Assembly Log 
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 April 11, 2017

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 Empennage
  Horizontal Stabilizer
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 Firewall Forward
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  Misc

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  Finishing Up!

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Assembly

February 6, 2003 - 1.5 hours
Fabricated the up elevator stop and the two little spacers that go under the HS forward spar. Clamped the Horizontal Stabilizer onto the fuselage and measured it all.

Up elevator stop. It still needs to be trimmed a little.

Horizontal Stabilizer clamped in place.

February 8, 2003 - 4.5 hours
Finished installing the HS and started getting the VS clamped and lined up.

This distance from the aft deck to the tooling holes should be the same front and back to achieve the 0 degree incidence angle.

Eight bolts hold the horizontal stabilizer to the fuselage.

The horizontal stabilizer is installed!

Clamping the rear spar of the vertical stabilizer to the fuselage.

Clamp arrangement for the forward spar of the vertical stabilizer.

February 9, 2003 - 2.75 hours
Cleaned up a little bit and rearranged the garage for installing the wings. Vern, Steve and John all came over and we managed to get the wings installed. Thanks a million guys.

Trying to get the wing lined up.

Vern and Steve are trying to get the bolt into the spar.

There it is with the wings on. (The wheels were John's idea. Nice touch.)

The wings are on!!

A couple of hardware store bolts and a little wheel bearing grease hold the wings on for now.

February 10, 2003 - 0.5 hours
Checked the alignment of the wings and discovered that I have too much forward sweep. The wings are going to have to come back off so I can trim the rear spar a little more.

February 12, 2003 - 1.5 hours
Worked on aligning and drilling the VS to the fuselage.

February 13, 2003 - 2.2 hours
Shannon and Kelly came out to give me a hand with the wings and we managed to get them off and and after a little trimming they went back on and lined up just right.

To check the forward sweep of the wing, four plum bobs are hung from the leading edge of the wings.

If all four plum bobs line up then the wings are straight relative to one another.

After the forward sweep is checked and the wings are square with the fuselage I marked the rear spar with a sharpie.

February 15, 2003 - 3.5 hours
Measured the sweep, incidence angle and angle from the fuse again. Mounted the flaps to make sure that they would close properly, then took them off. Then I took a long break, came back out to the garage measured everything again, stood back and scratched my head, and then once I had measured everything one more time, I finally got up the nerve to drill a 1/8" hole through the rear spar attach point. Whew a whole day and two holes.

Measuring the incidence angle with my calibrated 2x4

It's hard to see but the center of the hole has to pass through that little square to maintain the PARAMOUNT 5/8" edge clearance. That square is only about 1/4" x 1/4"

The pilot hole is drilled and I am going to wait until tomorrow to drill it out.

February 16, 2003 - 3.5 hours
Measured the wings again, and then started enlarging the holes in the rear spar attach. Finally got them out to 5/16" and started breathing again. Then I drilled the holes where the bottom fuselage skin overlaps and will be screwed to the wing once that was done I started working on the fuel tank attach brackets.

The attach points are drilled, and I donít think that I screwed them up.

This is a little gadget that I made to mark the holes on the bottom fuse skin.

Marking the holes for the bottom fuse skin / wing attach point.

February 17, 2003 - 1.75 hours
Had some trouble getting the left fuel tank bracket stuff riveted together. Finally got it all drilled and ready to bolt on and primed the steel parts, I'll finish it tomorrow.

February 18, 2003 - 2 hours
Finished the fuel tank attach brackets and drilled the hole in the tank bracket. Attached the ailerons to the wings and set the pushrod lengths. Also mounted the flaps to the wings.

Finished tank attach bracket. All it needs now is a platenut.

The backside of the fuel tank attach bracket.

The flap attached to the wing and just hanging there.

February 19, 2003 - 2.1 hours
I didn't like one of the original flap push rods that I made so I made another one. I set the right flap pushrod length and cut the funny looking hole in the bottom of the fuselage for the pushrod to move through.

February 21, 2003 - 1.5 hours
Finished the flap pushrods.

This is flap push rod / actuator attachment and the hole where the rod passes through the fuseleage.

Close up of how the flap pushrod works the flap.

March 1, 2003 - 2.4 hours
Fit and drilled the wing root fairings. It is nice to do something easy and simple for a change.

The wing root fairing trimmed and clecoed in place. I just put the rubber on temporarily just to make sure it would fit.

March 13, 2003 - 1.5 hours
Measured and measured and measured the lower attach points for the VS and finally drilled one of the holes. I got nervous about the bolt callout and decided to call Van's tommorrow and ask before I continue, so I finished up by building a little stand to hold the fuselage up while I install the engine mount for good.

March 15, 2003 - 2 hours
Took the wings off and rearranged things to get ready to finish the tail installation, the fuselage and canopy.

March 16, 2003 - 2.25 hours
Drilled the VS attach plate (number two) to the HS forward spar. It shouldn't have taken two hours but I had already messed one up and I didn't want to mess up another one. I also got the VS aligned and a couple of the holes drilled that hold it to the attach plate.

March 18, 2003 - 1.5 hours
Finished drilling all the holes that attach the vertical stabilizer, and started working on the empennage fairing.

March 22, 2003 - 1 hours
Worked on the lower emp fairing. F-794A. After I tried trimming it so that the rubber channel would fit I decided that I would rather not use the rubber channel. It is just too dificult to get it to fit well. So I'll do the other side by just cutting the aluminum piece to fit close.

March 23, 2003 - 5.2 hours
Spent all day on the !@#?% emp fairing. I am much happier with the 'close fit' method for the lower fairing as opposed to the rubber channel. I think I'll reorder the piece for the other side and do it the same way. The fiberglass piece is a real pain and I still don't have it fitting right.

April 27, 2003 - 2 hours
Vern came over and helped me with my painting technique. Now the inside of the cabin looks much better. He also helped me figure out how to fill the gaps in the emp fairing.

April 29, 2003 - 0.75 hours
Worked on the emp fairing a little more.

April 30, 2003 - 0.5 hours
Smeared some SuperFil on the emp fairing to fill the gaps.

I used Saran wrap to protect the aluminum and filled the gaps with Super Fil. Thanks Vern for the help.

Close up of how the Super-Fil fills in the fairing gaps.

May 1, 2003 - 0.5 hours
Put some more Super-Fil on the emp fairing and re-fit it to the tail. This should be the last time.

May 4, 2003 - 1 hours
Finished drilling the top forward skin holes out and started fitting the panel.

May 4, 2003 - 0.5 hours
Sanded the Super Fil on the emp fairing and took off the rest of the Saran wrap. It fit's pretty good.

The emp fairing fits pretty good. Now I just need to countersink the screw holes and attach the nutplates after the VS and HS come back off.

June 24, 2003 - 1.5 hours
Drilled a couple of holes for the strobe / position light wires to pass through the aft two bulkheads and the VS spar. I called Van's before I drilled the hole and they said that it would be okay as long as I drilled the hole close to the bottom hinge bracket. I also removed the VS and the HS from the airplane. I was going to need to do that anyway and I am really starting to need the room.

It's a little hard to see but the black spot is the snap bushing where the strobe and postion light will come through the vertical stabilizer spar, and aft bulkhead.

June 26, 2003 - 1 hours
Primed the little spacers and attach pieces of the tail assembly, and riveted the VS attach plate to the VS spar.

This plate is how the vertical stabilizer forward spar attaches to the horizontal stabilzer forward spar.


Disclaimer:
This web site and the infomation contained within it are for entertainment purposes only. The opinions expressed on construction techniques are my opinions only and should not be confused with proper construction techniques. There is undoubtedly more than one way to build an airplane and some methods that I use may or may not work in any given circumstance. If there is any question please call the kit manufacturer. I love to help but I am not responsible for the misuse of any information contained on this web site.

 March 3, 2016
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