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.
Flipped fuselage. Checked welded on under-side of those two tabs (look good!). Set-up for riveting. Riveted on two anchor nut plates.
Match-drilled all enclosure panels with anchor nut plate holes.
Riveted on (12) anchor nut plates.
Measured location of six holes on side stringer stand-offs, for enclosures.
Match-drilled rivet holes for six anchor nut plates in side stringer stand-offs.
Riveted on six anchor nut plates.
Attached stringers on sides to accurately fit-up the side enclosure panels. Fitted up the starboard panel.
Modified the existing form and made a completely new starboard enclosure panel.
re-Made the side enclosure for the port side.
Cleaned up the edges of the port side enclosure.
Filed down sides of enclosures. Fitted to stand-offs.
Match-drilled enclosures to stand-offs. Rivet on (6) anchor nut plates.
Filed aluminum slag from sides of enclosures (from my filing down the sides.)
Figuring out seat harness routing. Not happy with how it was. Actually wouldn't work anymore.
Cut and fitted (2) tubes for the seat harness anchor points.
Aliged and welded top half of both tubes. Still need to flip fuselage to weld other half of tubes.
Four half welds - other side of the four should harness anchor points (tubes.)
Mar 26 - Apr 2
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.
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
Thinking about the fuel system and electrical.
Deburred two sets of holes on the front Upper Wing Center Section spar brackets. Started "reaming" out hole in one of the front spars.
Completed "reaming" of first hole.
Started and finished the second hole.
Third hole completed; first on rear spar.
Reamed (fiiled/sanded) forth and final hole in upper wing center section spars.
Review of plans. Loose fit-up of upper wing center section parts. Cleaned slag from 3/4inch tubes for fitting up.
Put the main tank back in the fuselage. Figuring out the location of the fuel valves and fuel knob control.
CADing up of fuel vavle bracket.
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).
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.
Designing fuel selector panel and figuring out its location.
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.
More playing with the what if's of locating the fuel valve and the selector panel in different places.
Settled on a triangular shape for the fuel selector panel. Designed in on the CAD.
One fuel selector knob insert attachment made.
Second fuel selector knob insert attachment made.
Still trying to find the best location for the fuel selecctor panel. Think I found it. Need to redesign the fuel valve bracket.
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.
Made second bracket.
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.
Used the CAD to figure out the angles for the notching on the "L" channel.
Notching of the aluminum "L" channel to produce the sides of the triangular panel. Made a test, and then made a keeper.
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.
Filed/sanded sides of selector panel. Made four bushings (only need two but couldn't decided which wall thickness to use).
STILL trying to figure out the location of the selector panel. Found it?
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.
Re-aligned and welded up panel bracket.
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.
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.
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.
Design and CAD'd up cover plate for throttle quad.
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.
Completed the second throttle quad cover. Nice!
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".
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!
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"
Made two completly new hangers. Figured out where to located them on the fuselage and welded them on.
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.
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.
Figuring out the flooring for the turtledeck. Drew up both floor pieces on poster board.
Cut out and tried poster board patterns. Needed to modify. Made new patterns and tried out... fit perfectly!
Cut and fit first 2-piece floors for turtledeck. .040 aluminum
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.
Match-drilled holes for rivets in both panels. Counter-sunk holes in the attaching panels.
Tried sanding out the gouges on the back-side of one of the floor panels. No Joy! Re-made the panel.
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.
Match-drilled anchor nut plate holes and match-drilled the holes for the rivets that attach the anchor nut plates to the two pieces.
Looking over notes. Figuring out the next step after I alodine the above parts.
Cleaned off protective plastic. Cleaned with MEK.
Drilling, cutting, filing, and sanding two attaching plates for flooring.
Took off protective coverings and deburred holes on attaching plates.
Cleaned and alodined all flooring pieces for turtledeck.
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.
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.
Match-drilled front floor to turtledeck after tweaking attaching plate.
Match-drilled second turtledeck floor after tweaking.
Sanded turtledeck; ready for Clear Coat. Clear Coated the floor of the turtledeck.
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.
Drilled out anchor nut plates from the fuselage turtledeck tabs. Reamed out all six after a tight fit test.
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.
Review of upper wing cener section plans. Clear Coat upper wing center section - top side.
Clear Coat 2nd side of upper wing center section, plus corner blocks.
More Clear Coating of upper wing center section.
Sanding turtledeck and removing excess glue globs.
Cleaned off turtledeck using compressed air (getting out and hooking it up took most of this time). Reamed out (8) holes in turtledeck.
Clear Coat top-side of turtledeck.
Clear Coat under-side of turtledeck.
Bondo fill on fuel selector panel where sides meet. Started reading how to make an engine cowl ring article.
Sand fuel selector panel (scratches on the sides).
More Clear Coating of turtledeck.
Reamed out the holes in the spars for the upper wing center section (reaming excess glue after sealing holes with Clear Coat).
Not sure what I did... but I did do something! Probably out looking at the biplane thinking...
Sanded upper wing center section pieces to allow me to put the fittings on and bolts through sealed holes.
Made the two 7/8inch bushings for the rear spar of the upper wing center section.
Final fitting of the two bushings in the spar.
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.
Figuring out the hardware for the upper wing center section.
More figuring out and confirming of hardware. Still want to confirm again before ordering.
Figuring out the cabin access. High sides... will probably need to install a door on the port side.
Spending more time on figuring out the door.
Started making a few brackets for the door jam. Not sure if this is the way to go, but thinking it might be.