Wheel fairing day 5

I tried in the complete nose fairing. Then started working on the nose leg fairing. The leg fairing was clecoed in place and holes drilled into the leg as per plans. Epoxy was placed around the holes.

Time: 1 hr.

Nose wheel fairing in place.

Nose leg fairing clecoed in place.

Epoxy added.

Wheel fairing day 4

Continued work on the front wheel fairing. Nutplates were attached. A drill template was place and drilled as per plans. The doublers were then added. Nutplates were placed on the nose fork. The lower wheel fairing was then attached.

Time: 2.5 hrs

Nutplates attached

Drill template

Doublers attached

Nutplates on nose wheel

Bolt placed

Front lower fairing attached

Wheel fairings day 3

More work on the wheel fairings. I removed the main wheel fairings and cleaned off the tape that was placed. The nut plates were then placed on the main wheel fairings. The should now be ready to install later down the road.

I continued with the front wheel fairing. The pieces were fitted together with the strip. The strip had to be bent a few times and the halves trimmed some to get the proper fit. Eopxy was then placed as per plans and the strip riveted to place.

Time: 4.75 hrs.

Main wheel fairing nutplates.

Main wheel fairings complete

Front fairing clecoed

Front wheel fairing strip epoxy placed.

Wheel fairings cont.

More wheel fairing work. A little more time consuming than I thought it would be. I did start today by putting a coat of paint on the canopy frame.

The main wheel fairings were opened where the main gear legs go through. The fairing brackets were then fabricated and the brackets and fairings fit onto the wheels. Epoxy was placed around the screw locations.

While the epoxy is setting I started on the front wheel fairing by trimming the fairings and bending the strips.

Time: 3.5 hrs

Paint canopy frame

Gear leg openings

Main wheel brackets

Fitting main wheel fairings

Fitting main wheel fairings

Epoxy main wheel fairing

Front wheel fairing.

Tailcone / wheel fairings

Started today finishing the tabs on the tailcone fairing. The tabs were riveted to tailcone fairing. The upper and lower pieces were then attached together and fitted on tailcone.  The plans state to place the stabilator on to check fit.  I will need to wait until I get some other helping hands before I do that.

I then put a coat of  primer on the canopy frame. I did a few test of different primers and this one seemed to work the best.

I started on the wheel fairings. The main wheel fairings were trimmed to the line. The main wheel fairings were fitted together and the holes drilled and clecoed together.

Time: 3.5

Tailcone fairing tabs

Tailcone fairing tabs riveted

Fitting of tailcone fairing

Primer 

Canopy frame primed

Main wheel fairings fitted together

Wheel fairings clecoed

Tailcone fairing

I dreaded having to take the stabilator off because it was difficult getting it on in the first place. But in order to fit the fairing it needed to come off. N. helped me get it off. I then proceeded as per plans on the tailcone fairing. Masking tape was placed and the fairing clamped in place.  Fairing tabs were then lined up and drilled.

Time: 2.5 hrs.

Stabilator removed

Stabilator removed

Masking tape with markings

Lower fairing clamped

Upper fairing clamoed

Fairings tabs clecoed

Fairing tabs

Canopy cont. / soar pin switch / Tailcone

Continued on the canopy by removing canopy from frame.  The holes were then enlarge to #27 and the front holes countersunk. Guide blocks were then place and the guide plates attached. Canopy handles were then match drilled to the canopy skirt.  The canopy frame is now ready to be painted before I can attach the canopy.

I went back and installed the spar pin switch. I had to purchase the proper size wrench as I didn't have one that would fit the nuts.  Per instructions washer can be added to get the proper spacing for the switch and pin.  I ended up adding 5 washers on each side.

I then went back through the plans to see what else could be done that I haven't done yet.  I decided to start on the tailcone fiberglass.  I spend some time cutting and sanding the fiberglass to the scribe line. It was a dusty mess, but I was able to sit out in the nice cool evening air to do it.

Time: 3.25 hrs

Guide block

Guide plate

Left spar pin switch

Right spar pin switch

Tailcone trimmed

Canopy drilling

Well, today was the big day of drilling the canopy. With the help of N. we were able to get it all drilled. We started by drilling the holes in the front and rear. Then match drilling the canopy skirt to the canopy frame.  The holes were then match drilled from the canopy skirt to the canopy.  N. sat inside to help push against the canopy while the holes were drilled.  There was some minor sanding that had to be done to the canopy on the left side to get the proper fit.

Time: 3.75 hrs

Canopy taped in place

Front holes drilled

Rear holes drilled

Left canopy skirt holes drilled

N. inside

N. inside

Canopy clecoed in place

Fuel tank leak repair / canopy cont.

I received some carbon paper and marked on the canopy bar where the canopy touched the bar. The canopy was then removed and holes drilled in the bar as per plans.

I then cleaned and placed some fuel sealant on the area of the small leak of the fuel tank.  I was small enough and at an upper corner that won't get much pressure so I figured at this point placing sealant on the outside should suffice.  If not I will have to go in from the inside, which would be more of a project. While I had sealant out I decided to go around some of the seams and add a little more sealant. Probably not necessary, but since I had sealant mixed up I figured it wouldn't hurt.  I will wait another week before I test the fuel tank again.

I then fabricated the canopy blocks and handles.  

Time: 1.75 hrs.

Drill canopy bar

Fuel tank leak repair

Canopy blocks

Canopy handles