And now for the "good stuff"...the chronological journal of the construction of my Van's RV-7.

Preparation

The Decision

How did I decide on Van's RV-7? It's kind of a long story...if you really care, I wrote up a little description of my decision-making criteria & process.

Planning

• July 10, 2001 - Got confirmation from FAA of my custom registration number, N747DC
• August 10-12, 2001 -- Attended the SportAir RV Assembly workshop
• August 27, 2001 -- Ordered the RV-7 preview plans; Ordered the Avery tool kit w/3x Gun
• August 28, 2001 -- Faxed the order to Vans; Began converting my garage into my shop

Shop Environment, Equipment, etc.

• August 29, 2001 -- Set up the T-adapter for the air; Built an electric-integrated workbench
• August 30, 2001 -- Got metal prep chemicals & primer, touch-up sprayer; Preview plans arrived
• August 31, 2001 -- Picked up the lumber for the jig; Built the jig
• September 1, 2001 -- More shop prep (tool storage)
• September 2, 2001 -- More shop prep (air hoses); Built a 2nd smaller workbench
• September 3, 2001 -- More shop prep (electrical)
• September 4, 2001 -- Avery tool kit arrived
• September 5, 2001 -- Installed air filter & lubricator
• October 16, 2001 -- Tore down the jig; the garage is a garage again
• October 28, 2002 -- Gutted the shelf in the back of the garage (Santa Monica)
• October 29, 2002 -- Built the new (and final, I hope) compressor enclosure

Empennage

Horizontal Stabilizer

• September 6, 2001 -- Empennage kit arrived; Took inventory; Began working on the horizontal stabilizer
• September 7, 2001 -- Constructed the rear HS spar
• September 8, 2001 -- Completed rear HS spar; Started working on the front HS spar
• September 9, 2001 -- More front HS spar work
• September 10, 2001 -- Riveted/completed the front HS spar
• September 11, 2001 -- Constructed the HS skeleton
• September 12, 2001 -- Primed and assembled the HS skeleton
• September 13, 2001 -- Began mounting the HS skeleton in the jig
• September 14, 2001 -- Finished mounting the HS skeleton in the jig; Made "clothespin" clamps; Began drilling the HS skins
• September 15, 2001 -- Deburred & dimpled the left HS skin; Began riveting the left HS skin & skeleton
• September 16, 2001 -- Deburred & dimpled the right HS skin & skeleton
• September 17, 2001 -- More right HS skin work
• Vacation 9/18 - 9/24
• September 25, 2001 -- More left underside HS skin riveting
• September 27, 2001 -- Completed riveting left HS skin; Began riveting right HS skin
• September 28, 2001 -- COMPLETED THE HORIZONTAL STABILIZER (The hammock flies...)
• September 29, 2001 -- Suspended the HS from the ceiling for storage

Vertical Stabilizer

• September 25, 2001 -- Began working on the VS
• September 26, 2001 -- VS rear spar construction
• September 27, 2001 -- Completed VS rear spar
• September 28, 2001 -- Deburred, fluted, and drilled the ribs I have (one on back-order) to rear spar
• September 30, 2001 -- Mounted the VS hinge brackets on the jig
• October 2, 2001 -- Finished constructing the VS skeleton; Mounted the VS on the jig; Drilled the VS skin
• October 3, 2001 -- Deburred and dimpled everything
• October 4, 2001 -- COMPLETED THE VERTICAL STABILIZER...well, almost
• October 10, 2001 - Finished squeezing the remaining rivets

Rudder

• September 30, 2001 -- Fabricated the rudder stiffeners
• October 1, 2001 -- Riveted stiffeners to skin; Constructed skeleton
• October 4, 2001 -- Constructed the V-groove jig
• Vacation 10/5 - 10/8
• October 9, 2001 -- Primed and built the rudder skeleton
• October 10, 2001 -- COMPLETED THE RUDDER

Elevators

• October 11, 2001 -- Fabricated and drilled left elevator stiffeners
• October 12, 2001 -- Fabricated and drilled right elevator stiffeners
• October 13, 2001 -- Prepped and primed elevator components; Riveted left elevator stiffeners
• October 14, 2001 -- Riveted right elevator stiffeners; Built the elevator skeletons; Drilled skins to skeletons
• October 15, 2001 -- Riveted the elevators together; Fashioned trim servo brackets; Began elevator trim tab
• October 16, 2001 -- Completed the trim tab
• October 17, 2001 -- COMPLETED THE LEFT ELEVATOR
• October 19, 2001 -- Tested the electric elevator trim
• October 20, 2001 -- COMPLETED THE RIGHT ELEVATOR

Finishing the Empennage

• October 18, 2001 -- Fitted and balanced the left elevator to the horizontal stabilizer.
• October 20, 2001 -- Fitted the right elevator to the horizontal stabilizer.
• January 1, 2002 -- BACK AT IT! Mounted the VS fiberglass tip; Started working on the rudder tip
• January 2, 2002 -- Mounted the rudder fiberglass tip
• November 15, 2003 -- Worked on the right HS and elevator tips

Wings

Waiting until I sell my Mooney to order the wings kit...
Update 11/6/2001: I've gotten a bunch of email from lots of builders and prospective builders out there asking if I've made any progress. Nope, unfortunately I need to sell the Mooney to free up some cash to buy the next phases. One of these days I'll probably start working on the fiberglass tips on the empennage components. Be patient...I'm sure trying to be...
Update 1/1/2002: It's the new year already, and I still haven't sold the Mooney or come up with enough cash to buy the wings. But screw it, I need to keep making progress. So I'm working on the fiberglass tips.
Update 2/14/2002: The Mooney is SOLD!!! Time to order the wings...

Planning, Shop Environment, etc.

• February 15, 2002 - Faxed the wing kit order to Vans; waiting 8-12 weeks for the kit to arrive...
• March 11, 2002 - The wings are scheduled to ship the week of April 29.
• March 23, 2002 - THE BIG MOVE. Jen and I have moved. We rented a 26' truck but still didn't have room in there for the garage stuff (we own way too much CRAP). The new garage is full of crap, including the new landlord's desks and boxes and stuff. I'm dreading the "conversion" process. All of my shop equipment and the empennage components are still in the old garage at this point.
• March 26, 2002 - Rented a 14' U-haul and transported the shop and the empennage to the new garage, which is still a disaster.
• March 27, 2002 - Got confirmation from FAA of my 2nd custom registration number, N714D. I decided I wanted a shorter, easier-to-say N-number than N747DC.
• March 30, 2002 - Having just moved, I had to start from scratch with the new garage. It was a disaster...I cleaned it up, brought in the workbenches, set up my tools, etc. Still debating about what to do with the compressor.
• April 6, 2002 -- Shop ready for the wing jig
• April 7, 2002 -- Put up wing jig post (woop-de-doo)

Spars

• May 1, 2002 -- The wing kit arrived!
• May 2, 2002 -- Began countersinking the right spar
• May 3, 2002 -- Finished countersinking, began riveting nutplates
• May 4, 2002 -- Finished installing tank and inspection panel nutplates on spars; Fabricated the tiedown spacers
• May 5, 2002 -- Finished tiedown bracket spacers; Began drilling tiedown brackets
• May 6, 2002 -- Drilled and countersunk tiedown brackets and spacers for nutplates
• May 7, 2002 -- Worked on rear spar components
• May 8, 2002 -- Finished preparing spar components
• May 9, 2002 -- Finished the tiedown and aileron bellcrank brackets; Prepped and primed the rear spars
• May 12, 2002 -- Finished the rear spars

Ribs

• May 12, 2002 - Began deburring the ribs
• May 13, 2002 -- Prepared the ribs
• May 14, 2002 -- More rib prep
• May 17, 2002 -- A few more days of rib prep
• May 19, 2002 -- Finished flanging and fluting
• May 28, 2002 - Deburred the left main rib conduit holes

Right Wing

• May 19, 2002 -- Drilled the skeleton
• May 21, 2002 -- Finished deburring the skeleton
• May 22, 2002 -- Drilled conduit holes; Ready to prime the ribs
• May 24, 2002 -- Prepped and primed right wing ribs; started riveting right wing skeleton
• May 25, 2002 -- Finished riveting the rear spar
• May 26-27, 2002 -- Riveted the ribs to the front spar
• May 28, 2002 -- Drilled out some bad rib-to-spar rivets
• May 29, 2002 -- Re-riveted the skeleton; hung the skeleton on the stand
• May 30, 2002 -- Drilled the right wing skins to the skeleton
• June 1, 2002 -- Assembled and drilled the leading edge
• June 13, 2002 -- Deburring and dimpling
• June 14-20, 2002 -- Deburring and dimpling galore
• June 21, 2002 -- Leading edge skin is ready
• June 22, 2002 -- Primed leading edge ribs
• June 23, 2002 -- Completed leading edge
• June 24, 2002 -- Installed the leading edge landing light
• June 26, 2002 -- Riveted the leading edge to the wing; Made the "scarf joint"
• July 11, 2002 -- Riveted the inboard top skin on
• July 12, 2002 -- Finished riveting the top skins; Constructed a castering wing cradle/dolly; Moved the wing into the cradle
• July 14, 2002 -- Ran electrical wire conduit
• July 15, 2002 -- Drilled & deburred gap seals & aileron brackets
• July 17, 2002 -- Prepped & primed gap seals & aileron brackets
• July 22, 2002 -- Upgraded the 55-watt landing light bulbs to 100-watt
• August 11, 2002 -- Deburred and dimpled bottom skins
• August 15, 2002 -- Finished prepping bottom skins
• August 16, 2002 -- Began riveting bottom inboard skin
• August 20, 2002 -- Finished riveting bottom inboard skin
• August 25, 2002 -- Prepared the bottom outboard skin for riveting
• August 27, 2002 -- Almost done riveting bottom outboard skin
• August 28, 2002 -- FINISHED SKINNING THE RIGHT WING
• August 29, 2002 -- Mounted the aileron bellcrank
• September 1, 2002 -- Installed inspection hole cover plates
• September 2, 2002 -- Mounted and rigged the aileron
• September 5, 2002 -- Finished mounting the right flap

Right Fuel Tank

• June 2, 2002 -- Drilled the fuel tank Z brackets
• June 5, 2002 -- Re-drilled the fuel tank Z brackets
• June 6, 2002 -- More fuel tank work
• June 7, 2002 -- Fabricated & drilled tank stiffeners; Began fabricating tank attach angle
• June 8, 2002 -- Lots of random fuel tank prep
• June 9, 2002 -- Almost done preparing the right fuel tank
• June 10, 2002 -- Final preparation before sealing the tank
• June 11, 2002 -- Riveted & sealed the stiffeners & drain
• June 21, 2002 -- Riveted & sealed the filler ring and tooling hole cover plate
• June 27, 2002 -- Tested flop tube range; fabricated anti hang-up retainer strip
• July 4, 2002 -- Began sealing & riveting tank ribs
• July 6, 2002 -- Got two more ribs done, two to go
• July 7, 2002 -- Finished interior and inboard ribs; Installed capacitive fuel sender and vent line
• July 8, 2002 -- Installed attach angle and flop tube; Sealed & riveted the end rib
• July 9, 2002 -- COMPLETED THE RIGHT FUEL TANK
• July 10, 2002 -- Leak tested the tank, no leaks

Left Wing

• July 14, 2002 -- Prepped and primed ribs; Clecoed leading edge together
• July 15, 2002 -- Riveted skeleton together; Hung wing on jig; Drilled skins
• July 16, 2002 -- Trekked out to A/C Spruce for primer; Positioned leading edge joint plate
• July 17, 2002 -- Drilled the leading edge and joint plate
• July 18, 2002 -- Leading edge work
• July 19, 2002 -- Prepped & primed leading edge ribs; Riveted leading edge top
• July 20, 2002 -- Finished riveting leading edge
• July 22, 2002 -- Began mounting the Gretz Aero heated pitot tube
• July 24, 2002 -- Drilled pitot mounting bracket; Countersunk skin to spar holes
• July 25, 2002 -- Finished countersinking spar rivet holes
• July 27, 2002 -- Installed the leading edge landing light (minus the lens)
• July 28, 2002 -- Finished the leading edge light; Deburred the skeleton; Installed the leading edge (skin-spar rivets); Dimpled the skeleton top side
• August 4, 2002 -- Finished riveting the leading edge onto the spar; Deburred and dimpled wing skins
• August 5, 2002 -- Finished dimpling top wing skins; Spot-primed countersunk flange holes; Made scarf joint
• August 6, 2002 -- Riveted the top skins on
• August 7, 2002 -- Squeezed remaining top skin rivets; Moved the wing into the cradle; Drilled brace and gap seal
• August 8, 2002 -- Deburred, prepped, & primed the gap seal, flap brace, hinge brackets
• August 9, 2002 -- Riveted the hinge brackets, gap seal, and flap brace
• August 11, 2002 -- Deburred and dimpled bottom skins
• August 15, 2002 -- Installed grommets and ran conduit; Ready to rivet bottom skins
• August 25, 2002 -- Installed the pitot tube line and fittings
• September 1, 2002 -- Began riveting the inboard bottom skin; Installed the aileron bellcrank
• September 2, 2002 -- Tested pitot tube current draw; Finished riveting the inboard bottom skin
• September 3, 2002 -- FINISHED SKINNING THE LEFT WING; Rigged the left aileron; Drilled the flap hinge to the wing
• September 4, 2002 -- Finished mounting the left flap

