Flying!

It's kinda surreal... after over 9 years of building I now have an airplane.  That was always the goal... but when you consider the project 1000 little projects, you lose sight of that.

Not that I don't have bugs to work out.  But honestly there are few.

The header tank gave me some issues... now 7 hours of flying in with the changes and no issues.  That is a good feeling.

Aileron cables were either not tight enough or stretched.  Regardless, they are now back where they should be.

Airmate maps installed on my panel.  That is very cool.

No leaks... that is nice.

Tweaking my forward cylinder cooling.  The fronts are a bit cold, the middles are a bit hot, and the aft are just right.

Engine runs great... just burns a lot of fuel.  10 gph is normal.

Flight testing continues.  Next is to configure the AOA.  Needs some help with that one (2nd pair of hands).

Some pics from a friend on the ground last week.

7 hours and counting.  18 to go.

Minor prop issues... the controller would go into current limit when switching modes in the course direction (from TAKEOFF to CLIMB, or CLIMB to CRUISE).  Checked everything, and all I could find was one brush that was not wearing evenly.  Changed that, problem continued.

Airmaster had me increase the current limit from 4A to 5.5A.  That solved it, but they are sending me a new motor that is stronger and has higher gearing.

Need to do climb test, but that will not be a problem.

Lots of comments about the sound... does not sound 'normal', like a lycoming.  And the 4 blade prop has a distinct sound.

Update!

Posting an update... the last few weeks have been a blur.

A very large (if not the largest) number of E-AB issues on first flight are fuel related.  Specifically modifications to the fuel system, which I have done with the addition of the header tank and vents.

A good friend and mentor is going to come along for the first flight.  He has done many first flights, mainly in RV's.  He has a wealth of experience, is a good friend, and a wonderful person.  He mentioned this stat... his concern (and mine) are the header tank vents.  Specifically how they are all tied together under each wing tip.

His recommendation was to get a couple shop vac's on 'blow' and hold them up against the vents to verify the header stays full.  Ran this by a couple of my fellow UL builders, and the recommendation was to use leaf blowers instead as they have higher wind speed.

So this took me down an interesting side road.  How fast do leaf blowers 'blow'?  Google said between 150 and 200 MPH.  OK, that would work.  Purchased an anemometer from Vevor that would do 101 MPH.

I have a plug in electric leaf blower that was my Dad's in the hangar.  Let's start there... 81 MPH.  Huh.. .that is not enough.  A neighbour had a Ryobi cordless one... let's try that.  Slightly better... 83 MPH.  Not going to work...

I thought I could print some nozzles that would increase the air speed.  Designed one and printed it... EPIC FAIL.  It actually slowed the air down.  Found one online for the Ryobi and it wouldnt fit... was a good 1/4" out.  There are a lot of different models of Ryobi leaf blowers apparently.

Next was to grab my Stihl cordless from the house.  100 MPH!  OK, now we are talking.  

Another friend had a Stihl gas powered.... well it put the anemometer into overload.

Couple ladders to rest them on and two willing victims to hold them...

The 2/3rds header tank alarm never went off.  Ran at 10 GPH for 10 minutes.  That should have run over 1.5 gallons through the 2.2 gallon header.

After the initial euphoria of a successful test wore off I got thinking...  what if the header is not full... will it refill?  So going to do another test with that configuration.

I've had an ongoing issue of fuel leaking out of the filter assembly.  I got it down to less than a weep, but there was still fuel on the fitting.  Changed out the copper gaskets on the suction collector, still leaked and now started coming out of the seam in the reusable input filter.  Finally just took the whole thing out, replaced every gasket, torqued and reinstalled.  That got it.

Then there was the brake leaks.  This has been ongoing... months ago it was leaking out the park brake valve.  Rebuilt it with a kit from matco and had it pressure tested... no leaks.  Reinstalled... was fine for weeks and weeks... then it started leaking.  I think it was coming from the shaft.  I am tired of cleaning up 5606.  Pulled out the valve and put in 2 union fittings.  While testing, found a leak on one of the hoses on the co-pilot side.  Removed, re-terminated, pressure tested, fixed.  Reinstalled.  No more leak.  Plus endless cleaning of 5606.

Tweaking cowl fasteners for fit and height.

Anti chaff tape on flaps.

Polishing continues.

Went down to WA state for a checkride with an experienced Glastar / Sportsman instructor.  This was needed for insurance purposes.  Done!  Great airplane to fly...  

Friends have been asking for ages 'are you excited'?  Honestly I was not... had work to do.  NOW I am getting excited!  Last hurdle to first flight is passed.

Putting the interior back in today, test the vents tomorrow (Wednesday).  Fix any last minute gotchas on Thursday, fly Friday (3/28) weather permitting.  As of Tuesday, it's looking awesome.

Progress update... final stages

Well, progress has been steady.

Magnetometer and compass calibrated.  Magnetometer had to go back to Dynon, and they just sent me a new one.  I had standard AN bolts fastening the magnetometer, which are now replaced with brass.

The header tank sensors I used are... well... garbage.  Not going to live with that, so the tank is out and new sensors ordered.  Tank removed.  Parts arrive today (2/11), hoping to get the new bungs welded in tomorrow.  Have to create a circuit for the display.  Actually looking forward to that.  

Aircraft is at the paint shop for touch ups and polishing.  I still have access, but its on the other side of the field... lots of trips back and forth for tools.

Had a fuel leak around the pump assemblies.  Fixed.

Another brake leak on the park brake valve.  Fixed.  Need to top up the reservoir.

Prop settings updated for UL520T.  Was set for UL520IS.

Started log books / maintenance schedule / out of phase tasks.  Draft of prop log / maintenance schedule, etc complete and reviewed by peers.  Minor changes recommended.

Things left to do:

1. Finish log books
2. Print W&B
3. Lower aft strut fairing fasteners
4. Set fine pitch stop on prop.
5. Aft belly inspection panel
6. Document all control surface deflections.

After that, its time to get flying again and get my training plan ironed out.

Nice photo shoot on Sunday.

Lots and lots of progress on little things...

Progress is fast and furious.

Aileron bolts safety wired.  Boy, that was fun.  Had to make tabs for the outboard bolts to tie to.

Had another park brake valve leak.  5606 all down the belly (well, one long stream).  One fitting was not quite tight.  Tested extensively and no leak, and fluid level holding steady.

Compass swung and magnetometer received back from repair and calibrated.  Initially the magnetometer would not calibrate as I had used standard AN3 bolts to mount it.  Switched to brass, and all good now.

Full power run for 3 minutes.  Ran great.  Have downloaded engine logs and need to review.  Oil temps creaped up into the yellow.  Temp spread on intercooler was 26 degrees.  Prop spun up to 2680, but then came down to 2600.  Need to check prop settings.

Autopilot bridals for capstans installed.  Had to fine tune the forward elevator bracket, but got it.  Initial autopilot calibration complete.

Shims installed on main gear.  Looks good now.

All cotter pins, etc verified in aileron and flap systems.  All turnbuckles safetied.

Left wing servo tab pushrod fabricated and installed.  Perfect.

Aileron rigging complete and dead on.

Wing tips attached with screws and not clecos :-)

What remains...

• Logbooks and paperwork pre final inspection
• Paint touch up and polishing
• Header tank sensors... figure out a new plan.
• Fuel tank calibration.  I have a sticky sensor, or a bad wire in the left aux tank
• Exterior placards (door open, fuel tanks, etc).
• Install all inspection panels after final inspection

Getting closer...

Lots on the go.

Rigging of the control surfaces was 100% complete... then realized that the balls on the ends of the flap control cables had come out of their sockets.  Fixed.  Still need to check tension and safety those cables, but all of the rest are complete (ailerons, elevator, rudder).

Trim tabs set, calibrated on the EFIS and deflection measured.

Shims for main gear toe ordered and received... need longer bolts.  Should arrive Feb 3.

Magnetometer / compass swing:  My Dynon magnetometer was calibrated backwards - sent for recalibration.  Hopefully it will be back this week.

Cleaned fuel filters.

Fuel tank calibration partially done - right wing is complete.  May need to redo as sensors are sticky it seems.

Installing the autopilot bridles today.  Then that can be calibrated.

Placards started.

Fuel control system checks end to end for jam nuts, cotter pins, etc underway.

Wings! Back from paint, prep for assembly

Wings back from the paint shop!

I had slightly tangled the control cables and untangling them was impossible with them on the aircraft... piece of cake with them off the plane.  Quick little cardboard piece to hold them in place temporarily.

The wings are pretty much ready to go on.  The wing fold strut attach points are refitted post paint.

Wingtip lights are installed... but I need longer screws.  Holes are drilled at least.

Seat tubs are back from paint!  Same colour as the rest of the interior.  Jet flex slate grey.

I have never had the interior properly bolted in... always just clecoed in place, and the seatbelts were still in their bags... took forever to find the hardware for SB69... and the crossbar retrofit.

Waiting for a good weather window to put the wings on.  Hopefully this coming week.

Update(s) - week of April 7

Final push... 2 more days (hopefully) until she moves to the paint shop. 

Monday, April 7 - 3 days to go

• Finished up the elevator fairing, and made doubler plates, primed and riveted.
• Lots of filling and sanding on everything I could find
• Glassed up the last bit for the wing tip.
• Flange for starboard strut fairing.
• Fixed ding in port wing at tip.
• And a whole bunch of other stuff... 11 hour day.
• Aluminum tape on the stap
• Hatch cover fiberglass and sanding
• Cowling sanding
• Aluminum tape on stab
• And lots more I can't remember.  It's all becoming a blur.

Tuesday, April 7th - 2 days to go

• Filling and sanding, filling and sanding.

Wednesday, April 8th - the day... well, it was supposed to be... delayed until Thursday.

• Everything packed
• Windshield and glareshield out
• Struts and ailerons dropped off at paint shop
• Hatch covers attached, Rudder, HS and elevator on.  Easier to move this way.
• Everything else goes over tomorrow - I hope.  Fingers crossed.

Progress - week of March 31: the final push to Paint!

Getting tired... this has been a long haul.  But the end is in sight.  Well, the end of this phase.

Mon, March 31 (my Dad's birthday) - 8 days to go.

• Adjusted rudder stop plate to get required +/- 25 degrees of travel.  Bracket cleaned and painted ready to rivet.
• Geoff trimmed the elevator counterweight level arms.
• Continued fitting the strut to fuselage fairings.
• Texted with the paint shop.  Monday April 7 is a maybe to start.  Could be Tuesday, April 8.

Tuesday, April 1 - 7 days to go.

• Forward portion of both strut to fuselage fairings prepped and bonded to the fuselage.  All final trimming / fitting.
• They are not quite perfect, but they are pretty good.  These things are a PAIN to fit.  They have been on and off dozens and dozens of times.

Wednesday, April 2 - 6 days to go

• Night off.  Canucks game!

Thursday, April 3 - 5 days to go

• Another night off... long work day and had to finish some things before going on vacation / paint work.

Friday, April 4 - 4 days to go

• I can't even remember what we got done, but it was a long list.  Geoff helped me until well after 8.  So many little things.  We worked and worked and worked, then had a beer.
• Ailerons and flaps off, and hardware bagged.  Wingtips off.  Vent hardware off.  Control cables freed up and ready to remove.  Hatch covers off.  Rudder off.  All panels removed and tagged for paint.

Saturday, April 5 - revised date - now going to the shop on Wednesday, so 5 days to go (again).

• Wing wire harnesses removed and pulled back from fuselage.  Wings off and on the wing stand / trolley.  Riveted the trailing edge of the wings / flap and aileron coves... I had not put the rip stop rivets in, now they are.  All plastic wrap removed from wings.  Clean up and organized the hangar to fit everything.  Drilled final holes on aft section of strut fairing.  Tagged more parts.  Went and saw the paint shop, got paint chips.  Reviewed paint scheme.
• And probably more... I am just tired.

Sunday, April 6 - 4 days to go

• Prop removed and packed - Thank you Jim!
• Exhaust removed - Thank you Jim!
• Fuselage lower heat shield removed - Thank you Jim!
• Remaining plastic wrap from flaps and ailerons removed - Thanks Shannon!
• Fasteners fixed on elevator
• Door seals removed - Thank you Jim!
• Wing tips fit and clearance for vent corrected - Thank you Jim!
• Fuel cap assemblies removed
• Elevator fairing fasteners finished / fixed and fit.  One left to do.
• All parts tagged for paint
• Paint colours chosen
• And probably more I can't remember.  Was a productive day.

Progress - week of March 24

The countdown is on... and continues.

Monday, March 24 - 14 days to go

• Removed cowl
• Drained fuel
• Unbolted park brake valve... need to find the leak

Tuesday, March 25 - 13 days to go

• Fitted starboard lower strut fairing.  Still needs some tweaking, but its on.

Wednesday, March 26 - 12 days to go

• Removed park brake value (that I suspect is leaking), which involved lifting the header tank and taking off the side skirts from the center tunnel.  Drained rest of fuel from header tank.
• Cleaned up the mess.
• Tweaked and sanded wing tips
• Drained rest of the fuel.

Thursday, March 27 - 11 days to go

• Night off... LAAA meeting

Friday, March 28 - 10 days to go

• Final fitting of fuselage struts
• Make new starboard lower outer seatbelt bracket

Saturday, March 29 - 9 days to go

• Modifying the strut fairings to the bolt on the strut attach fairing can come off.  Came up with a new plan, and partially executed today.  I bonded together the two halves where I need to extend the aft portion.  Then cut it with a coping saw.  2nd one in progress.
• Elevator and stab removed.  Prepped, primed, deburred, fasteners and final riveting on an inspection ring on the bottom of the stab i forgot to install years ago.  
• Made all new pin keepers... the previous owner had made them, and I couldnt find them.  Searched for an hour.  Had everything to make new ones, so I did.  Plus spares :-)
• Figured out exactly how to get the pins and keepers in the elevator.  I had been trying to insert on the plane, which does not work.  You have to bring the elevator up to almost 90 degrees to get the pins and keepers in.  So that is solved.
• Helped Peter weigh his amphibious ultralight.
• Very productive day... I'm tired.

Sunday, March 30 - 8 days to go.

• Elevator trim hinge pin finally fit in place.  As with the elevator itself, needs to go in from the bottom.  Added a few rivets that I cannot remember why I missed them.
• Potted the holes for the park brake valve.  Need to come up with a better solution for this.  It's a royal pain it its current location.
• Disassembled elevator trim servo and bagged everything for paint.
• Assembled all inspection panels for paint
• Worked on starboard strut to fuselage fairing.  Not fitting well at all.  I have done something wrong here.
• Added flange for port strut fuselage fairing so nutplates can be added later.  Needs 1 more layer of glass.
• Packed it in early.  Was starting to get frustrated and make mistakes.

Progress - week of March 17

The push to get ready for paint is in full swing.

March 17 - 21 days to go

• Starboard aileron counterweight slot and vent cut
• End of wingtip sanded and made flush with the trailing edge of the aileron.
• Sanded the seam... to get ready for a layer of glass.

Tuesday, March 18 - 20 days to go

• Forced night off.  Crazy work day...

Wednesday, March 19 - 19 days to go

• Zip... flying club meeting.

Thursday, March 20 - 18 days to go

• Wingtip / aileron closeout started on both wingtips.  Foam cut, fit and bonded in.
• Starboard fuselage to strut fairing roughed in and meeting up.

These suckers are a lot of work.  Put in on, mark it, take it off, trim, rinse and repeat.

Friday, March 21 - 17 days to go

• More strut fairing.  Bolts are back in, holes cut.
• Had lots of visitors... did not get much done.

Saturday, March 22 - 16 days to go

• Thanks to Jim and Bruce, all the fuselage bolts are in and tight!  VERY GRATEFUL FOR THE HELP.
• They also got all the fasteners in the hatch covers, and Jim started the starboard wing tip fasteners.
• Weighed the plane.  She has gotten fat.  Need to check the numbers.
• One layer of glass on the port wingtip closeout.  All temp holes have a fiberglass backing.  Added glass inside the port wingtip nose to fix the curvature problem.

Sunday, March 23 - 15 days to go

• Thanks again to Jim for helping!
• All nutplates installed for wingtips
• Next round of filler on wingtips
• Aircraft weighted again, but not in level attitude.  Weighed about 40 lbs less.
• Covers for flap track pockets cut, fit and drilled.
• Hatch covers installed.  Lower hatch cover holes drilled on port side.
• Finished trimming port side strut fairing around tab for wing fold brace.  Reinstalled.

Progress - week of March 10, 2025

Another week... 28 days to go until paint.

Monday, March 10 - 28 days to go

• Flap track fairings... rivnuts installed
• Outboard delta wings - drilled

Tuesday, March 11 - 27 days to go

• Night off... other plans

Wednesday, March 12 - 26 days to go

• Rudder base fairing.  Final trimming and fasteners installed.

Thursday, March 13 - 25 days to go

• Fuselage inspection hole / cover (forward of tailwheel attach point)
• Worked on the elevator and trim tab hinge pins.  They are very tight to insert.

Friday, March 14 - 24 days to go

• Finished trimming starboard hatch cover and filler on seam
• Bonded trailing edge of starboard wing tip
• Ordered ELT and fire extinguisher.  Aircraft Spruce Canada wanted $400 CAD to ship.  Aircraft Spruce US was on $100 USD.  Robbery.

Saturday, March 15 - 23 days to go.  3 full weekends left.

• Fasteners in all switch panels on the panel.  No need for any to come out except the breaker panel 
• Starboard wing vent started.
• Starboard aileron counterweight drilled.
• Door seals fit
• Antenna doublers in wing fabricated, drilled and primed.

Sunday, March 16 - 22 days to go

• Riveted antenna doublers and mounted antennas properly
• Found 6 missing rivets on the right aileron.  Fixed
• Mounted aileron trim hinges pin retainer.
• Right aileron mounted with new rod end (long story...)
• Started pulling vinyl off the wing panels
• Fixed pilot side door.  C clips kept popping off.  
• Messed around with elevator trim tab.

Productive week

Progress - week of March 3, 2025

As of Monday, March 4.... 36 days to go.  Detailed progress:

Monday, March 3 - 36 days to go

• Fuselage holes potted for exhaust shield in bottom of fuselage
• Flap track fuselage pockets bonded

Tuesday, March 4 - 35 days to go

• Took the night off.  Worked on checklists a bit.

Wednesday, March 5 - 34 days to go

• Left wing tip.  Drilled counterweight arm, cut slot for counterweight.  Cut and fit vent fitting.  Trimmed trailing edge of wing trip.  Clearanced aileron / wing tip gap.  Sanded for fiberglass.
• Checked fuselage flap track pockets.  All good.

Thursday, March 6 - 33 days to go

• Next step on hatch covers... sanding and fiberglassing.
• Next step on port wing tip.  Trimming and filling.

Friday, March 7 - 32 days to go

• Night off.  Work function.

Saturday, March 8 - 31 days to go

• Drilled holes for fuselage exhaust shield
• Strut fairing - got the port side started
• Flap tracks - all drilled.  Need a different die for my rivnut tool... 8-32.  Ordered.

Sunday, March 9 - 30 days to go.

• Fiberglass on port wing tip.
• Strut fairing continuation
• Cleaned the hangar so I could get to the starboard wing tip (shelf was in the way).
• Pilots drilled on the starboard wing tip.  Aft cut for aileron.

Status Update - Wed, Jan 8 2025

Things are really moving now...

Engine bay is done, except for swapping a few nylocs out for all metal lock nuts.  Plus the exit hose for the breather (on order).

Prop pitch change motor is out for a SB.

Advanced Flight Systems PFD is out for a screen repair (developed a horizontal 'line' 1/3rd up from the bottom).

Need to finish the vents.

Need to finish the wing fold pockets and hatches, and complete the wing to fuselage fuel system.

Wing tips... need to seam them and fit them, plus fasteners.

Need to finish the tip fairings for the horizontal stab and elevator (all drilled and fit).

Need new lower rudder hinge bracket.  Needs to be offset 0.2".

Brake lines are done, just need to add fluid and bleed.  I have the pump, just need fluid.

Cowl:  Minor cosmetic finishing.  It fits, is easy to get on and off (with 2 people for the lower cowl).  No rubs.

Front window... need to finish sand the edges, will bond in after paint.

Reassemble interior.

Push rod for starboard aileron.  Got new one (lost one).

Finish taxi / landing light assemblies (screws and aft bracket).  Parts ordered.

All BNC connections are complete and everything works.

Need to buy ELT, and fabricate bracket.

Need to work on paint scheme.

Calibrate fuel senders, and perform fuel flow test(s).  This is crucial for my peace of mind.

Reassemble prop... RUN THE ENGINE!  This will be a great day.

Stainless fuselage exhaust plate.  Need to make hardpoints for aft mounts.

Prop wiring... done, but I want to find a more elegant solution for the connector.

The list is getting smaller... having the engine and panel virtually done is HUGE.

Goal is to be ready for Smiley and OSH 2025.  Going to be a GREAT year.

Have booked vacation for the last 2 weeks of March.  That is when I plan to paint it.

Update - August 2023

I haven't posted much lately, but that is because things are not finished and ready to post.  I have actually been making pretty good progress.

The cowl has been a lot more work then I planned on, but it is getting close.  More sanding and filling, and then I can start priming it.  I have all the fasteners and have been playing with them on some scrap fiberglass.

The engine plenum is ready for fasteners - but i am waiting to figure out the intercooler plumbing from the front of the cowl to the back.

Waiting on exhaust parts.  I bought some amazon 304 stainless, and did not like the look of it so I am getting bends from the factory in Europe.  Hopefully I will have pricing and shipping details soon.

The intercooler is completely mounted, and the intercooler plenum is build, finished and riveted.

I bought an air fuel ratio monitor.  Need to weld in the bung, which i am going to do when welding the exhaust.

All the firewall forward fuel lines are done.

Played around with wrap on the control surfaces.  Pretty sure I am going to paint.

Oil cooler is done, except I need to make 1 new bracket.  All the oil lines are done and the oil filter adapter is mounted.

The oil filler door is on, but needs some tweaking.

The glareshield is almost ready for upholstery.

I have the crimper for the plug leads, but havent started that yet.

1 window is in, and in the process of fitting 2 more of 7 total.

So lots of progress, and lots to go.  BUT ITS PROGRESS!

5 Stages of Building a Kit Plane

 Got an email from a friend commenting on the project progress.  In two sentences he went from "I can do this" to "No way in hell".  

Made me thing of the standard 5 emotional stages of X, modified for building a kitplane (of course).

I am somewhere between stage 3 and 5 depending on the day.  Currently hovering around stage 4.

6 years: Dec 26, 2016 to Dec 26, 2022

6 year anniversary of my Sportsman project.  It all started 6 years ago today with the rudder.

What has been accomplished in 6 years...???

1. Slow build tail (rudder, horizontal stab, elevator).  Purchased used (unopened) in Canada, saved a bunch of money.
1. Tail complete except for tips and paint
2. Slow build wings.  Purchased new from the factory.  At the time, this kit was $17.5K USD, now its 25K USD (43% increase).  Quickbuild wings are now 47.5K USD.  OUCH.
1. Wings complete, except for wing tips, paint and fuselage wiring integration.  Wings closed, struts cut, etc.
3. 'Ultra quick build fuselage'.  Quick build fuselage, that had a bunch of work already done (doors, firewall blank, control cables, bulkhead A, horizontal stab mounts and closeouts, etc.  Got a really good deal.  Purchased in 2019, but the real work started in early 2021.
1. Tail dragger conversion complete (T3, Pekola Tundra Light Tailwheel, tailwheel service bulletin)
2. Interior completely repainted.  This took 2 weeks of disassembly, prep, masking, paint, cleanup and reassembly.
3. Tail pull handle.  Such a cool feature... but I dont want to do this again.
4. Vertical fin spar service bulletin
5. Brake master cylinders, park brake valve.  Still need to run the lines from the valve to the callipers.
6. Seat tubs cut and fit (plus Zach's seat pan inserts)
7. Overhead console / light / tailwheel lock.
8. Rear seat assembly and tunnel covers (100% made from scratch)
9. Rear baggage floor.  Zach special... but needed a lot of fitting and other touches to complete.  2 weeks last Xmas.
10. Forward tunnel covers
11. Header tanks and fuel line plumbing
12. Overhead cable cover
13. Instrument panel design, fitting, cutting and wiring (90% complete).
14. Control sticks, grips and wiring
15. Autopilot servo tray, mounting and wiring.  Control cables not complete.
16. Glareshield fitting complete, holes cut for fans, fan wiring complete.  Needs upholstery and to mount compass.
17. Temp engine fitting
18. Firewall frame - custom frame for batteries, coils, fuel pumps, filters, gascolator, etc.
19. Cowl extension (still lots of work to do, but the cowl is extended)
20. Front / rear seat fitting (front done, rear not fully complete)
21. Static ports installed, and static line run - still need to finish pitot and AOA
22. Wiring schematics - 80% complete.

There is probably more, but those are the big items.

Other non-aviation projects completed during the same timeframe:

1. Full bedroom set (bed, headboard, side tables, dresser)
2. Kitchen nook
3. 3 years of quarter midget racing with my son
4. 2 year build of a street stock, and 1 season of racing
5. Small amounts of flying... like 15 to 20 hours a year small.
6. Hanger purchase and remodelling (floor paint, mezzanine completion (new stairs, new railings, flooring, drywall, wiring, solar power)
7. Full time job plus business travel (travel non existant during COVID...)

OK - thats enough.  No wonder I am always tired LOL.

Reflecting on the decisions I made.  What would I do differently...

• Tail:  I wouldn't change anything.  Saved money, and learned a lot.
• Wings:  Same as the tail.  The slow build kit is half the price of quick build.  Building both wings at once was the right move - but takes more room.
• Fuselage:
• I am questioning my decision to go UL power (not backing out now... but...).  I had to design everything, and countless modifications are required.  This added 6+ months to the build minimum.
• Panel:  I thought going advanced would save me time, and if I had done a standard install that would probably be the case - but everything I did was custom.  The wiring between the avionics and UL ECU is 10 lbs of poop in a 2 lb bag.  Took a long time to figure it out.  If I had to do it again, I would have gone Garmin.  Canbus is soooo slick.
• Buying a 3rd hand fuselage saved me money (like about 40%), but I ended up redoing a lot of things already done - or at least taking apart and checking everything.

Keys to success:

• Tools:  
• Bandsaw is huge.  I use it a lot.
• Tablesaw is super handy for building jigs.  Takes up a lot of room in the shop, but I used it a fair bit especially during the wings.
• Rivet squeezers.  Having multiple is awesome and saves changing bits all the time.
• Pneumatic rivet squeezer:  Super awesome.  Dont use it much, but when I do it saves lots of time.
• Right angle drill adapter.  I'm on my third.  They are cheap with plastic gears.
• Belt sander.  I do not know where I would be without this.  Use it all the time.
• Break and sheer.  I have access to one, and would not have done as many parts myself without it.  Its a 20 min drive each way for me.  If I didnt have that, I would have bought a small bench-top version.
• Work Space and Storage
• Having the project at home has been great.  
• The mezzanine in the hanger is Sportsman parts storage for big stuff.  So helpful.
• I took over a room in the basement for part storage.  Nice to be able to store finished parts and just parts close at hand.  I need to get better at organizing.
• Amazon!
• I cannot understate how awesome Amazon has been.  If I need something that just broke, a tool, drill bits, etc being able to find it and order while you are in the shop and go right back to work on something else is just massive.  I have saved so much time not having to drive around and find stuff.  They dont have everything needed, but for common stuff its just awesome.
• Supportive family
• This is huge.  If the family is not on board, building will be slow and progress difficult.
• Local knowledge
• I am very lucky that I am surrounded by other builders.  Having access to knowledge, sharing tools (works both ways), and getting help when needed is massive and cannot be understated
• Specific knowledge
• I did not want to pick an orphaned kit (where the manufacturer is out of business).  Having access to parts and support is key.
• Having an active forum comprised of other builders is key.  Both being able to search for solutions, or ask specific questions when you get stuck.
• Local EAA chapter or the like.  Huge resource that can help with knowledge, tools, experience, etc
• Plan the work, work the plan
• When you start a project (you need to consider building an airplane 1000 small projects, and not a single large one), do as much research as possible in advance.  Order parts, ask questions, get advice.  Doesnt always work, but works more than it doesnt.
• Document, Document, Document
• Have a build log, and keep it up to date.  It's useful for some many reasons:
• Helping others
• Keeping motivated
• Remembering what you did
• Lots and lots of pictures.  Being able to look back and see where you were 3, 6 or 12 months ago is huge for me to keep motivated.  When I get stuck on something, knowing that I have solved problems in the past and gotten through it is key.

The big question I keep asking myself:  Would I do all this again?  Maybe.  While I have never bought an airplane, when i see other people that have purchased a used airplane there is always a list of things they want to change, dont like, upgrade, etc.  Hopefully i am getting what I want and the compromises will be minimal.  What I regret the most is the time spent not flying.  I like working on projects, but this is by far larger than anything I have ever done.  I am convinced I will not build another airplane (famous last words).

OK - I have blathered on a lot.  I wrote this more for me than anyone else as I need some motivation.  6 years is a LONG time (almost 12% of my life), but the end is near and I need to keep pushing through.

Happy holidays.  Going back to the shop...

Update...

Progress is being made... albeit slowly.

The wiring on the 'Longnose' Sportsman is pretty much done.  The last bits remaining:

1. Wire fuel pumps from the switch to the pumps.
2. Alternate air switch / panel indicator
3. EarthX battery fault wires
4. UL regulator to main bus

And thats pretty much it.  Everything else is installed, wired an functions as expected.

I have the next 1.5 weeks on vacation, and have a few goals to accomplish:

1. Clean up the rats nest of wiring.  OK, its not THAT bad, but needs some TLC
2. Finish the last of the firewall penetrations and determine routing for the prop controller to prop cable, EGT's/CHT's, cabin heat cable, fuel injection return, boost controller lines, and thats about it (as if that's not enough LOL).
3. Pull the engine and put it back in the crate
4. Drill the 'real' firewall
5. Rivet the flanges on the real firewall
6. Adhere the firewall blanket
7. Install the firewall and rivet it in place.
8. Rehang all the firewall components (regulator, coils, fuel pumps, relays, batteries, etc)
9. Reinstall the engine

Is all that doable?  Maybe - we will see.  I think I can get 1 through 7 done before January 2nd, maybe more.  But you have to have goals, right?

IF I can get all of the above done, then its onto engine / firewall forward 'stuff':

1. Oil cooler mount and lines
2. Oil cooler opening in the front of the cowl
3. Intercooler mounting
4. Ducting for the intercooler
5. Air intake and filter mounting / plumbing
6. Alternate air inlet
7. Finish the exit air ramp on bottom of cowl
8. Cowl 'finishing'
9. Cowl fasteners
10. Windows (front, top deck, doors (x3), fuselage) - the front window will be last (and probably just temp bonded until after first engine run)
11. Brake lines from park brake valve to calipers
12. Throttle and engine throttle (capture) bracket

Once all that is done, its off to the airport.  Hoping for mid 2023, then its onto final wing integration (wiring, fuel lines, hatch covers, wing tips, lights) and final wiring, etc for the tail.

80% done, 80% to go.  Will be finished on Tuesday.  Just not saying which Tuesday... 

5 years in, and still going strong...

I started my Sportsman project at Christmas 2016... Xmas 2021 is 5 years.  I was hoping to be done in 5 years, but obviously not.

Here is the short version of what has been accomplished in 5 years:

• Horizontal Stabilizer, Elevator and Rudder complete (including inspection) from standard kit.
• Wings, flaps, and ailerons complete (including inspection) from standard kit.
• Fuselage - quick build, purchased partially complete in 2019:
• on its gear
• tail dragger conversion
• Service Bulletins
• interior paint
• firewall template, plus all firewall components fitted (fuel filters, batteries, cabin heat, relays, ground blocks, etc)
• header tank
• wing struts cut
• instrument panel 'virtual' layout, components ordered
• overhead console 90% complete
• park brake
• overhead cable cover cut and fit
• rear seats 80% complete
• baggage floor purchased, need to fit
• battery box

Its a pretty long list.... the wings alone took me just over 2 years to complete.

'Life' did get in the way a bit.  

• Built complete bedroom set for my eldest daughter (between finishing tail and starting wings)
• Built breakfast nook for eldest son.
• My youngest son started racing quarter midgets, which took up over half the weekends for a year and a half.  2018/2019
• Building my son a new racecar, along with my father-in-law and son.  That has been ongoing from late 2020 through early 2022.
• Plus work, kids, etc, etc.  COVID definitely helped with the build.  Prior the to pandemic, I travelled 1 to 2 weeks a month.  As of December 2021, I have not travelled for almost 2 years.

What I learned from the past 5 years:

• The build never goes as fast as you planned.  Deal with it.
• Building is a hobby, and is on the bottom of the list for the family.  Deal with it.
• Plan the build, build the plan.  When you go out to the shop, you need an objective in mind.
• It's a thousand little projects.  Do not treat it as one big one.
• If you aren't happy with something, start over.  Trying to fix something will take longer, and be of lower quality.
• Do something every day, even if that is just reading the manual or buying a part or tool.
• "When you don't know what to do, do something".  If you are stuck on something, pick something you can do and do that.  Even if its just deburring a hole.  Then move on to the next thing.
• Decide what your objective is.... building or flying.  As soon as you stray from the plans you have opened up a giant time suck.
• Example:  I decided to build my own rear seats as I thought the $4K from Glasair was too expensive.  First off I had to design them, then build the metal components, then fit them, etc.  Then I had to learn how to vacuum bag, and get all the materials to do so.  Then there was all the fitting and finishing.  I have been at it for almost 3 months.  Now I know why the kit is $4K.
• Example 2:  I decided to go with a UL power engine.  Modern, FADEC, lighter, etc.  However, there are no kits for this engine - so you are completely on your own.  UL power requires a header, which I decided to mount on the forward truss assembly.  The UL filters and pumps do not fit in the stock locations, not will they fit under the stock covers.  So all of that had to be designed, material procured, built, fit and finished.  On the 3rd go round, I finally got the top cover right.
• I miss flying.  I have gone from flying 60 to 70 hours a year, to 15.  When everyone else is hanging out at the airport, I am going home to build.

It's been fun, but I am doing this to get an airplane.  I doubt I will build another one.