Monthly Construction Log - January 2010

Date
1	Installed fuel scupper in top skin. Started riveting top skin.
2	Finished riveting top and leading edge skins.
3	Gathered parts for flap construction.
4	No work.
5	Started flap frame assembly. Marked hinges for rivet locations.
6	No work.
7	Drilled flap hinges. Modified horn angles and clecoed together right flap frame.
8	Transfer drilled right flap hinge #40, then transfer drilled entire flap frame #30. Drilled 1/4" hole for flap extension rod bolt.
9	Assembled and transfer drilled left flap frame. Disassembled both frames for priming.
10	Deburr/polish/clean flap parts.
11	Deburr/polish/clean flap parts.
12	Deburr/polish/clean flap parts. Started fitting up left wing tip. Found that the joggled section on the rear section on reaches about halfway across where it needs to be riveted on the tip extension. Talked to Ed - he suggested gluing an extension on the joggle area. The tip is made from ABS so I ordered some 0.040" ABS sheet to do the extension.
13	No work.
14	No work.
15	No work.
16	No work.
17	Started work on a new electrical system design, similar to the Vertical Power system. Decided against the old design for two reasons - first, the area it would have occupied in the subpanel is where I want to put the choke/carb heat/cabin heat controls (I don't want to put them in the panel itself). Second, I wanted to add power monitoring and annunciation using a display in the panel. Will have a control unit mounted behind the instrument panel, and a control head mounted in the panel. The control head will have a graphical display for showing power status.
18	No work.
19	No work.
20	No work, but received main gear legs - the last backordered item!
21	No work.
22	Deburr/polish/clean flap parts.
23	All flap parts now ready for priming.
24	Primed flap frame parts. Reassembled both frames. Upon review of the drawings, realized that there are eight #6 rivets in each frame, so drilled those holes #11 and deburred. Riveted both frames. Set up to form flap skin bend using PVC pipe.
25	No work.
26	No work.
27	Gave up on using PVC to bend skins. Am doing this alone and PVC flexes too much to get good bends all the way across the skin. Will get some metal tubing to bend with.
28	No work.
29	No work.
30	No work.
31	No work.