10 APR 17: FF 1-2, steps 4-5: 2 hours

Riveted together the oil cooler:

22 APR 17: Installed interior panels for move to PA: 5 hours

Came home from a few weeks of simulator training for my airline and am getting ready to move the project up to PA.  Not really looking forward to the move, but after 20 years of moving around with the military, I’m excited that this will be the last move, and that I can finally put down roots.  I’m moving the project myself in a 26’ Uhaul, so I decided to put all the interior panels in the plane to transport them.  I figured it would offer some rigidity to the fuselage and also lessen the chance of damaging the parts by transporting them loosely.  No pics.

23 APR 17: 46-2 step 1 (initial), getting ready for move to PA: 5 hours

I wanted to get the engine mount installed, so I could use it to secure the fuselage to the inside of the U-haul during the move.  I read some horror stories about drilling the engine mount, but it was easier than I expected.  Go slow, use plenty of cutting fluid, and it is one of the easier tasks. Reaming one of the holes:

This will have to come off when I get started on the project again, but wanted it installed for the move:

I expect to have a delay of a few months during our move.  We are moving from Georgia to Pennsylvania, where my wife and I are originally from.  It will be a pretty large undertaking moving everything up there, but I’m excited to get moved and get back into the project.  After a career in the military, and moving every few years for 20 years, I’m excited that this will be our last move, and that I can really ‘move in’ to my new workspace knowing that I can set up for good and it won’t be temporary like all the moves before this one.  It’s pretty cool seeing all the panels installed, but just like the engine mount, these will all come back out once the move is complete for finishing, wiring, etc.:

Ready for the move!

20 MAR 17: Sanding cabin top – no pics: 2 hours

21 MAR 17: Cabin top: 7 hours

Began by making some clips that I will epoxy to the cabin top inside of the overhead console in order to attach adel clamps for wire runs.  I’ll attach 3 on each side of the overhead console:

I then fit some left over parabeam into the b-pillars.  There is a joggle in the pillar that I want to fill in and smooth over with micro:

Next was fitting the conduit in the a-pillars for wire runs – took a while to sand the pillars so the conduit would sit in the pillars.  It still sits proud in a few areas, but it is much better than when I first fit the conduit.  I then used some 5-minute epoxy to secure the conduit and used some expanding foam to fill in the dead space.  Once the foam is cured, I will shave it down and glass in the conduit:

Doesn’t seem like that should have taken 7 hours, but I spent a lot of time thinking about how I wanted to do certain things and less time actually doing them!

22 MAR 17: Cabin top: 6 hours

This is what the parabeam looks like epoxied to the top with some micro around the edges to hold it down.  Pretty rough!

I then began to glass in the conduits into the a-pillars.  All glassed in with peal ply attached:

At the end of the work session, I removed the peal ply.  Looking fairly good.  It will take quite a bit of filling/sanding to make the two sides symmetrical, but I believe the final, finished look will be well worth the work:

Finally, I epoxied parabeam to the other b-pillar, and sanded and spread a thick coat of micro to the pillar that had already cured.  Once this is cured, I will sand to a nice even shape.  Just like frosting a cake!

23 MAR 17: Drilled instrument panel: 5 hours

Began by drilling the panel inserts for the Aerosport panel.  I will then install nutplates into the panel flanges allowing the inserts to be screwed to the panel:

I installed the cabin top back on the fuselage one more time to double check my gap between the gutter and the doors for the McMaster-Carr seals.  I wanted to ensure this gap was consistent before I continued finishing the interior of the top and attached the overhead console.  While it was installed, I test fit one of the Rosen visors to ensure I would have no interference with the way I am planning on closing out the pillars:

A shot from the inside.  It’s pretty awesome seeing these little things come together.  I can begin to see little snapshots of the plane that it will become – pretty exciting!

I have to go away for a couple weeks to do simulator training for my airline, so this is how she will remain.  Beginning to come together!

9 APR 17: Prekote / Prime: 3 hours

Made it home for a few days – have to go back for another couple weeks of simulator training – and had such a nice afternoon, I decided to finish up some priming.  This is really the last of the metal in the airplane.  Primed the panel inserts, oil cooler mount, tail light adapter, door strut brackets, and some brackets that I made for wire runs throughout the fuselage: