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Thread: And so it begins

  1. #161
    wireweinie's Avatar
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    My thought was similar. Use a standard blue bulkhead fitting and machine off the correct flare connection and tap that spot out for a smaller fuel drain valve.

    Web
    Life's tough . . . wear a cup.
    Thanks mixer, j3doc thanked for this post

  2. #162

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    dgapilot…you may have found the solution. Thanks!

  3. #163
    brown bear's Avatar
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    I did what dgapilot said , I took an AN804-6D fitting , cut off one flared end and drilled and taped for 1/8" pipe Click image for larger version. 

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  4. #164

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    mated the wings to fuselage today to see if anything I moved would conflict with cable routing. All worked out ok.

    Click image for larger version. 

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    Held the Pstol flaps in position. I was not aware that the trailing edge extended beyond that of the ailerons.

  5. #165

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    Need some help here…both my aileron cables contact the upper surface of the wing. The cable eye and the swage drag. Suggestions???

  6. #166

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    when i built my wings, i used a hammer to fix that problem. ok, i better add, dosent take much and if done right it looks like it belongs there. and its been a long time, but i cant remember if i used a piece of tubing to hit on or some type of bodymans bar to make a nice rounded shallow dip. ask jay, im curious to what he says.
    Last edited by tempdoug; 02-15-2022 at 10:28 PM.
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  7. #167
    Gordon Misch's Avatar
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    Yeah, I've seen that. One fix I've seen is to beat down the interference. On the exp here, I had Steve make swaged fitting, and moved the turnbuckle to the interior of the fuselage. Might have to get some more cable - - -

    p.s. sent you a txt
    Last edited by Gordon Misch; 02-15-2022 at 11:25 PM.
    Gordon

    N4328M KTDO
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  8. #168

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    Once covered, Lay a punch flat on wing and tap with a hammer. First dent on the wing to get it out of the way.

  9. #169
    skywagon8a's Avatar
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    Quote Originally Posted by vj88 View Post
    Once covered, Lay a punch flat on wing and tap with a hammer. First dent on the wing to get it out of the way.
    Do it before you cover, then the fabric can be stuck into the dent without dinging the fabric.
    N1PA
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  10. #170
    skywagon8a's Avatar
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    Quote Originally Posted by Mr. Ed View Post
    Click image for larger version. 

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    Need some help here…both my aileron cables contact the upper surface of the wing. The cable eye and the swage drag. Suggestions???
    Also make sure your aileron bell crank is tweaked towards the pulley first so the turnbuckle is pulling the aileron horn straight rather than offset. I believe the number 3 degrees is shown on the drawing.
    N1PA
    Thanks mixer, gisli thanked for this post

  11. #171

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    Fabricated the ELT ground plane today. It’s 471 square inches. Mounting instructions call for a minimum 452 square inches, double that preferred. I could attach vertical sections but will probably not do that at this time. It’s in a place I can get to so could add area later if testing indicates a need.
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  12. #172

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    Started fabric work a couple days ago. No experience with this so it’s slow going. Left side to go, then tapes and inspection rings.

  13. #173

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    Making slow progress on fabric work. Stitching done on elevators and stabilizers. Still applying finish tapes.
    Click image for larger version. 

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  14. #174
    Olibuilt's Avatar
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    Watch out for the the excess glue or crooked glue line, it tends to show through the topcoat (in my case..)


    Awesome work. Your big baggage door is amazing!

  15. #175

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    Thanks Olibuilt, I hope it doesn’t. The guy putting on the Stewart’s class said it won’t show through as long as it’s wiped off. We’ll see.

    I was researching Bill Rusk’s thread trying to get answers to a couple covering questions and had to laugh at myself. In one post Bill says he had 45 hours into covering the fuselage and it should be ready for paint the next day. Damn. I have 245 hours into the fuselage and tail surfaces and am ready to paint…I think.
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  16. #176

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    Been doing some painting. Metallic silver, metallic blue, midnight black pin stripe and 3M vinyl stripe that looks and feels like carbon fiber.

  17. #177
    Bill Rusk's Avatar
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    Looks awesome!!!

    Bill
    Very Blessed.
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  18. #178

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    Not making much progress lately…spent some time at the AK cabin and have had visitors (family) at home for a week. Will be on the road for the rest of September so the cub will be on the back burner until October.

    Daughters boyfriend is a graphic designer and cut me a paint mask for a checkerboard tail. Paint is metallic blue like the accent color on the rest of the plane. My daughter will be doing the tail art, still in the design phase.

  19. #179

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    Made a little progress today after a few weeks off. Got these mounted up and holes drilled. Next task is to make all the inspection hole covers and get those painted.

  20. #180
    Formandfunction's Avatar
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    Very nice,looks to be on the downhill slope about to pay off.
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  21. #181

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    I made paper templates for all fuselage opening/inspection covers. Then used those to cut Kydex blanks which I glued to a piece of melamine.

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    Did a carbon fiber lay up over the Kydex and vacuum bagged.

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    Cut the individual covers out of the panel, trimmed, sanded and drilled. The covers fit perfectly over the grommets which fit into the recess from the Kydex templates. These will get removed, coated with a UV protective and then painted to match the metallic silver fuselage color.

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    For those folks that noticed there seems to be no way to remove the cover over the aft stabilizer tube…you can see in this photo that the front upper part of the cover is a separate piece. That piece will be permanently attached to the grommet just to give a finished look. Also, yes I know that opening is upside down. My upper longeron is located at the top of the fuselage, not through the middle like Piper designed. So the aft stabilizer support bracket mounts under that longeron instead of over. To allow the elevator horns to be inserted into the openings the openings needed to be inverted. And, the rectangular cover had to be moved up to allow access to the control cable attach points. That rectangular opening is only on one side of the vertical fin.
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  22. #182
    G44's Avatar
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    Wow! Looks fantastic! Thank you for posting, its fun to follow along.



    Kurt
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  23. #183

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    I painted the carbon fiber covers and metal belly pan. ADSB antenna is mounted in the belly pan. I made poster board templates for the windows and had Tap Plastics in Portland cut the windows out of 3/32” plexiglass. Original plan was to put an exterior door handle on the lower door per Piper drawings. I fabricated that when I made the door. I didn’t like that it contacted the fabric with the door opened so I modified the door. Steve had mentioned in a post that he welds the head of a hex head bolt to the handle post and puts a small Allen key on the key ring. Sounded like a clever solution so that’s what I did. I also have a key lock in the forward corner of the lower door. Getting the interior panels installed slowly. I plan to remake the aft bulkhead out of carbon fiber and put an access door in the upper left corner for quick access to the ELT. I’m not loving the Kydex interior panels at this point but will live with it for now. They were all made a couple years ago, they fit well and I need to get this thing done. I’m tired.

  24. #184
    skywagon8a's Avatar
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    Quote Originally Posted by Mr. Ed View Post
    Original plan was to put an exterior door handle on the lower door per Piper drawings. I fabricated that when I made the door. I didn’t like that it contacted the fabric with the door opened so I modified the door. Steve had mentioned in a post that he welds the head of a hex head bolt to the handle post and puts a small Allen key on the key ring. Sounded like a clever solution so that’s what I did.
    This is my solution to the door handle contacting the fabric issue. Sew a thin piece of leather to a scrap of fabric, glue that fabric to the fuselage covering fabric, then paint the airplane.
    this picture shows the amount of abuse over a ten year period.

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    N1PA
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  25. #185
    wireweinie's Avatar
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    Be aware that landing in rough stuff will cause damage to the transponder antenna. Keep an eye on it for chips and cracks.

    Web
    Life's tough . . . wear a cup.
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  26. #186

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    Thanks for the heads up Web, I hadn’t considered that. I probably won’t leave the antenna mounted. I don’t have a transponder for this project but did all the wiring so if I decide I need one it will be a simple installation.

  27. #187

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    I want to keep the water from running down the sides of the fuselage and into the metal belly. I found some “D” channel rubber molding that looks like it will work well. I glued that to the edges of the belly panel and it looks like it makes a good seal.

    Nothing else done on it today…went flying instead of working.

  28. #188

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    Everything fails over time, make sure you have a simple drain hole at low point and all will be well. DENNY

  29. #189

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    Denny, thanks for the reminder. I have drain holes everywhere but didn’t put one in this belly pan. Will do so.

    Picking away at some small jobs in between typical fall chores. Started to make the carbon fiber “wraps” around the door openings. They capture the interior panels as well as protect the fabric. The cargo door opening is done in three pieces. The top of the opening doesn’t get wrapped as it shouldn’t be subject to the abuse the other three surfaces will endure. The cockpit door (lower) will be made in one piece. Click image for larger version. 

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    I don’t know why these uploaded sideways…?
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  30. #190
    SJ's Avatar
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    Quote Originally Posted by Mr. Ed View Post
    I don’t know why these uploaded sideways…?
    We have a plug in to flip iPhone photos the correct way (apple decided to ignore the orientation standard some years ago) but for some reason it does not always work.

    Were these taken with an iphone or something else?

    sj
    "Often Mistaken, but Never in Doubt"
    ------------------------------------------

  31. #191

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    Yes, iPhone.

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