What did you do on your airplane project today?

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dwalker

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I spent some quality time with cardboard and foam working on templates for the bulkhead for a header tank to attach to, measuring and making a pattern for the header tank, and some other interior panels that need to be made soon.
 

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dwalker

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Since it was raining dogs and cats today, and rolling the D-Fly out, firing up the air compressor, and sanding off the bondo ladled on at some point was not going to happen. Instead something that has needed to get done for a while got done- which is protecting the canopy.
There are a couple of options for this- a spray-on coating or some fort of tape. Since "Spray-Lat" was hard to find it seemed like blue painters tape was the thing to use, but of course much like Spray Lat there are stories of the tapes adhesive taking a lot of effort to remove if left on too long, and no one wants that hassle.
So in this case a 3M product called Paint Defender, which it looks like is discontinued, was used, as I had a couple of cans left from a few years ago.
To process is fairly simple and quick. Start with cleaning the outside of the canopy with glass cleaner. Next mask the edges off, apply the supplied wax, then spray on the coating. Unlike spray paint where you go for think coats, in this case the product needs to go on fairly thick, so heavy coats are applied one right after the other to build up that thickness. Then just let it dry. Any overspray- there just is not much- is cleaned up with a little mineral spirits or lacquer thinner.
Pictures show the canopy before and after the coating has been applied.
 

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Doran Jaffas

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It's not so much on my airplane but for my airplane.. Then driving a 140 miles 1 way every weekend since the middle of July to work on my hangar at a place I bought up in Lake City, Michigan.

It is now 80% or so complete. That's including all of the structure. It is open ended for now and I plan to close it up next Spring. Much to do in the land phase of it such as putting in a ramp out to the taxi way, adding peegravel around the pad for the airplane inside the hangar and then planting grass on the outside of the structure but all of that in due time. My main issue now is getting the basic structure done before the snowflies in a couple of 2 or 3 weeks up there.
 

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dwalker

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With few hours spent on the Dragonfly today the bulkhead and instrument tray templates were cut, fitted, and taped/hot glued in place. These were made using foamboard used for posters or display, or in my case Flite Test RC Airplanes
😉

Since the boards are 24x30, and the pieces needed were 38" and 41", they were joined together. Using 5-min epoxy and Foamtac two panels were edge glued, taped up, and allowed to set. They were then cut using a simple Xacto knife to shape. Once they sorta fit, the pieces were hot glued and taped into place.
In the pic you can see the tape and maybe the hot glue and it would seem the finished product would work as a single piece, and it very well could. However, in the case the bulkhead will be floxed in place permanently, as it will support both the header tank and the canopy hinges, and no good comes from either of those things coming loose.
The instrument tray will be pinned to the bulkhead and bolted to the instrument panel. This increases rigidity and spreads the loads while allowing the instrument tray to be dropped down or removed without having to pull the header tank etc. for access.
Next up is a decision on a composite, plastic, or aluminum header tank. Once that decision is made- or made for me- then templates for the header tank can be made. In the meantime more foamboard will be used to create the final templates for the armrests, center console- still probably going to be cut out and moved back to the 4" width per plans- headrests, , and probably a few more thins I have forgotten
 

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gtae07

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Over the last couple weeks I've wired in most of the primary power system, the lights (within the fuselage anyway), trim, transponder, and a few of the sensor inputs. I've also prepped and painted the sliding canopy frame and marked the aft canopy bubble for masking and Sika prep, and test fit seat cushions so I could mark the stick for height and grip angle.

Aiming to glue the canopy by November, and finish the non-sensor wires so I can wire the panel itself.
 

dwalker

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What I did for my project today was to frustrate myself a little more than normal.

It started off OK, spent some time figuring out how to locate the canopy while finalizing the hinges and fit, did a quick bit of sanding to see how hard the automotive Bondo is going to be to sand off, and then....

I started to go over my order to ASC which I intend to drive down and pick up in the next week or so, when of course, things get more complex than needed-

I had the templates for the elevator and ailerons printed finally, mostly to measure up so when I pick up the foam on my trip to ASC I get the right stuff and enough of it. Reading through the Construction manual it seems a little short on critical dimensions, which I suspect are somewhere on the actual drawings, of which I only have the templates that were graciously sent to me by a fellow forum member. Hopefully he can help with this as well, but for now I hesitate to move forward on the ailerons/elevator/rudder,.
 

Deuelly

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I've got most the fill work done on the bottom of the Dragonfly canard. Then I sprayed it all one color so it was easier to see what was left. Once this is finalized, all the major fill work is complete.
20211006_192113.jpg

On the big project I've got the hydraulic lines finished out to the gear legs. Hopefully be doing gear swings for the first time in quite a while next week!
20211009_132108.jpg
20211009_132043.jpg

@dwalker, I'll be in touch soon reguarding the templates.