Left Fuel Tank

• July 17, 2002 -- Drilled Z brackets; Clecoed tank together; Cut stiffeners
• July 18, 2002 -- Finished Z brackets; Drilled tank to spar
• July 19, 2002 -- Prepped & primed Z brackets; Rounded & deburred stiffeners; Initial cut attach angle
• July 21, 2002 -- Drilled the skin to ribs and baffle; Drilled the filler ring and drain; Deburred & dimpled the stiffeners and ribs
• July 24, 2002 -- Deburred tank skin
• July 25, 2002 -- Dimpled the tank skin; Countersunk the filler ring; Countersunk skin-to-baffle holes
• July 26, 2002 -- Scuffed components; Fabricated "trap door"; Cut the attach angle; Fabricated vent line retainer & anti hang-up strip; Drilled fuel level sender holes
• July 27, 2002 -- Installed nutplates on capacitive fuel senders; Drilled BNC & vent line fitting holes
• July 29, 2002 -- Sealed & riveted the stiffeners, filler ring, & drain flange; Finished attach angle; Fuel tank wiring
• July 30, 2002 -- Sealed & riveted two ribs
• August 1, 2002 -- Sealed & riveted 3 remaining interior ribs; Drilled attach angle & reinforcement plates; Trimmed capacitive plates
• August 2, 2002 -- Sealed & riveted the end ribs & attach angle; Installed the vent line
• August 3, 2002 -- Installed and wired the capacitor plates
• August 4, 2002 -- COMPLETED THE LEFT FUEL TANK
• August 5, 2002 -- Leak tested the tank, no leaks; Installed the tank on the wing

Ailerons

• August 8, 2002 -- Cut the aileron skin stiffeners
• August 9, 2002 -- Shaped, drilled, deburred, dimpled, primed the stiffeners
• August 11, 2002 -- Dimpled, riveted stiffeners; Assembled/drilled left aileron
• August 12, 2002 -- Assembled/drilled/deburred right aileron
• August 15, 2002 -- More drilling out, countersinking, dimpling, etc.
• August 18, 2002 -- Prepped and primed aileron skeleton parts; Countersunk and dimpled
• August 19, 2002 -- Finished deburring/dimpling/filing aileron skins
• August 21, 2002 -- COMPLETED THE AILERONS
• August 26, 2002 -- Constructed the short aileron pushrods
• August 30, 2002 -- COMPLETED ALL PUSHRODS

Flaps

• August 22, 2002 -- Drilled the left flap
• August 23, 2002 -- Finished drilling and deburring the left flap
• August 24, 2002 -- Dimpled the left flap components; Drilled the right flap
• August 25, 2002 -- Deburred and dimpled the right flap components
• August 26, 2002 -- Finished dimpling the second skin
• August 28, 2002 -- Prepped and primed flap components; Built V-block jig; Began riveting flaps
• August 29, 2002 -- COMPLETED THE LEFT FLAP
• August 30, 2002 -- COMPLETED THE RIGHT FLAP

Fuselage

Order, Arrival, Unpacking, Inventory

• March 29, 2002 - Faxed in the order for the fuselage and finish kits! Woohoo!
• April 5, 2002 - Got confirmation from Van's, estimated ship date is June 10.
• June 11, 2002 -- Riveted & sealed the stiffeners & drain
• June 18, 2002 -- The fuselage kit arrived!
• September 5, 2002 -- Unpacked the fuselage components
• September 6, 2002 -- Inventoried fuselage components
• September 7, 2002 -- Inventoried & organized fuselage hardware

Firewall

• September 8, 2002 -- Fabricated firewall angles; Clecoed firewall together
• September 9, 2002 -- Drilled firewall components
• September 10, 2002 -- Finished drilling firewall; Deburred and countersunk firewall components
• September 12, 2002 -- Deburred firewall; Prepped & primed firewall components
• September 13, 2002 -- COMPLETED THE FIREWALL (minus the recess)

Bulkheads

• September 8, 2002 -- Seamed & fluted bulkheads
• September 14, 2002 -- Worked on the F-704 center section bulkhead
• September 15, 2002 -- Almost done with the F-704 center section bulkhead
• September 16, 2002 -- Completed the F-704 bulkhead; Began constructing the F-705 bulkhead
• September 17, 2002 -- Worked on the F-705 bulkhead
• September 18, 2002 -- Drilled the flap bushing blocks
• September 25, 2002 -- Tinkered with the aft bulkheads
• September 26, 2002 -- Finished drilling the F-705 seat back braces; Fabricated aft bulkhead components
• September 27, 2002 -- All fuselage bulkheads ready to be primed and riveted
• September 29, 2002 -- COMPLETED ALL BULKHEADS

Longerons & Aft Fuselage

• September 30, 2002 -- Cut the longerons
• October 1, 2002 -- Bent the longerons; Drilled the aft canopy decks
• October 2, 2002 -- Completed the longerons; Worked on J-channel stringers
• October 3, 2002 -- Completed J-channels; Drilled tailwheel spring mount to bulkheads; Aft fuselage ready for drilling
• October 4, 2002 -- Drilled tailwheel spring to mount; Finished drilling the aft fuselage
• October 5, 2002 -- Disassembled aft fuselage; Deburring and dimpling galore
• October 6, 2002 -- Deburred & dimpled; Riveted tailcone skin to bulkheads
• October 7, 2002 -- Finished dimpling; Clecoed aft fuselage back together for riveting
• October 11, 2002 -- Began riveting aft fuselage
• October 13, 2002 -- More riveting
• October 14, 2002 -- More riveting
• October 23, 2002 -- More riveting...a little at a time
• October 25, 2002 -- Finally finished riveting the aft fuselage (for now)
• October 28, 2002 -- Marked the longerons for notching; Revamping the garage for more space

Center Fuselage

• October 9, 2002 -- Fabricated some spacers and shims
• October 11, 2002 -- Modified seat ribs
• October 12, 2002 -- Constructed and drilled center fuselage
• October 13, 2002 -- Deburrred most of the skeleton
• October 15, 2002 -- Finished edge prep and skeleton deburring/dimpling
• October 16, 2002 -- Deburred and started dimpling the bottom skin
• October 17, 2002 -- Dimpled the bottom skin
• October 24, 2002 -- Prepped & primed the seat & baggage ribs; began assembling center fuselage
• October 25, 2002 -- Riveted the seat ribs to the F-704 bulkhead
• October 26, 2002 -- Finished riveting the center fuselage skeleton; Fluted outboard seat ribs
• October 27, 2002 -- Riveted the center fuselage skin; Drilled the seat & baggage skins
• October 30, 2002 -- Cut the notches in the longerons; Added the forward half of F-704
• October 31, 2002 -- Joined the center & aft fuselage; Worked on the side skins
• November 1, 2002 -- Side skins in place; Drilled longerons

Forward Fuselage

• November 2, 2002 -- Finished drilling longerons & all bulkheads; Mounted and drilled the firewall
• November 3, 2002 -- Fabricated strips & clips; Drilled auxiliary longerons
• November 4, 2002 -- Drilled skin stiffeners & clips; Drilled F-704 straps; Fabricated lower longerons
• November 5, 2002 -- Finished fabricating and twisting lower longerons
• November 6, 2002 -- Drilled lower longerons; Fabricated & drilled gussets; Fit forward bulkheads
• November 7, 2002 -- Wavered about using F-7101s
• November 9, 2002 -- Trimmed & drilled F-902 bulkheads; Fabricated forward fuel tank attach hardware
• November 10, 2002 -- Borrowed more clecos
• November 11, 2002 -- Drilled F-7101s & forward brackets
• November 12, 2002 -- Constructed the brake pedals
• November 13, 2002 -- Countersunk brake pedal components; Drilled & cut rudder pedal bushings
• November 14, 2002 -- Assembled brake pedals & rudder pedals
• November 15, 2002 -- Drilled center floor stiffeners
• November 16, 2002 -- Drilled baggage bulkheads; Finished drilling floor stiffeners; Drilled rudder pedal adjustment holes

Preparation and Riveting

• November 17, 2002 -- Disassembled, deburred, countersunk, dimpled forward fuselage
• November 18, 2002 -- More of the same...firewall is done & side skins are off
• November 19, 2002 -- Deburred center fuselage; Installed outboard seat ribs
• November 20, 2002 -- Deburring, dimpling, countersinking
• November 21, 2002 -- Finished deburring & countersinking longerons; Started side skin prep
• November 22, 2002 -- Prepped & primed everything; Deburred & began dimpling side skins
• November 23, 2002 -- Dimpled/countersunk F-705; Bolts in F-704; Dimpled side skins; Reassembled fuselage
• November 24, 2002 -- Finished assembly; Began riveting
• November 25, 2002 -- Began riveting the forward fuselage
• November 26, 2002 -- More riveting
• December 2, 2002 -- Riveted the right side baggage area
• December 3, 2002 -- Installed blind rivets; Gusset fabrication
• December 4, 2002 -- Finished riveting the center fuselage & F-706 joint
• December 5, 2002 -- TIPPED THE CANOE!
• December 6, 2002 -- Finished aft bulkhead riveting; Built false spars & legs; Fuselage is on legs!
• December 7, 2002 -- Drilled the aft deck
• December 8, 2002 -- Riveted the aft deck; Drilled various gussets
• December 9, 2002 -- Riveted gussets & side rails, etc.

Top Skins, Cabin, Seats

• December 10, 2002 -- Drilled aft top skins
• December 11, 2002 -- Riveted interior baggage skins
• December 12, 2002 -- Finished baggage floors; Drilled lower baggage bulkhead
• December 13, 2002 -- Trimmed and drilled upper baggage bulkhead; Installed nutplates
• December 14, 2002 -- Finished baggage bulkheads; Started working on seat backs
• December 15, 2002 -- Finished aft seat skins
• December 16, 2002 -- Finished the tunnel cover & seat skins; Fabricated seat back braces
• December 17, 2002 -- Constructed the seat backs
• December 18, 2002 -- Finished the seat backs; Worked on cabin cover details
• December 19, 2002 -- Finished forward cabin cover
• December 20, 2002 -- Installed flap actuator system & housing

Wing Mating, Plumbing, etc.

• December 26, 2002 -- Studied plans & made wing mating checklist
• December 27, 2002 -- Trimmed rear wing spars; Installed control column & sticks
• December 28, 2002 -- Built a sawhorse for the fuselage, removed legs
• December 29, 2002 -- Fabricated the flap pushrods
• December 31, 2002 -- Removed top skins; Installed rudder cables; Rearranged the shop for wing mating
• January 1, 2003 -- Mated the right wing
• January 2, 2003 -- BOTH WINGS MATED!
• January 3, 2003 -- Rigged the ailerons & stick; Rigged the right flap
• January 4, 2003 -- Rigged the left flap; Fabricated tank-to-fuselage vent tubing
• January 5, 2003 -- Routed fuel supply tubing; Finished flaps; Drilled left wing root fairing
• January 6, 2003 -- Drilled right wing root fairing; Routed right fuel vent line
• January 7, 2003 -- Routed left fuel vent line; Removed right wing
• February 11, 2003 -- Drilled and countersunk nutplate rivet holes for the wing root fairings

Mounting Tail Surfaces

• January 7, 2003 -- Re-rigged elevators to horizontal stabilizer
• January 9, 2003 -- Random deburring & dimpling; Installed the HS on the fuselage
• January 10, 2003 -- Prepped & primed a bunch of stuff; Made & rigged aft elevator pushrod
• January 11, 2003 -- Attached the VS to the fuselage
• January 12, 2003 -- Finishing mounting the VS; Rigged the rudder
• January 13, 2003 -- Removed tail surfaces from fuselage

Aileron Trim, AFP Fuel Pump, Cabin Frame, Front Deck, Paint, etc., etc.

• January 14, 2003 -- Various stuff; Worked on electric aileron trim system
• January 15, 2003 -- Started the Airflow Performance fuel pump installation
• January 16, 2003 -- More progress on the AFP pump installation
• January 17, 2003 -- Worked on the tip-up canopy cabin frame
• January 18, 2003 -- Installed brake pedals & master cylinders; Fabricated fuel vent fittings; Deburred & dimpled top skin
• January 19, 2003 -- More cabin frame work; Played around with the panel & sub-panel
• January 20, 2003 -- Finished Airflow Performance pump & filter installation
• January 21, 2003 -- Finished installing fuel lines at the selector valve
• January 22, 2003 -- Worked on some miscellaneous loose ends
• January 23, 2003 -- Bought interior paint, drilled F-704 side covers
• January 24, 2003 -- Worked on the front deck
• January 25, 2003 -- Painted interior parts; Assembled & skinned the front deck
• January 26, 2003 -- Front deck work
• January 27, 2003 -- More paint decisions; Front deck work; Cabin frame work
• January 28, 2003 -- Riveted side covers; More cabin frame work
• January 29, 2003 -- Finished drilling the cabin frame
• January 30, 2003 -- Stripped old paint from panels; Prepped fuselage interior
• January 31, 2003 -- Primed the interior
• February 1, 2003 -- Painted the interior (most of it)
• February 3, 2003 -- Paint prep; "Finished" the interior paint
• February 4, 2003 -- Unmasking
• February 5, 2003 -- Garage back to normal; Deburring & countersinking the cabin frame
• February 6, 2003 -- Finished riveting the cabin frame
• February 7, 2003 -- Finished the cabin frame
• February 8, 2003 -- Fabricated an extended instrument panel
• February 9, 2003 -- Modified the left panel rib; Began "final" instrument panel layout; Fabricated rudder cable fairings
• February 10, 2003 -- Tapped the cabin frame screw holes; Ran the static tubing
• February 12, 2003 -- Finished the static system installation
• February 13, 2003 -- Discovered interference between the seats and the cabin frame
• February 14, 2003 -- Front deck work; Drilled NACA vent inlets
• February 15, 2003 -- Finished the panel rib mod; Riveted forward deck rails; Drilled panel attachments
• February 16, 2003 -- Finished the instrument panel attachments

Finish Kit

• March 29, 2002 - Faxed in the order for the fuselage and finish kits! Woohoo!
• April 5, 2002 - Got confirmation from Van's, estimated ship date is June 10.
• June 18, 2002 -- The finish kit arrived!
• December 29, 2002 -- Unpacked the finish kit

Canopy

• February 16, 2003 -- Canopy component prep and fabrication
• February 17, 2003 -- Fabricated more canopy components
• February 18, 2003 -- More canopy fabrication; Working on the latch slots
• February 19, 2003 -- Cut the canopy latch lever slots
• February 20, 2003 -- Finished the latch lever slots; Drilled the canopy hinge blocks; Fabricated the side latch lever mechanism
• February 23, 2003 -- Finished the latch lever; Began working on the canopy frame
• February 24, 2003 -- Drilling and fitting the canopy frame
• February 25, 2003 -- Fitting the canopy frame
• February 27, 2003 -- More canopy frame fitting; Installed the aft latch weldment
• March 1, 2003 -- Finished the side/lower canopy latch mechanism
• March 2, 2003 -- Painted the side latch components; More canopy frame fitting
• March 3, 2003 -- Resolved cabin frame/seat brace interference issue
• March 5, 2003 -- Riveted the canopy frame; Began drilling the hinges
• March 6, 2003 -- Drilled the canopy frame hinges
• March 7, 2003 -- Worked on the aft frame channels
• March 8, 2003 -- More canopy frame work
• March 9, 2003 -- Almost done with the canopy frame
• March 10, 2003 -- Riveted the canopy frame together
• March 11, 2003 -- Got the canopy out into the garage
• March 12, 2003 -- Started cutting the canopy
• March 13, 2003 -- Hooked up the Battery Tender
• March 16, 2003 -- Finished initially trimming the canopy
• March 17, 2003 -- Fitting the canopy to the fuselage
• March 19, 2003 -- Trimmed and refit the canopy
• March 20, 2003 -- Trimmed and refit the canopy
• March 21, 2003 -- Finishing touches before making the big cut
• March 22, 2003 -- MADE THE BIG CUT
• March 24, 2003 -- More canopy frame work
• March 25, 2003 -- More trimming and fitting
• March 26, 2003 -- Trimmed the sides; Started trimming and fitting the slots/ears
• March 28, 2003 -- Trimming and fitting the canopy skin slots
• March 29, 2003 -- Finished trimming the forward canopy bubble
• March 30, 2003 -- Trimmed and fit the rear window
• March 31, 2003 -- Laid out the rear window screw hole pattern
• April 1, 2003 -- Played around with drilling plastic; drilled pilot holes in top aft skin
• April 5, 2003 -- Finished drilling the canopy frame
• April 6, 2003 -- Drilled the canopy bubble to the frame
• April 7, 2003 -- Enlarged screw holes in the canopy; Finished edges
• April 8, 2003 -- Drilled the rear window
• April 9, 2003 -- Trimmed the rear window front edge
• April 12, 2003 -- Riveted the rear bow together; Began working on the canopy reinforcement kit
• April 13, 2003 -- Worked on the canopy reinforcement kit
• April 15, 2003 -- Began drilling the canopy reinforcement braces
• April 16, 2003 -- Finished the canopy reinforcement; Countersunk & dimpled the canopy frame
• April 18, 2003 -- Finished the rear window front edge; Enlarged & deburred roll bar screw holes
• April 19, 2003 -- Countersunk & enlarged the rear window screw holes; Prepared the final trim
• April 20, 2003 -- FINISHED THE PLEXIGLAS
• May 2, 2003 -- Tapped the screw holes in the roll bar
• November 26, 2003 -- Used kerosene to clean masking tape residue off canopy
• November 29, 2003 -- Started fitting to resolve canopy skin joint interference
• November 30, 2003 -- Resolved front skin joint interference; Fabricated gas strut mounts
• December 2, 2003 -- Installed gas struts
• December 3, 2003 -- Cleaned masking tape residue off canopy edges
• December 5, 2003 -- Fabricated side skirts; Painted gas strut mounting hardware
• December 6, 2003 -- Pre-drilled side skirt rivet holes
• December 8, 2003 -- Drilled side skirts to canopy
• December 10, 2003 -- Riveted canopy skirts to frame
• December 11, 2003 -- Fabricated hold-down clips
• December 12, 2003 -- Finished riveting canopy frame
• December 13, 2003 -- Painted the canopy frame
• December 14, 2003 -- Canopy and rear window fitting

Engine Mount & Landing Gear

• January 12, 2003 -- Trimmed fuselage for landing gear legs; Drilled & bolted the engine mount to the fuselage
• February 6, 2003 -- Repacked the wheel bearings; Assembled the tires, tubes, and wheels.
• April 3, 2003 -- Finished drilling engine mount holes in firewall
• April 4, 2003 -- Assembled landing gear brake flanges
• April 9, 2003 -- Began installing main landing gear
• April 11, 2003 -- ROLLING ON LANDING GEAR

Other Finishing Work

• April 17, 2003 -- Random finishing work
• May 4, 2003 -- Sealed and riveted vent inlets
• May 8, 2003 -- Fabricated the forward elevator pushrod

Engine, Firewall Forward, Propeller

• December 10, 2002 - Sent a deposit to AeroSport Power for an overhauled Lycoming IO-360-A1B6
• February 28, 2003 -- Fabricated the Odyssey PC680 battery box
• March 1, 2003 -- Painted & riveted the battery box
• May 5, 2003 -- The firewall forward kit arrived!
• May 11, 2003 -- Installed the battery & starter contactors; Installed the brake reservoir
• May 16, 2003 -- Installed firewall fittings for AFP purge valve and fuel supply
• May 18, 2003 -- Fabricated copper contactor bars; Riveted recess; Installed heat bypass box; Set up transducer manifold
• May 19, 2003 -- Installed the AFP purge valve return line and tee
• May 20, 2003 -- Fuel flow transducer plumbing
• May 21, 2003 -- Worked out the throttle quadrant; Installed the Matco parking brake valve
• May 30, 2003 -- Installed nutplates and cushioned clamps for hoses on firewall
• June 10, 2003 - The engine shipped from AeroSport Power
• June 20, 2003 -- The engine is here!
• June 25, 2003 -- Borrowed an engine hoist
• June 27, 2003 -- The propeller is here!
• July 12, 2003 -- HUNG THE ENGINE!
• July 20, 2003 -- Installed the alternator; Installed various hoses & fittings
• July 21, 2003 -- Deliberated about the AFP control cable setup; Installed the left brake line
• July 22, 2003 -- Installed the prop governor; Installed the exhaust; Various firewall forward gotchas
• July 27, 2003 -- Covered the vacuum pad; Various wiring
• July 28, 2003 -- Installed left mag harness; Toyed with baffling; Resolved AFP control cable routing plan
• July 29, 2003 -- Finished manifold pressure tubing; Fabricated right brake line
• July 30, 2003 -- Drilled the firewall for the LSE coil wires
• July 31, 2003 -- Installed the LightSpeed coils on the engine
• August 3, 2003 -- Messed with the FAB; Installed the heat muff (twice)
• August 12, 2003 -- Replaced rocker box cover gaskets; Finished shaping/drilling prop spinner bulkhead
• August 13, 2003 -- Finished spinner bulkhead; Installed the propeller
• August 25, 2003 -- Finished riveting firewall hinges; Installed exhaust hangers
• August 29, 2003 -- Fabricated throttle quadrant cable bulkhead
• August 30, 2003 -- Control cable madness
• September 4, 2003 -- More control cable madness
• September 22, 2003 -- Fabricated throttle bulkhead bracket
• September 23, 2003 -- Finished throttle & prop cable installation
• September 24, 2003 -- Routed the mixture cable
• September 26, 2003 -- Finished mixture cable bulkhead
• September 27, 2003 -- Drilled & safetied mixture cable bulkhead bolts
• October 21, 2003 -- Installed the AFP purge valve control cable
• October 23, 2003 -- Re-routed prop cable
• October 25, 2003 -- Secured wires; Tightened fittings; Calculated hose lengths; Relocated heat exchanger
• November 1, 2003 -- Installed AFP purge valve hose; Installed various terminal boots
• November 2, 2003 -- Tinkered with the FAB; Completed the heat system
• November 3, 2003 -- Resolved the oil cooler hose/fitting issues
• November 5, 2003 -- Installed the oil cooler; Fabricated new LightSpeed coil bracket
• November 6, 2003 -- Tweaked the LightSpeed coil bracket; Replenished preservative oil
• November 8, 2003 -- Phased & wired the LightSpeed coils
• November 14, 2003 -- Replaced dehydrator plugs; Played with breather hose
• November 15, 2003 -- More fun with 5/8" tubing
• November 18, 2003 -- Sugar-filled fun
• November 19, 2003 -- Finished the breather tube
• November 21, 2003 -- Ground strap; Fuel pump overflow tube; Safety wiring stuff
• November 25, 2003 -- Secured governor oil hose
• November 29, 2003 -- Used Mil-Spec tie wrap gun to replace all FWF tie wraps
• December 13, 2003 -- Safety wired the propeller
• December 18, 2003 -- Setting up the AFP alternate air duct/ram air

Systems, Electrical, Panel, Instruments, etc

• December 25, 2002 -- Began formalizing the electrical system design
• May 4, 2003 -- Measured avionics wiring runs
• May 7, 2003 -- The ACS2002 arrived!
• May 22, 2003 -- Finished cabin fuel lines; installed brake lines; worked on flap position sensor
• May 23, 2003 -- Remade reservoir supply lines; finished flap position sensor
• May 24, 2003 -- Finished throttle quadrant installation
• May 25, 2003 -- Fabricated strobe power supply mounting brackets
• May 26, 2003 -- Trimmed the sticks; Started dabbling with wiring
• May 27, 2003 -- Got the ACS2002 capacitive fuel sender adapters
• May 28, 2003 -- Installed the diode on the starter contactor
• May 29, 2003 -- Protected static tubing; Worked on throttle quadrant clevises and panel pass-through
• May 31, 2003 -- Installed ground block, voltage regulator, & ANL limiter base
• June 1, 2003 -- Tech counselor visit; Worked on battery cable
• June 2, 2003 -- Installed electrical system components
• June 3, 2003 -- Installed the ACK ELT; Tested the flap relay circuit
• June 4, 2003 -- Installed a baggage floor compartment; Ran extra wiring conduit
• June 5, 2003 -- Got my custom stick grips
• June 6, 2003 -- Finished the baggage floor compartment
• June 7, 2003 -- Lots of wiring progress
• June 8, 2003 -- More electrical system planning; Installed stick function terminal block
• June 10, 2003 -- Installed trim & flap relays
• June 11, 2003 -- Wired the stick grip
• June 13, 2003 -- Cut the avionics hole in the panel
• June 14, 2003 -- More panel cutting
• June 15, 2003 -- Finished ACS2002 cutout; Drilled panel for switches; Began installing radio trays
• June 16, 2003 -- Riveted angles to panel; Worked on radio tray support
• June 17, 2003 -- Finished radio tray support; Riveted center sub-panel; More panel work
• June 18, 2003 -- Instrument knob cutouts; Passenger vent and overlay
• June 21, 2003 -- Installed light dimmer circuit, LightSpeed brain box
• June 22, 2003 -- Control cable installation
• June 23, 2003 -- Locating capacitive sender adapters; Temporarily installed the avionics wiring harness
• June 24, 2003 -- Finished panel construction; Getting ready to paint the panel
• June 25, 2003 -- Sub-panel work; Stick wiring work
• June 27, 2003 -- Painted the instrument panel
• June 28, 2003 -- Second coat of paint; Aft fuselage wiring/planning
• June 29, 2003 -- Changed trim relay mounts
• June 30, 2003 -- Installed harnesses on radio trays
• July 1, 2003 -- Assembled the radio stack and instrument panel
• July 2, 2003 -- Relay mounting changes
• July 3, 2003 -- Installed cables, vent tubing, stereo jacks; Routed fuel sender wires; Wiring harness work; Finished aileron trim
• July 4, 2003 -- Began running wires and punching snap bushing holes
• July 5, 2003 -- Fun with wiring
• July 6, 2003 -- More wiring madness; Fired up the avionics
• July 7, 2003 -- Did I mention I've been wiring?
• July 8, 2003 -- Wiring du jour; On landing gear for good!
• July 9, 2003 -- Would you like fries with your wiring? Received the Dynon EFIS-D10
• July 10, 2003 -- Why ring? Wiring.
• July 13, 2003 -- Wiring; Install the VS; LightSpeed prep
• July 14, 2003 -- Finished wiring the trim & flap relays, stick
• July 15, 2003 -- Wired headset/mic jacks; Tested radios; Finished position sensor wiring
• July 16, 2003 -- Extended & rewired the stick to the terminal strip
• July 17, 2003 -- Strobe power supply wiring
• July 18, 2003 -- Wired the Dynon harness
• July 19, 2003 -- Audio input wiring, etc.
• July 20, 2003 -- Hooked up the strobe wires
• July 27, 2003 -- Sensor wiring; Canopy map light connector wiring
• July 29, 2003 -- Drilled aft bulkheads for tail light wire run
• July 31, 2003 -- Fun with avionics wiring
• August 1, 2003 -- Finished the audio panel entertainment enhancements
• August 2, 2003 -- LightSpeed wires, magneto wire, future autopilot connector, etc.
• August 3, 2003 -- Started on the alternator battery wire; ACS2002 amp sensor mounting
• August 6, 2003 -- Fabricated support for the Dynon remote compass
• August 9, 2003 -- Finished wiring Dynon remote compass; More ACS2002 wiring; Alterator battery lead
• August 10, 2003 -- Finished wiring the ACS2002
• August 12, 2003 -- Updated the Dynon OS
• August 23, 2003 -- Moved the encoder; Worked out the control cable situation
• August 24, 2003 -- Antenna installation & wiring
• August 26, 2003 -- Antenna wiring
• August 27, 2003 -- Securing wire bundles; More antenna wiring
• August 31, 2003 -- Finished GPS antenna wiring; Finished static system
• September 1, 2003 -- Tweaked a portion of the static tubing; Wired the ELT antenna
• September 6, 2003 -- Finished the antenna wire runs; Two-year anniversary of this project
• September 7, 2003 -- Secured all fuselage wire bundles; Installed AFP pump/filter; Installed forward elevator pushrod
• September 25, 2003 -- Finished forward elevator pushrod installation; Installed ELT remote switch; Fabricated cabin frame cover plate
• September 27, 2003 -- Shortened ELT remote wire; Resolved elevator pushrod rubbing
• October 23, 2003 -- Wired & installed the LightSpeed brain box connector
• October 24, 2003 -- Wired the starter
• November 9, 2003 -- More wire securing, terminal boots, etc.
• November 10, 2003 -- Secured encoder wires & static tubing
• December 3, 2003 -- Relocated fuselage wire exits
• December 18, 2003 -- Made the ACS2002 serial cable; Upgraded the ACS2002 firmware

Cowling, Spinner, Baffles

• August 7-8, 2003 -- More work on the propeller spinner bulkhead & doubler
• August 14, 2003 -- Started working on the top cowling
• August 15, 2003 -- Drilled hinges along top of firewall; Trimmed the top cowl aft edge
• August 16, 2003 -- Sanded the top cowl aft edge
• August 17, 2003 -- Drilled the top cowl to the firewall; Trimmed lower cowl landing gear relief holes
• August 18, 2003 -- Fitting the lower cowl
• August 19, 2003 -- Trimming the lower cowl
• August 21, 2003 -- Finished trimming the lower cowl; Sanding and more sanding
• August 22, 2003 -- More sanding; Drilled hinges
• August 23, 2003 -- Finished drilling the cowl hinges
• September 2, 2003 -- Began working on the baffles
• September 5, 2003 -- More side & rear baffle fitting
• September 9, 2003 -- Riveted doublers to side baffles
• September 10, 2003 -- Trimmed side baffles for clearance; Fit top cowl; Built a bench at the hangar
• September 11, 2003 -- Rear baffle work; Removed oil filler
• September 12, 2003 -- Began fitting baffle brackets
• September 13, 2003 -- Baffle work
• September 14, 2003 -- Baffle work
• September 15, 2003 -- Baffle work
• September 16, 2003 -- Baffle work (trimming slowly but surely)
• September 19, 2003 -- Baffle work; Trimmed lower cowl inlets
• September 20, 2003 -- Baffle work; Made initial cutouts in the spinner; Played around with oil door hinge designs
• September 26, 2003 -- More baffle work
• September 30, 2003 -- Started oil cooler installation
• October 13, 2003 -- More oil cooler duct work
• October 14, 2003 -- Oil cooler duct/baffle work
• October 16, 2003 -- Trimmed the duct
• October 17, 2003 -- Finished the oil cooler duct & rear baffle riveting
• October 19, 2003 -- Front baffle bracket work
• October 20, 2003 -- Finished trimming front baffles
• October 25, 2003 -- Countersunk rivet holes on top cowl
• October 26, 2003 -- Trimmed oil door; Countersunk rivet holes on bottom cowl
• October 27, 2003 -- Tinkering with cowl edges for paint clearance
• October 28, 2003 -- Sanded cowl paint clearance
• October 29, 2003 -- Installed invisible oil door hinges
• October 30, 2003 -- Riveted hinges onto top cowl
• October 31, 2003 -- Finished epoxying & riveting cowl hinges
• November 1, 2003 -- Governor hose hole in baffle; Installed heat air flange; Oil door latch cutouts; Drilled latches to oil door
• November 4, 2003 -- Began riveting right front baffles
• November 5, 2003 -- Finished riveting right front baffles
• November 6, 2003 -- Worked on the top cowl inlet ducts
• November 7, 2003 -- Installed nutplates for lower cowl fasteners
• November 9, 2003 -- Started on the top hinge pin clip
• November 10, 2003 -- Finished the top cowl hinge pin clip
• November 26, 2003 -- Fabricated left rear baffle support "strut"
• December 4, 2003 -- Epoxied top cowl ducts in place
• December 18, 2003 -- Cut hole for Airflow Performance alternate air duct/ram air
• December 19, 2003 -- Spinner clearance hole work
• December 21, 2003 -- Drilled the spinner bulkheads; Installed nutplates
• December 26, 2003 -- Cut air filter hole; Riveted front left baffle
• January 2, 2004 -- Spinner gap plate work
• January 3, 2004 -- Finished spinner gap plates; Spinner is done
• January 13, 2004 -- Restructuring the front baffles
• January 14, 2004 -- Rebuilt front baffles, reoriented air filter, etc.
• January 17, 2004 -- Trimmed side baffles to ramps; Laid up inboard ramp extensions
• January 18, 2004 -- Finished trimming baffles for new ramp extensions
• February 4, 2004 -- Made posterboard templates for baffle seals
• February 5, 2004 -- Cut and drilled baffle seals

Wrap-Up

• November 15, 2003 -- Right HS & elevator tip work
• November 16, 2003 -- A little more emp tip work
• November 19, 2003 -- Right elevator tip work
• November 21, 2003 -- Dimpled & countersunk right elevator/HS & tips
• November 22, 2003 -- Left empennage tip work; Installed wing root nutplates on wings
• November 23, 2003 -- Sealed the firewall, etc.
• November 24, 2003 -- Cut front deck access panel holes
• November 25, 2003 -- Fabricated front deck access panel reinforcement rings
• November 26, 2003 -- Re-routed inboard portion of pitot tubing in wing
• December 6, 2003 -- Installed foam end caps in empennage tips
• December 7, 2003 -- Glued backing strips to left elevator tip
• December 12, 2003 -- Riveted left elevator tip
• December 16, 2003 -- Riveted nutplates on tank skin wing root; Prepped wings for mating
• December 17, 2003 -- Getting ready to mate the wings
• December 19, 2003 -- Trimmed the emp fairing; Ran wires through the left wing
• December 20, 2003 -- Mated the wings; Installed OAT sensor; Completed fuel & vent plumbing
• December 21, 2003 -- Started filling the emp tips; Installed & rigged ailerons & flaps
• December 22, 2003 -- Finished rigging; Sanded empennage tips; Wired pitot heat, capacitance senders, landing lights
• December 24, 2003 -- More emp tip work; FAB prep work
• December 28, 2003 -- Fiberglassed emp tip gaps; Installed tail light; Drilled left lower empennage fairing
• December 30, 2003 -- One coat of micro filler; Ram air cable setup
• December 31, 2003 -- Filling elevators & HS tips; Ram air cable; Wing tip hinges
• January 1, 2004 -- Completed pitot tubing run & connections; Empennage fairing work
• January 3, 2004 -- Finished lower empennage fairings
• January 4, 2004 -- Finished intersection fairing; Re-fit wing root fairings
• January 5, 2004 -- Tips, fairings, and fairings, oh my
• January 6, 2004 -- Lower rudder tip, filling and more filling
• January 7, 2004 -- Sanding emp tips; Sanded rear window
• January 8, 2004 -- Rear window work; Fiberglassed remaining emp tips
• January 9, 2004 -- More filler; Trimmed wing root fairings
• January 10, 2004 -- Sanding, glassing, molding
• January 11, 2004 -- Glassing, Filling, sanding, tubing
• January 12, 2004 -- Finished airbox plug, laid up airbox fiberglass
• January 17, 2004 -- Primed over the HS & VS tips
• January 19, 2004 -- Drilled wing tips
• January 20, 2004 -- Tweaked wing tips; Wing tip lighting; Primed elevator tips
• January 21, 2004 -- Wing tip screw holes and nutplates
• January 22, 2004 -- Countersunk wing tip screw holes; Filling & sanding elevators & rudder
• January 23, 2004 -- Finished & rigged elevators; Still filling & sanding rudder
• January 24, 2004 -- Finished elevator trim
• January 25, 2004 -- Calibrated ACS2002 for trim; Finished filling & sanding emp; Primed tailwheel structure
• January 26, 2004 -- Finished rudder; Installed Rocket Steering Link; Wing tip work
• January 27, 2004 -- Various crap; Wing walk
• January 28, 2004 -- Balanced elevators; Installed wing tip antennas; Wired strobes & position lights
• January 29, 2004 -- Started trimming wing tip lenses; Airbox plug #2
• January 30, 2004 -- Finished airbox plug; Initial lay-up
• January 31, 2004 -- Airbox lay-up; Wing tip lenses
• February 1, 2004 -- FINISHED THE AIRBOX
• February 2, 2004 -- FINISHED WIRING; Antenna wiring complete; Fun with EMI
• February 3, 2004 -- Experimented with Dynon EMI; Wing tip lenses; Access panel cover plates
• February 4, 2004 -- Countersunk hinge spacers; Tweaked front deck skin
• February 6, 2004 -- Firewall soundproofing
• February 7, 2004 -- Too much to go into, very productive
• February 8, 2004 -- Canopy fairing & cowl blister
• February 9, 2004 -- Glassing & soundproofing
• February 10, 2004 -- Access covers, baffle seals, canopy fairing
• February 11, 2004 -- Sealed & riveted access panel rings & plates
• February 13, 2004 -- Fiberglassed the ram air inlet
• February 14, 2004 -- Sanding & filling; Checked mag timing; Gapped plugs
• February 15, 2004 -- Sanding & glassing & filling
• February 16, 2004 -- Sanding & filling; Spark plug gapping; Front baffle seal
• February 17, 2004 -- Sanding & filling
• February 18, 2004 -- Sanding & filling; Access panel gaskets done; Front baffle seal work
• February 19, 2004 -- FINISHED CANOPY FAIRING; Cowl work; ELT batteries; Rudder links
• February 20, 2004 -- FINISHED RAM AIR INLET
• February 21, 2004 -- Bled the brakes; Laid up cowl hinge pin hole covers
• February 22, 2004 -- Finished cowl hinge pins & hole covers
• February 23, 2004 -- IFR Check; Riveting top front skin
• February 26, 2004 -- Transition Training
• February 27, 2004 -- Transition Training
• March 1, 2004 -- DONE RIVETING; Installed the canopy
• March 2, 2004 -- Finished canopy latches
• March 3, 2004 -- Brought the engine out of long-term storage
• March 4, 2004 -- Installed front canopy seal
• March 5, 2004 -- Weighed the plane; Calibrated right fuel tank; Fuel flow test
• March 6, 2004 -- STARTED THE ENGINE!
• March 7, 2004 -- PRE-INSPECTION INSPECTION; Calibrated left fuel tank; Tested unusable in right tank
• March 8, 2004 -- Finished weight & balance; Finished fuel testing; Cleaned fuel filter
• March 10, 2004 -- Wrapping up a few final details
• March 12, 2004 -- Installed data plate; Got seat cushions; Wrap-up details
• March 13, 2004 -- Got screws ready; Installed seat belts & shoulder harnesses
• March 14, 2004 -- Cut the carpet; Worked on leg fairings
• March 22, 2004 -- Enhanced Archer antenna ground contact

Phase I

• March 27, 2004 -- AIRWORTHY and AIRBORNE!!!
• April 4, 2004 -- Flying off my hours
• April 5, 2004 -- Phase I stuff
• April 6, 2004 -- More Phase I stuff, oil change, etc.
• April 7, 2004 -- Taking advantage of daylight savings, Travel John, etc.
• April 8, 2004 -- More Phase I stuff
• April 9, 2004 -- COMPLETED PHASE I

Miscellaneous

• July 13, 2002 -- Paul Rosales' 1000-hour BBQ celebration at Rosamond
• August 14, 2002 -- Video of Paul's Landing at SMO; Jen gets to try out an RV-6A cockpit
• September 6, 2002 -- Formation flight with Ron's Skylane
• April 21, 2003 -- TRANSPORTED THE FUSELAGE
• May 13, 2003 -- Riveted the front deck sub-panel sides; More panel layout
• August 12, 2003 -- Mostly riveted the aft top skin on
• August 20, 2003 -- Installed shoulder harness anchors and cables
• September 28, 2003 -- Painted the inside of the top skin; Began riveting the top skin
• September 30, 2003 -- Riveted most of the top aft skin
• October 18, 2003 -- Painted the cabin frame & various other stuff
• October 19, 2003 -- Installed the cabin frame
• October 21, 2003 -- Finished riveting the aft top skin
• November 11, 2003 -- Chiriaco Summit breakfast fly-out; Got the garage ready for the hangar move
• November 12, 2003 -- Moved the wings, benches, tools, etc. to the hangar
• November 13, 2003 -- THE PLANE IS HANGARED!

Here's my instrument panel (before the autopilot was installed; click for a larger image):

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Dan Checkoway ()