Deburred holes in belly former tabs. Match-drilled rivet holes for belly enclosures of belly stringer stand-offs. Deburred/enlarged holes to number 12 bit on all machine screw holes. Welded 2nd side of those two tabs.
Mar 2
1.2hrs
Flipped fuselage. Checked welded on under-side of those two tabs (look good!). Set-up for riveting. Riveted on two anchor nut plates.
Mar 4
.9hrs
Match-drilled all enclosure panels with anchor nut plate holes.
Mar 6
1.7hrs
Riveted on (12) anchor nut plates.
Mar 9
.9hrs
Measured location of six holes on side stringer stand-offs, for enclosures.
Mar 10
1.3hrs
Match-drilled rivet holes for six anchor nut plates in side stringer stand-offs.
Mar 11
.7hrs
Riveted on six anchor nut plates.
Mar 12
2.1hrs
Attached stringers on sides to accurately fit-up the side enclosure panels. Fitted up the starboard panel.
Mar 13
2.2hrs
Modified the existing form and made a completely new starboard enclosure panel.
Mar 14
1.4hrs
re-Made the side enclosure for the port side.
Mar 16
.9hrs
Cleaned up the edges of the port side enclosure.
Mar 17
2.6hrs
Filed down sides of enclosures. Fitted to stand-offs.
Mar 18
1.3hrs
Match-drilled enclosures to stand-offs. Rivet on (6) anchor nut plates.
1.3hrs
Filed aluminum slag from sides of enclosures (from my filing down the sides.)
Mar 19
1.3hrs
Figuring out seat harness routing. Not happy with how it was. Actually wouldn't work anymore.
Mar 20
1.8hrs
Cut and fitted (2) tubes for the seat harness anchor points.
Mar 24
1.3hrs
Aliged and welded top half of both tubes. Still need to flip fuselage to weld other half of tubes.
Mar 25
1hr
Four half welds - other side of the four should harness anchor points (tubes.)
Mar 26 - Apr 2
N/A
Working
through/thinking about how to 1. wire the electric,
2. the fuel system, 3. correct the oops on the uppper
wing center section rear spar. Many hours, just not recording them.
Apr 3
1.4hrs
Reamed the upper wing center section rear spar brackets from 3/4inch to 7/8inch to fix the oops. Will insert a 7/8inch x .065 tube reamed to 3/4inch I.D. and will insert tube into the bushing instead of directly into wood spar
Apr 4 - 6
N/A
Thinking about the fuel system and electrical.
Apr 7
1.9hrs
Deburred two sets of holes on the front Upper Wing Center Section spar brackets. Started "reaming" out hole in one of the front spars.
Apr 8
1.1hrs
Completed "reaming" of first hole.
.8hrs
Started and finished the second hole.
Apr 10
1.2hrs
Third hole completed; first on rear spar.
Apr 11
.6hrs
Reamed (fiiled/sanded) forth and final hole in upper wing center section spars.
Apr 12
1.9hrs
Review of plans. Loose fit-up of upper wing center section parts. Cleaned slag from 3/4inch tubes for fitting up.
Apr 15
1.5hrs
Put the main tank back in the fuselage. Figuring out the location of the fuel valves and fuel knob control.
1.5hrs
CADing up of fuel vavle bracket.
Apr 16
2.1hrs
Refind the CAD for the bracket. Made a flat bracket from the CAD drawing. Re-figured where to locate the bracket on the port side. Decided on the outside of the fuselage (between the fuselage and the skin of the biplane).
Apr 17
1.9hrs
Not happy with the first bracket, I decided to put a bend in the bottom of the bracket (actually I thought of this originally and had the line on there for the bend) so that it would be a little bit more stout. Made both of the brackets' start to finish.
Apr 18
2.1hrs
Designing fuel selector panel and figuring out its location.
Apr 19
2hrs
Spent a few hours trying to figure out the best design of the selector panel. Looking at fuselage seeing if I put it here... what would be the consequences of it in that location.
Apr 20
1.4hrs
More playing with the what if's of locating the fuel valve and the selector panel in different places.
Apr 21
1hr
Settled on a triangular shape for the fuel selector panel. Designed in on the CAD.
Apr 22
2.2hrs
One fuel selector knob insert attachment made.
Apr 23
1..4hrs
Second fuel selector knob insert attachment made.
2.7hrs
Still trying to find the best location for the fuel selecctor panel. Think I found it. Need to redesign the fuel valve bracket.
