Log 37

Monday - Just to record more work from 4 to 11 pm:
Enlarged holes in rear spar of wing, and fuselage bulkhead for larger systems tunnel, installed larger tunnel. Cut out forward tunnel from wing to panel, but will need a second tunnel for air and coax. Cut two holes in panel for (2) fuel lines from fuel selector and system tunnel. Removed selector valve. Two more connectors on Strobe lights finally complete with new pins/connector modified for size (now just need power wires). Cleaned wingtip clearance for aileron counterbalances, a few coats of paint on elevator counterbalances & horizontal to fuselage join. Cut off passenger control stick...will make it removable. Strobe & ELT wire in aft tunnel run (now need COM coax, pitch servo wires & static air run from empennage).

Log 36

Someone asked, when will I finish?? I'm hoping this summer, but you never know. Maybe even early summer.....depends on focus.

Thanks to hang glider pilots like Bill Jensen, Andrey Gusev, Steve Alford, Len Baron, Paul Dees, a few others, my Boeing friends, my other flying friends, I've been moving along.

Sunday June 24th: 

A few years back, I went to the Reno Air Races with no idea I'd work on a glasair project. Bill Jensen and I went to the glasair booth/Jeff Lavelle's pit location, got a free shirt and Jeff signed it. http://www.glasairaviation.com/inthenews/Glasair%20Sets%20New%20Speed%20Record%20At%20Reno%20Air%20Races1.pdf .Jeff's been up to 362 mph, a speed I'll never go, but he's local at Paine Field. Today, he was passing by and stopped to look. He came in and examined my project and looking at everything, said it looks really good from what he can see. My day was made at that point and it was pretty cool to chat with him.

Rodney Tong and Robert Grigson, RV8 and Long EZ owners came by for an inspection. Robert is an expert with the Dynon D180 system I have. We went over things I need to do for retrieving data and hooking up the autopilot servo's. I'll have to modify some pin configurations on the connectors for the NAV and GPS, and add another connector to the wires for the magnetometer. All parts are ordered...not too expensive.

Andrey and other friends came by to help and have dialog for the electrical system overview and a few connections. We did quite a bit of electrical system testing. We spent time with the strobe system and wiring. I've epoxy'd the light covers on the wingtips, cleaned up yesterdays fiberglass on wingtips and a few other items. Added intercom knobs... I'll be moving the plane better tomorrow for first time loading the hangar with two full airplanes.

Log 35 - Wing/Body Join Milestone

June 22, 2012 Marks the wing/body Join.

First, thanks to Jim, Paul Dees, Len Baron and Dan Thomas for joining me for the plan thought up a couple days ago to join the wings to the fuselage! No way I could have done it myself. Everything went smooth. Jim and Dan are experienced airplane builders and all of us work at Boeing. There was some grunting and moaning but we got a plan, thought it out and got everything pinned in place and fastened. WHAT AN ACCOMPLISHMENT! It feels really good to get this done and timing has to be precise as once the wing is in, access is extremely limited in critical areas. It was perfect!!

Wing installed, (2) leading edge (LE) fasteners, (12) shear load fasteners on LE, (2) trailing edge (TE) fasteners.

Also, thanks to Nick Smith for helping to resolve rudder system deflection clearance issue (can be viewed in photos). Thanks to Kurt for Brake system check and other work.

Post wing/body join accomplishments: elevator push rod, trim wheel, cables, springs, electrical for lights, cables, systems tunnel clearance and fastened. Full rudder systems check, rudder deflection check/repair. Fabricated rudder stops, headlight/camera electrical bracket run, headlight mounting bracket, extra fiberglass on wingtip protectors for aileron counterbalance stay out area, and closed foam on systems center tunnel.

Another good couple days. When I find the keys on the shelves somewhere, I can have engine run up milestone, but a few other items to cover first. :)

Sorry to get carried away but over 30 photos added at the end of this album.

Log 34 - Upcoming Milestone, Wing Installation

Took a day off for flight of 2 to Chelan to drop off Steve's 172. He covered fuel but it was only 15 gal round trip, very nice evening flight after work.

Inventoried and prepared for tomorrow's wing join to fuselage. I've written a few people and hoping to have help tomorrow loading the wing to the fuselage. Anybody want to join us for ideas and help tomorrow? Contact me russlfboe at g mail com .

Current: pumped in brake hydraulic fluid, completed more connectors to wing bus bar. May items mostly complete. Sanded on fuselage....cowling parts, dorsal fin... etc. for hours. Went over design with Kurt.

Post 33

A few more days of work: Sized, cut, rosined tunnels on Rib A and wingbox for systems. Connected/set up wires for wing electrical. Have plans for auto pilot servo's and strobe lights. Cleaned shop and organized new shelves. New roller tray for fathers day.

Post 32

Had a couple long days working on cowling seal, electrical, systems tunnels, canopy installation and a few other smaller items. Also did some fit checks and clearances of the cowling with the baffle gap seals. Some work included Brian Jensen and Nick Smith to check the project out and help with a few things. Great progress and planning lately. I hope to stay on a roll.
Again, photos chronological here.

Post 31 - Registration

Just a quick note for another milestone. With a few tries since Dec 2011, I received my registration from the FAA today. It's been a long road but still traveling forward! I also got most of the engine baffling gap seal completed today. It is very custom and takes hours to size, cut, rivet and clean but glad its close to finished.

Photo link here in chronological order.

FAA REGISTRY:

Aircraft Description Serial Number 202 Type Registration Individual Manufacturer Name RUSSELL A GELFAN Certificate Issue Date 06/05/2012 Model GLASAIR

Post 30 - Wing at Paine Field Now

Noting another breakthrough. My wing and almost everything is now at Paine Field. I was able to unload it off the truck myself and get it in. Wish I could weigh it but guessing around 450 lbs. It will be a chore storing and positioning in the hanger with my hangar partner.

Recent: cut plexi, installed and retained with fasteners. Organized.
Next: wires, headlight bracket, baffling finish, wire tunnels, fluidize breaks. On to rest of list.

Post 29

Last 3 days have been very productive. Not lots of fabrication but with ideas and plans to fabricate and a few processes to move forward. Upper cowling access door and door surrounding: hinges, cut/sand/rivet/countersink/supports, heated to shape, refitted... all was good. Head/taxi light located fitted, hole cut and checked. Besides this, Aaron Rinn and Kurt Hartzog have visited and while explaining aspects of the plane, I've taken  some notes, advise and information that will help complete parts of the project. We discussed the brake fluid and system, engine, instruments and all related electrical system. I'm looking forward to some short term work and not too far from installing the wing when I bring it to the hangar. I also have more lower cowling to be sanded and fiberglass checked and cleaned up.

Post 28 - Organizing and starting to Roll Again

Since moving to Paine Field, I've had a cold and the weather turned good for flying. Not always easy to work on the Glasair. Once settled, I seem to roll and get a few things done. Today, Clico'd, located, drilled, countersunk and riveted the access door on. Cut out the hole complete and finished the top 7 Camloc 1/4 turn fasteners. Your welcome to view the last photos. Next, I need to form the door with a heat gun, and cut out lower cowling light and camera locations.

****In case there are any locals reading this, I could always use help and ideas. You can contact me to meet weekday afternoons or any time.

I also found a completed Glasair 1 on Youtube for your enjoyment.