Look Mom, no clecos! We spent about three hours on Sunday finishing some deburring, corrosion protecting, and riveting.

About mid afternoon, about 15 minutes after hauling the bottom wing skins, spar, and a few other pieces out... and spraying them... the skies opened up with a freak rain storm. All the pieces were quickly taken back into the garage and dried off.

A good bit of time was spent using the lessons learned from the other wing and attempting to get the rivet order correct. The brackets on the fuel tank channel and rear channels were done first, followed by the flaperon brackets to the ribs, followed by the ribs into the spar.

The rear channel needs to be done in a specific order: work from inboard to out board leaving the outboard side of the channel being riveted unclecoed so the channel can be pushed for clearance of the gun head. Since it is easily accessible, the root rib should be riveted last to the wing channel.

Project Status:
Wings: ~107h ( 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 )
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: ~208.5

No building Wednesday night, just flying.

Thursday is the solstice, so I wanted to take advantage of the beautiful lighting conditions that occur in the northwest.

EAA 1440 met tonight with a talk by Precision Airmotive. Honestly it was more info about carbs and fuel injection that I hopefully will ever need to know.

Due to the meeting, I only spent about an hour actually working on the plane. All wing parts ( except for the spar and skins ) were corrosion protected. The rest of the time was spent watching paint dry.

All the wing ribs, brackets and channels amazingly fit into a produce delivery box.

Project Status:
Wings: ~104h ( 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 )
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: ~205.5

We spent another two hours deburring. The skins still need attention, and everything still needs Zinc Chromate.

Project Status:
Wings: ~103h ( 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 )
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: ~204.5

We spent about three hours finding more holes that needed to be enlarged to A5 or A4 while starting the deburring and disassembly of the left wing.

There was a light drizzle today so none of the parts were corrosion protected.

The garage needs to be rearranged so the left wing can be hung as well, so the shelves will have to be moved with perhaps some more storage.

Project Status:
Wings: ~101h ( 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 )
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: ~124.5 hours

We spent two hours on the project and made great progress. The jury strut supports are now in and all of the skeleton has been drilled to the proper hole size. The skeleton is now ready for deburring and can be riveted along with the bottom skin.

We also crossed over the 200 hour mark of the project.

Project Status:
Wings: ~98h ( 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 )
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: ~202.5 hours

We spent an hour first cutting the the 8 pieces of L angle, then positioning the flaperon arms with the template, then verifying the position of the arms with string..... then drilling the arms into place.

With this wing the flaperon arms were more forward on the brackets, so I drilled an additional hole into the arms to compensate for the holes I did not feel to have adequate edge distance.


Project Status:
Wings: ~96h ( 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 )
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: ~199.5 hours

It took about two hours to get the strut angle in place and drilled. The strut attach point is also now pilot drilled to the support. Most of the time was spent waiting for the compressor since the right angle attachment wastes a large amount of energy and drilling out various holes to A4 so A3 clecos could be reclaimed.

I think I have my lights picked out. A set of LEDs offered by Wicks. LED lighting is one of those "must haves" given the limited output of the Rotax alternator and the expected draw from the Dynon and radios.

Project Status:
Wings: ~95h ( 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 )
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: ~198.5 hours

We were camping all weekend, so Friday night was all we got in until today ( Monday ). Two hours were spent getting the bottom edge of the front nose skin in. I had only drilled a few holes in the spar from the bottom skin, so it was easy to get the entire skin lined up. The strut support hole had to be enlarged on the inboard side exactly like on the other wing, but this time I bolted on the strut attachment with the skin off, saving time and frustration.

The strut angle is marked and ready to be drilled. The only issue is that we are running low on silver clecos ( AGAIN!?!?!?!? ), so more A3s had to be enlarged to A4s. This helped eliminate some of the ( very limited ) beer canning anyway.

And now for some purty pictures:



Project Status:
Wings: ~93h ( 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 )
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: ~196.5 hours

I finally found some energy to get back into the garage. It took about two hours to get the rear bottom skins drilled into place. The biggest time sinks were having to cleco myself and reclaiming silver clecos. It is hard to imagine that we are low on A3 clecos again, but we are. To get clecos back I drilled some holes out to A4s.

