Log Entries

Project Location: TX US

Entry Date Summary Description
Entry Date Summary Description
2014-10-17 Zenith Builder's Workshop Attended Rudder Build Workshop at Zenith Factory, Mexico, MO. 2.5 days. Build CH-701 rudder, met with designer, builders, and factory personnel. Rudder completed, except for tail light and mount of rudder horn
2014-10-22 Ordered CH-701 Full Kit Ordered a full CH-701 kit from Zenith. Added FWO (Folding Wing Option), ETO (Electric Elevator Trim Option), and VGO (Vortex Generators Option). Added 2 quarts of Cortec anti-corrosion primer. Scheduled delivery: 19 January 2015
2014-11-05 Research - Jabiru 80 HP Researched 80 Hp, Jabiru 2200 engine. Performance, weight, installation, costs. Checked Zenith Builder's Website for comments of engines flying.
2014-11-06 Plans Serial # 7-10221 Received Ch-701 plans from Joyce at Zenith. Serial #: 7-10221
2014-11-07 Research: Viking 110 HP Researched 110 Hp Viking 110 engine. Performance, weight, installation, cost. Checked Zenith Builder's Website for info on flying engines. Major discussions with Chumphol (Champ) Sirinavin building 3rd CH-701 in Thailand. Recommended the engine highly for performance and cost/benefit.
2014-11-08 HomeBuiltHelp DVD's Received and previewed HomeBuiltHelp DVD's from Jon Croke covering 701 construction techniques. Excellent.
2014-11-09 Research: Noral Seats Researched Noral Seats ... Price/comfort looks good: ~ $100/ea. www.NoralEnterprises.Com (~$80/ea)
2014-11-10 Slats jig construction Built Slats Jig from spare shop lumber. Lent completed jig to Doug Boggs (Ft. Worth 701 builder).
2014-11-11 Research: Jabiru 105 HP Researched 105 Hp Jabiru 3300 engine: Performance, weight, installation, cost. Checked Zenith Builder's Website for comments on engines flying.
2014-11-12 Marine Nav/Pos lights Researched marine navigation/position lights and ordered a single clear (tail) assembly for inspection. Also ordered a red lens and green lens. Thought is to build 2 or 3 arrays of 9-15 LED for sources.
2014-11-14 Research: "Steam Gage" instrument sources Researched avionics sources. Manufacturers List: www.UltraLightMarket.Com Chinese non-certified instruments: BST Technologies, Ltd
2014-11-16 Research - Strut farings PVC Fairings: www.uflyit.com/streamline_fairings.html
2014-11-17 Welding Aluminum Home Aluminum Welding: www.muggyweld.com
2014-11-19 Lavon North Airport - 46TS
www.airnav.com/airport/46TS ... Approximately 10 miles away. Unimproved, 2 long gravel/grass runways. Parasail operator. Possibly move storage trailer to site. 214-241-8132: Manager: Future Flight Inc
2014-11-21 Building space rental Wylie Rental Space off US78 and Sanden Rd: (214) 808-6336. Possible source shared with hot-rod builder and paint shopPossible source shared with hot-rod builder and paint shop
2014-11-25 Build Shop Worktable 4' x 14' worktable (casters too small - replace later)
2014-11-27 Research - 40' Hi Hat Storage Trailer Rene@OnSiteStorage.Com $2400 + $350 delivery - used 40'x10'x10' storage trailer. Possibly move to Lavon North.
2014-12-01 12v LED lights array Found 15 LED, 12v, clear-bright, column array replacement parts for Ford lights. #14/pair WalMart
2014-12-14 Viking "Steel Bungee" Nosegear Spring Ordered steel nose gear spring replacement for bungee cords on CH-701 ($345). Highly recommended modification.
2014-12-18 Marine Buss Bars Blue Sea Systems: 10 Gang Common 150A Bussbar & cover ~$12
2014-12-20 Research: LiFePo Batteries (EarthX ONLY) Deltran Lithium-Ion (360 CCA, 24 Ahr, 2.6 lbs, $150). www.ebay.com/381044582015 ... Possible replacements for $350

!!!! EarthX batteries recommended by Viking. Jan @ Viking says ONLY EarthX batteries have an internal cell management system for the recommended dual battery configuration.
2014-12-22 Research Angle-of-Attack kit Studied AOA kit from www.BarkerAviation.Com At $60 this seems to be a bargain. Ordered.
2014-12-22 Barker Aviation Angle-of-Attack kit Studied AOA kit from www.BarkerAviation.Com At $60 this seems to be a bargain. Ordered.
2014-12-24 Research: Dual Battery Configuration Long discussion with Jan @ Viking and others about EarthX requirement. Viking says that EarthX is the only small, light, LiFePO batteries that can be used in a dual battery system because of the built-in batttery management system. Other manufacturers are reluctant to support/recommend dual operation
2014-12-26 Research: iPad Air iPad Air, 32 Gb, Christmas Present. Downloaded basic Apple software, setup, and registration.
2014-12-27 Research: iPad Air Panel Mount iPad Air panel mount: Aircraft Spruce
2014-12-28 Bad Elf GPS Antenna for iPad Air Ordered Bad Elf external GPS antenna for iPad Air. Also bought Lightning-t--30-pin adapter ar Apple Store Willow Bend
2014-12-30 Research: 12V wiring systems Wealth of info on 12v systems and parts: Automotive wiring: www.WiringProducts.com

Mike Gleason (701 flying) Aircraft electronics wiring source www.SteinAir.Com

Mike is reviewing possible panel lay-outs. SteinAir does CNC panel bulkhead preparation.
2015-01-06 3-D parts printing (UPS) 3D Printing services - UPS Store Frisco (Ian: 972-540-5130). Nav/Pos light retainer rings from SeaDog sample. CAD file and 3 black ABS plastic copies made $40 ($23/ea from SeaDog)
2015-01-09 Viking Engine Ordered Ordered Viking 110 HP Engine, Viking View EIS, installation parts "grab-bag", and 701 firewall-fwd. mid/late-Aug delivery
2015-01-10 Nav/Pos Lights Controller LEDs & housings for lights (3D rings, circuit boards, controller). Built controller box : 7 Amp breaker, 4 mini-toggle switches, 4 mini-phono plugs, CrazedPilot Stobe/Wig-Wag controller, in 140x90x30mm plastic hobby project box for mounting under the panel
2015-01-12 Angle-of-Attack instrument kit Received & studied AOA instrument kit from Barker Aviation ($60). Decided that the circuit boards were too small for my soldering skills. Found Andrew's Electronics (Andrew is an EE student at UTA). He said no problem and quoted $75 for the build. AOA instruments price at ~$300. The build is a bargain.
2015-01-14 iFlyGPS software Visited with Chris at iFlyGPS in McKinney. He loaded the software on my iPad Air and gave some instruction. I have a 30-day free trial period, but the application looks good for my IFR usage. The company (and Chris) were most helpful and are close by so I'll probably go with this application.
2015-01-15 Viking engine Installation video Watched the 701 installation videos (including cowling) at www.VikingAircraftEngines.Com/installation-701
2015-01-16 Angle-of-Attack kit complete Andrew finished the AOA kit build and discussed the installation. Suggested that I seal the sensor board since it will be in the slip-stream (mounted among the port side jury strut. Purchased silicone circuit board sealer for the job.
2015-01-17 BAM Manufacturing 5 gal header tank Viking engine requires a header tank. Viking offers a 3.75 gal. spun aluminum cylindrical tank with six 3/8" NPT to 5/16" id barbed hose fittings. Found similar tanks (different fittings) on E-bay. Contacted the manufacturer (BAM Manufacturing - dune buggy and hot-rod tanks) and asked for a quote to my specifications (see sketch). This tank is slightly larger than the Viking tank (~5.1 gal) but will fit in the same locaton. I was quoted $185 for the tank including the 6 fittings, 2 circular steel band mounting straps, and shipping (Witchita, KS). I included a pix of their Viking tank with the drawing. BAM informed me that the Viking tanks are actually spun and welded by BAM.
2015-01-18 Van rental & drive to Zenith for kit pickup Rented a long-wheelbase, cargo van from Capp's Van Rental, Plano and drove to Mexico, MO for kit pickup on the 19th. Overnight stay: Bugett Inn
2015-01-19 Load van with kit & return Zenith folks loaded van in under 40 min. Great job and fit easily. Skins flat on corrugated cardboard on van floor. Landing gear spring on further cardboard and furniture blankets on top of the skins, Spars fit well. Large box is the major portions of the metal parts. Other boxes contain Matco wheel-rims and brakes. Welded cockpit superstructure and plexi-galss parts went in last covered in furniture pads. Rode well for the 550 mi, trip back.
2015-01-20 Unload & return van - Start inventory & storage Unloaded van into garage to return van to Capps. Started inventory and storage process. Logged parts and storage locations to spreadsheet
2015-01-21 Inventory & store kit parts Completed the inventory and parts storage process. No parts missing from pick-list/BOM other than 3 small parts (for the folding wing option) on Back-Order. One small part duplicated. Informed Joyce, she said to keep it.
2015-01-24 Start H. Stab build - Front Spar Front Spar layout (doublers & ribs). Drill & cleco (silver) front Hor. Stab front spar.
2015-01-25 H. Stab. Sttructure Rear spar layout (doublers & ribs). Drill & cleco (silver) H. Stab Rear spar. Mate front & rear.
2015-01-26 H. Stab, (7-H-0) structure ready for skinning H. Stab structure and attachments drilled, (#40) deburred, and ready for skinning
2015-01-27 H. Stab bottom skin (7-H-4) initial fitting Laid out center-lines on bottom skin surface. Aligned skin to rear spar and drilled and clecoed (silver) in preparation for strapping (5 straps) to evenly pull the skin over the structure. Verified alignment across front spar and ribs, then drilled out for silver clecos. Strapping process is difficult with just one person. However bottom skin alignment is good around the nose and curved surfaces.
2015-01-28 H. Stab. - Bottom skin fitting Bottom skin fitted, drilled out to A4, deburred, & riveted. Added stab rear bracket Cut blind holes in lower skin for stab to fuselage mounting brackets. Laid out positions for drilling upper skin.
2015-01-30 H. Stab hinge bracket & top skin final preparation Removed skin and applied RustOx to bottom interior and H. Stab structure. Prepared center hinge bracket & gusset for install. Constructed center hinge installation tool(7-H-5).
2015-01-30 4130 Parts & Firewall to A1 for Powder Coating A1 Powder Coating, Garland. Alex (owner) gave $50 discount if I promised to send him pictures of the completed project for his customer's brochure. $300 total ... all other quote above $500.
2015-02-01 Complete H. Stab. skin install (7-H-4) Tough aligning top skin stb. It is either flat at trailing edge with bulge at the center of the end rib or nicely fitted at the end rib with dimple and small ripples at the trailing edge. Roger (Zenith ) and Jon (HomeBuiltHelp) suggest best fit. I added a doubler L-angle to help smooth the dimple. Added a non functional doubler on the port side for symmetry. Still has slight oil-can effect, but much better with the doubler. Drilled and clecoed (copper). Ready for removal, deburr, corrosion protection, re-strap, re-cleco, and riveting.
2015-02-02 Complete H. Stab skinning process (7-H-4) Removed copper clecos, deburred all holes, and applied RustOx. Sprayed on the diluted RstOx with the small Kobalt gravity-fed gun. Re-strapped, re-clecoed, and riveted the structure, which is now ready for center center hinge assembly and cutouts for control cables
2015-02-03 H. Stab Assembly ready for center hinge (7-H-5) Final riveting of H. Stab skin with A4 rivets and preparation of center hinge parts. Laid out locations for center hinge assembly (7-H-5).
2015-02-04 H, Stab center hinge install (7-H-3) Located and installed H. Stab portion of the center hinge assembly. A5 rivets throughout
2015-02-05 Pickup 4130 Powder Coated parts Alex (A1 Powder Coating) did a great job of flat black on all the 4130 parts & the firewall.
2015-02-05 Elevator(7-H-4) Parts Preparation & Layout Gathered elevator parts & laid out center-lines & rivet locations on spar and ribs. Installed (silver) end and outer-center ribs on spar
2015-02-06 Elevator center spar (7H1-4) install Installed the elevator center spar (short, 7H1-4) and remaining ribs in preparation for skinning process
2015-02-08 Elevator bottom skin Completed positioning and clecoing (silver) elevator bottom skin in place. Fit looks very good. Removed clecos to layout bottom skin rivet lines.
2015-02-09 Elevator (7-H-5) top skin Laid out rivet lines and positioned elevator top skin for strapping, drilling, and clecoing (silver).
2015-02-10 Elevator (7-H-5) trim & controls installaion Removed elevator straps and skin from structure. Installed elevator trim tab and servo. Laid out and cut away areas for control horn and rudder travel. Re-strapped and clecoed skin in preparation for drilling out to A4 and riveting.
2015-02-11 Elevator (7-H-5) riveted ready for horn installation Drilled out for A4 rivets, dis-assembled, deburred, applied RustOx corrosion protection, Re-strapped and did final riveting on skinned elevator. Ready to make control horn and end hinge attachment to horiz. stab.
2015-02-12 Elevator Controls Installation Initial positioning & installation of elevator control horn. Drilled out to #30 - final assembly will be A5. (Note one AN3 bolt in horn mount to H.stab rear spar. Air drill slipped when drilling out A4 to A5 resulting in concentric A5 hole. Drilled out and replaced with AN3-4 bolt and celastic nut.)
2015-02-13 Mating H. Stan & Elevator Center Horn Hinge Final placement of elevator control horn mating elevator to h. stab. Completed several bracing structures on top and bottom of both h. stab and elevator. All A5 rivets. Laid out positioning of outer hinge locations. Drilled hinge pins (tough job: 1/16" dia. hole in 3/16" dia. pin). Primed and painted 4130 steel hinge pins, and installed on outer elevator ribs with A5 rivets. Outer hinge plates on h.stab will be drilled out and riveted (A5) at a later time to facilitate dis-assembly of the structure for mounting to aft fuselage
2015-02-14 Install Trim Tab and Servo Actuator wiring (ETO) Installed the male-end of a 5-pin waterproof connector on length of 8-wire cable and matching female-end to the 4 wires of the elevator trim servo cable. Cable connector will be located in the aft fuselage (added to aid installation/removal of h. stab & elevator structure mating to fuselage). Added the male-end of a 2-pin waterproof connector to 2 of the remaining 3 wires in the 8-wire cable and matching female-end to the 2 wires of the tail-light assembly ready for mounting in the rudder. The last wire (8th, orange) of the cable is unused. These connectors work well in marine applications and I have several more 2-pin connectors to be used in installing the wing-tip navigation/position lights, angle-of-attack sensor, fuel level transmitters, and possibly a landing light
2015-02-15 Final installation of elevator horn (7-H-5) Final placement of elevator control horn mating elevator to h. stab. Completed several bracing structures on top and bottom of both h. stab and elevator. All a5 rivets. Laid out positioning of outer hinge locations. Drilled hing pins (tough job: 1/16" dia, hole in 3/16" dia. pin). Primed and painted 4130 steel hinge pins, and installed on outer elevator ribs with A5 rivets. Outer hinge plates on h.stab will be drilled out and riveted (A5) at a later time to facilitate dis-assembly of the structure for mounting to aft fuselage.
2015-02-16 Slat parts preparation (7-S-0) Located, identified, and marked all slats parts for build of all 4 slat sections. 2 short inboard skins (port & starboard) and 2 longer outboard skins. 6 left and 6 right ribs, (3 each section). Center ribs for each section are unmodified. All others require left and right copies of slat mounting flanges and doublers from L-angle slotted and curved to match contour of inside of slat rib. Completed mods to 1 set of slat ribs.
2015-02-16 Elevator Trim-tab wiring Installed the male-end of a 5-pin waterproof connector on length of 8-wire cable & matching female-end to the 4 wires of the elevator trim servo cable. Cable connector will be located in the aft fuselage (added to aid installation/removal of h. stab & elevator structure mating to fuselage). Added the male-end of a 2-pin waterproof connector to 2 of the remaining 3 wires in the 8-wire cable and matching female-end to the 2 wires of the tail-light assembly ready for mounting in the rudder. The last wire (8th, orange) of the cable is unused. These connectors work well in marine applications and I have several more 2-pin connectors to be used in installing the wing-tip navigation/position lights, angle-of-attack sensor, fuel level transmitters, and possibly a landing light
2015-02-17 Assemble ALL Slat Ribs (7-S-0) Fabricated slat ribs for both wings.
2015-02-18 Port-Inboard Slat (7S1-2) Completed remaining 6 slat rib assemblies and installed L-angle stiffeners into all 4 sections of the slat skins. Ready to build 1st slat (Port-inboard).
2015-02-19 Port-Inboard Slat (7S1-2) Laid out and inserted center slat rib into Port-inboard slat skin. Cut slots in skin end ribs with mounting flanges. Critical dimension 1204mm flange to flange - will match slat mounting flanges in wing. Drilling for center rib requires 2 sets of hands to hold bend while drilling. Thanks Brett
2015-02-19 Port-Outboard Slat (7S1-3) build Completed installation of final (outboard slat rib (with flange) onto bottom skin. Strapped assembly to underside of slat jig with flanges through slots in jig and strapped to position skin properly over the curve of the slat ribs. Drilled and clecoed (silver). Ready to drill out to A4.
2015-02-20 Skinning Port inboard slat (7S-0) Completed installation of final (outboard slat rib (with flanges) onto bottom skin. Strapped assembly to underside of slat jig with flanges through slots in jig and strapped to position skin properly over the curve of the slat ribs. Drilled and clecoed (silver). Ready to drill out to A4
2015-02-21 Underside, traling edge, port inboard slat (7S-0) Un-strapped and mounted slat in jig topside down. Strapped in place with blocks to ensure curvature of slat while drilling & clecoing underside trailing edge (7S1-4). Drilled out to #40 every other hole (inside rivet line) then drilled to A4 (copper). Removed from jig, turned over and drilled #40 (final dimension for soft rivets at trailing edge) & clecoed (silver).
2015-02-23 Completed Port, Inboard slat (7S-0) Removed clecoes from underside. Applied RustOx to interior of slat structure and trailing edge. Deburred and re-strapped structure in jig and clecoed every other location (copper) and #30 (silver) at trailing edge. Removed straps and riveted top skin to structure. Cut 20mm notch from both ends of trailing edge to facilitate installation of fibeglass tip and insertion into outboard slat at later time. Flipped to underside and riveted all A4 locations. Installed soft rivets in trailing edge
2015-02-24 Wiring -- waterproof multi-pin connectors Components for waterproof (marine) wiring connectors and marine navigation/position lights.
2015-02-25 Start on Stabboard Slats Installed ribs end ribs in stb outboard skin. 1st to #40 (silver) then to A4, Removed all ribs, deburred, and applied corrosion protection. Re-clecoed in place, and riveted. Ready to place on slat jig to drill/cleco top skin to ribs.
2015-02-26 Stb Outboard Slat Construction Applied RustOx protection to all interior surfaces. Strapped to underside of slat jig . Positioned topside skin, drilled/clecoed (#40 - silver). Drilled out & clecoed to A4 (copper). Ready for deburr and riveting.
2015-02-27 Firewall (7F7-1) layout for Viking Steel Nosewheel Spring Cold-snap. Worked in office on firewall components lay-out. Scribed firewall (7F7-1) reference lines. Scribed rivet lines on vertical lower channel (7F7-2C), vertical top channel (7F7-3) left & right firewall stiffeners (7F7-5), and top channel stiffener (7F7-7SP). Scribed rivet locations and bungee pin holes locations in left & right channel doublers (7f7-8C). Verified pre-drilled left & right gear gussets (7F7-9C). Since I am replacing the elastic bungee supplied with the Viking steel bungee, laid out locations for 9mm mounting holes for the upper viking gear assembly on the upper channel (7F7-1SP). The upper channel supplied with my kit came pre-drilled for the spring/gear-tube assembly. Dis-assembled the Viking spring assembly, primed, and painted mounting legs and spring.
2015-02-28 Firewall modification for Viking Steel Spring Drilled out and added doubler to 7F7-1SP firewall upper channel to accept Viking "steel bungee". Installed upper nylon bearing into upper channel with 4 AN3-6A bolts.
2015-03-01 Firewall/Nosegear Spring assembly Lots of parts attach to the firewall and all seem to cross, overlay, or abut so rivet locations must be checked and adjusted against the adjoining parts. Check & double-check locations. Clecoed channel doublers (7F7-8C) in place for the steel sprig arms pin. Drilled out pin holes (5/8" dia) through both 7F7-8C doublers and the 7H7-2C channel. Locaed and scribed position for the steering arms pass-thru on either side of 7H7-2C. Prepared Rear (7F8-4) and Front (7F8-5) Lower Bearing plates. Nylon Lower Bearing (7H7-4C) will need to be split for mounting to the twp parts of the lower bearing plates so that the nose gear assembly can be removed.
2015-03-02 Stb Slat Construction Somewhat warmer today so I'm back on slat construction. Clecoed (copper) exterior ribs with slat mounts onto the starboard-outboard skin panel. Strapped assembly to jig and positioned/clecoed (silver) skin top to the slat ribs. Slight crease at leading edge of center rib. Unstrapped and worked the crease out with rubber mallet. Looks good. Re-strapped; alignment was perfect. Strapping into jig to insures slat airfoil by adding the trailing edge (7S1-5).
2015-03-03 Stb Inboard slat construction Starboard inboard slat skinning using slat jig.
2015-03-04 Completed stb inboard slat Finished starboard inboard slat using jig to position underside skin for clecoing/riveting.
2015-03-05 Port outboard slat construction Positioned and clecoed slat ribs to port outboard slat skin.
2015-03-06 Completed port outboard slat assembly Positioned port outboard slat in jig for clecoing/riveting underside skin.
2015-03-07 completed all slats Finished all slats by adding fiberglass tips.
2015-03-08 Slat support fixture/tool Prepared slat support positioning fixture. Completed 1st nose-rib/support assembly.
2015-03-09 Completed all nose-rib/slat support assemblies Completed installation of all 8 (both wings) nose-rib/slat support assemblies.
2015-03-10 Start Starboard Wing - Identification & Layout Located, identified, sorted, and labeled all wing components (starboard and port). Researched location of AOA vane and pitot assembly (decided on port wing). Will start with starboard wing.
2015-03-11 Stb Wing layout & positioning components Laid out positions for spar doublers/stiffeners and nose ribs.
2015-03-12 Install wing ribs to spar Laid out and started mounting ribs to wing spar.
2015-03-13 Rear Spar Allignment Tool (7V6) 1st tool built did not perform well. Spar angle too great. 2nd tool works much better. Added metal stiffener to allow repeated drilling operations. Also added an L-angle to allow sme clamping in place.
2015-03-14 Assembled 600mm rear spar sections (7V6-2SP) Laid out and assembled 4 identical sections (7V6-SP) of the rear spar for installation between ribs 2-3, 2-3, 4-5, and 5-6.
2015-03-14 Positioning top skin (7V7-2) Unroll top skin into position. Much use of duct-tape and much shifting & aligning.
2015-03-15 Rear Root & Center Section Channels (7V6-1) Laid-out and assembled the rear root channel with heavy wing/fuselage attachment doubler. Laid out and assembled heavy center section channel. Trimmed tip channel (7V6-2SP) to 45 deg. to acomodate wing tip plate.
2015-03-16 Fuel Tank Channel (7V1-2K) laid out an assembled the fuel tank channel (7V1-2K). All rear spar and tank channels complete and ready for installation.
2015-03-17 Rear spar channel installation Using the rear spar alignment tool, fitted and installed prepared 7V6-2SP channel sections between ribs 1-2, and 3-4. Tedious job requiring fitting and clamping of alignment tool in place against the front spar and rib. L-angle on tool allows clamping of channel end in place so that the drilling of the rib end can be done using a rt-angle attachment in the air-drill. Tight fit. I may re-position the alignment holes in the jig to allow more clearance for drilling and later riveting ... possibly for the port wing.
2015-03-18 Rear spar channel installation (7V6-1 & 7V6-2SP) Installed rear spar channel section (heavy center section: 7V6-1) between ribs 3-4. Installed standard channel section (7V6-2SP) between ribs 4-5 and 5-6.
2015-03-19 Install root (7V6-1) & tip (7V6-2SP) rear spar channels Installed root and tip rear spar channel sections. Verified alignment.
2015-03-20 Installed fuel tank channel (7V11-2K) & spar tip (7V3-3) Completed most of the basic wing structure by installing the furl tank channel (7V11-2K) and the front spar tip (7V3-3). All clecoed. Lots of drilling out to #30 and deburring in the future.
2015-03-21 Wing basic structure Removed nose ribs for installation of slat mounts. Moved structure o work table and added root rib.
2015-03-22 Installing top horizontal stiffeners between ribs Started adding horizontal L-angle stiffeners between the ribs (topside). L-angle is 0.75x0.75 L-angle (6063 aluminum). Will also add longitudinal stiffeners once the skin clecoed in place.
2015-03-23 Completed installation of top horizontal stiffeners Completed the installation of the topside horizontal stiffeners between all the ribs. Ready to unroll the top skin onto the structure for positioning and #40 drilling/clecoing.
2015-03-24 Rolling/Unrolling Skins to structure This is the method I used to roll/unroll the skin in place. This gets done several times during construction. I found that one end of the skin to the box keeps the skin in relatively good position so that I can work one end of the structure without totally removing the skin. The method works pretty well for a one-man operation.
2015-03-30 Positioning and drilling top skin & Bottom center skin Placed stb. wing topside down (still clecoed) on 2" sq. steel channels and started preparations for installing the bottom horizontal stiffeners between the ribs. Much roll-out/roll-up positioning of top skin. Able to get good fit and start drilling front spar/skin #40 and clecoing.
2015-03-30 Repositioned wing structure for bottom skin installation Placed stb. wing topside down (still clecoed) on 2" sq. steel channels and started preparations for installing the bottom horizontal stiffeners between the ribs.
2015-04-01 Stb wing top skin in place (7V7-2) Stb wing top skin silver clecoed in place.
2015-04-02 Fabricate logitudinal stiffeners for top skin Bent 1.75" strips of 5053 0.032" aluminum sheet into L-angles for stiffeners. Used 18" bending break from Harbor Freight. Worked well if a little slow. Bent stock for all 24 (6 upper and 6 lower each wing). Placement will be centered in the open bays between the ribs running from rear channel to horizontal stiffener and from horizontal stiffener to front spar).
2015-04-03 Install longitudinal stiffeners in wig bays Used crimping tool to set the airfoil curve into the 6 stiffeners in of the stb. top skin. Drilled and clecoed with #40.
2015-04-04 Completed installation of topside stiffeners All stiffeners clecoed into position (silver).
2015-04-05 Installed underside horizontal stiffeners Completed installation of stiffeners between ribs 2-3, 3-4, 4-6, & 5-6. In the same manner as with the topside stiffeners.
2015-04-06 Position and prepare stb wing for bottom skin (7V7-3) Prepared to unroll bottom center skin (7V7-3) for trial positioning. Much rolling/unrolling to adjust proper positioning on front spar.
2015-04-07 Positioned bottom center skin (7V7-3) Verified alignment of front edge against front spar Drilled & clecoed #40 approximately every 3rd hole in the skin/structure. Much rolling/unrolling will be required to install longitudinal stiffeners.
2015-04-09 RustOx interior of wing structure * internal top skin Apply RustOx corrosion protection to interior of stb. wing structure and internal surface of top skin.
2015-04-10 Position and set bottom skin Roll/unroll bottom skin into position. Drill/cleco leading edge of skin to front spar (silver).
2015-04-11 Install longitudinal stiffeners in bottom bays Much unrolling/rolling of center wing skin to position and cleco (silver) longitudinal stiffeners in place. Method follows that of top skin stiffeners installation.
2015-04-12 Install Flaperon Brackets to underside of ribs Prepare and install (#40)Flaperon Brackets (7V4-6) at ribs 1, 3, 4, & 6.
2015-04-13 Bottom skin trailing edge (7V7-4 & -5) & strut fitting Fabricate, position and install Rear Upper Strut Fitting (7V7-4) to rear channel at rib # 4. Install bottom skin trailing edges (#40): 7V7-3, inboard section and 7V7-5, outboard section. Note clots cut in trailing edges for flaperon brackets.
2015-04-14 Flaperon Arm Positioning Jig & Arms (7V4-7) Build Flapoeron Arm Positioning Jig (7V5). Use jig to position and install (#40) flaperon arms to brackets (ribs 1, 3, 4, & 6). Will eventually be drilled out to A5.
2015-04-15 Pepar to install nose-rib skin (7V7-1) Re-cleco nose ribs to front spar. Remove clecos from front spar/bottom-skin. Unroll nose rib skin (7V7-1) into position, sliding nose rib skin UNDER bottom-skin to 20mm line. (This is for positioning & drilling only as nose skin will OVERLAP both top- & bottom-skin at final assembly. Allow skin to droop over nose ribs noting positioning of the pre-cut slots in the skin to acomodate the slat mounting brackets. Once positioned, drill through bottom-skin holes thru nose skin into front spar (silver clecos).
2015-04-17 Strap wing to curve nose-skin into position Remove the clecos from the top-skin/front spar. Strap the wing to curve the nose-skin (7V7-1) around the nose ribs (passing the slat brackets through the pre-cut slots which needed to be extended by ~5mm to fit). Slide the nose skin UNDER the top-skin at the front spar to the 20mm line. Once in position, drill and cleco (silver) into position. Lots strapping/unstrapping to make alignments.
2015-04-20 Fabricate tie-down fittings Laid-out and fabricated both optional tie-down fittings from 0.125" 6061T6 stock per 7V8-0.
2015-04-21 Install Stb wing tie-down Install stb wing tie-down to Rib #4 with five A5 rivets. For port wing, determine slot location and rivet before final skin placement. Should be easier.
2015-04-23 Researched Dual Sticks Configuration Purchased drawings for 750 Dual Sticks Option. Spoke with George Race about his dual sticks installation in the 701. George suggested that the manual flaps actuator be discarded and replaced with a linear actuator under the pilot seat. George says that he used a the Ray Allen Electric Elevator Trim indicator and switch.

