Construction Log:
Shop Prep:
Empennage (199 hours as of 6/13/05):
- January 20, 2005 -- Received, Inventoried Empennage
- January 22, 2005 -- Tool shopping, Started filing spar stiffeners
- January 23, 2005 -- More Filing
- January 25, 2005 -- Rounded corners of HS-710 and 714
- January 28, 2005 -- Broke edges of HS-710 and 714
- January 30, 2005 -- Trimming before tools arrive
- February 4, 2005 -- Tools arrived, rear spar work
- February 5, 2005 -- Lot of HS work, defective HS skin
- February 6, 2005 -- HS Work, 1st screweup, started VS
- February 7, 2005 -- VS spar finishing and dimples
- February 8, 2005 -- More VS dimpling and deburring
- February 9, 2005 -- Fabricated rudder stiffeners
- February 10, 2005 -- Rudder stiffener work
- February 11, 2005 -- Finished rudder spar stiffeners, started rudder skeleton
- February 12, 2005 -- Lots of rudder skeleton work
- February 13, 2005 -- More rudder skeleton work, first attempt at metal prep
- February 15, 2005 -- Elevator stiffener trimming
- February 16, 2005 -- Drilled right elevator stiffeners
- February 17, 2005 -- Drilled left elevator stiffeners
- February 18, 2005 -- Electric trim cover and mounts
- February 19, 2005 -- Finished elevator stiffeners, alodined everything
- February 20, 2005 -- Primed everything
- February 21, 2005 -- First rivets (and mistakes)
- February 22, 2005 -- More riveting
- February 23, 2005 -- Riveted hinge brackets on VS spar
- February 24, 2005 -- Riveted rudder parts
- February 25, 2005 -- More rudder spar rivets, right elevator drilling
- February 26, 2005 -- Right elevator skeleton
- February 27, 2005 -- Left elevator skeleton
- March 1, 2005 -- Replacement parts arrived, I screwed one up again
- March 2, 2005 -- Got squeezer yokes, set rudder rivets with them
- March 3, 2005 -- Got DRDT-2, dimpled VS skin
- March 5, 2005 -- FINSIHED VERTICAL STABILIZER!
- March 6, 2005 -- Dimpled and riveted stiffeners to right elevator skin, nearly completed rudder
- March 7, 2005 -- Thinking about finishing the rudder trailing edge
- March 8, 2005 -- Dimpled left elevator skin
- March 9, 2005 -- Riveted stiffeners, trim plate to left elevator skin
- March 10, 2005 -- Back to the horizontal stabilizer
- March 11, 2005 -- Right HS final drilled
- March 12, 2005 -- Left HS final drilled, all HS skeleton parts deburred and dimpled
- March 13, 2005 -- Prosealed rudder trailing edge
- March 15, 2005 -- Started work on trim tab
- March 16, 2005 -- Bent trim tab trailing edge, built end tab bending jig
- March 17, 2005 -- Bent trim tab ends, ordered wing kit
- March 19, 2005 -- Cleaned, etched, and alodined all parts
- March 20, 2005 -- Primed all parts, FINISHED RUDDER!
- March 21, 2005 -- Deburred right HS skin
- March 22, 2005 -- Deburred and started dimpling HS skins
- March 24, 2005 -- Started final assembly of HS skeleton
- March 25, 2005 -- Continued with HS skeleton riveting
- March 26, 2005 -- FINISHED HORIZONTAL STABILIZER!
- March 27, 2005 -- Assembled elevator skeletons and trim tab
- March 29, 2005 -- Bent elevator skins, deburred edges and clecoed right elevator together
- March 30, 2005 -- Riveted on right elevator skin
- March 31, 2005 -- FINISHED RIGHT ELEVATOR!
- April 3, 2005 -- Worked on left elevator a little
- April 4, 2005 -- Started riveting left elevator
- April 5, 2005 -- Riveted left elevator, attached trim tab
- April 6, 2005 -- Installed electric trim servo
- April 9, 2005 -- FINISHED LEFT ELEVATOR!
