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C
O N S T R U C T I O N L O G |
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F
E B R U A R Y 2 0 0 5 |
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935
hours and counting... |
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1 |
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Went
back to the bike shops and found a throttle cable assembly
that is perfect. All I had to do was cut of the ball at one
end to install it. It is a heavier and more flexible cable
than the bicycle brake cable, and the housing has a protective
rubber cover.
Drilled 3 holes in the firewall to run the cables
through and fitted them with rubber grommets.
Glued a small piece of plywood to support the cablesbehind
the firewall and attached them with clamps.
Glued a piece of 3/8" plywood with propper spacers
to the vertical member the front quadrant is mounted to,
and drilled 3 holes for the cable housing stops.
The throttle
cable is attached to the bottom hole of the longer lever with
a B-NUT, which luckily happens to give just the right amount
of travel from full closed to full open.The 2 choke cables
are also attached with B-NUTS to the top hole of the shorter
lever and another hole drilled slightly above. The travel of
the lever is very short.
The front to back throttle levers linkage goes in the top hole,
and the choke levers linkage in the bottom hole.
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Put
the panel in place and attached a ground bus bar and a power
bus bar to the front bulkhead. I used the kind of aluminum
ground bus bars made for electrical panels rather than those
I had ordered from Aircraft Spruce, which were just strips
of brass with 8 holes, but no screws. |
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8
hrs |
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2 |
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Kept
on working on wiring the panel. Got some yellow, blue, green and
pink wire to color code the different instruments. I ended up with
a pretty good wad of wire to run from the panel to the front of
the plane. I will tape them together as a harness with black electrician
tape.
In order to make it easier to take out the
panel, I used diconnect pairs between the harness and the instruments
and switches. |
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4
hrs |
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4 |
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The
weather was still beautiful and even warmer this morning, so I got
an early start covering the other side of the first top wing. This
is my third, and I am begining to feel I know what I am doing.
So I will not impose the lesson to everybody, but for those of you
up to it, I put together a detailed photo step by stw I
do it. Keep in mind that
this is only the best way I found to do it , and is not a replacement
for the Polyfiber manual. You
can follow the link below to see it:
WING
COVERING STEP BY STEP DEMONSTRATION |
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5
hrs |
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Well,
I got lazy these last few days and did not keep the daily logs too
well. I got the last wing covered, and te engine installed. But I did
shoot pictures, so here they are. |
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The
fourth and last wing was covered, shrunk, and got its coat of Polybrush.
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12hrs |
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The
engine mount was finally welded together, cleaned up, and bolted
in place to the firewall. . |
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4
hrs |
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The
mount was slipped in place under the engine by lifting the tail up
and sliding the fuselage forward , and the engine was bolted to
the mount .
Some
wood blocks were placed under the forward channel of the landing
gear, and the wood blocks supporting the engine
were removed . |
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2
hrs |
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The
fuselage was front heavy, and I had
to place the battery all the way near the tail and add about 9 lbs
to get it to balance on the gear channel.It seemed to me like I had
a problem ,so I called Gene about this , and he said it was OK. |
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2
hrs |
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The bracket waswelded
to the bottom of the gas tank, and I
screwed on the valve . |
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5
hrs |
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The
gas gauge was mounted to the top.
The
tank was strapped in place with 2 one inch stainless steel strips
in rubber channels. |
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2hrs |
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The
remote valve control cable was connected. For safety reasons, so
the gas is not turned off unintentionnaly, the valve is open when
the T-handle control is pushed in , and closed by pulling it out. |
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5
hrs |
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I
found an electrical aluminum fitting that screwws on the gas filler
neck, and fill cut it and grind it to fit my antique filler cap.
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1
hrs |
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The
exhaust manifolds and muffler were bolted on . There is a problem with
the lower right bracket of the mount interfeering with the manifold,
so I will have to cut it a little shorter and have it rewelded. The
muffler is not centered , and there is nothing much I can do . |
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2
hrs |
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I
made a cardboard pattern for the gascolator bracket, and cut it
out of 1/8" aluminum. Drilled a hole to fit the gas intake, and bolted
the gascolator on. |
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2
hrs |
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I
cut a piece of angle aluminum and bolted it to it. |
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1
hrs |
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The
gascolator was attached to the firewall, and fits vertically as
planned. |
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5
hrs |
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Got
one of the wings out on the stands top side up to figure out the
best spacing and location for the stitches so there is no interference
with spars or the geodetic strips. It took trial and error , marking
potential positions on masking tape , to arrive at a solution. |
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2
hrs |
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There
will be 17 stitches per rib, and the spacing will be 2 3/8"between
the leading edge and the main spar, and 2 1/2 "" between the main
spar and the trailing edge. That was the only way to work around
the geodetic and the spars.
I
then drew vertical lines between the top and bottom of the root
rib, , and markes the spacing for the bottom of the wing. Made
another tape template for the top of the full ribs, and
one for the bottom . |
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2
hrs |
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I
do not want to strike a bunch of chalk lines on the fabric, since it will
not be painted, so I am going to use the tape templates to mark
each rib individually. |
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1
hrs |
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TOTAL 1000hrs |
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