N3471
Construction/Maintenance Log
 

Log Entry	Date Purchased/ Labor Done	Receipt Amt.	Received On	Section	Labor Hours	Done By	Description
1	07/24/2005	$17,380.00					Purchase full kit and accessories
2			12/05/2005	Mult.			Base Kit (Serial No.: CH2-0705-2657)
3			08/24/2005	Prop			Warp blade propeller
4			12/05/2005	IV			10-gal fuel tank
5			12/05/2005	II			Hoerner Style Wing Tip Kit
6			12/05/2005	III			Streamlined Fairings
7			12/05/2005	II			Flaperons
8			12/05/2005	III			Shoulder harness set
9			12/05/2005	IV			Plexi glass sections
10			12/05/2005	II			Superflite Wing covers
11			03/16/2006	III			Landing gear, tires, hydraulic brake system
12			10/06/2005	IV			Rotax 503 Engine (Serial No.: 6352821)
13			10/06/2006	IV			GPL Electric Starter
14			10/08/2006	IV			EIS w/Airspeed and Altimeter
15	01/22/2006	$7.19	01/22/2006	Mult.			Polyester Batting
16	03/02/2006			I	4.00	Rob & Connie	Rounded edges of metal gussets, tapped overhanging edges of gussets down around tubes.
17	03/11/2006			I	3.50	Rob & Connie & Don Zank	Taped tube gussets, glued fabric sock to rudder frame. Shrunk fabric to 250 deg.
18	03/12/2006			I	8.00	Rob & Connie	Rounded edges of gussets, tapped down edges of gussets on leading edge for elevators. Taped gussets on Vertical Fin.
19	03/16/2006			I	8.50	Rob & Connie	Sanded, taped & covered Vertical Fin, Horiz. stab., and elevators. Heat shrank 1 horiz. stab. to 250F
20	03/18/2006			I	4.00	Rob & Connie	Finished covering all remaining pieces. Shrunk Vertical Fin and Rudder to 350F
21	03/19/2006			I	4.00	Rob & Connie	Shrank remaining pieces to 350F except 1 horizontal stabilizer. Added top hinge to Rudder.
22	03/19/2006			I	1.00	Rob	Shrank remaining horizontal stabilizer to 350F. Added top hinge to Vertical Fin.
23	03/20/2006			I	2.00	Rob	Connected hinges to one horizontal stabilizer and mated to one elevator.
24	03/21/2006			I	2.00	Rob & Bill Schifferl	Connected hinges to one horizontal stabilizer and mated to one elevator.
25	03/30/2006	$505.00	04/20/2006	II			LED-XPAC Strobe System with Belly Strobe(From Aircraft Spruce Order 548109 Invoice 897370)
26	03/31/2006			II	4.00	Rob & Connie	Checked counts on Section II kit parts.
27	04/05/2006			II	3.00	Rob & Connie	Checked counts on Section II kit parts. Laid out W5X holes to be drilled.
28	04/06/2006			II	4.00	Rob & Connie	Drilled holes in one W5X piece and riveted to ribs.
29	04/08/2006			II	4.00	Rob & Connie	Completed construction of RB1X - W5x assemblies.
30	04/09/2006			II	4.00	Rob	Mounted RB1X - W5X assemblies to wings and began planning how to put curved ribs (RB2X), W5X, DR-1, and DR-2 on wings.
31	04/10/2006			II	8.00	Rob & Connie	Mounted curved ribs (RB2X), W5X, DR-1, and DR-2 on inboard portion of right wing.
32	04/11/2006			II	4.00	Rob & Connie	Drilled remaining W5X pieces and partially mounted RB2X to one of them.
33	04/11/2006			II	4.00	Rob & Connie	Drilled remaining W5X pieces and partially mounted RB2X to one of them.
34	04/14/2006			II	8.00	Rob & Connie	Mounted curved rib and W5X assemblies to wings. Added DR-1 and DR-2 supports to inner right wing.
35	04/15/2006			II	4.00	Rob & Dad	Cut right wing outer panel from W5X sheet. Added DR-1 and DR-2 supports to outer right and left wing tips.
36	04/18/2006			II	2.00	Connie	Drilled holes in rib gussets.
37	04/19/2006			II	3.00	Rob & Connie	Made additional DR-1 and DR-2 pieces and added to wings.
38	04/29/2006			II	8.00	Rob & Connie	Completed both wing ends. Prepared rib gussets (W1X). Began preparation of ribs (RB1X).
39	04/30/2006			II	6.00	Rob & Connie	Completed preparation of middle ribs (RB1X) for both wings. Stretched strings and began layout of ribs on right wing.
40	05/03/2006			II	4.00	Rob & Connie	Layed out and drilled holes in left wing for middle ribs, and clecoed ribs to wing.
41	05/04/2006			II	4.00	Rob & Connie	Completed prep and riveted ribs to both wings.
42	06/03/2006			II	6.00	Rob & Connie	Reviewed instructions and prepped right wing for covering by sanding, cleaning with MEK, taping edges, applying polytak, and applying batting. Also, started stretching cloth.
43	06/04/2006			II	4.00	Rob & Connie	Glued fabric bottom to left wing. Did NOT shrink at this time to avoid prolonged stress on frame.
44	06/05/2006		06/06/2006	II			100 AD42ABS 1/8" x 1/8" Aluminum Rivets (Quad City Ultalight Aircraft Corp Invoice 31402)
45	06/05/2006		06/06/2006	II			100 AD44ABS 1/8" x 1/4" Aluminum Rivets (Quad City Ultalight Aircraft Corp Invoice 31402)
46	06/05/2006		06/06/2006	II			100 SSD44SSBS 1/8" x 1/4" Stainless Steel Rivets (Quad City Ultalight Aircraft Corp Invoice 31402)
47	06/05/2006		06/06/2006	II			100 SSD42SSBS 1/8" x 1/8" Stainless Steel Rivets (Quad City Ultalight Aircraft Corp Invoice 31402)
48	06/05/2006		06/06/2006	II			(M-SP) Medium Spares Kit (Quad City Ultalight Aircraft Corp Invoice 31402)
49	06/05/2006		06/06/2006	II			2 W5X (Aluminum) Sheets (Quad City Ultalight Aircraft Corp Invoice 31402)
50	06/11/2006			II	4.00	Rob & Connie	Shrunk bottom of left wing to 300 deg. Glued on top fabric of wing with polytak. Shrunk top of wing to 300 deg.
51	06/13/2006	$55.80	06/16/2006	II			100ft 1/4" spiral wrap wire protector (Part 11-12314 Aircraft Spruce Order 463825 Invoice 630313)
52	06/13/2006	$19.50	06/16/2006	II			1 Gallon Certified Methyl Ethyl Ketone (Part 09-13800 Aircraft Spruce Order 463825 Invoice 630313)
53	06/14/2006			II	4.00	Rob & Connie	Taped left wing ribs with 2 inch tape.
54	06/14/2006	$24.50	06/16/2006	II			25yds Poly-Fiber P-106 Tape (Part 09-03400 Aircraft Spruce Order 476790 Invoice 631213)
55	06/17/2006			II	6.00	Rob & Connie	Taped left wing ribs with 3/8" reinforcing tape. Punched holes using soldering iron. Riveted fabric to ribs. Began fitting wing tip.
56	10/12/2006			II	2.00	Rob & Connie	Wired left wing.
57	10/17/2006	$22.57	10/18/2006	II			Replacement for missing strut support bracket WS-1.
58	10/19/2006			II	8.00	Rob & Connie	Trimmed Left aileron to fit to left wing. Drilled holes for aileron hinges. Taped and prepped left aileron for covering. Finished left position light mount and laid out on wing tip.
59	10/20/2006			II	2.00	Rob & Connie	Riveted left wing tip in place. Applied surface tape to wing tip.
60	10/21/2006			II	8.00	Rob & Connie	Riveted aileron on left wing. Shunk left wing and aileron fabric at 350F. Bolted strut mounting on left wing. Added batting on cross-members or right wing. Taped edges on right wing. Covered lower portion of right wing. Shrunk lower portion of wing to 250F.
61	10/22/2006			II	12.00	Rob & Connie	Covered the upper portion of right wing. Shrunk upper portion of right wing to 250F. Completed right position light bracket.
62	10/25/2006			II	1.00	Rob & Connie	Started to layout right wing tip rivet holes.
63	10/25/2006			III	1.00	Rob & Connie	Inventoried Section III
64	10/26/2006			III	2.00	Rob & Connie	Assembled flaperon mechanism on fuselage.
65	10/28/2006			II	2.00	Rob & Connie	Trimmed fabric from right wing. Polytacked and taped outer half of right wing.
66	10/28/2006			III	2.00	Rob & Connie	Per Quad City Ultralight recommendation, pounded out 2 dents of unknown origin discovered in rear of fuselage frame. Began coverplate layout.
67	10/29/2006			II	1.50	Rob	Polytacked and taped inner half of right wing.
68	10/30/2006			II	1.00	Rob	Put reinforcing tape on right wing. Shrunk some bubbles spotted on trailing edge of wing. Began cleaning up right aileron frame.
69	12/08/2006			II	1.00	Rob	Put surface tape over several ribs of right wing. Cleaned up a couple of polytak bubbles.
70	12/11/2006			II	1.50	Rob	Put surface tape over the rest of ribs on right wing. Cleaned up a couple more polytak bubbles.
71	12/12/2006			II	2.50	Rob	Started wiring right wing position lights.
72	03/25/2007			II	3.00	Rob & Connie	Finally able to get back to plane. Verified right wing position lights wired OK. Mounted aileron and brackets on right wing. Started back on main body.
73	06/26/2007			III	2.00	Rob	Finally able to get back to plane. Riveted aluminum formers in place on both sides of frame.
74	06/27/2007			II	2.00	Rob	Put leading edge tape on wings.
75	06/28/2007			II	6.00	Rob	Painted top of wings with polyybrush coat 1.
76	06/29/2007			II	6.00	Rob	Painted bottom of wings with polybrush coat 1.
77	07/02/2007			I	3.00	Rob	Painted Horizontal and Vertical Stabilizers with polybrush coat 1.
78	07/02/2007			III	3.00	Rob	Deburred and taped port front quadrant of fuselage in prep for covering. Added control handle grips. Fixed minor touch point where aluminum formers didn't clear flaperon mechanism in specific aileron position.
79	07/03/2007			I	3.00	Rob	Painted Elevators and Rudder with polybrush coat 1.
80	07/03/2007			III	3.00	Rob	Mounted gas tank in fuselage. Deburred and taped some of starboard side of fuselage.
81	07/09/2007			I	6.00	Rob	Set up spray paint booth and sprayed Elevators and Rudder with polybrush coat 2.
82	07/12/2007			I	6.00	Rob	Redid spray paint booth and sprayed Horizontal and Vertical Stabilizers with with polybrush coat 2.
83	07/14/2007			I	6.00	Rob	Redid spray paint booth and sprayed Elevators and Rudder with with polybrush coat 2.
84	07/15/2007			I	6.00	Rob	Sprayed Horizontal and Vertical Stabilizers with with polybrush coats 2 and 3. Sprayed Elevators and Rudder with polybrush coat 2. Both will need 4 coats as sprayer ran low at end of both.
85	07/16/2007			I	3.00	Rob	Sprayed Horizontal and Vertical Stabilizers with with polybrush coat 4. Sprayed Elevators and Rudder with polybrush coat 3.
86	07/30/2007			I	3.00	Rob	Sprayed Horizontal Stabilizers, Vertical Stabilizers, Elevators, and Rudder with poly spray coat 1.
87	07/31/2007			I	3.00	Rob	Sprayed Horizontal Stabilizers, Vertical Stabilizers, Elevators, and Rudder with poly spray coat 2. Spray gun fell apart shortly after painting. Crack had propogated during painting -- many drips, rough spots, and other problems created as a result.
88	08/03/2007			I	6.00	Rob	Ironing and sanding tail section.
89	08/04/2007			III	6.00	Rob & Connie	Reviewed progress with Don Zank at hangar. Riveted dent patches in place. Riveted seats and support struts in place. Began prepping fuselage for covering.
90	08/05/2007			I	6.00	Rob	Ironing and sanding tail section.
91	08/06/2007			I	5.00	Rob	Ironing and sanding tail section.
92	08/07/2007			I	6.00	Rob	Ironing and sanding tail section.
93	08/08/2007			I	4.00	Rob	Ironing and sanding tail section.
94	08/09/2007			I	4.00	Rob	Ironing and sanding tail section. Not much silver left.
95	08/10/2007			I	4.00	Rob	Painted tail fins with coat of poly spray (silver) with new HVLP gun. 76F 77% humidity.
96	08/11/2007			I	4.00	Rob	Painted tail fins with coat of poly spray (silver). 82F 82% humidity turns out to be too far outside curve for proper application.
97	08/12/2007			I	4.00	Rob & Dad	Ironing and sanding tail section.
98	08/13/2007			I	6.00	Rob & Dad	Ironing and sanding tail section.
99	08/14/2007			I	6.00	Rob	Ironing and sanding tail section. Painted tail fins with coat of poly spray (silver). Essentially first coat of silver all over again.
100	08/15/2007			I	6.00	Rob	Ironing and sanding tail section.
101	08/16/2007			I	4.00	Rob	Painted tail fins with coat of poly spray (silver). Only minor touch ups performed late in evening.
102	08/18/2007			I	4.00	Rob	Painted tail fins with final coat of poly spray (silver).
103	08/19/2007			I	4.00	Rob	Checked with light test as best one could. All pieces throughly opaque to light. Found one less than ideal spot on top of dorsal fin. Touched up. Too humid to paint (97% humidity).
104	08/23/2007			II	4.00	Rob	Started building rotisserie for turning wings while painting.
105	08/24/2007			II	2.00	Rob	Finished wing rotisserie and supported starboard wing. Still waiting for humidity to drop. Changed port wing light connector to a single 6 wire power connector.
106	08/25/2007			I	6.00	Rob	Painted tail pieces with two coats of blue poly tone. First coat in morning and second coat late at night when about 72 degrees F to facilitate finish.
107	08/26/2007			III	16.00	Rob & Connie	Baked tail pieces in sun for 2 hours to facilitate drying. Cut and fitted alternative instrument panel. Began prepping for covering fuselage. Reworked wing rotisserie to facilitate painting tip. Mounted vertical stabilizer and rudder. Attached control wires to rudder, but did not wire tie. Using iron, fixed fabric on starboard horizontal stabilizer where pulled away from rivet head. Began mounting horizontal stabilizers.
108	08/27/2007			III	6.00	Rob	Fitted instrument panel to fuselage and drilled mounting holes. Identified problem with recently purchased turn coordinator prior to mounting. R. C. Allen (mfg.) agreed to replace.
109	08/28/2007			III	4.00	Rob & Connie	Layed out instrument holes on instrument panel (still need to do switches). Mounted rear struts for horizontal stabilizers.
110	08/29/2007			III	4.00	Rob	Mounted forward struts for horizontal stabilizers. Attached elevators to control horns and horizontal stabilizers. Began working on elevator control rods.
111	08/30/2007			III	6.00	Rob	Mounted elevator control rods. Wire tied all controls. Drilled holes for dorsal fin in fuselage. Continued prep for covering.
112	08/30/2007			II	4.00	Rob	Sprayed two coats of polybrush on wing.
113	09/02/2007			II	4.00	Rob	Ironing drips on wing.
113	09/09/2007			II	4.00	Rob	Ironing drips on wing.
113	09/16/2007			II	2.00	Rob	Ironing drips on left wing.
113	09/16/2007			III	2.00	Connie	Prepping fuselage for covering.
114	10/28/2008			II	6.00	Rob	Painted left wing with Polyspray (Coat 1).
115	10/29/2008			II	4.00	Rob	Mixed paint and painted left wing with Polyspray (Coat 2).
116	10/30/2008			II	4.00	Rob	Painted wing with left Polyspray (Coat 3). Tried Light Test. Needs another coat.
117	10/31/2008			II	6.00	Rob	Painted left wing with Polyspray (Coat 4). Tried Light Test. Needs another coat.
118	11/01/2008			II	6.00	Rob	Painted left wing with Polyspray (Coat 5). Went too thick and got runs. Tried light test again. Needs touch up in one spot.
119	11/03/2008			II	6.00	Rob	Painted left wing with Polyspray (Coat 6?). Finally passed light test.
120	11/04/2008			II	6.00	Rob	Painted left wing with first coat of polytone insignia white 105. (Coat 1) It ran and deposited unevenly. Tried to fix, but just made a mess of.
121	07/15/2009			II	12.00	Rob	Mixed polytone lemon yellow 136 and painted over white on left wing. (Coat 2) I went light to avoid runs. Unevenness of white coat clearly visible.
122	07/16/2009			II	4.00	Rob	Painted left wing polytone 136 lemon yellow. (Coat 3) Uneveness fading.
123	07/17/2009			II	4.00	Rob	Painted left wing polytone 136 lemon yellow. (Coat 4) Uneveness almost gone.
124	07/18/2009			II	4.00	Rob	Touched up left wing where unevenness still obvious. (Coat 5) Afraid to risk thicker.
125	08/02/2009			II	7.50	Rob & Connie	Switched wings in spray booth. Repaired spray booth and cleaned up wing to be coated (right).
126	08/10/2009			II	4.50	Rob	Cleaned up right wing. Added rivnuts to left wing at position light mount.
127	08/11/2009			II	4.50	Rob	Hand Painted right wing with 50:50 mix of polybrush and R65-75 reducer to rejuvenate hand brushed coat per manual. Added RP-1 and 2 mounting brackets to left wing.
128	08/12/2009			II	2.50	Rob	Painted right wing with polybrush (Spray coat 2).
129	08/13/2009			II	2.50	Rob	Painted right wing with polybrush (Spray coat 3).
130	08/14/2009			II	2.50	Rob	Flattened down raised ends of tapes on right wing with iron and parchment paper.
131	08/24/2009			II	5.50	Rob	Flattened down raised ends of tapes on right wing with iron and parchment paper. Mixed polyspray for application.
132	09/01/2009			II	2.50	Rob	Sprayed right wing with silver polyspray (Coat 1).
133	09/03/2009			II	4.25	Rob	Flattening paint gun spatter on right wing with iron and parchment paper. Compressor apparently popped circuit breaker at end of 09/01/2009 application. Under pressurised, the paint gun made a mess of splatter at the end.
134	07/12/2010			II	2.00	Rob	Painted coat of polyspray (silver) on right wing (Coat 2). Painted horizontally along length of wing. Used new paint gun.
135	07/13/2010			II	1.00	Rob	Cleaned up defects in paint job with hot iron. Prepped paint for tomorrow.
136	07/14/2010			II	1.50	Rob	Painted coat of polyspray (silver) on right wing (Coat 3). Painted vertically from leading edge to aileron.
137	07/14/2010			II	0.50	Rob	Checked amount of silver on right wing using light test -- 60W florescent bulb inside wing. I found the coating was still too thin just about everywhere and it needs another coat.
138	07/05/2011			II	5.50	Rob	Mixed Polyspray 4:1 with R75/85. Sprayed two coats on right wing: first horizontally root to wing tip, second coat from leading edge to aileron vertically. Temp 77F Humidity 25%. No drips but small overspray (berries) spotted during dry inspection after second coat.
139	07/05/2011			II	0.50	Rob & Connie	Surface rougher than I would have liked, but OK. Checked amount of silver on right wing using light test -- 60W florescent bulb inside wing. I found the coating was still too thin in certain parts of bottom on wing.
140	07/06/2011			II	7.50	Rob	Ironed berries flat. Mixed Polyspray 4:1 with R75/85. Sprayed two coats on right wing: first horizontally root to wing tip, second coat from leading edge to aileron vertically. Temp 80F Humidity 30%. Surface rougher than I might like, but OK otherwise.
141	07/06/2011			II	0.50	Rob	Surface rougher than I would have liked, but OK. Checked amount of silver on right wing using light test -- 60W florescent bulb inside wing. Opaque!
142	07/07/2011			II	2.50	Rob	Used previously mixed 105 Insignia White Polytone 4:1 R65/75 Reducer. Sprayed one coat on right wing at 70F, 45% Humidity. Wing picked up a lot of garbage threads (mouse hair?) and solid paint flecks from somewhere during painting.
143	07/08/2011			II	2.50	Rob	Threads turned out to be insignia white paint. Ironed flat flecks and threads from top of right wing from tip to middle.
144	07/09/2011			II	4.50	Rob	Ironing out flaws in insignia white paint job on right wing.
145	07/11/2011			II	6.00	Rob	Ironing out flaws in insignia white paint job on right wing.
146	07/12/2011			II	3.00	Rob	Painted right wing with premixed 136 Lemon Yellow Polytone 4:1 R65/75 reducer. Temp.: 72F, Humidity: 50%.
147	07/12/2011			II	2.00	Rob	Began construction of wing holder.
148	07/13/2011			II	3.00	Rob	Painted right wing with premixed 136 lemon yellow polytone 4:1 R65/75 reducer. Temp.: 68F, Humidity: 55%.
149	07/14/2011			II	1.00	Rob	Tacked down tapes in 4 positions where lifted during final coat of right wing. Touched up locations on right wing with premixed 136 lemon yellow polytone 4:1 R65/75 reducer. Temp.: 64F, Humidity: 40%.
149	07/15/2011			II	3.00	Rob	Began constructing wing rack to hold wings until needed.
150	07/16/2011			II	3.00	Rob	Constructing wing rack to hold wings until needed.
151	07/18/2011			II	4.00	Rob & Connie & Dad	Put wings in rack. Added light to right wing. Changed plug on right wing from 3-connector to 6 connector. Section II is complete!
152	10/11/2011			III	4.00	Rob & Connie	Polytakked left rear portion of fabric to fuselage.
153	10/15/2011			III	2.50	Rob	Shrank fabric on left rear portion of fuselage to 225F.
154	10/22/2011			III	4.50	Rob & Connie	Shrank fabric on left rear portion of fuselage to 300F. Put patch on suspect spot near left rear section. Applies patches around left wheel mount. Started applying fabric on right rear portion of fuselage.
155	10/24/2011			III	2.00	Rob	Continued applying fabric on right rear portion of fuselage.
156	10/26/2011			III	2.00	Rob & Connie	Continued applying fabric on right rear portion of fuselage. Started left front portion of fuselage.
157	10/28/2011			III	2.00	Rob	Completed applying fabric on right rear portion of fuselage. Shrank to 250F
158	10/29/2011			III	4.50	Rob & Connie	Completed adding fabric to right front portion of fuselage. Shrank fabric on left rear portion of fuselage to 345F. Began taping in preparation to paint.
159	10/31/2011			III	1.50	Rob & Connie	Started covering left front section of fuselage. Began rigging fuselage for painting.
160	11/04/2011			III	1.00	Connie	Finished covering left front section of fuselage. Heated on left front section to 265F.
161	11/05/2011			III	3.00	Rob & Connie	Heated right rear section to 325F. Cleaned up wrinkles on left front. Did select right front areas to 340F.
162	02/24/2012			III	4.5	Rob	Heated rest of fuselage fabric to 340F.
163	03/04/2012			III	3.0	Rob	Added extra layer of fabric to nose for added protection from bug impacts and to improve appearance. Re-ironed critical areas to 340F.
164	03/08/2012			III	4.5	Rob & Connie	First coat of polybrush (3:1 R65-75 Reducer) on fuselage brushed onto fuselage. Temp 65F 35% Humidity.
165	03/09/2012			III	4.0	Rob	Brushed out defects in first coat using diluted R65-75:Polybrush solution
166	03/11/2012			III	4.0	Rob	Sprayed second coat of Polybrush (3:1 R65-75 solution) onto fuselage. Temp: 65F Humidity: 37%
167	03/13/2012			III	4.0	Rob & Connie	Repaired second coat using diluted R65-75 reducer: Polybrush solution.
168	03/14/2012			III	2.0	Rob & Connie	Repaired second coat using iron.
169	03/15/2012			III	4.0	Rob & Connie	Sprayed third coat of Polybrush (3:1 R65-75 solution) onto fuselage. Temp: 70F Humidity: 40%
170	03/27/2012			III	4.0	Rob & Connie	Sprayed first coat of Polyspray (4:1 R65-75 solution) longitudinally onto fuselage. Temp: 65F Humidity: 35%
171	03/30/2012			III	2.0	Rob & Connie	Ironing paint job to fix turned up tapes and drips.
172	04/01/2012			III	2.0	Rob	Ironing paint job to fix turned up tapes and drips.
173	04/02/2012			III	4.0	Rob	Sprayed second coat of Polyspray (4:1 R65-75 solution) top-down onto fuselage. Temp: 67F Humidity: 40% Small portion of nose done with Polyspray (4:1 R8500 solution) when ran out of R65-75.
174	04/03/2012			III	2.0	Rob	Sprayed third coat of Polyspray (4:1 R8500 solution) longitudinally onto fuselage. Temp: 60F Humidity: 40%.
175	04/04/2012			III	4.0	Rob	Ironed out defects. Sprayed fourth coat of Polyspray (4:1 R8500 solution) top-down onto fuselage. Temp: 67F Humidity: 45%.
176	04/11/2012			III	4.0	Rob	Ironed out defects. Sprayed fifth coat of Polyspray (4:1 R8500 solution) longitudinally onto fuselage. Temp: 60F Humidity: 37%.
177	04/12/2012			III	4.0	Rob	Ironed out defects. Sprayed sixth and final coat of Polyspray (4:1 R8500 solution) top-down onto fuselage. Temp: 65F Humidity: 27%.
178	04/17/2012			III	2.0	Rob	Ironed out defects. Fabric lifted/bubbled in multiple locations. Ironed flat.
179	04/24/2012			III	2.0	Rob	Ironed out defects. Fabric lifted/bubbled in multiple locations. Ironed flat. Painted over defects
180	05/08/2012			III	2.0	Rob	Painted over defects (Coat 2) Polyspray (4:1 R8500 solution) Temp: 60F Humidity: 42%.
181	05/09/2012			III	2.0	Rob	Painted over defects (Coat 3) Polyspray (4:1 R8500 solution) Temp: 60F Humidity: 45%.
182	05/09/2012			III	2.0	Rob	Painted over defects (Coat 4) Polyspray (4:1 R8500 solution) Temp: 65F Humidity: 42%.
183	05/09/2012			III	2.0	Rob	Painted over defects (Coat 5) Polyspray (4:1 R8500 solution) Temp: 60F Humidity: 47%. Passed light test, though still wet! Turned hangar furnace up to 85F to bake for evening.
184	05/10/2012			III	0.5	Rob	Verified passed light test in all repainted locations.
185	05/11/2012			III	5.0	Rob & Connie	Worked out painting plan for fuselage colors. Plan: Day 1 - Black (both coats), Day 3 - Blue and Green (both coats), Day 5 - White Coat 1 in white and light yellow areas followed by Coat 2 in white areas only, Day 6 - Yellow (both coats). Day 7 - Speckle White with Green and Silver. Remove all masking materials. Pinstripe black when return from vacation and all paint is thoroughly dried. Masked fuselage for painting with Polytone Dakota Black 4:1 R-8500.
186	05/11/2012			III	1.0	Rob	Painted fuselage sections with Dakota Black Polytone (4:1 R8500 solution) Temp: 65F Humidity: 47%.
187	05/12/2012			III	1.5	Rob	Painted fuselage sections with Dakota Black Polytone (4:1 R8500 solution) Temp: 65F Humidity: 47%.
188	05/14/2012			III	1.5	Rob	Tried to fix paint run on fuselage by ironing and repainting with Dakota Black Polytone (4:1 R8500 solution) Temp: 67F Humidity: 47%.
189	05/19/2012			III	3	Rob & Connie	Started masking off black sections of fuselage in preparation for Green and Blue Sections
190	05/20/2012			III	4	Rob	Finished masking off black and painted fuselage sections with 170 Bahama Blue and 157 Cub Sport Trainer Green Polytone (4:1 R8500 solution) Temp: 72F Humidity: 52%.
191	05/20/2012			III	2	Rob	Painted fuselage sections with second coat of 170 Bahama Blue and 157 Cub Sport Trainer Green Polytone (4:1 R8500 solution) Temp: 70F Humidity: 52%. Turned heat up to 85F for two hours to accelerate drying.
192	05/21/2012			III	2	Rob & Connie	Masked off blue and green areas. Unmasked light yellow chevrons so it would have a white undercoat. Painted fuselage sections with first coat of 105 Insignia White Polytone (4:1 R8500 solution) Temp: 68F Humidity: 47%.
193	05/21/2012			III	2	Rob & Connie	Painted fuselage sections with second coat of 105 Insignia White Polytone (4:1 R8500 solution). Unmasked dark yellow center chevron. Painted chevrons with Lemon Yellow 136 Polytone (4:1 R65/75 solution). Temp: 68F Humidity: 45%.
194	05/22/2012			III	3.0	Rob & Connie	Painted fuselage sections with third coat of 105 Insignia White Polytone (4:1 R8500 solution). Painted chevrons with Lemon Yellow 136 Polytone (4:1 R65/75 solution). Temp: 66F Humidity: 42%. Touched up two small spots on tail (top of rudder, left horizontal stabilizer) with Bahama Blue Polytone (4:1 R8500 solution). Heated hangar to 85F to facilitate drying.
195	05/22/2012			III	0.5	Rob & Connie	Removed all tape and masking from fuselage.
196	07/12/2012			III	2.0	Rob	Repainting major drip on nose.
197	07/13/2012			III	2.0	Rob	Repainting major drip on nose.
198	07/14/2012			III	4.0	Rob & Connie	Finished repainting major drip on nose. Pinstriped.
199	07/15/2012			III	4.0	Rob	Painted metal components of main gear. Touched up paint job. Installed landing gear struts, and toed in gear by 1 degree per specification. Installed brakes on gear (not connected). Mounted main wheels.
200	07/16/2012			III	8.0	Rob & Connie	Ran brake lines. Bled brakes. Installed nose wheel. Replaced tail wheel. Tested brakes. Began work on main doors. Began installing control panel.
201	07/17/2012			III	1.0	Rob	Burned hole in fuel tank for sending unit. Fitted sending unit to tank.
202	07/20/2012			III	9.0	Rob	Redesigned, remade (using 0.40 inch thick sheet of 2024-T3 Al), and remounted Instrument Panel. Added ignition key, EIS, and fuel level indicator. Recorded all measurements and materials on template drawing.
203	08/03/2012			III	2.0	Rob	Laid out, drilled holes, and screwed Lord Mounts into bracket
204	08/04/2012			III	2.0	Rob	Added L-beams to engine mount. Fitted engine mount to root tube.
205	08/05/2012			III	2.0	Rob & Connie	Cut out lexan panels for windows. Began assembling left main door.
206	08/06/2012			III	2.0	Rob & Connie	Cleco'd left main door together except for rear panel. Tried several alternative schemes for mounting rear lexan panel using paperboard templates.
207	08/09/2012			III	4.0	Rob & Connie	Opened engine box for Rotax 503 Engine (Serial No.: 6352821). Mounted engine to mounting bracket and mounted assembly on root tube. Used red Locktite on bolts where not specified.
208	08/10/2012			III	3.0	Connie	Continued experimenting with various rear window panel implementations for main doors.
209	08/10/2012			III	2.0	Rob & Connie	Mounted drive gear to engine. Tensioned belt to 5/16 inch deflection at 30 lbf using spring scale, C-shaped rod (C-clamp), and ruler. Main bolt still needs tightening due to lack of appropriate socket wrench attachment.
210	08/11/2012			III	2.0	Rob & Connie	Tightened main bolt to 150 ft lbf. Reverified tension 9/32 inch deflection at 30 lbf. Backed out top block bolt, added red locktite, and retightened all components to 15 ft lbf. Added propellor plate using red locktite and screws tightened to 15 ft lbf.
211	08/12/2012			III	3.0	Rob	Installed exhaust system per instructions.
212	08/13/2012			III	1.0	Rob	Installed carburetors and air cleaner per instructions except for adding throttle control. Waiting for oil unit to complete because it requires a different throttle cable.
213	08/14/2012			III	3.0	Rob & Connie	Began Starter kit installation: Removed drive gear from engine using puller. Countersunk holes in starter bracket when discovered not done. Mounted Starter bracket and tightened bolts to 13 ft lbf. Added Starter gear to drive gear (Used Red Locktite 271 and tightened bolts to 5 ft lbf). Remounted drive gear on engine (Used Red Locktite 271 and tightened main bolt to 50 ft lbf). Mounted starter on bracket (Used Red Locktite 271 and tightened bolts to 13 ft lbf. Retensioned drive belt to 5/16" deflection at 30 lbf. Tightened redrive main bolt to 150 ft lbf. Need to buy new cotter pins of appropriate size to replace. Recheck of tension found only 1/4 inch deflection at 30 lbf. Waiting to re-lock top block bolt until cotter pin replaced. Meanwhile, added positive cable to starter. Located optimal site and began designing battery mount.
214	02/13/2013			III	3.0	Rob	Replaced exhaust springs with exhaust clamps. Redid linkage bolts for rudder and elevators (moved large washer to opposite side and replaced nyloc nuts). Both done per EAA Tech recommendations from review of 8/13/2012.
215	03/20/2013			III	6.0	Rob	Constructed battery compartment. Inserted battery.
216	03/21/2013			III	2.0	Rob & Connie	Installed main switch and starter switch in instrument panel. (Not yet wired.)
217	03/22/2013			III	3.0	Rob	Installed ignition relay and rectifier.
218	03/23/2013			III	3.0	Rob	Installed starter cables. Constructed frame ground cable. Constructed bracket for starter/engine ground cable mounted on rectifier. Wire tied cables.
219	03/25/2013			III	3.0	Rob	Constructed brackets to simplify connecting wires to battery.
220	03/26/2013			III	3.0	Rob	Constructed two extension cords. One to connect engine lighting power supply to rectifier. One to connect magnetos, tach, and ground to main avionics cable. Began zip tying in place.
221	04/04/2013			III	5.0	Rob	Constructed junction box to link from instrument cable to instrument panel. Constructed and mounted brackets to facilitate. Wired instrument cable to junction box per wiring diagram.
222	04/05/2013			III	3.0	Rob	Constructed NPN diode circuit (TIP3055 with 110 ohm base resistance) to prevent engine start unless master is in the "ON" position. Began putting ends on instrument cable.
223	04/07/2013			III	6.0	Rob	Drilled holes in frame, grommeted, and strung, 10 gauge wire for main power supply for instrument panel. Wire surrounded with anti-abrasion material as a precaution even though it should touch nothing. Zip tied wire in place. Also re-polytacked and re-ironed a few seams internal to the fuselage that had worked loose during the process. Vacuumed out interior of plane fuselage.
224	04/08/2013			III	5.0	Rob	Drilled additional holes in frame and zip tied wire for main power supply for instrument panel by rudder pedals to insure no chance of interference. Drilled holes in frame and grommeted holes for instrument cable. Super glued rubber stripping on key points for appearance and to prevent chafing issues with instrument cable. Inserted spark plugs and CHT gauges but did not tighten to specified torque pending documentation review. Vacuumed out fuselage interior again.
225	04/09/2013			III	3.0	Rob & Connie	Tightened spark plugs to 133 inlbs per Rotax Installation Manual. Connected wires to spark plugs. Routed CHT wires to instrument cable. Installed instrument cable on right side of fuselage near bottom and bolted/zip tied into place.
226	04/25/2013			III	5.0	Rob	Installed 35A master breaker and 15A breaker for engine current. Installed 50A capable master switch. Wired and tested engine starter circuit. As designed, confirmed it will not close starter relay unless the master switch is on also.
227	04/26/2013			III	3.0	Rob	Wired EIS to Engine EGTs, CHTs, and tachometer. Fused EIS with 3-Amp Breaker. Wired Ignition switch. Tested EIS as well as possible.
228	05/04/2013			III	4.0	Rob	Drilled holes in fuselage for engine choke and inserted grommets. Drilled hole in engine mount for holding choke and throttle cables. Affixed choke cable at two points along root tube of fuselage. Mounted engine choke control lever on root tube.
229	05/08/2013			III	6.0	Rob	Designed, constructed, and mounted choke cable bracket. Added another point on cable to clamp to root tube. Adjusted length and tension of choke cables: cut cables to appropriate length, swaged inserts into new locations, adjusted at cable ends as needed for even tension on both choke cables.
230	05/13/2013			III	6.0	Rob	Connected throttle cables to carburetor and clamped where needed using AN724 clamps. Drilled holes for throttle levers for both seats. Adjusted length of throttle lever connector and tailored for aircraft. Accidentally ripped 5/8 inch hole in fabric under forward (pilot) throttle while drilling. Used soldering iron to melt ends of rip to prevent further tearing. Also melted rip itself to seal fabric.
231	05/14/2013			III	6.0	Rob	Cut patch for rip in fabric under forward throttle lever with 2-inch margin on three sides and 1-inch margin on bottom where fabric meets tube. Mounted patch on inside of fabric using polytak. Ironed patch at 345 degrees after giving polytak 12 hours to dry. Hand (brush) painted patch on both sides with polybrush 3 : 1 reducer mixture. Designed, fabricated, and mounted fuel pump bracket. Mounted fuel pump. Sized and initially placed hoses for fuel system. Cut wire ties for air filter in preparation for carburetor calibration.
232	05/15/2013			III	9.0	Rob	Painted tear patch by forward throttle lever with second coat of Polybrush 3:1 Reducer with small airbrush. Coated both sides of fabric. Re-cleaned fuel tank confirming nothing in it. Black dot at bottom is drip from epoxy used to seal tank at fuel level sensor. Epoxy can be scratched with difficulty, but it is only a cosmetic issue. Added fuel filter and priming bulb to fuel system. Gasket clamped fuel system -- now ready for use. Bolted prop together and initially set pitch to 12 degrees per suggestion of Warp Propellor employee who called me back. Installed prop serial number C70194(?). Tightened propellor mounting bolts to 12 foot-pounds (144 inch-pounds) per Challenger manual as it was lower than the 175 inch-pounds recommended by Warp Propellor Installation Document and bolts are to be eventually wire tied. Did not get to wire tying bolts before end of day.
233	05/16/2013			III	2.0	Rob	Painted tear patch by forward throttle lever with third coat of Polybrush 3:1 Reducer. Coated both sides of fabric. Wire tied propellor mounting bolts with .032-inch stainless steel wire. Confirmed pitch on propellor correct.
234	05/17/2013			III	3.0	Rob	Painted tear patch by forward throttle lever with first and second coats of Polyspray 4:1 R-8500 Reducer. Coated both sides of fabric. Removed instrument panel and removed all instruments, switches, etc.
235	05/18/2013			III	3.0	Rob	Painted tear patch by forward throttle lever with third and fourth coats of Polyspray 4:1 R-8500 Reducer. Coated both sides of fabric. Used wire brush on instrument panel to provide texture. Used plastic border material to sharp edge on instrument panel.
236	05/19/2013			III	1.0	Rob	Painted tear patch by forward throttle lever with fifth and sixth coats of Polyspray 4:1 R-8500 Reducer. Coated both sides of fabric.
237	05/22/2013			III	2.0	Rob	Painted tear patch by forward throttle lever with two coats of Dakota Black Polytone 4:1 R-8500 Reducer. Coated both sides of fabric. Touched up select other areas as well. Re-installed and retested instrument panel.
238	05/25/2013			III	5.0	Rob	Added second throttle cable for second carburetor. Fitted new bracket between throttles for better control. Slipped while riveting under forward throttle and created second tear just above first. Melted end of holes to prevent tear growth. Cleaned area with MEK. Cut new patch; Polytacked patch into place; heated with iron to 225F and 345F to tighten; painted with first coat of Polybrush.
239	05/26/2013			III	5.0	Rob & Connie	Painted second tear by throttle with Polybrush coat 2. Riveted left main door together and tried fitting to fuselage. Found multiple problems. Drilled out rivets to aft panel. Recut lexan for aft panel for better fit. Added 9 new brackets to connect aft portion of panel to main portion.
240	05/27/2013			III	6.0	Rob & Connie	Fitted left main door to fuselage. Made three new brackets for aft panel of left main door. Riveted aft panel into place. Added edging and weather stripping to left main door. Began constructing right main door. Drilled, fitted, and riveted main lexan portion of right main door. Drilled hinges and clecoed right main door into place.
241	06/03/2013			III	6.0	Rob & Connie	Riveted hinges on right main door -- noting that two had been switched during drilling. Cut, and fitted tube for rear portion of right main door. Fitted rear lexan portion on right main door. Added clips to facilitate riveting rear lexan portion to main portion of right main door. Drilled and riveted rear lexan portion in place. Added edging and weather stripping to right main door.
242	06/04/2013			III	1.0	Rob	Painted second tear by throttle with Polybrush coat 3.
243	06/05/2013			III	1.0	Rob	Touched up with iron and painted second tear by throttle with Polyspray coat 1.
244	06/06/2013			III	1.0	Rob	Touched up with iron and painted second tear by throttle with Polyspray coats 2 and 3.
245	06/07/2013			III	1.0	Rob	Touched up with iron and painted second tear by throttle with Polyspray coat 4.
246	06/08/2013			III	3.0	Rob	Painted second tear by throttle with Polyspray coats 5 and 6. Light test OK. Painted with first coat of Dakota Black Polytone 4:1 R-8500.
247	06/12/2013			IV	1.0	Rob & Connie	Added Radio to instrument panel.
248	06/13/2013			III & IV	1.0	Rob	Added ELT controls to instrument panel. Converted Bus A to a red wire to simplify panel. Mounted Bus B (Grounding lug) to back of panel. Re-installed panel (again).
250	06/14/2013			III	1.0	Rob & Connie	Added bungee door handles to main doors. Cut out rough shape of windshield. Began working on frame for windshield doors.
251	06/13/2013			IIIg	2.5	Rob, Connie, Dad, Mom, Chip Day, Jerry Goodyear	Burned holes in fabric for high strength strut brackets to frame. Added four high strength strut brackets to frame. Added main wing brackets to frame. Added struts to both wings. Mounted wings. Note: bolts connecting brackets to wings are STILL LOOSE and NOT cotter pinned.
252	06/19/2013			IIIg	3.0	Rob & Connie	Checked dihedral of wings without jury struts yet mounted. Found 0 degree dihedral for both wings. Laid out left jury strut mounting points 57 inches from bolt mounting wing to root tube bracket -- midway between that point and where nearest bolt to wing connects bracket to main strut. Drilled holes for two (2) ST-16L brackets mounting front rod jury strut to front spar of left wing. Drilled hole to connect two (2) ST-16L brackets to left middle jury strut.
253	06/24/2013			IIIg	4.0	Rob	Mounted ACK Model E-04 ELT behind battery using a riveted loop of 0.040 6061-T3 Aluminum and four McMaster Carr 6614K58 (MS3367-6) cable ties each rated to 120 lbs made with a stainless steel locking mechanism and UV-Resistant plastic. ELT Serial Number is 007153. ELT Hex Code is 2DC86 A37E2 FFBFFF. Duracel PX28L battery newly installed in remote has an expiration date of March 2021. Duracel CR2 battery newly installed in audio alert indicator has an expiration date of March 2019. ELT transmitter battery has a stamped expiration date of March 2018. Covered GPS connector and cable tied in place. NO GPS installation at this time. Cable tied audio alert indicator under dash on right side using three MCMaster Carr 6614K53 (MS3367-1) cable ties each rated to 50 lbs made with a stainless steel locking mechanism and UV-Resistant plastic. Wired remote to audio alert indicator and audio alert indicator to ELT using provided cabling and connectors. Replaced one RJ-11 4-pin connector and shortened wire to facilitate routing. Cable tied relevant sections to prevent wear related issues. (See photos)
254	06/25/2013			IIIg	3.5	Rob & Connie	Drilled and clecoed left middle jury strut to left front and rear lift struts with four (4) ST-16L brackets. Aligned rear set of ST-16L brackets longitudinally along left rear lift strut. Adjusted position of brackets to eliminate horizontal component of bow between left forward and rear struts. To facilitate further work, riveted rear two (2) ST-16L brackets to left rear lift strut using six (6) ABS-64 rivets. Connected left rear jury strut to rear spar of left wing via ST-16L brackets. Fitted left rear jury strut between rear spar of left wing and left middle jury strut to eliminate bow in left rear lift strut on vertical axis.
