Drilling Axle Nuts: 2 hours

Short post, but important. Most of the information out there is about how to properly pre-load the style of wheel bearings that don't have the integrated dust seal. The new Matco brakes come with integrated seals on the bearings and need a special procedure for install. According to the guide, the bearings should have 18-26... Continue Reading →

Fuel, Brake, Static Line Install: 18.0 hrs

Let's start with the simple one, static line install. My first install wasn't going to cut it. I ran the static lines down and put a water catcher loop at the bottom that would hopefully keep the line going forward dry. After looking at it, I didn't like it, and my tech advisor agreed. Kacy... Continue Reading →

Gear and Engine Install: 16.5 hrs

Exciting times, as its starting to look like more than a fuselage. The instructions for installing the gear are a single line that says "round tube in round hole, install one bolt", which is just insanely understating the amount of effort this took. While the idea is simple, it took hours and hours of sanding... Continue Reading →

Fiberglass Canopy Fairing: 44.5 hrs

I started the canopy fairing by cutting out the suggested patterns and mocking them up into place. It didn't take long to realize that the metal fairings weren't going to fit. Because the rear of the canopy frame was a bit wider than Van's expected (in order to clear the skin), I couldn't get a... Continue Reading →

Empannage Intersection Fairing: 26.0 hrs

The stock Van's fairing fit like crap. It needed to be excessively pulled into place and even once screwed into place, had large gaps everywhere. We decided to make our own. We started by laying out the basic shape we wanted, then taping up gaps and laying laid foam over that. This only took an... Continue Reading →

Canopy Glueing and Install: 70.5 hrs

Our tech advisor came by for an inspection prior to glueing the canopy on to the frame and doing the install. He highlighted a few areas that needed to be tweaked on the frame, so I spent a day with a conduit bender going over the rear bow. It matches the curvature of the upper... Continue Reading →

Empannage Fiberglass Closeouts: 70.5 hrs

This is the first post in a very long time, mainly because I've only been working on a single thing since halloween. So far I finished all the work on the tail and the canopy. I ended up making a new empannage fairing since I didn't like the one Van's supplied. I also made the... Continue Reading →

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