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Date: 5/28/2002

Pulled outside for pictures

It's actually starting to look like a real airplane.

Task Hours: 1

Date: 6/1/2002

More Interior Work

Finished laminations on hat-shelf, foot rest, rear lower baggage bulkhead.  Marked baggage bulkhead for mounting holes and removed foam from these areas.  Refilled these with milled fiber to keep from crushing when bolts installed.  Measured and marked for center console and dash attachment points.  Cut foam, sealed and laminated one side for rear control tunnel lid.

Task Hours: 8

Date: 6/8/2002

Still On That Interior

Laminated control tunnel lid in place to form attachment lips.  Fabricated and installed front cowling joiner plates.  I found the little stainless marine vents to cover the cowling camloc receptacles at Harvey Marine.  The dimensions I purchased are 1 3/8"x1 3/8".  These covered the 1/2 that protrudes outside of the firewall covering.  Installed 17 of these little buggers to cover all of them.

Task Hours: 9

Date: 6/17/2002

Another Day At The Hangar

Fabricated center console fiberglass sides and aluminum top.  Drilled and countersunk holes.  Measured and marked for forward center panel.  Started laminations from seat back to control tunnel.  Installed two remaining upper cowl camlocs and covers.

Task Hours: 6

Date: 7/2/2002

Seatback/control tunnel

Applied remaining laminates to lower seatback-to-control tunnel flanges.

Task Hours: 1

Date: 11/30/2002

Wing Root Fairing Prep and Prime

Final sanded and primed modified wing root fairings.  They are still the GI shape, but with a twist... They are installed like the newer fairings.

Task Hours: 3

Date: 2/15/2003

More Plumbing

Fabricated brake lines and installed them.  Finished fabricating fuselage fuel lines and mounted fuel pumps and pre-filters.  Installed master cylinders.  Reinstalled dual battery tray after having it anodized.

Task Hours: 10

Date: 3/2/2003

Final Brake and Rudder Pedal Work

Final assembled brake master cylinders, rudder pedals and brake lines.  Bled entire system.  I used a method I found on an RV list somewhere.  I took an old style bicycle pump, replaced the rubber hose with 3/16" vinyl line, and filled the pump with brake fluid.  I then pushed the brake fluid up through the bleeder valve at the calipers.  I was surprised how easy and quick this method was and the pedal feel is very firm.  If anyone wants info on this procedure, let me know.  I'm sure I can find the link again. (have you noticed that when I use the word "final" it rarely is? You'll see what I mean later :-)

Task Hours: 5

Date: 5/4/2003

Elevator Bellcrank Reinforcement

Fabricated a reinforcement triangle for mid-span of the elevator bellcrank pivot bolt.  Drilled out 1" holes of inner skin of floor and inserted 40lb foam for bolts through the floor to hold the reinforcement.  Laminated two layers over foam.

Task Hours: 1

Date: 5/10/2003

Throttle and Heater Cable

Created the throttle cable and heater valve cable pass-throughs in the firewall.

Task Hours: 2

Date: 9/28/2003

Laminated Upper Seatbelt Attach Points

Measured, marked and installed seatbelt attach point laminates.

Task Hours: 3

Date: 9/29/2003

Static System Install

Installed static system sump bottles.  See previous picture for rest of system install.

Task Hours: 5

Date: 9/2/2005

Completed Reinstallation of Controls

Installed the remainder of the controls back into the plane. Then spent about an hour going over all the nuts and bolts of the flight controls to be sure they were all tightened and/or safety wired.

Task Hours: 2

Date: 10/3/2005

Elevator Hinge Screws

Removed sixty temporary screws and nuts and installed aircraft screws and nuts to elevator hinges.

Task Hours: 2

Date: 10/22/2005

Lower cowl and nose gear opening

Fabricated opening in lower cowl for nose gear. This was performed over the course of 3 weeks.

Task Hours: 6

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