Full steam ahead!


Another day of checking off boxes. I got the tail strobe wired up and threw down a thick layer of micro on the VS tip fairing. While that cured, the final skin got riveted. Wow, that felt great – even if it was quite loud bucking the rivets. The fuel servo was next up and thankfully the throttle and mixture…

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Fingers crossed the doors are good


Big project today, getting the doors halves glued together. The prep involved drilling for more clecos, sanding (this seems never ending), mixing up lots of epoxy, flox, and taping off the fuselage. The actual gluing and affixing the doors to the didn’t take a ton of time. Lots of clecos and clamps to hold things in place. As there seemed…

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Not going to be building a composite aircraft


There I said it – I am not fan of epoxy, flox, micro and sanding. My day was kicked off with 150 minutes of sanding and cleaning up. But the cabin top was to be installed! Whew. Next up was finishing up the door prep. Those door pins, filing the correct amount off the ends of the rods to get…

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Sanding finish line in sight


Big progress on the cabin top today. I figured out a way to apply micro to the vertical surfaces which greatly reduced the waiting time. All told today I major sanded twice and applied micro three times. I think after tomorrow morning’s sanding session I should be ready to attached the cabin top to the airframe! Also up today was…

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Lots of sanding


So I started the cabin top fairing this morning, which meant three hours of sanding. The raw fiberglass out of the Van’s mold is wavy and full of fabric patterns so it was go time. That was a fun morning. I got a layer of micro laid down on the flat top section and put a first coat to smooth…

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Doors.


Whew, those doors with the PlaneAround and Aerosport parts sure do require a lot of time and effort. Heck a lot of time figuring out what to do as well. Anyhow, the mechanics are complete for one door. The second door I’ll bang out tomorrow. Today I got the PlaneAround 3rd latch installed so that helps make tomorrow easier. Also…

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The cabin top has a parasite


Sooo, I finished up the sanding/priming of the right elevator trip fairing before moving on to wiring the overhead console lights. I needed to get the console finished so it could be attached to the cabin top. This meant putting in the eight single lug nutplates that I had to order way back when I last worked on attaching the…

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Begin the doors…


Seems I will be living in the world of fiberglass and epoxy for awhile. The engine cowling hinges are now all drilled, this took two people – one to squeeze and one to drill. After all the filling of the sides and back there is poor alignment on the front corners. Got a layer of flox down to start filling…

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Elevator Tip Filling


First, I think the top cowl is in a good place. The sides are now built up and there are no longer gaps on the sides. However, now material needs to be built up on the bottom cowl so the thickness matches the top cowl. MaƱana Also, got the Elevtor tips filled in and floxed. Sanded that and coated with…

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Fiberglass, ugh


So the cowling fit is shit. To get it to line up in the back, the front is off – not terrible but off. The sides are the issue. On the pilot side there is a 7/16″ gap. WTF. So today the sides got built up to fill the gap. More fun tomorrow. The cabin top is now drilled and…

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Lots of bouncing around today


It started with the cowling. This things is way off, ugh. Even the top (without sanding the air inlets) will need a good 1/2 to 3/4 inch of fairing to make the cowling line up with the spinner. And the sides seams, yep that is going to be a ton of work too. Moving on… With a call to Stein…

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Let the cowl fitting begin!


Oh my, oh my. The bottom cowling was not fabricated ideally from Van’s… Took a lot of cutting, grinding, filling, and sanding to get the cowling to line up pretty well. The sides, bottom, and front all look great. The issue was getting the curves on the bottom to match the fuselage. They are close but there will be some…

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