Brandon
 

dwalker

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I've got most the fill work done on the bottom of the Dragonfly canard. Then I sprayed it all one color so it was easier to see what was left. Once this is finalized, all the major fill work is complete.
View attachment 116737

On the big project I've got the hydraulic lines finished out to the gear legs. Hopefully be doing gear swings for the first time in quite a while next week!
View attachment 116738
View attachment 116739

@dwalker, I'll be in touch soon reguarding the templates.

Brandon
Awesome progress and work!
I appreciate the help with the templates!
 

bifft

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As part of my condition inspection, getting to the "been meaning to do that" list. Removed the aileron trim. Never touch it except at the "center aileron trim" step in the preflight checklist. Saved half a pound! Kinda weight weeniesh of me, but that is how I got the second lightest RV-8 I know of.
 

dwalker

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Today I mocked up the tablets, dash display, switch panel, and one of the Talos units to get an idea of wire routing etc.
The past few days have been spent figuring out the setup and operations of the Talos and adsb receiver, updating firmware, etc. so it all works.
 

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Dana

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Worked with the local A&P today to lap the valves on my Hatz (O-290-D) in place on the engine. Compression was down to 35-40 on three cylinders (with the other at 70/80), with air heard leaking through the intake valves on three cylinders and also through the exhaust valves on two cylinders. After, compression on those cylinders are 67-70-70 with the engine cold so it should be even better when warmed up. I'm really glad I don't have to pull the jugs. Tomorrow I'll recheck the valve clearance and button it back up.

What's less certain is why the intake valves were leaking? Tappet clearance (solid lifters on this engine) was OK.
 
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dwalker

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On the Dragonfly I started on the aileron/elevator templates, ordered more nichrome wire to replace the wire that has wandered off into oblivion, and got an email from AS that my carbon fiber cloth is at will call, in Georgia :(. At some point today I will give them a call and just have it shipped up here, as that will be cheaper than the 8+ hour drive from here to there and back.
I did not update last week, but I did lay out and test the Talos Avionics box, Stratux ADSB-in, tablets, etc. for fit on the panel. Wire and switch panel bits etc. should be here middle of next week and I should start cutting, carving, and laying up the panel, bulkhead, instrument tray, etc., at least until I get to where I need the carbon fiber that is sitting in Georgia right now...
I put the O-235 core I picked up last week in the warehouse right next to the Vari-EZ, and started to consider rebuilding it for the V-EZ instead of a Corvair motor.
 

bifft

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Finally got my magneto back after sending it in to the manufacturer for a "mandatory service bulletin". (of course, once they had it hostage it "needed an overhaul as it was over 12 years old" so that took one AMU). Tried to install it today. Got it timed and the first clamp in place. Put the top clamp on, then was trying to put on the washer before the nut.

Due to the geometry it is one of those places where you can look at it or you can touch it, but not both at once. Reached for a tool, the magneto shifted in my hand and heard a single "ping". The clamp had slipped off the stud, hit something and then vanished forever from the ken of man.

Spent the next four hours looking for it. Don't find it. Looked every possible place and some impossible ones. As a break put the wheel pants back on and put in the baggage shelf. Looked some more. Hangar floor is dusty, but not so cluttered a 1x1x0.5 inch block of aluminum can disappear.

Maybe it hit the magneto face and bounced into the engine? There is a gap between the gear and the face that I can just get two fingers into, the clamp is a little smaller than that. Tried taking off the cover for where a prop control would go spilling about a quart of my new oil, don't see anything in there. Doesn't sound like anything hitting when I turn the prop.

Getting dark so came home. May look again tomorrow. Hope I find it outside the engine somewhere. Don't want to have to drop the sump. Don't mind buying a new one, but if it really went into the engine can't fly with it in there..

This plane may fly again someday, but who knows when.
 

dwalker

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Today I only got a short time in the airplane shed, so worked on the foam board templates for the interior panels. The dashboard cover still needs a bit of work but the armrests are pretty much there. Really the next step is to break out the MDF flat panel, cover with plastic sheet and start cutting foam and mixing epoxy.
Was also able to work at my desk a bit on the arduino controller for the annunciator.

In the "I'll take the win" column ACS is shipping me my carbon fiber, which is going to really help.
 

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bifft

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Maybe it hit the magneto face and bounced into the engine? There is a gap between the gear and the face that I can just get two fingers into, the clamp is a little smaller than that. Tried taking off the cover for where a prop control would go spilling about a quart of my new oil, don't see anything in there. Doesn't sound like anything hitting when I turn the prop.
So, bought a borescope (always wanted one). Drained out the oil, and put the scope down the magneto hole. Yep, there it was lying in the bottom. Fashioned a hook out of safety wire and with more than a little fiddling fished it back out. Since I had a borescope, checked out my exhaust valves. Looked good.

Putting everything back together took a while, got dark again before I finished. But, sitting in the cockpit doing the ELT check felt like I would fly again. Probably this year!
 
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