When you are placing your holes for the outboard side of the flaperon brackets the manual states that the hole is 10mm from the bracket, but there is a better way of finding the hole. Simply extend your rivet line from the ribs down to the rear channel. Drill where the two lines intersect.


Project Status:
Wings: ~91h ( 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 )
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: ~194.5 hours

I spent about two hours on Sunday getting the trailing edge skins ready on the right wing. They are all ready to be drilled.

This week will be light on the building. More to follow.

Project Status:
Wings: ~89h ( 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 )
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: ~192.5 hours

It took me an hour on Thursday to cleco the left wing skeleton back into one piece. Then I went flying for a couple of hours...

Friday we spent about four hours getting both the top and bottom skins into place and drilled. I learned my lesson this time and only drilled a few holes into the spar on the top skin. The bottom skin also only has a few holes drilled into the spar, although it did not cause any problems last time.

The left wing went much faster and we had a much easier time getting the flange lines into place.

Thursday I did another cross country in a Super Cub, this time to Whatcom lake and Lake Cavanaugh near the Canadian border.



Project Status:
Wings: ~87h ( 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 )
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: ~190.5 hours

I once again spent my afternoon in a Super Cub... with an 84" prop.

We had lunch at Lake Wynooche in the Olympic Mountains while talking shop in a way that satisfied my BFR.

Is there a better way of spending the day?



In project news I have the nose skin now in place. Only a few of the holes for the slat support and the spar extension need to be placed.

Those fuel tanks are just around the corner!

I spent about an hour Tuesday morning struggling with the nose skin, only succeeding in giving it more "smilies". I ended up calling Zenith and realized that I needed to use a loop strap that wrapped around the wing.

Later in the afternoon I made a trip to Home Depot for new straps. I placed some wood up against the flaperon brackets to protect the trailing edge and everything worked well. I slipped the nose skin underneath the top skin and have had good success with the existing spar holes. I am simply using low speed on the drill and stopping as soon as I feel the nose skin being penetrated. I then inserted a cleco and searched for the existing spar hole.

My after noon was spent with a Cub Crafters Top Cub on the Snohomish River. Today I have a couple of hours and am going to take care of that pesky BFR.




Step Taxi near the 522 bridge





Taking off





Project Status:
Wings: ~82h ( 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 )
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: ~185.5 hours

Some photos from Paine Field's General Aviation day that was held on Saturday the 19th.

It took one hour to get the jury strut attachment ( 7v10-4SP ) points into place. The plans were a little hard to read, and the presence of predrilled holes further exacerbated the issue. A partial solution for both the front and rear was to drill the middle hole and then cleco it onto the wing. The foreward support then needed to be removed, the nose rib moved into place and then drilled to the skin in two places. Then the cleco that should hold the jury strut had to be removed, the jury strut attachment replaced and then back drilled into from the rib side.

It took four hours to rivet the remaining skeleton and bottom skin. A few A4s were accidentally put where A5s should go, so I had to drill those out.

Currently the nose skin is clecoed to the skeleton. Strapping the nose skin is always the hardest part. To complicate matters I already drilled through the pre-drilled top skin into the rib. To work around this I will drill the skin to the nose ribs first THEN slip the nose skin under the top skin, then mark where a few holes are supposed to go. I will then slip out the skin, drill those few marked holes with an A4 bit, slip the skin back under and cleco the top skin back onto the spar through those holes. Once that is done all the holes on the top skin should align with the existing holes in the spar and the nose skin can be pilot drilled. Once the nose skin is pilot drilled, I will then slip the skin out and place the nose skin over top the top skin. To help I used the edge distance tool to mark where the nose skin should reach.

Project Status:
Wings: ~80h ( 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 )
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: ~183.5 hours

I did my first building since our vacation and recovering from the food poisoning associated with said vacation...

It took three hours to put the wing skeleton back together and rivet the rear channel and the fuel tank channel.

Part of the time was spent drilling out rivets due to some thoughtlessness on the rivet order. Here is what I learned:

• Rivet the rear channel and their angles first.
• Rivet the (L) angle to the fuel tank channel second.
• Rivet the Fuel tank channel to the ribs before riveting the rear wing channels to the ribs. This allows easier access on the inboard side with a pneumatic gun.
• Rivet the flaperon support brackets before riveting the wing channels.
• With the wing right side up, rivet the rear channel to the ribs from the outboard working your way inboard. Have the inboard piece of the channel you are riveting disconnected so you can push the nose of the gun inside. Use a hand riveter with a swivel head to get the heavy channel that has the strut support.
• Have someone else help you so you don't have to put down the rivet gun!
  

Project Status:
Wings: ~75h ( 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 )
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: ~178.5 hours

Seven hours of deburring, disassembly and chromating. The wing is still in pieces. Lets hope I can put it back together again when I return from vacation.

In other news I splurged and flew a Cirrus for the first time. One point seven in an SR-20.

Project Status:
Wings: ~72h ( 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 )
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: ~175.5 hours

We spent two hours Friday morning fabricating the flaperon supports and then drilling them into place. An easy job, but it takes a large amount of un-clecoing and re-clecoing. You also have to be careful about protecting the skin.

Saturday night we spent about 3 hours. I went back and drilled out all the A3 holes on the skeleton to A4s and A5s. There are still a few places that need to be enlarged but the skin must be removed to reach those ( all on the rear channel ).

It took a long time to change to color of the skin clecos. Only the bottom skin was drilled out, but it was a long process. We also cleaned the garage out.

Project Status:
Wings: ~65h ( 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 )
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: ~168.5 hours

Saturday had about 3 hours of building, and Sunday had about 4 hours.

On Saturday we got the forward strut attach point bolted along with all the other related pieces drilled into place. Tightening the bolt closest to the skin is a major pain. Maybe some sort of inspection port nearby would be a benefit.

Sunday I fabricated the flaperon positioning template and got the flaperon arms into place. I found a good way to check if the holes are co-linear. Just use a spool of thread. Have one person hold the thread tight on one end, and then hold it tight on the other. If the holes are not co-linear then the thread will indicate which way the bracket needs to be moved.


I bought a right angle adapter from Home Depot a while ago, and it came in handy. The builders manual shows a nice way of not damaging the skin when using the drill in tight spots... a nice tip to have had earlier. My variation used an extra piece of heavy wing channel that had to be trimmed off. Since the wing channel is bent on both sides, the chuck can not move the protecting piece out of the way.

There is an optional step to place the tie down rings. I do not remember receiving the tie down brackets, although I could fabricate my own. The position of the brackets confuses me. It seems that attaching the bracket to the fifth rib is not the strongest place. Why is the loop not attached to the strut support? The strut support already is attached to the spar which would be a better place in case of a wind storm around here.



Project Status:
Wings: 60h ( 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 )
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: ~163.5 hours

On Sunday we 1) Finished trimming the rear wing skins 2) Drilled them into place 3) Got the nose skin clecoed into place and confirmed the slat support slots were in the correct position.

The manual shows how to cut the flaperon hinge slots into the rear skins with a drill. I tried to do that for a few holes and ended up wandering with the bit too much. A much better approach is to use a reinforced cutting blade on a Dremel.

Thursday we got a package of 200 silver clecos from Wicks... which is possibly too many clecos.

I freshened up on my float skills today with splash downs in Lake Washington and the Snohomish river. Drivers on the 522 bridge got a show as we approached down into the river and passed overhead by less than 50 feet. Then some fishermen got a show as we flew along the river about 10 feet off the deck making tight turns to follow the river bed. I could make out details on one of their faces....

Project Status:
Wings: 53h ( 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 )
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: ~156.5 hours

Monday I got a little time in to start trimming and placing the rear right trailing edge wing skins. While the plans normally show the right side of an object, the skins are sometimes shown as they appear on the left side. Take note and be careful.

EAA is tonight, so probably no building will happen. I expect Wednesday, Thursday and Friday to be a full on spree!

Project Status:
Wings: 53h ( 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 )
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: ~153.5 hours

Another 200 silver clecos are on their way.

We found some time over the week and on Sunday to align the spar and support the trailing edge in such a way to ensure no twist. The bottom skin was pre-drilled and fit over the skeleton fairly well. Since there is a bit of a curvature to the bottom of the wing ribs we ended up using some duct tape to help hold the skin towards the trailing edge to help keep the skin from beer canning. Over all this was the easiest skin to apply yet.

Project Status:
Wings: 52h ( 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 )
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: ~152.5 hours

We did not build on Sunday, but rather took a nice long file up to the tulip fields.

The weather was threatening on Saturday so we drove to Wick's. The traffic was horrible and conditions only improved.

In the end they only had 70 silver clecos, but anything helps.

Wednesday night we spent about half an hour securing the spar and ribs to the table.

We ended up having to remove several of the small shims securing the ribs since they interfered with moving the skeleton to match the pre-drilled holes on the skin. Using several rafter squares clamped to the rib and spar worked wonderfully.

Thursday saw a good two hours of drilling the top, rear starboard wing skin into it's respective skeleton. This would not have been possible without the generous lending of clecos to me.

The electric drill did a much better job of drilling into the spar, while the air drill was faster drilling into the ribs.

Hopefully I can get up to Wicks on Saturday and buy another two hundred clecos or so. I'm also low on zinc chromate.

I also got to see one of the many RV-7 projects our chapter has. Van's is really onto something with matched-pair drilling. If the RV-12 kit has the same amount of pre-drilling on the skins AND the ribs, then the 601 will have some real competition in the LSA area.

Project Status:
Wings: 49h ( 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 )
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: ~149.5 hours

Quick project update:

I have a bunch of photos to upload, but my home computer has been overheating, and it is low on the "fix list'.

Recently I got the tank channels into place, drilled and clecoed along with all the prep work to get the right wing ready for the top rear skin.

Project Status:
Wings: 45.5h ( 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 )
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: ~147 hours

Wednesday I spend a few minutes making the jig for the fuel tank channel, and almost an hour cleaning up my workshop.

Monday some jerk broke into my Jeep at about 9:15AM, right before I normally leave for work, and stole my Garmin 496.

Sunday I finally flew a CH-701, albeit only for a little while and from the right seat. It gave me some renewed vigor to finish the project.

Project Status:
Wings: 44h ( 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 )
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: ~145.5 hours

We spent about three hours on the wings today. The skin support for strut hole was fabricated and placed on the right wing. The left wing got the full treatment of the flaperon brackets, strut attachment and skin support being drilled into place.

More visitors came through the garage. This time a couple interested in building, but also on their way to visit a Czech 701 to potentially buy.

Sunday will hopefully bring high ceilings and actual time in the cockpit.


Project Status:
Wings: 43.5h ( 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 )
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: ~145 hours

I spent about two hours measuring 7V4-4, cutting it, drilling the holes for the left and right wing, and then drilling the right piece to the right wing.

Some "L" angle was also cut and drilled that acts as a brace.

It has taken some time for me to realize this, but the drawing for a piece like 7V4-4 will be found on page 7-V-4. I was trying to determine the dimensions of the piece from the drawing of 7V4-4 that was on 7-V-5.

Right now my plan is to work only on the right wing for the moment since space is now at a premium. Once the right wing is finished, it will be hung on the wall and the left wing will be finished.

Project Status:
Wings: 40.5h ( 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 )
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: ~143 hours

Already got a response!

Caleb got back to me with Zenith's uncanny quickness. The problem was me.

... I would suggest removing all the lines you have marked and starting over. Go to page 7-V-4 in your drawings, at the bottom is the part geometry and dimensions. I would start at the smaller end, draw a line at 16mm from the end, this is the line that the bolt hole is on. From the line you just made, mark a line at 115mm. Measuring from the edge that is 90 degrees to the larger end, measure along the second line you made and mark a point at 27mm. Then from the second line you made measure back towards the smaller end 15mm, make a point on the bottom. Draw a straight line between the bottom point and the point you made at 27mm. Now at the top of the part from the second line you made measure back towards the smaller end 41mm, make a point there and connect that point and the point at 27mm. All of the dimensions and part geometries are in your drawings.

I already used these ( better ) directions and the piece looks like that in the manual. Tonight I'll cut it.

Finally some time to work on the project....

We spent about two hours. The first hour and a half was spent figuring out the best way to get the flaperon brackets consistently placed. The end result was using some extrusion clamped to the top of the rib, then using some "L" angle to hold the bracket to the rib. The ends of the brackets were all made flush with the end of the rib.

I'm not sure how I got into this position in the first place. I drew out the rivet lines on the spar and channel, and the pre-drilled holes of the skin line up perfectly.

But as always, progress must be stopped. I believe that the 7V7-4 supplied with my wing kit may be mal-formed.

Basically making a mark 41mm from the 115mm mark to the right is past the piece. Making the 41mm mark to the left doesn't look right

The instructions in the manual are somewhat confusing, so I would be happy to find out I mis-interpreted them.


Project Status:
Wings: 38.5h ( 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 )
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: ~141 hours

Honestly I have not been working on the 701 much recently. We had some visitors on Sunday and I used the top rear wing skin to verify that the distance between the spar and rear channel is correct.

So what is the reason I've been so busy?

http://download.microsoft.com/download/0/8/8/08878f81-138c-4bad-a7fd-a06d11945178/Shadowrun_Esrb_360p29_51_1800k.wmv

Enjoy.

EAA 1440 had another meeting last night, with a great analysis of accident rates and causes for homebuilts, along with comparisons to the production fleet.

I've had this idea of formalizing risk mitigations knocking around in my head for a while. At Microsoft an employee determines a set of commitments and accountabilities for those commitments, which determine the results of the annual performance review.

This model seems like a good fit for something like the homebuilding process. Considering that the fleet accident rate for all Zeniths is about 2.14% ( higher than Lancairs, less than Seareys ), then I need to do something to minimize my individual exposure to risks.

At the moment I have no idea what the largest contributor is to the Zenith fleet accident, my commitments will be based on my perceived cause of accidents and the root causes of the overall homebuilt fleet.

Commitment: Flight training
Execution:

• Meet with our EAA flight advisor. Meet with an EAA flight advisor who has specific experience with the CH701.
• Obtain an additional 20 hours of float training. Attempt to find a reasonable source of amphibious training.
• Attempt to find a source of CH701 specific training.
  

Commitment: Technical and safety review
Execution:

• Hold a project open house before transport for final assembly
• Meet with an EAA technical advisor, with a review of all airframe, fuel line, and FWF assemblies.
• Have a trusted A&P do a review of the airframe assembly
• Perform a full inspection at the following intervals of flight time:
• 1, 5, 10, 20, 40, 60, 100
  
• Have a trusted A&P do the annual condition inspection with me so I can learn how to maintain the aircraft.
  

Commitment: Fuel line & FWF safety
Execution:

• Obtain help with the FWF installation by an experienced Rotax installer
  

Commitment: Further Mitigation
Execution:

• Determine more commitments that are relevant for a safe completion of the project.
  

We spent about two hours on Sunday. Part of that time was spent getting the inboard wing channel into place, and the rest on the flaperon brackets.

I believe that my rear wing channels may be a few mm aft, as I am having a problem with 7V4-6.

When I attempt to place the bracket, the after edge is more rearward than the rib. If I move the bracket forward then it gets between the rib and the channel.

Is the correction to attempt to move the channel forward, or to shim between the rib and the channel?

Project Status:
Wings: 36.5h ( 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 )
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: ~139 hours

Saturday night we were able to sneak in about an hour and a half of work. Tasks completed included cutting the outboard rear wing channel for the wing tips, discovering that the inboard heavy duty rear wing channel required trimming, trimming them, figuring out the measurements and hole placements for the 7V4-3 ( doubler ) and then pre-drilling it.

Luckily all the trimming produced enough scrap to fill in for some 7V6-3. I found Zenith really does not provide enough of that piece. I can't imagine that it cost's that much, or would be too difficult to produce.

Project Status:
Wings: 34.5h ( 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 )
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: ~137 hours

Building will be slow for the next several weeks...

Superbowl Sunday was productive and most of the rear wing channel for the left wing was finished. The remaining center piece was done on Monday.

Working on the rear channels alone is a challenge, an assistant is a necessity.

After much discussion on the Zenith list, I bought and tried a Drill Doctor XP2. What a piece of crap. I tried two #30 bits that we past their life and it made . A #40 was also tried and destroyed. If I hadn't received a refund from Home Depot you can bet that angry mails would be sent, but I really don't have the time. All three bits were made blunt, not matter what I attempted.

Project Status:
Wings: 33.0h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 1h, 2h, .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: ~135.5 hours

We only spent an hour on the left wing. The rear channel positioning template was used for the first half of the drilling. Attaching the inboard halves still needs to be done, and the rear channels do need to be trimmed to fit.

Project Status:
Wings: 30.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 3h, 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: ~133 hours

Sunday was busy even though only about 3 hours of work got done.

Dave and Pat from EAA dropped by to see what a Zenith project is all about. They are about to embark on the journey with a 601XL.

The 60mm jig worked perfectly, and I did drill the channels into place from the middle of the spar outwards, but did the middle heavy channel last. I did have to trim the rib channel position template a small amount.

Everything seems to be square.

For the middle heavy channel, we used two bookshelf brackets ( as pictured ) to keep the ribs square as the rib angle and channel were squared into place. We had to mark the holes into the rib angle and then precision drill them since clamping would have been impossible.

The left wing's rear channel should not take near as long.

Saturday we actually flew the old 150 and saw the new Olympic Sculpture Garden from the air.


Project Status:
Wings: 29.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 1h, 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: ~133 hours

Finally got a little time to work on the project. Spent about and hour playing with the rear template placement jig and the rear channels.

When I had my last major question, I was trying to determine the jig distance for the rear channel ( 380 or 400mm ). I called Zenith and Roger gave me a better way: do not even use the jig. His suggestion was ( working center outwards ) to square the ribs, place the wing channels and THEN drill the angle to the channels.

Having already jigged the long sets, I decided to do this for the short channel.

Here is the problem: I first test fitted the 600mm channels and the angle ( 7V6-3 ) was not protruding far enough from the channel. The mating surfaces were about 3-4 mm apart. The obvious fix is to trim away a small portion of the flange from the wing rib. Because the piece must be 600mm for proper rib alignment, moving the 7V6-3 or the fabricated end cap are not options.

I'm still going to follow Roger's advice for the shorter channels since I can trim the entire channel for clearance before adding the 7V6-3 and still maintain proper edge distance.

Project Status:
Wings: 26.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h, 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: ~130 hours

We spent about four hours fabricating the rear wing channels for the left and right wing.

The manual gives a kernel of a good instruction, but there was an easier way. If you mark the edge distance and then mark your rivet holes on the outside of the channel, you can support the piece ( placed in the jig ) during drilling with a small piece of wood underneath it. When you back drill, use the same piece of wood with a clamp to keep parts from shifting.

The first jig was set to a length of 600mm for 7V6-2SP. The manual states that for 7V6-1 the jig should be set to 380mm, BUT the length of 7V6-1 is 380mm. The plans state that the flange-to-flange distance of the completed part is 400mm, so I think the manual is in error.

The Zenith list seems to concur, but I'm going to call Mexico, MO in the morning.

Also, Robert from my EAA chapter dropped by curious to see what the Zenith build process id like compared to the RV-7 he is working on.

Project Status:
Wings: 25.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 2h, 4h )
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: ~129 hours

The amount of wood used so far to make an "all aluminum plane" has probably been enough to make a Fly Baby.

We spent about two hours cutting the false rib template and making the first rear channel jig ( both shown in the photo ). Most of that was figuring out the fancy new tool. It even can with an instructional DVD.

The router also came in handy cleaning up the workbench edge that 1) wasn't cut very straight 2) has been drilled more than Paris Hilton.

Project Status:
Wings: 21.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 1h, 1h, 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: ~124 hours

Thursday night was spent laying out the false rib template.

This was an easy task, except on the plans many of the measurements are relative to each other, making some easy parts hard.

More tools are needed... like a router to do the tight spots. Should also come in handy for the slat jig.

Project Status:
Wings: 19.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 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: ~122 hours

On Monday we spent about an hour fabricating the bends in the rear channel for the right wing. Wood was used instead of a backing bar. I used a file to bevel of the edge for the radius to be about the correct size.

Project Status:
Wings: 18.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5, 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: ~121 hours

Saturday consisted of powertools and football. As an added bonus the Cowboys snatched defeat from the jaws of victory.

We spent 4.5 hours fabricating the skin supports for the left wing, drilling the supports, mounts and tip ribs. Everything got deburred, protected and riveted. For both wings. It was a large amount of work for very little visual payoff.

The next mini-project is the rear wing channel. This will involve some templates and a simple jig.

Project Status:
Wings: 18.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5, 4.5 )
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: ~120 hours

I spent about an hour and a half fabricating the skin supports for the ribs that also have the slat brackets.

The whole affair was straight forward, but I found it slightly difficult to drill the bend release holes. Getting a good angle to cut the L angle was also a little tricky.

Only the right side was fabricated so I could avoid any problems of mirrored parts getting mixed up.

Someone asked me if I worked on the project every night... and recently I have been. But there was a while when work prevented such progress. Even if I don't actually drill, cut, deburr or corrosion protect something, working at least every other night keeps the project in your mind and avoids having to REALLY spend some time reorienting yourself.

Project Status:
Wings: 14h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 1h, 1.5 )
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: ~115.5 hours

I spent about an hour making the slat placement template tool. The extrusion came from Home Depot and the 1/8" plate came from Ballard Sheet Metal Works. Most of the time was spent using the hacksaw on the plate. The plate is 7000 series and really hard stuff. A little extra time was spent using scotchbrite on the extrusion to obtain a nice brushed metal look. One small deviation from the plans was made: I riveted a small piece of plate between the extrusion at the end of the tool to maintain a constant gap between the extrusion and provide for better stability.

What is a massive project that takes years to finish? An airplane yes, but also a video game. I am preparing for another crunch at the office, but you can see the fruits of my labor. If you have a Xbox 360 with a Xbox Live Gold account and a Xbox hard drive, then please sign up for the Shadowrun beta. http://shadowrun.com/behindthescenes/articles/BetaApplication.htm

Should you accept the offer from Mr. Johnson you will be given the chance to geek those dandelion eaters without having to pay any Nuyen to enter the matrix.

Project Status:
Wings: 12.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h, 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: ~114 hours

An hour and a half was spent drilling the left wing. The rear ribs, spar tip, and root ribs were all drilled into place.

Next is the slat placement template. I need to stop by the metal shop in the morning to get some aluminum plate ( t=.125, 80mm x 150mm )

There are some things the every good workshop should have... like an iPod. Seriously, having every CD you own in something in the equivalent volume of a CD case is perfect for keeping in the shop.

In other good news: http://www.can-zacaviation.com/floats/floats.htm

Project Status:
Wings: 11.5h ( 1h, 1h, 0.5h, 2.5h, 4h, 1h, 1.5h )
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: ~113 hours

We spent only an hour today, but managed to get the tip ribs drilled into place for the left wing. A friend was over helping with the build, so all the tools that are normally taken for granted become cool and new again.

The left tip ribs took about 1/4 of the time compared to the right wing, and I can only imagine how much faster the rear ribs will be.

Project Status:
Wings: 10h ( 1h, 1h, 0.5h, 2.5h, 4h, 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: ~111.5 hours

New Years Eve: About four hours were spent on the right wing. The rear ribs were drilled into place, along with the root rib. The spar tip extension was drilled into place. The slat brackets were predrilled. We also bought a new work light and some extrusion for the slat placement template. I could not find any t=.125 plates at the Home Depot, so I bought some thinner plate that will just be layered.

Project Status:
Wings: 9h ( 1h, 1h, 0.5h, 2.5h, 4h )
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: ~110.5 hours

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.