Finishing the fabrication and fitting of the wing root and horizontal tail root fairings

August 20, 2012

Tonight I spent the evening finishing up the fabrication and fitting of the lower wing root and horizontal tail root fairings. I borrowed the 90 deg adaptor for the drill and finished drilling the lower side of the horiztonal tail fairings (both sides). The lower wing root fairings I pre-drilled the holes in the metal the fitted the top side fairing up to the wing and drill those holes as well. Then I fitted and drill the holes for the leading edge fairings. And finally I made the bottom and top fairings come together nicely at the trailing edge.

Time spent today 4 hours
Total time spent 1574 hours

Fabricating the lower wing nose fairings and drilling and attaching the horizontal tail fairings.

August 19, 2012

Today I again feel like I didn’t get much done but everyday I get something done is a good day. I decided to tackle the nose fiairngs so I needed to install the lower forward belly panel/exhaust channel and side kick panels to get the profile correct. I again used the poster board technique to scribe a line in pencil on to the poster board then cut that out with scissors. This worked really well and required almost no tweeking afterwards it just fit the first time. (sorry no pictures forgot I’ll get them when I go out next time)

After that was done I moved on to attaching the horizontal tail fairings. I needed to do some more trimming on the lower side fo the horzontal tail fiairngs so I did that and temp attached the rubber channel. I then marked the out side of the fairing using masking tape then measured back in to wher I wanted screws to go into the inboard rib and then marked my screw holes and drilled and clecoed them in place. This worked really well and was very accurate. I did this for both the upper side and most of the lower sides but I was unable to drill the rear screw holes because my drill didn’t fit. I will borrow a 90 deg adaptor from my buddy to get those completed tomorrow. I also marked out the lower wing upper fairing for the screw holes but didn’t drill them yet.

Time spent 6 hours
Total time spent 1570 hours

Fabricating the lower wing lower fairings and lower horizontal tail fairings

August 18, 2012

I spent most of the day working on the lower fairings for both the lower wing and the lower side of the horiztonal tail. However it should be noted that I did spend an hour installing the silcone baffle seal on the engine baffles not much to talk about there simply measured cut then drill the hole and install a screw and nut.

I then moved on to the lower fairings. The lower side of the lower wing fairings looked like they should be fairly straight forward so I simply followed the exact dimensions on the drawings and cut a 3 1/2 piece of 0.032 and made the 5/8 10 deg folds on both sides (opposite directions) then the 10 deg diagonal fold for the aft end and viola they fit right up perfectly. I then drilled some holes for the screws and mounted them up to the wings. Both sides were pretty easy.

The cutting and fitting of the lower horiztonal tail fairings were a bit more difficult. I used my pencil “scribe” all it is is a pend zip tied perpindicular to a pencil and the I attach a piece of poster board to the sabilizer and use the capped pen as a “standoff” to trace the profile on to the the poster board. I then cut that out with scissors and trace it on to alumnium. It’s never perfect so I need to proabably an hour of trimming and fitting to get them to fit right. After those were completed I called it a night.

Time spent 6 hours
Total time spent 1564 hours

Fabricating the upper horizontal tail fairings

August 12, 2012

Today I took some time to work on the horizontal tail upper fairings. I started by creating the fairings out of poster board then I transferring them over to 0.025 6061-T6 sheet and cut them out with snips an the straight side on the sheet metal shear.

Time spent today 3 hours
Total time spent 1540 hours

Finishing and topcoating the forward belly pan and gear leg fairings

August 11, 2012

Again another two day roll up. I sanded the belly pan smooth and shot the blue onto it. While that was drying I sanded the gear leg fairings after the body putty dried I used the 80 grit to smooth the putty then followed it with 220 and then finally 320 to get it nice and smooth once that was compelete I could see that it successfully filled the pin holes. The next day I shot an other coat of primer on to them and once that was dry I was able to shoot the blue on to them and they came out great.

Time spent 5 hours
Total time spent 1537 hours

Etching priming and painting the forward belly panel/exhaust channel

August 10, 2012

Two day roll up. I brought the belly panel home for etch, prime, and paint. I started off by etch of course which goes pretty quick. Clean with the Eko clean, rinse with fresh water, spray on the eko-etch scrub with scotch brite for atleast 3 min then rise with fresh water let dry. While it was drying I re sanded the gear leg fairings with 80 grit and then shot them with primmer so I could see where the the pin hole are. I then too a long break to continue to let the panel dry. After a several hours I primed the belly panel and gave everything a rest for the evening. The next day I sanded the belly panel smooth and then shot it the blue Eko-poly. I also covered the gear leg fairings with 3m body putty/filler to hopefully get the pin holes filled. I left the vacuum at the airport so I will have to sand those another day since it is such a mess with out it.

Time spent 5 hours
Total time spent 1531 hours

Fabricating top of lower wing root fairings

August 6, 2012

Tonight I spent the evening laying out and fabricating the top pieces of the lower wing root fairings. To custom fit them I layed out some masking tape and every 2 inches I measured over to the side panels. I then plotted that on to some 0.032 sheet and cut it out with my snips. It took a little more trimming but I was able to get both the lower right and lower left tops fab’d by the end of the evening. I also spent some time laying out the lowers but I didn’t cut any metal yet.

Time spent 3 hours
Total time spent 1526 hours

Seat Pan #2

August 1, 2012

Tonight I tackled the second try at the seat pan with much improved results. Last night I had marked the cut dimensions and rough cut the seat out. Today I cut the notches at back of the seat as the drawings show and then folded it over a 3/4″ tube I had clamped to a table. I also cut I then check the fit on the aircraft and drilled and clecoed the aft part of the seat to the aircraft. Then I folded the front of the seat around the front tube and marked the location of where the two connected. I removed everything and drilled and clecoed the front. I trimmmed everything up and checked the fit again with clecos. Once everything looked good I drilled the holes out to #8 size screws and the debured all the edges and filed radiuses into the cut outs and installed the seat with screws to make it removeable if I desired.

Time spent 2 hours
total time spent 1523 hours

Riveting the lower firewall attach angle, routing the brakelines, and starting seat pan #2

July 31, 2012

Tonight I spent an hour or so routing the brake lines from the firewall bulkhead fitting down the gear leg and then into the brake caliper. Since I don’t have my brake calipers installed (still trying to figure out these Matco wheels) I only flared the top fitting, but I routed the bottom close to where the caliper input will be. After that I debured the 1/8″ holes on the lower firewall angles and firewall itself and squeezed those rivets. I also installed both #8 nut plates on the inside angles to hold the exhaust channel. After that I started working on the second attempt at a seat pan. The first one just didn’t fit well as I screwed up the 3/4″ roll around the tube (no quite square to the seat) so it never fit right and the straw that broke the camel’s back was that when I drilled through for the scews it was so tight that I couldn’t get the seat back on and there was no 1/2″ to 1″ sag so I just scrapped it and started over no big deal its just sheet metal. Anyway I transfered the dimension off the drawing to new piece of sheet metal and rough cut it with the sheer but it was getting late and I needed some dinner.

Time spent today 3 hours
Total Time spent 1521 hours

Matco wheels and brakes and fuel vent line and drain line

July 26, 2012

Today I recieved my Matco Wheels and brakes. I went with the WE-51L which are 6.5 pounds each and are goo looking. Dimensionally I new they may pose a dimensional issue as they are slightly smaller than the standard clevland 40-78 wheels. The first issue is the brake plate to wheel hub on the vans brake plate is only 3/4″ when you add in the standard 1/4″ spacer it come to 1″. This wheel needs about 1.4″ so I will have to add to the vans brake plate/spacer by 3/8″ because I want to keep the 1/4″ thick spacer so that would bring it out to 1.388 inchs on the brake plate to axle spacing. All the vans brake plate tube is is a 1 3/8 0.058 4130 tube. So I have a little work to do to get them to fit.

I also routed the fuel tank vent line and drilled a hole in the forward belly panel and installed a grommet. I used my polyurethane tubing for half of the vent line so that I avoid making a bunch of complicated bends and routing lines. I also did some bends to route the fuel drain line and now I need to weld on the union fitting to a plate install the nut plates drill the hole through the forward belly panel and screw it in place.

Time spent 4 hours
Total time spent 1512 hours