|2006-11-18||RG system removed||Main gear and nose gear, pump, etc., removed and returned to Velocity. To be replaced with fixed gear equipment. Continued through the 19th. Cleaned & vacuumed the hull.|
|2006-12-03||Canard measurement||The canard had been built at the factory. So it was no surprise to find all measurements were accurate to 1/64 of an inch.|
|2006-12-04||RE-Measure||Canard get the re-measure treatment again.|
|2006-12-06||test mix epoxy||I mixed a small batch of epoxy & micro balloon. It set up properly.|
|2006-12-06||Frosted the canard||2 to 1 Velocipoxy mix with micro balloon, mixed to peanut butter thickness. Frosted the bottom and top 1/3rd of the canard.|
|2006-12-12||sanding||Sanded the bottom of the canard|
|2006-12-21||finish frosting canard||Upper surface frosting completed.|
|2006-12-30||sanding||Canard sanded inside shop. Won't do that again. Moved it outside to sand some more. Cleaned up shop.|
|2007-01-05||oiled engine||IO540 is on an engine stand. I oiled the cylinders and rotated the crank. The block if filled with oil to keep rust out.|
|2007-01-13||frost elevators||Set up and frosted 1 side of both elevators.|
|2007-01-21||sanding||Sanded frosted side of elevators.|
|2007-01-28||filled holes||Set up canard and filled holes/defects in the first coat of micro balloon.|
|2007-01-29||More canard work||Filled holes/dips on the canard bottom surface.|
|2007-01-29||More canard work||Filled holes/dips on the canard bottom surface. Frosted bottom side of both elevators.|
|2007-02-11||re-work||11FEB, 24FEB, 10MAR, 14MAR, each day, 2 hours was spent either filling or sanding the canard. It is STILL not straight. I induce dips where non were there before, in an attempt to remove a high spot near by. I need a longer sanding board, 2 feet is just NOT long enough, even for the elevators.|
|2007-03-26||inventory||Toe brake kit arrived and inventoried. Section 6A3. Fit one assembly. Works good.|
|2007-04-01||brake/rudder pedal assembly||Fit all parts to build up the pedal assembly. Check for interference fit, etc.|
|2007-04-07||measure & check||Canard re measured for level, straightness, dips and high spots. I found 1 large dip, holding the measuring tape. Marked areas for further work.|
|2007-04-07||measure & check||Canard re measured for level, straightness, dips and high spots. I found 1 large dip, holding the measuring tape. Marked areas for further work.|
|2007-04-11||brake cylinder assembly||Installed brass elbows to the master cylinders, using permatex #2|
|2007-04-14||toe brake assembly||Rudder cable pull arms & stop screw/nut adjusters installed onto rudder pedal assembly.|
|2007-07-27||Level plane||Leveled plane for & aft/side to side, with digital & bubble levels. Cleaned shop|
|2007-07-27||measured installation points on lower hull/bulkheads.||String line run from front bolt hole at nose, all measurements taken from this known point. Engine bulkhead, canard bulkhead are in correct position.|
|2007-08-11||Door latching hardware||Sorted and dry fit both sets of latching hardware. It is like a jigsaw puzzle.|
|2007-11-25||prep wings||Both wings set on horses and leveled per manual.|
|2007-11-26||wings||Measured out wings and confirmed all points. Measurements from the outboard wing attach bolt hole CL to trailing edge tip on both wings is 133 7/8 inches. To the front LE tip measured to 123 7/8 inches. Mark "S" at the front tip of the spat, measures to 124 inches, both wings.|
|2007-12-05||cut winglets||Winglets were prepped already for cutting. I taped on the template to confirm the measurements were correct. I also remeasured the geometry of the winglets to ensure both were the same. After much hemming and hawing, I took out the saw and made the cuts. Both came out good.|
|2007-12-30||Prep winglets to glass to wingtip.||Winglet cut dimensions were measured and confirmed to be =. The newly cut area had the foam removed per plan to create 2 cavities, outboard & inboard, to which glass will be applied (lay up A and B.) These cavities run from the LE tip back to the rudder conduit tube.|
|2007-12-31||More sanding||While OUTSIDE, continued sanding the canard.|
|2008-01-05||Wing & winglet prep||Removed the foam from the wingtip in a wedge form, to provide the space to glass the winglet on. Co-pilot wing. Pilot wing tomorrow. Set winglet into place, measured for correct geometry and bondo used to hold.|
|2008-01-11||type 1s just arrived||I ordered 4 type 1 dynafocal mounts from AERO last week, experimental only. They arrived today. They are machined from billet stock and are very nice. No sharp corners anywhere. 4 of these for the price of ONE from Lycoming.|
|2008-02-20||Frustration||CP wing/winglet is in place to be glassed. Pilot wing/winglet is playing cat & mouse. Move 1 part of the winglet into place, the rake is off. Move the rake and the winglet trailing edge moves. I got tired and had coffee.|
|2008-02-28||Secure nose gear doors up.||The gear doors were removed and sanded clean of filler. The fuselage around the gear doors was also sanded clean of filler. Alcohol wipe down.
String, bondo, sand bags... The nose gear doors are securely in the UP position.
|2008-02-29||Nose gear doors are no more.||After securing the nose gear doors up, and sanding off the filler, I have glassed the doors closed from the outside.
Flox was added to transition from the fuselage the gear doors.
2 BID was used. After cure, I will remove the interior structure of the doors, sand, add foam and add 2 bid to the inside of the gear door.
Overlap to the fuselage is about 2 inches.
|2008-02-29||Glassed outer hull at nose gear door||Nose gear door was closed and bonded up. 2 Bid over the hull with 2 inch overlap of glass onto hull. peal ply was used around the edges and plastic film was used over the rest to prevent bubbles.|
|2008-03-09||Nose gear door glassing||Over the week, I glassed the exterior of the gear doors closed, placed foam in the inside ares with dry micro, then applied 2 bid over the foam to create the floor. Gracious help was given from my friend, Kevin, who has already built a Velocity.|
|2008-04-04||Parts arrival||The main gear bow and nose gear arrived on 03APR. All attachment parts too. The main gear bow is wrapped in carbon. All very nice.|
|2008-04-19||Glassed layup "A" to wing/winglet||Co-Pilot wing to winglet layup "A". The 8 layers of glass get inserted between the top of the wing's triax and foam. It then makes a 90 degree turn up, and fits into the in-board side of the winglet, between the glass and foam. Foam wedges hold the new glass to cured glass, and micro slurry holds the foam together.|
|2008-05-14||Lay Up B||Wing to winglet lay up B is done on the CP wing. Pilot wing tomorrow.
Peel ply used over glass.
|2008-05-15||Lay up B trim, Prep pilot wing||This morning I trimmed and sanded the excess glass from layup B on the CP wingtip. The next coarse involves a foam plug to round out this area, followed by a glass lay up from the wing bottom to the outside skin of the winglet, over the plug. It is a large layup.
The pilot wing tip needed some filling & trimming to ready it for lay up B. It goes on tomorrow.
|2008-05-20||Pilot wing lay up B||Layup B was performed on the pilot wing/winglet.|
|2008-05-20||Lay Up B||Lay up B was completed on the pilot wing.|
|2008-06-04||foam blocks added||Prior to Lay up C, foam blocks need to be installed & fitted. Here they are.|
|2008-07-01||Part 1 of lay up C||Over the past 2 weeks, I have trimmed & sanded both wing/winglet joints. Today, I applied 2 BID on the CP wing. Lay up C is a total of 9 layers. 2 BID followed by 7 of UNI. Since I was working alone, and it was 112 degrees in the shop, I opted to lay just the BID and peel ply it. I will put on the 7 layers of UNI at night or early AM when I have enough working time.|
|2008-07-06||Lay up C||CP wing lay up C is done. 2 BID followed by 7 uni. Really way too hot to be doing this. The epoxy started to cook off way too fast. 114 degrees in the shop.|
|2008-08-25||More layup C||After staying out of the 120 degree shop for a month, I have started early in the morning prepping the pilot wingtip for lay up C.
I have cut all of the layers of glass and will get them on the week of 25 AUG. I will then flip the wings and do the same layers of glass on the top of the wing to the inside of the winglet.
|2008-09-08||Layup C done on Pilot wing||I will ALWAYS use peel ply, I will always use peel ply, I will always use peel ply.....
I used a plastic layer to hold the 7 top layers of glass down. It was very hot and air bubbles were forming beneath the glass. The plastic worked by keeping air out, but looks like CRAP. Compare the CP winglet to the pilot side. Both are the same layup, however, the pilot side needs much sanding
|2008-09-18||Cut glass for lay up D||18 layers of glass were cut this AM per schedule. 4 BID and the remainder UNI. Each wing top to winglet inside surface joint will receive 2 bid and 7 UNI, bonding them into a single unit. This lay up is the same as lay up C, which wraps from the bottom of the wing to the outside of the winglet.
Cooler weather is on the way!
No pictures, just a pile of glass.
|2008-10-13||last lay up done||Lay up D was performed on both wings/winglets. These lay ups bonded the wing top to the winglet inside surface.|
|2008-10-16||Prep for main gear installation||My kit was a retract, with the gear installed. I removed all of the retract hardware and swapped it for the fixed gear parts. (Thank you Velocity!)
Today, I removed the reinforcing brackets and pulley bracket from the area in front of the main gear bulkhead. They are not needed in the FG model. I also sanded the area between the main bulkhead and the back of the main gear bulkhead, preparing it for one layer of triax reinforcement.
|2008-10-19||Finding the center line||Main gear, locating the center line.|
|2008-10-21||Tilt & Push||Lower fuselage pilot side tied to the rafters, tilting the plane at about 45 degrees. This allowed me to insert the gear leg through the back of the plane.
I had to grind away a small amount of the transverse bulkhead, and rear lip of the gear well, to get it in. Much more fitting is required.
I will determine the amount of transverse bulkhead to be removed to fit the gear saddle at the proper position. Trimming of the body hole to reduce interference will also be done.
|2008-10-29||gear saddles||Both main gear saddles were sanded, then 8 layers of triax was applied to the outside. Photos show the progression.|
|2008-11-09||Bushing removal & build||All 4 main gear bushings were removed. 2 from the main gear bulkhead and 2 from the engine bulkhead. I made plugs to fill the holes with ply from AC Spruce, and triax. These plugs will be inserted with flox to fill out the holes and make a structural repair which is as strong as the rest of the bulkheads.
|2008-11-11||Filling in the floor, RG nose gear door repair.||
After I removed the RG parts (18NOV1006), I filled in the retract nose gear door. I had left a 5X4 area behind the canard bulkhead, inside the keel, unfinished. It had been part of the nose gear door. I laid a layer of foam/micro to the floor and applied 2 bid over the foam, 2 inches onto the floor behind, and 2 inches up onto the canard bulkhead.
The new FG nose gear will enter the fuselage in this area, so it needed to be filled.
