Fuselage 2
Fuselage 3
 Fuselage 4 

Fuselage 5
Fuselage 6

ELT Installation
Securing Control Stick
Flap Position Indicator
Landing Gear Assembly
Up On the Gear!
Riveted the Top Skin
Interior Installation
Firewall Forward


Fuselage 6


Description of Task   Hours
  ELT Installation
4/18/08 I decided to forego spending ~$900 on a 406mH Emergency Locator Transmitter (ELT) until a few more manufacturers enter the fray and bring the prices down.  Since I have already installed an ELT mounting tray in the rear fuselage that is pre-drilled to fit the Ameri-King AK-450, that was my choice.  I went ahead and installed the mounting bracket to the mount.  I also safety-wired the portable antenna to the bracket to keep it secure.

  Securing Co-Pilot Control Stick
  Vans has issued a Service Bulletin (SB) detailing how the right-side co-pilot stick needs to be secured in order to avoid the stick coming out inadvertently during flight.  Vans recommends installing a bolt and nut to secure the stick, however, this "fix" would make it very inconvenient to remove the stick regularly.  I solved the problem by drilling a 0.25" hole through both tubes and installed a 1/4"x1 1/8" hitch pin.

I am also installing a 1/8" mono mini plug for the co-pilot PTT.  This will make removing or installing the stick a 15-second activity.  In the picture above, you can see the small bracket ready for me to install the mini-jack plug.

4/19/08 My buddy Ben came by today and was a big help.  We installed the COM 2 antenna and secured and torqued the brake fittings through the gear weldments.  These were tasks that I had been putting off until I had a second pair of hands.

4/27/08 I removed the tank attach brackets from the fuselage and cut the notch.  I also drilled and installed the platenuts on the tank brackets. 

  Installing the Flap Position Indicator
5/10/08 Today I went ahead and installed the flap position indicator sensor from Ray Allen.  I got the clevis pins and threaded rod from Mike Behnke.  These parts are actually made for RC model aircraft but they work just fine.

5/23/08 I have to wait until Lynne can help me drill the canopy side skirts so I installed the main push rod tube to the bellcrank and the small pushrod from the bellcrank to the control column.

  Landing Gear Assembly and Installation
8/24/08 I started the assembly of the landing gear by collecting all the various nuts, bolts and components.  The drawing in the plans is pretty useless so I resorted to following the pictures on Mike Schipper's website.

After loosely assembling the brake calipers to the gear legs, I am ready to assemble the wheels and tires.


8/29/08 Up On the Gear!

Today I got my neighbor Don to come over and help me lift the fuselage while Lynne placed a sawhorse under the spar carry-through.  Lynne and I then installed the main gear legs as well as the nosegear.

I then removed the battery tray and sealed the firewall recess with high-temp red RTV silicone and clecoed in place.


9/1/08 I installed the braided brake lines I received from Brett at Bonaco.
  Riveted the Top Skin
10/10/08 My Tech Counselor, Jim Olson, agreed to come over and help me rivet the top skin.  I had held off as long as possible riveting this final skin because I wanted to be absolutely sure I had everything installed and the wiring finished since access will be extremely limited afterwards.

10/11/08 I got some padded carpet from Bill Repucci that he had left-over from his plane.  This stuff is super soft and is actually the "loop" used with Velcro fasteners.  I can apply the "hook" to any items I want to keep handy and stick it to the dash.  I also cut out the holes for the fans before I riveted the top skins and then installed the fans after the carpet was glued.  I used some 3M spray adhesive and it worked great.

I had to take some shots of a template for my interior fabricators.


  Interior Installation
12/12/08 I received my interior package from Classic Aero Designs and temporarily installed it in the plane in order to check out how it looked.  I have to admit that they do excellent work and it really makes the plane look nice.  I ordered the complete Aviator package which includes the seats with headrests, the side panels, leather side pockets, baggage area panels, rear bulkhead panel, leather glare shield trim and carpet.


Total Hours this Page


Total Hours Fuselage (as of 11/4/07)

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