Chapter Log

Step 0 -
Status: Not Started 
Est Time: 0.00, Actual: 0.00
Est Cost: $ 136.20, Actual: $ 0.00
Date Completed: Incomplete

Step 1 - Map Pockets
Status: Completed 
Est Time: 3.00, Actual: 2.00
Est Cost: $ 0.00, Actual: $ 0.00
Date Completed: 04/09/2009

2009-04-09 (2 hours):
I made these map pockets almost two years ago, but never installed them because I was waiting until the strakes were completed. I HAD however made the actual pockets, and they've been floating around the shop since then. I finally installed them today. I had to fiddle with their locations a bit to avoid interference with the control rods, which is why they look sort of lopsided, but they'll do.

Step 2 - Arm Rests
Status: In Progress 
Est Time: 4.00, Actual: 2.00
Est Cost: $ 0.00, Actual: $ 0.00
Date Completed: 04/16/2009

2009-04-12 (1 hour):
I decided to do something a little different than the plans for my arm rests. Others have complained about not having access to the hidden area here for maintenance purposes, so I decided to make a removable access panel (as others have done).

To do this, I prepared the right-side top arm rest surface to fit around the stick and map pocket. I then 5-minute epoxied two small lips onto it. The first is at a 90-degree angle, and sits between the stick and instrument panel. This will support a vertical filler panel that goes from the arm rest down to the thigh support. The second is at a 45-degree angle from the stick back to the seat. This will eventually be sanded away, but for now forms a lip against which I did a BID layup. My plan is to sand away this section, then install quarter-turn fasteners on it to support an access panel. I'll put a matching lip along the fuselage wall to support the bottom of the panel.

Today I just made the right side because I want to fit it together and see how it works before I do the left to match.

04-16-2009 (1 hour):
I now have the second layer of BID on the right side arm rest, and I was pleased enough with how it turned out that I started the left side as well. I did remove the foam under the lips I had made on the right side, so there's now a 3-BID lip for the fasteners. There's plenty of clearance around the torque tube.

I suppose I could have done this as part of the previous layup, but it was just easier to do it as a separate step. Today I floxed on nut plates along the arm rest edges to hold the side plates. I also put a 1 BID ply on top of them to keep them in place. Job done.

Step 3 - Thigh Supports
Status: In Progress 
Est Time: 6.00, Actual: 3.00
Est Cost: $ 0.00, Actual: $ 0.00
Date Completed: 04/17/2009

04-16-2009 (1 hour):
I cut the panels for the front seat thigh rests, shaped them, and made their under-side layup. Not much to say - it was a quick job.

04-17-2009 (2 hours):
Tonight I stopped by the hangar for a bit, and trimmed up yesterday's layup. I made the kerfs, taped up the thigh rest area, 5-minute epoxied the thigh rests in, then did the layup over the top. A bit of trimming tomorrow and this step is done!

04-18-2009 (0 hours):
I tried removing the thigh supports this morning, but the layup hadn't cured enough to pop out without delaminating. I'll wait another day on this - no rush.

I had previously made the rear seat support panels as part of making the front seat sections. All I had to do today was glass them in their final curve. I did change one thing from the plans. They call for you to set the curve in the plane, then remove the supports and carve out the reinforcement area to do a 4-BID reinforcement. I set the curve on the bench, which let me carve this area out ahead of time. So I was able to do the main and reinforcement layups in one step. It looks a bit cleaner, not that anybody will EVER see it.

This weekend I finished off the rear seat thigh and back supports. I prepared all of the hinges, then bent each hinge pin slightly so it wouldn't back out after it was installed. I then riveted each hinge to the respective attach tab. However, I did NOT install them in the plane yet. I'll save that for later for two reasons:

1) I'm doing a lot of work in this area and don't want the seats in the way. They're removable, but I also don't want to damage the hinges that get riveted to the floor.

2) When I was removing the thigh support from their curved form, I had a slight delamination at the top of each. I fixed it by working some epoxy into the gap with a brush, then making a flox corner right at the end of each support. I want to let this cure before I install them in the plane.

As I work, I'm trying to coat the edges of finished parts with micro to clean them up. I usually have a bit of micro left over from each step, and it takes very little to trim these edges. Hopefully this will save some time later.

Step 4 -
Status: Not Started 
Est Time: 0.00, Actual: 0.00
Est Cost: $ 0.00, Actual: $ 0.00
Date Completed: Incomplete

Step 5 -
Status: Not Started 
Est Time: 0.00, Actual: 0.00
Est Cost: $ 0.00, Actual: $ 0.00
Date Completed: Incomplete

Step 6 - Cowl
Status: Not Started 
Est Time: 0.00, Actual: 0.00
Est Cost: $ 0.00, Actual: $ 0.00
Date Completed: Incomplete