Log Entries

Project Location: MO US

Entry Date Summary Description
Entry Date Summary Description
2009-04-19 Making the first fuselage parts I actually started building airplane parts today. It feels good to start making metal filings. I started with the fuselage making the vertical channel parts F27-02 through F27-05 for left and right sides. Eight parts made and several hundred to go! Can you really eat an elephant one bite at a time?
2009-04-20 Fuselage parts and phenolic fairlead mount blocks I spent today making fuselage parts. I did lots of measuring, cutting, drilling and deburring aluminum. I made the fairlead mount blocks which was my first experience with phenolic. This turned out to be a learning experience, but went easier after I slowed down the speed on the drill press.
2009-04-22 Cutting Angle Parts I did not get to work on the plane yesterday. But today I was back at the project. I spent all day cutting angle parts. There are a lot of parts to make, but I feel like I'm making progress. I have read a lot about the best tool to use in forming the angle parts but I like to use all the tools. The table saw is best for rip cuts. I like the miter saw for most of the angle cuts, and the band saw is best for inside corner cuts. I don't think a person can ever have to many tools. :)
2009-04-23 Making more angle parts I am now 32 hours into the project. Sonex says it takes 200 hours to make all the angle parts, so I have a good bit left before I can move on to more interesting things. I did finish all the 1x1 angle parts today and started on the 1.5x1.5 angle parts. Making part #SNX-F14-09 was a real job. The angle had to be bent open to more than 90 degrees and that aluminum is tough stuff to bend.
2009-04-24 Still working on angle parts I managed to get in 8 hours on the plane today. I'm still working on cutting and shaping angle parts. I have finished with the 1x1 and the 1 1/2 x 1 1 /2 angle parts. I'm just getting started on the 2x2 inch angle parts. Some of the larger angle parts require a lot more measuring and cutting. D-02-14 and C-09-12 were real time consumers today, but I'm pleased with the final parts.
2009-04-26 More angle parts I'm still working on making the 2 inch angle parts. As the angle that I'm working with gets larger, the parts are getting more complex which means that it takes longer to make each part. However, I enjoy the challenge of making the more complex shapes. I am amazed at the different shapes that can be formed from a simple piece of angle.
2009-04-27 Still building angle parts I managed to get in a good days work on the plane today, and made a bunch of angle parts.
2009-04-28 Angle parts I had other things I had to tend to today so I only got to put in 5 1/2 hours, but I feel like I am still making good progress. I finished the 2 inch angle parts and am now working on the 2 1/2 inch angle parts. The completion of all the angle parts is now in sight.
2009-04-29 Another day working on angle parts I put in a good day on the project today. I finished cutting out the last of the angle parts. I still have to drill the holes in some of the parts, then file and polish the parts. This will take some time, but if all goes well I should finish the angle parts tomorrow.
2009-04-30 Drilling, filing and polishing angle parts There are a lot of holes to drill in the angle parts. I worked 11 hours today just drilling holes, filing the edges with the vixen file and polishing the finished parts with the scotch bright wheel. Of course there is a lot of measuring and marking to get the holes drilled in exactly the right place on the part.
2009-05-01 Finished angle parts I finished all the angel parts today. They are drilled, filed, polished and ready to assemble.
2009-05-06 EAA Technical Counselor Visit & Fuselage Cross Ties Clinton Allen, the Technical Counselor from our local EAA Chaper 1218, made his first visit to see my project today. He was very complementary of my project and the job that I was doing. We talked a great deal about electrical details. This is one of those areas I need a lot of help. He also encouraged me to find a flight instructor and start getting in some flying time. I wanted to get a picture of Clinton to add to this construction log, but I got so caught up in the plane talk that I forgot all about getting his picture. I'll include a picture on Clinton when he makes his next visit. Hopefully by then I'll have something that looks more like a plane to picture with him.

