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Friday, 14 November 2025

Starting to look like an Airplane...

Slow but satisfying progress.



First door installed.  Starting to look like a finished airplane (kinda).

Working on the doors (silpruf between window and doorframe) and ailerons in parallel.  The temp has gotten cold so doing the door silpruf at home.  On my last tube... which is PERFECT.

Right aileron installed.  Push rod not connected yet.  Balance is spot on with the servo tab installed.  Still need to install the pushrod for the tab.


Getting all the bits together for the fuel vent.  Everything sealed and installed.



New connector for the wing tip nav light / strobe (forgot to take picture).  4 position Deutsch bulkhead connector.

The weak bit of the wing tip broke by the fuel vent, so its coming apart.  Need to strengthen that section.  Easy yet time consuming job.


Flap adjustment for full travel, stops and cable tension.  Works like butter.  So happy and grateful.

Prepping the next door for the silpruf layer between the window and the door.






Right wingtip vent assembly.  New connector for the wingtip light.

Aileron in place, but needs spacers, etc.

One last door to silpruf.




ELT... and ELT woes... and fire extinguisher

Ordered the last two major items I need to complete the build... my ELT and fire extinguisher.

Wanted to get this in before the tariffs come into effect.  Picked them up from my box in Blaine, WA on the weekend. NO TARIFFS!  

However... upon opening the box, the ELT does not appear to be programmed.  And even though I ordered the Canadian version, I appear to have received the USA version.

Emailed Aircraft Spruce... response, please call.  So that is what I did.

I went with the Kannad Integra 406 with integrated GPS unit.  It's more expensive, but simpler wiring and better overall reputation.

Been struggling to determine where to put the fire extinguisher.  Usually most builders mount it on top of the fuel selector tunnel... however I dont have that option because of the header tank.  Will most likely go between the seats attached to the cross bar.  Will have to see.

Fast forward a few weeks... after a bunch of run around from Aircraft Spruce USA (they freely admit they screwed up and are going to fix it), enter Aircraft Spruce Canada.  They provided me with a Canada Post shipping label, and off the ELT went to Ontario to get programmed.  It arrived on Monday, March 31 and they shipped it back on Wednesday, April 2nd.  Will have it next week.  Very happy about that, and they are paying for all the shipping etc.  Glad to have that sorted.

Fast forward... months!

Bracket fabricated and installed in fuselage.


Next is wiring and antenna.

I boxed myself into a corner on the fire extinguisher.  Most of the common places to install it are used for other things.  The center of the overhead is used up with a center console.  The top of the tunnel ahead of the fuel selector has my header tank.  So my plan is to either build a bracket that goes from the aft of the center seat rails up to the crossbar for the rear seat, or a bracket that runs along the center seat rails.  I need the seats installed to figure out the best (or least bad) spot.  The seat pans (aka tubs) are still at the paint shop.

Wire bundle run up front for the RC200.  The wire diagram is bizarre, but I wired it to the diagram.



On the RC200, the ON and RESET pins are bridged, and then connected only to the reset pin on the ELT.  This makes no sense.  So I wired pin K on the ELT and brought that wire up but have not connected it.  Left additional slack in the cable in case I have to cut it and start over.


Installed in panel. That is the last component to go in.

Will test once I get the antenna installed.  Not looking forward to that.

Build the bracket on the weekend to hold the antenna.  The fiberglass L brackets are attached to the floor with resin / cabo / milled fiber.  Going to overlay some fiberglass strips.


Next is ground plane. Going to use copper foil, 24" radius (48" diameter).  A screw head is bonded under the bracket to the floor, and will serve as the bridge point for the ground plane / copper foil.

This was a royal pain to install, essentially 1 handed (one hand holding myself up).  I finally cut a piece 48" long, doubled it up in the middle, and removed the backing paper at the middle and left myself some tags to pull.  Then pull, stick, pull, stick along is length.


ELT install complete.


Just need to tie wrap everything up.  3 of the cable tie mounts came loose... re epoxied.

I installed the strap upside down... had to take the mount apart to fix.

I armed it and the buzzer went off as expected, and the LED on the panel came on.  Just need to test the switch - after I read the manual.

All the tidy up is done except a final vacuum.



Finally found a home for the fire extinguisher, and simple mounting solution.  2 adel clamps to the cage on the starboard side up high.



Done done... put a fork in it.

Tuesday, 4 November 2025

Assembly... ongoing.

Big day today (Tue, Oct 14).  Was laid off today, AND got my wings back on the Sportsman!




Such a great bunch of folks at Langley Regional Airport.  8 people showed up to help. 35 min start to finish.

And my friend flew his RV6A today for the first time.


Now I have clear runway for a TON of stuff to get done.

Fuel sender wiring underway, fuel lines connected, fuel filler necks installed, and antenna installed.


Crossover cables connected, but not yet tensioned.

Wing umbilicals fed through and connected.  Cleaned up the wiring for the inboard tank sensors.


First landing / taxi light installed.  Just need to put the pins in the connector (once I remember how I wired it... luckily I have documentation).

4 outboard strut attach bolts installed and torqued.  Total pain in the rear.  Using the clevis bolts inboard for tie down points.

Progress is so slow.... life is getting in the way - but I have a bunch of stuff I can work on.

Inboard delta wings installed.


Plan is the install the pins in the forward spar for good!

Flaps are connected.  Need to tweak the tension a bit, but everything works well.

Ailerons next.

Forward spar pins installed!



Lights attached and wired.


Pilot side door getting its final silpruf.



Spinner!


Lots more to come...