- April 10, 2005 -- Attached elevators to horizontal stabilizer
- April 12, 2005 -- Drilled elevator horn hinge holes
- April 13, 2005 -- Working on left HS tips
- April 14, 2005 -- More work on right HS tips
- April 15, 2005 -- Worked on rudder and VS tips
- April 25, 2005 -- Cut foam and Al backing strips
- April 27, 2005 -- More tip work
- April 30, 2005 -- Drilled backing strips, countersunk, filed tips
- May 8, 2005 -- Fun with fiberglass
- May 9, 2005 -- Removed foam, cut off excess
- May 12, 2005 -- Backing strips glued into tips
- May 13, 2005 -- Tips riveted on
- May 15, 2005 -- Floxed, sanded, filled elevator tips
- May 16, 2005 -- More sanding and filling of elevator tips
- May 19, 2005 -- The elevator filling and sanding continues
- May 21, 2005 -- More sanding and filling
- May 22, 2005 -- And more sanding and filling
- May 29, 2005 -- Floxed VS tip
- May 30, 2005 -- Floxed, sanded, filled HS and VS tips
- June 11, 2005 -- Continuing work on empennage tips
- June 12, 2005 -- More tip work
- June 13, 2005 -- More fiberglass
Wings (283 hours as of 12/20/06):
- June 24, 2005 -- Received and inventoried wing kit
- June 25, 2005 -- Got Jig?
- June 26, 2005 -- More shop work to get ready for wings
- June 27, 2005 -- The jig is up! And a concern with my right wing spar...
- June 28, 2005 -- Started countersinking spars
- June 29, 2005 -- Finished tank attach countersinks
- June 30, 2005 -- A few more countersinks, and deburring
- July 1, 2005 -- All nutplates riveted on
- July 2, 2005 -- Tiedown brackets and spacers
- July 3, 2005 -- Started on rear spars
- July 4, 2005 -- Mostly done with rear spars
- July 5, 2005 -- Started rib deburring
- July 7, 2005 -- Rib preparation
- July 8, 2005 -- More ribs
- July 10, 2005 -- Even more ribs
- July 12, 2005 -- Main ribs all prepared and clecoed on spar
- July 13, 2005 -- Drilled spar rib attach
- July 15, 2005 -- Deburring leading edge ribs
- July 16, 2005 -- Got a few leading edge ribs on the spars
- July 17, 2005 -- Finished LE ribs, clecoing skins on
- July 18, 2005 -- Drilled right leading edge skin
- July 19, 2005 -- Drilled right top main skins
- July 20, 2005 -- Drilled right bottom main skins
- July 22, 2005 -- Left wing clecoing
- July 23, 2005 -- Drilling, dimpling, deburring
- July 24, 2005 -- Right ribs almost ready for primer, damaged leading edge skin, more countersinks on main spar
- July 26, 2005 -- Left top skins drilled
- July 27, 2005 -- Left bottom skins drilled
- August 1, 2005 -- Deburred, dimpled right rear spar
- August 2, 2005 -- Left leading edge ribs deburred, dimpled, drilled conduit holes in right ribs
- August 10, 2005 -- A little rib deburring
- August 11, 2005 -- Dimpled left main ribs
- August 13, 2005 -- Finished left rib work, and dimpled/countersunk left spars
- August 14, 2005 -- Deburred left main spar holes, started on tank z-brackets
- August 16, 2005 -- Right tank z-brackets
- August 17, 2005 -- Left tank z-brackets
- August 20, 2005 -- Drill, deburr, dimple aileron and flap seal/supports
- August 21, 2005 -- Built priming stand and started MEKing parts
- August 22, 2005 -- More MEKing
- August 24, 2005 -- Parts all clean
- August 27, 2005 -- Etched and Alodined
- August 28, 2005 -- Primed wing skeleton
- September 24, 2005 -- Started skeleton riveting
- October 15, 2005 -- Assembled, riveted right wing skeleton
- October 16, 2005 -- Alodined left spar countersinks
- October 23, 2005 -- More skeleton riveting
- November 19, 2005 -- Worked on right leading edge
- November 20, 2005 -- Right leading edge and main spar riveting
- November 23, 2005 -- Spar riveting lessons
- November 24, 2005 -- Left spar riveting
- November 25, 2005 -- Finished left spar rivets
- November 26, 2005 -- Left leading edge deburr, dimple, rivet
- November 27, 2005 -- Leading edges done and clecoed on to spar
- December 3, 2005 -- Started on right tank
- December 4, 2005 -- More right tank work
- December 5, 2005 -- Tank stiffener deburring
- December 6, 2005 -- Drilled and deburred right tank stiffeners
- December 10, 2005 -- Drilled and deburred right fuel cap and drain
- December 11, 2005 -- Tank attach bracket
- December 12, 2005 -- More bracket work
- December 17, 2005 -- Capacitive sender work and deburring
- December 18, 2005 -- Right fuel pickup
- January 1, 2006 -- Left tank rib prep
- January 7, 2006 -- Clecoed left tank skin
- February 1, 2006 -- Drilled left tank baffle to z-brackets
- February 4, 2006 -- Deburred, countersunk left tank skin
- February 12, 2006 -- Finished left z-brackets, other parts
- February 25, 2006 -- Deburred left tank ribs
- March 4, 2006 -- Left tank attach bracket
- March 5, 2006 -- Leading edges riveted onto spars
- March 18, 2006 -- Misc tank parts, wing skin dimpling
- March 19, 2006 -- Lots o' dimpling
- March 26, 2006 -- Deburring and dimpling wing skins
- March 28, 2006 -- More wing skin deburring
- April 22, 2006 -- Primed, riveted tiedown brackets, spacers
- April 29, 2006 -- And the proseal-ing begins...
- April 30, 2006 -- Prosealed stiffeners and drain
- May 6, 2006 -- Misc tank stuff
- May 7, 2006 -- Prosealed filler rings
- May 14, 2006 -- Aileron stiffeners
- November 25, 2006 -- Continuing on ailerons
- November 26, 2006 -- Aileron spars
- November 27, 2006 -- A little deburring
- December 2, 2006 -- Riveted some left tank ribs
- December 6, 2006 -- 1 more left tank rib done
- December 9, 2006 -- 2 more left tank ribs done
- December 13, 2006 -- Finished capacitive senders and vent line
- December 16, 2006 -- Inboard left tank rib, prep for baffle
- December 20, 2006 -- Left tank baffle installed
- December 29, 2006 -- Misc left tank stuff
- December 30, 2006 -- Right tank sealing/riveting
- December 31, 2006 -- LEFT TANK FINISHED!
- January 1, 2007 -- More right tank sealing
- January 6, 2007 -- Right tank baffle
- January 7, 2007 -- RIGHT TANK FINISHED!
- January 13, 2007 -- Started riveting left top main skins
- January 15, 2007 -- More top skin work
- January 16, 2007 -- Riveted right top main skins
- January 17, 2007 -- Wings off the jig
- January 20, 2007 -- Started on flaps
- January 21, 2007 -- Continuing with flap work
- January 27, 2007 -- Deburring, dimpling ailerons
- January 28, 2007 -- Deburring, dimpling ailerons and flaps
- February 3, 2007 -- Attached aileron brackets
- February 4, 2007 -- Deburred, dimpled inboard bottom skins
- February 10, 2007 -- Pitot line, aileron bellcranks
- February 11, 2007 -- Primed bottom inboard skins, started aileron pushrods
- February 17, 2007 -- Pushrods and priming
- February 18, 2007 -- Right aileron riveted
- February 24, 2007 -- More aileron, flaps, priming
- March 17, 2007 -- FLAPS FINISHED
Fuselage:
Miscellaneous:
