The front was buttoned up, the rear half of the engine mount was bolted on, the nose strut bolted on and the main gear were installed.

The plane is now rolling on its own.

Another monster six hour session finished the drilling for the slats. Only a few "gotchas" were hit.

First with the trailing edge skin be careful with the holes of the ribs. The last hole for each rib intersected the skin. This normally would not be a big deal but the ribs were already riveted ( per instructions ) to the bottom half of the main skin. In two cases ( outboard skins ) there was enough edge distance to drill out the rivets and use a strap duplicator to carry the hole onto the edge skin. With my inboard skins I had to make notches for the rivet heads.

All four slat pieces are drilled to final hole sizes and are ready to be deburred, primed and riveted.

First, to anyone who is about to order their wheels please, please, please pay attention. Just spend the extra $30 a wheel and buy the tubes. The Matco tubeless tires are a nightmare. Seriously, I would rather rivet my hand to a rabid raccoon than deal with those things again.

I probably spent 15 hours trying to get them to inflate.

Some of that time was spent trying to separate the wheels. They can be really tight a large amounts of brute force will need to be applied.

The valve stems are a pain to install. A local tire shop was kind and let me borrow a valve stem installer. After that you need to get the wheel somehow beaded with the tire AND then slip a crazy rubber band gasket on between the two halves of the wheel.

If you use the tubes then the valve just slips on through and the wheels self bead.


A huge amount of progress was made thanks to the help of another local 701 builder. Together we made substantial progress on the slats. The slats are pretty straight forward, except for a few gotchas that got me. The biggest has to do with the "L" angle that reinforces the slat skin near the supports.

Trying to be industrious I went and cut the "L", notched it, bent it to match and then located the holes and drilled them into one piece. I used one of the ribs to back drill into a mirrored rib and then duplicated the holes to all the ribs.

What I forgot to do was check that all the holes of the "L" went into the support. Luckily all the holes that made it into the support were within minimum edge distances, but one hole missed. So I had to drill a fifth hole into the "L" that then made it into the slat support.

In one monster eight hour session we got the "L" spar drilled into all four slat skins, all the ribs, supports and "L"s riveted together and on one piece the ribs drilled into the skin.

Quick status update:

The doors are on, the latches installed, the hinges hinging.

The main gear have had their notches made and are test fit. The front fork is ready for the wheel and tire. The landing gear and strut fittings have finally been bolted into place.

I did have some problems with the Matco wheels. Despite following the drawing, I can not separate the front wheel halves. There does not seem to be a retainer clip or anything like it.

The pilot side door is now installed along with the door handle and strike plate. The directions were lacking, and a backing plate needed to be made for the provided handle. I unscrewed the inside latch and measured the distance between the screw posts and the center piece.

After making the backing plates the handle was positioned using the backing plate and internal handle to determine where the strike plate needed to be.

The backing plate was then used as a template to drill into the fiberglass door and the handle as screwed together.

On the passenger side the door was thicker than the pilot side. This caused the screws not to reach through and thread into the door handle.

PROGRESS:
Controls ~2h ( 2h )
Fuselage ~251h ( 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, 5h, 6h, 3h, 5h )
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: ~510h

The door problem has been resolve. the solution was to trim 20mm off the top edges of the door sills. The major issue was matching the already existing holes into the fuselage frame. This was achieved by using a strap duplicator and the trimmed section of metal itself.

Once that was done, the hinges were drilled into the top of the door frame, then the hing was drilled into the door at some key spots to make sure the holes would clear.

After that one of the Dremels was revived with new motor brushes and the doors marked and trimmed.

PROGRESS:
Controls ~2h ( 2h )
Fuselage ~243h ( 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, 5h, 6h )
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: ~502h

Detailed photos of the bubble door fit problems I am having.

It has been a while since the log has been updated, but that is not to say progress has not been made.

The roof has been drilled into place. The doors have been test fitted, and problems have been found. The windshield is sitting in place. The front landing gear is not being worked on.

PROGRESS:
Controls ~2h ( 2h )
Fuselage ~237h ( 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, 5h )
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: ~496h

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

Spent three hours working on the instrument panel.

The gussets that join the panel to the cabin frame were fabricated and drilled into place. The panel bottom channel ( 7F15-1 ) was also drilled into place.

First I would suggest drilling the channel into the panel first. This gives you a better idea of where the gussets should go.

Despite some careful initial fitting and measurement, the gussets ( 7F15-2 ) are a little further inside that I would like. By centering the panel channel first you can get a better idea of where the radius of the gusset should be.

Also you will have to trim the top of the gusset so it can clear the panel. The plans call for a line at 75mm up, but try making the line at ~100mm. Of course, your milage may vary.

PROGRESS:
Fuselage ~208h ( 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 )
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: ~470h

Got about an hour of work in. The ("Z") angle on the forward fuselage skin on the passenger side got measured, trimmed and drilled into place.

Once the initial rear hole is drilled into place and the position where it crosses the plate is determined, it is much easier to predrill the required holes into the channel, then drill into the fuselage skin.

The Rotax was finally uncrated ( mostly ). The shipping crate was secured in an unusual manner and required bending of metal to open. A quick inspection did not reveal anything missing or damaged.

PROGRESS:
Fuselage ~204h ( 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 )
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 )
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: ~466h

Finally got some flying in!


Takeoff from Boeing Field from John Marzulli on Vimeo.

I spent about an hour on the fuselage. First we finished drilling the side skin extrusions into the nose skin, then we trimmed and drilled into place the upper ("Z") length that runs along the nose skin.

It turns out that the best way to approach the placement is to drill the aft most hole, then have a help hold the piece AND provide a buttress on the outside while you drill from the inside.

Also one of our EAA chapter members held a project visit today for their very nice looking 5151. Metal really dominates building so seeing how a wood project goes together was refreshing.

PROGRESS:
Fuselage ~203h ( 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 )
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 )
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: ~465h

Saturday was the first building session attempted since the birth.

I reconfirmed the positioning of 7F14-6 on the pilot and passenger side and then laid out the drill holes on the extrusion that extends from the fuselage sides.

Instead of drilling from the outside as was suggested by the HBH video, I ended up drilling from the inside to ensure edge distances.

At first I took a contortionist's approach by laying on the seats with my elbow resting on the floor pan, but I realized that I could simply sit on the edge of the workbench and lean in.

PROGRESS:
Fuselage ~203h ( 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 )
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 )
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: ~465h

We just had another delivery today. Only this baby eats premium gasoline, is Austrian, makes 100hp instead of diapers, and weighs 160lbs.

So it will be some time before the plane gets worked on again. My wife just finished a nine month long project, and we just started a project that will take a minimum of 18 years...



http://www.genevievemarzulli.org/

Most of Monday night was spent doing the inventory for the remaining FWF shipment. There were a few small parts back ordered, and I accidentally received the 601 equivalent part... but most of it was there. The cowling is night and smooth, really slick looking.

The actual hour of work logged was getting the aluminum plate measure and clamped into place before hitting a realization about needing to drill the side skins partially into the firewall for a smooth fit.

PROGRESS:
Fuselage ~202h ( 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 )
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 )
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: ~464h

Saturday night we trimmed and drilled into place the ("Z") angle that runs along the floor and the ("L") angle that supports the forward skins right above that.

The ("Z") was fairly easy, except I had to remove the firewall to slip the ("Z") in. Replacing the side skin and the firewall took effort as nothing wanted to line up initially.

The side skin support angles were another story.

Wanting a tight fit, the ("L") was crimped before it was drilled into place so the end point that connected to the firewall would be just right.

The problem with this is the actually accessing of the point. I had to crawl into the cabin at a crazy angle such that my shoulder was resting on the floor panels, but my hip was on the seat.

PROGRESS:
Fuselage ~201h ( 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 )
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 )
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: ~463h

Friday, Saturday, Sunday - Work picked back up. The engine mount finally got drilled into the firewall and into the V-Brace. After that work started on the forward side skins. These were easy, but I found that the bottom edge of the skins will interfere the forward most rivets of the extrusion.

The trick to achieving a good fit is to have someone pushing on the skin while a second person drills.

Before I can drill the supporting Z-Angle into the side skins I will have to do some amount of trimming so the engine mount can hold the firewall into position.

PROGRESS:
Fuselage ~197h ( 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 )
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 )
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: ~459h

We had a streak of great weather ( for the winter ). It would have been criminal not to take advantage of it.


Lake Cushman And Back from John Marzulli on Vimeo

The fuselage is corrosion protected, deburred and riveted together ( excluding the tubular frame ).

One thing to consider is the accessibility of the small piece ("L") angle that ties the side skins together with the seat pans on the outboard side. If I could call a mulligan then I would rivet the ("L") to the pan first, then cleco it to the side skin and rivet it with the rest of the seat.

Of course the momentous occasion was celebrated with the first sitting in the plane. The seats are as comfortable as can be hoped for. Skyshops really did a great job matching my colors and providing an overall well made product.

Next I will drill the engine mount to the firewall ( finally ) and make the instrument panel.

PROGRESS:
Fuselage ~190h ( 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 )
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 )
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: ~452h

Spent three hours drilling out the remaining holes and corrosion protecting. The gear strut fittings were somewhat brutal to drill as I broke a bit on the left and right side each.

PROGRESS:
Fuselage ~184h ( 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 )
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 )
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: ~446h

I finished drilling out the side skin attachments to the rear fuselage. I also fabbed the side skin doublers ( 7F16-6? ). Due to having already pilot drilled the seat gussets into place the first holes in the doubler were back drilled from the bottom. This required an extra person, a flashlight, an inspection mirror and an angle drill.

The only holes remaining are in the gear strut attachment.

Everything was deburred and is now ready for priming.

PROGRESS:
Fuselage ~181h ( 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 )
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 )
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: ~443h

Some nights just do not got the way you want. The whole session ended just about where I thought I started.

First the rear and front fuselage would not cooperate and mate together. Then I realized that the middle baggage area truss was not riveted to the baggage area flooe, so I drilled out the rivets... to the doubler extension that I had to fab... only to find out I drilled out the wrong row of rivets and that the truss was upside down... and had to be drilled out.

Everything fits together now AND I riveted a portion of the rear fuselage that had been kept clecoed together just in case.

Instead of a photo, here is a quick tour of the Seattle skyline:



Seattle Skyline Tour from John Marzulli on Vimeo


PROGRESS:
Fuselage ~178h ( 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 )
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 )
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: ~440h

Weekend roundup ( Friday, Saturday, Sunday )

First, my upholstery arrived late Friday. It looks great. I am making a big push to be able to finally sit in the plane... which leads me to the next part:

Drill out, debur, prime, rivet.

There are still a few holes that need to be drilled out that I am finding. Most everything is now covered in primer. The entire torque tube cover assembly is now riveted together. I also have the baggage compartment riveted together. To avoid some installation and reach issues the side skin gussets have been riveted.

I also fixed a mistake caused by misinterpreting the plans. For some reason I installed the interior gussets with the cutout for the rudder cables on the upper locations. These were drilled out and replacements were made without the cutout. The lower gussets were modified to include the rounded notch.

As getting in and out of the rear fuselage is a pain, it is highly suggested to install them the correct way before riveting any of the baggage area.

PROGRESS:
Fuselage ~175h ( 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 )
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 )
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: ~437h

Detail photos of the old 7F3-3SP and the newly fabricated piece with edge and hole distance.


Old piece. The holes that went into the diagonal tube are "highlighted" with blue:


The new piece installed:

Monday night I drilled out almost all of the remaining holes in the forward fuselage. When the holes in 7F3-3SP got enlarged to A5 it became very apparent that distance between the holes was not sufficient for my standards. I ordered a new tube and a sheet of .040 from OnlineMetals.com so I could fab up new pieces. I finished the night by deburring a good bit of the fuselage.

Tuesday night I un-installed the passenger side 7F3-3SP lined it up with a flat edge of my new 0.040 sheet and clamped and back drilled all the holes that did not go into the diagonal tube. I then expanded the gusset about 20mm inboard so as to gain an additional 15mm or so on the diagonal. I left the width of the gusset the same as before at the fore and aft, connected up my lines, cut it out and cleaned it up.

The new piece fit perfectly. I then trimmed the tube, inserted it into the fuselage receiver, clamped, lined up and drilled. The new holes are dead on with about 4D space between holes. I back drilled the remaining holes in the frame and the lower gusset.

PROGRESS:
Fuselage ~166h ( 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)
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 )
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: ~428h

The pilot and passenger seat pans are now both drilled into place. In addition the seat corner gussets were both fabricated and drilled into place, the backing ("L") of the seats is in place and several tie together gussets were put into place to deal with over trimming of the side extrusion.

In addition, most of the A3 holes were drilled out into A4, with some becoming A5.

Drilling seat backing ("L") angle into place took two people and the access hole. First I trimmed the piece to length and drew the centerline. Then I identified the center position ( left to right ) drilled the pilot side most hole that was not shared with extrusion. Then the helper from the outside clecoed the seat back, seat pan and ("L") together and removed some of the clecos that pushed against the ("L"). It was then a job of matching the line and back drilling through the seat, clecoing and then moving more towards the passenger side.

PROGRESS:
Fuselage ~161h ( 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)
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 )
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: ~423h

We spent about three hours getting the seat floors ready. First figuring out the procedure, then determining what needed to be fabricated. The pilot side seat is mostly drilled into place. A gusset needs to be fabricated and a supporting piece of ("L") needs to be positioned.

Tip: When drilling the seat pan into the ("L") angle that runs along the torque tube cover, the proper place for the holes was significantly further in than 10mm ( referenced by the skin ). The curvature of the skin combined with the closed angle of the ("L) essentially moved the skin edge more inside than I expected. The 10mm edge line drawn on the skin translated to the holes being about 4mm from the radius of the ("L").

I also found that to place the ("L") the seat front channel had to be pulled forward away from the torque tube cover to allow space for the angle to get slipped in.

PROGRESS:
Fuselage ~151h ( 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)
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 )
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: ~413h

First some building footage:



Grinding Metal from John Marzulli on Vimeo.


And then some flying video.



Flying and Sunset from John Marzulli on Vimeo.