The dual sticks installation allows for a single, centrally mounted throttle and a small console running from between the seats to the bottom of the Instrument Panel. Panel is a nice pace to mount the Viking View EIS & the dual VDO Fuel Gauges.

Actuator/mounting bracket from www.CentralSupply.com
2015-04-24 Fabricate and install Front Upper Strut Fittings Bolt front upper strut fitting (7V2-5) to the front strut with three AN3 bolts. Fabricate and install front strut fitting doubler (7V8-1SP) & angle (7V8-4-SP).
2015-04-25 Fabricate & Install Jury Strut Mounts (7V10-4SP) Fabricate all 8 Jury Strut Mounts (7V10-4SP front & rear) & install starboard wing mounts.
2015-04-27 Install Tail Light Assembly Trim fiberglass housing per the plans. Drill 1" hole for light base. Drill AN3 mounting holes in the housing and install #6-32 riv-nuts. Insert the PSA tail-light assembly into the fiberglass housing and secure with the 2 #6-32 stainless machine screws provided.

Riv-nut installation tool of very poor quality. Had to re-thread the mandril after each use.

Crimp and solder the fixture wires to the cable assembly passed thru the rudder spar (with grommet.

Position the fiberglass housing to the rudder skin 160mm up from the trailing edge of the rudder as per the plans. Drill 7 #40 holes per side and cleco. Remove and deburr the rudder skin. Drill out all holes to #30 and secure with A4 rivets.
2015-04-28 Prepare Stb Fuel Tank (7V11-1K) for Installation Located and cut 59mm level sender hole on fwd/inboard side of the tank using fly-cutter. Slow drill/cutter speed important. Scored hole and broke out with needle-nosed pliers using center hole. Clean/deburr circumference of the hole.

Located and prepared tank/sender components for installation: DX2021 Finger-screen, CAV-110 Quick Drain, F124-4B nipple fitting (to screen). F124-4A nipple fitting (vent line), VW fuel sender (317004), VDO Fuel Sender Mounting kit (226-451). Put aside screen, nipples and drain for installation AFTER tank is in place between ribs 1 & 2 wit appropriate holes in the ribs to allow access/connections.

Bent fuel sender float arm to provide optimal levels range and prepared the mounting ring/gaskets per the instructions in the build manual & DVD. Tested the range with ohm-meter to assure that the unit was operating (10 ohms/full - 70 ohms empty).

Followed the DVD/manual to insert the mounting ring into the 59mm hole in the side of the tank noting the position of the sender plate (top/up/full). IMPORTANT to note that the mounting screw holes are NOT symmetrical!! Made many tries to complete the mating of the internal ring/gasket/sender before this became obvious. Used liberal amounts of Form-A-Gasket to seal the rings/gasket/sender/screws. NOTE for Port Wing Tank install: wait until the assembly is ready for final closure before adding the "gunk" sealer.


2015-04-29 Fuel Tank Filler neck cutout in top skin Used matched hole pattern method to locate/position hole in top skin required for fuel tank filler neck.

2015-04-30 Install Stb Fuel Tank (7V11-1K) Used drain boss weld on bottom of thank to locate/ream hole for acess in bottom skin (per the DVD). Located and reilled holes for fuel and vent lines. Positioned and riveted in 6 stand-off U-channels in fuel tank bay to isolate tank and restrict shifting.
Added cork stripping to the channels to reduce friction on tank sides, bottom and top.

Inserted tank into bay and added fittings. Used Locktite 542 sealant/anti-sieze as noted in plans. Clamped 5/16" fuel line hose to vent line and connected to 1/4" Excelon tubing with barbed reducer, routing line to wing root abay. through grommets in ribs 1 & 2.

Clamped 1/4" Excelon tubing to line fittting at screen nipple. routed tubing to wing root bay.

Added (and labeled) 1/4" quick disconnects to both fuel and vent lines for folding wing option.

Wired fuel level sender and ground wires into wing root bay adding labeled disconnect plug (for folding wing). Grounded sensor to one of the AN4 bolts attaching the folding wing bracket to the front spar.
2015-05-02 Rout Navigation/Position Light cables through nose ribs Rout 22 AWG, shielded pair cable through open nose ribs. Riveted nylon cable routing clamps for strain relief and stand-off to prevent chaffing. Added/labeled quick connect/disconnect plug at root bay end for folding wing.
2015-05-03 Crimp, bend & fit the upper (7V8-2) and lower (7V8-3) wing tip angles to fit the curve of the wingtip. Position, drill, and cleco (silver) in preparation for attaching the wing tip sheet (7V9-1). Crimp, bend & fit the upper (7V8-2) and lower (7V8-3) wing tip angles to fit the curve of the wingtip. Position, drill, and cleco (silver) in preparation for attaching the wing tip sheet (7V9-1).
2015-05-04 Install wing tip sheet (7V9-1) & fiberglass tip (7V9-2) Used duct-tape to position wing tip sheet (7V9-1)into place on tip angles (7V8-2 & 3). Drilled and clecoed in place (Silver).

Prepared fiberglass tip (7V9-2) for mounting nav/pos light assembly (PSA green) by drilling 1" hole in the tip and installing 3/16" rivnuts for the two #6-32 mounting screws.

2015-05-05 Completed twing tip and nav/pos light fixture install Passed the fixture wire through the mounting hole. Crimped & soldered the power wires to the fixture. Sealed the connections with heat-shrink & riveted a strain-relief clamp to the spar tip (7V3-3). Secured the fixture to the fiberglass tip with two #6-32 mounting screws then verified that operation of the fixture by py adding power to the connector in the wing root bay.

Completed the installation by fitting & clecoing (silver) fiberglass tip in place. The tip flange slides ~20mm under the end of the compound curve of the nose skin. Could not get perfect alignment of the 7V9-1 or 7V9-2) due to the compound curves of the win tip structure. Will fill the gaps with epoxy fiberglass resin & micro-balloons to sand smooth.
2015-05-06 Preparation of wing root angle (7V9-3A) Compound curve crimped into flat wing root L-angle and fitted to the wing root at rib # 1.
2015-05-07 Layout Wing Root Top Skin (7V9-3) Plot coordinates from plans table for compound curve of wing root top skin (7V9-3). Used nibbler to cut out the part.
2015-05-11 Trial fit of wing root top skin (single piece - 7V9-3) Spent several hours trying to bend/fit the compound curve of 7V9-3 to conform to the wing root. Could not make the difficult compound curve around the tapered nose skin. Decided to try Jon;s method of cutting the piece (7V9-3) into two by cutting along the position of the front spar.

Rear portion of the top skin fell into place nicely. drilled and clecoed (silver).
2015-05-13 Wing root leading edge top skin mold Made plywood copies of #1 nose rib and root nose rib. Fastened into position on another piece of plywood. Used 2-part poly-urethane foam to construct the compound curve of the part & laid-up the skin with 4-oz. fiberglass cloth using West System 105 marine epoxy resin.

2015-05-14 Trial fit of wing root top skin leading edge - No Joy After many hours, could not get the wing root top skin leading edge to make the compound curve. Decided to make a male mold to lay-up a fiberglass part.
2015-05-15 Fiberglass Wing Root Nose Skin Install Added epoxy resin with micro-balloons to the nose skin and sanded smooth. Removed skin from the form and trimmed to fit for installation.

Will try the aluminum sheet nose skin (7V9-3) again on the port wing, but will probably require a port side form for another fiberglass skin.
2015-05-18 Fabricate Wing cradle With stb wing almost completed. Built a cradle to vertically store the finished wing. Used 2x4 lumber and tie-down straps.
2015-05-19 Layout & fabrication of misc. wiring harnesses Added Molex pins to various lengths of cables for later electricals installations.

22 AWG, 2-conductor, shielded (Radio Shack):
(1) 18' tail-light assembly connector to inst. panel
(2) 6' stb wing-tip light connector at wing root to inst. panel
(3) 6' port wing-tip light connector at wing root to inst. panel
(4) 6' AOA vane to port wing root connector
(5) 6' AOA vane port wing connector to inst. panel (indicator)

22 AWG, 3-conductor, shielded:
(1) 4' AOA indicator (inst panel) to busses

28 AWG, 5-conductor, shielded:
(1) 18' elevator trim servo to inst. panel & pilot stick grip
2015-05-21 4mm A/C plywood fuel pumps mount Laid out and drilled mounting holes for the dual fuel pump assembly mounting platform. This platform can be mounted on the tank Adel-like straps or under the passenger seat. This decision to be made when constructing the forward fuselage.

*** 11/13/2015: Mounted on the aft side of the passenger seat-back. ***
2015-05-24 Gather Port Wing components & make intial layouts Collected all components for construction of the port wing. Labeled all parts and scribed all center-lines in preparation.
2015-05-25 Install spar doublers & nose ribs Using the station lines as references, installed the 3 front spar L-angle doublers at stations 480, 1160, & 2760. Installed all 6 nose ribs in their proper locations assuring vertical placement with square.
2015-05-26 Install port wing ribs Install (silver) port wing ribs behind the nose ribs. Assure vertical placement with square.
2015-05-27 Started installation of rear channels to create rear spar Install the rear channels (prepared with the stb wing build) to create the rear spar. Used the template from the stb wing construct & same method.
2015-05-28 Complete install of rear channel (spar) components Finished installation of the rear channel (spar) components.
2015-06-02 Install Rear Upper Strut Fitting (7V4-4) Installed rear upper strut fitting (7V4-4) to rear channel at rib #4. Difficult assembly (pg 7V5). Requires 12 A5 rivets through 7V4-4 into rear channel, a short L-angle doubler at the rear channel and flaperon mount; and a longer l-angle bent to match the bottom surface of the wing lying along the rear channel. All require A5 rivets in tight spaces. Angle drill required.
2015-06-03 Fabricate & attach horizontal stiffeners to top of ribs Fabricate L-angle doublers and mounting angles. Attach to top of the wing ribs between ribs 2-3, 3-4, 4-5, & 5-6.
2015-06-05 Square port wing structure in proparation for skinning Align wing structure so that the front spar is 90 deg. to the tabletop. This is accomplished via rt. angle brackets secured to the tabletop and the front spar. Note that the structure is positioned with the top-side up in preparation for attaching the top-skin.
2015-06-06 Un-roll and position top skin in place Un-roll top-skin into position on port wing structure. Position with just a few #40 clecos along front spar. Check alignment via the pre-drilled holes along the ribs (look for centerlines visible through holes). Drill & attach (center outwards) with #40 clecos approximately every 3rd or 4th hole position.
2015-06-06 Square port wing structure in proparation for skinning Align wing structure so that the front spar is 90 deg. to the tabletop. This is accomplished via rt. angle brackets secured to the tabletop and the front spar. Note that the structure is positioned with the top-side up in preparation for attaching the top-skin.
2015-06-07 Turn wing structure & install horiz. bottom stiffeners Once the top-skin is positioned & clecoed (silver). The wing is turned to allow installation of the bottom skin horizontal stiffeners between the ribs.
2015-06-13 Attach Flaperon Brackets (Rib # 4 - typical) Fabricate 8 L-angles for flaperon arm installation. Use flaperon jig to position arm on inboard side of mount at rib #4. Drill and cleco L-angles to aft wing skin. Drill & cleco (2 positions) thru L-angles to secure the arm. These two moles will eventually be drilled out to accept AN3 bolts.

2015-06-14 Attach flapron Arms to Ribs 1, 5, & 6 Repeat process for remaining 3 arms. Rib #6 placement is inboard. Arms at ribs #1 & # 5 are outboard.

Drill out all #40 holes to size. Note two holes each in L-angles thru arms at to AN3 size all others are for A4 rivets.
2015-06-15 Initial fiting of nose skin (7V7-1) Level structure on worktable with front spar at Rt. angle across the length. Used wall-hanger brackets clamped to the table surface and secured to the face of the front spar with heavy-duty rubber bands through the lightening holes.

Position nose skin across the front spar aligning the pre-drilled holes along the center-line of the spar as transferred to the bottom skin verifying the alignment of the slots in the nose skin with the slat mounting brackets affixed to the nose ribs. Secure with silver cleco in a few places along the spar for initial fitting.
2015-06-16 Spar root (7V3-1SP) & tie-down (7V8-0) fittings While the nose rib area under the skin is still accessible position and attach the spar root fitting to the front spar (at rib #4) with 3 AN3 bolts.

Cut a slot in the bottom of the nose skin adjacent to the inboard surface of rib #5. The optional tie-down ring fitting (7V8-0) is passed through this hole and riveted to the nose rib with A5 rivets.
2015-06-17 Install front strut fitting (7V8-1SP & -4) Layout, cut, & drill the strut angle (7V8-4SP). This is positioned along the bottom of rib #4 such that the spar strut fitting bolted to the front spar and protruding through the bottom skin, just touches the short side of the L-angle. 7V8-4SP is clecoed (silver) in place so that the front strut fitting doubler (7V8-1SP) can be fitted against the L-angle and under the spar root fitting.

Once clamped in place, the doubler is drilled (using the rt angle drill) and clecoed (silver) to hold the doubler in position against the spar root fitting and the L-strut angle. The strut angle is then removed from the wing (rib #4( so that the assembly can be drilled out (on the drill press) and riveted in place using 7 A5 rivets.

The riveted assembly is then re-clecoed to the wing and sapr root fitting.

2015-06-18 Port Fuel Tank Preparation Located positioning for fuel level sender. Used fly-cutter to drill out a 59mm hole for sender. Bent the sender unit float arm per the DVD. Another difficult time inserting sender into position in the tank aligning all 5 screws through the external and internal mounting rings and rubber seals. Added Form-A-Gasket on all internal and external mating surfaces (nasty, goopy, sticky stuff) and tightened the 10-32 screws to set the sender in position.

Fabricated and added 7V11-4A rib channel spacers to the inside of ribs 2 & 3 as standoffs for mounting the tank in the open wing bay.
Trial/positioning fit of tank into bay marking position of the fuel tank channel (7V11-2K) for installation. Also noted locations for drilling plumbing holes in the bottom skin (for the tank drain valve), the fuel out fitting (through rib 2) and the vent line (through rib3).

2015-06-19 Fuel tank installation & plumbing Used step-drill to drill out fuel drain fitting hole through bottom skin; fuel-out fitting hole (through rib 2) and vent line fitting (through rib 3). Positioned and riveted in place the 7V11-4K rib channel spaces/standoffs (7V11-4K). Added cork strips to standoffs, fuel tank channel (7V11-2K), and tank top & bottom.

Inserted tank into position and verified fit before installing (silver clecos) the fuel tank channel into place.

Installed (with thread sealer) the quick drain (CAV-110). Installed the vent fitting (5/16" hose barb/nipple fitting), & the finger-screen (DX2012)/0.25" hose barb/nipple fitting.

Installed short length of 5/16" fuel injection hose to the vent line fitting and added a 5/16" hose barb to 1/4" hose barb and routed the vent line to the root bay. Installed a length of 1/4" fuel line to the fuel out fitting in the root bay. NOTE: Hose ends will get quick disconnect fittings for folding wing.

Attached sender and ground wires to the level indicator. Will attach the ground wire to the AN4 bolt through the front spar that attaches the folding wing bracket to the wing (4130 steel).
Wires terminate in a plug (in the root bay) for quick disconnect in folding the wing.

2015-06-20 Wire and tube routing Routed wing tip light cable through open wing structure from tip to root bay. Added disconnect plug at root bay end for quick disconnect (folding wing).

Routed pitot static and pressure lines through open wing structure from root to pitot position in nose between ribs 3 & 4. Used Olfa knife to cut a slot in the bottom nose skin for mounting the pitot mast.

All cables and lines were anchored to the wing structure at intervals using nylon wire ties.
2015-06-21 Dual EarthX Battery mount Constructed mounting platform for dual EarthX ETX36D batteries.
2015-06-22 Install
2015-06-22 RustOx interior of bottom wing structure Applied RustOx ant-corrosion protection to the interior of the bottom wing skin, ribs, stiffeners, and spar structure.

Applied Cortec anti-corrosion protection to the fuel tank.
2015-06-23 Positioned/drilled rear jury strut brackets (7V10-4SP) Positioned/drilled/clecoed the rear jury strut brackets in place on the underside of the wing. Routed AOA cable through the bottom skin at the forward jury strut fitting. Cable will be attached to the AOA vane which will be tie wrapped to the horizontal jury strut arm. Internally the cable (shielded, 3 wire) is routed around the fuel tank into the wing root bay where it will get a 3-pin Molex connector (for quick release in folding the wing).

Strain-relief throughout the cable run as the wires are tiny and only soldered to the instrument sensor.
2015-06-24 Prepare jury strut ends with doublers (7V10-3SP) The jury strut tube (7V10-3SP) ends are reinforced with short lengths of aluminum caps (7V10-7SP) to provide greater bearing area for attachments to the wing and lift struts.

The caps are prepared by rounding the edge surfaces into an oval cross-section that is inserted into the "squashed"ends of the tubes. The flat ends will later be drilled for AN3 bolts.

Prepared only one end of each section. Remaining end will be completed during rigging of wing & lift struts to the fuselage.

2015-06-25 Prepare AOA vane for installation Cabled AOA vane sensor (shielded, 3-conductor cable). Drilled cable routing hole at fwd jury strut mount and installed grommet.
2015-06-26 Pitot Mast (7V1-3A) Positioning Located position of pitot mast (7V1-3A) between ribs 3 & 4 (centered on lightening hole in front spar. maid-out this position on bottom of nose skin and cut slot for mast insertion corresponding to the pre-routed, static and pressure lines in wing structure.
2015-06-27 Positioning nose skin to bottom of front spar Clecoed wing structure place bottom-side up and leveled on worktable for initial positioing fit of nose skin to front spar.

Drilled A40 through nose-skin, bottom-skin and front spar clecoing (silver) nose-skin tnto position.
2015-06-28 Position & cleco nose skin to front spar Strap nose skin into position around ribs. Drill & cleco A4 (silver) skin in position.
2015-06-29 Remove, deburr, & corrosion protect nose skin Use straps to remove the nose skin. Debur all A4 holes and apply Cortec corrosion protection to interior of nose skin, ribs, and front spar.
2015-06-30 Install nose skin on wing structure re-strap nose skin into position with copper clecos in aprox. every 3rd hole. Working from the center outwards (to both ends) rivet the skin into position with A4 rivets.
2015-07-01 Soft rivet trailing edge of wing Working from the top-skin, clamp the top and bottom skins into position and drill out the trailing edge securing with silver clecos. Use soft rivets to complete the basic wing skinning process.
2015-07-02 Reconfigured Lights Controller box Reconfigured the Crazed Pilot Strobe/Wig-Wag controller box into a smaller enclosure. Extended the Crazed Pilot control module to extend outside the back of the box and secured the 8-pin Molex connector to the rear of the box. Removed the lights circuit breaker form the box as it will be positioned on the instrument panel (3 Amp, MP 1400-100-030 breaker).

Box will mount under the instrument panel for easy access.
2015-07-03 Assemble & install bottom skin diagonal stiffeners Cut and fit 6063 aluminum L-angle (0.75" x 0.75" 0.63" thick) diagonal stiffeners (3). Use 40 mm pitch for #30 clecos.
2015-07-05 Prepare wing tip upper & lower angles Mark the approximate positions of the rivet holes on the un-crimped wing tip angles so that crimps will not be placed a these locations when setting the compound curves in the upper wing tip angle (7V8-2) and lower tip angle (7V8-3).

Drill and cleco (silver) the tip angles in place in preparation for fitting the fiberglass tip (7V9-2) and tip sheet (7V9-1).
2015-07-06 Cleco (silver) wing tip angles and tip skin in position Position, drill, and cleco the angles and tip skin in position.
2015-07-07 Fiberglass tip fitting (7V9-2) with nav/pos light Trim the excess material off of the fiberglass tip fitting (7V9-2). Position and drill 0.75" hole in tip for nav/pos light fitting (port side - red). Using the fitting as a template, mark the position of the rivnuts for attaching the fixture. drill 0.25" rivnut mounting holes and secure the #6-32 rivnuts in place using the installation tool (from Harbor Freight).

Mount the fixture in-place on the fiberglass tip with the two #6-32 stainless screws provided.

Crimp, solder, and heat shrink-wrap the leads from the fixture to the shielded, 2-2ire cable run through the wing structure from the root to the tip. Stress relieve the connections at the tip.

Remove the wing tip sheet(7v9-1)and apply RustOx to the interior surfaces. Position the fiberglass tip/light assembly in place on the wingtip nose. And secure with several #40 clecos (silver).
2015-07-08 Reinstall the wing tip sheet (7V9-1) and rivet Cleco (#30 - copper) the wing tip sheet (7V9-1) into position wit the leading edge portion over the fiberglass tip/light assembly (7V9-2). Drill out the fiberglass tip to A4 size and rivet both tip pieces in place (7V9-1 & 7V9-2).

Note the gaps along the top and bottom skin at the tip angles and at the leading edge skin against the fiberglass tip. Apply epoxy resin/micro-balloon filler paste to fill these gaps sanding to a smooth finish.
2015-07-09 Fabricate & install wing root angle (7V9-3A) The wing root angle (7V9-3A) is flattened on the trailing edge end, crimped to conform to the curvature of the upper wing skin and fitted under the upper wing skin at the root opening. The edge protruding into the open root area is "tweaked" to form an angle consistent with the slope from the top of rib #1 to the top of the root rib (Approx 45 deg.).

2015-07-10 Positioning & trimming Wing Root Top Skin (7V9-3) The one-piece (over-sized by 20 mm at the nose end). Is inserted between the top skin and the rear channel. The edge cord edge is placed flat against the edge of the top skin along rib 1 flush with the wing root angle (7V9-3A).

With proper positioning, 7V9-3 is drilled and silver clecoed at the rear channel and every 40 mm along the 7V9-3A wing root angle face conforming to the compound curvature of the rib and slope to the root rib.

With the wing root top skin secured, the nose portion is laid out with on a line corresponding to the rear edge of the front spar. 7V9-3 is then removed and the nose portion is trimmed off for separate installation. (Could not get this piece to fit properly on the starboard wing, but will try again here on the port wing.)
2015-07-11 Fitting wing root top skin (7V9-3) Clecoed one piece wing root top skin in place to the wing root angle (7V9-3A) after verifying that the lip of the angle extending from rib 1 matches the top surface of the root rib.

Tried bending the nose portion of the wing top skin into the compound curve around the nose rib #1 an the small root nose rib (7V4-1). Could not get a smooth curve.

Traced a line across the wing root top skin from rib #1 to the root rib at the leading edge of the front spar. Removed 7V9-3 and cut the nose section off along the front spar line.

Copied this nose piece onto a sheet of 0.016" thick 6061-T6 skin material OVER-SIZED by about 20% (per Jon' HomebuiltHelp video) and cut this over-sized nose piece for fitting in place. Used the small Harbor Freight bending brake to bend the bottom of the nose section approximately 60 deg. for trial fit.

Re-clecoed the rear portion of the now cut 7V9-4 top skin into place. Clecoed the forward (nose portion) into place ONLY along the bottom skin at the bend checking the size/positioning.

2015-07-12 Fitting wing root top skin (7V9-3) ,,, continued After several trial/bends/alignments/trimming operations a reasonably good contour was achieved for the leading edge compound curve and held in place with copious amounts of duct tape, the nose portion was drilled (#40) and clecoed (Silver) in place. A long, tedious, process.

The entire 2-piece assembly was then drilled out to #30 for A4 riveting after dis-assembly, deburring, and application of Cortec corrosion protection.

Once the Cortec was dry the two piece assembly was refitted using copper clecos and riveted in place.
2015-07-14 Wing Storage Cradel completion Added a 2nd bay to the sing storage cradle in preparation for storing both wings in the storage shed with the empennage, flaps, and slats.
2015-07-16 Completed port wing Put the finishing (almost) touches to the port wing assembly. Added epoxy-resin/micro-balloons to the wing tip curve and filled some gaps between the nose skin and the fiberglass tip.

Moved the wing into the cradle with the stb. wing ready for storage in the back-yard shed with the empenage, slars, and outboard flaperons.
2015-07-17 Outboard flaperon sections layout Prepared the outboard sections of the flaperons for assembly. Cannot complete strapping & skinning until the wings are mounted to the fuselage so that the proper clearance can be maintained between the flaperon root and the fuselage skin. Slight changes are in order because of the no-slot flaps option.

Skins (7A2-1, left and right) were prepared and RustOx applied. Spars (7A1-4) were laid-out for the ribs. The hinge brackets (7A1-5) were fabricated.
2015-07-18 Identify and Prepare Aft Fuselage Skins & Fittings Locate and identify Aft Fuselage skins (Top: 7F2-1, Sides: 7F2-2, & Bottom: 7F2-3). Locate and mark center-lines on 7F1-3 (Rear Horizontal Tail Frame) and 7F2-4 (Front Horizontal Tail Frame).

Locate and apply center-lines to the Rear Fuselage Longerons(7F3-1 - note the 10 mm vs 22 mm sides as the longer sides are placed on the top & bottom of the structure).

Inscribe center-lines on several lengths of L-angle for use as uprights.

Inscribe center-lines on several lengths of Z-angle for use as stiffeners around the Access port in the bottom skin.

Inscribe center-lines on several lengths of 6063 aluminum for use as diagonal stiffeners.
2015-07-19 Install bottom skin - Port side longeron sections Locate the 3 series of 3 pre-drilled holes at ~ 1875 mm aft end of the bottom skin (on either side). Draw a line 10mm from the end of the longeron L-angle (7F3-1) on the inside of the 22 mm leg). Slide this edge under the bottom skin so that the 10 mm mark is visible through the forward-most of the series of 3 pre-drilled holes. #40 drill & cleco (every 3rd hole) along the skin/longeron. Position the L-angle such that the edge of the skin does not "curl up" onto the vertical leg, but rather is snug against the longeron leg.

# 40 drill the remaining holes. When completed drill out to A4 and cleco (copper).

Take a 2nd length of 7F3-1 angle and mark a line at 10 mm from the aft end onto the 22 mm leg. Remove the clecos from the 3 holes at the joint. Slide this under the bottom skin until this line is visible through the aft-most of the 3 holes at ~1875 mm. The forward longeron overlaps the aft longeron for these 3 holes.

#30 drill these 3 overlapping holes and cleco (copper). Now #40 drill & cleco (silver) every 3rd hole keeping the longeron snug against the bottom skin.

# 40 drill the remaining holes. When completed drill out to A4 and cleco (copper).

Drill out & cleco (black) the 3 overlapping locations to A5 size.

2015-07-20 Install Starboard side bottom longerons Repeat the steps from yesterday for the starboard side.
2015-07-21 Install Port side top longeron sections Use the same technique as for installing the bottom longeron sections to the port-side skin to install the top longeron sections.
2015-07-22 Assemble & install Port-side diagonal stiffeners Cut and fit 6063 aluminum L-angle (0.75" x 0.75" 0.63" thick) diagonal stiffeners (3). Use 40 mm pitch for #30 clecos.
2015-07-23 Assemble & install Stb-side diagonal stiffeners Cut and fit 6063 aluminum L-angle (0.75" x 0.75" 0.63" thick) diagonal stiffeners (3). Use 40 mm pitch for #30 clecos.
2015-07-24 Assemble & install bottom skin diagonal stiffeners Cut and fit 6063 aluminum L-angle (0.75" x 0.75" 0.63" thick) diagonal stiffeners (3). Use 40 mm pitch for #30 clecos
2015-07-26 Assemble & install top skin cross members Cut, fit, & silver cleco top skin cross members in preparation for fuselage assembly.
2015-07-27 Grounding posts & 6-Terminal Pos & Neg Buss Bars Prepare and install 18 AWG wire bridges to span the 6-Terminal buss bars (pos & neg) $ grounding posts for later installation to the cockpit firewall.
2015-07-28 Bottom skin (7F2-3) assembly riveting Remove all longerons, cross-members, stiffeners, and fittings (bottom doublers, 7F6-2; z-angles, and bottom channel, 7F6-1); deburr, apply corrosion protection, and rivet prior to adding side skins to create the rear-fuselage structure
2015-07-29 Starboard (passenger) side skin (7F2-2) riveting Remove all longerons, diagonals, & cross members. Deburr, apply corrosion protection, and rivet in preparation for rear fuselage assembly.
2015-07-30 Pilot (Port) side skin (7F2-2) riveting Remove all longerons, diagonals, & cross members. Deburr, apply corrosion protection, and rivet in preparation for rear fuselage assembly.
2015-07-31 Prepare access port cover for installation (7F2-4) Layout a 10 mm edge-line around the perimeter of the access port cover (7F2-4). On the bottom side of the bottom skin, position the access port cover over the access hole maintaining a 20 mm edge margin all around. Tape the cover in place over the access hole. Drill a #8 screw hole in each corner and two equally spaced #8 screw holes along the sides on the 10 mm perimeter line. Drill through the cover and bottom skin.

Remove the access cover. Using a #8 (MS21069L08) nut-plate as a template on the bottom skin, drill the two nut-plate mounting holes for A3 blind rivets (#40 bit) for each of the 12 nut-plates and rivet in place on the INSIDE of the bottom skin. Use a flat-head mandril for setting the A3 rivets flush with the bottom skin.

Check the fit of the access cover by installing with 12 #8 washer head screws (AN535-832R7).
2015-08-01 Build Viking header tank pumps mount Used scrap 8mm A/C plywood to construct a mounting pad for the Viking fuel pumps assembly. Bolted the fuel pumps assembly to the mount with 4 AN3 bolts & wood bearing washers.

The pad & pump assembly mounts to the tank via 4 3/8" bolts through the barrel-hoop strap mounts provided with the BAM Mfg. 5.1 gal., spun aluminum tank.

NOTE: Abandoned this mount method after trial install (8/5/2015). Still used mount pad, but moved pad from the barrel-hoop strap to the fuselage floor.

2015-08-02 Prepare top Skiin (7F2-1) for Fuel Tank Mount Purchased 3' length 1.5" 6061T6 L-angle (0.125) for header tank support structure (Metals Supermarket), Plano. Also purchased 3' length of 1.5" (0.125) 6061T6 bar stock for support structures.

Layout, cut, & fit support structure. Placement is aft of the baggage compartment wall cross-member. Tied the L-angle support structures together to help distribute the loads.
2015-08-04 Construct header tank mount structures Used scrap (0125") 1/125" 6061T6 L-angle to fabricate the vertical mounting struts for the header tank. Added 1.5" (0.125") 6061T6 bar stock to fabricate the X-braces (inhibits fore-aft & port-stb) shifting of the tank).

Verticals & X braces mount at the tank via AN6 bolts through the barrel-hoop mounting straps. 3/8" washers are used to fill & space the mount structure.

The vertical L-angles will bolt to the 1.5" (0.125) L-angle cross member approximately 8" aft of the baggage compartment wall structures. Verticals & X-braces will mount with AN4 bolts.
2015-08-05 Construct pump assembly mount Initial thought was to mount the assembly to the 3/8" bolt locations provided in the barrel-hoop strap mounts for the tank. After test fitting a plywood mount in this position. It was determined that the design added weight to the suspended tank structure and was difficult to access to make the required attachments to the fittings and electrical contacts.

Used scrap 8mm A/C birch plywood and 0.75" 6061T6 L-angle (0.063) to construct the Viking dual/redundant pumps assembly mount. The design now uses two double L-angle "mount rails" that will be riveted to the floor of the aft fuselage under the baggage area. This places the 5 lb pump/mount assembly very near the aircraft CG.
2015-08-06 Passenger side skin jigged to bottom Used more shel-bracket rt-angles affixed to the worktable to jig the passenger side skin in place with the bottom skin. Spring clamps at top and A4 clecos along the bottom longeron.
2015-08-07 Jig fuselage bottom and pilot side in place Used shelf-bracket rt-angles affixed to the worktable to jig the fuselage bottom and pilot side skins together. Side skin held in place with spring clamps (at the top) as the bottom longeron is clecoed (A4). Note that the forward section of side skin slips between the longeron & the bottom longeron doubler (7F3-2).
2015-08-08 Position horizontal tail frames (7F1-3 & 4) Position the two rear horizontal tail frames (7F1-3 & -4) in place using the pre-drilled holes in the bottom and pilot side skins. Note that the frames as supplied are about 3mm too tall. Remove and trim to fit.

Before re-installing and drilling #40 pilot holes into the frames for silver clecos, used a step drill to drill out holes in the upper surface for 7/16" grommets for tail lights & elevator trim control cable routing.
2015-08-09 Jig passenger side skin in position Add 2 additional rt-angle supports to workbench to support the jig the side skin into position against the bottom skin longerons. Hold in position with copper clecos.

Position, drill (#40), and copper cleco the horizontal tail frames (7F1-3 & -4) into position on the passenger side.
2015-08-10 Add L-angle stiffeners to side skins at horiz tail frames Cut, fit, drill, & cleco (#40) L-angle stiffeners running from fed top to aft bottom longerons between the two horizontal tail frames (port & starboard).

Cut, fit, drill, & cleco (#40) L-angle cross members to the top of each horizontal tail frame (between the port & starboard top longerons). L-angles face each other (7F1-3 facing fwd; 7F1-4 facing aft).
2015-08-11 Identify and template instruments/indicators/controls I-Pad Air (10")
VikingView ECU
Viking Starter Switch
Aircraft Spruce 0-140 MPH (3.125") airspeed indicator
Aircraft Spruce Airpath 2.25" Compass
Aircraft Spruce A-700 Throttle Control (3' Pilot)
Aircraft Spruce A-700 Throttle Control (4' Co-Pilot)
Belite Digital Altimeter & VSI (2.25")
Belite Dual Tank Fuel Level Gauge (2.25")
Level Developments BI-25 Ball Inclinometer (25 deg; 127mm x 51mm)
Crazed Pilot FL-760 Comm Radio/Intercomm (2.25")
AmeriKing AK-450 ELT Remote Control Panel
Barker Aviation AOA LED Indicator
Ray Allen Electric Elevator Trim Indicator
ATI 12mm Red 12V LED Alternator Indicator Lamp
ATI 12mm Red 12V LED ECU Indicator Lamp
ATI 12mm Red Flaps Indicator Lamp
Allied Elect. SPST Toggle Switch(60A) Master (w/switch guard)
Allied Elect. SPDT Toggle Switch(60A) ECU 1/2 (w/switch guard)
Allied Elect. SPST Toggle Switch(60A) Battery 1 (w/switch guard)
Allied Elect. SPST Toggle Switch(60A) Battery 2 (w/switch guard)
Allied Elect. SPST Toggle Switch(60A) Pump 1 (w/switch guard)
Allied Elect. SPST Toggle Switch(60A) Pump 2 (w/switch guard)
Allied Elect. SPST Toggle Switch(60A) Comm (w/switch guard)
Allied Elect. SPST Toggle Switch(60A) Nav Lights (w/switch guard)
Allied Elect. SPST Toggle Switch(60A) Access. (w/switch guard)
E-bay DPDT Momentary-Off-Momentary Switch (Elevator Trim)
E-bay DPDT Momentary-Off-Momentary Switch (Flaps Linear Actuator)
TemCo Long-arm MicroSwitch (+ Flap Extend Limit)
TemCo Long-arm MicroSwitch (- Flap Extend Limit)
TemCo Long-arm MicroSwitch (+ Flap Retract Limit)
TemCo Long-arm MicroSwitch (- Flap Retract Limit)
TemCo Long-arm MicroSwitch (Flap Extend LED)
Carling CLB Breaker 15Amp - Alternator
Carling CLB Breaker 10Amp - Ignition
Carling CLB Breaker 10Amp - Linear Actuator (Flaps)
Carling CLB Breaker 5Amp - VikingView EIS
Carling CLB Breaker 3Amp - Elevator Trim
Carling CLB Breaker 3Amp - Nav/Pos Lights
Carling CLB Breaker 3Amp - Fuel Sensor & Gauge
Carling CLB Breaker 3Amp - Intercomm
Carling CLB Breaker 3Amp - Spare
Carling CLB Breaker 1Amp - FL760 Radio



2015-08-12 Comm Antenna Dorne & Margolin DMC 70-1. Repair (Epoxy fill) slight crack in casing.
2015-08-12 AK-470 ELT & Antenna AmeriKing AK-470 ELT & Antenna preparation. 6 AC-Delco Super Alkaline batteries installed and ELT Tested. Will mount antenna on bottom fuselage aft of access panel (Centerline). Will mount ELT under passenger seat and rout cables to remote control on panel.
2015-08-13 Adjust Rear Horizontl Tail Frames The rear Horizontal Tail Frames (7F1-3 & 4) bot were 5-6 mm too wide, causing a bow in the trial fit of the tops skin. Removed each to cut off one flange edge and rivet in an L-angle to fit the 160 and 252 mm required dimensions. Re-installed verifying final dimensions prior to trial fit of top skin to fuselage box structure. Riveted in place only to the bottom skin.
2015-08-14 Top skin Trial fit to rear fuselage box Trial fitting of tops skin to to fuselage box structure revealed some interference with edge fits due to diagonal stiffener placement. Trimmed the ends of the stiffeners to allow the top skin to lie properly in place. Ready for squaring and riveting.
2015-08-15 Prepared rear fusleage for squaring & riveting clamped/clecoed the top skin in place to complete the basic box structure. Removed the rt-angle desktop supports. Placed furniture pads under the bottom of the fuselage on the worktable to allow entry into the box structure to install gussets which will "set" the structure in proper alignment.
2015-08-16 Baggage Compartment Back (7F5-8B) replacement The kit provided baggage compartment back (7F5-8B) is a diamond bend sheet of 0.016" 6061T6 which provides stiffness to the aft fuselage structure but provides no easy access to the aft part of the fuselage. This has been replaced with a 0.032" flat sheet of 6061T6 in which a hinged access panel (18"x13") has been installed. This will provide access to the header tank which is suspended from the top skin & longerons just aft of the panel.

The original 7F5-8B has a 22mm flange bent into the bottom surface. The fabricated replacement has a 20mm x 22mm section of 0.032" L-angle riveted in place to form the flange.
2015-08-17 Fabricate rear fuselage gussets (7F3-2A) Layout and fabricate the 10 rear fuselage gussets (7F3-2A). 8 are of the standard triangular design and 2 (to be placed at the rearmost vertical & horizontal cross-members) are L-shaped to allow free routing of the rudder control cables.
2015-08-18 Install rear fuselage gussets (7F3-2A) Placed furniture pads under the rear fuselage structure to prevent crushing while working inside the structure to install 10 aft fuselage gussets at the uprights and cross members to help maintain the fuselage square.

Difficult process drilling inside the confined space and the tight corners of the structure. Used rt-angle drill attachment starting with #40 (for silver clecos).

Due to having added diagonal stiffeners to the large open areas of the fuselage skins to help prevent oil-canning, several corner holes will not be accessible for riveting. These are be secured with #6-32, stainless-steel, hex-head bolts with elastic stop-nuts.

Was able to only install the forward 6 gussets during this session due to the cramped area, high temperatures, and humidity.
2015-08-19 Install rear fuselage gussets (7F3-2A) Installed rearmost fuselage gussets (L-shaped at bottom for rudder cable clearance). Cramped work area. Hot, sweaty work. Also routed 5-wire elevator trim cable.
2015-08-20 Header tank to barrel-hoop straps ** REMOVED/REPLACED ** Used 2 AN6-20 bolts to attach the steel barrel-hoop mounts to the 5.1 gal.. spun aluminum header tank and truss mount fixture in preparation for installation into the area behind the baggage compartment back.
2015-08-21 Fabricate tail section electrical cable assemblies Added 0.062 Molex connector pins/plug to the 22 AWG, shielded, 2-wire cable that will connect the tail-light assembly to the nav/pos lights controller box at the instrument panel.

Added 0.062 Molex connector pins/plug to the 22 AWG, shielded, 5-wire cable that will connect the elevator trim servo to activator switches on the control stick and to the display instrument on the instrument panel.
2015-08-21 Fabricate flaps linear actuator mount
2015-08-22 Fabricate flaps linear actuator mount Layout and build the L-angle bracket mounts for the pinned-end of the linear actuator from 6061-T6 0.125" thick 0.25" L-angle. These will be riveted to a 0.063" doubler sheet which will mount to the floor under the pilot's seat.
2015-08-23 Route tail-lights & elevator trim servo cables Routed 2-wire tail-light cable along interior starboard side of rear fuselage and 5-wire elevator trim servo cable along interior port side of rear fuselage.

cables strain relieved and affixed to diagonals/cross-members with PVC tubing protectors and cable ties.
2015-08-24 Prepare positive & negative busses with jumpers Added jumpers to one of each positive & negative terminal block (buss). Added braided-wire connector from negative bus to one grounding pin.
2015-08-25 Prepare & trial fit new baggage compartment back Layout and drill pilot (#40) holes (40) along the perimeter of the new baggage compartment back (7F5-8B). Trial fit, drill, and silver cleco the back in place.
2015-08-26 Trial install Header Tank ** REMOVED/REPLACED ** Test installation (for placement and layout of lower support fabrication) of the Header tank from the 0.125" thick L-angle across the fuselage top skin. Access port allows relatively easy installation and will allow plumbing of the fuel system.

***** Decided that 50 lbs total (tank, 5 gal. fuel, and mounting structure) situated aft of the baggage compartment might have too large an impact on weight & balance. Redesigned tank (see Oct. entries) and moved forward accessible through access port. *****
2015-08-28 Install Pilot side upright (7F5-4) More difficulties on the pilot side. Same trim required as with the passenger side. However, the side skin showed a fairly significant tendency to "bow" outwards.

Used a length of wood to push the longerons slightly apart and clecoed (silver) in a piece of scrap L-angle to determine if the "bow" would diminish. This process removed the "bow".

Removed the L-angle and installed the upright channel (7F5-4).

Skin lies flat at this point.
2015-08-29 Install passenger side upright (7F5-4) Install passenger side upright forward of baggage compartment. Some difficulty. Plans call for a 950mm dimension. Actual fuselage dimension closer to 940mm. Checked with Jon Croke (HomebuiltHelp) and Roger at the Zenith Factory. Bot indicated that trimming is "normal".
2015-08-29 Final installation of uprights (7F5-4) Drilled out uprights to #20 for A5 rivets. Removed uprights, deburred, applied corrosion protection and re-installed with black clecos.

Riveted both side uprights into place with A5 rivets.
2015-08-30 Installed L-angle doubler at tail top-skin Install the required L-angle doubler at the rear of the fuselage top skin. Assure that the center-lines of the top and bottom skins align.
2015-08-31 Viking Engine Installation "Grab-Bag" Viking engine "grab-bag" of installation parts arrived. Inventoried and found 2 missing components: Small Viking Engine Decal and the High Pressure Fuel Filter. Reported these discrepancies to Jan at Viking. Will ship.
2015-09-01 Master Relay diode installation Wired the current limiting diode to each of the master relays.
2015-09-02 Layout & trial install extended baggage floor (7F8-9B) Layout, fit, trim, & trial install extended baggage compartment floor panel (7F8-9B).

Extended area floor, base floor (7F5-7), and seat back (7F6-4) will stay removable for ease of access until header tank plumbing, battery, pumps, and linear actuator assemblies are installed.
2015-09-03 Flaps Linear Actuator Circuit Design Laid out the logic/circuit for operation of the flaps using the Firgelli linear actuator (150 ft.-lbs torque, 4" stroke). Since the direction of the rotation of the L.A. motor determines the extension/retraction of the arm, the circuit uses separate long-arm micro switches for both positive and negative feeds to the motor (thus 4 switches are utilized to control the limits of travel). The direction (extend/retract) is selected using a DPDT (momentary-off-momentary) switch to be located on the panel (through a 5A breaker).

An additional micro switch at the retracted arm position powers the single flaps extended indicator lamp on the panel.
2015-09-04 Mount Horiz. Tail Attachment fixtures to rear fuselage Drill, position & cleco (silver) the 4 horizontal tail attachment fixtures (7F3-4)to the rear fuselage. Will eventually be drilled out for A5 rivets.
2015-09-05 Baggage area floor (7F5-7) Measure & trim the baggage area floor. Add L-angle to forward lip for attaching the seat back.
2015-09-06 Baggage area supports (Tapered Channel: 7F5-6) Prepare the tapered channel that supports the sides of the baggage area floor (7F5-7) by filing a slot to clear the inboard flange of the side channel (7F5-2SP) and install using the pre-drilled holes in the side skins to maintain alignment. Assure that the baggage area floor is parallel with the fuselage floor and at the proper location for mounting the seat back.
2015-09-07 Seat back (7F6-4) placement & access port Remove the clecos from the side channels (7F5-2SP) & top portion of the upright doublers (7F11-6) to insert the seat back (7F6-4) for initial fit.

Maintaining alignment across the baggage floor L-angle, drill through the upright doubler mounting holes at the lower end and the side channels at the upper end to position the seat back, Cleco to hold the positioning and drill through the existing holes for mounting across the baggage floor L-angle and sides.

Mark the sides of the seat back panel that extend past the upright doublers; remove the seat back & trim off this excess, then re-install (silver clecos).
2015-09-08 Fabricate Flaperon Bellcranks (7C1-4 & -5) Layout, cut, and trim 2 sets of flaperon bellcrank arms (7C1-4) and two belcrank spacers (7C1-5). Assure alignment, drill A4 and cleco the assemblies. Drill out to for A5 soft rivets the 6 rivets positioning the arms against the spacers. Drill out the 5/16" holes in the arms for the rod-end bearings. Drill a 3.16" pilot hole in the center for locating the pivot hole location, then drill out the assembly with a 3/4" bit.
2015-09-09 No-Slot Flaps parts The original CH-701 design required a large, semi-circular slot be cut into the fuselage side to allow the flaperons to be activated (extended/retracted). A modification using a pair of "pillow-block" bearings supporting a 1/2" shaft through the fuselage sides attached to the flaperons has been tested and well documented on the Zenith.Aero 701 builder's site.

The parts required were fabricated from 6061T6 aluminum stock (0.125" plate, 1/2" solid rod, and 1/2" id. 0.062 wall, tube). The aluminum welding was done at a local hot-rod shop.

The bearings were obtained from a local mechanical supply house as discontinued stock.

All parts will be trimmed to fit when the wings are position on the fuselage and the flaperons mounted to the wing.
2015-09-10 Mount Comm Antenna Layout comm antenna mount doubler (0.032" 6061T6). Pre-drill #40 (for positioning) mount, rivet, and cable holes. Mark center-line on doubler and on fuselage top-skin just aft of the baggage compartment wall. Drill & cleco #40 through top-skin with doubler as template. Drill out doubler/skin for A4 rivets. Drill out the 4 antenna mounting holes to #20 (for #8 stainless screws. Remove clecos, deburr, apply Cortec and re-position doubler from inside the fuselage with A4 clecos in preparation for antenna installation.

Layout, cut, and trim a rubber gasket/insulator to match the base of the Dorne & Margolin comm antenna base. Rivet doubler in place and trial mount the DM-C-70-1 comm antenna.
2015-09-11 Fuel Probe control Mount ** RE-DESIGNED/RELOCATED ** Fabricate 4mm aircraft plywood mount for Belite Fuel Probe control unit. Sand & seal with 3 coats of marine spar varnish. Attach the unit to the plywood mount with 2 AN3 bolts. Attach the mounted assembly to the header tank barrel-straps mount with 2 AN5 bolts. Strain relieve the units wire bundles to the plywood mount.

*** RE-DESIGNED/RELOCATED: With the removal/replacement of the large 5 gal. header tank the Fuel Probe Control is to be relocated to the aft side of the passenger seat next to the fuel pumps assy.
2015-09-12 Layout & construct 7F13-1 Font-to-Rear gussets Per the plans, layout and construct the gussets that help anchor the front and rear fuselage sections together. 7F13-1 0.063 6061-T6. Drill #40 pilot holes for later A5 rivets.
2015-09-13 Layout & Prepare Cabin Floor, Bottom, & Channel Sections Scribed center-lines and pattern for cabin floor (7F8-7, bottom (7F8-8), & channel (7F10-1) in which the main gear spring will mount. Clecoed (silver) the 4 channel doublers (7F10-2) into the channel ends using the angle drill.
2015-09-14 Fabricate Seat Front (7F11-1) and Doublers (7F11-1A) Layout and cut the eccentric hole in the bottom center of the seat front to accommodate the flaperon control lever (7C3-2) to the flaperons and rudder rudder control bellcrank (7C1-1) Carefully locate and drill the positioning hole for the torque tube assembly (7C2-2)

Layout and drill the holes in the ends of the seat front for routing the rudder cables (3/4" hole - utilizing a nylon fairing); the brake lines (7/16" hole), the battery cable (13/16" hole); the elevattor trim and tail light cables (13/16" hole).

Layout the 7F11-A doubler drilling matching holes.
2015-09-15 Add floor & seat front to left & right cabin sides (7F9-1L & R) Clecoed the floor sections and bottom channel together and positioned in place against the cabin sides. The cutouts in the cabin sides needed to be trimmed to fit the height of the bottom channel to allow a flush fit of the gear strut fittings (7F17-1SP)
2015-09-16 Check alignment of cain floor/bottom channel to cabin sides Verify the proper width of the cabin between the cabin sides at the bottom channel. The distance outside to outside at the aft end of the bottom channel is 1044mm and 825mm at the fwd end. Pieces of scrap board were cut as gauges to verify these distances.
2015-09-17 Install cabin floor stiffeners (7F8-1, -2, & -3) and control tube bearing blocks Drill and cleco (silver) in place the longitudinal cabin center floor stiffener (7F8-1).

Drill and cleco (silver) in place the longitudinal cabin center floor stiffener (7F8-1). Cut the front (7F8-2) and rear (7F8-3) horizontal floor stiffeners from the V-shaped angle stock. Position across the cabin floor, drill and cleco (silver) in place.

Fabricate the control torque tube bearing plate blocks (2 pieces) from 0.25" stock. A 1.125" hole is drilled into the top section and shaped to allow the tube collar to abut the bearing plate top (7F11-. The two pieces are positioned on the seat front (7F11-1 installed earlier) such that the plates center on the 1.25: torque tube hole in the sea front. This larger hole allows the torque tube to slide into position and the split bearing blocks will help lock the tube in place.

2015-09-18 Fabricate Seat Belt Attach Fixtures (7F16-2 & -3) Frill out the lateral (7F16-2) and central (7F16-3) seat belt attachment fixtures and install the lateral fixtures to the cabin frame sides (A5 rivets).

The central fixtures (with doublers, 7F16-3A) will mount on the tunnel stretching between the seat front and the and seat back covering the control torque tubes.
2015-09-19 Fabricate & Install Seat/Controls Tunnel (7F11--4) Trim the channel blank to accommodate the bottom channel ((7F10-1) and rivet in the Central Seat Belt Attachments (7F16-3) and doublers (7F16-3A) to the tunnel with five A4 rivets.

Use L-angle sections to install the tunnel between the seat from and seat rear sections.
2015-09-20 Install Top Longeron Gussets (7F3-3SP) & Top Channel (7F5-3SP) Slide each of the top longeron gussets (7F3-3S) into position under the top skin and longerons at the forward ends of the rear fuselage top & side skins. Align the horizontal axis with the pre-drilled pilot holes in the top skins.

Clamp in place and drill for initial (silver) clecos. All of these will eventually be replaced with A5 rivets.

Place the top channel (7F5-3SP) into position along the forward edge of the top skin. Mark the length to the corners of the top skin (under the gussets) and against the vertical uprights. remove and cut these ends at 45 deg. angle. Replace and trim to get a good fit and square corners. Clamp in place and drill through the tops skin into the channel and cleco in place.

The top channel will be further secured when installing the rear wing spar brackets ((7F5-1SP)
2015-09-22 Mate front & rear fuselage sections With the rear fuselage section flat on the worktable, the two long L-angles (7F9-8) extending aft of the front fuselage sides are marked with a center-line along the outside length. The 7F9-8 arms then slide into the gap between the side upright doublers (7F116) and the side channels (7F5-2SP). The trial fit shows be that these L-angles arms need to be trimmed in order to fit into the corner of the upright side channels (7F5-4) and the L-angle bottom of the baggage area floor.

After trimming (~ 30mm), the arms are re-inserted with the ends of the cabin frame sides flush against the side channels (7F5-2SP). Note that the center-lines are visible through the pre-drilled holes in the rear fuselage side skins.

The bottom corner of the side channels (7F5-2SP) are trimmed to allow installation of the gussets (7F13-1).
2015-09-23 Install Seat Back Channel (7F6-5) and Seat Back (7F6-4) Prior to installing scribe a vertical center-line down both sides of the Seat Back panel(7F6-4)and the Seat Back Channel (7F6-5). Also scribe a vertical line 265mm on either side of the center-line and drill #40 pilot holes down each for the L-angle flaperon Control Mount (7C3-2) supports to be installed later.

Remove the clecos aft section of the gussets (7F113-1)and position the Seat Back Channel (7F6-5)into position horizontally over the aft portion of the gussets. Back-drill from inside the access port up through the gussets and cleco the channel in place. This channel will add stability and support to the lower portion of the seat back panel (7F6-4)

Remove the clecos from the Upright Doublers (7F11-6) and slide the Seat Back into position with the top edge flush with the L-angle supporting the baggage compartment floor and square with the Upright Doublers on either side; then back-drill through the doublers and cleco the Seat Back in place.

Layout the rivet lines (pitch 40) along the front edge of the l-angle of the Baggage Compartment floor and along the center-line of the Seat back Channel (7F6-5). Drill and cleco the Seat back in place.
2015-09-24 Install Shoulder Harness Attachment Brackets (7F5-5) Radius the shoulder harness attachment brackets (7F5-5 - port & starboard) and drill the 3/16" hole for the AN3 bolts that will attach the harness to the bracket.

Position the bracket on the side skin just aft of the 7F3-3SP gusset align with the pre-drilled holes in the side skin and cleco in place. Drill out for a total of 7 A5 rivets per the pattern (7F5-5).

Remove, deburr, apply corrosion protection (Cortec) and finally rivet in place.
2015-09-26 Flaperon Control Bearing (7F6-3) installation Fabricate the Flaperon Control Bearings (7F6-3) by drilling the 0.75" holes (for the Flaperon Control Mount) and #40 pilot holes.

Layout, cut to length, and scribe a center rivet line on the two L-angle flaperon control assembly supports. From inside the access port, position and drill (from outside) the L_angles in place following the scribed center-line visible through the pilot holes in the seat back. Note that these vertical L-angles abut the L-angle baggage compartment floor supports.

Position the control bearings (7F6-3) in the corners of the vertical, horizontal, and baggage floor L-angles on the inside surface. Using the rt. angle attachment, back-drill through the flaperon bearings and cleco them in place.

NOTE: After drilling out to A4 size, dis-assembly, deburring, and corrosion protecting the structures, Rivet only ONE control bearing in place as the control assembly will need to be positioned several times prior to final assembly.

2015-09-27 Flaperon Bellcrank Assembly (7C1) Layout and drill the pilot holes (#40) in the Flaperon Bellcrank arms (7C1-4) and Spacer (7C1-5). 6 attachment holes will get AN470-AD-5-12 soft rivets. The ends will be drilled out to 5/16 for AN5 bolts securing the rod-end bearings of the Flaperon Controls Rods (7C1-6).

The center hole is 0.75" and mounts each of the bellcranks to the Flaperon Control Assy (7C3-1).
2015-09-28 ELT Installation Fabricate a mount for the King AK-450 ELT for installation under the passenger seat. The mount is made from L-angle stock using a 0.25" bolt in a cross-bar configuration. The bolt is accessible from either the access port or via the lightening hole in the seat front to allow removal of the ELT to replace the 4 D-cell batteries. The unit is equipped with a remote control panel which will be mounted on the Instrument Panel and connects via a standard 4-wire flat telephone cable (straight thru connections).

The ELT antenna will be mounted later on the underside of the fuselage between the gear leg channel and the access port.
2015-09-29 Horizontal Tail Bellcrank Assembly (7C1) In the bellcrank arm (7C1-1) locate and drill a pilot hole (#40) for the pivot location. Locate and drill the bottom front 0.25" hole in the arm and 3/16" holes in the other locations at the ends of the arm.

In the aluminum spacer block (7C1-2) locate the center of the block and drill a #40 pilot hole, then cleco (silver) the block to the bellcrank arm and center the block longitudinally. With the spacer positioned clamp the assembly firmly in place and drill the 2 #20 holes on either side for the solid rivets that will attach the spacer to the arm. Cleco (black) through these; remove the center (silver) cleco and drill this pivot hole out to 5/16" for an AN5 bolt.
2015-09-30 Install Flaperon Control Mount (7C3-1) Insert the horizontal ends of the flaperon control mount (7C3-1) into the bearing blocks. Once in position the clecoed bearing can be riveted (A4) in place. Cotter pins are installed to keep the assembly in position on the bearing blocks.

Now the flaperon bellcranks can be mounted on the longitudinal arms of the control mount. Note that cotter pins are installed on either side of the bellcranks to keep them in position.
2015-10-01 Install seat support brackets Starting with the passenger side, insert the seat (7F16-1) into position and trace the contour lines on the cabin sides and the controls tunnel. Remove the seat and prepare L-angle supports to math the contours (same method as with the nose rib doublers to create the contours). Drill in place and cleco (silver).

Test fit the seat for support and contour. Drill & cleco (silver) the seat-to-support mounting holes. Verify configuration and fit, then drill the seat out to A4 rivet (#30) size. Remove the seat (7F16-1) then drill & cleco to A4 rivet (#30) size.

Repeat for pilot seat.

Do NOT install the seats as there are many fixtures/controls to install/rig under the seats.
2015-10-02 Fabricate & install the the control tunnel to seat back support On a piece of 0.025" sheet stock, trace the contour of the re controls tunnel (7F11-4). Duplicate the contour approx. 25mm above and below the traced line and cut out the shape. Drill #30 holes along the center contour line approx. every 20mm and from the top of the piece notch (wedge) to the holes to allow the bottom portion to be bent around the curve and perpendicular to the vertical.

Cut a matching doubler of the upper two contour lines. This be placed on the aft side of the seat back to provide additional support.

Matching the curvature of the controls tunnel, drill and cleco (silver) the "upper "tabs" of the support piece into the seat back and doubler; then drill and cleco (silver) mounting holes into the support & controls tunnel pitch 30.
2015-10-03 Test fit and trim passenger side seat (7F16-1) Rough trim the passenger side seat (7F16-1) to clear the controls tunnel (7F11-4) between the seats and the cabin frame sides L-angles. The process is repeated several time trimming small sections until a nice fit is obtained.

With the seat bottom clamped in place 7F16-1 is drilled and clecoed (silver) through the fed edge into the seat front lip; the seat back. The curve of the seat bottom is traced onto the cabin frame sides and the tunnel and the seat bottom skin is removed.

L-angle stock is cut to fit the cabin frame sides between the frame L-angle upright supports (3 locations). Another length of L-angle stock is cut and crimped top fit the curve traced on the controls tunnel.

The L-angle support sections are held in place (2 person job) and secured with silver clecos (lip upwards).

The sear bottom is re-fit into position and clecoed in place via the previously drilled front seat support and seat back. The seat bottom is the secured by drilling (pitch 40, #40) and clecoing (silver).

The seat bottom will NOT be installed until much later as thee are numerous control structures that will mount under the seats.

2015-10-04 Pilot side seat bottom Installation Repeat the installation process done yesterday for the passenger side seat bottom install.
2015-10-09 Fabricate Flaps Linear Actuator mount & arm extension Used twp pieces of 3/16" L-Angle (6061T6) 2" x 3" to fabricate the mounting brackets for the Firgelli linear actuator being used to extend/retract the flaps. The brackets will be used to mount the actuator under the pilot seat.

A piece of 0.065" wall 0.57" id 6061T6 tube was used as an extension of the actuator arm.
2015-10-10 Assemble Matco wheel rims & mount tires Assemble the split rims for all three Matco wheel rim assemblies. Used O-ring grease/sealant on the large ring that fills the gap between the two sections of each rim.
2015-10-11 Trim main gear spring for matcco brakes clearance The wheel/brake mounting pad of main gear leaf spring (7L2-1J) must be trimmed to allow the Matco brake assembly to clear the mounting pad. The pad must also be notched to clear one of the brake pad/caliper attachment bolts.

Much filing and fitting was required to complete this task before the wheel/brake assemblies could be mounted with 4AN3 bolts in each.
2015-10-12 Mount Nose gear on fork and leg Use the nose gear leg (7L1-1J) to locate the four 3/16" holes for the AN3 bolts that attache the leg to the nose wheel fork (7L2-3J). Drill and mount the leg to the fork.

Position one axle spacer (7L1-4J) on the axle (7L1-3J) and drill a #30 hole through the aluminum spacer and into the axle to a depth of approx. 3/16" about 1" from the end. This is used to help "lock" the axle when tightening/loosening the AN5H-5A bolts at the threaded ends of the axle when assembling/removing the nose wheel.

Slide the axle (7F1-3J) through the nose wheel rim hub. Add a spacer (7L1-4J) on either side. Slide the wheel, axle, spacer assembly into the fork and fix with an AN5H-5A bolt on either end.

Drill a #30 hole in the lower corner of each aft bottom end of the fork to affix the safety wires from the drilled heads of the AN5 bolts.
2015-10-13 Initial sketch of possible panel layout Used Front Panel Designer Software to develop an initial pass at the instrument panel design. The software pkg has built-in patterns for the 701's instrument panel blank and a library of stensils for most of the instruments/components/controls/etc. required. It's functions are fairly intuitive and provided a 1st pass design for the panel.

This design and a list of desires/requirements/on-hand components was sent to SteinAir for comments/suggestions from Mike Gleason (an aircraft electronics technician and 701 builder). It is noted that the 701 panel area is relatively small causing clutter in many panel designs. Mike has much experience in working around this restriction.

Much correspondence, suggestions, and comments on design and components were to follow.
2015-10-14 Leveling fuselage/cabin frame for assembly Insert the two longitudinal cabin frame tubes (7F12-1) and diagonal tube (7F12-2) into the cabin frame (7F18-1SP). With the firewall (7F1-1) clamped into position to help establish the geometry, position the the cabin frame assembly onto the fuselage by sliding the ends of the tubes int position at the attach flanges (7F12-4) on the top sides of the fuselage and the forward uprights using spring clamps to temporarily fix the assembly in place.

Now establish a level fuselage fore-aft/port-starboard by stretching a string from the aft wing mount tab (over the top of the tab) to the tail. Note that there is a curve to the upper fuselage longerons and the string-line will fall below the top of the fuselage sides. Raise the tail until the fuselage is level. verify also that the fuselage is also level port-to-starboard.

2015-10-15 Install Cabin Frame Carry-Thru Strut for Folding Wing Drill out the sliding-tube ends of the carry-thru strut for the AN4 bolts that attach the strut to the support brackets mounted under the wings.

Clamp the carry-thru strut in place on the cabin frame assembly (assure proper alignment with the horizontal center-line and that at there is at least 3/8" clearance between the ends of the carry-thru strut and the cabin frame assembly.

Drill AN3 mounting holes through the carry-thru mounting tabs and the tubes of the cabin frame and bolt in place. Now drill a 3/16" mounting hole through the center tab of the carry-thru strut into the cabin frame and attach with an AN3 bolt.
2015-10-16 Positioning cabin frame assembly Using the wing wood pickup templates to position the wing attach tabs at the required distances and angle (both sides), clamp the ends of the 3 cabin frame tubes into position and mark the points where the inter tubes meet the sleeves of the cabin frame. This establishes the proper positioning of the cabin frame to the fuselage.

The cabin frame is then removed, tubes cut to proper lengths, and the assembly re-positioned (squared and leveled) assuring wing mount distances. The ends of the tubes are now drilled and clecoed into position at the fittings on the top of the rear fuselage and at the cabin frame sides.

2015-10-18 Cut, fit, & cleco upper cabin frame tubes on fuselage After fixing the position of the cabin frame assembly with the firewall and wing spar jigs. Drill & cleco the tubes into position using A5 (black) clecos. Install the upper tube gussets (7F12-4) to the 7F12-1 upper frame tubes and the rear wing attachment plate (7F5-1) installed on the rear fuselage frame with A5 (black) clecos.
2015-10-19 Fabricate & Install Rudder Pedals Assembly Mounts (7C4-2 & -3) Drill the 0.75" holes in the Outboard Pedal Bearings (7C4-3) and trim the excess material at the top of each into a 16mm radius.

The bottom half of the split green Nylon66 Pedal Center Bearing (7C4-2) is positioned along the longitudinal center-line of the cabin floor with the center 3/16" hole positioned 70mm forward of the front floor stiffener (7F8-2). The 3 AN3 bolt holes are drilled and the the lower half of the bearing is set in place to help verify the positioning of the Outboard Pedal Bearings.

The Outboards bearings (7C4-3) are positioned such that when in position on the tubes of the lower tubes of the pedal assembly, the mounting tabs of the bearing blocks fall over the L-angle longeron (7F10-3) underneath the fuselage cabin floor. Two 3/16" holes (for AN3 bolts) are drilled thru the tabs, floor, and longerons. The bearings are NOT bolted in place at this time.
2015-10-20 Install Rudder Pedals Assembly (7C4-1J) Drill the 3/16" holes in the tabs of the rudder pedals assy for later cables attachment.

Drill the 3/16" holes in the "ears" of the toe-brake mounts and install the MC-5 Matco Master Brake Cylinders.

Install the ruder pedals assy in place through the outer bearing blocks (7C4-3) and into the split Nylon66 center bearing and bolt in place with AN3 nuts and bolts.
2015-10-21 Trim firewall upper channel (7F7-1SP) to fit engine mount The engine mount for the Viking requires that the upper channel (7F7-1SP) of the firewall assembly be trimmed to provide clearance for the mount to properly seat (on the underside) and clear (on the lip) the channel.

Several discussions with Zenith (Roger), Viking (Jan), and other 701/Viking builders assured that the required trimming would not sufficiently weaken the structure enough to cause concern.
2015-10-22 Attach cabin frame to engine mount thru firewall Along the vertical center-line of the firewall (both fore and aft), scribe a line parallel to the floor 570mm from the floor. Also mark a horizontal center-line on the firewall mounting tab of the cabin frame and a similar line on the cnter mounting tab of the engine mount.

With the engine mount clamped in place on the firewall, align the horizontal center-lines in the vertical channel and the engine mount tab (the 570mm line). 10mm from the ends of the engine mount tab drill pilot holes through the tab and the firewall for the AN3 bolts to follow.

Using deep throat clamps, position the cabin frame such that the frame's firewall mounting tab is in position against the firewall and along the (570mm) center-line and back-drill the pilot holes. Now cleco one end and with the clamps securing the location, drill-out to 3/16" and secure in place with AN3 hardware.
2015-10-23 Control Torque Tube (7C2-2), Horn (7C2-3), & Horiz. Tail Bellcrank (7C1-2) Remove the black clecos from the top half of the torque tube bearing (7F11-2) at the seat front and slide the torque tube (7C2-1) into position from the access port. Slide the rear end of the torque tube through the rear torque tube bearing (7F6-2) mounted on the bottom channel (7F6-1) just forward of the access port. Re-cleco (black) the upper front bearing back in place on the seat front to secure the torque tube in place.

Slide the control horn (7C2-3) into position on the aft end of the torque tube. Assure that there is sufficient clearance between the forward surface of the horn arms and the aft surface of the bottom channel (7F6-1) to allow the head of an AN5 bolt which attach the flaperon push rods to the rod-end bearings free clearance. Verify that the top of the control horn is even & parallel with the top of the bottom channel and mark the location of the AN3 bolt that will attach the horn to the torque tube

Attach the Horizontal Tail Bellcrank (7C1-2) to the torque tube with an AN3 bolt and nut.
2015-10-24 Install Nose-gear Steering Rods (7L1-2J) Trial fit the steering rods (7L1-2J) on the AN5 bolts welded to the rudder pedals. With the pedals aligned (centered) and the nose-gear centered, measure the proper lengths of each rod. Note that the passenger side rod is shorted than the pilot side due to the offset of the pedals assembly.

Cut the rods to length for and add a lock-nut and rod-end bearing to each rod and install with two AN5 washers UNDER each rod end bearing at the nose-gear bolts and a single washer on the top under the nut.

Check alignment and tighten the nuts including the jam nuts on the threaded rods to lock the rod-en bearings in position.
2015-10-25 Research/Redesign Viking Header Tank Removed the BAM Mfg. 5 gal. tank and mounting structure (50 lbs tot.) as a negative impact on CG.

New tank is 3.25 gal, ~23 lbs.; of 0.125" thick, 5" x5" x 30" 6061T6 tube (McMaster-Carr, $65). Design will allow easy mounting along the forward baggage compartment floor channels (horizontally) and vertically tied to the fuselage vertical L-angle frames. This placement is easily accessible through the access port in the floor of the aft fuselage and makes easy connections to the fuel pumps (mounted on the passenger-side seat back) and the fuel & vent lines from the wing tanks.

End plates and fitting bosses welded by Lee Zundel (Z-Fab, Princeton, TX). Beautifully done in 3 hours.

2015-10-26 Trial linstall of new header tank Test fit of new square header tank. Will drill 2 AN3 mounting bolt holes in each of the L-angle mounts on the top of the to attach through the L-angle baggage floor support brace. Also will drill an AN3 mounting bolt hole to attach the bottom-end mounting tabs of the tank to the vertical fuselage L-angle structures.

The tank has 3.8" FNPT bosses to accept 1/4" if barbed fittings for both fuel inflow and vent lines from each wing tank. dual 5/16" id barbed fittings for fuel outflow to the pumps assembly. It also has a 5/16" id barbed hose fitting for the un-used fuel return line from the pumps assembly and a 1/8" FNPT fitting for the Belite fuel probe.

Will probably mount the Belite Fuel Probe controller on the aft side of the pilot seat-back.
2015-10-27 Header tank leak test Added fittings to the new header tank in preparation for the leak test. Added short lengths of 5/16" fuel injection hose and clamped shut. Used the 1/8" fnpt boss (for the Belite Fuel Probe) to inject 50+ psi of compressed air into the tank while holding it under water in the bathtub. Inspected all fitting bosses and seam welds and found NO BUBBLES. Test successful.
2015-10-28 Belite Fuel Probe Controller Mount on New Header Tank Rivet a flange (0.025" 6061T6) to the pilot side vertical mounting tab (backed with a piece of 1/8" A/C ply) on which the Belite Fuel Probe Controller is mounted with two AN3 bolts. The probe leads are within the 10" maximum distance from the controller.
2015-10-29 Updated Panel Design Received from SteinAir Mike Gleason of SteinAir returned an updated panel design for the 701 incorporating all of my desires/requirements/components. He provided good information replacement of the Panel Bottom Channel (7F15-1) with a full panel bottom span length of 1/8" 6061T6 L-angle (1.5" x 1.5"). This provides 1.5" wide strip below the panel which can be used for additional mounting space for dual throttles and the switches for the Nav/Pos lights controller.

Mike also designed the panel with a removable center section which allows easier access for building & maintenance. Excellent feature.

After review of the design several relatively minor changes were made/requested and sent back to Mike for comment/incorporation:

(1) Replace the dual fuel gauges with a single Belite gauge.
(2) Relocate the two rows of breakers parallel to the bottom edge of the starboard side of the panel and add space for two additional (10 total)
(3) Relocate the flaps position indicator LED to a vertical string of 3 LED indicators
(4) Move the starter switch slightly to port and relocate the slip-ball there as well
2015-10-30 Design & Breadboard Flaps Linear Actuator Control Circuit Researched the circuit required to control the flaps linear actuator (Firgelli Automation, 150 Lbs torque, 4" stroke, 5A). Reversing the polarity of the actuator motor allows the extention/retraction of the arm which moves the flaperon control assembly activating the flaps.

Replacing the manual flaps actuator with the linear actuator and installing the "No-Fuselage-Slot Flaps" modification allows a full range of flap settings from 0-30 degrees. Thus the circuit needs micro switches to limit the range of travel of the actuator arm and switch the polarity of the current to the motor. The easiest way to do this is to use a DPDT (momentary-off-momentary ... extend-off-retract) rocker switch on the panel to activate the circuit and separate dual micro limit switches energized/de-energized by the movement of the arm. Dual switches (positive & negative) to easily reverse the polarity of the current to the motor.

a 5th micro switch is included on the retracted end of the arm to activate an LED indicator on the panel when the flaps are in ANY position other than fully retracted.
2015-11-01 Finalized Panel Design from SteinAir Received, reviewed and finalized the panel design from Mike at SteinAir. Really looks good. Shipped off the blank, powder-coated panel to him for CNC fabrication.
2015-11-02 Mount Fuel Pumps Assy aft of passenger seat Mounted the fuel pumps assembly on the aft side of the passenger seat back. Considering a new header tank to be place closer to the CG area.
2015-11-03 Fabricate & install doubler Z-channel (7F8-10B) for new tank support Cut and bent strip of 80mm x 804mm 0.025mm 6061T6 into Z-channel profile (90 degree & 102 degree legs) to match 7F8-10B fwd baggage area cross-member. Adding this doubler to support the new header tank. It is riveted (A4, pitch 40) to match the fwd baggage floor support. The tank is then dolted to the structure using 6 AN6-5A bolts along the length of the Z-channel and is tied to each horizontal upright with an AN6-5A bolt.
2015-11-04 Install Rudder Cable Fairleads in Seat Front Cut 2 45mm x 35mm pieces of 1/8" white nylon sheet for the rudder cable fairleads. IN the center of each drill a 1/8" hole for the cable to pass through and install in the center of each pre-drilled 0.75" hole in either end of the seat front (7F11-1). Secure with 4 A4 rivets.
2015-11-05 Pilot - Front Side Skin Preparation (7F14-3) Layout, cut, and bend passenger side front side skin (7F14-3). Used Jon Croke's technique for the hard right angle bend at the cabin frame end to the gentle curve at the firewall end. Used a piece of 1.5" dia. aluminum tube section rather than the shovel handle.
2015-11-06 Passenger side front side skin preparation After trial fit of pilot side "cheek" skin, repeat yesterday's procedure for passenger side.
2015-11-06 Flaps Linear Actuator Limit Switches Install From std L-angle fabricate a 102 degree bracket to secure one end of a 0.25" threaded rod to the fwd end of the actuator arm position. The rod will allow the
2015-11-07 Set Passenger Side Cheek (7F14-3) in position Slide the side skin under fwd fuselage floor at the cabin side skin and along the cabin fame upright tubes. Layout a line of rivet holes along the joint maintaining the 10mmm edge margin and along the center-line of the cabin frame upright tube. Clamp the front of the cheek in place against the rim of the firewall. Drill and cleco in place (silver).

Assure that the right angle joint of the cheek skin is flat against fwd fuselage floor and with the cabin frame side skin.
2015-11-08 Front Side Skin interior bracings (Z- and L- angles) There are 4 bracing structures radiating from the cabin frame side and floor running along the inside surface of the front side skin to the firewall.

1st is Z-angle running along the fwd fuselage floor. It is positioned with the "top" (small curved lip) facing outward. The long flat lip slides under the horizontal stiffeners of the fwd fuselage floor and is drilled pitch 40 and clecoed (silver, later A4).

Next the long L-angle at the top (7F9-7) that is part of the fwd fuselage cabin assembly is drilled and clecoed in place (silver, later A4) at pitch 40 ONLY for 8 positions. The remaining length to the firewall (and beyond into the engine area) will have thick aluminum plate doubler inserted later.

2015-11-09 Front Side Skin - Z and L- angle braces install A 2nd Z-angle is inserted with the small curved lip pointing downwards and the long flat lip against the side skin running from the 4th rivet position up from the cabin frame floor to the firewall lip approx. 30mm below the lower line of rivets attaching the upper channel (7F7-1SP) to the firewall. The location needs to be in a flat area of the firewall crimps. The Z-angle is drilled and clecoed silver, later A4) at pitch 60

Finally a length of std L-angle is cut and fit to run from the 3rd rivet position up from the fwd fuselage floor at the cabin frame assembly to a position on the firewall lip 200mm along the skin curve up from the lower fuselage longeron. The L-angle is positioned with the lip facing upwards as the angle will be crimped ~ every 60mm to fit the curvature of the side skin. It is clecoed in place (silver,, later A4) between the crimps (~ pitch 60).
2015-11-10 Plate Doubler (7F14-6R) installation Scribe a line down one end of the square 0.040" thick aluminum doubler and another perpendicular line from the center to the short edge. The doubler is now slipped into position against the firewall and the front skin angled such that the short ends extends 50mm fwd of the firewall face and is aligned with the extended lip of the firewall top channel stiffener (7F7-7SP).

The doubler can now be drilled and cleoed (initially silver, but final riveting will for A5). Maintaining the 10mm edge margins, 5 rivets in the 7F9-7 long cabin frame assembly long L-angle arm (to the firewall lip) and 3 in the lower Z-angle (to the firewall lip).

An upper longitudinal L-angle will be added later at the top of the structure to provide a means of fastening the front top skin (7F14-4) over the firewall & instrument panel.
2015-11-11 Install Steel Angle Brackets securing firewall to side skins Clamp the 7F14-5R 4130 steel engine mount support bracket in place with the long leg (40mm) against the firewall aft face and the 25mm leg against the fuselage side skin. The positioning is such that the bracket lies flat (between crimps in the firewall lip). The top of the bracket approximately even with the line of rivets securing the firewall upper channel (7F7-1SP) to the firewall. This positioning is verified by placing the engine mount in place on the firewall to assure that the mounting bolts will be centered in the long leg of the bracket.

Once clamped into position, the bracket is secured with two AN3 bolts. One centered, ~10-15mm from the top of the short leg through the side skin, the plate doubler, and the firewall lip. The 2nd is positioned ~10-15mm from the bottom of the long leg and ~10-15mm from the inboard edge of the bracket.

Later, the engine mount will be positioned on the firewall and the AN6 mounting bolt holes will be drilled through the mount sleeves into the firewall and brackets.
2015-11-12 Pilot Side front skin (Cheek, 7F14-3) installation Repeat the installation steps for the pilot si=de "cheek" installation (7F14-3)

Slide the side skin under fwd fuselage floor at the cabin side skin and along the cabin fame upright tubes. Layout a line of rivet holes along the joint maintaining the 10mmm edge margin and along the center-line of the cabin frame upright tube. Clamp the front of the cheek in place against the rim of the firewall. Drill and cleco in place (silver).

Assure that the right angle joint of the cheek skin is flat against fwd fuselage floor and with the cabin frame side skin.
2015-11-13 Pilot forward side skin (Cheek) internal bracing Repeat passenger side installation steps for pilot side:

There are 4 bracing structures radiating from the cabin frame side and floor running along the inside surface of the front side skin to the firewall.

1st is Z-angle running along the fwd fuselage floor. It is positioned with the "top" (small curved lip) facing outward. The long flat lip slides under the horizontal stiffeners of the fwd fuselage floor and is drilled pitch 40 and clecoed (silver, later A4).

Next the long L-angle at the top (7F9-7) that is part of the fwd fuselage cabin assembly is drilled and clecoed in place (silver, later A4) at pitch 40 ONLY for 8 positions. The remaining length to the firewall (and beyond into the engine area) will have thick aluminum plate doubler inserted later.

A 2nd Z-angle is inserted with the small curved lip pointing downwards and the long flat lip against the side skin running from the 4th rivet position up from the cabin frame floor to the firewall lip approx. 30mm below the lower line of rivets attaching the upper channel (7F7-1SP) to the firewall. The location needs to be in a flat area of the firewall crimps. The Z-angle is drilled and clecoed silver, later A4) at pitch 60

Finally a length of std L-angle is cut and fit to run from the 3rd rivet position up from the fwd fuselage floor at the cabin frame assembly to a position on the firewall lip 200mm along the skin curve up from the lower fuselage longeron. The L-angle is positioned with the lip facing upwards as the angle will be crimped ~ every 60mm to fit the curvature of the side skin. It is clecoed in place (silver,, later A4) between the crimps (~ pitch 60).

2015-11-14 Pilot Side Cheek to firewall plate doubler installation Repeat passenger side plate installation steps for the pilot side:

Scribe a line down one end of the square 0.040" thick aluminum doubler and another perpendicular line from the center to the short edge. The doubler is now slipped into position against the firewall and the front skin angled such that the short ends extends 50mm fwd of the firewall face and is aligned with the extended lip of the firewall top channel stiffener (7F7-7SP).

The doubler can now be drilled and cleoed (initially silver, but final riveting will for A5). Maintaining the 10mm edge margins, 5 rivets in the 7F9-7 long cabin frame assembly long L-angle arm (to the firewall lip) and 3 in the lower Z-angle (to the firewall lip).

An upper longitudinal L-angle will be added later at the top of the structure to provide a means of fastening the front top skin (7F14-4) over the firewall & instrument panel.
2015-11-15 Fabricate & install Firewall Brackets (7E1-Lower & 7F15-5R, upper) The brackets are of 0.125" 4130 steel. The upper brackets (7F15-5R) are positioned against the front side skins (7F14-3) and aluminum plate doubler (7F14-6R) and the interior surface of the firewall. The vertical location against the firewall is positioned such that the engine mount pad is roughly centered in on the wide surface of the bracket and the short surface lies flat against the rim of the firewall and the fuselage sides (avoiding the "crimps" in the firewall edge.

The lower brackets are specific to the engine/mount configuration but generally conform to the 7E1-Lower diagram. For the Viking engine, the underside leg of the bracket is trimmed to an angle that allows the leg to rest against the 7F10-3 lower front longeron (laterally) at the firewall cabin floor junction (approx. 30 degrees). Fitting the lower bracket into position reveals a 0.125" gap between the trimmed bracket leg and the lower front longeron. An aluminum spacer is cut to fit and inserted into this gap.

The brackets are installed to the cabin/firewall using AN3 bolts. Once installed the engine mount can be positioned, clamped in place and AN6 mounting bolt holes precisely drilled through the brackets & firewall using the tubular sleeves welded into the mount assembly.
2015-11-16 Install pilot side upper engine mount bracket (7F14-5R) Clamp the 7F14-5R 4130 steel engine mount support bracket in place with the long leg (40mm) against the firewall aft face and the 25mm leg against the fuselage side skin. The positioning is such that the bracket lies flat (between crimps in the firewall lip). The top of the bracket approximately even with the line of rivets securing the firewall upper channel (7F7-1SP) to the firewall. This positioning is verified by placing the engine mount in place on the firewall to assure that the mounting bolts will be centered in the long leg of the bracket.

Once clamped into position, the bracket is secured with two AN3 bolts. One centered, ~10-15mm from the top of the short leg through the side skin, the plate doubler, and the firewall lip. The 2nd is positioned ~10-15mm from the bottom of the long leg and ~10-15mm from the inboard edge of the bracket.

Later, the engine mount will be positioned on the firewall and the AN6 mounting bolt holes will be drilled through the mount sleeves into the firewall and brackets.
2015-11-17 Drill out all fwd fuselage parts for appropriate size rivets Remove each silver cleco, drill out for the proper size rivet, and re-cleco.

All rivets in the fwd fuselage section are A4 (copper) EXCEPT:

All rivets into the firewall lip are sized A5 (black cleco).

The 5 rivets in the duobler plate along the 7F9-7 L-angle are A5.

The 3 rivets in the lower portion of the doubler along the z-angle are sized A5.

The 5 rivets attaching the cabin assembly side skin to the 7F18-1SP cabin frame tubes are A5.

2015-11-18 Disassemble, deburr, and corrosion protect the fwd fuselage Disassemble the entire fwd fuselage assembly; debur all the rivet holes; and apply Cortec corrosion protection
2015-11-19 Reassemble (cleco) the fwd fuselage assembly for riveting Cleco the cabin frame, side skins, and cabin tube frame assemblies prior to final riveting.

The fwd structures are not as yet complete. The front top skin (7F14-4), top cover plate (7F14-2) and instrument panels assemblies will be added later.
2015-11-20 Rivet the Fwd Fuselage Assembly Final rivet the entire forward fuselage assembly including the cabin frame and cabin sides. AN3 bolts & nuts to attach the engine mount brackets to the firewall & forward fuselage assembly (floor & cheeks).

2015-11-21 Trim firewall nosegear steering rods pass thru With the nose-wheel steering rods in place from the rudder pedals to the AN5 bolts welded to the nose-gear strut it was determined that the rods were binding against the firewall at the pass thru. The pass thru slots were filed down closer to the walls of the firewall vertical lower channel to alleviate this binding and give a free range of motion.
2015-11-22 Panel Warning Lights Wiring Diagram Created the wiring diagram for the 3 LED indicator lamps on the panel.

Top: RED Alternator Warning - activated via NEGATIVE signal from the Alternator Sensor Circuit on the Viking Engine. The warning light is wired so that it has 12V to one side when the ignition switch is on. The other end is connected to the alternator. The alternator provides the grounding and will illuminate the light any time it is not charging. The grounding is removed with the alternator running / providing a charge.

Middle: GREEN Flaps Indicator - activated from the micro switch in the flaps linear actuator circuit. Illuminates whenever the flaps are NOT in the Fully retracted position.

Bottom: AMBER Low FUEL LEVEL - activated from the Belite Fuel Probe and Fuel Gage - programmed at 25% fuel level remaining (~3.25 gal.).
2015-11-23 Fabricate & install the Flaperon Control Rods (7C1-6) Cut 2 lengths of 5/15" threaded rod to 365mm. Thread an AN316-5R jam nut on each end followed by a rod end bearing (CW-5-12). Make sure that the ends of the threaded rod are visible thru the 1/16" inspection hole in the rod end body.

Insert one end of each bearing into the arms of the flaperon Bellcrank (7C1-4) and secure with an AN5-10A bolt placing the head of the bolt on the fwd arm. On the aft end of the bolt use a 5/16" washer and nut.

Check that the head of the AN5 bolt (fwd surface) clears the bottom channel (7F6-1) to give a free range of motion (~5mm).
2015-11-25 Fabricate flaps linear actuator mount & shaft extension Fabricate the actuator piston pivot mount from 1/8" 6061T6 L-angle. Install 0.032" sheet mount doubler to floor under pilot seat. Measure & cut a length of 0.75" id 6061T6 tube extension for piston arm.

Drill 0.25" AN4 bolt hole in mount arms for piston body and 3/16" AN3 holes in the ends of the extension tube.
2015-11-26 Locate & design modified rudder cable pulley assemblies Run strings from the rudder pedal cable attachment tab through the set front (7F11-1), doubler (7F11-1A), and nylon failead (7F5-6); back to and through the nylon fairlead in the aft bottom channel (7F6-1). The taunt strings show the rudder cable paths througg the structure.

A small square is used to project the path of the cable across the top of the bottom channel (7F10-1, spring gear channel). This establishes the centerlines for mounting the pulley assemblies.

Using a 10mm clearance distance from the bottom channel. A modified pulley bracket (7C5-7) was designed to mount on the top of the bottom channel rather than aft of the channel. The position of the pulley was moved to allow easier access and range of motion of the flaps linear actuator. The pulley bracket height was shortened by 20mm.

2015-11-27 Fabricate and install the rudder cable pulleys Two shortened rudder cable pulley brackets (7C5-7) were constructed and corrosion protection applied.

The bracket assemblies were located in position on the top of the bottom channel (7F10-1) assuring that the center of the nylon pulley wheel was along the axis of the cable path traced from the taunt string routing.

The pulley assemblies were riveted in place to complete the installation.
2015-11-28 Add electrical wiring to fuel pmps assembly Fabricate wire harness assemblies for the dual fuel pumps.

(1) 6' 18AWG black runs for grounds - each pump will ground to a separate grounding post for redundancy

(2) 6' 18AWG white runs for dual master switches (+12VDC from separate 15AMP breakers)

(3) 6' 20AWG purple run from VDO pressure transducer to the ECU. VDO representative said that the transducer grounds via the mounting assembly and does not require a separate grounding wire run.

(3) Added a short 6/16" id fuel injection hose L-connector to the top pressure output line from the pump manifold. Will complete the run from this connector to the high pressure return fitting on the header tank later.
2015-11-29 Cable Tie Mount Adhesion Test Flat electrical cable tie mounts appear to be a good method of securing cable runs using tie-wraps. I had some concern about heat deteriorating the adhesive used on the tie mounts to test this a tie mount was applied to a scrap piece of 6061-T6. A tie wrap was installed and a heat gun at high-heat applied directly for 45 sec. The tie wrap was used to try and pull the mount from the surface. The adhesive held the assembly in place.
2015-12-01 Cable Tie Mount Test *** FAILURE *** Soaked the test piece in gasoline. Adhesive failed in less than 36 hours. However, the gasoline did clean the mount's surface very well. I can now use the suggestions of several builders from the Zenith.Aero site. I can attach the cleaned mounts to the fuselage & structures using Locktite RTV Silicone Adhesive or Gorilla Epoxy Adhesive Glue.
2015-12-02 Fabricate Gear Plates (7L2-2J) for mounting leaf spring Layout and trim the basic gear plate structure from 3/4" L-angle stock (1/8" thick). Locate and drill the 3/8' holes in either end for the gear strut mounting studs. Deburr and corrosion protect (flat black Rust-o-Leum to match exterior structures).
2015-12-03 Notch rubber spacers (7L2-2A) for studs clearance In the gear strut fittings (7F17-1SP) the main leaf spring (7L2-1J) is supported above and below with rubber spacers (7L2-2A). These must be notched to clear the mounting studs the same as the leaf spring.

As the rubber material does not drill easily (it tends to melt from the friction of the drill rather than bore) and since only semi-circular notches are required; the hard rubber pads are best notched to fit using a Dremmel tool with a 3/8" diameter ball or cylinder. I found that the best results were obtained using a ceramic ball.
2015-12-04 File notches in main leaf spring for mounting bracket cleaance Locate the center-line of the leaf spring (7L2-1J). Measure the distance between the mounting studs on the port and starboard gear brackets (7F17-1SP) attached to the fuselage sides. scribe lines for the location of the notches in the leaf required to clear the 3/8" studs.

Clamp the leaf spring to the end of the worktable and use a round file to form the 4 notches required. The depth need only be sufficient to allow clearance for the studs. This required many trial fittings.
2015-12-05 Mount Main Gear The main gear leaf spring (7L2-1J) is rather cumbersome to move around by one person. I used rather short wooden chairs & 2"x4" blocks to roughly position the spring under the bottom channel between the gear strut mounts.

On each side, slide one of the rubber pads into position along the studs and flush with the bottom of the mount against the fuselage bottom. The lift one end of the leaf into position with the studs between the notches, supporting with 2"x4" blocks. Repeat the process for the other side.

Slide the remaining rubber pads into position followed by the 7L2-2J gear plates and loosely secure with AN6 nuts.

Secure the gear leaf in place by cross-tightening the 4 stud bolts until a good fit is obtained.
2015-12-06 Attach fuel vent lines to header tank Installed 1/4" id polyurethane fuel line hoses to the Tee-vent fitting on the header tank. Secured with Oteiker clamps at the Tee and routed across the top of the tank to 90 deg. elbows attached to the tank with cable tie mounts secured with Permatex RTV Silicone Adhesive.

The vent lines will be completed later by adding upright lengths of fuel line hose through the flaperon push-rod bay then across to the aft wing root attachment point where the quick disconnect fitting will complete the vent line runs to the wing tanks.
2015-12-07 Elevator Trim switch & indicator wiring The 5-wire cable running from the Ray Allen T2-7A-TS trim servo mounted in the elevator is routed along the port interior fuselage side anchored via cable ties through the aft bottom channel and seat front to a position that will allow later connections to be made to the Ray Allen (RP3 LED Position Indicator) mounted in the upper left of the panel.

The rather large Ray Allen supplied RS2 Rocker Switch has been replaced by a Temco mini-DPDT, momentary-off-momentary switch (matching the one used for the flaps). It is mounted on the panel to the outboard of the keyed ignition switch.

The rocker switches have spade terminals for wiring and a harness has been made that will allow easy access to the connections on the indicator & servo.

2015-12-08 Flaps Control Switch installation A Temco mini-DPDT, momentary-off-momentary rocker switch (same as for the elevator trim) is installed in the panel just inboard of the keyed ignition switch. The switch has spade terminals for wiring.

The wiring is somewhat unique in that both negative and positive connections are made form the micro switch to the each pole of the linear actuator motor. This is because the direction of movement is controlled by reversing the polarity at the poles. The positive & negative flows are isolated by the limit switches such that the circuits are only energized in one direction at a time.

The circuit requires separate limit switches for positive and ground circuits (a separate limit switch for each at each "end" of the linear actuator arm's travel). One additional limit switch (+12V only) is included to energize the flaps indicator light on the panel only when the flaps are not fully retracted. Thus a bundle of 10 wires is routed. Eight are required at the panel switch. The center (common) connectors each get two feeds: one gets 2 positive inputs from the limit switches at each end of the arm's movement and the other the 2 grounds.

The +12 feed from the retracted micro switch goes directly to the indicator LED.
2015-12-09 Fabricate Panel Side Gussets (7F15-2) Layout, cut, and bend the two (port/stb) panel side gussets from 0.016" Stock. These will requires some trimming & fitting against the curvature of the panel ends. Make sure that there is a relief hole (~#30) at the right angle bends.

Fit the gussets in place on the panel; mark the curve of the panel end on the gusset; remove and trim to shape. The tab of the gusset will lie against the cabin frame tubing and will need further trimming at installation.

The upper tab will fit around the curve of the upper portion of the panel under the front top skin (7F14-4).
2015-12-10 Fabricate the Front Skin Top Cover Plate (7F14-2) The top skin extends over the curve of the fuselage from the firewall to the panel bulkhead and, when installed, is riveted to the firewall, panel, and forward fuselage sides. To do achieve this the skin must be trimmed to fit around the two Y-shaped, cabin frame members that help anchor the upper cabin frame structure (7F18) to the fuselage and firewall. A doubler, the top cover plate (7F14-2), proves an underlying anchoring structure and a convenient template pattern for transferring the required areas to be cut out of the top skin to allow for the cabin frame members.

7F14-2 is a plate of 0.025" stock. The area to be trimmed away is laid out per the plans and is carefully mounted & trimmed to fit the structure. It will also be used later to transfer the cutout pattern to the top skin structure.

In position, the plate will extend 50mm fwd of the firewall to match the leading edge of the top skin and will act as a duzus plate for attaching the cowling.
2015-12-11 Test fit pitch control rod & torque tube Cut channels in one end of the pitch control rod (7C1-3) and drill the 1/4" hole for the 3/16" bushing that attaches to the lower fwd end of the horizontal tail bellcrank (7C1-1).

Remove the fwd bearing blocks clecoed to the seat front and slide the torque tube (7C2-2) into position through the seat front and aft bottom channel & doubler at the access panel. Re-clecoing (A4) the front bearing plates bak in place to secure the torque tube in position with its collar against the bearing plates.

Slide a 5/16" washer onto 5/16" pin of the torque tube as a spacer; then slide the bellcrank into position with the bellcrank block (7C1-2) against the washer. Add a temporary clevis pin to secure the bellcrank in position.

Slide the pitch control rod (7C1-2) into position with the bellcrank leg fitted into the notch/1/4" hole drilled in the notched end of the rod; then insert the busing into the ends of the rod and bellcrank arm. secure with an AN3 bolt and nut.

Temporarily mount the yoke to the torque tube. St the Yoke perpendicular to the fuselage floor (neutral position) then set the bellcrank in position perpendicular to the fuselage floor (neutral position) using a spring clamp to hold the position.

Hold the fwn end of the pitch control rd in position against the pin welded to the lower end of the yoke and mark the center-line position of on the pitch control rod. This fixes the required length of the rod and it can no be removed and drilled 3/16" to match the pin on the yoke.

2015-12-12 Cut Pitch Control Rod and test fit before assembly/installation The torque tube, pitch control rod, & yoke assemblies are removed and the control rod trimmed to the proper fit for freedom of movement of the assembly.

The control rod (7C1-2) was drilled at the proper length to fit the pin on the yoke. To ensure that this hole is in alignment with the bellcrank mounting hole, a jig was constructed by drilling aligned 0.75" holes in two blocks of wood. The center-lines of these hole were project onto the control rod shat at the marked distance and the hole precicely drilled in alignmetn with the bellcrank arm.

It was also noted that the bottom of the yoke tube required trimming for a full range of motion.

Upon completion of the trimming & drilling, the parts were assembled on the workbench and checked for proper fit.
2015-12-13 Pull Radio/Intercom Wires thru Hartsell Dual Sticks The Hartsell Dual Sticks configuration modifies the std Y-yoke and is designed to be adjustable in height above the fuselage floor and horizontally to position the stick grip in a comfortable position for the pilots. The adjustments are made by removing an AN3 bolt in either the vertical of horizontal tube members of the yoke assembly; re-positioning to suit the used; and re bolting.

Each stick uses a Ray Allen single switch (Push-to-talk) button for actuating the microphone of the headsets for either radio transmission or intercom. Each grip requires two 24 AWG wires (short to ground connections) to run from the switch in the grip across the horizontal tube and down the vertical tube of the yoke. The wires exit at the bottom just above the floor and are routed into the tunnel between the seats and on to the FL760 radio/intercom and ground.

The wires were "snaked" through the tubes and positioned for later wiring into the radio/ground circuits for the headsets
2015-12-14 Fabricate FL760 Radio wire harness The FlightLine 760 Radio/Intercom has a male, J001, 15-pin connector for all wiring. The female J001 connector harness wiring was done using two 22 AWG cables. The grey cable contains 8 wires and the white cable 7.

The cable/wire color index is:

Grey/ Purple - Pin 1 -- Mic 1 input (Microphone Element)
Grey/Black - Pin 2 -- Mics/Input ground
Grey/Yellow - Pin 3 -- Mic 2 input (Microphone Element)
Grey/Blue - Pin 4 -- Aux input - UNUSED
Grey/White - Pin 5 -- Intercom Active Grnd to pin 2 to activate
Grey/Green - Pin 6 -- Squelch Out UNUSED
Grey/Red - Pin 7 -- PTT Activate Grnd to pin 2 to activate
Grey/Orange - Pin 8 -- LED Backlight On/Off/Dimmer. Optional
White/Purple - Pin 9 -- Input voltage + (positive 12)
White/White - Pin 10 -- Same as pin 9. Use both
White/Green - Pin 11 -- Input voltage - (negative ground)
White/Orange - Pin 12 -- Same as pin 11. Use both
White/Yellow - Pin 13 -- Memory change, momentary to input grnd
White/Blue - Pin 14 -- Headphone out (mono).
White/Red - Pin 15 -- Speaker out (4-8 ohms (mono)
White/Black ------ Ground (case)

Power is provided via a 1 AMP breaker.

Wire terminations will be completed during installation
2015-12-15 Install Fuel System Quick Drain Attached a 1/4" id fuel drain hose from the bottom of the header tank to the aft fuselage floor on the pilot side of the access panel. The fitting extends below the fuselage skin approximately 1/2". Draining can be accomplished by inserting the exterior portion of the fitting (with a length of hose attached). This portion can be carried in the A/C for use in the field
2015-12-16 Trial fit of Instrument Panel The instrument panel needs to be positioned in order to make several measurements for installation components: Front Top Skin (7F14-4) L-bracket mounts and Top cover Plate (7F14-2).

The panel is inserted between the cabin frame tube uprights 436mm from the cabin floor (distance measured to the bottom of the panel bulkhead NOT to the bottom of the 1.5" L-angle added to provide dual throttle mount area). To achieve this a jig was clamped together providing the proper distance and allows some support of the panel in position while clamping.

Additionally the top center of the panel is 410mm from the top center of the firewall. A length of std. L-angle is clamped (later clecoed and riveted) in place to set the position.

Once the proper positioning is achieved, the Front top skin L-angle mounts can be fabricated and installed allowing the panel to be clecoed in place at the cabin frame upright tubes.

2015-12-17 Install Front Tops Skin L-angle mounts The front top skin (7F14-3) covers the curved area from the top of the panel to the firewall. As such it needs to be secured not only to the firewall and the top of the panel (establishing the curve), but also along the fuselage sides ("cheeks"). This area needs to be reinforced with std L-angle stock fitted along the top of the side skin between the firewall and the panel mount area (vertical cabin frame tubes).

With the panel clamped to the cabin frame tubes in it's proper position, std. L-angle stock was cut to the approximate length (~560mm). he stock is then trimmed to fit the location with the top lip of the L-angle running along the top of the side skin (cheek). Once the proper fit is made, the L-angle is drilled (#40) pitch 30, then clamped into position and back drilled (from the interior)/clecoed (silver) through the side skin, fwd plate doubler, and firewall lip.

Once the front top skin is positioned (later) it will need to be drilled to match these hols using the blind hole transfer tool.
2015-12-18 Fabricate Angle-of-Attack electrical connections The Barker Aircraft Research AOA kit required 7 connections of 26 AWG (tiny) wires. The sensor is mounted to the vane (on the wing strut) and is wired up along the jury strut into the port wing and then to the display/processor board mounted on the panel. It has 3 wires (power, signal, and ground). It connects to the display board via 26 AWG Molex-type connectors.

The Display board also gets power * ground (for the indicator) from the instrument bus via a 1AMP breaker. These connections are also 26 AWG Molex-type.
2015-12-19 Fabricate Electronics Shelf Mount With the instrument panel in place I was able to take enough measurements to determine that I could add a removable shelf stretching between the bottom of the panel and the firewall.

The shelf will be approx. 20" wide by 18" deep (panel to firewall). The ECU is 7.5" x 8" x 2" (including the rather large connector plug) and could mount on either side of the removable shelf (top or bottom). This leaves more than enough room to mount the dual EarthX batteries and coils. Other components mounted on the shelf will include:

(1) CrazedPilot Strobe Lights Controller
(2) 12VDC "cigarette lighter" plug for USB port charging
(3) Dual positive & negative (ground) terminal busses
(4) Instrument terminal busses (positive & ground)
(5) Terminal busses for distributing rated power to the instruments (1A, 2A, 3A, etc).

The shelf mounts are constructed of std. L-angle stock bent to 90 degree corners with gusset braces to form an L-bracket. The short arms of the mounts will be riveted to the firewall and the straight ends riveted to the lip of the L-angle secured to the bottom of the instrument panel bulkhead. The shelf will be secured to the mounts using 3/16" nut-plates for AN3 bolts.

Sufficient lengths of cabling will be included in the wiring to allow the shelf to be un-bolted from the mount and to rest on the cabin floor for ease of maintenance.
2015-12-20 Install Elevator Trim & Flaps DPDT Switches in Panel The Ray Allen T2-7A-TS elevator trim servo is controlled via a Temco micro DPDT switch (momentary-off-momentary) on the pilot's side of the panel (just outboard of the keyed ignition switch). The 6 pole-contacts of the switch are wired as per the photo 1.

The flaps linear actuator is controlled via another Temco micro DPDT (momentary-off-momentary) switch on the pilot's side of the panel (just outboard of the keyed ignition switch). It's 6 pole-contacts are wired as per photo 2.
2015-12-21 Install ELT Antenna The Ameri-King AM-450Emergency Locator Transmitter "black box" is installed under the passenger seat with am RJ-11 cable connecting the box to the remote control unit on the passenger side of the instrument panel.

The antenna is mounted on the underside of the fuselage center-line just aft of the gear spring channel. It was installed by adding a 50mm x 80mm (0.025" thick) doubler inside the fuselage through which the antenna is attached.

A 50 ohm, coax-cable, with rt-angle connector, carries the signal from the ELT to the antenna.
2015-12-22 Fuel Probe Harness install Add male Molex 4-pin connectors to the Belite Fuel Probe wires at the controller mounted on the header tank. Add female Molex 4-pin connector to a 4' length of 22 AWG, 4-wire cable harness.

Install a tie-wrap mount (glued to the controller mount on the header tank to provide strain relief for the cable.

Later the cable harness will be routed under the pilot seat to the Belite Fuel Gauge on the instrument panel.
2015-12-26 Rout Fuel Injection Hose from Pumps to Seat back The one remaining fuel pump assembly hose to mount/route runs from the high pressure side of the pumps assembly manifold to the engine (fuel rail on the pilot side of the engine). Thus, the 5/16" id fuel injection hose is routed from the barbed manifold fitting; across the seat back, affixed with cable tie mounts to the seat back channel (7F6-5); to a 90 degree fitting passing the line through the bottom of the seat back under the pilot's seat.

An additional length of fuel injection hose will late be routed from this elbow under the seat, through the seat front & doubler to the lower plot quadrant of the firewall. At the firewall a bulkhead fitting will pass the line upwards 90 deg. where it will attach to the fuel rail of the Viking Engine.

All hose to barb connections are made with Oietker clamps.
2015-12-28 Fabricate Front Top Skin (7F14-4) Layout and make the cutouts in the front top skin (over the firewall to the instrument panel bulkhead) that allow the cabin frame tubes to extend thru the skin. The placement of the slots is facilitated by the use of the existing top cover plate (7F14-2).

The stock for the front top skin in a sheet of 0.016" 6061T6 that is 580mm x 1219mm. The Y-shaped cutout allows the top cover sheet to be fitted in positioon with the cabin frame tubes extending through. The top cover plate will eventually be used to cover the long slot in the Y-leg.

The top curves of firewall and panel bulkhead are predrilled with #40 pilot holes at pitch 40. Later the front top skin and cover plates will be affixed to the firewall and panel using a blind-hole locator in a manner similar to the method used to locate the rivet holes for the wing root skins.
2015-12-30 Extend Elevator Trim Cable The elevator trim servo requires 5 wires. Previously, a 5-conductor, 26 AWG harness with a 5-pin Molex connector was routed from the servo (inside the elevator)to a point outside of the assembly. When the empenage is mounted to the aft fuselage structure the a long, 5-conductor cable harness previously routed through the fuselage to the access bay area will connect with the servo. However, an additional length of cable is required to complete the run from the access bay to the instrument panel and connect to the trim control mini DPDT switch and Ray Allen indicator. The additional length of cable was spliced together using 26 AWG butt splice connectors. Each of the wires was crimped and covered separately with heat shrink. Then the 5-wire ends bundle was sealed in a heat shrink cover.

The extended cable was then routed thru the access bay, under the pilot's seat where it will further be bundled with the linear actuator controls harness and radio/intercom wires from the control yoke for routing thru the seat front and on to the instrument panel at a later date.
2016-01-02 EarthX Battery Box/Mount Finally decided that the dual EarthX (ETC36C) batteries and coils will mount under the front top skin on an "electrical components shelf" between the firewall and instrument panel.

Modified the previously built 6061T6 battery box/mount by removing the platform on which the coils were to be mounted as they will now simply bolt to the components shelf. Added cork dampening and anti-chafe tape to the the rails of the mount.

Note the tab on either side of the mount frame. A wood (non-conductive) strip will run across the tops of the batteries with 1/4" bolts securing the batteries to the components shelf thru the tabs on the box/mount.
2016-01-04 Install Electronis Shelf Mounts Much of the aircraft electronic components for engine, instruments, are mounted behind or adjacent to the instrument panel. An "electronics shelf" is installed running roughly parallel to the floor from the bottom edge of the instrument panel to the firewall. It is sheet of 5mm aircraft ply mounted on two L-angle brackets. The brackets attach to the firewall with A4 rivets (4) on each bracket and secured to the L-angle running below the instrument panel bulkhead with A4 rivets (2) on each bracket end. Since the firewall is angled back approximately 17 degrees, the panel end of each bracket has a 17 degree bend secured with a gusset for strength.

The actual shelf is of 5mm A/C ply and is secured to the mounts with AN4 bolts and nut-plates. This makes the shelf and components easily removable for electronics installation and maintenance.





2016-01-06 Route Pilot-Side Brake Lines On the port side, drill a 7/16" hole for a 5/16" grommet in the fuselage floor just aft of the gear leg. Snake the semi-rigid, 1/4" id, nylon brake-line tubing up through the grommet; over the bottom channel (7F10-1) making the run close to the port-side cabin wall into the area under the pilot seat. Continue the run through 7/16" grommet in the front seat support and along the cockpit floor adjacent to the cabin side up to the firewall ; finally connecting to the fitting on the port side brake piston resorvior.

At the gear end of the run, route the brake-lien down the port gear leg to the brake caliper connection on the wheel and attach.

Secure the line to the gear leg with two;self-adhesive plastic clips.

Under the pilot's seat, secure the line with a plastic cable clip riveted to the fuselage floor. Do the same at the firewall end of the line where it curves back to make connection with the piston.

Further clips may be added later once all electrical cables are routed.
2016-01-07 Route Passenger-Side Brake Lines Repeat yesterday's operations for the starboard side brake lines.
2016-01-08 Route/Bundle Passenger-Side Aft Fuselage Wiring Runs to Panel There are many wires to bundle and route from the aft fuselage to the area of the panel and electrical shelf. These need to be Labeled, secured to the structure, and bundled.

Passenger Side:

(1) 2-conductor 22 AWG, cable (grey) from tail light - secured to the fuselage side along the run; thru the access bay and a grommet (at the rear channel to the seat back.

(2) At the seat back, 2 pairs (black/white) of 18 AWG wires (one pair from each pump) and one 22 AWG, purple wire from the pressure transducer. These secured to the seat back and bundled with the tail light cable secured together with wire ties; then routed under the passenger-side seat.

(3) Under the passenger-side seat the 3-conductor, flat telephone cable for the ELT is added to the bundle (secured to the fuselage floor with a riveted [plastic wire clip. The bundle is tie wrapped prior to passing thru the seat font support into the cockpit area through a 7/16" grommet.

Tie wraps keep the bundle together along the cockpit floor adjacent to the cabin side. The bundle will later be secured and covered with plastic wire-loom for protection.

For the present, the wire ends are left loose for later connections at the electrical shelf mounted components.





2016-01-09 Route/Bundle Pilot-Side Aft Fuselage Wiring Runs to Pane There are many wires to bundle and route from the aft fuselage to the area of the panel and electrical shelf. These need to be labeled, bundled, and secured to the structure.

Pilot Side:

(1) 5-conductor 22 AWG, cable (grey) from elevator trim servo - secured to the fuselage side along the run; thru the access bay; mating with the fuel probe cable at the header tank; and then thru a grommet at the rear channel into the flaps limit-switch area.

(2) At the header tank, the servo cable mates with the 4-conductor 24 AWG, cable from the fuel probe sensor/controller. This bundle is secured to the fuselage floor in the access bay and thence trough a 5/16" grommet in the rear channel into the flaps limit-switch area.

(3) There are 5 pairs of 20 AWG wires for the limit-switches that will be bundled with the servo and probe cables to run under the pilot's seat (next to the linear actuator). 12 connections must be made in this area per the Linear actuator schematic. Once the connections are made (later) the wires will be bundled together with tie wraps and passed thru the seat front support into the cockpit area.

Tie wraps keep the bundle together along the cockpit floor adjacent to the cabin side. The bundle will later be secured and covered with plastic wire-loom for protection.

For the present, the wire ends are left loose for later connections at the electrical shelf mounted components.
2016-01-11 Route Fuel Lines from Header Tank thru Firewall Added a support bracket at the seat back to support a nylon, 5/16" id barbed hose rt-angle fitting to carry the fuel line into area under the pilot seat anf thru the seat front gusset to the lower port-side area of the firewall.

A brass bulkhead pass-through fitting was installed at the firewall and the 5/16" id fuel injection hose run from the seat back to the fitting and secured with 14mm Oeitker clamps.

An additional 5/16" id brass barbed rt-angle fitting was installed on the fwd end of the bulkhead fitting. This fitting will later be used to complete the fuel line run from the tank system to the fuel rail of the Viking engine.

All threaded fittings were treated with Locktite sealant.
2016-01-13 Fabricate Electronics Shelf The shelf for mounting electronics components behind the panel is cut from 5mm marine ply sized (19.5" x 15.25") to fit through the removable central section of the panel.

The mount for the dual EatrthX batteries is bolted to the shelf with the coils close inboard.

Battery positive and grounding cables are attached (6 AWG) and routed to the coils per the Viking Wiring Diagram.

Many additional components will be mounted to the top surface and the Viking ECU wil mount on the underside.
2016-01-15 Mount Firewall In-Line Fuel Filter Mounted the in-line fuel filter from the pumps to the engine on the port-side of the firewall. Fuel injection hose secured with Oeitker clamps.
2016-01-17 Strobe/Lights Controller Wiring With the Crazed Pilot Strobe/Wig-Wag controller mounted on the electrical shelf and the shelf installed between the firewall and panel, Basic wiring was completed as follows:

Pin 1: Ground wire to avionics negative buss
Pin 2: +12VDC from LIGHTS rocker switch (power from 7A breaker)
Pin 3: +12VDC from STROBE rocker switch (power from LIGHTS switch)
Pin 4: +12VDC from Wog-Wag rocker switch (power from LIGHTS switch)
Pin 5: +12VDC to port light
Pin 6: Ground to Port light
Pin 7: +12VDC to starboard light
Pin 8: Ground to starboard light

Pin 1: Ground to tail
Pin 2: +12VDC to tail and fuel gauge LED

2016-01-18 Install Negative Instrument Buss Installed the Negative Instrument Buss on the Electronics Shelf behind the panel adjacent to the 1A Positive Instrument Buss. The 1A buss is fed from 2 1A breakers and distributes power to much of the avionics and radio equipment.
2016-01-20 Fabricate & Install 60A Fuse Circuit The Engine started circuit gets power via a 6AWG cable from the coils (mounted on the electrical shelf. The input power is regulated via a 60A fuse mounted on the firewall in the engine compartment (high on the port-side) to the alternator. It is secured to the firewall with two 10-32 stainless screws and nuts.

A grommet is used for the pas-thru and an additional 8AWG cable supplies unregulated power from the coils to the starter.
2016-01-21 Trial Throttle Installation Both A800 throttle assemblies were installed at the panel to determine the optimal cable routing paths to/thru the firewall (for later installation). This was done to assure that starboard throttle's 4' length was sufficient to reach the linkage at the engine. Also the trial mounting demonstrated that there is sufficient space to rout the starboard cable behind the batteries.
2016-01-22 Customize pilot-side door sill (7F19-12A) - Aft The door sills (7F19-12A) need to be customized to fit the folding wing mechanism.

Starting with the port-side, aft junction of the sill with the wing mount. A template was created of scrap materials to fit the junction. The template was then used to transfer the dimensions and angles to the channel sock which was then trimmed to fit.

This was a tedious task, but a nice fit was obtained. The result will be reversed and used as a template for the starboard-side.

A similar technique will be used for the more difficult fwd junctions (because of the folding wing mechanism).
2016-01-23 Port-Side Door Sill Fabrication Constructed a cardboard template for the fwd joint of the door sill (7F19-12A). Complicated pattern due to the folding wing structure.

The template cut-out was transferred to the fwd end of the stock and trimmed with snips to the basic shape. Much fitting/trimming required.
2016-01-24 Port-Side Door Sill Ready for Installation Completed the trimming & fitting of the port-side door sill (7F19-12A). It will be removed and used as a template for the starboard side.

Also, at ether end of the port-side, pass thru hols must be positioned, drilled , and grommets inserted for:

one fuel line and one vent line aft
one pitot pressure line and pitot static line fwd
one port nav/pos light cable
one AOA cable
2016-01-25 ECU Harness Pass-thru Install Used Bob's pneumatic hole punch to install the 1-1/8" dia. nylon firewall pass thru (with rubber grommets. The hole punch does a nice clean job on large diameter holes.

The ECU will mount on the bottom side of the electronics shelf and the harness will pass thru this fixture to connect to the engine. Location probably dictated that the coolant overflow reservoir will mount on the starboard side of the firewall.
2016-01-27 Route Radio (VHF) Antenna Cable The FL760 radio is a std aircraft radio VHF antenna (Drone & Margolin) that is mounted on the upper fuselage deck just aft of the baggage compartment wall. It was mounted at this location for ease of access for cable mounting & maintenance via the access panel in the baggage compartment aft wall.

The radio/antenna requires a 50 ohm coaxial cable running inside the fuselage from the antenna across the top deck to the starboard side and down into the access bay to the area under the passenger seat where it passes through the seat front bulkhead to the panel (bundled with the tail-light and ELT remote cables as well as the brake line).
2016-01-29 Starboard-side Door Sill Fabrication Completed the layout, trimming & fitting of the starboard-side door sill (7F19-12A). The port-side sill was used as a template for the starboard side.

Also, as with the port-side sill, at ether end of the starboard-side, pass thru holes must be positioned, drilled , and grommets inserted for:

one fuel line and one vent line aft
one fuel level sensor line fwd
one port nav/pos light cable fwd
2016-02-01 Problems with Door Sills and New Bubble Doors Since no installation information was provided with the new bubble doors kit, the Zenith.Aero Builder's website was searched for any information. Several posts indicate that the (7F19-12A) door sills that were just installed should have been trimmed down 20mm so that the piano hing line is not positioned at the plexiglass. Reported this problem to Roger at Zenith but have not as yet had a reply.

Two possible "fixes" are being contemplated:

(1) Drill out the 30+ A4 rivets securing each sill to the upper cabin frame tube, trim off 20mm from the top, and re install using a strap duplicator to locate the already drilled holes in the tubes.

(2) Trim 20mm off the bottom of each (in place) and rivet in a length of 0.75" U-channel (probably the easiest solution). However, the bottom edge of the folding-wing carry-thru tube at the fwd end of the sill sits at approximately 20mm from the un-trimmed sill.

Also need direction as to how the bubble door fits around the folding wing mechanism.
2016-02-03 Replaced BNC connectors on 50 Ohm Coax Cable Replaced the antenna end of the 13' length of RG58, 50 ohm coax
straight BNC connector with a right angle BNC connector.

Terminated the panel end of the coax with another right angle BNC connector for attachment to the FL-760 radio.
2016-02-04 Replaced Carling Circuit Breakers with Tyco Located a source for Tyco W58 series circuit breakers with the amp rating imprinted on the pushbutton VERTICALLY. Replaced the 10 existing Carling CLB series breakers with these.
2016-02-05 Replaced/re-wired the toggle switch panel The new 2016 Viking Engine ECU has built-in redundancy. Previous versions used two panel toggle switches to alternate between the two redundant ECU circuits. The latest version (Nov. 2015) replaces the two SPST toggle switches with a single On-Off-On toggle switch. This frees up a panel switch location into which I have added a separate SPST switch for Comm Radio (removed from the Avionics switch) tied to a 1A breaker circulit.
2016-02-07 Re-wired Nav/Pos Lights Controller/Switch Bank Rewired the switch bank controlling the nav/pos lights to have the tail light activated from the Steady switch rather than from the power-on switch. Also removed the fuel gauge light from this circuit to activate from the Comm toggle switch in order to use a 1A circuit.
2016-02-09 Add Slide Potentiometer to control instruments lamps Added a 10K ohm slide potentiometer to control the brightness of the altimeter and fuel gauge instruments. The pot is mounted under the pilot's side of the instrument panel between the throttle and the side wall (out of sight) under the ignition switch.
2016-02-10 Added ECU Alarms LED Added a Red, 12mm LED indicator lamp to the instrument panel adjacent to the ECU. The indicator is activated/controlled by the ECU. The wiring will be completed from the ECU wiring harness.
2016-02-11 Wire Stick Grips to PTT Radio/Intercom Wired and installed the Push-To-Talk (PTT) switches in the Ray Allen control yoke stick grips. Each (pilot & Passenger) will connect with pin 7 of the radio/intecomm wiring harness J001 connector.
2016-02-13 Fabricate & Install Channel Doubler Under Tunnel Skin During the installation of the controls push-rods, it was noted that the bottom skin area under the controls/seat tunnel showed a tendency to oil-can. In the open wing bays, fuselage areas, and other locations, installation of a doubler alleviated this problem.

Extending the 7F8-1 Central Floor Stiffener from the seat front to the gear bottom channel seemed to be the easiest solution. No surplus 7F8-1 channel stock was available, so two lengths of Z-channel were utilized.

Problem solved.
2016-02-15 Replace EXT36C batteries with ETX680C Since my dual EarthX ETX36C batteries were essentially unused and in warranty, EarthX offered me the option of returning them for replacement with their new aircraft version of the same battery.

The ETX680C has the same built-in BMS (Battery Monitoring System) but also features a fault monitoring/indicator circuit. The circuit illuminates an LED to indicate a fault in the battery. The circuit connects with Dynon and Garmin EIS devices and I have requested info from Grand Rapids Technologies about an interface with the Viking View ECU. If no such interface is possible, I will add two LED lamps to the panel to utilize the feature.
2016-02-16 Trim Fwd Door Frames & add L-angle Trimmed the excess side-cheeks material from the pilot's side and added an L-angle to cover the sharp edge of the side-skin. The Door itself would cover this, but added the L-angle strip for safety in entering & exiting the door.

Will do the same for the starboard side door.
2016-02-17 Install Stb Side Door Sill Trim & install stb side door trim as done on port side. Trimming required to accommodate the folding wing mechanism.
2016-02-17 Mount Engine to Airframe Assembled the hoist; cradled the engine at the lifting points and attached the engine to the fuselage with the AN6 mounting bolts and shock absorbers. Process went fairly smoothly with the help of brother Bob.
2016-02-18 Install Oil Cooler & Braided Hoses The oil cooler mounts to the unused lower engine-mount fixtures with rubber shock absorbers. This placement out of any sufficient air-flow requires that an NACA air-scoop will have to be incorporated into the lower portion of the passenger-side cowling and flexible duct hose connected between the scoop and the cooler box.

The flexible braided cooler input and return hose fixtures are also in rather difficult locations. However there is sufficient hose length and flexibility to allow the connections to be made (using high temperature Locktite 565. The hoses have been provided with strain-relief with cable clamps to the engine structure.

In addition to the lines to/from the oil cooler, a blowback vent hose is routed from the oil filler cap down the starboard side of the firewall extending slightly below the air-frame (its length can be trimmed later after fitting of the cowling). It is secured to the firewall and strain relieved using cable clamps.
2016-02-19 Install Coolant Overflow Tank & Hose The engine uses between 4 and 5 qts Evans NGP+ cooling fluid that protects the engine between -40 and +375 degrees F. As the coolant fluid heats, its volume expands and thus an overflow tank is required. It is mounted in the engine compartment on the starboard firewall. The expansion line enters the tank from the bottom and the cap has been drilled with a small hole to allow for the expansion.

Adding coolant through the rather small fill line near the throttle body on the top of the engine is a slow process done in many small increments to allow the fluid to seeep into all cooling passages. The initial fill has taken slightly less than 4 qts. The engine specifications say between 4 & 5 qts. Will check the level and add fluid after initial quick/short start of the engine that will hopefully allow the existing fluid to get to as yet unreachable portions of the block.
2016-02-20 Install Exhaust & Muffler The exhaust stack and muffler mount to the underside of the engine vertically (on the port side) with a thin, stainless steel exhaust plate gasket and 4 M8x1.25 copper lock nuts over the mounting studs. The nuts are torqued to 200 inch-lbs.

The exhaust pipe extends below the line of the cowling and may be trimmed at a later date if required.

2016-02-21 Fabricate/Install Microphone/Headphone Jacks Mounts To locate the pilot & passenger microphone/headsets jack panels , a small jack panel was fabricated and riveted into place above the outboard shoulder of each. Each panel will contain one std 3-contact microphone jack (Switchcraft S11, 0.25") and one aircraft 2-contact headphone jack (Switchcraft S12, 0.217"). Each will be installed using insulated fiber washers to help minimize noise..


2016-02-22 Wire Microphone/Headsets (FL-760 to Jacks) The FL-760 radio uses a DB-15 connector for all electrical and communications signals distribution. Since many of the circuits required only short wire runs (for connections near the rear of the instrument panel) and others required much longer runs (to the control sticks and the jacks), the DB-15 harness was fabricated using two, shielded, 8 connector, 24 AWG cables (one white the other grey for identification).

All wire runs/connections are described in the attached diagrams using a white/color or grey/color descriptor. The longer runs mostly use the grey bundle and make Molex connections under the pilot's seat.

As required to help eliminate noise, as each individual wire exits the bundle to be distributed through the Molex connectors, a grounding shield is also associated and since the 8 wires of the grey bundle are split & distributed to the microphone jacks (3 connectors plus shield) and headset jacks (2 connectors plus shield), both shielded, 24 AWG, 4 connector and 3 connector cables; wires in these cables are of different colors as indicated in the attached diagrams.

All shielding runs are grounded at only one end (the closest to the power source behind the panel - the avionics grounding buss).

The Push-to-Talk (PTT) switches mounted in the control stick grips simply ground the circuit to operate the intercom.

The microphone pin outs are: A = PTT, B = Ground, C = Audio.

The headsets pin outs are: A = Ground and B = Audio.
2016-02-23 Mount Viking Engine ECU The 2015 version of the Viking ECU is mounted to the "electronics shelf" behind the panel on the pilot's side using 2 AN3 bolts. The ECU, as delivered, is a dual purpose device designed for both the 110HP and 130HP engines and as such has two A35 connectors. The forward Red/Black connector is used for the 110HP Viking. the unused, open Blue/Black 130HP connector has been sealed with a polyethylene dust-cover).

The ECU harness provided is a new incarnation for the 2015 ECU and as such the existing documentation (wire color codes and some functionality) does not exactly match. These discrepancies have been noted and updated on the diagrams and will be included in the As-Built Operator's Manual).

The 2015 harness splits again into a DB-9 connector bundle that can be used to externally program updates into the ECU. This harness has been coiled and secured to the fuselage side skin under the panel on the pilot's side.

The harness is routed through the firewall passthru installed earlier and the Viking View DB-25 connector is attached.
2016-02-24 Breakers & Switches Diagram The panel components are controlled by Eight 20 Amp SPST toggle switches (protected by U-switch guards). The associated circuits are protected by 10 push-to-reset Tyco circuit breakers in two rows of 5 breakers).

Panel switches (left to right):

Master - 10 Amp circuit - provides power to the positive busses.
Engine Control Unit (EC) - 15 Amp circuit
Battery 1 - to ground to activate Battery 1 as the power source
Battery 2 - to ground to activate Battery 2 as the power source
Pump 1 - 15 Amp circuit - selects Pump 1 as the primary
Pump 2 - 15 Amp circuit - selects Pump 2 as the primary
Avionics - 2 Amp circuit - supplies +12 Vpower to the Avionics buss
Radio - 1 Amp circuit - provides power to the radio/intercom



2016-02-25 Pop-up Resistor Wiring The Viking View can display tachometer readings from the engine via the Black/Yellow wire in the ECU harness. However, in order for this function to work a 1K ohm, 1/4 watt resister is required between the +12V and the sensor line. It was soldered in as per the attached diagram.
2016-02-26 Viking View Connector Wiring The Viking View makes connections via a DB-25 connector with pin-outs per the diagram. The harness provided by Viking requires that a few of those tiny wires need to be spliced into some existing, external circuits on my "electronics shelf".

I installed a red 12VDC LED on the panel just inboard of the instrument. The red power & voltmeter wire (pin 9) of the harness is connected to the +12V LED lead and continues on to the Avionics switch (source of power). The ground wire from the LED is terminated on the avionics grounding buss.

The green/white fuel flow input wire (pin 25) is connected to the fuel flow wire (yell0w) of the Viking ECU wire bundle.

All other connections are made within the DB-25 and harness.
2016-02-28 Install Nav/Pos Lights Switch Bank Four 12V, 5A, illuminated rocker switches are used to activate the lighting circuits via the Crazed Pilot Lights Controller. The switches are mounted to the L-angle extension below the panel on the passenger-side.

Power enters the 1st (leftmost power) switch from a 5A breaker. The 2nd switch provides a steady power signal to the lights (tail and wing tip). The 3rd provides a strobe signal and the 4th a wig-wag signal.
2016-03-01 Install Elevator Servo/Indicator & Switch Replaced the large Ray Allen DPDT rocker switch controlling the elevator trim servo with a mini DPDT rocker switch matching the one used for controlling the flaps. The switch is mounted in the left corner of the pane; just outboard of the ignition switch. The ribbon LED indicator is mounted just above the switch.

The DPDT switch and indicator is wired as per the attached diagram and all wires are bundled in a 5 conductor, 24 AWG cable and are routed via 5-pin Molex connectors from the panel to the servo in the elevator.
2016-03-02 Added Battery Circuits Warning Lamps The new EarthX ETX680C batteries each provide a lead for use with an LED warning indicator. The lead has a spade connector and is wired to the ground terminal of a 12VDC LED indicator lamp, The positive terminal is connected to the positive avionics buss.

The lamps are amber and are mounted on the panel under the FL-760 Radio and just to the right of the toggle switch bank.
2016-03-03 Slats Positioning Tool The slats are mounted to the leading edge of the win on 4 brackets/supports (wing: 7V4-5 and slat: 7S1-6) with 2 AN3 bots in each. To properly position the slats to the wings a positioning jig is made from scrap L-angle and aircraft ply.

The small trailing edge template blocks were laminated up from aircraft ply to the specifications on the diagram. Several will be cut from a length of stock.

Actual mounting will be done later after painting.
2016-03-04 Front Top Deck Center Brace Added the L-angle between the panel and the firewall in preparation for fitting the Front Top Deck.
2016-03-05 Layout Front Top Skin & Cover Plate The front top skin (7F14-4) requires a Y-cutout to me made in the forward end 9at the firewall) to allow the cabin-frame legs to pass thru. The top cover plate (7F14-2) also requires that matching slots be cut into the aft end to cover the base of the Y-cutout in the front top skin.

The front top skin will naturally be curved over the instrument panel (aft) and the firewall (fwd). At the panel end a 50mm overlap is required and a 60mm overlap is required at the firewall.

The process required many sequences of fitting & trimming.
2016-03-07 Route wing cables & pitot tubing On the pilot side, cables for the AOA sensor and wing-tip position lights and bot static and pressure lines for the pitot system must be routed from the backside of the panel, through the panel corner brace. A 5/8" rubber grommet is used to protect the cables/hoses as they pass thru the corner of the panel.

Once thru the panel the cables & lines are wrapped in a wire loom and will be secured to the cabin frame leg leading up to the wing attach point where (later) they will be passed thru the door sill to enter the wing structure near the fwd wing attach point.

For the folding wing, inside the wing root the pitot lines will be attached with quick disconnects and the AOA & tip lights connections will be made with Molex connectors. All of the connectors are accessible via the hinged inspection port/door in the bottom of the wing root.

On the passenger-side, the only cable run required is for the starboard wing-tip position lights. The routing is done in manner akin to that of the pilot-side.
2016-03-09 Top Deck Fitting After much fitting & trimming, the y-cutouts for the cabin frame legs to pass thru the top deck skin over the area from the panel to the firewall appears to align properly.

The skins (top deck and cover) now need to be drilled for clecoing and later riveting. This is a difficult job in that all of the holes must be located using the strap duplicator. 1st located and drilled to #40 (silver) clecos later to be drilled-out to #30 (A4) and #20 (A5) dependent upon the location and thickness of the skins/supports to be mated.

The skins are first secured along the top center-line L-angel running from the panel to the firewall. This fixes the position allowing the holes in the curved sections of the panel & firewall to be located (strap duplicator) working from the alternately center to the fuselage sides to ensure a smooth curvature of the decking to ensure a proper fit of the windscreen to the deck installed later.

The next step is attachment of the top deck skin to the fuselage sides again requires much trimming and fitting (including more strap duplicator location of mounting holes in the Side-skin (cheeks) and L-angle support structures.
2016-03-10 Top Deck Skin Fitting Curving the top deck skin to the fuselage sides (cheeks) is also a difficult operation. The skin must be trimmed to fit around the cabin frame legs at the ends of the panel and secured along the opening for the doors.

Also the strap duplicator must be used to locate the holes in the skin that match the pre-drilled holes along the top od the side skins (cheeks) and L-angle support structure.

In curving the top skin to follow the contours of the panel-firewall curve, an oil-canning of the skin at the center was noted, so a section of standard L-angle was fitted longitudinally along the inside of the skin at the "dent" to add support and smooth the curve. For some reason this was only noted on the pilot-side and thus there is no additional rivet line on the passenger side. The pilot-side rivet line will be mostly covered by the placement of the windshield.
2016-03-12 Battery Charging Terminals Two positive battery charging terminal posts were installed thru the firewall on the upper-starboard side. These posts will allow the EarthX ETC680C batteries to be charges (or jumped) via an EarthX Optimate LiFePO4 battery charger (model TM471). The posts are provided for easy access with standard removal of the top cowling section.

The posts are standard Summit Racing bulkhead connectors (SUM-G1431-RED).

The negative posts are also located thru the firewall on the lower-starboard. The two grounds are common; one to the firewall/airframe and the other to the engine block,
2016-03-15 Stb Slat Mount The slats are constructed in two sections per wing and are attached using the mounting 4 tabs attached to the wing nose ribs during wing construction. The sections are positioned using the jig constructed earlier. The jig helps position the bottom leading edge of the slat flush with the bottom surface of the wing 110mm from the nose.

The spacer blocks maintain the alignment of the trailing edge between 14mm & 18mm from the upper surface of the wing's nose rib.

The attachment is made with 2 AN3-4 bolts at each of the 4 mounting tabs. The two sections of the slat skins are riveted in place once the slat has been positioned on the wing.
2016-03-17 Port Slat Trial Fit The port slat is mounted to the wing mount tabs in the same manner as the starboard slat using the same jig and spacers for positioning.
2016-03-18 Starboard Flap Mounts Prep The Flaperon Arms are drilled to 6.5mm hole, which is a little larger than 0.25" hole. On each side of the bushing there is a washer AN969-416. The slats for each wing are in two sections and the 7A2-2 splice plates are also drilled for the 0.25" bushing as well. A little grease will be added when mounting the flap to the wing.
2016-03-20 Angle-of-Attack Display & Sensor The Barker Aircraft Research AOA kit consists of two very small circuit boards with tiny components that required delicate soldering technique beyond my abilities. It was assembled for me by a Sr. EE student at UNT. When first tested it was found to be faulty. I returned the completed instrument to David Barker. He repaired the faulty Hall Sensor and assured me that the instrument/sensor is now working properly.

When building the port wing I ran the 3-conductor, shielded cable (Red-Power, Blue-Signal, Yellow-ground) from the fwd jury strut fitting thru the wing to the root. I added 4-pin Molex connectors on each end.

At the wing root a matching 3-conductor cable/connector is routed down the fwd cabin strut, thru the port end of the panel into the electrical bay behind the panel. Here the AOA LED Display circuit board is mounted to the panel and the appropriate connections made (also with Molex connectors).

The instrument will be calibrated using the two pots on the display board once the port wing is in place on the fuselage and the vane is mounted to the jury strut.
2016-03-21 Test All Wiring Circuits Verified the proper operation of all wiring circuits (except fuel level & probe) in preparation for installing the top deck and seats:

(1) Verified Master toggle switch operation

(2) Verified ECU power toggle switch operation

(3) Verified ECU warning lamp operation

(4) Verified Battery 1 & Battery 2 toggle switch operation

(5) Verified Battery 1 & Battery 2 warning lamps operation

(6) Verified Pump 1 & Pump 2 toggle switch operation

(7) Verified 3 Amp Avionics power toggle switch

(8) Verified 1 Amp Radio, Digital Altimeter, & Fuel Gauge power toggle switch operation.

(9) Verified Alternator Charging lamp operation

(10) Verified continuity of AOA power & signal wires and molex connectors from vane to wing/jury strut; jury strut to wing root; wing root to power & LED display circuit board.

(11) Verified operation of linear actuator flaps control and panel LED display circuits.

(12) Verified operation of elevator trim circuits.

(13) Verified operation of slide reostat dimmer circuit.

(14) Verified Lighting Panel Master switch operation (power to Crazed Pilot Strobe Controller)

(15) Verified operation of tail position light operation (steady thru all controller modes)

(16) Verified both port & starboard nav/position lights operation via lighting panel switches (Crazed Pilot Strobe Controller)

(17) Verified USB charging port (for iPad Air and GPS receiver)

(18) Verified remote (panel) operation of the AmeriKing ELT

(19) Verified operation of the FL-760 Radio/Intercom circuits (headphones, microphones, and stick PTT switches).
2016-05-01 Construct Slat Mounting/Positioning Jigs The slats need to be position on the wings (using the wing & slat mount supports (7F4-5 and 7S1-6). The bottom of the slat leading edge needs to be even with the bottom surface of the wing and 100mm from the tip of the wing nose skin. The trailing edge of the slat needs to have a ~17mm gap between the rear edge of the slat and the top of the wing.

Several trailing edge gap blocks were made of 17mm thickness and the leading edge template jig (7Ss) was constructed to set the 100mm lower slat position.
2016-05-02 Trial fit stb slat to wing The inboard and outboard sections of the stb slat were pieced together (20mm overlap). The 4 slat supports (7S1-6) were fitted against the wing nose rib slat supports (7V4-5) and clamped in place.

The slat leading edge template was constructed per the diagram (7S2) and is used to set the 100mm gap between the wing nose skin and the bottom of the slat leading edge. Several slat trailing edge gap template blocks (7S2) were used to set the gap between the trailing edge (top) of the slat and the wing nose skin at ~17mm.

The trial fitting showed that the leading edge of wing nose rib slat supports (7V4-5) needed to be trimmed back ~4mm at the top in order to set the slat position properly at the 100mm and 17mm gap locations at all 4 supports.
2016-05-03 Skylight Lexan Trim The top skylight is cut from the 1/8" thick Lexan sheet (7F19-1). The cutting/trimming was done with a 3" rotary cut-off saw and the fwd edge, which fits under the windscreen, was further trimmed with a 1/8" bead via a a router.
2016-05-04 Skylight Aft Trim Fixture Construction The aft edge of the top skylight will be held in place with at strip of 0.016" 6061T6 that has been "joggled" to fit the 1/8" thick Lexan sheet. It will be glued in place against the lexan using 3M 5200 Marine Adhesive Sealant. The aft portion of the joggled strip will be riveted to the top fuselage.

The sides of the Lexan skylight will be glued (3M 5200) to the cabin frame tubes. The wing root skins will eventually cover these areas at final assembly.
2016-05-05 Skylight & Windscreen Mounting Hardware The Windscreen and skylight will be secured to the canopy frame tubes with 3M 5300 Adhesive/Sealant (black); oval head screws, 1/8" polytube busings, and finishing washers.
2016-05-08 Cowling fit Problems - Gearboox Sensor Interference Inspection of the gearbox/prop mount mount area indicated that a prop extension would be required in order to clear the sensor attached to the front of the gearbox housing. Jan at Viking said that this is the case with the 2015 version of the engine. He said he would ship out a 1.5" Warp Drive prop extension.
2016-05-12 Prop Hub Extension The 1.5" prop hub extension (from Jan at Viking) was installed and a 38" crush plate (Saber Manufacturing) was added to provide a larger surface area for mounting the spinner plate.

Sam (Saber Mfg.) suggested the use of NordLock washers and Locktite on the six 8mm, schedule 8 mounting bolts.
2016-05-14 More Cowling Clearance Problems With the 1.5" Warp Drive Prop Hub Extension in place a trial fit of the upper and lower cowling pieces was attempted. The exercise showed that the configuration of the gearbox plumbing on the 2015 version of the Viking 110 engine does not allow sufficient clearance for mounting the standard CH-701/Viking cowling with only a 1.5" prop extension (per Jan at Viking).

The sensor mounted on the upper port-side of the gearbox has less that 0.25" of clearance for the cowling. However the placement (lower starboard-side) of the gearbox oil return fitting and hose forces the cowling too far forward. This both interferes with the prop hub rotation and requires modification of the fiberglass cowl parts. The parts must be extended at the aft surfaces and around the radiator scoop "mouth".

These extensions are required to provide sufficient surface areas to attach the cowl to the fuselage and the radiator shroud and to move the interior, lower, forward surface of the cowl away from the oil return hose.

After further discussion with Jan, he is supplying an ADDITIONAL 1.5" prop hub extension. Using both should provide more than enough clearance for the cowl to be mounted. However, the process will be difficult with much fiberglass work required.
2016-05-16 Rotate Nose Wheel Fork Mounting Bolts & Safety Wire Removed and reinstalled the nose wheel fork mounting bolts to place the heads on the inside of the fork (more clearance).

