8/26/95 1hr Shopping for wing table parts 4hrs Table building
8/27/95 1hr Table building
9/15/95 4hrs Table leveling
9/30/95 2hrs Practice layups - Rutan book
9/31/95 2hrs Practice layups
10/5/95 2hrs Practice layups
10/6/95 3hrs Longeron fabrication (never used)
10/7/95 1hr Template cutting
10/8/95 1hr BL14.5 Canard templates (two)
10/13/95 3hrs BL 18/BL126 Wing templates (2 x 2)
10/16/95 1hr Reading plans & BL 78.5 canard templates
10/22/95 4hrs Bookend building - Rutan book
10/25/95 4hrs Expoxy oven
10/28/95 2hrs CS2 fittings cut (x4) Seatbelt fittings cut (x3) Setup drill press
10/29/95 4hrs lift/drag fittings (x9) cut and drill
10/31/95 2hrs grind ³fittings and drill seatbelt fittings
11/1/95 2hrs CS1 bellcrank cutting fix bandsaw
11/3/95 1hr CS1 bellcrank grinding
11/4/95 4hr CS1 bellcrank cutting Canard jig BL 117.5 cut x2 Canard jig BL 78.5 cut
11/5/95 2hr add level strips to wing/canard jigs
11/8/95 2hr CS1 bending
11/9/95 1hr CS1 fab/drill
11/11/95 2hr CS1 fab/cleco
11/12/95 .5hr Fix vise
11/13/95 1hr CS1 fab
11/18/95 1hr CS1 fab 3hr Fabric rack fab
11/19/95 8hr Acquire foam and molded parts!
11/22/95 2hr Trip wing lift bulkhead - trimmed off too much of the glass to glass edge for about three inches. This will need to be fixed later
11/23/95 2hr Clean shop 4hr Mark and begin trimming the fuse 2hr Finish trimming left half of fuse
11/24/95 3hr Finish trimming fuse 1hr Mate fuse halves! 2hr Trim bulkheads 1hr Fit bulkheads
11/25/95 3hrs Trim bulkheads and discover the wonderous peel-ply
11/26/95 3hrs Repair the forward fuse cover (the prefab part was incorrectly molded - honeycomb was in the glass to glass fuse seam)
11/27/95 1.5hrs Install forward fuse cover. Yea! Begin repair of the turtledeck (also too much honeycomb)
11/30/95 1hr Mark fuse for trimming Seperate fuse Remove peel-ply from right half of fuse
11/31/95 1hr Turtledeck repair (more honeycomb removal) 1.5hrs Trim more from fuse joggles More honeycomb work on forward fuse cover The bulkheads almost fit! Need more trim & fit
12/2/95 4hrs Fuel cell fitting Learn about circle cutters
12/6/95 1hr Cut fuel cell access holes Cut wing lift lightening holes (at 3DO)
12/7/95 2hr Cut/trim lower seatback/intercostal
1/8/96 .5hr Clean shop .5hr Trim fore fuse bow 1.5hr Trim and fit fuel tank
1/18/96 .5 hr Cut fuel filler hole/fit filler neck .5hr Trim fit upper seatback 2hr Trim/fit lower seatback/intercostal
1/29/95 2hr Trim/fit wing lift/drag Trim/fit upper seatback Finish fuel filler opening
2/3/96 5hr Fab aft bulkhead Remove peelply from left fuse Final bulkhead test fit Break apart fuse Trim firewall
2/8/96 3hr Trim/fit cowling
2/10/96 5hr Fab and install right longeron Mark waterline on inside of fuse
2/11/96 4hr Fab and install left longeron Flowcoat (seal) top of fuel tank Flowcoat left side of fuel baffle
2/12/96 .2hr Sand right longeron
2/16/96 1hr Sand and radius the longerons
2/17/96 5hr Reassemble fuse Clean garage Cut longeron slots in canard lift and upper seatback Final upper seatback trim Canard lift trim Final intercostal trim Mount cowling and cowling fairings
2/17/96 4Hr Install aft bulkhead in right fuse Trim fuel drain plate
2/20/96 1hr Begin replacing 1/8" of foam/honeycomb on fuel tank with flox. This is as recommended in Task plans. Bed fuel drain in fuse with flox
2/23/96 3hrs Sand/prep joggles for bonding (damn it I'm out of pop rivets)
More floxing of fuel tank
2/26/96-2/29 8hrs Join and glue fuse joggles
Drill out pop rivets
Sand and prep for taping
3/2/96 6hrs Tape bottom outside fuse (2ply 10oz BID)
Tape alt side of aft bulkhead
The last floxing of the fuel tank
4/10-11/96 15hrs? stuff
Fabricate fuel level sender mounting flange
Cut fuel sender hole in fuel tank
Glass right longeron
4/13/96 6hrs Glass left longeron
4/15/96 3hrs Trim firewall - ready for plumb and balance of fuse &
firewall layup
4/17/96 8hrs Mount firewall
Install COM antenna
4/20/96 12hrs Install fuel tank - extremely unpleaseant ;-)
Install NAV antenna
Flox in aft fuse cover
4/24/96 1hr Trim and fit of upper and lower seatback - things are
tighter now that the fuse is held in almost the final
shape.
5/12/96 8hr Cut fabric for gear
5/16/96 10hr Lay-up gear (ugh! - incredibly long layup, and still not
done
with side supports)
5/22/96 2hr Finish gear layup
5/23/96 30min Clean shop
5/24/96 5hr Sand and trim upper/lower seatback
Trim aft fuse top (to match upper seatback)
Sand seatback areas
5/25/96 8hr Install upper/lower seatback (aft face only on upper)
Sand seatbelt attach points
Sand fuel cell tape areas (to begin repair of leaky aft
section)
5/26/96 7hr Final trim of aft upper fuse
Tape and upper seatback with a glass to glass edge
Put flox slurry over leaky fuel cell tapes
Peel fply upper seatback
Install level (on centerline and parallel waterline)
5/27/96 4hr Attach seatbelt attach bases
Tape aft side upper seatback (now done with seats!)
5/29/96 1hr Clean shop
5/31/96 1hr Relevel table - I've marked the low spots on the front of
the table. Need to reuse the laser to level and
twist the
wing and canard.
6/1/96 10hr Visit and inspect Rondefly's and michael's DFs
Return landing gear mold
6/2/96 3hr Cut carbon fiber for wing and canard (ugh!)
6/7/96 7hrs Fit canard cores and level table
6/8/96 6hrs Canard shearweb layup (Johnny Z., Adam W., Kristen)
6/9/96 4hrs Remove peelply
Drill and tap lift fitting inserts
6/10/96 3hrs Relieve leading edges for lift fittings and pads
Flox/bolt lift fittings
6/11/96 2hrs Trim and fit canard leading edge sections
4hrs Jig canard bottom up on table
1hr Buy food for helpers
5hrs Canard bottom layup (Stu, Mike B, Clay Jackson, ? helpers)
3hrs Flip canard, trim leading edge
5hrs Canard top layup (Lee Marrs, Mr. Marrs, Jim Saur, George,
MikeD helpers)
7/20/96 3hrs Remove canard and post cure
2hrs Clean garage and move fuse into storage
7/?/96 2hrs Clean and relevel table
4hrs Level and join central wing aft sections
7/?/96 4hrs Wing spar layup (Rick R, Laura H. helpers)
7/?/96 3hrs Drill, tap, and install lift fittings
1hr Fit wing leading edge sections
8/3/96 ? Join wing leading edge sections
Join outboard panels
1/4/97 2hr shape wing tips & TE
2/27/97 1hr wing te glass-glass prep
2/28/97 4hr wing te prep/assemble toolset
3/8/97 6hr mount wing to tbl/fix twist
3/15/97 8hr Subaru disassmbly (mock-up engine)
1/18/98 12hrs Set up shop
1/19/98 6hrs (See Engine #2 log)
1/22/98 6hrs
* shape left wing tip
* fab inboard/outboard aileron/elevator bearings
* change epoxy pump to new ratio for aeropoxy
1/26/98 6hr
* sand bondo blocks on wing
* rebuild epoxy pump
2/6/98 8hr
* build engine
2/8/98 8hr
* fuel cell layup
2/10/98 2hr phenolic disc fab
2/14/98 4hr
* left aileron torque tube
* build flat table for aileron layup
2/20/98 4hr mount aileron torque tubes
2/21/98 2hr shape alieron fairings
1hr paint valve cover/oil pan
2/22/98 1hr tap 1/4" npt in 1-3 cyl head for turbo cooling source
2hr fab phenolic doughnut for aileron reflexor
2/24/98 2hr check piston ring gaps
RECORD IN ENGINE LOG
begin fitting piston rings
8hrs engine final assembly
6hrs avionics hack work - The Java UI now works
3hrs header tank layup/6oz BID cutting
3hrs trim and fit the side/center consoles
1hr basic assembly of center console
10min move canopy to the garage
5/20/98 2hrs Becky 5min epoxy of side consoles
5/25/98 8hrs Trim aileron fairing
Calibrate and test epoxy pump ratio
Cut landing gear
Clean shop
6/6/98 6hrs
Glass left aileron bottom side
Glass inside of side consoles
6/7/98 1hr
Becky sanded side/center consoles
Becky sanded bottom of left aileron
4/23/96 The inner front of fuel tank has voids
The rear of fuel tank has voids
Ugh! I forgot to flox the fuel filler neck.
Ugh! I used 10oz BID on the longeron - I guess 6oz
would be better.
A couple of bubbles on the longeron layup
To do:
Flox/tape fuel baffle bottom
Install upper/lower seatback
Install side consoles and control hardware
Test fuel tank
Tape aft fuse cover