Tail Graphics

I mounted the N number and the stars and bars on the the left side of the tail today. I made some deviations from the way the graphics were printed. I moved the bars closer to the star because I preferred having a little wider stripe at the trailing edge of the rudder than what was laid out. That took quite a bit of ciphering to get it all to look right with the proper spacing etc. 

Anyway, I started by cutting everything into individual pieces, the star and the stripes. I had to mount the N number first. The laser level really came in handy for all of this. I double checked I had the head rack of the plane zeroed out and then set the laser level where I wanted the bottom of the N number to be, cleaned the surface again, mounted it and admired my work. Actually, the next step was to take the laser level to the other side and repeat the process since it was already at the correct height. So, I mounted the right side N number,

I came back to the left side and mounted the star. This is when I began by repositioning the bottom stripe, closer to the star, since it is on level. Once I was happy with the position, I mounted it. The next stripe to mount was the most vertical one. I set the distance from the leading edge of the vertical stab and used a round object I found in the shop to set the radius around the star. This allowed me to set the point of the stripe to match the relative point of the first stripe. Once that stripe was mounted I just had to split the distance between the other two stripes. Again, I set the point relative to the other two and mounted the stripe.

Main Landing Gear

I finished up mounting the main landing gear today. I started by mounting the shocks. Once they were all fitted I put some thread locker on the rod end jam nuts. Then I started applying grease on all the connections and tightened them. Next up was the Beringer Brakes, I mounted them after coating the axle with anti-seize. Torque seal was applied to all the nuts.

Taxi light. Small camera is a backup camera that will be used as a taxi cam, hooked into the G3X screens. And of course, a GoPro camera.

I lifted the plane with my engine hoist so I could mount the tires. Once the tires were on, I filled the shocks with a small amount of nitrogen to level the stance and take the squat out of the gear. It's now back on the gear. Now to clean the shop up and make room for mounting the wings.

Main Landing Gear

I set up the main landing gear today. First off was to determine whether the gear was parallel. I attached the gear legs to the mounts with the proper bolts and washers in place. I then used a metal yard stick braced against the brake flange on each gear leg to draw a line on the concrete. Once both lines were drawn, I measured the distance between the lines at the extents of each line. In effect, these two measurements tell me whether the axles are parallel or have a toe in or toe out. The first measurements told me the gear had a toe out situation. To correct this situation I needed to adjust the rod ends screwed into the gear legs at the mounts. After several adjustments I was able to equal out the measurements meaning the axles are parallel.

The next measurement is taken from the tail of the aircraft center line to the same point on each axle. This measurement tells whether the gear is square to the fuselage. Again, this is adjusted using the rod ends screwed into the gear legs. Eventually, I was able to get each of the measurements to be equal or as close as possible without better measuring equipment.

Tomorrow I'll tighten up all the bolts and mount the shocks.

Left gear leg.

Right gear leg.

Tail Gear, Rudder and Miscellaneous

Today was a big day. This morning I went over to help Paul put the wings on his Kitfox. He has some trimming to do for the wings to fold properly. After that, I came home to get back to work on mine.

First off, I removed the rear fuselage rotisserie. I had to do this to mount the rudder and to be able to turn the tail wheel straight. I leveled the head rack by putting the tail wheel on a box with some extra wood to get the fuselage level in preparation for installing the "Star and Bars" on the tail. With an excuse to use my new laser level, I checked the alignment of the SuperSTOL decal on the side to see how close I was. When I installed it I just used a tape measure, turns out I was spot on. The laser will make installing the tail stripes much easier or, at least to get them level.

I painted the tail gear pivot bushing collars yesterday and installed the cotter pins today. 

I also installed the tail wheel lock cable, grip locked the cable, greased the pin and verified that it works correctly.

Then I installed the rudder. I have a couple of things that need to be done to be finished with it. I am rethinking the routing of the tail strobe wire. I had originally planned to route it through the inspection port for the elevator but after looking at it mounted, I'm thinking about a more direct route. I could cut a small hole in the tail to route the wire directly which would put it lower (under the horizontal stab) and out of the way of the elevator Jesus bolt area. I am also upgrading the rudder cable to 1/8"  and need to route it into the fuselage. This requires a couple of holes to be punched in the fabric.

Next up was to finish the shock mounts. Here are a couple of pics of the second pass of SuperFill from yesterday.

I debated about trying to sand the SuperFill to clean it up a bit but decided that I would probably mess it up and make it look worse, so I just left it as is. After painting, they look like excess weld material and really don't look bad. They are certainly far better being sealed up. Now I can mount the main landing gear tomorrow.

Lastly, I mounted the required passenger warning label on the panel.

Slats & Main Landing Gear

I've taken several days off to catch up on my manual. Just trying to catch up on the paper work. Back to work on the plane today.

The last item needed to complete the slats is to set the trailing edge gap. Each slat has two square cutouts on the bottom side next to a rib. This allows access to drill three holes in the rib and set rivets which will set the gap on the trailing edge. The factory recommends the gap be set at 1/16th to 1/8th inch. Once I set the gap, I drilled the holes and set the rivets. The wings are now ready to be mounted.

Riveting the last of the 24 installed.

A pic of the three rivets installed in a slat rib.

The next task for today was to seal up the gaps around the main gear mounting bracket on the fuselage. I taped the area off and mixed up some SuperFill and applied it. It will take a couple of applications to be satisfactory. Once I'm happy with the fill, I'll sand it as best I can and paint it to match the surrounding area. Here are pics of the first pass of fill.

Left Side Front

Left Side Rear

Right Side Rear

Once I get this finished I can mount the main landing gear.

Tail Gear

Happy New Year! Today, I mounted the tail gear back on the plane. I had previously mounted it so there weren't any surprises getting it re-mounted for the final time. To complete the install, I've got a little finish painting on the main pivot tube and I have to hook up the tail wheel locking push/pull cable.

Stol Speed Vortex Generators

I installed the VG's on the left wing today. Just a repeat of yesterday.