Drilled an #40 hole in each leg of the fork to accept the safety wire of the axle mounting bolts ans safety wired the bolt heads.
2016-05-17 Fuel Xfr Pump: Specification, Design, & Parts Order Calibration of the Belite Fuel Probe & Gauge demonstrated the need for a fuel xfr pump to help fill/drain the aircraft tanks. The high-wing configuration and placement of the wing tanks would require a ladder of some sort during fueling operations.

Researching 12VDC fuel transfer pumps I found most of the the components on E-bay at reasonable prices.

The Flowmaster is a $400 unit (Dill Instruments). It is old/used but serviceable ($29 including shipping). The Airtex E2882 pump ($35) is the same pump used in the Viking Fuel System (40-50 psi) and the fittings are readily available from McMaster-Carr (~ $16).

Once assembled (total weight < 4 lbs), I will mount the pump/meter components in a hobby box so that it can be stored in a mesh baggage net behind the aft baggage compartment wall accessible via the hinged access port. (The Optimate LiFePO4 battery charger will be stored there as well.)

2016-05-18 Assemble Fuel Xfr Pump With most of the components on-hand, prepared (cut, drilled, & painted) a 1/4" aircraft ply board to accept the components.

Disassembled the EAA Electronics Workshop controller circuit project to create a panel containing a toggle witch and 15A fuse holder to control the pump circuit and mounted it to the plywood base.

Secured the 12VDC, 50psi automotive pump to the base with the barrel clamps and #10 mounting bolts. Secured the flow meter to the base with tie-wraps.

Attached the negative lead of the 16AWG power cord to the pump and and attached a ground wire from the negative terminal of the pump to the pump clamp (per the manufacturer's instructions).

Attached the positive lead of the power cord to one terminal of the 15A fuse and the the other fuse terminal lead to the toggle switch input lead. Completed the circuit by wiring the positive terminal of the pump to the load lead of the toggle switch.

The 16AWG power cord is strain relieved on the underside of the mount and will have battery charger clips attached when they arrive (McMaster-Carr).

NPT-barbed hose fittings (5/16" id high pressure lines) will complete the plumbing (McMaster-Carr).

Four 1/2" rubber feet will be attached to the mounting board when they arrive (McMaster-Carr) to complete the assembly.
2016-05-19 Lexan Skylight Preparation The ploycarbonate skylight (top window, 7F19-1) is placed into position on the opening the cabin fop fuselage and marked for trimming to fit. The sheet is cut using a 3" hand cut-off saw and the edges smoothed with a hand plane.

The skylight will be secured to the top fuselage & cabin frame tubes later using a strip of aluminum trim (forward, 7F19-9M) & 10Rx3/4 oval head screws and finishing washers (SNW-2012) per the diagram below. 3M 5200 silicone selant/adhesive will also be applied to the attachment points. (Note: the same method will be used to secure the windscreen to the cabin frame tube sides.)

To secure the aft end of the skylight to the fuselage a 50mm strip of 0.16" 6061T6 was "joggled" lengthwise (1/8"). It will be riveted to the top aft fuselage skin and the lexan will slide under the "joggled edge" (secured with adhesive).

The sides of the lexan skylight are only secured with adhesive (these areas will be covered with the wing root top skins). The skylight lexan will also be secured to the cabin frame diagonal tube with only adhesive.
2016-05-20 Skylight Bow Installation The Lexan skylight is slightly bowed upwards via a crimped diagonal stiffener (7F12-3) that is riveted to the diagonal cabin tube that supports the skylight (7F12-2).
2016-05-22 Windscreen Positioning The windscreen is prepared for mounting by trimming the upper corners around the wing folding hinge tubes. The aft edges of the windscreen are also trimmed parallel with the cabin frame upright tubes.

In performing a trial fitting of the windscreen a crack of approximately 3" length was noted in a the starboard folding mechanism. After discussions with LP Aero (the windscreen manufacturer) it was determined that since the crack is in a non-critical area (visibility) a repair would be sufficient. To do so, a small hole was drilled at the end of the crack to keep it from propagating and a patch of polycarbonate sheet was glued over the length of the crack (on the inside surface) using PS 16 fast setting, clear polycarbonate solvent cement.

a length of 1/8" rubber u-channel is affixed to the bottom forward edge of the windscreen that fits against the curved top deck. After placement a bead of 3M black silicone adhesive/sealant will be run along the area where the surfaces meet sot seal and secure the windscreen to the top deck.
2016-05-24 Windscreen Mount - Stb Side The stb side windscreen trim (7F19-8) was cut to fit over the aft edge of the windscreen and pre-drilled (#40) for 9 oval head screws and finishing washers. The trim piece was clamped in place and using the pre-drilled the positioning holes were drilled thru the lexan and cabin frame tube (#30). The trim piece was removed and the lexan only was drilled out to 1/4" to accept plastic tubing bushings (#20 id). With the windscreen securely attached to the upper cabin frame tube and skylight (A4 clecos), the stb side trim was secured to the windscreen and cabin frame tube with 9 STS18-P oval head screws and finishing washers.

A piece of 0.016" stock was shaped to fit in the lower stb corner of the windscreen. It was attached with 3Msilicone selant/adhesive.

Additionally, in the lower corner where the windscreen meets the top deck and fuselage side, A 1032 stainless pan-head screw with large load bearing washer was used to further secure the windscreen to the fuselage. This screw also has a plastic tubing busing in place in the lexan.
2016-06-26 Belite Fuel Probe/Gauge Calibration Procedure The Belite fuel prob is mounted om the header tank at the bottom of the port side as far distant from the high pressure, unused fuel return lines as possible to minimize any turbulence effects to the probe.

The probe controller is also mounted to the header tank adjacent to the probe in order to keep the signal wire as short as possible (withing 4"). The probe calibration controls program the system in 25% capacity increments (0.00, 0.25, 0.50, 0.75, & 1.00) with a button on the device for each level.

Each wing tank is 10 gal. and the header tank is 3.25 gal.; 13/25 gal. total. Thus the 3 tank system will be calibrated in 3.25 gal. increments.

Calibration Sequence:

(1) A the panel, arm the MASTER, Battery (1 or 2), and Avionics switches.

(2) Cycle the power to the probe & gauge by switching off the Avionics toggle.

(3)At the probe controller (in the access bay), depress the o & 1 buttons and switch on the Avionics toggle. All lights on the probe flash.

(4) After a few seconds the probe controller lights stop flashing and the calibration process can continue.

(5) With ALL tanks empty, depress the 0 button on the controller. The 0 light comes on.

(6) At the wing tanks add approximately half (1.625 gal.) of the 3.25 gal. of fuel to each of the two wing tanks.

(7) The fuel will requires some time to drain from each wing tank into the header tank thru the fuel lines. To provide adequate time to fill the header tank from wing tanks, allow about 3-4 minutes).

(8) Depress the 0.25 button on the probe controller and note that the 0.25 light illuminates.

(9) As in step 6, add an additional 3.25 gal. of fuel to the wing tanks (approximately half to each tank). Allow a few minutes for the levels to stabilize.

(10) Depress the 0.50 button on the probe controller and note that the 0.50 light illuminates.

(11) Again as in step 6, add an additional 3.25 gal. of fuel to the wing tanks and allow a few minutes for the levels to stabilize.

(12) Depress the 0.75 button on the probe controller and note that the 0.75 light illuminates.

(13) Again as in step 6, add an additional 3.25 gal. of fuel to the wing tanks and allow a few minutes for the levels to stabilize.

(14) Depress the 1.0 button on the probe controller and note that the 1.0 light illuminates.

(15) Since the tanks are full, and the probe is calibrated at 1.0, all the controller lights will blink for about 4 seconds, indicating a proper calibration. A programming error in the calibration process is indicated if all the probe controller lights stay on steady and the Calibration process should be repeated from the start.

(16) Once the probe has been calibrated, the fuel gauge should illuminate and slowly climb to the top of the gauge indicating a full fuel system. The gauge will NOT display any level until the probe calibration process is complete.
2016-06-27 Fuel Probe & Gauge Calibration Preparation In order to calibrate the Belite Fuel Probe and Gauge, two 1/4" barbed hose fittings are inserted into the bottom of a 14 gallon plastic storage bin. The bin is placed on the top of the fuselage just aft of the top window area. The quarter inch wing tank to header tank fuel fill hoses are attached to these fittings. The two header tank to wing tank vent lines are attached to the top of the bin (above full fuel 13.25 gallons level - keeping the system vented).

At the header tank, the high pressure, unused fuel return and the fuel to pumps lines are shut off (to keep water from entering the system).

Since the calibration procedure requires that the panel toggle switch supplying 1A, 13.4VDC power to the gauge and probe be energized while simultaneously holding down the 0 and 1 switches on the probe controller (inside the access bay), a temporary toggle switch is wired into the RED (+12V) power line to the probe controller (inside the access bay).

2016-06-28 Belite Fuel Probe Calibration - Failure Following the calibration procedure outlined previously, the probe controller started up per the manufacturer's description. The 0 level sensor signal was duly set by depressing the 0 button on the controller.

2.9 gallons of water (a weight equal to 3.2 gallons of gasoline) was added to the tub on top of the fuselage. This represents the quarter tank level. However, when the controller's 0.25 button was depressed to enter the 0.25 sensor signal into the instrument, the 0.25 light did NOT illuminate on the controller.

The sensor signal from the probe controller to the panel gauge was monitored with a VOM to be 1.25 volts. Since the output of the probe required by the gauge is 0-5 volts (empty to full), this is the proper reading for one-quarter full tank. However the probe controller did not "set" in the instrument.

This was reported to James Weibe at Belite. He replied that the instrument must be faulty> I have returned the probe and controller for replacement.
2016-07-30 Initial Engine Startup After re-plumbing the fuel system and verifying fuel flow and the associated electrical circuits (ignition, starter, and EIS). The Viking 110 engine fired up after about 5 sec. of cranking and a loud backfire. The engine ran very smoothly and quietly.


The startup procedure was standard and all EIS parameters were "in the green" during the 30 sec. run of the engine. The shutdown procedure was also normal with no abnormalities noted.

The initial startup was done without the propeller mounted. Once the air-frame is moved to the work-space (boatyard). The propeller will be mounted; pitch set; and and the engine restarted for a longer run period to verify gearbox, coolant, and oil temperatures.

MAJOR MILESTONE as there was some concern because the engine had been in storage for over 6 months prior to startup.
2016-08-01 Prop Mounting & Pitch Set Procedure The 68" dia. Warp Drive Propeller (Serial # N19433) and HPL-R hub assembly mount to the Viking engine gearbox hub and 1.5" Saber Mfg. propeller hub extension with 6 Schedule 8.8 bolts and NordLock washers.

The pitch of the propeller blades is set using the protractor instrument provided by Warp Drive as follows:

(1) mount the propeller to the engine with the components as noted above ... finger tight, plus one-quarter turn on the 8.8 hub bolts and AN4 blade clamping bolts ... note the the blades have the edge protection strip on the upper surface of the blades.

(2) Place a brace under the tail to hold the nose down firmly

(3) Place the protractor against the prop hub and note the angle with the bubble centered. This need not be zero, but the pitch will be set by adding 12 degrees to this value for each blade.

(4) Rotate the propeller until the blade is parallel with the floor. Measure the distance from the floor to the tip of this blade. This height will be replicated for each of the other two blades as well.

(5) Mount the protractor at the tip and rotate the blade in the positive direction (top of blade forward) to a reading of 12 degrees (plus the offset from step 3). Be as precise as possible in centering the protractor bubble.

(6) Tighten the 4 AN4 blade clamping bolts to hold the blade in position. Accurate torquing will be done on completion of all 3 blades.

(7) Repeat steps 4, 5, & 6 for the remaining two blades.

(8) Torque the 6 schedule 8.8 bolts to 180 inch-pounds.

(9) Torque the 4 AN4 clamping bolts for each blade to 120 inch-pounds.
2016-08-03 Cowling Edge Extension Test Since the 2015 configuration of the Viking 110 engine requires 3" of prop hub extension in order for the cowling to clear the gearbox sensor and oil fittings, the after surfaces of the cowling halves (and the radiator intake fairing) need to be extended at least 2 inches. The method chosen to to this is to attach "joggled" strips of 0.016" 6061T6 to these surfaces.

(1) A "joggled" (~ 3/32" ... the thickness of the fiberglass cowling material) section of aluminum strip was prepared and fitted to a scrap portion of the fiberglass cowling material

(2) The strip was clecoed (copper) to the fiberglass for fit

(3) the clecos were removed and the cowling overlap area was fiberglassed (epoxy) then held in place with clecos until the fiberglass resin/cloth set.

(4) the clecos were removed and replaced with flush rivets.

A good/solid extension was produced and the method will be used to extend the aft surfaces of the cowing and the radiator intake fairing.
2016-08-05 Cowl Mount Fixture With the 3" prop hub extension in place a means of securing the fiberglass cowl in position at the hub end is required. A 12" square piece of scrap plywood was drilled to fit the prop hub (8mm) mounting bolts pattern. Affixed to the aft surface a 10" ring of 11/16" plywood was added to provide adequate clearance for the mounting bolts of the propeller blades into the prop hub and the front of the cowl.

Later, the front of the cowl will be positioned against the plywood ring to determine the amount that aft cowl edges must be extended to provide sufficient fuselage skin overlap surface to securely mount the cowling.
2016-08-06 Elevator Bellcrank Adjustment The bottom surface of the header tank has a drain plug slightly starboard of the center-line. The plug extends approximately 1/2" below the surface of the tank. The upper elevator cable (from the bellcrank to the elevator horn) must freely travel port-starbord and the plug fixture may, at the extreme starboard limit of the motion, be slightly impeded. Since the elevator bellcrank is offset approximately 1" starboard of the control rod center-line, moving the upper cable shackle towards the center-line will help alleviate the problem.

A 7" length of 0.09" thick 4130 was attached to the upper arm of the existing bellcrank and the shackle move to the new position providing a better range of motion for the cable.
2016-08-07 Tail Tiedown Ring A 1" eye-bolt (5/16" dia.) was installed in the fuselage floor thru the lower rudder mounting plates under a large diameter washer used to distribute the loads. Locktite and lock washers secure the bolt.
2016-08-08 Rudder Spar Fairings The pre-bent upper (7R3-3) and lower (7R3-4) rudder spar fairings were positioned , drilled, and debured. The fairings were treated for anti-corrosion and installed using A4 and A5 rivets.
2016-08-10 Mount Horizontal Stabilizer to Fuselage The H. Stab assembly (stabilizer and elevator) are affixed to the fuselage using via the 4 Horizontal Stab Attachment plates (7F3-4) which are riveted to the aft fuselage sides. The H. Stab is mounted with 4 AN3 nuts and bolts with the positioning centered on the tabs and the stabilizer assembly level with the top of the fuselage.
2016-08-14 Slats Prep The slats were 1st removed from the trial fit to the wings to be prepared for priming and painting. After inspection a balsa plug was made to fit the gap at the outboard port slat tip and was epoxied in place followed by an initial light sanding of all surfaces with 400 grit paper. After sanding, inspection showed a small dent in each of the slats and each was resurfaced with Bondo.

Later the slats will cleaned with warm water, primed with Eastman Self-Etching Primer and painted overall with 2 coats of Bright Purple (AE-1511) automotive acrylic urethane enamel.

2016-08-15 Forward Vertical Stab Fin The fwd vertical stab fin (7C6-4) was provided bent to shape but requires slotting at the rear surfaces to fit the leading edges of the horizontal stabilizer.

A cardboard template was made using a spare horizontal stab. rib. The template was used to trace the outline of the horiz. stab nose skin on the sides of the fwd vert stab fin which was cut to approximate shape using aviation sheers. The piece was then fitted/trimmed/fitted several time using a drum sander and half-round files.

The fin will be mounted to the top of the fuselage after the rudder and Aft Vertical Fin (7C6-5) are mounted.
2016-08-16 Re-route Oil Line for Cowling Fit The cowling for 2015 version of the Viking Engine as delivered from Jan did not fit due to the placement of the gearbox temperature sensor and the routing of both the gearbox oil line and the engine oil return line.

The gearbox related problems were partially fixed with extensions to the aft portions of the cowling. (Problems at the prop-hub end are being addressed with the design of a new nose ring.)

The factory routing of the engine oil return line (engine to oil sump) forced the lower cowling against against the line (lowering the placement of the cowling and causing friction between the hose and the rough inner fiberglass of the cowl). This necessitated the re-routing of the oil line as per the pictures.
2016-08-17 Trim Fuselage /Firewall Skin to Fit Cowling 0.75" of excess fuselage side skin (fwd of the firewall) was trimmed (3" cutoff saw) to allow for clearance at the propeller hub.
2016-08-18 Trial Fit Lower Cowling to Fuselage The lower cowling was attached to the fuselage and inspected for fit and positioning to assure clearance of the prop hub, oil engine/sump line, gearbox oil temperature sensor and return line.
With a suitable alignment, the lower cowling (with piano hinge attached) was clamped in place and the upper cowling positioned and the hinge line location noted for trimming.
2016-08-19 Lower Cowling Mount - Starboard Side The trial fitting of the lower cowling indicates that there will be sufficient space to allow the needed clearances and the fitting of the top cowling.

In order to provide relatively easy removal of the lower cowling for any possible major engine work, the lower cowling is being attached to the fuselage sides using stainless #10-32 truss head screws with large bearing washers. However, since in many locations there is very little space to access the AN3 elastic stop nuts inside the engine compartment, getting the washer/nut threaded onto the screws was accomplished by using scotch tape over the end of the 3/8" wrench (per the picture).

The excess 0.016" "joggled" skin will later be trimmed to allow clear the heads of the rivets securing the fuselage side skin (cheeks) to the firewall.
2016-08-20 NACA Oil Cooler Air Scoop Preliminary Installation A template for the opening in the lower cowling was made and used to locate the position on the starboard side of the lower cowling. A set of #40 holes were drilled along the perimeter of the required opening and an Exacto saw was used to remove the plug material. The scoop was then positioned on the inside of the lower cowling and clecoed into position. It will be fiberglassed in later.

The interior of the scoop has a 2.5" diameter collar matching the diameter of the collar on the oil cooler. A 2.5" ID flexible hose will connect the two.
2016-08-21 Bubble Doors - Trial Fit Each of the bubble doors required initial trimming of the upper surfaces (to provide clearance for the folding win mechanism) prior to positioning in the fuselage openings so that the excess edge surfaces could be marked for trimming.

The forward and aft surfaces were marked form the inside of the cabin as theses edges fit inside the fuselage/cabin frame. The lower surface extends outside the fuselage/cabin skin to provide a closing surface for the handle mechanism. The upper surface was marked for trimming at the hinge line.

2016-08-22 Prepared slats & primed slats The slat surfaces were prepared for priming by filling several small dented surface areas with bondo and sanding smooth. A gap at the port slat tip was repaired by epoxying a shaped plug of balsa. The slats were then hung in the "paint shed" and surfaces were wiped down with lacquer thinner and a tack-rag to remove any dust prior to spraying with Eastwood Self Etching Primer (2 light coats).

The results were good and the slats are now ready of a light sanding and application of the base color coats.
2016-08-23 Prepared and Primed the Access Bay Cover Panel As a test of the new Spray Fine HVLP System (1.3mmm tip), tha access bay cover panel was prepared for priming/painting (cleaned with lacquer thinner and wiped with a tack-rag). It was then hung in the "paint shed) and sprayed with two light coats of Eastwoo Self Etching primer. Excellent results.
2016-08-24 Slats - Base Purple Spray Coat Sprayed the 1st base color coat (Bright Purple, TCP Global, 1511).
Mix 8:1:1 (color:Hardener:Reducer). Results fair, some "orange peel", will light sand and add additional reducer for 2nd and final coat.
2016-08-25 Spray Self Etching Primer After preparing the rudder for priming (light sanding and cleaning with tack-rag), the tail-light assembly was masked with painter's tape prior to priming. The Rudder was sung in the "paint shed" and sprayed with two light coats of Eastwood Self Etching Primer. Used the new Spray Fine HVLP System to good effect.
2016-08-26 Attach NACA Oil Cooler Air Scoop The NACA scoop was riveted & epoxyed in place on the starboard side of the lower cowling. The exterior of the scoop mount was finished with bondo into a smooth surface.

A length of 2.5" diameter flexible vent hose was secured to the engine oil cooler with a vent hose clamp. The other end will be attached to the NACA scoop once the lower cowling is in place on the fuselage using an additional vent hose clamp.
2016-08-27 Attach Lower Cowling With the lower cowling roughly in place with the prob hub opening centered, a short length of 3/8" 6061T6 tubing was cut and bolted to the engine block and port side of the lower cowling hinge. The brace holds the lower cowling in position which will be further secured by fitting the upper cowl. A #6-32 screw and elastic stop nut are used at the cowl making it easier to remove the lower cowl for extended engine inspection and maintenance.

The lower cowl is attached to the fuselage sides with #10-32 satinless truss head machine screws (with oversized washers and elastic stop nuts internal). To complete the removable lower cowl assembly fabrication and installation of the baffling between the engine and cowl radiator air scoop will be completed later.

The NACA oil cooler duct hose routing is completed by attaching the hoe to the NACA scoop that was riveted/epoxyed to the starboard side of the lower cowl. The attachment is made with a 2.5" dia. duct hose clamp.
2016-08-28 Trim & Fit Passenger Side Door The passenger side bubble door was held against the door opening of the fuselage cabin and marked for trimming.

The door as provided is very much oversized and the folding wing mechanism hinders initial placement. It is held in place with the interior reinforcements inside of the fuselage cabin opening. The top of the door is positioned against the piano hinge and the ends marked. This excess is trimmed off (hand held rotary saw) so that the upper edge now fits cleanly in position under the folding wing mechanism so that the side and bottom edges can be marked.

The fore and aft edges are marked to allow the door to fit INSIDE the cabin frame. The two section of the bottom are marked to allow a 6mm overlap of the door OUTSIDE the cabin frame.

The fit/mark/trim process is repeated several time until a good fit is obtained. The door handle and latching mechanism will be installed later.

The process will be repeated for the pilot side door.
2016-08-29 Passenger Side Door - Trim Trial Fit After much fitting/trimming/fitting/trimming. The passenger side door now fits the fuselage/cabin opening. The picture shows the door held in place for fitting and drilling for mounting to the hinge.

A 6" section of the lower front portion of the door will require a fiberglass "plug/extension" of about 5/8" to fill a gap below the area where the bottom of the windscreen meets the fuselage side.

2016-08-30 Build Folding Wing Cradle The process for the CH-701 folding wing option requires a cradle to support the wings at the aft fuselage. A full-sized template (FWO-4)was provides with the FWO kit and was used to trace the pattern for the cradle on a sheet off 0.75" plywood. The piece was cut out with a jig-saw and trimmed and sanded into the final configuration.
2016-08-31 Passenger Side Door Fitting The bubble doors attach to the fuselage cabin opening via the top piano hinge. Both the forward and aft edges are trimmed to fit inside the opening and the bottom edges are trimmed ~ 6mm oversized to fit flush against the side of the fuselage in order to help provide a tight fit once the latching mechanism is installed.

To get a proper fit, the lower portion of the fiberglass reinforcement must be trimmed. The semi-circular reinforcement was cut and trimmed to fit and the resulting opening filled with quarter-round wood strips epoxied in place to help provide continued rigidity to the structure.

The latching mechanism utilizes a steel L-angle strike-plate riveted to tho the lower, forward cabin door frame. The door handle and latch mechanism are positioned on the door such that the interior latching arm and handle engage the strike plate to lock the door closed.

The forward and rear edges of the door will be fitted with rubber U-channel to ensure a good seal between the door and the fuselage/door frame.

The door/handle/latch/U-channel are not riveted/screwed/glued in place but are left as a removable assembly so that the door can be more easily painted.
2016-09-02 Passenger Side Bubble Door Problems Fitting the passenger side bubble door has been more of a problem than anticipated. This is probably due to the folding wing mechanism and the lack of information on fitting the bubble doors to the 701 with the folding wing. The instructions for the std door require that the fwd top edge of the doo be trimmed ~50mm to clear the mechanism. Trial fits indicated that this is not the case.

Repeated fit/trim operations were required to even get the door to fit the opening. Still have problems with an 18mm gap at the lower fwd edge. Repeated discussions with Roger at Zenith have given me a few things to try.
2016-09-04 Passenger Side Bubble Door Problems (Part 2) Roger at Zenith suggested that I relocate the door piano hinge further inboard of the top door sill. This required drilling out the rivets attaching the hinge to the sill. In order to strengthen the mounting surface I added a length of std L-angle inside the cabin and over the bottom edge of the sill.

I re-installed the hinge with the hinge-pin line just inside the fuselage frame (rather than outside, per the std door plans); then again trimming and fitting the bubble door. This reduced the gap at the lower fwd edge somewhat, but still not enough.

More discussions with Roger and we feel I have but two possible solutions:

(1) Trim back the lower edge of the door that overlaps the fuselage side to provide a surface for securing closed door to the airframe thus allowing the full door to fit inside the cabin frame.

I am loath to do this except as a last resort as I fear that the door will not seal properly and that the lower aft area will be very loose.

(2) I can fabricate an additional latching mechanism to be installed on the inside of the door in the area of the gap. This means that the passenger will need to close the door with the std door handle/latch AND the fwd latch (to seal the gap.

This seems a viable solution easily designed and implemented. The question then arises that if the pilot side door fits well WITHOUT the 2nd latch should one still be installed if for nothing but summetry?
2016-09-05 Battery Charging Terminal Block The battery charging terminal posts thru the upper starboard portion of the firewall for access with the top cowling removed provide an opportunity to extend the terminals to a position on the bottom of the starboard firewall making access to the charging posts possible without removing the top cowling.

This required the design and fabrication of a non-conductive terminal block thru which the charging posts could be mounted. Visio was used to design the block which Fred was kind enough to fabricate using his 3D printer.

AN4 bolts were inserted as posts and the block was riveted in place on the lower starboard side of the firewall. 6 AWG cables were run from the upper posts, thru the firewall upper channel (7F7-1SP), and down to the lower terminal block.

A VOM was used to verify the circuits.
2016-09-07 Prepare Air Scoop Baffle With the extension to the cowling to fit the engine (as delivered), the molded radiator air scoop of the cowling requires a baffle to mate with the engine radiator air intake. Spray polyurethane foam was inserted into the space between the inside of the cowl and the engine to provide a surface for laying up layers of fiberglass for the baffle. Once the fiberglass has set & cured much of the foam will be removed (trimmed/cut away and, where possible without damaging the fiberglass, dissolved using acetone).

2016-09-08 Air Scoop Baffle - Fiberglassing After the 1st layer of fiberglass has set & cured, the area is roughly sanded and the 2nd (final) layer is laid up.
2016-09-09 Air Scoop Baffle - Finishing With the final (2nd) layer of fiberglass set and cured, the baffle is rough surface sanded for finishing with body putty. The Bondo is liberally applied and allowed to cure while the interior urethane foam is cut/dissolved away.

Once cured, the exterior surfaces of the baffle are finish sanded smooth and the baffle is ready for painting at a later date.
2016-09-11 Passenger Side Bubble Door (Part 3) After further discussions with Roger at Zenith I opted for solution 1 (trim the dor to fit entirely inside the fuselage door frame.

Numerous trial mount/fit/mark/trim operations and the door fits fairly well into the fuselage door frame. There is still about an 8mm gap at the lower front surface. Two possible solutions t the problem:

(1) Add an additional latch mechanism to the lower forward area of the door.

(2) Fabricate and rivet what appears to be a 3/8" thick bar to the latch strike plate to pull the door further into the frame.

In either case additional stop strips will be necessary at along the lower fuselage door frame to keep the door seated properly when closed. I have designed these stop strips and Fred will attempt to make them up for me using his 3D printer.

As a trial, I will fabricate a 3/8" strip to place over the frame latch plate as a solution.

2016-09-12 Passenger Side Bubble Door (Part 4) In order to close the gap at the lower forward edge of the door, I designed, constructed, and installed an additional latch mechanism that mounts thru the door and closes the gap when secured. This means that to close the door the passenger must secure both the lock/handle/latch mechanism and the additional latch.

The latch was constructed of scrap 6061T6 strip and round stock with the handle at an acute angle in order to clear the std lock handle mechanism.

The long latch handle arm will be trimmed to clear the fwd cabin frame strut and the length of the round bar bushing will be trimmed to length to have the door close the gap when secured.
2016-09-13 Port Outboard Tip Gap Fix The plastic slat tips included in the kit all fit rather poorly into the slat ends. The sharp corner of the aft leading edge does not readily conform to the rounded plastic tip without gaps.

Three of the 4 plastic tips fit rather better than the port outboard tip (~ 20mm tapered gap). As a solution I carved a filler block from balsa and used epoxy to sit it in place to somewhat aerodynamically fill the gap.
2016-09-14 Compound Buffing - Port Slat Spraying the slats with two coats of base purple (after priming) resulted in many small runs and "orange peel". After discussions with TCP (paint provider) I purchased a 7", 10A, variable speed rotary buffer (Harbor Freight) and pint of Meguair's Fine Cut (~1200 grit) buffing compound per TCP's recommendations.

The port slat was 1st lightly sanded 800 grit (dry) paper to remove the tops of the run "bubbles" and the higher ridges of the orange peel. A through sanding with 1500 grit wet paper to smooth out the rough areas of the surface. Finally, the surface was compounded with the rotary buffer and find cut compound to a flat, smooth finish.

In a few locations the process took the finish down to bare metal. When I next mix a batch of the urethane enamel, I will sue a 3" roller to cover these areas. I will finish the areas by wet sanding to feather the spots and apply a light buffing.

The forward surfaces of the slat will be finished in the orange checkerboard pattern. The present plan is to use the mats provided by Greg Judy to layout the checkerboard and apply the orange squares with a hobby airgun.

The completed slats will be given a polishing coat of Turtle Wax to complete the finishing.
2016-09-16 Compound Buffing -Stb Slat Same orange peel problems. Wet sanding and compounding as per the port slat.
2016-09-18 Compound Buffing - Slats Continue compound/buffing process to remove orange peel.
2016-09-19 Pilot Side Door Install - Part 1 The Pilot side door seems to present the same problems as with the passenger side. After much fitting/marking/trimming it was determined that the this door also needs to fit inside the cabin/fuselage frame.
2016-09-20 Pilor Side Door Install - Part 2 The door now fits inside the cabin/fuselage frame but as with the passenger side, there is about and 12mm gap at the lower front. I will not remove and re-position the hinge (as done on the passenger side) as this did not provide much gap relief. I will fabricate and install a lower-forward latch as with the passenger side.
2016-09-21 Pilot Side Door Install - Part 3 Fabricated and installed a latch handle identical (mirror image) to that installed on the passenger side. Door now fits pretty well. I will add the lower frame stops once Fred returns from his holiday visit to Argentina and we can use his 3D printer to fabricate the parts.
2016-09-22 Fiberglass Door Surfaces The bubble doors were removed and the fiberglass surfaces cleaned (interior & exterior) prior to painting. The factory masking of the clear plexi-glass is left in place.

The interior surfaces were sprayed with Light Ford Gray Magic Tractor & Implement Enamel.

The exterior surfaces were sprayed with Sheman-Williams Dimensions Gloss Orange Automotive Enamel.
2016-11-12 Install Rivnuts for Removable Pilot Seat The radio/intercom PTT wiring, headsets & microphone connections, and flaps linear actuator are mounted under the pilot seat. To provide relatively easy access to this equipment it was decided to install the curved aluminum seat bottoms (7F16-1) using #6-32 rivnuts (37 per seat).

This proved to be a difficult process because half of the rivnuts were found to be steel rather than aluminum and the relatively small size (#6) put a strain on the Harbor Freight hand rivnut setter (two mandrels snapped off setting these steel rivnuts). The aluminum pieces went in easily so I ordered another 50 to do the passenger side.

The steel rivnuts required a larger mounting hole (7/64" dia), so I added a strip doubler to the fuselage seat back wall.
2016-11-13 Pilot Seat Gusset Install A rather complex gusset (7F11-7) is required to cover the ouside edge of the seat where it joins the seat front (7F11-1) and the fuselage cabin side. A rough outline of the gap to be covered by the gusset was made by tracing the outline of the gap on a piece of cardboard. The edges of the template were extended (for folding-planes which provide internal surfaces for mounting.

The template was trimmed to fit the opening and then was used to trace the outline of the required gusset on s piece of 0.025" 6061T6 sheet. The sheet was cut, bent, and fitted with the flanges inside the opening. It is riveted (A4) to the seat front and fuselage side rail. A single rivnut secures the top pf the gusset to the seat front flange and to the front of the seat itself. Two rivnuts are used to secure the aft flange of the gusset to the forward portion of the sat bottom.

To access the equipment under the seat, all 37 #6-32, phillips, truss-head machine screws must be removed.
2016-11-14 Removable Seats Installed Completed the installation of all 74 rivnuts securing both the pilot & passenger seats to the cabin/airframe. The seats are secured with #6-32, phillips truss-head screws.

As noted, problems were encountered with the original steel #6-32 rivnuts. The mandrel for the Harbor Freight installation tool was not strong enough to set the rivnuts. a total of 3 mandrels broke during the operation before replacement aluminum rivnuts were obtained and installed.

Rose is making custom, foam filled, seat cushions which will be secured to the seats with snaps.
2016-11-16 Stb Slat Fix When applying the base color coat to the slats, it was noted that the stb slat had a slight bow where the two sections were riveted together. To remove the bow the A4 rivets at the joint were drilled-out and the slat secured to a flat, level surface with cargo straps to set the two pieces in proper alignment. Doublers (strips of 0.016" aluminum) were inserted in the joint between the top and bottom surfaces. The existing A4 rivet holes were re-sized and A5 rivets were installed to secure the joint.

In drilling out the A4 rivets, the rivet bodies slipped into the interior of the slat structure. To remove them a 0.75" hole was drilled in the rear surface and the slat rotated until the rivet barrels were removed. A piece 0.016" aluminum sheet was riveted in to cover the hole.
2016-11-21 Install Forward Dorsal Fin The forward section of the dorsal fin is attached to the top of the fuselage with 20 phillips #6-32 truss head machine screws an rivnuts. Thus the forward portion of the dorsal fin is easily removable for servicing the elevator cables.

The upper section of the dorsal fin mounts to the top of the elevator using standard L-angle and will also be attached using rivnuts.
2016-11-23 Rudder Leading Edge Sanded primer of the fwd stb surface of the rudder with 1500 grit wet paper in then masked off the aft surface (purple) in preparation for applying the orange urethane.

Applying the 1st coat of orange it is noted that the purple over-spray is not covered well with the Dimensions-2 orange urethane mixed per the (4:2:1, color:hardener:reducer) instructions. It appears that at LEAST three coats will be required. I will try to avoid purple (base) over-spray as much as possible on other surfaces.
2016-11-24 Jig for fitting aft dorsal fin The aft portion of the dorsal fin is mounted on the tip of the horizontal stabilizer. It extends upwards into the lower area of the rudder. Without enough ceiling space to actually mount the rudder to determine the dimensions for the dorsal fin, a jug was created to determine the angle to which the top of the fin must be trimmed to fit under the rudder.

The jig was mounted and measurements taken to make the dorsal fin mods.
2016-11-26 Assemble Aft Dorsal Fin The aft section of the dorsal fin mounts on top of the horizontal stabilizer and requires positioning and trimming so that the top portion provides clearance for the one-piece rudder to travel.

With the forward section of the dorsal fin in seated on top of th fuselage and around the leading edge of the h. stab., the aft portion is positioned and marked for trimming such that the top is situated under the jig arm.

The area is trimmed to fit. The aft section re-positioned on the top of the h. stab. and the #40 holes drilled thru the fin's mounting flanges and into the h. stab.

Both the forward and aft sections of the dorsal fin assembly will mount using rivnuts and #6-32 stainless, phillips, pan-head screws.

The aft section is removed for capping the upper end prior to final mounting.
2016-11-27 Fabricate & Install the Aft Dorsal Fin Cap A scrap piece f 0.025" aluminum is cut and bent to cap the opening in the upper end of the aft dorsal fin section. It is riveted in and the fabrication holes are sealed with fiberglass putty prior to covering.
2016-11-28 Prme and Sand Rudder The rudder was cleaned 1st with warm soapy water; then flushed with clear, clean, warm water followed by a wipe-down with lacquer thinner to remove any oils on the surfaces. A coat of Eastman Self-Etching Primer was applied and allowed to dry prior to light surface sanding with 1200 grit paper (wet) in preparation for applying the color coats and vinyl wrap of the leading edge.
2016-11-29 Vinyl Wrap Dorsal Fin Sections The aircraft will be trimmed using 3M-1080-G14 (Gloss Burnt Orange) vinyl wrap material. To test the application process on a complex surface, a scrap h. stab. nose rib section was covered in the material. The process was found to be relatively easy and good results were obtained.

With the promising results of the vinyl application test, the process was repeated in covering the two dorsal fin sections. It is noted that that the smaller the area to be covered the more taxing is the process which is definitely aided by an additional person.

The process produced excellent results.
2016-12-01 No-Fuselage-Slot Flaps Mods The as-is design for activating the 701's flaperons requires a crescent shaped 1.5" x 8" slot in each fuselage side in the baggage compartment area aft of the cabin/door where the sides start tapering (7 degrees) to the tail. Many builders have reported that this slot makes the cabin noisy and is a source of wind and moisture entering the baggage compartment. An 801 builder has developed a modification for flaperons control that translates well to the 701 and many builders have successfully incorporated the modification. However, I can find no documentation on this modification in conjunction with the folding-wing mechanism. As such I have modified the design to allow the no-slot-flaps mechanism to work with the folding wing.

The basic problem is that the folding-wing requires that the wing assembly slide out along the folding tube/collar (at the forward spar) to clear the mounts to the fuselage. However, the flaperon control (hinge) rod passes thru the aft fuselage a t a 7 degree angle and as such cannot slide out of the mating collar on the inboard flap rib (it needs to be parallel to the folding wing rod, perpendicular to the cabin side). to facilitate this a wedge block (7 degree taper) is affixed to the fuselage side (inside the baggage compartment) putting the control rod bearing parallel to the cabin side. Additionally the hinge plate affixed to the inboard flap rib has the control rod collar bent making the connection parallel to the cabin side (wing root).

To fold the wing, in addition to the standard folding procedure, an AN3 bolt is removed from the control(pivot) rod and collar; allowing the wing to be moved outwards to clear the attachments for folding.
2016-12-02 Fabricate Gear Plates (7L2-2J) for mounting leaf spring Layout and trim the basic gear plate structure from 3/4" L-angle stock (1/8" thick). Locate and drill the 3/8' holes in either end for the gear strut mounting studs. Deburr and corrosion protect (flat black Rust-o-Leum to match exterior structures).
2016-12-02 Fabricate fuel/vent line pass-thrus The header tank mounted in the fuselage just below and aft of the baggage compartment is fed from and vented thru the wing tanks. These lines are routed thru the door sill U-channel and as such require 1/4" id barbed-hose panel fittings. Since the U-channel has a 3/4" gap between the interior and exterior skins, fiberglass mounting panels were installed allowing the pass thru fittings to be mounted/accessed.

Originally the panels were to mount quick disconnect fittings to allow for the wing folding process, but it was decided that it would be easier to access the quick disconnect fittings thru the inspection doors mounted in the lower wing skins at the wing root.

2016-12-03 Replace/Re-route fuselage fuel/vent line hoses When installing the fuel and vent line pass thru fittings between the header and the wing tanks, a discoloration of the tygon fuel hose was noted so it was decided to replace these hoses with 1/4" Honda auto fuel line hose (SAE 30R7).

The tygon hoses were originally routed from the header tank thru the baggage compartment floor skin with rubber grommets. These were replaces with 1/4" barbed-hose panel connectors (for both the port & stb fuel & vent lines).
2017-01-06 Elevator Cables Spacer/Spreader & Guide Design The elevator control cables from the control stick bell-crank passes very close to the bottom of the header tank and extreme stick movement (up-down elevator and left-right aileron) positions may cause some rubbing against the bottom of the tank. To reduce this:

(1) a 3mm teflon sheet was epoxied to the bottom of the tank

(2) a rounded cable guard/guide (wood) was also added to smooth the passage of the cables over an unused lower tank fitting

(3) a plastic spreader was designed (3D printer) to keep the cables separated and provide a mounting surface for the light bungee-cord required to route the cables from the bell-crank to the elevator horn.
2017-01-08 Lift Struts Preparation The 2040mm lift struts have U-fittings welded into the gear/fuselage end. They need to be drilled out for AN5 mounting bolts and trimmed to allow some freedom of movement at the gear/duselage fitting.
2017-01-10 Upper Wing Strut End Fittings The 2040mm long wing lift struts slide into the forward and aft upper end fittings. The fwd U-ends have a slightly wider opening than the aft U-ends in order to fit over the thicker fwd wing strut attachment points.

The ends of the 4130 steel tubes are each pre-drilled for 3 AN3 bolts. The U-ends are rounded to allow some freedom of movement when bolted to the wing fittings with AN5 bolts. The long strut ends slide into these short fittings and are drilled to fit at rigging.
2017-01-12 Air File Port Side of Cowling Hinge The piano hinge for attaching the upper & lower cowling sections is a tight fit. To make the mating easier for the long hinge pin Jam suggests filing a bevel on the hinge barrels. Since the hinge is steel and has 35 barrels per side, as a test, I used an air file to slightly bevel the aft portion of the lower hinge barrels. This is a tedious operation, but appears to really help in seating the upper & lower cowl sections. I will repeat the operation for the starboard side.
2017-01-14 Port Wing Strut Fittings The fore and aft wing strut attachment fittings are drilled for AN5 mounting bolts. The holes are located by using the upper strut fitings and drilled out from 1/8" to 3/16", to 5/16" (AN5). Note fwd attachment fitting is thicker than the aft fitting.
2017-01-16 Stb Fwd Door Latch Strike Plate As noted previously, once installed, the bubble doors leave a gap at the lower fwd area of the cabin door-frame. An Additional latching handle mechanism was added to alleviate this problem. However installation of the additional latch/handle mechanism showed that a strike plate (approximately 13mm thick) is required to have the door secure properly flus with the fuselage side.

A mount for the plate was designed and constructed from two lengths of std L-angle and a laminated plywood strike plate surface was riveted to the assembly which is secured to the fuselage side just fwd of the cabin strut with 4 AN4 rivets.

The prototype constructed and fitted for the starboard side appears to work well and will be duplicated for the port side.
2017-01-18 Folding Wing Support Cradle In order to fold the wings against the fuselage for storage or transport. The wings must be supported at the tail. The support structure is a 3/4" plywood cradle that rests on the top of the fuselage at the dorsal fin. It is cut such that the slats/leading edges of the wings are supported in a fitted cradle.

To protect the fuselage, slat, and wing skins the support structure was lined with indoor/outdoor carpeting.
2017-01-19 Folding Wing Support & Hinge Mechanism The Folding wing support tube mounted in an extension of the cabin frame is drilled for an AN4 bolt that passes thru the U-mount attached to the bottom of the wing at the fwd spar and rib 1.
2017-01-20 Pre-drill & Shape Fwd Wing Mount Fittings The fwd wing mount U-fittings need to be trimmed and pre-drilled (under-size) prior to mounting the wing. At rigging these under-sized pilot holes will be used to locate the mounting bolt holes for the wing mount ab at the wing root.
2017-01-23 Oil Cooler AirScoop Paint The cutout in lower stb cowling for the oil cooler air scoop was masked with tape and butcher-paper to allow painting the interior (throat) of the scoop with gloss black engine enamel.

Later the interior of the throat will be masked to allow the cowling to be painted.
2017-01-26 Wing Stand #1 In order to rig and/or fold/unfold the wings a support stand is needed for placement at each wingtip. The 1st of these stands was constructed of scrap lumber and 0.75" PVC pipe. They proved to be rather flimsy and difficult to adjust so a 2nd, more substantial and easily height adjustable stand was designed and built.

The fore/aft and lateral bracing lath strips were made to be removable and the base legs can be rotated in order for the stands to lie flat for transport.
2017-01-28 Wing Stand #2 Constructed 2nd wing stand similar to the design of #1.
2017-02-01 Angle-of-Attack Vane Mount The Barker Aircraft AOA instrument vane will mount on the pilot-side jury strut. The mounting collar of the instrument vane contains the Hall sensor that converts the magnetic field swinging vane into a signal passed to the display on the instrument panel. The collar slides onto a 5/8" diameter rod that is molded into a flat plate that attaches to the lower-fwd jury strut bracket.

The vane mount was designed using the Design Spark CAD software and made on Fred's 3D printer.
2017-02-15
2017-03-25 Move N701LT to Boatyard Facility The project has outgrown the garage workshop in both height (vertical tail) and space to mount/rig the wings. With little or no hangar space available in North Texas (2-3 year waiting lists) The project is being moved to a boatyard storage facility in Lucas (3.8 miles away). While the space has a 20' ceiling and roll-up door and excellent concrete floor, it is without power and is only 12' wide. Storage and work will require the use of the folding wing mechanism.

The move is being made using a modification to my 4'x 8' utility trailer. Since the track (wheel to wheel) is 6'2", a 3/4" plywood extension is bolted to the trailer bed just aft of the wheels.

The project is rolled up onto the trailer using my bob's ramps. It is then secured using cargo straps and transported to the facility.

The wings are transported on the trailer separately.
2017-04-02 Surface preparation for painting Removed all of the vortex generator plates (2 #6-32 screws each). Cleaned and primed the 16 VGs.

Repaired several dings in the surface skin with epoxy filler paste. Smoothed and sanded the surfaces. Wiped down with lacquer thinner to remove any oils. Cleaned the surfaces with warm, soapy water; let dry and primed with Eastwood self-etching primer.

After drying, lightly wet finish sanded the surfaces with 2000 grit paper.
2017-04-06 Surface Preparation for painting Repaired several dings in the surface skin with epoxy filler paste. Smoothed and sanded the surfaces. Wiped down with lacquer thinner to remove any oils. Cleaned the surfaces with warm, soapy water; let dry and primed with Eastwood self-etching primer.

After drying, lightly wet finish sanded the surfaces with 2000 grit paper.
2017-04-06 Basecoat color Sprayed on a 1st coat of AU1511 purple automotive enamel on the VGs and let dry the re-installed the VGs on the underside of the elevator leading edge.

Used a tack-cloth and micro fiber towel to removed any dust from the surfaces and hung the horiz. stab. in the storage shed/paint facility for spraying.

Applied two coats of the AU1511 (purple) automotive enamel.
2017-04-08 Basecoat color Used a tack-cloth and micro fiber towel to removed any dust from the surfaces and hung the horiz. stab. in the storage shed/paint facility for spraying.

Applied two coats of the AU1511 (purple) automotive enamel.
2017-04-09 Slats - Checkerboard Vinyl After application of the purple base-coat 3M knifeless cutting tape was applied in the 110 mm checkerboard pattern in preparation for covering with 3M 1080=G14 Bright Burnt Orange Vinyl.
2017-04-11 Slats Vinyl Checkerboading The 3m Knifeless Tape process worked well for applying the alternating 110 mm orange checkerboard squares to the leading edge surfaces of the slats. Cutting and peeling away alternating squares was a time-consuming process.
2017-04-19 Slats Checkerboarding - 3M Knifeless Tape Many hands were required to apply the full span (un-cut) orange vinyl over the outer surfaces of the slats priot to using the knifeless tape to cut the 110 mm squares.
2017-04-21 STOL CH-701 id on Rudder Port Side Laid-out stencil to port side of rudder and applied 1st coat of orange. The lighter orange color over the purple base-coat bleeds thru and will require 2-3 more coats.
2017-04-22 STOL CH-701 id on Rudder Port Side After 3 coats of orange to overcome the purple base-coat bleed thru the many coats of orange extend significantly above the surface of the rudder. At best it will require a coat of clear to seal the application. Will try applying a coat of masking color prior to 1st orange on the stb side.
2017-04-24 STOL CH-701 id on Rudder Stb Side Laid-out the id stencil on the stb. side and applied a rattle-can coat of masking enamel prior to the 1st orange coat. After drying, the 1t coat of orange appeared to cover well and was allowed to dry.

When removing the stencil mask parts of the lettering lifted away from the rudder surface. I attribute this to a poor bond between the base-coat purple acrylic enamel and the rattle-can enamel mask.

Allowed the lettering to set and attempted to repair the lettering by free-hand application of orange with artist brush. The results were an uneven distribution of the paint. It looks pretty good at a distance but not so well up close. Possibly a coat of clear will improve the appearance.
2017-05-02 Checkerboarding Slats - Paint/Vinyl Wrap Preperation 1st the leading edge slats are primed with automotive self-etching primer; then sanded and sprayed with the base coat of purple.

The checker-board pattern will be applied using 3M-1080 Burnt Orange Vinyl Wrap.
2017-05-02 Spinner Painting The spinner is painted with burnt orange Sherwin-Williams Automotive Enamel
2017-05-03 Vinyl Wrap Starboard Slat The checkerboard squares pattern is laid-out on the leading edge surface of the slat using 3M "knifeless" cutting tape in 4 squares. The 2 span-wise lengths (4" apart) are applied 1st followed by the shorter cord-wise lengths applied every 4".

The full leading edge of the slat is then completely wrapped with 3M-1080 Burnt Orange Vinyl Wrap material. As the backing is removed the adhesive surface is very difficult to work with and many hands are required to apply it smoothly. Once applied a teflon squeege is used to smooth out the vinyl removing any trapped air bubbles and securing the vinyl around the many rivet heads. A heat-gun on low setting aids in this process.

Once the entire leading edge surface is wrapped, the cord-wise cutting tape is used to "cut" the wrap into 4" wide sections. Once that is complete the forward and aft span-wise cutting tape is used to "cut" the vinyl into the 4" square checkerboard pattern.

Next alternating 4" square sections of the vinyl are removed to complete the pattern.

Finishing is accomplished by using the teflon squeege to assure adhesion along all of the edges of the squares and around the rivet heads.

Later a coat of clear enamel will be applied to seal the pattern to the slat.
2017-05-03 Cowling Nose Masked for Painting The forward part of the cowling will be painted burnt orange to match the flaperons, horizontal stabilized, and checker-boarding of the wing slats. Masking with painter's tape and shop paper in preparation.
2017-05-04 Port Slat Checker-Boarding Repeat the starboard slat finishing process on the port leading-edge slat.
2017-05-05 Mask Cowling Air-Scoop for Painting The interior throat of cowling air-scoop will be painted black to match the color of the radiator. The radiator is covered over with cardboard and painters masking tape to protect the radiator and to delineate the interior and exterior sections of the cowling to be painted.
2017-05-06 Vinyl Wrap Vertical Stabilizer Applied 3M-1080 Burnt Orange Vinyl Wrap to the vertical stabilizer.
2017-05-06 Cowling Paint The interior of the air-scoop (throat) is sprayed with flat black automotive enamel to match the radiator and the Cowling nose-bowl is sprayed with burnt orange Shewrin-Williams Automotive Enamel.
2017-05-07 Apply Stencil to Vertical Stabilizer Purchased vinyl cut stencils from BoatUS-Graphics. I had to provide the 3M-1080 Burnt Orange material as their orange was not a match.

Application was straight-forward and easy.
2017-05-10 Dorsal Fin Jig Rather than have a large gap between the dorsal fin and the rudder, the fairing that sits atop the horizontal stabilizer extending the dorsal fin has been modified to extend under the rudder leading edge. To determine the proper angle and placement of the modification to assure clearances and range of a was constructed and mounted to the aft fuselage. The fairing extension was then constructed.

2017-05-12 Vinyl Wrap and Mount Dorsal Fin The dorsal fin and fairing parts are wrapped in 3M-1080 Burnt Orange vinyl prior to mounting

For ease of access to the elevator control horn and cables, the fairing and the dorsal fin are mounted to the elevator and fuselage top skin using rivnuts and #6 screws.
2017-05-13 Flaperon Control Mounts (Slottless) The standard slotless flaperon controls design seems to work well for most builders. However there is a problem with its use with the folding wing option. The mechanism for the folding wing design requires that the wing assembly (which naturally attaches perpendicular to the forward fuselage side) slide away from the wing mounting tabs at the forward fuselage; the flaperon control rod must also be perpendicular to the forward fuselage side. However, the interior control mechanism is located aft of the forward fuselage in an area that is sloped 7 degrees to the tail; so the control arm needs to be re-aligned to remove this 7 degree offset.

To achieve this a 7 degree sloped wedge mount is attached to the interior of the baggage compartment side skin. The 5/8" flaperon control rod is supported on this wedge with a pillow-block bearing connecting the interior actuating arm with the flaperon.

To fold the wing two AN3 mounting bolts that attach the actuator arm to the flaperon are removed and the standard folding process can then be used to complete the process.
2017-05-14 Stb Flaperon Controls After unfolding and rigging the starboard wing in position, the inboard flaperon section was mounted to the wing. The hinge mount tube was used to located the position of the 5/8" diameter hole for the hinge rod to pass thru the side of the fuselage into the baggage area where the control actuator arm will be mounted.

The 7 degree wedge mount will be affixed to the fuselage skin inside the baggage area via 4 sheet metal screws. The Bearing block supporting the hinge rod will similarly be attached to the wedge block with 2 sheet metal screws

The hinge rod and arm mechanism will be positioned for drilling the mounting holes (for AN3 holes in the hinge rod ends and AN4 hole in the actuator arm) once the flaperon and control stick are secured in the neutral position. The flaps deflection will be set to 15 +/- 1 degree and the aileron deflections will be set to 13 +/- 2 degrees.

The installation process will be repeated for the port wing.

The 1st step in folding the wing is to remove the 2 AN3 bolts securing the hinge rod to the mount on the inboard end of the flaperon. Then the 4 AN5 wing and strut mounting bolts are removed allowing the wing to be pulled outwards (onto the tip support fixture); then rotated and folded back onto the transport saddle at the tail. Should there be any difficulty sliding the wing outwards on the flaperon hinge rod; the entire rod can be removed from inside the baggage area by removing the interio3 AN3 bolt.
2017-05-17 Clean and Prime Starboard Wing - Top Surfaces Prepared the starboard wing for painting by wet sanding top surfaces with 1000 paper. Sanding followed by thorough flushing with water; towel drying the surfaces; and thorough wipe down with micro-fiber absorbent towel to thoroughly dry the surfaces.

A light coat of Eastman automotive self-etching primer was applied.
2017-05-18 Clean and Prime Starboard Wing - Top Surfaces Final light wet sanding of primer coat with 1200 grit followed by thorough rinsing with clear water and towel drying leaves the surfaces ready for color coats of purple automotive enamel
2017-05-19 Clean and Prime Starboard Wing - Bottom Surfaces Prepared the starboard wing for painting by wet sanding the surfaces with 1000 paper (including the flaperon and strut mounting brackets). Sanding followed by thorough flushing with water; towel drying the surfaces; and thorough wipe down with micro-fiber absorbent towel to thoroughly dry the surfaces.

A light coat of Eastman automotive self-etching primer was applied
2017-05-20 Clean and Prime Starboard Wing - Bottom Surfaces Final light wet sanding of primer coat with 1200 grit followed by thorough rinsing with clear water and towel drying leaves the surfaces ready for color coats of purple automotive enamel
2017-05-21 Clean and Prime Port Wing - Top Surfaces Prepared the port wing for painting by wet sanding top surfaces with 1000 paper. Sanding followed by thorough flushing with water; towel drying the surfaces; and thorough wipe down with micro-fiber absorbent towel to thoroughly dry the surfaces.

A light coat of Eastman automotive self-etching primer was applied.
2017-05-24 Clean and Prime Port Wing - Bottom Surfaces Prepared the port wing for painting by wet sanding top surfaces with 1000 paper (including the flaperon and strut mounting brackets). Sanding followed by thorough flushing with water; towel drying the surfaces; and thorough wipe down with micro-fiber absorbent towel to thoroughly dry the surfaces.

A light coat of Eastman automotive self-etching primer was applied
2017-05-25 Clean and Prime Port Wing - Bottom Surfaces Final light wet sanding of primer coat with 1200 grit followed by thorough rinsing with clear water and towel drying leaves the surfaces ready for color coats of purple automotive enamel
2018-05-26 Clean and Prime Wing Tip Panels Prepared each wing tip panel for painting by wet sanding the surfaces with 1000 paper. Sanding followed by thorough flushing with water; towel drying the surfaces; and thorough wipe down with micro-fiber absorbent towel to thoroughly dry the surfaces.

A light coat of Eastman automotive self-etching primer was applied.

Once thoroughly dry the panels were lightly wet sanded with 1200 grit then thoroughly rinsed with clear water and dried. Ready for painting.