|2008-11-24||Plugged the holes...||4 plugs were FLOXed into place, filling the bushing holes for the retract main gear. The plugs were made of A/C ply with 8 layers of triax, (4 on each side) and were inserted into the main bulkhead and main gear bulkhead bushing holes. 2 bid was applied over the forward sides of the gear bulkheads. Any depth issues will be filled with triax to the level of of the surrounding bulkhead surface.|
|2008-11-29||last of the cleanup before the gear goes in||Today, I removed the main gear and finished the cleanup on the back side of the bulkhead plugs. This coming week, I will remove the ship from the cradle, place the main spar on adjustable stands/front on a horse. It will then be leveled. After that, I will begin the measurement for the main gear install.|
|2008-12-29||Filling RG hole||Fitting the foam to span the gap left by the installation of the retractable gear. 2 BID in & out after the contour is finished|
|2009-01-02||Glassed CP side main gear area||The CP side main gear retract gear slot was foamed in, then 3 BID inside and 2 BID outside was applied to span the gap.|
|2009-02-22||Fitting the gear||Since the beginning of February, 10 hours have been spent installing, fitting, removing, trimming, reinstalling.... the main gear. I am close to the final work on the install.|
|2009-03-09||Wing attach bolt holes||I moved one wing into the garage this past weekend and cleaned it up. I then measured and cut the top and bottom holes for the wing attach bolt access.|
|2009-04-08||Frosting||Last 2 weeks, prepped for frosting. Got a 3 gallon kit of super fil. CP wing in the garage, part done.|
|2009-05-18||since 01MAY2009||I have frosted the CP wing top, and the winglet. I turned the thing over and have about 90% of the bottom filled. Oh the fun i had cleaning up the sanding dust in the garage before the wife got home!|
|2009-06-10||filling sanding & moving||CP wing moved out of the garage to the now covered side of the shop. Much sanding performed June 6 to 10 on the bottom surface. Superfil works out nice.|
|2009-07-07||Landing gear hole||July 1 to 7. Pilot side hole was patched last year. I did not like how it looked, so I removed what I had done and will re-do it.
I removed the outer skin patch and foam down to the inner skin patch, which I kept. New foam was laid down, much nicer looking and sanded to contour. I will add 2 bid on the outside, tomorrow.
08 July, 2 bid applied on the exterior, spanning the foam.
09July, 1 bid applied to span the inside of the repair.
This 1 piece of bid covers 3 bid, which was a multi layer layup. This covers the entire interior wall from the rear of the gear bulkhead to the forward face of the firewall. From the top of the lower fuselage to the gear hole.
|2009-08-09||grindinggggggggggggggg||Last two days were spent fitting the gear legs to the saddles in the fuselage. I needed to grind away a bit of the triax I added to the rear of the gear bulkhead to get the gear angle correct. The center line was also established and gear tips measured from the nose point. If all goes well, the gear will be bonded to the saddles this week.|
|2009-09-24||add additional lay up at gear bulkhead/strake area||My EAA councilor took a look at my work and made a suggestion, based on what he had seen on another Velocity. The suggestion was to add several layers of BID on the forward face of the gear bulkhead, extending forward on the inside fuselage skin, to a point forward of the strake rear fuel bulkhead. A second lay up is on the outside, from the main bulkhead flange area, forward to a point forward of the strake rear fuel bulkhead. A third layup was to strengthen the gearbox its self. This small layup goes from the forward face of the firewall, forward on the inside of the fuselage above the gear hole, and ends on the rear face of the gear bulkhead.
These all added about 2 pounds to the plane. However, the reason to add now was to reduce the chance of cracking anything in the area of the fuel strake do to a hard landing, and to add general strength to the gear box area.
|2009-10-19||Main gear glassed||The saddles were bonded to the bottom of the gear leg, and 10 layers of triax was added to the saddles across the gear leg. Going to trim the excess and bolt them in.|
|2009-11-03||Drilled bolt holes||Today I drilled the co-pilot main gear bolt holes. They aligned up just fine.
|2009-11-11||Gear mounts in||Over the past week I have drilled, bonded, filled with micro and now, put 6 bid over the main gear steel bushings. Waiting for the 1 5/8 inch knurled bushings for the main gear bulkhead.|
|2009-12-01||Main gear fully installed||6 hours were spent over the past week finishing the main gear install. Bushings were installed & microglass transitions applied. 2X triax was put over each bushing.|
|2009-12-12||fit nose strut||The area at the top front of the keel needed to be ground down a bit to allow the T top of the strut to fit between the inside surfaces
The 2 inch diameter hole in the forward floor center line was drilled for the strut to extend through.
|2009-12-22||drilled top NG bushing holes||The location of the nose strut bushing mount holes was measured and the holes drilled. They were finished sanded to allow the knurled aluminum bushings to slide into place. I included 2 AN steel washers on the bearing surface between the aluminum buchings and the much smaller diameter steel tube which carries the top bolt. My EAA Tech councilor liked that idea. he also pointed out that the bolt threads were inside the bushing.
I move from a 7 inch bolt to an 8 inch bolt, which moved the threads outside of the bushing. I cut off the extra length of un-needed threads.
|2009-12-28||CL established||With the hull leveled, I chalked a center line on the floor from the nose to the CL between the inside measurement of the main gear legs. I set the nose strut in place and assured it lined up with the center line.|
|2010-01-19||EAA meeting||16 & 17 Jan 2010 was spent in Prescott at the EAA Builders meeting. I took the 2 day electrical course. Highly recommended.|
|2010-01-20||Nose Gear assembly||I discovered that my nose gear bushings stuck out of the keel on both sides almost 1/5 inch. This intruded into the knee area in the cabin. I also discovered that the 7 inch bolt, supplied with the kit, had 1/2 inch of threads inside the bushing. I located a 8 inch long 3/8 grade 8 bolt, and threaded it to fit the bushing/washers correctly. The keel holes were opened and the bushings were fitted. The king pin rake was established and the center of the gear leg tube was placed on the center line of the fuselage.
My EAA tech councilor wanted a steel surface to sit between the end of the tube and the soft aluminum face of the bushing. 2 AN washers were filed to fit and placed. This placed the side load(not supposed to land with a side load) steel to steel instead of steel to aluminum. Smart idea.
NEXT.... potting in the parts...
|2010-01-20||shock||The Velocity supplied nose gear shock/bumper has been used for years. Recently, several V owners have found the shock badly bent. It is a hard rubber biscuit encased in 2 pieces of steel. When the plate contacting the nose strut bends, lots of fore/aft movement begins. One of the builders found this bumper and has his son, an structural engineer, do some analysis on it. The numbers looked good. Several have been installed and all have reported a big improvement. The new shock is solid rubber with a single steel plate, which bolts to the canard bulkhead. The nose strut is forced into the face of the rubber during the build, and held there with the captivator plate supplied by V. No steel face to strut contact, just stiff rubber.|
|2010-01-26||Potted in nose strut bushings||Both bushings were coated in flox and the top strut assembly was installed with Vaseline to lube the removable parts. I set up 2 incandescent bulbs on reflectors to help the goo cure. It was 55 in the shop.|
|2010-01-27||Nose strut removed||Post cure, the strut was removed and I began contour sanding the flox ramps I built up on the outside of the keel/bushing.
I was able to reinstall the strut with little difficulty.
|2010-02-04||Captivator plate built||Over the past 2 days, I assembled and fit the nose strut captivator plate. I now need to properly shim the front bumper.|
|2010-02-13||Nose gear installed||The nose strut is fully installed against the bumper.|
|2010-02-19||toe bell crank/brake assembly||Drilled & assembled the bell crank/toe brake set.|
|2010-03-17||All wheels on!||Over the past week, I have installed both main axles. Today, I put on the wheels and rolled her outside for the first time. Happy day the Lord has made.|
|2010-05-25||Nose oil cooler||I cut out the nose cooler and fit the ducting. I had to split the "naca" duct and make it 1 inch wider duct to the larger oil heat exchanger I am installing.
AN3-42a bolts to connect the exchanger to the fiberglass ducting. I created a ramp on the inside forward lip of the opening and covered it with 1 UNI.
|2010-07-08||Fitting nose oil cooler||June/July in AZ. So work is SLOW. 125 in the shop. I have been working on the nose oil cooler and the associated ducting.
The duct is cut and the flange is made. Will be cutting the nose floor this week to make the air exit.
|2010-09-16||Nose heat exchanger||Outlet top part was fitted. Inside was filled & sanded smooth.
Bottom section with flapper door was built & fitted. Needs to be filled & sanded.
|2010-10-05||nose heat exchanger partially galssed|
|2010-10-20||Nose cooler outlet duct glassed in.|
|2010-10-20||Guide tube for brake lines installed on MG legs||Per plans, I installed guide tubes on the back of each gear leg. This allows the nylaflow brake line to be a serviceable item.|
|2010-11-02||mains filled and sanded||The main gear legs were filled with micro and sanded to contour.
|2010-11-18||Fuel sump||I trimmed the sump tank and forward tank bulkhead. Hard points were drilled/tapped and glassed in.|
|2010-12-17||Sump fuel coating||Jeffco 100% solids epoxy applied to the sump lid and interior. Hard points glassed & tapped.|
|2011-01-02||brake lines under sump||The fuel sump will be mounted above the two brake line guide tubes. The sump will sit on a pad of micro,which will also hold the guide tubes. The brake fluid lines will run from the rear bulkhead, under the sump, to the back of the keel. There are guides in the keel bottom to secure the lines forward.|
|2011-01-09||Sump mounting tabs||The sump was placed into position and marked for the mount tabs. Per plans, the tabs were made. Position fit is good. Curtis drain in the bottom fits to the center of the hole drilled into the bottom of the fuselage.|
|2011-01-11||Sump installed||The fuel sump is set in and bolted in place. The 2 tubes extending below the front of the tank are the brake line guide tubes. I will cut them back a bit. They guide the brake lines from holes in the main gear bulkhead, under the tank, and into a tube to the brake masters.|
|2011-01-18||Heat exchanger side shrouds||Made of 2 bid, formed over a foam core sanded to shape. Will seal the end tanks from air escaping from the cooling block.|
|2011-03-03||Installed the windows||Both side passenger windows, and the wind shield have been installed.|
|2011-03-17||The past 3 weeks...||Saw the installation of the 3 fuselage windows. I also ran the brake lines from the main gear stubs to the canard bulkhead. The oil lines were run through the pilot side conduit and fit to the oil cooler in the nose. Much playing with a flare tool lead me to buy a new one. Test flares are perfect. On to the oil lines...|
|2011-03-25||Installed oil cooler/lines|
|2011-04-11||air vents & scat||Installed 2 1.5 inch flanges for the 1.5 inch scat from the heat exchanger.|
|2011-08-15||Bonded top to bottom||Over the past 45 days, in the heat of summer, I have finally bonded the top of the fuselage to the bottom. Door holes were opened to allow access. The front hatch was fit.|
|2011-08-23||Glassing...||I have almost finished glassing the halves together forward of the doors. The inside is done, but I need to finish up on the outside, then do the rear 2/3rds.
It is difficult to go outside in 117 degree afternoons, with the shop over 120.
|2011-09-02||hull glassing finished||All of the body glassing to bond the 2 fuselage half together is done. On to the doors and canard dog house,|
|2011-09-21||doors trimmed, templated, holes cut||Over the past week I trimmed the doors per plans. I then used 1 ply of UNI over plastic, over the finished door, to create a template. This UNI had epoxy applied, and the result was a non wrinkling template. These templates were affixed to both sides and the correct door size was marked onto the fuselage.
The door holes were then cut out with a saber saw. Almost a perfect fit on the first try.
|2011-10-29||Cut out Dog House||The canard dog house was cut out per plans. No issues.|
|2012-03-09||Pilot door install||Over the past 2 months, between softball and soccer with the kids, I flanged the pilot door hole, fitted the pilot door and now, made the door hinge pockets and installed the hinges into the fuselage.|
|2012-04-07||Co Pilot door flanged||I finished the flange on the co pilot door today. the only thing left to do is to trim it to 5/8 inch after the glass cures. The P:pilot door is finished, through the hinge install. After trimming the co pilot flange, I will install the door hinge pockets
and then be ready for the carbon beams.
|2012-05-10||both doors on||Over the past month, between kids soccer and softball, I flanged and mounted both doors. Today, May 10, I set the pilot door lock assembly into place with Structural Adhesive.|
|2012-09-16||Elevators....||Sanded the Canard and elevators. Measured and trimmed the trailing edge and fit the pilot side elevator.|
|2013-10-16||Canard installed||Soccer, football, softball, school.... all conspired against building. However, I have the canard installed. Incidence is set and the tips measure out =. Torque tabs are done front and rear. Of course, the dog house is cut out too.|