Log Entries - March 2000

Wed 1 5 In preparation for starting chapter 6 very soon I decided it would be a good idea to have an EAA Technical Advisor check out my work to date. Terry Sickler from Chapter 301 came to my shop and looked over my fuselage sides and bulkheads. He was very pleased with my glass work. Needless to say I was please that he was pleased. All my worrying in the past about possibly dry layups from peel ply were for not. He said there was nothing wrong with what I have done. Sanded the previous layup. Glued the other electrical channel into place and filled the surrounding space with foam. 2
Mon 6 5 Sanded all the foam smooth and even with the surrounding wood. Did the six ply BID layup on the right fuselage side. Peel plied. 2
Tue 7 5 I popped (literally) the right fuselage side off of the jig. I carefully scraped off foam I wished to glue back into place and then scraped the rest of the glue and foam off the masonite. Sanded the UNI strands along the top of the upper longeron smooth. Made measurements to cut the side to length. 1
Wed 8 5 Did the six layer BID layup on the other fuselage side. Glued a foam divot back into place on the removed fuselage side. Cut the right fuselage to length - 101.75". Cut out the 5.5" x 8.7" area for the spar. 5
Fri 10 5 Cut the other fuselage side to length and made the spar cutout. Sanded along the top longeron. Cleaned up in prepartion for the next chapter. 3
Sat 11 6 Sized and cut the longeron and doubler holes in the temporary firewall. Test fit F-22 against the front of the fuselage sides. Cut the corners of the front seatback to fit into the fuselage. Cut the corners of the IP to fit into the fuselage. Built the 2x10 and 2x4 fuselage jig. Mounted the temporary firewall in place on the jig. Put the fuselage sides into place in the temp firewall. Blocked so the upper longerons were level. Clamped F-22 into place on the jig and ajusted the fuselage sides to fit. Placed the seatback and IP into position in the fuselage and used nails to hold them into place. Cleaned off the worktable by removing the fuselage jigs and all the bondo. 11
Sun 12 6 Removed fuselage sides and bulkheads. Added more supports to firewall to keep it straighter. Put sides and bulkheads back into place. Fit was better and all was level, plumb, and straight. Made cutouts in center of front seatback. Took the plunge and floxed the front seatback, IP, and F-22 to the fuselage sides. Lots of tweaking, floxing, and checking. Locked the room for the night. 4
Wed 15 6 Sanded all the bulkhead corners in preparation for taping. Cut all the BID for the tapes. Wet it out and cut into 2" strips of proper length. Taped seatback, IP, and F-22. Added 4 layer BID reinforcement at canard cutout on F-22 and fuselage side. Peel plied all tapes. Releveled everthing for cure. 6
Thu 16 6 Trimmed F-28 to fit into fuselage. Sanded fuselage sides where F-28 and tape would go. Made up some 2" tape. Floxed F-28 into place at the 6.25" position (per FAQ). Clamped into position. Added tapes and peel ply. 2
Sun 19 6 Spent some double checking measurements of firewall and landing gear bulkheads. In end decided best thing was to trim bulkhead a bit. Trimmed outside edges of aft landing gear bulkhead. Attached 5" spacers to firewall to keep bulkhead in proper place. Floxed aft bulkhead into place and added 2" BID tape on front face. Peel plied tape. Layed out parts for front seatback support and heat duct on 0.25" foam. Cut some of parts out in preparation for glassing. 4
Mon 20 6 Trimmed front lower landing gear bulkhead to fit into place. Made 8" spacers to properly locate bulkhead. Floxed bulkhead into place. Will do BID tape when doing UNI layups. Applied 2 layers of BID to seatback brace triangles. Applied two layers UNI to heat duct parts. Made 1/4" plywood cutouts for fuel valve mount. 6
Tue 21 6 Trimmed the layups on the heat duct and seatback brace parts. Cut out eat piece and sanded even. Cut the 1/16" aluminum for the fuel valve bracket. Carefully bent the ends around a radiused piece of wood. Discovered I had the wrong nut plates. Ordered new ones from Wicks. 3
Wed 22 6 Drilled the 1/4" holes in the aft hardpoints using the 8" jigs as guides. Floxed the upper, forward landing gear bulkhead into place. Had to trim sides a bit to get it to fit. Built a pair of saw horses. Finished cutting all the holes in the fuel valve bracket. Sanded the round on the plywood brace to accept the bracket. Chiseled the foam from the seatback brace to replace it with the plywood brace. 4
Fri 24 6 Prepared the front landing gear bulkhead for the 3 layer UNI layup. Cut all the glass and peel ply. Added tape along the joint between the two halves and then added the UNI on the ears and down the front. Peel plied. Attached the nut plates to the fuel valve bracket. Floxed the plywood braces into place on the seatback braces. 4
Sat 25 6 Removed the fuselage from the original jig and with the help of Shelly we got it turned over onto the saw horses. I jigged until the fuselage was level and straight in all directions. Cut all the glass for the 6 ply UNI layup on the aft face of the forward landing gear bulkhead. Also cut the BID for the needed taping. Spent some time adjusting my pump to the proper ratio. Did a test layup to see how it is in the morning. 3
Sun 26 6 Added the 6 layer UNI layup on the landing gear bulkhead. Added BID tape at the seam and fuselage sides. Prepared all the spacers and seatback brace to joining. 3
Mon 27 6 Taped the aft side of the aft landing gear bulkhead. Cut the holes in the lower permanent firewall. Floxed the firewall in place and taped the joint. 4
Tue 28 6 Floxed the seatback brace spacers into place and joined the two triangle pieces of the seatback brace. 1
Wed 29 6 Floxed the three pieces of the heat duct together. Floxed the landing brake support (aluminum tube) into place. Floxed the fuel valve bracket into place. Prepared the fuselage bottom by sanding the lower longerons and bulkhead bottoms smooth. 3
Monthly Total 71