Spinner / Tail Fairing

I finished the propeller section by installing the spinner. I then worked on fitting the tail fairing and adjusting for any interference. It was a little tight in areas of the trim rod so the fairing was adjusted slightly with a file. I checked with the trim tab in both the extended and retracted positions.

Time: 2 hrs.

Spinner installed

Tailcone fairing installed

Stabilator / Steps / Fuses / Pitot tube

Started today with several misc. items. With the help of S & N I was able to re-attached the stabilator. I then installed the steps and the fuses. The replacement fuses were then placed in a block on the back of the map box door.

I then started section 47 - Spinner & Propeller. The pitot tube was prepared with the pitot block as per plans. This involved making a slight dimple (or drilled indentation) in the pitot tube. The block and pitot tube were then installed. The pitot tubes were then attached with safety wire. I prepared the spinner by trimming and sanding to the time line. The bushing was then placed in the spinner. I used superglue for this step.  The spinner plate and hub mount half was then installed. Bolts were torqued as per specified with the propeller.

Time: 3.5 hrs

Stabilator Re-attached

Step

Fuses placed

Fuse replacements

Pitot Block

Pitot Tube

Pitot Tube attached

Spinner

Spinner Plate and Hub mount Half

Canopy fiberglass 6, Tailcone nutplates

I added a layer of fiberglass across the front of the canopy to replace the one that the epoxy didn't harden. I also added epoxy to fill in some voids in the fiberglass.

I then match drilled the tailcone nutplates with an extended bit. The nutplates and holes were then dimpled and nuteplates riveted into place.

Time: 1.75 hrs

Layer of fiberglass added

Tailcone nutplates in place.

Canopy, fuel tank test, seat backs, gas struts, Tailcone

Today was a day of various aspects of the build. I first sanded and added more epoxy for fill on the canopy.  I then finally tested the fuel tank again. A balloon was placed and pressure added. I then went around the seams with soap solution. No Leaks!!!

I then primed and painted the seat backs.  New gas struts were drilled. There was a notice of installing new metal gas struts in place of the plastic ones as they have had issues with plastic ones breaking.  With some help I was able to remove the stabilator and proceeded with the tailcone. Nutplates were positioned in place and ready for match drilling. The only thing is that it required a long #40 bit which I didn't have, So time to order another bit.

Time: 4.25 hrs

More epoxy added for fill.

Fuel tank test

Seat backs painted

Metal struts drilled

Tailcone nutplates ready for drilling.

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

AST install / trim servo install

Finally!!! I was able to complete the AST assemblies (again) and get them installed.  They lined up great! A tremendous improvement to what the first ones looked like.  I then installed the push rod and trim servo.  I tested both the fully extended position and the fully retracted position and verified all clearances as per plans. Everything looked great.

Time: 3.25 hrs.

AST assemblies installed

Push Rod installed

Trim servo installed

Trim servo

AST assembly round 2

I picked up the replacement parts for the anti-servo tabs yesterday.  I spent a short time today preparing the parts by deburring and priming.  Hopefully this time everything will come out in alignment.

Time: 1 hr.

Priming of AST parts

AST ready to assemble