Apr 24
1.7hrs
Re-design of the bracket made on the CAD. Made one new bracket. Figured out the new positioning of the bracket and which direction is OFF, ON, RESERVE.
.5hrs
Made second bracket.
Apr 25
1.6hrs
Notching the aluminum "L" channel for the sides of the fuel selector panel. Made a test and learned. Marked out the second, marked and drilled the stress relief holes.
Apr 26
.7hrs
Used the CAD to figure out the angles for the notching on the "L" channel.
Apr 27
3.7hrs
Notching of the aluminum "L" channel to produce the sides of the triangular panel. Made a test, and then made a keeper.
Apr 28
3.7hrs
Work on the selector panel; drilled holes for rivets, then riveted the "L" brakcet to the two loose ends, made face plate and glued to edges/sides.
Apr 29
2.1hrs
Filed/sanded sides of selector panel. Made four bushings (only need two but couldn't decided which wall thickness to use).
Apr 30
2.9hrs
STILL trying to figure out the location of the selector panel. Found it?
May 1
3.9hrs
Aligned and welded on the fuel valve bracket. Made the bracket for the selector panel, aligned and tacked on to the fuselage. Checked for squaring up t the panel... needs a tweak.
May 2
1.6hrs
Re-aligned and welded up panel bracket.
May 3
4hrs
Cut extension tube to length. Drilled holes for roll pins to attach fuel valve to extension tube. Match-drilled holes for selector panel/bracket. Match-drilled rivet holes for anchor nut plates and attached plates.
May 4
2.4hrs
Drilled/tapped adapter inserts; (1) practice, and (2) useable. Set up the fuel valve, extention tube, and fuel panel. Glued fuel selector in place to let cure/set over night.
May 5
1.8hrs
Tried drilling holes for roll pins to connect the adapter insert to the extension tube. NO JOY! I haven''t used that bit that much and it's dull already! Ordered new bits.
May 6
2.6hrs
Design and CAD'd up cover plate for throttle quad.
May 7
5.2
Received the drill I needed. Drilled two holes at 90 degrees for attaching the adapter insert to extension tube using roll pins. Cut, filed and bent throttle cover. Front face not long/wide enough for drilling hole (not enough meat between hole and edge of panel. Test piece! Re-design and cut blank out for new cover.
May 8
3hrs
Completed the second throttle quad cover. Nice!
May 9
1.7hrs
Disassembled the throttle quad, match-drilled quad cover to front plate then put it all together with the cover. Needs a slight tweak and a spacer on it... to keep the front lever off of the front side of the slot. Maybe an 1/8".
May 10
2.8hrs
Made two aluminum bushings for the pilot's throttle quad cover. Most of this time was taking apart and putting back together the throttle quad!
May 11
5.2hrs
Design of seat harness hooks (to hook the sholder harness on instead of throwing over the edge of the cockpit and damaging the paint), made one set and was unhappy with them after modifying them. "Practice"
May 12
3.7hrs
Made two completly new hangers. Figured out where to located them on the fuselage and welded them on.
May 13
4.0hrs
Cut pieces to make hanger for crotch-strap (to keep it from laying on the floor - easy to reach when in the cockpit), welded the pieces together (filed them smooth - since they aren't a structural piece I made them look nice), cut and squared off the metal inserts that I still need to drill/tap so that I can screw these onto the seat pan.
May 14
3.1hrs
Drilled and tapped first set of inserts. Decided to make longer so that I could glue AND put roll pins in to connect. Created longer inserts (5/8inch) on lathe, drilled, tapped and glued into hanger.
May 15
2.0hrs
Figuring out the flooring for the turtledeck. Drew up both floor pieces on poster board.
May 16
2.4hrs
Cut out and tried poster board patterns. Needed to modify. Made new patterns and tried out... fit perfectly!
May 17
2.1hrs
Cut and fit first 2-piece floors for turtledeck. .040 aluminum
May 18
2.0hrs
Cut and fit second 2-piece turtledeck floor. Cut and fit the two attaching plates for the floors (these will be riveted to one 1/2 and screwed to the second half. Marked and measured for placement on flooring.
May 19
2.9hrs
Match-drilled holes for rivets in both panels. Counter-sunk holes in the attaching panels.
May 20
1.8hrs
Tried sanding out the gouges on the back-side of one of the floor panels. No Joy! Re-made the panel.
