Started front Wheel Fairing per Sect 46A-08 Steps 1-3. Lots of dremel small drum sanding to get good fit front to aft shells.
Tuesday, July 10, 2018
Finish Kit
Nose Wheel Fairing ( 2 hrs )
Started front Wheel Fairing per Sect 46A-08 Steps 1-3. Lots of dremel small drum sanding to get good fit front to aft shells.
Started front Wheel Fairing per Sect 46A-08 Steps 1-3. Lots of dremel small drum sanding to get good fit front to aft shells.
Finish Kit
Main Wheel Fairings completed ( 3 hrs )
Completed nutplates on both Main Wheel Fairings, and Machine C'sunk for all (18) 6-32 and (16) 8-32 screws per Sect 46A-07 Steps 9-11. Finished cutting to size two Standoffs for nose gear #U-1024 per 46A-09 (final smoothing and rounding edges remain).
Completed nutplates on both Main Wheel Fairings, and Machine C'sunk for all (18) 6-32 and (16) 8-32 screws per Sect 46A-07 Steps 9-11. Finished cutting to size two Standoffs for nose gear #U-1024 per 46A-09 (final smoothing and rounding edges remain).
Friday, July 6, 2018
Finish Kit
Wheel Fairing flox ( 2 hrs )
Removed Fairings after flox cured. Relieved they came off relatively easy, except one of four hung up due to excess flox rolling over edge. All 8 surfaces turned out OK, which is relief since essentially positioned blindly. Ground off excess with dremel. Started nutplates per Sect 46A-07 Steps 5-9.
Removed Fairings after flox cured. Relieved they came off relatively easy, except one of four hung up due to excess flox rolling over edge. All 8 surfaces turned out OK, which is relief since essentially positioned blindly. Ground off excess with dremel. Started nutplates per Sect 46A-07 Steps 5-9.
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| RH with Aft Fairing installed. Can see white flox where Bracket interfaces with Fairing |
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| Example result epoxy/flox mix on Fwd Fairing. Smooth area is Bracket contact area. Green is Turtle wax used as mold release. |
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| First nutplate added between Aft and Fwd Fairing shells. Shows Aft contact area on left, and Fwd contact area on right. |
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| RH inner Bracket |
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| RH outer Bracket |
Thursday, July 5, 2018
Finish Kit
Wheel Fairings mounted ( 7 hrs )
Completed 46A-03 for LH Fairing, so proceeded cutting Gear Leg openings per 46A-04. Mounted LH and RH Fairings to Wheel/Leg assemblies. Only small tweaks needed at Gear Legs to insure 1/16" clearance. Marked 5/8" clearance around tire at bottom (this is challenging while laying on floor !). Trimmed off and reattached to confirm good, uniform clearance to tire to complete 46A-06. Final drilled #19 holes in Fairing aligned with Brackets/nutplates. Removed Fairings ...again. Mixed epoxy/flox mix, applied 1/16' - 1/8" thick layer on inside where Brackets contact Fairings per Steps 1-5 at Sect 46A-07. Re-mounted Fairings to "mold" flox mix to internal contour vs flat Brackets. This was very messy and difficult since hard to align and start screws with flox in the way. Persistence paid off. After cures, sure hope they all come off ! (tape layer, Boelube on threads, and Turtle Wax should work)
Completed 46A-03 for LH Fairing, so proceeded cutting Gear Leg openings per 46A-04. Mounted LH and RH Fairings to Wheel/Leg assemblies. Only small tweaks needed at Gear Legs to insure 1/16" clearance. Marked 5/8" clearance around tire at bottom (this is challenging while laying on floor !). Trimmed off and reattached to confirm good, uniform clearance to tire to complete 46A-06. Final drilled #19 holes in Fairing aligned with Brackets/nutplates. Removed Fairings ...again. Mixed epoxy/flox mix, applied 1/16' - 1/8" thick layer on inside where Brackets contact Fairings per Steps 1-5 at Sect 46A-07. Re-mounted Fairings to "mold" flox mix to internal contour vs flat Brackets. This was very messy and difficult since hard to align and start screws with flox in the way. Persistence paid off. After cures, sure hope they all come off ! (tape layer, Boelube on threads, and Turtle Wax should work)
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| Completed LH drilling and cleco'ing |
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| tweaked clearance at Gear Leg and brake line |
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| Super pleased with fit and alignment |
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| floor level showing tire clearance prior marking/trimming for 5/8" clearance all around |
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| final trim to 5/8". (block used to mark & check when installed) |
Tuesday, July 3, 2018
Finish Kit and Avionics
Wheel Fairings & delivery of Instrument Panel ( 3 hrs )
Cont'd assembly of Wheel Fairings per Sect 46A-03 Steps 1-5 for RH side. Will repeat for LH side before continuing with remaining steps. Received from Stein Air the crate with all instrumentation and Panel. Really well packed. Looks great ! Yay....Christmas in July!
Cont'd assembly of Wheel Fairings per Sect 46A-03 Steps 1-5 for RH side. Will repeat for LH side before continuing with remaining steps. Received from Stein Air the crate with all instrumentation and Panel. Really well packed. Looks great ! Yay....Christmas in July!
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| Add caption |
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| top is laser etched with my Panel design |
Sunday, July 1, 2018
Finish Kit
More sanding Wheel Fairings ( 1 hr )
Completed trim to scribe lines for wheel openings per 46A-02. Lots more dust!
Completed trim to scribe lines for wheel openings per 46A-02. Lots more dust!
Saturday, June 30, 2018
Finish Kit
Wheel Fairings ( 4 hrs )
Cont'd working on Wheel Fairings. Riveted 8 nutplates to 4 Brackets per Sect 46A-04 & -05. Then mounted to Main Gear Legs. Started trimming Wheel Fairings per 46A-02, Steps 1-5. Created a ton of fiberglass dust following Van's instructions "remove material that prevents the halves from matching smoothly" and "take time to precision fit wheel fairing halves".
Cont'd working on Wheel Fairings. Riveted 8 nutplates to 4 Brackets per Sect 46A-04 & -05. Then mounted to Main Gear Legs. Started trimming Wheel Fairings per 46A-02, Steps 1-5. Created a ton of fiberglass dust following Van's instructions "remove material that prevents the halves from matching smoothly" and "take time to precision fit wheel fairing halves".
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| Mach C'sunk then riveted on nutplates |
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| Lots of grinding to improve overlap fit. And trim to scribed lines |
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| Only 1 of 2 "done", but progress |
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