Paint step & Fuel vent

Well I have a little time to kill until I pick up the avionics and power plant kits so I decided to do some misc painting and painted the steps and fuel vent line.

The shop was looking pretty messy with tools everywhere, so I did a little shop clean up. We will see if I can keep it a little more straightened up during the rest of the build, but you know how that sometimes goes.

Time: 1 hr.

Painted steps

Painted fuel vent

Clean shop

Fuel vent line, canopy sanding

I spent some time today on the fuel system. I installed the fuel tank enough so that I could work on the fuel vent. The vent lines were installed as per plans. I then re-installed the flap handle now that it is painted.

I also worked on sanding the canopy and applying another coat of epoxy.

Time: 2.25 hrs.

Fuel tank in place

Fuel vent installed

Flap handle re-installed

Prime fuel tank, SB 16-08-24, canopy trim, interior paint

Quite a bit got accomplished today. Started by drilling out the holes in the canopy to gain access to the bolts. I drilled a little too low initially, but those areas can be filled in later.  I was then able to remove the canopy after a lot of careful work loosening up the edges. Tape and paper was removed from fuselage. It took some work with acetone to get the remnants of the duct tape off the metal.

I then primed the fuel tank and installed the safety wire on the seat backs.  I worked on the canopy catch removing the rivets as per update and installing catch. I also worked on SB 16-08-24 since I still had good access to the engine mount brackets.  The rivets were replaced with new as per SB.

I then marked and trimmed the canopy and filled in some voids.

There was a new flap knob that could be placed to minimize pinching of fingers, so I installed it. I then tried in the interior to look and see what areas needed painted as I am only painting the interior in the locations that are not covered by the interior package. Once taking note of the areas to paint I taped off the interior and primed and painted.

Time: 9.25 hrs.

Drill holes in canopy

Seat back safety wire

Canopy off

tape removed

Rivets removed for canopy catch

Upper FWD fuselage removed

Rivets removed

New rivets installed

Bottom trim line marked

Template placed

Template traced

Canopy trimmed

Voids filled in

Flap knob replaced

New flap knob installed

Canopy catch installed

Seat cushion tried in

Carpet tried in

Control stick

Power plug area

Seat belt connection

Interior tried in

Seat hinges

Head phone jack

Interior taped

Interior painted

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.

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

Fuel tank test / latch handle

After waiting over a week for the fuel tank sealant to cure good I pressure tested the tank.  As instructed a balloon was placed.  I let it set there for a bit to see if it changed. While I was waiting I fabricated the latch handle. I then checked the balloon and it had gone down some.  I made a mixture of soap water and sprayed on all the seams. There was one small leak noticed on the UR rear corner.  All the other seams seemed to be good.

Time: 1 hr.

Fuel tank test

Latch handle

Fuel tank leak

Sender plate / fuel vent line

Installed the sender plate and tested connectivity. The fuel vent bracket was then installed and the vent lines fabricated.  I then installed the snap bushing and rivet for the vent lines.

Time: 1.75 hrs

Sender plate

Fuel vent line bracket

Fuel cent line bracket

Fuel vent line

Vent rivet and snap bushing

Fuel tank neck / canopy attach angles

Temporarily installed the fuel tank so I could adjust and match drill the fuel neck. The nutplates were then installed in the flange. The fuel return line was cut, bent and installed. Then the top skin was riveted in place.

I then fluted, match-drilled and installed the canopy attach angles.  I noticed that the cardboard I had originally on the sides was a little too thick so I replaced them with one that was 1/8 inch.  I also had to slightly bend the canopy bow to get the proper measurement between it and the instrument panel.

Time: 3 hrs

Fuel neck

Top skin

Inside view

inside view

Canopy frame clamped with blocks

Attach angles installed

Attache angles installed.