May 21
3.9hrs
Got the panels ready to be alodined; took off portective plastic, sanded sides, deburred remaining holes. Discoered that I shouldn't have counter sunk the holes in the attaching panels. Re-made attaching panels... then counter sunk the holes made in the floor panels.
May 22
2.8hrs
Match-drilled anchor nut plate holes and match-drilled the holes for the rivets that attach the anchor nut plates to the two pieces.
May 23
N/A
Looking over notes. Figuring out the next step after I alodine the above parts.
May 24
1.9hrs
Cleaned off protective plastic. Cleaned with MEK.
May 25
3.4hrs
Drilling, cutting, filing, and sanding two attaching plates for flooring.
May 26
.7hrs
Took off protective coverings and deburred holes on attaching plates.
May 27
3.2hrs
Cleaned and alodined all flooring pieces for turtledeck.
May 28
4.2hrs
Alodine process to turtledeck hatch. Counter sunk holes in attaching plates. Needed to remake one entire attaching plate because I counter sunk the holes on wrong side. Riveted together the attaching plates to one side of each of the floors. Re-did the alodine on one side of one of the flooring panels becase I made a small scratch by drilling out a rivet and then sanded it.
May 29
3.7hrs
Riveted on all (8) anchor nut plates to mounting tabs. Match-drilled mount tabs to turtledeck. Reamed out holes in mount tabs. Finished riveting anchor nut plates (missed one earlier and re-did one). Tapped anchor nut plates with 8-32 tap, which allows for them to go in more easily.
May 30
1hr
Match-drilled front floor to turtledeck after tweaking attaching plate.
May 31
.5hrs
Match-drilled second turtledeck floor after tweaking.
Jun 1
1.1hrs
Sanded turtledeck; ready for Clear Coat. Clear Coated the floor of the turtledeck.
Jun 2
1.6hrs
Glued and secured mounting tabs on turtledeck. Drilled relief holes for 10-32 screws that connect the turtledeck to the fuselage to allow the heads of the screws to pass through the aluminum flooring.
Jun 3
2.1hrs
Drilled out anchor nut plates from the fuselage turtledeck tabs. Reamed out all six after a tight fit test.
Jun 4
3.2hrs
Rivted on six anchor nut plates. Saw the remain four turtledeck mounting tabs that are behind the storage area. Drilled out rivets on those as well. Reamed out center hole then riveted on replacement anchor nut plates.
Jun 5
2.4hrs
Review of upper wing cener section plans. Clear Coat upper wing center section - top side.
Jun 6
1.2hrs
Clear Coat 2nd side of upper wing center section, plus corner blocks.
Jun 7
.9hrs
More Clear Coating of upper wing center section.
Jun 8
2.4hrs
Sanding turtledeck and removing excess glue globs.
Jun 9
1hr
Cleaned off turtledeck using compressed air (getting out and hooking it up took most of this time). Reamed out (8) holes in turtledeck.
1.1hrs
Clear Coat top-side of turtledeck.
Jun 10
1.4hrs
Clear Coat under-side of turtledeck.
.9hrs
Bondo fill on fuel selector panel where sides meet. Started reading how to make an engine cowl ring article.
Jun 11
.6hrs
Sand fuel selector panel (scratches on the sides).
1.2hrs
More Clear Coating of turtledeck.
Jun 12
2.6hrs
Reamed out the holes in the spars for the upper wing center section (reaming excess glue after sealing holes with Clear Coat).
Jun 13
Not sure what I did... but I did do something! Probably out looking at the biplane thinking...
Jun 14
1.6hrs
Sanded upper wing center section pieces to allow me to put the fittings on and bolts through sealed holes.
Jun 15
1.4hrs
Made the two 7/8inch bushings for the rear spar of the upper wing center section.
.9hrs
Final fitting of the two bushings in the spar.
Jun 16
Spent 3 1/2 hours looking for the lugs for the upper wing center section. Found them! Ain't adding those hours onto the build.
Jun 17
2.4hrs
Figuring out the hardware for the upper wing center section.
Jun 18
1.5hrs
More figuring out and confirming of hardware. Still want to confirm again before ordering.
1.8hrs
Figuring out the cabin access. High sides... will probably need to install a door on the port side.
Jun 19
1.8hrs
Spending more time on figuring out the door.
1.5hrs
Started making a few brackets for the door jam. Not sure if this is the way to go, but thinking it might be.