I got in 6 1/2 hours this afternoon and finished page F24 of the plans which is the fuselage lower cross ties, upper cross ties and the cross tie box assembly. I then finished up page F23 which is just miscellaneous assemblies used in the fuselage. All in all a very good day.
2009-05-07 Spar tunnel details & Misc. brackets I finished plans pages SNX-F22 and SNX-F15 today. This consists primarily of the Spar tunnel and various mounts and brackets for the fuselage forward side panels. I had planned to build the plane from the back of the fuselage foreword, but the aft fuselage side panel was damaged in shipment. Therefore, I decided to work on the forward fuselage until the replacement aft fuselage side panel arrives. I am a long way from running out of parts to work on.
2009-05-08 Forward Fuselage I finished page SNX-F14 today. This is the Forward side panel verticals and gussets.
2009-05-09 Forward side panel longerons I made the forward fuselage side panel longerons today. The side that the canopy hinges from was quite easy. However, the side that the canopy latches to was a considerably bigger challenge. While it was very difficult to accurately cut the slots in the longeron, I was very pleased with the final outcome. The latch is a bit tight, but I can always file it out a little larger if I need to.
2009-05-10 Fuselage forward side panels I worked on the fuselage forward side panels today. A lot of little parts start to combine at this point to make one large part. I spent a lot of time simply studying the plans to be sure of how each part fit together. I succeeded in getting all the parts laid in place and fitted together, except for part SNX-F15-09 which was a lower gear gusset plate. There were supposed to be two of these parts in the kit, but the package only had one part. I'll have to call Sonex and have them send me the other part before I can finish the final assembly of both of the forward side panels.
2009-05-11 Drilling and fitting right forward fuselage side panel Today I pilot drilled and clecoed all the parts on the right forward fuselage side panel. I was really impressed with how well everything fit and how well it went together.
2009-05-12 Finished right forward fuselage side panel I finished the right forward fuselage side panel today. After it is finished it doesn't look like it should take anywhere near as long to make as it does, but there are a lot of steps in doing the project right. First lay out all the parts to make sure the parts fit together and are turned the right way. Then pilot drill all the parts to 3/32 inch and cleco the parts, then take out the clecos and drill up to 1/8 inch, then disassemble the whole thing and deburr both sides of every hole in every part, then reassemble and cleco back together and then rivet all the parts together.
2009-05-13 Finished left fuselage forward side panel I finished the left fuselage forward side panel today. It went much faster than the right side. Not nearly as much time was spent checking plans to make sure no part was left out or was turned around backward. The second side was much easier and faster to build after having built the right side.
2009-05-14 Started working on the Aft Fuselage side panels today I got in a real good day of work on the aft fuselage side panels today. This is another one of those places in the project where the picture doesn't show all the parts and work invested in the part being built. The biggest challenge being getting all the parts positioned with the correct end up or down and correct orientation front to back. Sometimes the smallest angle, hole, or notch in a part can make a real difference in the way all the parts fit together.
2009-05-15 Continued working on aft fuselage side panels I continued work on the aft fuselage side panels today.
2009-05-16 Aft fuselage side panels I continued to work on the aft fuselage side panels today. Making good progress.
2009-05-18 Finished aft fuselage side panels I finished the aft fuselage side panels today.
2009-05-19 Started working on the fuselage tail cone box Today I started with my finished aft fuselage side panels and started working on putting them together with the upper and lower cross ties to form the fuselage tail cone box. I got all the lower cross ties and the forward channel clecoed in, being very careful to keep the assembly straight and square.
2009-05-20 Continued working on the fuselage tail cone box Today I continued working on the fuselage tail cone box. I looks about like it did when I quit working yesterday, but today it has been up drilled from 3/32 pilot holes to 1/8 holes then taken apart and both sides of every hole deburred, then put back together and riveted.
2009-05-21 Finished the fuselage tail cone box I finished the fuselage tail cone box today, page F-21 in the plans and on the building tree.
2009-05-22 Started working on the turtle deck skin assembly I started the turtle deck skin assembly and finished it today. This completes another page of the plans SNX-F20 and another step on the building tree. Then with some help from Lisa, we fit the turtle deck assembly to the fuselage tail cone box. The parts are definitely getting larger and I can tell that I'm making real progress on the plane.
2009-05-23 Installing the turtle deck formers Today, with help from Lisa, I installed the turtle deck formers. This would have been a very difficult if not impossible job for one person. The challenge was to line up the turtle deck formers from inside the plane with the holes drilled in the skin on the outside of the plane. Lisa says the inside of the turtle deck was very warm today, but we did get the initial installation finished. Now I have to take it apart, deburr all the holes and put it back together, and then rivet it.
2009-05-24 Finished turtle deck installation I finished the turtle deck installation today. Lots of deburring and riveting.
2009-05-25 Fuselage firewall and Misc. details I finished up page SNX-F18 of the plans fuselage tail cone assembly today and almost finished page SNX-F17 fuselage firewall and misc. details. Not a real exciting day, mostly just working on small parts that will be used to assemble the forward fuselage and connect it with the aft fuselage.
2009-05-26 Firewall and fuel filler box I finished FNX-F17 on the plans. That page is firewall and firewall/lower stiffeners, upper firewall assembly with fuel filler box. All these parts will be used when attaching the forward fuselage containing the gas tank, cockpit, seat, and controls to the aft fuselage I have already completed.
2009-05-27 Spar tunnel and seat I finished plans page FNX-F16 lower skins & spar tunnel details today. I then made all the cutouts in the seat for the dual sticks, and seat belts. I attached the forward fuselage panels to the aft fuselage and am ready to install the lower skin. However, the lower skin, firewall, and seat have to be bent and I don't have a metal brake to do this job, so this is a good stopping place for today.
2009-05-29 Bending the larger parts Local EAA chaper 1218 has a very nicely equipped hanger that includes a 52 inch metal bending brake which was just the thing to bend my seat pan, firewall, and cockpit floor. Many thanks to Bill, Jared, Jim, Ben, and Bob for their help adjusting the brake and then helping to be sure the part was right on the line before pulling the handle.
2009-06-02 Forward fuselage, firewall, bottom skin & wing spar tunnel. The hay is in the barn and I'm back to the airplane! After getting the larger parts bent last Friday, I got most of them fitted to the plane today. I mounted the forward side panels, the bottom skin, lower firewall, upper firewall, and the wing spar tunnels. A lot of time was spent measuring and fitting the parts together to be sure that the parts went together just right. I was pleased with the results, now I have to drill out all the holes, take everything apart, deburr the holes, reassemble, then rivet it together.
2009-06-03 Still working on forward fuselage, firewall, bottom skin & wing spar tunnel. I don't feel like I made a lot of progress today. I test fitted the engine mount and did not really like the way it fit, so I spent most of the day tweaking the fit of all the components of the forward fuselage. I want everything to fit perfectly before I up drill the holes for the rivets or bolts.
2009-06-04 Still working on forward fuselage, firewall, bottom skin & wing spar tunnel. I got all the holes up drilled to size for rivets and bolts today. I'm now ready to disassemble, deburr, reassemble, then rivet and bolt. Lots of drilling today.
2009-06-05 Still working on forward fuselage, firewall, bottom skin & wing spar tunnel. Today I took the forward fuselage apart to deburr all the holes. I spent a lot of time deburring and a little time reassembling and installing bolts and rivets. There is not any new construction to show, but I'm still making progress.
2009-06-06 Still working on forward fuselage, firewall, bottom skin & wing spar tunnel. I did a lot of deburring today, and installed a bunch of bolts as I reassembled the forward fuselage. Still making progress.
2009-06-07 Finished forward fuselage, firewall, bottom skin & wing spar tunnel. I finished SNX-F11 fuselage box assembly today. This is the page in the plans that consists of the forward fuselage firewall, bottom skin, and wing spar tunnel that I have been working on most of this past week. The upper firewall, lower firewall, firewall stiffener, floor stiffener, misc. connecting plates and forward bottom skin are riveted. The wing spar tunnel is ready to rivet but the plans call for the wing spars to be fitted into the wing spar tunnel before riveting the wing spar tunnel.
2009-06-08 Aft lower cabin details I finished page SNX-F10 of the plans today. This consisted of making several small parts that are used in other assemblies that will support the seat, some of the controls, seat belts, and various other misc. details.
2009-06-09 Aft lower cabin details installation Today I got all the parts I made yesterday fitted and clecoed into the lower cabin. These are the parts that support the seat, some of the controls, and the seat belts, as well as provide additional bracing for the floor pan and airframe structure. Now I have to up drill to 1/8 inch for the rivets then take the assembly apart, deburr all the holes, then reassemble and rivet in place.
2009-06-11 Aft lower cabin details installation complete I finished the SNX-F09 page of the plans today, which is the aft lower cabin details installation.
2009-06-12 Seat pan assembly installation I installed the seat pan assembly today. The seat seems to be very well supported with 3 piano hinge attachments and almost 200 rivets. It should hold me.
2009-06-15 Engine mount and landing gear I worked on installing the engine mount today. The engine mount is also the attach point for the main landing gear. The engine mount was actually very easy to fit to the fuselage. Installing the bolts was another major challenge. The bolts are MS24694-S100 which are flush mount bolts with only a phillips screwdriver top on them and the nut is a very strong self locking nut. I could not hold the bolts with my screwdriver to even run the nuts down, much less get them tight. I'll have to see about getting a better screwdriver.

I moved on to fitting the landing gear, which is two 1 1/8 in titanium rods. The first step in fitting them is to drill a 1/4 inch hole through the rods 1/2 inch from the end. Titanium is not real easy to drill. I had read about keeping the drill speed real slow, with a lot of cutting oil, a lot of down pressure on the drill, and stopping frequently to keep the titanium or the bit from getting to hot. I started drilling on one rod until it started to get hot, then I would drill on the other rod. This worked just fine until the bit broke. I'll have to get some more 1/4 inch drill bits.

I then decided that if I get the engine mount bolts tightened down, and the landing gear rods installed I would need the tires mounted on the wheels, which I did get completely done today.
2009-06-16 Landing gear fitting and axel alignment Today my new screwdriver made quick work of securing the mounting screws of the engine mount to the fuselage. All I needed was a new number 3 phillips screwdriver. I finished drilling the holes in the top of the landing gear rods with my new drill bits, and mounted the rods to the engine mount. I used the Sonex method of axel alignment (a good straight board) to set the alignment and toe in for the wheels. After getting the landing gear rods and axels set just where they need to be, I filled all the joints with plenty of loctite to glue them in place. Tomorrow, if all goes well, I will take the landing gear rods off the plane with the axels glued in place and drill the holes in the bottom of the landing gear rods to bolt on the axels.
2009-06-17 Installed main landing gear and tail wheel As of today Ozark Moonshine is no longer laying on its belly on a couple of sawhorses. The plane is proudly standing on its own legs. Main landing gear, wheels, brakes, tires, and tail wheel have all been installed.
2009-06-19 Vertical stabilizer details Today I finished page SNX-T12, vertical stabilizer details. This consisted of making various parts that will be used in constructing the vertical stabilizer.
2009-06-20 Vertical stabilizer main and forward spar assemblies Today I finished page SNX-T09, vertical tail main and forward spar assemblies.
2009-06-21 Vertical stabilizer ribs and other misc. details I worked on the vertical stabilizer today. I finished plans page number SNX-T10 which is the vertical stabilizer ribs and some other details.
2009-06-22 Vertical stabilizer assembly I did not get to work on the plane much today, but got a little work done on fitting the skin on the vertical stabilizer.
2009-06-24 Finished the vertical stabilizer assembly Today I finished the vertical stabilizer assembly.
2009-06-26 Rudder assembly details I only worked 4 1/4 hours today. Sure is hot out there in the shop and the heat has somewhat slowed the work pace. I did get some work done on the rudder assembly details.
2009-06-29 Finished the Rudder Today I finished the rudder. This finishes page SNX-T08 in the plans which is the Vertical Tail Assembly.
2009-06-30 Horizontal Stabilizer Misc. Details I spent most of today making parts and pieces for the horizontal stabilizer. I have various clips, brackets, ribs, skins, and spars ready for assembly. I got the forward spar and the main spar clecoed together, ready to be taken apart and debured.
2009-07-01 Horizontal Stabilizer Frame Assembly Today I finished the horizontal stabilizer main spar and the horizontal stabilizer forward spar. I then assembled the horizontal stabilizer frame assembly. The assembly still needs to be up drilled, disassembled, deburred, reassembled, and riveted. Then it will be ready for the skins.
2009-07-02 Still working on Horizontal Stabilizer I finished the horizontal stabilizer frame today and just started fitting the skins.
2009-07-05 Still working on Horizontal Stabilizer I worked on the horizontal stabilizer today. I fitted the skins to the frames, drilled pilot holes, and clecoed them. I lost some time when I realized that I had installed the skins upside down and on the opposite side. The plans were very specific about keeping both sides symmetrical and I guess I did that very well, because when I flipped the skins over every hole in the frame lined up almost perfectly with the holes in the skins.
2009-07-06 Elevator assembly As I was getting ready to fit the elevator hinge to the horizontal stabilizer I discovered that there were no measurements for the hinge on the horizontal stabilizer. I was to use the elevator hinges to locate this hinge. So today I worked on the elevators and finished the elevator assembly. I had already fabricated most of these parts while making various parts for the horizontal stabilizer, so I just had to assemble the parts, cleco, up drill, disassemble, deburr, reassemble, and rivet.
2009-07-06 Seat upholstery Lisa is working on the upholstery for the plane. She has picked out a camel colored vinyl that really looks and feels like a real soft leather for the glare shield, side panels, seat trim, stick boots, and rear bulkhead cover. For the seat covers she has picked out a southwestern design fabric that she is quilting.
2009-07-07 Working on Horizontal Stabilizer I installed the elevators to the horizontal stabilizer with the piano hinges. I then up drilled the horizontal stabilizer, took it apart, deburred, reassembled, then started riveting. I have about 1/4 of the horizontal stabilizer riveted. Should finish this part tomorrow and maybe get started attaching It to the fuselage.
2009-07-08 Finished the horizontal stabilizer I finished the horizontal stabilizer today and began the process of fitting it to the fuselage. Most of the time was spent trimming the inboard edge of the skins to not touch, but fit as close as possible to the fuselage skin. The only measurement in the plans is to move the stabilizer forward until the stop on the stabilizer gives exactly 160 degrees of upward elevator.
2009-07-13 Attaching the horizontal stabilizer to the fuselage After being stopped by the flu for the past week, I finally got back to work on the plane. Today I attached the horizontal stabilizer complete with elevators to the fuselage and installed the elevator control push rod.
2009-07-14 Rudder control petals I installed the rudder control petals and pulled the cables through the fuselage.
2009-07-15 Flight controls misc. details I spent today making various small parts that will be used when installing the flight controls, breaks, flaps, etc.
2009-07-16 Attaching the vertical stabilizer to the fuselage I fit the vertical stabilizer to the fuselage today.
2009-07-17 EAA Technical Counselor Visit Clinton Allen made another technical inspection visit today. It's always interesting to talk airplanes with Clint, and as last time he was very complementary of my project. Brent Humphreys, a member of our EAA chapter who is building a RV-10, joined us looking at my project and then I went with Clint and Brent to see Brent's project. Brent's RV-10 looks like a huge plane compared to my Sonex. Brent is doing a great job on his project and it will be a really nice plane when he's finished.

After getting back home, I spent the rest of the afternoon working on my vertical and horizontal stabilizer trying to get the elevator movement that I needed.
2009-07-18 Finished assembling the empennage Today I finished assembling the horizontal stabilizer, complete with elevators, and the vertical stabilizer, complete with rudder, to the aft fuselage. Then I installed the tail wheel.
2009-07-19 Working on flight controls Today I installed the flaps control lever and the brake lever.
2009-07-20 Working on flight controls I attached the rudder cables to the rudder peddles and then installed the return springs on the rudder peddles today. I can now sit in the front of the plane and move the rudder on the back of the plane. The rest of the day was spent putting the dual control sticks assembly together.
2009-07-21 Working on flight controls I installed the duel flight control sticks today. I then made several parts that will be used in installing the gas tank and glare shield, I started work on fitting the glare shield.
2009-07-22 Glare shield, instrument panel, and gas tank Today I installed the gas tank supports and did a rough fitting of the gas tank. Then I fit the glare shield and the instrument panel to the front of the fuselage.
2009-07-24 Glare Shield fittings and details I worked on the glare shield today, installing the tank stops and the brackets which are used to attach the front of the glare shield to the firewall.
2009-07-25 Working on glare shield and instrument panel I continued working on installing the glare shield and instrument panel today. I've got the glare shield up drilled, so it's ready to take apart, deburr, and then rivet. I'm going to paint the glare shield with a flat black paint. Therefore, I have to wait for my last Wicks order, which includes the paint, to arrive before I will be able to paint the glare shield then rivet the glare shield in place.
2009-07-25 Seat upholstery Lisa worked on the foam cushions today. It looks like we will end up with 5 inches of foam cushion on the bottom of the seat and 2 inches of foam cushion on the back of the seat. Feels like the seats will be very comfortable.
2009-07-26 Seat upholstery Lisa cut out and sewed up seat cushion upholstery and side panels today.
2009-07-26 Pitot/static probe assembly I started the wings today. The first page in the building tree for the wings is SNX-W23 which is the pitot/static probe assembly which I finished today. One small wing part done with a bunch of wing parts to go.
2009-07-27 Control stick boots Lisa cut out, sewed up, and installed the boots for the control sticks today.
2009-07-27 Small parts, brackets, and connectors. I spent today working on various small parts, brackets, and connectors that will be used in the construction of the wings.
2009-07-28 Seat upholstery - Seat back storage pockets Lisa made a padded bulkhead cover with attached storage pockets that hang over the back of the bulkhead into the luggage space. It will make a good place to keep sectional maps, log books, and even a couple of smaller pockets to keep sunglasses.
2009-07-28 Starting on the main wing spars Today I started putting all the little parts I've been working on together into a larger part. I have got one wing spar fitted together and am just starting on the second one. These things are really like putting a puzzle together, with a bunch of pieces that are very similar, but have to be put in place just right. Sometimes just figuring out which part goes on top or in the middle, or on the bottom of this assembly can be a real challenge.
2009-07-29 Working on the main wing spars I continued working on the main wing spars today. I got all the parts that make up the main wing spar assembled, drilled all the pilot holes and clecoed it all together on one spar and got a good start on the pilot holes in the other spar.
2009-07-29 Painting the glare shield I cleaned, primed, and painted the glare shield today. I painted the glare shield with a flat black paint that should prevent any reflections on the windshield.
2009-07-29 Ordered the engine! I ordered the AeroVee engine today. Sonex has a deal on the engine if I order this week, I get the nikasil cylinder upgrade for no charge, this saves $500. Sonex is running a little behind on filling orders and says it will be about 4 weeks before they can ship the engine. I think the timing is just about right. If all goes well I should be ready to start on the engine in about 4 weeks.

(Update August 3, 2009) Sonex confirmed my engine order today and said it will be shipped during the week of September 23. So unless something goes wrong or really slow with the project, I should be ready for the engine when it arrives.
2009-07-30 Working on the main wing spars I'm continuing to work on the main wing spars. Today I finished pilot drilling the second wing spar, then I updrilled one of the spars and started updrilling the second spar.
2009-07-31 Working on main wing spars I got in a good days work today. I finished updrilling the wing spars, took one apart and got it deburred, dimpled, and countersunk the parts that needed to be flush riveted.
2009-08-01 Working on the main wing spars I did not get in much time on the plane today. I did get the spar that I had taken apart and deburred, put back together and the bolts and screws put in. It is now ready to rivet. I took the other spar apart and started deburring it.
2009-08-02 Working on the main wing spars I finished deburring, counter sinking, and dimpling the second wing spar. I then reassembled the spar and installed the bolts and screws. Both wing spars are now ready to be riveted. I started on the first one and drove about 100 rivets with the bolt and hammer method. This works well and the rivet set looks very good. There are a lot of rivets to be driven.
2009-08-03 Working on the main wing spars I spent today driving solid rivets in the main wing spars. I think I drove between 400 to 500 rivets and have about that many left to drive. Working on the floor, to get a solid base for the bucking bar, is sure hard on my knees.
2009-08-05 Finished the main wing spars Today I finished the main wing spars. Glad to be off my knees.
2009-08-10 Aileron Bellcrank Pivot Assemblies I made the aileron bellcrank pivot assemblies today. Part number W21-02L and W21-02R in the plans.
2009-08-11 Aileron bellcrank installation in aft wing rib #9 Today I completed the aileron bellcrank installation in aft wing rib #9. Plans page SNX-W21 of the plans.
2009-08-12 Parts for wing assembly I spent today making a lot of small parts that will be connectors or bracing used to connect the wing ribs and the wing spars.
2009-08-14 Web spacers I spent today dressing all the edges of the wing spars, then making and installing the web spacers on the wing spars. The spacers are small parts that equalize the thickness of the wing spar and reinforce the mounting points where the ribs attach to the wing spars.
2009-08-18 Fitting ribs to main wing spar I finished making and fitting small parts, so today I worked at fitting bigger parts. I started fitting the forward ribs to the main wing spar.
2009-08-19 Fitting ribs to main wing spar I finished doing the initial fitting of the forward wing ribs to the main wing spar today. I pilot drilled the forward ribs by removing 1/2 the clecos and drilling through the ribs, the 2 web spacers, and the wing spar. Then I rotated the clecos to drill out the rest of the holes. This insured that all the holes were lined up perfectly. I then started on the aft wing ribs by removing the forward wing ribs and fitting the aft wing ribs to the other side of the main wing spar.
2009-08-20 Fitting ribs to main wing spar I finished removing the forward wing ribs and fitting all the aft wing ribs today. I then spent a good bit of time making the parts to install the root rib.
2009-08-21 Starting on the aft wing spar I finished up the wing root ribs and started on the aft wing spars today.
2009-08-24 Working on the aft wing spars I worked on the aft wing spars today. I made the various pieces, fit them together, pilot drilled, then up-drilled. The aft wing spars are now ready to take apart and deburr.
2009-08-25 Finished the aft wing spars I finished the aft wing spars today. I then started up-drilling and deburring the forward and aft wing ribs to the main wing spar.
2009-08-26 Up-drilling wing ribs to main wing spar I up-drilled and deburred all the ribs to the main wing spars today. Then I fitted and pilot drilled the right wing ribs to the aft wing spar.
2009-08-27 Working on wing ribs I continued working on the wing ribs today. I finished up-drilling and deburring the ribs to the aft spar. I riveted the fore and aft ribs to the main wing spar (except for ribs 1-3 which I left clecoed to make it easier to attach the root rib). I then used the wing skin to square up the wing in order to attach the root rib.
2009-08-28 Installing the left wing root rib I finished the ribs on the left wing today. The root rib is a major challenge to install. I used the pilot drilled lower wing skin to square up the wing, so I could fit the root rib to the wing perfectly. On to the right wing tomorrow!
2009-08-29 Installing the right wing root rib I finished installing the ribs, including the root rib on the right wing today. I used the same method to square the wing that I used on the left wing. That is, fitting the pilot drilled lower wing skin to the wing then fitting the root rib. I then remove the skin and drill and rivet the root rib in place.
2009-08-31 Fitting the right wing skin I fitted and pilot drilled the top skin, bottom skin, and the leading edge on the right wing today.
2009-09-14 Working on wing skins After a trip to California to visit the family, I'm back at work on the project. Today I up-drilled the pilot holes in the right wing skin. Then I removed the skin to deburr and dimple all the holes.
2009-09-15 Working on wing skins I spent today deburring and dimpling the right wing ribs and skins. I installed the wiring for the nav/position lights and the strobe light through the wing ribs and installed the control rods in the wing for the aileron.
2009-09-16 Working on wing skins I continued working on the right wing skin today. I finished deburring and dimpling the leading edge skin. I cut the hole and installed the anchor nuts for the Pitot/static probe assembly then I riveted the bottom skin and the bottom of the leading edge skin in place.
2009-09-17 Working on wing skins I finished the right wing today! Now it's on to the left wing.
2009-09-18 Working on wing skins Today I got the lower, top, and leading edge skin fitted on the left wing. Now it is ready to up-drill, deburr, dimple, then reassemble, and rivet.
2009-09-19 Working on wing skins I up-drilled the upper skin, lower skin, and leading edge of the left wing today, then disassembled the wing and started deburring all the holes.
2009-09-20 Working on wing skins I spent today de-burring and dimpling the left wing parts.
2009-09-21 Finished the wings I finished the left wing today!
2009-09-22 Starting on the flaps I started working on the flaps today. I got both flaps fabricated and assembled, ready to be up-drilled, taken apart, deburred, reassembled, and riveted.
2009-09-23 Finished the flaps! I finished the flaps today! They are ready to be mounted to the wings. Now on to the ailerons.
2009-09-24 Starting on the Ailerons I started work on the ailerons today. I fabricated all the individual pieces and started the assembly process.
2009-09-25 Engine Arrives The engine was delivered today! However, the nikasil cylinders have been back ordered. There sure are a lot of pieces packed into 4 boxes.
2009-09-28 Working on Ailerons I continued working on the ailerons. I didn't get to work much today. I had to tend to some other things after taking the weekend off to attend the ASA gathering in Crossville TN.
2009-09-29 Working on Ailerons Today I finished one of the ailerons, except for attaching the counterweight and balancing it. The other aileron is assembled and ready to up-drill and deburr.
2009-09-30 Finished the ailerons I finished the ailerons today. When I balanced them, they balanced to within 1/4 inch without drilling out any material from the counterweights.
2009-10-01 Windshield and canopy details I worked a good portion of the day on the rear spar carry through which is the last component needed to rig the wings. I'm to the point now that I need to get some help with rigging the wings. Most of the day I spent working on the windshield and canopy parts.
2009-10-02 Prepairing to rig wings A couple of friends from EAA chapter 1218, Brent Humphreys and Robert (Bob) Brantley have volunteered to help me rig the wings on Sunday afternoon. Brent is currently building a RV-10 and Bob has built an award winning Falco that is a beautiful plane. You can see a picture of Bob's Falco in my Flight-prep section. I feel very lucky to have this kind of expertise to help me with my Sonex. I spent today making sure all is ready for the wing rigging on Sunday and I found a few things that I had to change. First, I removed the upholstery and seat. Then I removed the duel stick control unit that I had clecoed in place. I next removed the aft tunnel web assembly that I had clecoed in place. Then, while studying the wing rigging plans, I discovered that the aft wing attach angles (F14-09L & F14-09R) that I had riveted in place, both had to be removed. So I spent a good deal of time drilling out these angles. I am now ready to rig the wings!
2009-10-03 Flaps and Ailerons to wings I fitted the ailerons and the flaps to the wings today. I then removed them by pulling out the hinge pins. They will be be easy to reattach, and I thought it would be easier to rig the wings to the fuselage without the extra weight of the flaps and ailerons.
2009-10-04 Rigging the wings Today Bob Brantley and Brent Humphreys, from EAA chapter 1218, and another friend Paris Amend helped me rig the wings. This was not nearly as difficult as I thought it might be. Although we had to make some tweaks and adjustments, the wings went in just as they were designed, and the measurements were nearly perfect.
2009-10-04 Prepairing the crankshaft I removed the 4 hex plugs from the crankshaft, cleaned it with mineral spirits, then applied locktite to the hex plugs and re-installed them. Failing to remove the hex plugs would be disastrous, as they were not even finger tight in the crankshaft.
2009-10-05 Rigging the wings With the wings shimmed and blocked in place from yesterday, I set about installing the rear spar carrythrough. This required drilling in a very hard to get to place in the inside bottom of the fuselage. I couldn't have done it without a small angle drill kit that Brent loaned me. After getting the rear spar carrythrough drilled, up-drilled, taken apart, deburred, and reassembled I found that there was no way to get my air rivet puller in there, so I ended up pulling the rivets with the hand puller. After riveting the rear spar carrythrough in place I drilled the holes mating the rear spar carrythrough with the aft wing spars. Then I moved up to the main wing spar, removed the aft wing spar tunnel web, checked that the wings were still positioned correctly, then drilled the attach holes through the wing spars forward through the forward wing attach angles. This proved to also be a challenge, but I got the holes drilled and the aft wing spar tunnel web clecoed back in place ready to up-drill the attach holes from the front through the aft wing attach angles.
2009-10-06 Crankshaft assembly I did the crankshaft assembly this evening and it turned out to be a very simple and easy process. I did put the crankshaft in the freezer last night so it had been chilling for about 24 hours and I put the timing gear and prop hub in the oven at 500 degrees for about a 1/2 hour. The hardest part was getting the snap ring on the shaft next to the hot timing gear, but all went well.
2009-10-06 Rigging the wings Today I finished rigging the wings, up-drilling the main wing spar attach holes, trimming and installing the wing root skin doublers. Then with help from Bob, Brent, and Clint we removed the wings so I could deburr the holes, and finish riveting the wing spar tunnel. I was very pleased with the fit of the wing spars in the spar tunnel, it was a very tight fit, those wings will not be moving around in there. All the bolts were good tight fits.
2009-10-06 EAA Technical Counselor Visit Clinton Allen made the third Technical Counselor visit this afternoon. He was pleased with my project, I'll just use Clint's words from his written comments "Project progressing very well - builder is following Sonex instructions exactly and accepting all advise offers. I was present for wing removal after initial fitting and I was pleased at the accuracy that was evident by the wing fit - very good."
2009-10-07 Spar tunnel, Controls, & Seat Belts After getting the wings off, it was time to take the spar tunnel apart, deburr the holes, reassemble, then rivet it back together. The nice thing about this time is, it should be the last time I have to take the spar tunnel apart. After riveting the spar tunnel, I reinstalled the duel stick controls and then installed the seat belts.
2009-10-08 Seat pan, Shoulder Straps, Rudder linkage, Brakes I did the final fitting and trimming on the seat pan today and installed it in the plane. Next I installed the shoulder straps, then I reinstalled the rudder linkage and spent the rest of the day installing the brake components and cable.
2009-10-09 Center controls, glare shield I installed the center controls today. They are the aeroconversions center quadrant throttle and dial-a-trim system. I reinstalled the flap control leaver and then riveted the glare shield in place. It's nice to know that things are finally going together to stay. There has been so much putting things together for fitting purposes, then having to take them apart again that it seems like I'm not making much progress. However, thankfully I'm getting to the point in the build that things are now going together to stay.
2009-10-13 Bolts, cotter keys, and misc. hardware I spent today installing bolts and securing the bolts with cotter keys. I mounted the voltage regulator and the 2 ignition coils to the firewall and did some prep work to the gas tank getting it ready to install.
2009-10-14 Riveted the bottom fuselage skin Today I riveted the bottom fuselage skin until I ran out of rivets. I'll have to order more rivets along with some other item from Sonex. I also inventoried my hardware trying to figure out what I need to order before I can finish. I measured and fitted the wheel pants. Seems like I'm just looking for things to do while I wait for Sonex to send me the engine cylinders as I need to mount the engine before I can fit the cowling and I want to fit the canopy before fitting the windshield and canopy.
2009-10-15 Crankshaft rods and block prep. I attached the crankshaft rods to the crankshaft and cleaned the engine block. I damaged one of the rod bearings while trying to install it so I had to order another set of bearings from Sonex. Not to expensive (only $11.00) but now I have to wait for the order to arrive before I can continue work on the engine. Well, that's not to bad since I'm still waiting on my cylinders to arrive anyway. Sonex tells me I might get the cylinders next week!
2009-10-16 Cylinder head studs I installed the cylinder head studs today. They were only supposed to be screwed in finger tight with red locktite applied to secure them in place. One thing about having to wait on the cylinders to arrive is I can take my time doing one thing at a time which gives the locktite plenty of time to set before moving on to the next step in the engine assembly.
2009-10-16 Avionics arrived today! My avionics package arrived today! I am now the proud owner of a MGL Stratomaster Enigma glass panel. The package is rounded out with a MGL VHF airband transceiver model V10 with built in voice activated intercom, a set of trio servos for the auto-pilot, and all the wiring harnesses to put the package together.
2009-10-17 Cockpit vents Today I cut the openings in the side of the fuselage for the cockpit vents. I bought a vent kit from Vans RV that included 2 NACA scoops, SCAT hose, and 2 eyeball vents which I will mount in the panel.
2009-10-19 Cam shaft, cam bearings and valve lifters I put the cam shaft together, installed the cam bearings and installed the valve lifters in the engine block today. I installed the dowel pins that keep the crankshaft bearings from turning and the center crankshaft bearing. This is all I can do to the engine until the replacement crankshaft connecting rod bearing arrives.
2009-10-21 Auto-Pilot Servos I spent today planning and designing the parts necessary to install the auto-pilot servos. This turned out to be more of a challenge than it would seem at first glance. The lowered seat option really makes for a tight fit under the seat where the servos have to be installed in order to connect to the control linkages. It was also quite difficult to find a place where the servos have full range of movement without interfering with the full range of movement of all the control rods.
2009-10-22 Assembling the block I received the new crankshaft bearing today, so I could continue assembly of the engine. I installed the new bearing then attached the last crankshaft connecting rod. Then the crankshaft was ready to install in the right half of the engine block, next the camshaft was lined up with the crankshaft cam gear and installed in the right half of the engine block. The flywheel was installed next, the gland nut tightened, and the gap between the flywheel and the rear main bearing was measured. In my engine the measurement was .049 inches. The shims supplied with the engine were .043 inches which left .006 inch of play in the crankshaft which is just what is specified for the engine. I then removed the flywheel, put the right half of the engine block back on the stand, cleaned the contact surfaces, applied sealant, then attached the left half of the engine block. Now I'm ready to install the cylinders that I'm still waiting on Sonex to send, but it is now starting to look more like an engine!

Update 12-20-09. I used RTV silicon sealant as the sealant between the engine block halves and found out that was not the sealant to use, so I disassembled the engine, cleaned off all the RTV and reassembled with aviation flange sealant #3.
2009-10-22 Auto-Pilot Servos I finished installing the auto-pilot servos today.
2009-10-23 Auto-pilot (AHRS) SP-4 I designed and built a small bracket to mount the MLG SP-4 sensor. This sensor is the artificial horizon roll and slip indicator (AHRS). It is to be installed as close to the center roll and pitch of the airplane as possible, while keeping it away from heat and vibration. I made the bracket to mount under the seat right behind the wing spar tunnel next to the elevator push rod.
2009-10-24 Landing gear fairings I made the landing gear fairings today. Not to difficult to make, but the ends seem unusual. It's almost like they change shape as the fairings are bent around the gear.
2009-10-26 Battery box My battery arrived today, so I made the battery box to mount the battery to the forward side of the firewall.
2009-10-27 Battery box & RDAC I mounted the battery box on the right forward side of the firewall. The RDAC unit fit very nicely below the battery box. The RDAC is the attachment point for all the sensors that feed into the Stratomaster Enigma.
2009-10-29 Empennage fairing I made and installed the empennage fairing.
2009-10-30 Rudder control cable fairings I made and installed the rudder cable fairings.
2009-10-31 Wheel pants Mounting the wheel pants requires threading a hole in the end of the axles. My first attempt at threading this hole resulted in shearing the cutting edges off my threading tap. I went to town and got a better 10-32 threading tap which would cut the threads, but just as I was finishing the first hole the tap broke off in the hole. My plan now is to remove the axles and take them to a machine shop to see if they can remove the broken tap and then thread the hole in the other axle.
2009-11-01 No painting - polishing I started polishing the plane while I wait for the engine cylinders to arrive. Our plan is to polish the aluminum to a bright silver and paint the fiberglass parts gold, thus the name Precious Metal. The fiberglass parts are the wing tips, horizontal and vertical stabilizer tips, wheel pants, and cowling. I am using the Nuvite polishing system with a cheap Harbor Freight polisher/buffer. I started with the F9 Nuvite compound and was very pleasantly surprised with how easy the metal polished and the way it looked after only one pass. I spent about 3 hours and did one wing top and bottom. Another 3 1/2 hours did the bottom of the other wing and one side of the turtle deck and empennage.
2009-11-03 No painting - polishing Another 8 hours of polishing just about finished the first pass over the plane with the F9 Nuvite polish. A lot of work, but I like the way it looks.
2009-11-05 Nikasil cylinders arrive! The Nikasil cylinders arrived today! I installed cylinders 1 and 2, then installed the cylinder head. I am working on installing the rocker shaft. I had to cut down the head studs and also had to trim the pushrods about 1/4 inch. I could not install cylinder 3 and 4 because one of the small snap rings that hold the piston pin in place was damaged. I'll go into town tomorrow and get another snap ring and then I can work on the other side of the engine.
2009-11-06 Cylinders and heads installed I've installed the cylinders, heads, push rods, rocker arms, valve covers, and oil pump. All the parts are going together and starting to look like an airplane engine.
2009-11-08 Engine building I took the engine off the stand and mounted it on 2 boards, that I could clamp to my work table, so I could get to the back and install the flywheel. The magnetos were mounted to the flywheel and then the flywheel was installed on the back of the crankshaft with the 36 mm gland nut which was torqued to 228 foot pounds. Getting the mags adjusted to the .001 inch clearance from the magnets on the flywheel proved to be a major challenge. I installed the stator, electronic ignition, prop bushings, and the blocking plates.
2009-11-14 No painting - polishing I have now logged 36 hours polishing the plane, while I'm waiting for my axles. I have applied 3 complete passes using the Nuvite F9 and the finish looks very good. I think polishing might be addictive. I plan to do 1 application of the Nuvite grade C polish. Then after the plane is finished, wings installed, and controls rigged I plan to do another application of the grade C polish followed by an application of the Nuvite grade S polish. This should give the plane a really good shiny finish.
2009-11-18 Mounting the Engine! I mounted the engine to the airframe today! A major milestone in the project.
2009-11-19 Engine exhaust, starter motor, misc. I installed the 2 into 1 exhaust system, the starter motor, the Aeroconversions oil reclaimer, and other miscellaneous items on the engine today.
2009-11-19 fitting the cowling I made a prop hub block and started fitting the cowling over the engine to the fuselage.
2009-11-21 fitting the cowling I now have both sides of the cowling attached on the sides and top of the cowling where it attaches to the fuselage and I have the top center seam almost trimmed to fit. I still have to trim the bottom center seam and where the bottom of the cowling attaches to the bottom of the fuselage. This is taking quite a lot of time, but a good fit will make the plane look so much better than if it has lines that don't match just the way they should.
2009-11-24 Fitting the cowling I've got all the seams fitted with piano hinges and clecoed in place. Fuel tank filler, engine cooling vents, exhaust vent, and oil cooling vent are cut into the cowling. I think I must have taken the cowling on and off at least 500 times getting it to fit, but I'm now ready to start up-drilling and riveting everything in place permanently.
2009-11-27 Fitting the cowling I finished fitting the cowling today.
2009-11-29 Fitting the windshield I spent today fitting the windshield which is made out of a flat piece of lexan plastic. Lexan is very strong, but will scratch very easily, and is quite easy to work with. I could not figure out any way to measure the lexan to fit other than to trim it a little then put it on the fuselage then fit and trim again, getting a little closer fit with each trim. The pictures show a pretty good fit, but there is still a good bit of work yet to be done.
2009-12-05 Trim System, Throttle, Fuel Mixture Controls I've installed the AeroConversions Trim System, the AeroConversions Center Mounted Throttle Quadrant, Fuel Mixture Control, and the AeroConversions Trim System.
2010-01-18 Installed oil cooler The oil cooler mounts on the bottom of an air baffle that directs air from the bottom opening in the cowling down through the oil cooler. The air baffle is attached to the bottom of the engine.
2010-01-19 Installing the AeroVee Fence Baffle Kit I'm now installing the AeroVee Fence Baffle kit which directs the air from the 2 top cowling vents over and through the engine cylinders and heads to keep the engine from overheating.
2010-01-20 Trimming the AeroVee Fence Baffle to fit the cowling Continuing to fit the fence baffles. Today I started the process of trimming the top of the AeroVee Fence Baffle to fit to the cowling. The baffle has to be trimmed to within 1/2 inch around the inside of the cowling, then a rubber trim will be riveted to the fence baffles to seal that opening.
2010-01-21 Trimming the AeroVee Fence Baffle to fit the cowling Continuing to work on the AeroVee Fence Baffles. Trimming the top of the baffles to fit the cowling.
2010-01-22 Making & fitting baffle trim strips I am making and fitting the trim strips that serve as a backing to hold the rubber gasket in place to the baffle.
2010-01-24 Panel design I've been working on panel design for some time now, trying to decide where to locate what. After several different designs, I think I've got what I want. With Lisa's help, we made a full size mock up of the panel on poster paper. Unless I decide to change something, this mock up will become the template for my panel. The blue lines represent the surface mount lines of the various items that will be mounted on the panel and the red lines will be the cut lines to make the openings in which the items will be mounted. Throttle, mixture, and trim wheel will be center mounted below the instrument panel.
2010-01-26 Installing the rubber P gasket on the AeroVee Fence Baffle I installed the rubber P gasket on the AeroVee fence baffle, then mounted the baffles to the engine. This seals the baffle to the cowling so cool air entering the front of the airplane is forced through the cooling fins on the engine cylinders and heads.
2010-01-28 Oil cooler trim and P gasket install I installed the trim pieces and the P gasket on the oil cooler.
2010-04-26 Installing the EGT probes and the CHT sensors I installed the exhaust gas temperature probes and the cylinder head temperature sensors. With these installed I will be able to monitor the individual temperature of each cylinder on my MGL Enigma. Those stainless steel exhaust pipes sure are tough to drill and I found it a bit scarry to drill holes in the engine heads for the CHT sensors, but everything went without a hitch.
2010-04-29 Install ELT Radio I installed the Amer-King AK-480 Emergency Locator Transmitter today. I made a bracket where I could mount the ELT in the real fuselage on the second bulkhead right behind the luggage compartment. I took a couple of different attempts to get the mounting as solid as I thought it should be, but I was pleased with the final installation.
2010-04-30 Making the instrument panel I made the instrument panel today. I was really concerned that with all the cutouts it would be very weak in some places. However, I was pleasantly surprised that it turned out to be quite strong. I painted it flat black to match the glare shield.
2010-05-03 Working on wiring Over the last couple of days I:

Drilled the holes in the control sticks for the PTT wires.

Mounted the SP2 electronic compass in the top of the turtle deck in the aft fuselage.

Mounted the fuse block.

Mounted the NACA air vent inlets.

Installed the emergency backup avionics battery.

Mounted the comm extender.

Installed the fuel level probe.

Installed the gas line.


2010-05-08 Working on wiring The last few days have been spent working on wiring. I have done most of the ignition wiring, RDAC wiring, and installed the throttle cable, mixture cable, and the trim cable.
2010-05-13 Working on wiring I've spent the last few days working on the wiring, but I just about have the instrument panel ready to go. I think I have all the wires connected in all the right places and I have tested each circuit using a regulated 12v power supply. Everything appears to work as it should. I need to get some small tubing that is used to attach the pitot and static tubes to the enigma.
2010-05-14 Wiring and installing the instrument panel I finished the wiring and the installation of the instrument panel today!
2010-05-15 Paint color decision for fiberglass parts. We have decided on a color for the fiberglass parts. The wheel pants, cowling, wingtips, and tail tips will be painted this gold/copper color.
2010-05-18 Windshield I finished installing the windshield over the last few days.
2010-05-19 Installing the canopy frame I worked on installing the canopy frame today. This is another one of those assemblies that is somewhat like putting together a puzzle. After a good bit of studying the plans, and figuring out what should be done in what order, it when together quite well.
2010-05-22 Wing tips, strobe/position light fairings I fit the wing tips to the wings and then fit the light fairings that I bought from gaugepods.com to the wing tips. The light fairings were then drilled for the strobe/position lights that I purchased from Skybright.
2010-05-22 Trimming the canopy to fit With Lisa's help I trimmed the canopy to fit. This was one of those jobs that I had been dreading because I have heard so many stories from the folks in the broken canopy club. However, the trimming went without any problems. I did have a nice warm day. the temperature was 89 degrees and I put the canopy out in the sun to warm up for about 5 hours before we started working on it. We put the canopy on the plane where it was supposed to be, then I held the canopy in place while Lisa marked the cut line with masking tape. We would then move the canopy on to a large cardboard box on the workbench where I would cut it with a rotary cutting tool. I would then sand the cut smooth and we would put the canopy back on the plane, tape the line, cut, sand, and repeat. I cut each side at least 3 times and ended up with what I think is a perfect fit.
2010-05-24 Installing the canopy I discovered that there is a lot of work left to be done to the canopy after it is trimmed to fit. This started with drilling the holes in the canopy to mount it to the canopy frame. I found out that when the canopy is drilled and clecoed to the frame, the fit of the canopy changes as it is pulled down tight against the frame. This required more trimming on the canopy. The perfect fit that I thought I had changed into an acceptable fit after a lot more fitting and trimming.
2010-05-25 Fuel tank filler cover & vent I made the fuel tank filler cover and installed the fuel tank vent today.
2010-05-26 Labeled instrument panel, carpet, upholstery Today was spent putting the finishing touches on the cockpit interior. The instrument panel was labeled and trim was added to the edge. Carpet was installed on the floor. Final fitting of the upholstery was done.
2010-05-27 Installed spinner, propeller, and fitted cowling. I installed the propeller and spinner today. This went quite easily. Then, most of the day was spent refitting the cowling. After adding the fence cooling baffles the cowling did not fit well enough to install the piano hinge pins or clear the air intake filter. After many hours of fitting and refitting we got a good tight fit that we were pleased with.
2010-05-28 Prepping, sanding, and painting the fiberglass parts Most of today was spent prepping, sanding and painting the fiberglass parts. This included the cowling, wheel pants, wing tips, light pod fairings, and the tail tips.
2010-05-29 Installed wing tips, light pods, and nav/strobe lights I installed the wing tips, light pods, and the nav/strobe lights. I used the Skybright light system with the pre-wired harness. One thing to be very aware of is that the wires that extend through the wing appear to be the same on both ends, they are not. If these are installed with the wrong end out they will not fit to the lights.
2010-05-30 Fabricating and installing Gear Fairings I fabricated and installed the gear fairings today. These were somewhat difficult to make as there are very few straight lines to measure from or to use as reference points. It is hard to measure accurately between the back of the brake drums and the bottom of the fuselage. The shape seems very strange until the fairings are bent into place, then they seem to almost change shape as they fit at the top and bottom. The plans dimensions were about 2 inches too long to fit my gear legs.
2010-05-31 Inspection plates, wheel pants, air filter Today was spent taking care of odds and ends, getting the plane ready to take to the airport. I installed the inspection plates using nut-plates rather than the screws called out in the plans. I drilled and threaded the mounting holes in the AeroCarb to mount the air filter. I drilled and threaded the holes in the brake drums to mount the wheel pants.
2010-06-02 Installed the wings With the help of EAA Chapter 1218 members Ben Andre and Berlin Batsel (Technical Adviser) we tackled installing the wings.
2010-06-03 Control surfaces installed and weigh the plane We installed the ailerons and flaps along with the control rods. The installation of the control surfaces was relatively easy, but installing the control rods was very difficult. Some of those bolts are not located where a normal person can get to them. After adjusting the control rods we weighed the plane. The left gear weighed 298 pounds, the right gear weighed 302 pounds, and the tail wheel weighed 34 pounds for a total weight of 634 pounds.