|
| Position & Drill the Upper Main Skins |
| Wings
|
| General
|
| 2 hours
|
Began with the upper outboard skin. Placed, aligned and drilled a few index holes.
Repeated this process with the other upper skins.
|
|
|
|
|
| Entry Date: Saturday, Jan 13, 2007 (details) |
|
|
|
| Finish Drilling the Leading Edge Skins |
| Wings
|
| General
|
| 4.5 hours
|
Made sure the leading edge skins were properly placed and that the jig was straight.
Drilled all remaining spar holes (#40's) except for the lower spar flange for the inboard leading edge skin.
|
|
|
|
|
| Entry Date: Tuesday, Jan 02, 2007 (details) |
|
|
|
| Install the Forward Spar Caps |
| Wings
|
| General
|
| 2.5 hours
|
Cut the aluminum for the caps, marked out the location and placed.
Deburred the ends and rounded the 'inner' edge of the caps.
Finalized placement and drilled a few index holes in the caps.
|
|
|
|
|
| Entry Date: Wednesday, Dec 27, 2006 (details) |
|
|
|
| Position, Clamp & Index Drill the Leading Edge Skins |
| Wings
|
| General
|
| 3 hours
|
Placed each leading edge skin and clamped to check the general fit.
Removed the center and inboard skins, supported the nose ribs (glue/wood support technique), and realigned the outboard skin.
Clamped the skin and drilled a few index holes.
Repeated this process with the other skins.
|
|
|
|
|
| Entry Date: Tuesday, Nov 14, 2006 (details) |
|
|
|
| Drill Wing-Assembly Holes (ribs, spars, etc) |
| Wings
|
| General
|
| 7 hours
|
*Note: We'll use one date, and maybe multiple big entries, 'cause this is being done over a loooong time.*
After attaching all ribs/etc to the spars, drilled up each hole to #30's.
Before drilling checked the alignment of each piece.
|
|
|
|
|
| Entry Date: Saturday, Nov 04, 2006 (details) |
|
|
|
| Mount the Strut Beam |
| Wings
|
| General
|
| 1.5 hours
|
Installed the assembly between the spars and fastened.
|
|
|
|
|
| Entry Date: Saturday, Oct 14, 2006 (details) |
|
|
|
| Assemble the Strut Beam |
| Wings
|
| General
|
| 3.7 hours
|
*We have the earlier kit which will have two holes at the aft angle, later kits will only have one.*
Cleco'd the strut beam halves and their attach angles together.
Pass drilled all holes common to the forward angles and reamed to 1/4".
Made sure to keep the holes aligned and the angles parallel to each other.
|
|
|
|
|
| Entry Date: Thursday, Oct 12, 2006 (details) |
|
|
|
| Reinforce the Root Main Rib |
| Wings
|
| General
|
| 2.5 hours
|
*not complete yet*
Made the upper/lower root rib doublers, the reinforcement angles and the web doubler angles.
Placed all reinforcement according to the manual and drilled rivet holes.
|
|
|
|
|
| Entry Date: Wednesday, Sep 27, 2006 (details) |
|
|
|
| Fabricate Aft Spar Center Supports |
| Wings
|
| General
|
| 0.5 hours
|
Built three supports for the aft spar.
|
|
|
|
|
| Entry Date: Tuesday, Sep 26, 2006 (details) |
|
|
|
| Mount the Ribs to the Spars |
| Wings
|
| General
|
| 1.5 hours
|
(Marked rivets lines on the main ribs.)
Cleco'd the main ribs to the spars.
|
|
|
|
|
| Entry Date: Sunday, Sep 17, 2006 (details) |
|
|
|
| Fasten the Spars to the Jig Brackets |
| Wings
|
| General
|
| 2 hours
|
Mounted the forward spar to the inboard bracket with a 1/2" bolt. Attached the outboard side with a cleco.
Double checked placement of outboard bracket and drilled/attached to the jig.
Once the forward spar was in place measured down from the brackets and placed the aft set.
Placed spar as before and checked level.
|
|
|
|
|
| Entry Date: Tuesday, Sep 12, 2006 (details) |
|
|
|
| Mark Rivet Lines on the Forward Spar Flanges |
| Wings
|
| General
|
| 0.5 hours
|
Made a tool out of leftover 2x2 aluminum angle. Drilled holes in the angle to measure out the distance from the spar edge the lines needed to be.
Marked the lines relative to the spar edges.
|
|
|
|
|
| Entry Date: Tuesday, Sep 12, 2006 (details) |
|
|
|
| Install the Inboard Spar Brackets |
| Wings
|
| General
|
| 0.5 hours
|
Used the jigs we made for the horizontal stabilizer build and attached one side of the brackets according to the manual specifications.
|
|
|
|
|
| Entry Date: Sunday, Sep 10, 2006 (details) |
|
|
|
| Fabricate the Wing Jig Spar Brackets |
| Wings
|
| General
|
| 2 hours
|
Fabricated four brackets to 'attach' the spars to the jig.
Used 2"x2" aluminum angle and measured hole locations (for attaching and leveling) per manual instructions.
|
|
|
|
|
| Entry Date: Thursday, Aug 24, 2006 (details) |
|
|
|
| FYI: Please Excuse Our Building Boring-ness |
| Wings
|
| General
|
| 0 hours
|
*EDIT* We've finished the left flap. Started setting up for *gasp* WINGS!!!*
Will still leave up the FYI that Shawn now has his Tail-Dragger Endorsment thanks to the J3 Cub at Northwest School of Aviation. WOOHOO!!! (aimee is also trying to figure out a new camera so pictures may be... odd... for awhile.)
|
|
|
|
|
| Entry Date: Friday, Jun 30, 2006 (details) |
|
|
|
| Bolt the Lower Rudder Hinge and the Fin Spar to Bulkhead C |
| Fuselage
|
| General
|
| 0.5 hours
|
Removed an edge of each washer used in connecting the two pieces (aka: 'relieved').
Mounted the lower rudder hinge to the lower flange of the spar and Bulkhead C.
|
|
|
|
|
| Entry Date: Friday, Jun 30, 2006 (details) |
|
|
|
| Mark, Drill & Rivet the Vertical Fin Rivet Holes |
| Fuselage
|
| General
|
| 2.8 hours
|
Measured out a line on each side of the fin and marked out 40 rivet holes.
Drilled each hole out with a #30 (along with the four previous ones) and countersunk.
Cleaned and deburred all holes.
Flush riveted both lines using the pnuematic squeezer.
|
|
|
|
|
| Entry Date: Monday, Jun 26, 2006 (details) |
|
|
|
| Bed the Vertical Fin Spar Between the Fin Shells |
| Fuselage
|
| General
|
| 0.5 hours
|
Sanded and cleaned the bonding surfaces of the shells.
Mixed a batch of resin, milled fiber and Q-cell and spread evenly along the edges of the shell.
Place the spar between the fins and held in place with the four cleco's and bar/clamp combo's.
Cleaned up any excess Q-cell and left to cure.
|
|
|
|
|
|