255	06/25/2013			IIIg	4.0	Rob	Connected left rear and left middle jury struts with two (2) ST-16F brackets, AN525 bolt, and AN365 nyloc nut and clecos where ABS-62 rivets will go in the near future. Cut, drilled, and clecoed bottom of left front jury strut to left middle jury strut via two (2) ST-16F brackets, an AN525-10R14 bolt and an AN365 nyloc nut. Left front jury strut length adjusted to eliminate vertical bow in left front lift strut. Fitted and connected left N jury strut to left front strut and left middle jury strut using four (4) ST-16F brackets, one AN525-10R16 bolt, one AN525-10R14 bolt, two (2) AN365 nyloc nuts, and twelve (12) clecos where ABS-62 rivets will go in the near future. (See photos)
256	06/26/2013			IIIg	2.0	Rob	ELT tested OK per ELT manual: Temporarily connected antenna to ELT transmitter and armed ELT at 6:00pm (11:00 UT). Heard short beep followed several seconds later by second beep from audio alert indicator. There was also a burst of alarm from the radio at 121.5MHz (emergency frequency. At 6:02pm local time (11:02 UT), used remote "on" button to activate. Confirmed transmission with radio set to 121.5MHz. After 5 seconds, used remote "Off/Test" button to stop transmission. Confirmed transmission ceased at 121.5MHz. Switched ELT transmitter to "off" and disconnected antenna. Moved brackets fixing cables to engine mount to a location that did not interfere with the left aileron.
257	06/27/2013			IIIg	9.0	Rob & Connie	Drilled, fitted, and clecoed right jury struts. Riveted brackets connecting right rear lift strut to right middle jury strut. Checked aileron range of movement. Found that rear strut attach brackets limited downward range -- 27 degrees for right aileron and 32 degrees for left aileron. Removed 1/8 inch from both brackets. New downward limits: 36 degrees for right aileron and 41 degrees for left aileron. Further improvement for right aileron limited by aileron bracket under fabric.
258	06/29/2013			IIIg	4.0	Rob & Connie	Riveted remaining brackets that connect jury struts to lift struts and wing after deburring holes and melting fabric at wing rivet hole boundaries. Marked front, rear, and N jury struts for both sides with L/R using engraver to avoid later confusion. Painted front, rear, and N jury struts with Rustoleum black spray primer and two coats of Rustoleum glossy black enamel spray paint. Both middle jury struts left in place with ST-16F brackets to make sure none are switched during painting. Began laying out lift strut fairings.
259	06/30/2013			IIIg	2.0	Rob & Connie	Painted front, rear, and N jury struts with one coat of Rustoleum glossy black enamel and two coats of Rustoleum clear coat spray paint. Left to dry in sun. Slumped lexan at 375F and 5lbs force over a 1/2-inch diameter rod for compass mounting bracket.
260	07/01/2013			IIIg	4.0	Rob	Riveted ST-16F brackets to front, rear, and N jury struts with 3/16-inch rivets. Painted both middle jury struts with one coat of Rustoleum primer, three coats of Rustoleum glossy black enamel, and one coat of Rustoleum clear coat spray paint. Left to dry in sun.
261	07/08/2013			IIIg	2.0	Rob & Connie	Had accident while working near right wing root. Tore one inch rip near root of wing and damaged one rivet with minor bend in sheet metal. Other damage nearby only to paint job. Removed right wing.
262	07/15/2013			II	3.0	Rob	Began repairs to tear and dent in right wing near middle of root. Melted edges of tear with hot iron to prevent further tearing. Cut away additional fabric to reveal damage. Bent sheet back as best could. Riveted in place two 1/8 stainless steel SSD42SSBS rivets -- one in the original hole, the other a half inch from removed rivet. Removed coatings from original fabric using methyl ethyl ketone. Recovered damaged area with 6.5x3.5 section of fabric and polytacked into place as appropriate. After four hours, heat shrunk with iron to 250F and 350F to remove all bubbles and tighten fabric. Coated with Polybrush 3:1 R-8500 Reducer doped with blue polytone to aid in visibility.
263	07/16/2013			II	2.0	Rob	Used brush to apply second coat of Polybrush 3:1 R-8500 Reducer -- temp 76F, 49% humidity. Eight hours later, brushed third coat of Polybrush 3:1 R-8500 Reducer -- temp 77F, 51% humidity. After additional eight hours, sprayed first cross coat of Polyspray 4:1 R-8500 Reducer -- temp 85F, 38% humidity.
264	07/17/2013			II	3.0	Rob	Sprayed second and third cross coats of Polyspray 4:1 R-8500 Reducer -- temp 83F, 37% humidity. No way to do a light check on the fabric in question plus area in question is in a spot hidden from light. Sprayed coat of Insignia White Polytone 4:1 R-8500 Reducer on repaired section -- 85F, 37% humidity.
265	07/18/2013			II	2.0	Rob	Sprayed first coat of 136 lemon yellow Polytone 4:1 R-8500 Reducer on repaired section -- 80F, 34% humidity. After nine hours, sprayed second coat of 136 lemon yellow Polytone 4:1 R-8500 Reducer on repaired section -- 84F, 34% humidity. Right wing root damage repaired.
266	07/19/2013			IIIg	1.0	Rob & Connie & Mom & Dad	Reattached right wing.
267	07/21/2013			IIIg	5.0	Rob & Connie	Reconnected jury struts on all sides. Tightened all wing and strut connector bolts. Inserted safety pins into bolts connecting front wing spars to root tube rony brackets. Inserted safety pins into bolts connecting lift struts to fuselage. Inserted safety rings into bolts connecting rear wing spars to root tube rony brackets. Laid out and riveted with SSD42SSBS rivets the bottom four locations on right front lift struts at inch marks from the end of the rony bracket: 2, 37.3125, 72.6875, and 108. Found and corrected direction of pin from stabilizer frame to forward stabilizer strut.
268	07/22/2013			IIIg	2.0	Rob	Laid out and riveted with SSD42SSBS rivets the bottom four locations on the left front lift struts at inch marks from the end of the rony bracket: 2, 37.3125, 72.6875, and 108. Laid out and riveted with SSD42SSBS rivets the top three front lift struts at inch marks from the end of the rony bracket: 2, 37.3125, and 72.6875. Drilled and riveted rear struts at inch marks from the end of the rony bracket: 2, 38.3125, 74.6875, and 111 (bottom only).
269	07/23/2013			IIIg	2.0	Rob	Designed and began construction of brackets for mounting compass. Bent 11.25-inch radius tube for front of windshield as a part of also adding two additional front doors to facilitate entry/exit.
270	07/24/2013			IIIg	10.0	Rob	Completed construction of brackets for mounting compass and riveted brackets together and to horizontal tube just in front of foot pedals. Refer to diagrams and pictures in notes for details. Wired a red night LED light to light up compass in conjunction with built-in compass light which was inadequate on its own. Also wired a white LED light for daytime use. Used 16 gauge red wire or the red LED and yellow wire for the white LED. The 800 ohms (1/2 watt) of resistance for the red light and the 350 ohms (3/4 watt) resistance for the white light were covered in heat shrink tubing to insulate. Compass surface has an electrical hot spot that required taping over with wire insulating tape. zip tied wire into place. Put breaker in place, but I did not wire the switch yet as appropriate option not available. Tested rest of compass electrics successfully, however.
271	09/01/2013			IIIg	3.0	Rob & Connie	Centered joy stick and flaperon control. Measured proper length of aileron control rods using string and adjusting length to place both ailerons parallel too bottom of wing. Found hole-to-hole length to be 12 inches. After opening 6 threats of adjustment space, cut aileron control rods to 11 inches (-1 inch for fitting). Force fit and riveted fittings in place on aileron rods using 1/8 SS rivets. Mounted aileron rods between aileron control horns and flaperon assembly. Adjusted length as needed. Checked aileron range at full flaperon: max 45 down left aileron and max 37 down right aileron.
272	09/02/2013			IIIg	2.0	Rob & Connie	Created clips to hold semi-circular tube for windshield mounting from 1.25 inch sections of tube with a 120 longitudnal cut out section. Drilled and mouned semicircle so it fit to top cap and door mounting bracket.
273	09/04/2013			IIIg	2.0	Rob & Connie	Designed, cut, and fitted front windshield brackets to fit from semi-circular tube to frame using 5/8 x 5/8 Bulb-ended .050 thk L-channel made of T6061-T6 AL.
274	09/18/2013			IIIg	6.0	Rob	Created angle brackes to mount windshield brackets in place. Drilled and mounted rivnuts for screwing windshield in place. Burned holes in fabric where necessary for holes.
275	09/18/2013			II	0.1	Rob	Discovered small tear in left wing. Burned ends of tear to prevent expansion.
276	09/26/2013			IIIg	2.0	Rob	Notched top cap for windshield brackets. Cut Initial windshield template.
277	10/16/2013			IIIg	2.0	Rob	Riveted Top cap into single piece. Lined top cap with rubber edging to reduce wear issues. Used anti-chafe tape to seal gaps and stiffen joint further.
278	10/20/2013			IIIg	2.0	Rob	Fitted top cap back on plane. Completed aileron assembly. Tested very stiff.
279	10/22/2013			IIIg	2.0	Rob	Added ELT antenna to top cap.
280	10/23/2013			IIIg	1.0	Rob	Added Connector between ELT antenna and metal skeleton.
281	10/29/2013			IIIg	4.0	Rob	Not comfortable with windshield flexture. Added new bracket at middle of the windshield beam to support. Windshield much more rigid afterwards.
282	11/06/2013			IIIg	4.0	Rob	Constructed pitot tube and bracket for mounting through windshield.
283	01/12/2014			IIIg	2.0	Rob	Added communications radio antenna and Outside Air Temperature Sensor to top cap.
284	01/18/2014			IIIg	3.0	Rob	Began work on right front door by shaping paper template. Tried several hinging methods. Settled for top hinge, but kept my options open.
285	02/07/2014			IIIg	2.0	Rob	Cut lexan window and tubes for right front door. Used supplied piece for back portion, but trimmed it to allow door to open instead of forming edge of windshield. Drilled holes to mount tubes.
286	02/15/2014			IIIg	4.0	Rob	Trimmed lexan further and moved hinge to forward edge of door. Drilled holed in frame, and inserted rivnuts to allow three screws to hold hinge. Cannot add more above or below without risking hitting other rivets under fabric.
287	02/16/2014			IIIg	4.0	Rob	Made gussets for between tubes in right door, drilled and clecoed into place.
288	02/26/2014			IIIg	4.0	Rob	Began fitting left front door by rough cutting lexan and fitting into place.
289	02/27/2014			IIIg	4.0	Rob	Added right front door hinge using similar method as left. Cut,drilled and clecoed pipes of right door into place.
290	03/05/2014			IIIg	4.0	Rob	Trimmed door gussets and cleaned up as needed. Riveted front left door together. Used heat gun to form door lexan for closer fits.
291	03/07/2014			IIIg	4.0	Rob	Used bolt and bungee to make door latch for left front door.
292	03/12/2014			IIIg	2.0	Rob	Cleaned up gussets and riveted right door together.
293	03/12/2014			IIIg	2.0	Rob	Made latch for right door.
294	03/14/2014			II	3.0	Rob	Started engine and broke in per manual specifications. Time 1h5Min. Idle RPM 2300. Max RPM 6400. Ambient air temperature was a balmy 45F. No problems with overheating.
295	03/15/2014			II	3.0	Rob	Polytakked 4in X 4in patch over hole in left wing (discovered 2014.09.18) and ironed to 350F. Painted patch in left wing (discovered 2014.09.18) with first and second coats of polybrush 3:1 R-8500. Temp 65F, Humidity 25%, Polybrush mix precooled to 45F. Hangar heated to 75F afterwards.
296	03/16/2014			II	2.0	Rob	Painted patch in left wing (discovered 2014.09.18) with third coat of polybrush 3:1 R-8500 and first coat of polyspray 4:1 R-8500. Temp 65F, Humidity 25%, Polybrush and polyspray mixes precooled to 45F. Hangar heated to 75F afterwards.
297	03/17/2014			II	2.0	Rob	Painted patch in left wing (discovered 2014.09.18) with second and third coats of polyspray 4:1 R-8500. Temp 65F, Humidity 25%, Polyspray mix precooled to 45F. Hangar heated to 75F afterwards.
298	03/18/2014			II	2.0	Rob	Painted patch in left wing (discovered 2014.09.18) with fourth, fifth, and sixth coats of polyspray 4:1 R-8500. Temp 65F, Humidity 35%, Polyspray mix precooled to 50F. Hangar heated to 75F afterwards.
299	03/19/2014			II	1.0	Rob	Painted patch in left wing (discovered 2014.09.18) with one coat of Insignia White Polytone 4:1 R-8500. Temp 65F, Humidity 45%, Polytone mix precooled to 50F. Hangar heated to 75F afterwards.
300	03/24/2014			IIIe	5.0	Rob	Cut holes in instrument panel for Lighting switches and breakers. Inserted switches into panel. Wired Outside Air Temperature (OAT) sensor and confirmed operation. Began wiring compass light switch.
301	03/25/2014			IIIe	3.0	Rob	Cut holes in instrument panel for strobe light controls. Wired breaker and switches for compass lights. Began wiring brakers for position lights and strobes. Tested compass lights and breaker successfully.
302	03/26/2014			IIIe	2.0	Rob	Made jumper wires for breaker area on instrument panel. Made brackets for mounting strobe power box on frame over rear passenger seat.
303	03/30/2014			IIIe	5.0	Rob	Installed strobe control box over co-pilot/passenger seat. Wired position lights from wings and tested functionality at both high and low power mode. Added new ground to root tube.
304	04/01/2014			IIIe	5.0	Rob	Wired strobes and tested functionality at both high and low power mode.
305	04/02/2014			IIIe	5.0	Rob	Wired communications system into aircraft. Placed unit over pilots head attached to root tube. Comm system has an independent battery backup but drains 200mA when operating via 12VDC source. Routed power supply to 1/2 Amp fuse and master switch. Comm still works with master switch off, but it no longer draws from aircraft power. Placarded everything.
307	04/06/2014			IIIe	8.0	Rob	Wired A24 radio into comm system. Added transmit switch to pilot's stick. Tuned engine with Carbmate. Rewired air cleaner to engine. Taxi tested. Did wheelie just as airspeed came live at 30mph, but I did NOT leave the ground. Radio, controls, instruments all performed fine. Did additional taxi testing to run to no fuel. Did weight and balance on empty plane with no doors. Left: 206, Right: 203, