Friday night we got just a little done. We deburred, corrosion protected and riveted the L angles to the left wing.

Saturday night was very productive. Not only did we drill the L angles for the right wing, corrosion protect and rivet, but also got the tip ribs drilled into place for the right wing.

The tip ribs were just a bit of a problem due to the length of the spar and our need to keep the garage door closed for warmth.

We also had a bit of confusion over which spar was the right spar and which was the left. Luckily the builder's manual and some other drawings cleared everything up.

Project Status:
Wings: 5h ( 1h, 1h, 0.5h, 2.5h )
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: ~106.5 hours

We spent about an hour working on left wing spar. Nothing much, just drilling some L angle to the spar. This is the last progress until after Christmas... until then I'm on dipsolucious vacation.

Project Status:
Wings: 2h ( 1h, 1h )
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: ~104 hours

We spent about an hour reviewing the first steps on the wing skeleton, the plans and cutting the L angle required for the spar.

Joe told me that he spent about 100 hours each on his 601XL's wings. I believe that this estimate is probably high for the 701 kit based on several assumptions. First, the flaperons are not part of the wing. This greatly reduces the complexity. Second, more parts come pre-drilled then when Joe built. Third, I believe the overall structure of the 701's wings has fewer parts.

Project Status:
Wings: 1h ( 1h )
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: ~103 hours

Workbench 2.0 was finished tonight. There is a big difference in the sturdiness and look from the old workbench. Overall the height of the new bench is better ( slightly lower ).

The bench is also much flatter, as confirmed with the level ( made from 6061-T6! ).

Underneath the spars and skins can be kept safe, so we even gained additional room in the garage.

It only took two of us, an hour, a plywood plank and some cinder blocks to lift the frame onto the new base. Shimming, leveling, and attaching the table top took a few more hours.

Here is the first iteration of the old bench, followed by the second iteration:


v1.0:

v1.5:

Once again work is keeping me from the project. The workbench was a forbidding project for some reason, but we now have a plan, materials, and most of the work finished. We are going to use the wing crate as a base ( as mentioned previously ), but the question of how to add legs has been perplexing.

We finally settled on the simplest, most stable, and most ghetto idea: cinder blocks. The crate's frame rails will sit on slats which will rest on the cinder blocks, kinda like a mattress and a box spring. The only problem is lifting the crate... a problem that should be easily overcome with the help of a few people.

Using the crate has many advantages. It's better built than I could do. It already exists. It's about the right size. The wing skins and spars can be safely stored inside, yet easily retrieved. It's easy to make.

We bought 16 cinder blocks. The idea is to have four "legs" per side, with each "leg" two cinder block high. Each cinder block "leg" will have a footprint of 16"x8" and will be 6" high. .

Tuesday night we spent one hour closing the two remaining flaperon halves. Deburring, corrosion protecting and riveting are all activities I can now do in my sleep.

The fuel system and wing crate arrived on Wednesday just before Thanksgiving, and Saturday evening the inventory was done.

The fuel caps do not look like they are vented, nor do the tanks look like ten gallons capacity.

Before work on the wing can begin, the workshop needs to be redone. The table I built is not perfectly flat for it's 8 foot length AND it needs to be extended an additional four feet. My plan is to use the crate the wings came in as a workbench frame. All I need to do is raise the crate an additional two feet and provide for an adjustable shim method to keep everything level. I'm going to use the MDF from the current bench as the table top.

Project Status:
Wings: Inventory complete
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: ~102 hours

Surprisingly, the light at the end of the tunnel was not a train.

After a nearly month long break, work is ready to continue on the CH701. The wing and fuel tanks kits were ordered in early October and should be shipping any day now.

The slats are lamentably still untouched, but Tuesday should resolve that.

We spent about 30 minutes Saturday morning drilling the bottom skin to the spar and ribs, went and had breakfast and then I spent about 2.5hs deburring, riveting, corrosion protecting and then repeating the steps for the top of the skin.

I found that by using a 2x2 and some silver clecos on the trailing edge of the pre-drilled skin that I was able to ratchet down the top skin and drill it by myself.

The question is how to proceed with the "root" rib. I'm thinking that I should just drill it into place now.

We then spent about 4 hours in the evening making the port inboard flaperon section. The skeleton is made, the bottom skin riveted and the top skin drilled.

Project Status:
Flaperons: ( right outboard, left outboard DONE! ) 22.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h, 3h, 4h )
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: ~102 hours

We spent about three hours measuring and drilling the right inboard flaperon skeleton. The skeleton is now riveted, minus the splice rib.

Project Status:
Flaperons: ( right outboard, left outboard DONE! ) 15.5 hours spent ( 3h, 1h, 1h, 1h, 1.5h, 3h, 6h )
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: ~95 hours

The air compressor came back from the shop... and since it was still crammed into the back of a Jeep we decided to use the hand riveter to finish the flaperon half. A nail got stuck in the riveter and all attempts to get it out have failed.

We started the right inboard half and got as far as getting the pieces out and placing them on the pre-drilled skin.

Project Status:
Flaperons: ( right outboard, left outboard DONE! ) 12.5 hours spent ( 1h, 1h, 1h, 1.5h, 3h, 6h )
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: ~92 hours

We spent about 1.5 hours building Saturday... a grill that is. The building experience of the CH701 is much easier compared to a Char-Broiled grill. Seriously.

In my never-ending campaign to justify the expense of the Garmin 496 a little bit of aerial recon was performed... on pumpkin patches. We flew up and down the surrounding farm lands looking for patches, and when we found one that looked good we marked the location. The plan is to simply use to GPS to navigate us there in a few weeks. In 1.5 hours of flying we covered the same amount of ground that a whole day's worth of driving would take.

We spent another hour on the left outboard flaperon. The splice rib and associated bracket were drilled into place, the whole assembly was deburred and then protected from corrosion. The splice rib and bracket were riveted into place using the hand riveter.

After some exploration the electric drill does not differ from the air drill in regards to producing burrs. The electric drill is less ideal than the air drill in three main ways. 1) The chuck area is larger and thus much harder to get into tight spaces. 2) The drill is MUCH heavier so when it punches through the metal the chuck hits the metal skin with more force, and thus the protective rubber washers much faster and it is much easier to damage the skin. 3) The drill takes a long time to spool down after use making several seconds of delay required before moving onto the next hole. On the upside the drill generates much less noise.

Project Status:
Flaperons: ( right outboard DONE! ) 11.5 hours spent ( 1h, 1h, 1.5h, 3h, 6h )
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: ~91 hours

Slow progress this week due to outside issues including a weekend drive to Eugene.

The bottom of of the left outboard flaperon is riveted. The top was drilled using the new electric drill. The new drill has a very different feel in it's operation. The drill spools up, sits on the metal for a second and then instantly sinks into the metal. The time to spool down the drill takes much longer than the air drill. I haven't deburred yet, so I will not know how using a high RPM / low torque drill will vary in respect to the high torque . lower RPM air drill. My guess is that the holes will be cleaner.

Another building tip about the flaperons: The trailing edges are pre-drilled. The builder's manual says that the top edge of the flaperon may not reach the trailing edge, and just to trim the extra off. The problem is that the pre-drilled holes prevent this and trimming would ruin the skin!

So besides exercising extreme caution in the measuring of the ribs to make the bottom skin match up, I found an interesting technique to make the top skin "work".

After ratcheting down the skin with 2x2's, I slowly used some silver clecos in the trailing edge to "pull" the pre-drilled holes together. Initially it was hard to find holes close enough to start the process and it took another person to help pull and push the skin.

Project Status:
Flaperons: ( right outboard DONE! ) 10.5 hours spent ( 1h, 1.5h, 3h, 6h )
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: ~90 hours

The compressor is in the shop. For future reference: Do not buy an "oil less" air compressor. They are loud and light duty.

We bought a 2500RPM VSR drill for about $60 to hold us over. Unfortunately using the hand riveter takes about 10x longer than the pneumatic riveter.

