Three hours were spent trimming the door sills and getting them drilled into place on the outside.

I decided to modify the trimming on the inside rear. Having the flap of aluminum that goes up next to the wing mount seemed wrong. It could not have provided any strength to the hinge mounting below, it made installation a pain in the ass, it would be hard to reach for riveting and it obscures an inspection point. Given that, I just lopped it off.

PROGRESS:
Fuselage ~232h ( 3h, 3h, 2h, 3h, 7h, 2h, 5h, 2h, 3h, 2h, 2h, 3h, 6h, 2h, 2h, 1.5h, 2.5h, 1h, 2h, 3h, 2h, 3h, 4h, 1h, 2h, 1h, 3h, 4h, 3h, 3h, 4h, 3h, 4h, 4h, 6h, 3h, 3h, 4h, 2h, 2h, 2h, 4h, 2h, 2h, 10h, 4h, 4h, 6h, 3h, 4h , 6h, 3h, 2h, 2h, 5h, 2h, 3h, 3h, 2h , 2h, 3h, 4h, 1h, 1h, 1h, 1h, 3h, 1h, 2h, 2h )
Wings: ~157.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 1h, 1.5, 2h, 2h, 3h, 2h, 1h, 3h, 2h, 1h, 2h, 1h, 5h, 2h, 1h, 2h, 4h, 2h, 3h, 3h, 3h, 2h, 3h, 2h, 3h, 6h, 3h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~489h

I spent about two hours trying to figure out how to trim the door sill ( 7F19-12 ).

The plans and directions are very lacking about the door sills. The forward half of the sill is easy to figure out, the outside rear is strange ( but figure-out-able ), but the rear inside is an enigma.

A quick search of the Matronics list and Google provided nothing.

PROGRESS:
Fuselage ~229h ( 3h, 3h, 2h, 3h, 7h, 2h, 5h, 2h, 3h, 2h, 2h, 3h, 6h, 2h, 2h, 1.5h, 2.5h, 1h, 2h, 3h, 2h, 3h, 4h, 1h, 2h, 1h, 3h, 4h, 3h, 3h, 4h, 3h, 4h, 4h, 6h, 3h, 3h, 4h, 2h, 2h, 2h, 4h, 2h, 2h, 10h, 4h, 4h, 6h, 3h, 4h , 6h, 3h, 2h, 2h, 5h, 2h, 3h, 3h, 2h , 2h, 3h, 4h, 1h, 1h, 1h, 1h, 3h, 1h, 2h, 2h )
Wings: ~157.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 1h, 1.5, 2h, 2h, 3h, 2h, 1h, 3h, 2h, 1h, 2h, 1h, 5h, 2h, 1h, 2h, 4h, 2h, 3h, 3h, 3h, 2h, 3h, 2h, 3h, 6h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~486h

Arlington 2008 Flyin:

It has been a while since the worklog has been updated, but progress has not totally stalled.

About six hours of work have gotten snuck into the project between life and Arlington.

The firewall has been fully clean, protected, reassembled and riveted together. In addition all the forward fuselage parts have been clecoed back together.

Some amount of time has been spent enlarging holes, finding missed holes, ect.

The next order of business are the doors. The directions are skimpier on these parts, so inferences need to be made. One issue is the existing holes that join the V-brace with the aluminum tubing along the top. The door sill sits on top of the tube, and it is impossible to back drill from the tube side. After talking to Zenith it is acceptable to 1) Use a strap duplicator to find the holes OR 2) Trim the door sill in such a way that these holes are bypassed.

Also I received clarification on the install order. 1) Doors 2) Skylight 3) Windshield.

PROGRESS:
Fuselage ~227h ( 3h, 3h, 2h, 3h, 7h, 2h, 5h, 2h, 3h, 2h, 2h, 3h, 6h, 2h, 2h, 1.5h, 2.5h, 1h, 2h, 3h, 2h, 3h, 4h, 1h, 2h, 1h, 3h, 4h, 3h, 3h, 4h, 3h, 4h, 4h, 6h, 3h, 3h, 4h, 2h, 2h, 2h, 4h, 2h, 2h, 10h, 4h, 4h, 6h, 3h, 4h , 6h, 3h, 2h, 2h, 5h, 2h, 3h, 3h, 2h , 2h, 3h, 4h, 1h, 1h, 1h, 1h, 3h, 1h, 2h )
Wings: ~157.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 1h, 1.5, 2h, 2h, 3h, 2h, 1h, 3h, 2h, 1h, 2h, 1h, 5h, 2h, 1h, 2h, 4h, 2h, 3h, 3h, 3h, 2h, 3h, 2h, 3h, 6h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~486h

I spent about two hours Sunday cleaning up most of the firewall and then applying corrosion protections. The landing fork section still needs to be drilled to size.

One major problem is the lack of A5 clecos. Make sure you have at least 100 of them.

PROGRESS:
Fuselage ~221h ( 3h, 3h, 2h, 3h, 7h, 2h, 5h, 2h, 3h, 2h, 2h, 3h, 6h, 2h, 2h, 1.5h, 2.5h, 1h, 2h, 3h, 2h, 3h, 4h, 1h, 2h, 1h, 3h, 4h, 3h, 3h, 4h, 3h, 4h, 4h, 6h, 3h, 3h, 4h, 2h, 2h, 2h, 4h, 2h, 2h, 10h, 4h, 4h, 6h, 3h, 4h , 6h, 3h, 2h, 2h, 5h, 2h, 3h, 3h, 2h , 2h, 3h, 4h, 1h, 1h, 1h, 1h, 3h, 1h, 2h )
Wings: ~157.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 1h, 1.5, 2h, 2h, 3h, 2h, 1h, 3h, 2h, 1h, 2h, 1h, 5h, 2h, 1h, 2h, 4h, 2h, 3h, 3h, 3h, 2h, 3h, 2h, 3h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~480h

I have finally started drilling out the holes in the firewall. These have been A3 size since the initial assembly just in case I needed to adjust something when working on the rest of the fuselage.

Today I noticed a small amount of corrosion around one of the clecos on the firewall, so it was decided to drill everything out, deburr, acid etch, scotchbrite and then zinc as soon as possible.

All of the holes ( save the engine mount bolt holes ) that lay in the horizontal plane are drilled.

PROGRESS:
Fuselage ~219h ( 3h, 3h, 2h, 3h, 7h, 2h, 5h, 2h, 3h, 2h, 2h, 3h, 6h, 2h, 2h, 1.5h, 2.5h, 1h, 2h, 3h, 2h, 3h, 4h, 1h, 2h, 1h, 3h, 4h, 3h, 3h, 4h, 3h, 4h, 4h, 6h, 3h, 3h, 4h, 2h, 2h, 2h, 4h, 2h, 2h, 10h, 4h, 4h, 6h, 3h, 4h , 6h, 3h, 2h, 2h, 5h, 2h, 3h, 3h, 2h , 2h, 3h, 4h, 1h, 1h, 1h, 1h, 3h, 1h )
Wings: ~157.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 1h, 1.5, 2h, 2h, 3h, 2h, 1h, 3h, 2h, 1h, 2h, 1h, 5h, 2h, 1h, 2h, 4h, 2h, 3h, 3h, 3h, 2h, 3h, 2h, 3h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~478h

The color of the clecos on the nose skins have been changed from silver to copper.

PROGRESS:
Fuselage ~216h ( 3h, 3h, 2h, 3h, 7h, 2h, 5h, 2h, 3h, 2h, 2h, 3h, 6h, 2h, 2h, 1.5h, 2.5h, 1h, 2h, 3h, 2h, 3h, 4h, 1h, 2h, 1h, 3h, 4h, 3h, 3h, 4h, 3h, 4h, 4h, 6h, 3h, 3h, 4h, 2h, 2h, 2h, 4h, 2h, 2h, 10h, 4h, 4h, 6h, 3h, 4h , 6h, 3h, 2h, 2h, 5h, 2h, 3h, 3h, 2h , 2h, 3h, 4h, 1h, 1h, 1h, 1h, 3h, 1h )
Wings: ~157.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 1h, 1.5, 2h, 2h, 3h, 2h, 1h, 3h, 2h, 1h, 2h, 1h, 5h, 2h, 1h, 2h, 4h, 2h, 3h, 3h, 3h, 2h, 3h, 2h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~478h

Saturday brought another two hours of work on the dashboard.

The upper ( "L" ) angle was drilled into place. The lower rivet lines of the top skin were also drilled into place.

In addition the top skin was trimmed per the plans.

After getting some unexpected time off, I have decided to fly the 150 to Oshkosh this year. The preliminary planning has started. It will be a long flight in the 150 as it cruises at only about 85MPH... about the same speed as the 701!

PROGRESS:
Fuselage ~215h ( 3h, 3h, 2h, 3h, 7h, 2h, 5h, 2h, 3h, 2h, 2h, 3h, 6h, 2h, 2h, 1.5h, 2.5h, 1h, 2h, 3h, 2h, 3h, 4h, 1h, 2h, 1h, 3h, 4h, 3h, 3h, 4h, 3h, 4h, 4h, 6h, 3h, 3h, 4h, 2h, 2h, 2h, 4h, 2h, 2h, 10h, 4h, 4h, 6h, 3h, 4h , 6h, 3h, 2h, 2h, 5h, 2h, 3h, 3h, 2h , 2h, 3h, 4h, 1h, 1h, 1h, 1h, 3h )
Wings: ~157.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 1h, 1.5, 2h, 2h, 3h, 2h, 1h, 3h, 2h, 1h, 2h, 1h, 5h, 2h, 1h, 2h, 4h, 2h, 3h, 3h, 3h, 2h, 3h, 2h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~477h

A quick update -

It has been rare to find time into the garage but progress has been made. The top nose skin is now drilled into place along with the ("L") angles that line the tops of the side skins.

Saturday night saw three hours of progress.

The first draft of layout for the instrument panel was done. I found various pictures of the planed instruments and then printed them out at actual size. Some items got a hand drawn picture as a placeholder. A single piece of tape was used for each "instrument" or "control" to hold it onto the panel. Everything is very easily repositioned.

The instrument plane's flange was also drilled in preparation for the dashboard, and a piece of ("L") was drilled into place that holds the instrument plane at equidistance from the firewall.

I laid out and cut 7F14-2 per the plans, and had to open up the holes to make it fit well. The holes extend too far forward and are too wide at the inside to be a perfect fit. A much better plan would have been to cut a template from cardboard THEN use that to make the real piece. In the end I am going to cover the dashboard anyway with upholstery, but anyone wanting to keep it as bare metal may want to take precautions.

The big issue of the night was with the instrument plane and some ("L") angle that runs from it forward. The basic idea of the piece is to be even along the top edge with 7F14-3, the forward side skin. The problem is that a crimp in the flange of the instrument plane would interfere with it.

The obvious solution seems to move the ("L") down ~10mm, but since 7F14-6R ( aluminum plate ) is already drilled into position, I can not trim the side skin to be even. Given the size of 7F14-4 ( top skin ) there may be enough play for it to not matter.



PROGRESS:
Fuselage ~211h ( 3h, 3h, 2h, 3h, 7h, 2h, 5h, 2h, 3h, 2h, 2h, 3h, 6h, 2h, 2h, 1.5h, 2.5h, 1h, 2h, 3h, 2h, 3h, 4h, 1h, 2h, 1h, 3h, 4h, 3h, 3h, 4h, 3h, 4h, 4h, 6h, 3h, 3h, 4h, 2h, 2h, 2h, 4h, 2h, 2h, 10h, 4h, 4h, 6h, 3h, 4h , 6h, 3h, 2h, 2h, 5h, 2h, 3h, 3h, 2h , 2h, 3h, 4h, 1h, 1h, 1h, 1h, 3h )
Wings: ~157.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .5h, 1.5h, 2h, 2h, 2h, .5h, 1h, .5h, .5h, 2h,3h, 1h, 3h, 3h, 4h, 2h, 3h, 7h, 3h, 1h, 4h, 1h, 1h, 1h, 4h, 2h, 2h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 3h, 2h, 2h, 1h, 2h, 3h, 2h, 1h, 1h, 1.5, 2h, 2h, 3h, 2h, 1h, 3h, 2h, 1h, 2h, 1h, 5h, 2h, 1h, 2h, 4h, 2h, 3h, 3h, 3h, 3h )
Flaperons: ( DONE! ) 23.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h, 1h )
Paint Design: 2 hours spent ( 1h, 1h )
Elevator DONE!: ~31.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h, 6h )
Horizontal Stabilizer DONE!: ~28 hours spent, 3 pieces replaced ( 3h, 2h, 2h, 2h, .5h, 1.5h, 3.5h, 1.5h, 5, 4.5, 2h, .5h )
Rudder DONE!, minus horn : ~16 hours spent, ( ~8h, ~8h )
-----------------------
Total Done: ~473h