** Several years after starting, my website hosting company changed software, and I had to rebuild the site. Several pitures may have been relocated in the wrong place.
22 March 2009 Started the fuselage today. In several hours I had the table (2 pieces of MPF tied together) mounted on my counter top and started to build.Hours: 6.024-25 March 2009 After putting the fuselage longerons in the jig I decided there was too much pressure (in my opinion), so I made another bending jig, similar to the one I used for the rib cap strips. I steamed the first 5-6 feet. It came out nice, and it fit almost perfectly back into the jig with no pressure. I cut the rest of the braces, but now have to wait on my 1/8" plywood to arrive.Hours: 4.027 March 2009 Plywood arrived, cut several pieces of 1/8th for the left fuselage. The plans call for wedges between several braces, but I could not tell if required between all braces. I cut enough for all, however after looking at the plans and trying to interpret what they were for, I concluded they are only called for where pointed out for brackets.Hours: 2.028 March 2009 I glued the left side of the fuselage. I used several of the jig clamps from the rib jig, however, the 1" bracing was a little harder to clamp.Hours: 1.029 March 2009 Pulled out the left side of the fuselage from the jig. Pretty cool, strong, light and looks like a fuselage. 4-5 April 2009 Started the fuselage right side. With any luck, I won't forget and make two "left sides".I steamed the bottom longeron for the right side and fit it into the original jig. I cut all the braces.Hours: 3.08 April 2009 Glued the braces together on the right fuselage side.Hours: 2.09 April 2009 Cut and glued the gussets on the right fuselage side.Hours: 2.010 April 2009 Flipped and glued the gussets on the right fuselage side, side 2.Hours: 1.011 April 2009 Cut gussets and started gluing the left fuselage side, side 2, got about half way through, will finish tomorrow.Hours: 2.012 April 2009 Finished cutting and gluing gussets on left fuselage.Hours: 1.013 April 2009 Pulled left fuselage side out of the clamps.24 April 2009 Sanded most of the fuselage top and bottom longerons of excess epoxy.Hours: 1.022 May 2009 Started laying out the fuselage. Needed to order white ash for framing in.15 June 2009 New pieces of Ash arrived this week, began cutting braces to size and squaring up fuselage.Hours: 6.020 June 2009 Epoxied the first few cross bracesHours: 1.022 June 2009 Epoxied an ash brace on the bottom of the fuselageHours: 1.024 June 2009 Using a piece of 1/4" plywood and sandpaper glued to the plywood, formed a sanding board for the aft section of the fuselage sides. Some have told me they use a bench sander or belt sander and then finish off with this board sander. However, I found it gives a pretty straight sanding and if it gets off on one side, you merely tightened the opposite clamp for more pressure and the two side were sanded even again. I paused often to measure the sides to ensure it was sanding evenly. I sanded for about 20-30 minutes each day for about 3 days, that was about all my arms could take. It came out pretty good and very straight.Hours: 3.01-20 July 2009 Epoxied numerous brasses and cross braces. Paused at the end of July to enjoy Brodhead and Oshkosh 2009!!!!Hours: 10.0August More cross brasses and sanding accomplished in August. Also epoxied several gusset plates on fuselage. Not much else accomplished.Hours: 4.01-19 Sept 2009 Epoxied gusset plates. Sanded majority of the fuselage. Using the table belt sander adjusted in the vertical, sanded the fuselage tail area. First I aligned the vertical stabilizer on the fuselage and marked the angle and how much needed to be sanded. Then I adjusted the sander in the vertical position. I placed the sander on two small sections of pipe, so it could be rolled into the fuselage with a consistent angle and pressure.Hours: 6.017 Oct 2009 I contemplated the type of plywood to use on the sides and bottom of the fuselage. After searching several sources, I was able to obtain (2) sheets of 1/8" Okoume Marine grade (BS1088) and (1) sheet of 1/4" Okoume from North Carolina, where a friend picked it up on his way up for a visit. I cut the bottom piece using the 1/4" plywood, and a cardboard template to form the half-oval on the rear of the piece. One thing I have never been sure of, and this is not made clear in the plans, is the use of 1/8" x 1/4" edge strips. I overhung most gusset strips to take into account the need to round the longeron edges, and will fill between these with strips, however, not over the side plywood pieces.Hours: 1.023 Oct 2009 Prepped the fuselage for the bottom plywood piece, scraped off excess epoxy. Epoxied the 1/4" plywood bottom clamped all around, used weighted boxes in the middle to hold against cross braces.Hours: 2.025 Oct 2009 Removed clamps and sanded all edges of the bottom plywood piece.Hours: 1.04 March 2010 **After working on the empennage pieces and waiting to weld some metal pieces, I cut 1/8" plywood (Finnish Birch) into approximately 1/2" strips long enough to go between gussets as called out in the plans. I started gluing these on the fuselage. Near the tail section, where the HS will rest, it didn't seem prudent to use just 1/4" stips so I cover the entire top with small pieces of plywood.Hours: 1.012-15 Apr 2010 Cut out the Fuselage Port Side Plywood using 1/8" Okoume Plywood. Epoxied the side and using random weighted objects to hold it down epoxied it up. Once it dried, I sanded it up.Hours: 3.017- 25 Apr 2010 Cut out the Fuselage Starboard Side Plywood using 1/8" Okoume Plywood. Prepared the side, this time using tape to minimize and epoxy oozing out and getting on the fuselage inside. Epoxied the side and using random weighted objects to hold it down epoxied it up. Once it dried, I sanded it up.Hours: 3.018-20 October 2010 Cut out the Fuselage firewall and attached in place. Started running pieces of spruce strip down the sides of the fuselage, pieces 1/4 by 1/2 inch.Hours: 1.026-30 October 2010 Added fuselage strips on the sides of the fuselage using 1/4" X 1" spruce. The plans called for these to be 10" down from the top of the longerons, however this did not appear to place it in the middle of the fuselage (from top to bottom), so I placed it 11" down and parallel with the top of the longeron. This made it run perfectly where shown in the plans to the next to last gusset.Hours: 2.021-22 November 2010 Began varnishing using Poly system two part varnish, and reducing by 50% on the first coat.Hours: 2.012 January 2011 Attached the wheels to the axle and wrapped with temporary 5/8" rope on the gear.Hours: 1.0