The Matronics Kitfox list has been abuzz about LED lighting, and I am convinced this is the way to go, and I will probably follow this guys instructions: http://www.itsys3.com/kitfox/discover.shtml The current plan is still to use a Dynon Flightdek D180, the Garmin 496, a single com and a transponder. Light, sleek, modern.

We spent about 6 hours today on the flaperons..

One major build tip for these is when riveting the skeleton, rivet the hinge extrusions last so you have some extra play to sneek the rivet gun to the hole.

Another major tip is to wait to drill and place the splice rib and associated angle. We placed and drilled the angle first and then got major "beer canning" when ratcheting over the top of the skin.

The fiberglass tips fit somewhat poorly. You can even see this is the builder's manual. I played with them for a while and did my best. There is a little gap between the bend in the skin, but it shouldn't matter.

The compressor decided to die today while we were making major progress. At first it wouldn't stop the compressor when it reached 150 psi. Then it wouldn't compress past 120 psi, then 100 psi. Finally we heard a very loud "pop"/"bang" like a firecracker from the compressor followed by a doubling of it's pitch. I shut it off, unplugged it and then drained it's air pressure by using it. I got about half of the bottom of the left outboard flaperon riveted. Luckily we have the hand riveter, but no electric drill.






Project Status:
Flaperons: ( right outboard DONE! ) 10.5 hours spent ( 1.5h, 3h, 6h )
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: ~89 hours

We finally found some time to get back on the project. Between work, friends and the trip to Eugene something had to give.

The right outboard flaperon is coming along quickly. We almost made a deadly mistake a SECOND time... drilling mounting brackets upside down. The holes for the brackets already existed in the skin and cause me to double check my measurements and positions.

My guess is that we have maybe two hours more work on the piece. The left outboard flaperon should take less time, and the inboards seem to be a similar process.

If I can get part of Labor day, one night during the week and one day next weekend, all four pieces should be done by Sept 17. The slats shouldn't take much time, so the wings and tanks need to be ordered soon.




Project Status:
Flaperons: 4.5 hours spent ( 1.5h, 3h )
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: ~83 hours

The only word that can describe the H4 "Hercules" is ginormous.

8.6 hours in a C150. That is a long time. Highlights of the trip included visiting the Hughes H4- Hercules and attempting STOL operations that I decided were impossible at gross weight at high density altitude with wind shear in a tight mountain ravine airport.

The entire trip was done over two days. The first day was 4.8 hours and went from Seattle to Portland, fuel in McMinnville, over Eugene, attempted landing at Oakridge and the back to Eugene.

The return was 3.8 hours and was from Eugene, fuel in McMinnville, over Portland and then to Seattle.

Enough good things can not be said about the Garmin 496... especially the XM radio part. Listening to some music on the long legs really helped. The PMA audio panel would automagicaly mute the input audio when talking or receiving transmission. There are a few things that would change about the unit, but a full reviewing post will come later.

I'm spending most of my time in the office. So, I've had to stick to the builder's equivilent of "hangar flying". I've decided to buy a Garmin 496 for the CH701. In fact, I almost bought one this week for an upcoming cross-country trip to Eugene. In the end I couldn't justify the cost, but I don't want to settle for a 296, so I'm going to wait until Garmin releases a 596 and let the price drop.

Just for fun:

Hiatus:

Etymology

Derives from Latin “hiatus”, -us, m.: gap; cf. hiare, hio, hiavi (hisco); (χαίνω) έ-χαν-ον, κέχηνα; Old High German ginēn; German 'gähnen' -> "yawn")

Pronunciation

• Audio (US)^{?, file}

  Rhymes: -eɪtəs

Noun

hiatus (plural hiatus or hiatuses)

Singular hiatus

Plural hiatus or hiatuses

1. A break or pause.
2. A gap in a series, making it incomplete.
3. (linguistics)
   1. A syllable break between two vowels, without an intervening consonant. (Compare diphthong.)
   2. The condition of having such a break.

      Words like reality and naïve contain vowels in hiatus.

4. A gap in geological strata.
5. A fissure in a bone.
6. A small difference in pitch between two musical tones.
7. A vacation.

Synonyms

• break (1)

After a small break we took a final inventory of all the parts in the latest shipment from Zenith. Immediately I was struck by how heavy the skins are for the flaperons and the slats. The skins for the flaperons seems to be almost as heavy as the elevator and the stabilizer combined!

We will be making the flaperons first. I went ahead and cut the 26mm angle off the mounting brackets and pre-drilled the holes into the brackets per the plans.

About one hour was spent on the inventory, and another 1.5 hours spent cutting those angles.

Project Status:
Flaperons: 1.5 hours spent ( 1.5h )
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: ~80 hours

Is this thing on? tap, tap... tap, tap...

The blog was upgraded to the new beta version of Blogger today. If anyone has problems with the page let me know via email or comments.

Upgrading allowed a massive cleanup to the HTML/CSS code template that I had heavily modified. The new system also allows for much easier addition, movement, editing and subtraction of the embeded HTML in the sidebar.

Posts also now can get tagged with a few words that describe the nature of the post like "blog", "vacation", "construction tip", ect. This should make it easier for people to filter out stuff that isn't directly construction related. In addition, the archives widget is now more useful.

The layout is going to get tweaked over the next several days. Please leave feedback about what you like and hate.

I trimmed about 10mm from the gusset. Now the full range of motion on the elevator is defined by the horns hitting each other, so about 45 degrees each way.

Last night my neighborhood had a block party. This was a belated event from the "Neighborhood Night Out" that happened on the 1rst.

My place is on a small block in the NE corner of Ballard. It's fairly quite with many long time residents. Well as the new people, we were asked which house was ours. My response was normally something like "The house with all the strange construction noises". Based on the AOPA, EAA, SPA, and BFI stickers many had already figured out that I was a pilot, but hadn't realized what the noise was.

I got the normal questions and responses like: "Like a remote controlled plane?", "That's legal?", "How will you fit it in your garage?", and so on. In the end about 15 neighbors ( at once ) ended up in my garage to see the project. I tried to answers everyone's questions about the tools, materials and inspection process.

In the end a number of people expressed interest in flying and in experimental aviation. Hopefully more people will pop their heads into the garage.

It was a good experience, especially since I missed the Eastside EAA meeting.

I heard back from Zenith builder support today. For some reason my hinge hole is closer to the gusset bracket than it should be. I measured exactly 135mm from the center hinge bracket flange end, but I didn't verify the measurments of the gusset. According to Caleb the factory demo plane has 11mm from 7H5-3 to the edge of 7H5-4. So I'll trim about 10mm from the gusset and perhaps add a doubler to the gusset. Also according to Caleb, trimming the gusset is not an abnormal step to take to allow full motion.

It also turns out that you need to drill the holes for the cotter pins on the outboard hinge pins. I'll have to drill out the rivets ( getting those out of the elevator will be a pain! ) and then conscript a drill press to make a 1/16th" hole.

The empennage is riveted. A few small questions still remain. First the hinge pins do not seem to have holes for the cotter pins. The second question is about which side the center hinge bracket goes in relation to 7H5-3 ( horn angle ). If the bracket is on the outside then the upward elevator motion is interrupted by 7H5-4 ( center hinge gusset ). If the bracket is moved to the inside then the elevator is slightly out of position and more of the center elevator hinge will have to be removed to achieve full movement.

In total I spent about six hours working on the plane and another hour playing with Sketchup and the paint job.

Of course this photo was taken at the end of the six hours... and at about 11pm.

Next up flaperons!






Project Status:
Paint Design: 2 hour 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: ~78.5 hours

I took delivery of the flaperon / slats kit on Wednesday. The crate is still closed and an inventory has not been taken. While waiting for the crate I worked on the hinges for about an hour and cleaned up the garage to make room for the new crate.

When I skinned the elevator I went ahead and drilled the elevator channels not realizing that the horn brackets would go there. When it came time to put the horn brackets on I needed to drill out a few rivets and fit the brackets through the existing holes. That worked for the bottom, but for all four brackets to join nicely I had to drill new holes into the spar. One of the holes was a little close to the new hole, so I fashioned a "patch" that goes over the the previous holes and restores any strength that may have been lost without affecting the fit of the horn brackets.

Initially I thought I borked the newly received center hinge by drilling the hinge hole too early. I had measured the 135mm from the bracket flange tip up the centerline. When I did a quick test fit against the bracket it attaches too I freaked out when the hinge hit against the elevator spar and was at least 1/4" away from the desired hole.. After calming down a little I realized what needed to be done was the following procedure: I clecoed the center hinge to the bracket on the outside of the flange and rotated the brackets. While rotating I used a Sharpie to determine the area that needed to be ground away. After fifteen minutes of using the rasp I had the correct fit.

The next step is to deal with the outside hinges and make sure everything is co-linear. Yeah.

I hope to have a completed tail section on Saturday with the flaperons starting on Sunday.

Google Sketchup is a cool tool I've used in the past. When we moved I spent a few hours with it and made a mockup of our new dwelling along with the major furniture with real measurements. This worked better than the old graph paper alternative because the digital objects gave a better sense of volume. I'm taking the same approach to designing my paint scheme. I spent about an hour making a digital elevator and horizontal stabilizer. The next step is to create a texture to be applied over the base "paint". The paint scheme I have in my head is fairly grand. Spending at least 400 hours on construction and then not taking that extra step to make my plane stand out is inconceivable to me. I want to make sure that the paint job looks good from several conceivable angles and translates well.

Project Status:
Paint Design: 1 hour spent ( 1h )
Elevator: ~25.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h, 1h )
Horizontal Stabilizer: ~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: ~71.5 hours

I spent a total of 4.5 hours getting the elevator horns drilled along with the center hinge bracket. The new Zenith bracket was the right size!

Luckily there was some scrap aluminum to make the cable template out of.

The next steps are the side brackets, the mating of the elevator and stabilizer and the final riveting.

Saturday was spent getting my night currency back. The last time I logged night hours was November 2005. While I was practicing fireworks were being shot from Lake Washington in celebration of Seafair. The explosions were probably just a little over two miles away, and at about the same altitude.

Project Status:
Elevator: ~24.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h, 4.5h )
Horizontal Stabilizer: ~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: ~69.5 hours

Hurray! I got a new center hinge bracket in the mail today. A quick check with a nearby ruler indicates it may be correctly formed even!

The part came with a few lines on it, so I'm guessing Zenith did a little extra quality assurance on this one.

The Matronic's list has been hopping with talk about Zenith and customer care. Currently I have yet to have any bad experiences with them, and the fact that a new part was on it's way a day after I talked to Caleb really shows how committed they are to supporting the product.

Zenith called and told me that slats and flaperons are on the way. A few days ago I printed out the flaperon construction manual and became worried that I should have built the wing first. It turns out that building the flaperons first is possible. Caleb gave me advise and I can procede as intended.

I'm still waiting on the replacement hinge bracket, and I'm guessing that it will arrive after the slats. Oh well.

Work is getting crunchy so finding time to build durring 12+ hour work days is getting harder.

Seafair is this weekend, so I'll be on high alert and pay attention to TFRs. The last thing I want is to get shot down BY a Blue Angel.

Bogey's air speed not sufficient for intercept. Suggest we get out and walk.

Has anyone had the following problem?

I'm starting my elevator/stab hinges and noticed a difference between the builder's manual, the plans and the manufactured piece supplied by Zenith concerning the Center Hinge Bracket ( 7H3-3SP ).

Using the plans I measured 50mm into the flange to make a mark to draw the perpendicular line. This line was off center with the bracket tip by about 2mm. The builders manual states that the line should be centered with the tip.

When tried to figure out why this was and I realized that the flange was 109mm in length, not 107mm as stated in the plans.

Since these measurements are enclosed by boxes on the plans, I assume they are critical, especially since being off will cause problems with the elevator's movement.

Is it better to use the tip center to determine the line knowing that one side of the piece was manufactured 2mm to long, possibly grinding down that side? ( my guess )

Or would it be better to use the line drawn 50mm in? ( seems like that would weaken the hinge )

Update 1: I think that the piece was cut wrong AND that the flange was bent in the wrong direction.

Update 2: Zenith is sending me a new piece. Thanks to Caleb and Nick for their support.

Project Status:
Elevator: ~20 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h, 2h )
Horizontal Stabilizer: ~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: ~65 hours

Never fly anything that has a skull and cross bones on it that takes up, oh lets say 50% of the craft.

So Cessna has finally shown their LSA concept. If it is brought to market at a reasonable price, lets say ~$60k to $80k, then this plane could be a real winner.

First lets start with a list of cons.

• Cessna is not the cheapest company around. Cirrus offers a better airplane in the SR-20 for about the same price as a new 172. My guess is that Cessna will opt for the certified version of the Rotax 912, and that will sadly add $10k to $20k
• This plane also has a castering nose wheel, which makes me question the ground handling. A steerable nose wheel is a must for any plane that will serve as a primary trainer.
• Strength. Those main landing gear supports look wimpy. Once again this plane will be used as a primary trainer, so strength is key.
  

Now for the good stuff.

• A 100HP Rotax 912. Hurray. The rotax is a much nicer engine than the O-200 or O-235. Better fuel economy, less noise, less vibration.
• The styling is great. It has the sleek look of the early fastback 150's without the visibility problem.
• 6" inches wider than a 152? Sign me up?

The styling is really something. It reminds me of a Glastar and an early 150. The wings are raised above the cabin in the same way as the CH701.

My first hours as a student were in a 150. I got my ASEL ticket in a 152. I own a 150. The two seat Cessna has a special place in my heart due to it's docile handling, brainless landings and simplicity.


The source story and picture are from Aero-Net news.

Friday night we met a nice couple who are building a Murphy Moose. Normally it wouldn't be too odd of a conversation, but we met them at a live show of The Prarie Home Companion at the St. Michelle Winery in Woodinville.

Saturday was a marathon of building. First fours hours were spent drilling the top skin, deburring and zinc chromating and then riveting the elevator shut.

The next build session focused on cutting out the required sections of the elevator for clearance of the hinges, rudder, ect.

In total Saturday saw 5.5 hours of building.

Now the mounting brackets need to be positioned, drilled and riveted. My guess is eight hours or less.

Zenith announced a new cowl for the 701. It looks fairly sleek, not something you would normally associate with the bird. I do wonder if this cowling provides enought cold air to get the full 100HP out of the 912s.






Project Status:
Elevator: ~18 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h, 4h, 1.5h )
Horizontal Stabilizer: ~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: ~63 hours

Something non-aviation related for once.

I snuck away during lunch to get current again for my Aircraft Single Engine Sea rating. N9666P was my ride for 1.2 hours.

Has anyone else noticed in their log books how often 1.2 hours is entered???

Anyway, I had never flown 66P before. It only has 150HP ( compared to 0CC's 180HP ) and the floats were different. The ride was fine, but finding the step was much harder with this plane. The floats were a different design ( Edo? ), so that was the first factor. It also was a warm day and the water was slightly rough so feeling for the magic moment was harder with the pounding of the waves.

When it comes time to order floats I will have to track down someone local with the Zenairs so I can get a good idea of their handling.

Another two hours spent on the elevator. We pre-drilled the top of the skin in key spots, ratcheted everything down matched up the lines and drilled into the spar before stopping. No major goofs, although the drill line for one of the ribs was moved over a few millimeters.

Incidentally we got our first noise complaint... from an elderly lady... at 11pm... who could hear us drilling in her living room... from a block away.

Project Status:
Elevator: ~12.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h, 2h )
Horizontal Stabilizer: ~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: ~57.5 hours

I shot this movie back in March while taking the rudder workshop at Quality Sport Planes.

We spent three and one half hours skinning the bottom of the elevator ( aka "the flipper" as "Stick and Rudder" calls it ). This was a much easier process than the stabilizer. The skin fit perfectly and the pre-drilled holes we made matched the rib flanges.

Deburring took place, but on the steel beems I bought on Friday.

Next comes measuring out and pre-drilling holes on the top of the elevator which will be much harder to do without de-clecoing everything... again.

I found a used copy of "Stick and Rudder" at a book store on Phinney Ridge. I'm not sure if I completely agree with the way the description of how a wing works, but for a new pilot it may take some mystery out of stalls, climbs and landings.






Project Status:
Elevator: ~11.5 hours spent ( 3h, 1.5h, 3h, .5h, 3.5h )
Horizontal Stabilizer: ~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: ~55.5 hours

We spent about 30 minutes securing the elevator skeleton to the table. I also bought 2"x2" steel square tubes like those shown in the directions. I acquired six, five feet each, and two of two feet each in length. What I thought would be a quick drive turned into a nightmare of traffic in rural Snohomish county, at least 15 minutes further than I thought. For future reference Whiteside steel has 6061-t6 aluminum in small sheets and various extrusions.


Project Status:
Elevator: ~8 hours spent ( 3h, 1.5h, 3h, .5h )
Horizontal Stabilizer: ~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 )
Workshop Done: ~8 hours

We now have a riveted elevator skeleton! We spent three hours drilling the tip ribs into place along with making the elevator channel brackets and drilling those together.

Deburring and zinc chromate followed... then came the riveting.

I found that there are some pieces that are just impossible to rivet together without using the hand riveter. The half nose ribs are an example. Now I need to get some steel beams together so the skinning can start. With any luck Saturday can be spent skinning and then the rest of the week can be spent on the bracketry.

With at least three weeks until the flaperons and slats arrive I need to figure out what to do with my down time... besides crunch at the office.

Project Status:
Elevator: ~7.5 hours spent ( 3h, 1.5h, 3h )
Horizontal Stabilizer: ~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 )
Workshop Done: ~8 hours

We spent about 1.5 hours last night drilling the front ribs into place and measuring and positioning the tip ribs.

There was some confusion over how to drill the holes for the tip ribs. Nick from Zenith suggested drawing the flange line out onto the outboard side of the rib and measuring from there. He also told me that drawing 7H3-2 holds the edge distance for the A5 holes that go below it.

While I was talking to Zenith I went ahead and ordered the flaperon and slat kit. It will take about five weeks to get to our workshop.

Project Status:
Elevator: ~4.5 hours spent ( 3h, 1.5h )
Horizontal Stabilizer: ~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 )
Workshop Done: ~8 hours

We started on the elevator tonight after cutting the top stabilizer and re-clecoing it back down. About 30 minuts was spent on the stabilizer and about 3 hours on the elevator.

The elevator spar was drilled for the 7H1-7s and the side brackets were cut out. Finding the position of the ribs was an easy job made hard by the wording of the directions.

The side brackets still need to be drilled. According to the manual a tolerance is 1mm, so additional measuring and double checking needs to be done.

Project Status:
Elevator: ~3 hours spent ( 3h )
Horizontal Stabilizer: ~28 hours spent, 3 pieces borked ( 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 )
Workshop Done: ~8 hours

Quick Arlington report ( Saturday ):

The day was warm for Seattle ( ~85F ) and absolutely clear. Michael Heintz was at the Zenith/QSP booth along with a 601XL and a 701.

Skykits also showed up with a Savannah now sporting jury struts... hmm is that possibly related to the wing failures discussed a few weeks ago on the list?

We ventured over to the Lake Goodwin Splash-In, but only saw a Cessna, a Kitfox and a floating car.

Highlights of the day included a Storch, an Alpha Jet and some daring moves by Kathy Hirtz in a Pitts Special

Arlington Photos, Part 2: