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Date: 3/31/1999

Drilled four engine mount holes through firewall. ...

Drilled four engine mount holes through firewall.  Shaped and sanded custom washers for inside of firewall bolts.  Bonded washers with a mill-fiber mixture using engine mount as securing device.  Installed adjuster bolt at rear of fuselage stand and leveled fuselage.

Task Hours: 3

Date: 11/29/1999

Removed all of the upper landing gear mounting brackets...

Removed all of the upper landing gear mounting brackets to have them stripped and powder-coated.  They were spray-painted white by the original owner when he fabricated them.

Task Hours: 1

Date: 11/29/1999

Here is the fuselage after landing gear has been aligned...

Here is the fuselage after landing gear has been aligned, installed and drilled, then removed for powder-coating the parts.

This was the first of three times that I enjoyed installing new landing gear!

Task Hours: 0

Date: 12/5/1999

Began fabricating rudder pedal weldments.

Began fabricating rudder pedal weldments.

Task Hours: 1

Date: 12/11/1999

Fabricated rudder pedal pieces. None of this stuff...

Fabricated rudder pedal pieces.  None of this stuff was pre-made when kit 446 left SH.

 

Task Hours: 2.5

Date: 12/24/1999

Jigged Rudder Pedal pieces together and spot welded...

Jigged Rudder Pedal pieces together and spot welded with my new welder.

 
 

Task Hours: 2

Date: 1/11/2000

Began rough cutting hole for left canopy glass.

After a lot of thinking, I decided to build the new style gull-wing doors for my G1.  I began by rough cutting the hole for the left canopy glass.  Complete details of how the next fifteen log entries were accomplished see my gull-wing doors page. 

 
 

Task Hours: 0.5

Date: 1/12/2000

Trimmed and sanded left side window opening to final...

Trimmed and sanded left side window opening to final size.  Rough-cut right side window opening.

Task Hours: 1

Date: 1/13/2000

Trimmed back 1/2" of the inside laminates on the left...

Trimmed back 1/2" of the inside laminates on the left window opening. Finished trimming the right window opening.  Started trimming the foam back 1/4" for the left window installation.  Marked the inner laminates of the right window opening for trimming.  Drew plan for building-up the door jam area to be like the GII's.

Task Hours: 1

Date: 1/14/2000

Finished trimming foam in both side window openings...

Finished trimming foam in both side window openings.  Laid plexiglass against fuselage and marked cut lines.
Cleaned up huge mess of foam and dust.  Prepared for cutting plexiglass.

Task Hours: 1

Date: 1/15/2000

Cut, fitted and bonded both side windows in place....

Cut, fitted and bonded both side windows in place.  To install the side windows and get the look of the newer planes, I followed the instructions for the optional rear windows.  I used a small laminate trimmer-router to make the step in the outside edge so it would be flush after mounting.  I taped the inside edge in preparation for laminates.  Then I applied sign strip to both sides of both windows and applied a new coat to the windshield when done.  

 

Task Hours: 6

Date: 1/15/2000

This is another view of how flush I was able to fit...

This is another view of how flush I was able to fit the windows.

 
 

Task Hours: 0

Date: 1/15/2000

This is after applying the sign strip.

This is after applying the sign strip.

 

Task Hours: 0

Date: 2/27/2000

I REALIZED I MADE A MISTAKE! I cut the right canopy...

I REALIZED I MADE A MISTAKE!

I cut the right canopy glass opening 1" too low at the bottom.  The top was ok.  I had to painstakingly remove the portion of the glass that was too low, trim the edge to have the same groove, as if I had done it right, then rebuild the inside and outside of the canopy frame.  This has actually taken me about 9 hours worth of work and infinitely more just thinking of how to resolve it.  

Hindsight:  SLOW DOWN......

Task Hours: 9

Date: 3/5/2000

Applied two layer laminate to inside of both canopy...

Applied two layer laminate to inside of both canopy windows.

 

Task Hours: 4


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