Fuselage Completion
2017 Fairings and Wheel pants.
Total Build Time: 1303 Hours This is a long post with lots of photos spanning about 3 months of intermittent work. Here is the order of operations in this post: -Tail Fairing fabrication/installation -Jacking up the aircraft -Wheel pant fabrication/installation -Landing Gear fairing fabrication Quick note: I did fabricate but did not ultimately install … Continue reading
Time-lapse Video, 900 hours of work and move to airport.
This video includes all the time-lapse footage I have from January 2014 until August 2015. It’s essentially the entire build of the airframe. It’s missing the first 200 hours of the project because I didn’t have the camera setup for that portion of the build.
Fuselage Completion #24 (Control stick rigging and seat pan modification)
Total Build Time: 1041 Hours. Initially I found that, per the plans, the positioning of the stick-to-idler pushrod was offset in such a way that it would interfere with the path through the seat pan itself. In the below pictures you can see the angle of the pushrod. I did confirm that this setup … Continue reading
Fuselage Completion #23 (Fwd Floor, spar tunnel final installation)
Total Build Time: 1036 Hours. As my final task before permanently installing the forward fuselage floor, I decided to install 3 square attach points to the forward side of the spar tunnel (just below my knees when sitting) to allow for the future installation of cup holders or a storage pouch of some sort. The reason … Continue reading
Fuselage Completion #22 (Glareshield covering, intercom plugs)
Total Build Time: 1021 Hours. With my work under the instrument panel about 99% complete (fuel tank, electrical wiring and pitot/static/LRI routing done) I decided it was finally time to finish off the glareshield. Just before doing that, I finished the routing and installation of my radio intercom plugs, which are located high on the … Continue reading
Fuselage Completion #21 (Fuel Tank Installation, measuring and cleaning)
Total Build Time: 1015 Hours. This post details my testing and installation of the fuel tank. Included is my method for marking the fuel tank quantity and leakage testing. Also how I cleared debris from the bottom of the fuel tank. Additionally in this post is the installation of my cockpit air vent hoses. It may … Continue reading
Fuselage Completion #20 (Electrical Wiring #2)
Total Build Time: 1002 Hours. Continuing from my previous post on electrical wiring, this post covers my work on firewall penetration/protection, battery current sensor and intercom wiring. I’m still not quite finished with wiring but will follow up later. Firewall penetration for my electical wires passed through a large hole covered by a firewall penetration … Continue reading
Fuselage Completion #19 (Rudder Rigging)
Total Build Time: 996 Hours Today I rigged my rudders (prior to installing my glareshield/fuel tank which would restrict access to the pedals), and have a few closeup shots of some details. The first step of the Waiex rigging process links the rudder to the mixer in the middle of the aft fuselage. The cables … Continue reading
Fuselage Completion #18 (Elevator trim knob and pitot/static routing)
Total Build Time: 988 Hours This post includes the installation of of my elevator trim knob and my plans for routing of my pitot/static and LRI (lift reserve indicator) tube connections. My elevator trim knob will be located on the lower left side of my instrument panel. I located it to be as far from … Continue reading
Fuselage Completion #17 (Electrical Wiring #1)
Total Build Time: 964 Hours. I started my wiring by making connections forward of the firewall, and then passing initial wires through the firewall. I labeled all wires more than a few inches in length using printed labels and clear heat shrink. I used a pick tool to shove the labels into … Continue reading
Fuselage Completion #16 (Instrument Panel)
Total Build Time: 944 Hours. I began cutting holes in the instrument panel to install all of my avionics, switches and air vents. I started with the air eyeball vents since I wanted to set them as far outside on the panel as they would fit to give me the most room in the middle … Continue reading
Fuselage Completion #15 (Firewall Mounting)
Total Build Time: 931 Hours. I removed the engine after having marked up the firewall and planned for component installation. I installed nutplates where practical in order to ease removal/replacement in the future. I made a couple spacer plates for the gascolator installation in order to allow clearance for the sump drain past the … Continue reading
Fuselage Completion #14 (Swing Back Canopy Completion)
Total build time: 920 hours. I ordered the swing-back canopy kit offered by the American Sonex association. The kit inclues pre-rough-cut parts (all need some finishing work), including one welded part that I would not be comfortable making myself, hardware (nuts, bolts, rivets), and written plans that include pictures. Here is a link to the kit. … Continue reading
Fuselage Completion #13 (Firewall preparation and battery box)
Total Build Time: 910 Hours. Once I had the engine, exhaust and intake mocked into place I could plan the firewall layout. First step was to identify the usable area on the firewall. I then (with help from Bill) made some cardboard cutouts to assist with planning the layout. The cutout below represents my … Continue reading
Electrical System and Instrument Planning
Total Build Time: 873 Hours. To plan my electrical system, I studied other builder projects, the sonex plans and the book Aeroelectric Connection. Some general concepts I followed were to use fuse blocks (rather than circuit breakers) for wire protection, 2 main fuse-block-busses (main and avionics), in-line fuses to protect all wires not otherwise connected … Continue reading