Builder’s Notes & Comments
Page 5
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02 Mar. 04
Welded all of
the reinforcement plates to their proper place on the wing attach tubes and
cock-pit tubes.
03 Mar. 04
Made 10 cable
fairleads housings out of 7/8 x .058” molly tubes cut to aprox. 1” in length.
Marked on the
fuselage where they needed to be by running string from the rudder pedals to where
the rudder control arms are. Then tack welded the fairleads in place.
Worked on the
Tail Wheel assembly and trial fit to the fuselage.
08 Mar. 04
Fabricated brake caliper brackets out of soft steal as a pattern. First made paper patterns then traced on to the steal and cut them out with a dremal tool. After several trial fits and grinding for proper alignment, the soft steal templates were transferred over to chrome molly sheet and re-cut. Tack-welded. I am using the exact same brakes that Steve Kiblinger used on his LEU. Formula “Activa” mechanical disc brakes which were purchased from B & S performance in Onely, Ill.
10 May 04
Measured and
cut the tail brace wires to length for the elevator and vertical stab. Rigged
all of the individual cables with the shackles and thimbles.
21 May 04
Cover the
rivets and all of the sharp edges on the rudder with anti-chaff tape. Cover
rudder with 1.6 oz. poly cloth material and shrink to 275* with my house hold
temperature calibrated iron.
22 May 04
Cover the
rivets and sharp edges on the vertical stab and horiz. stab. with anti-chaff
tape and cover with 1.6 oz. cloth. Shrink to 275* with calibrated iron.
23 May 04
Apply bias tape
to all curved surfaces and straight tape to all of the ribs areas on the tail
surfaces. Applied one coat of poly brush by brush to all tail surfaces.
20 June 04
Measured and
cut the rudder cables to the proper length. Secured the cable shackles and thimbles
to the ends and trial fit for correct travel.
05 July 04
Used my
aluminum nose rib jig and cut 16 Styrofoam nose ribs out of 1” insulating foam.
Marked the areas on the left wing and glued 16 of the foam ribs in place with
T-88 epoxy glue. The purposes of the Styrofoam ribs are to help hold the proper
shape to the thin leading edge plywood. Not for structural support. Clean
excess glue off of the bottom of the left wing and cleaned the slots for the
wing attach and strut fittings.
06 July 04
Cut and fit all
three panels for the left wing leading edge “D” section. I used Leonard’s
method of using small nails with the heads cut off to help keep the alignment
of the 3 separate panels.
11 July 04
Sanded, taped
and varnished the inside of three left wing nose rib panels. Made the jury
strut fitting blocks and glued in place for the left wing. Fabricated the
aluminum jury strut fittings and primed with epoxy paint.
12 July 04
Glue Left wing
leading edge plywood with T-88 epoxy glue. Used 28 8” blocks of wood and 3 # 8
rubber bands and staples to hold the ply while the glue set up. Looks Great
16 July 04
Clean glue off
of bottom of right wing, glue 16 Styrofoam nose ribs in place. Measured, cut
and fit right wing leading edge plywood and trial fit.
17 July 04
Sand, tape and
varnish the inside of the right wing leading edge nose plywood.
18 July 04
Glue all three
leading edge plywood on the right wing. Same method as on the left wing.
22 July 04
Pull all of the
staples out of the Left And Right wing leading edge plywood, sand both “D” wing
sections with 220 grit wet/dry sand paper.
23 July 04
Measure, cut
and glued the jury strut and fittings for the right wing.
02 Aug.04
Joined the
aileron spar halves together by cutting scarf joints and gluing gussets on both
sides with T-88 epoxy.