Yearly Archives: 2015


Fuselage 15 (3.5)

First off, I have a hangar laptop! We had an old, very old, Sony laptop laying around the basement. The laptop is probably vintage 2006, and was anemically running Windows 7. It was so slow it was almost unusable. It probably was last used in 2010. I decided to re-purpose it. I wiped Windows off the system and replaced it with Lubuntu a light version of the Ubuntu Linux OS. Now the laptop runs just fine, and I will keep it at the hangar in an attempt to keep better track of things via this blog. Further, I can use it for research and probably most importantly; Pandora.

Secondly, Bryan from Showplanes contacted me. He has received my final payment, and hopes to have the kit shipped in the next two weeks. He also spent some time with me discussing canopy options. I have been looking at Todd’s canopies, but I think I will stay with the standard Van’s canopy.

I also spoke with Van’s about the parts I was missing in a previous post. The side consoles are missing, and it turns out they are supposed to be installed as part of the quick build fuselage! As a result they are sending me the replacements free of charge, and I included a couple of odds and ends to include a plans CD so that I can have the electronic plans on hand. We also discussed engine mounts, and he corroborated my research that the dynafocal 1 is the most common. As a result, I will soon submit my finishing kit order. I have multiple parts I will be deleting from the order. Those parts not needed due to the fastback conversion kit, and I will also leave off the rubber engine mounts, the tires, tubes and tailwheel which I will replace with other parts.

With all of those updates out of the way I turned my attention back to the fuselage. I’m essentially ready to either prime or mount the empennage, so I’m going through the instructions and picking out parts that I can prepare for priming in advance of when they are needed. I began this in the last post with some parts for the elevator horn. Today, I turned my attention to control rods. Van’s will tell you to cut a piece of paper to the circumference of the pushrod and then fold it in half three times in order to create the 8 equidistant rivet holes.  

I do essentially the same thing, less the folding. I measured out the circumference, divided by 8 and then measured that out.  
  

The pushrod will need to be primed both inside and out, but Van’s tells you to clean out the inside and rivet the rod ends before doing so because the rod ends can be darn near impossible to insert after priming. Here’s the result.  

I repeated the above process for the other pushrod. This one will need to be primed prior to final rivet for rather obvious reasons. I finished off the evening session by drilling the second control rod. 


Fuselage 14 (2.0)

Tonight I began working ahead in the instructions in order to have as many parts for priming as possible. Here is the pile of parts I have so far.  

I also needed to complete the gear installation. The alignment was done previously and all the main holes have been drilled, however, both of the wear plates required two outboard holes to be match drilled.  

Here is where the inner wear plate still needed to be drilled.   

The results of that drilling from inside the fuselage.   

The outboard wear plate required a little more access in the bottom skins before it could be drilled.   

I enlarged those holes enough to drill a proper straight hole through. The predrilled holes in the skins are not properly aligned. And then I still had a little more material to move from where the bottom skins rub the gear legs themselves.  

Here is an after photo.  

Next I skipped ahead to a few parts for the elevator control horn and bearing. These will need to be primed.     

Lastly, I cut the main control rod to length.      


Making a home paint booth

Since I began this project I intended to paint the entire aircraft myself. I’m confident with all the experts around that I can do it successfully. To that end, I began setting up a paint shop in my father’s barn. Yes, I won’t be painting the airplane for quite some time. Perhaps another few years, but in the mean time I have lots of parts to prime, and the interior will need painting. Painting at the airport isn’t feasible, and painting at my uncle’s or at friends is only ok on rare occasions. This paint booth will be of sufficient size and quality for the final paint job.

The barn is full of dust, and a mess currently. Here’s the before shot. My dad is retired and no longer uses the barn for anything other than storage. We decided to use the center aisle. This gives me a space of 10′ high, by 12′ wide, and 25′ long. More than enough for the plane.   The first step after a basic cleanup was to affix the plastic to the ceiling. Quick work with the staple gun. Then the walls. And finally the floor! There is still a lot to do. The exhaust fan is only up temporarily, and I’ll need to duct that to the outside and seal it up. I have a few furnace filters that will be used for the air inlet, which also hasn’t been added. I plan to use the spare particle board laying in the hangar for some basic flooring which will help hold the plastic in place. Also the seems will need to be taped closed, and I plan to use some wood strips to hold the plastic in place in the more difficult spots. And finally, I will need to add some better lighting. I suspect critters and time will cause some damage to my shop, but plastic is cheap, and I have a ton left over. Repairs will be cheap and easy. Now I might have a year or two (or three) before final painting, but this is going to make priming a breeze.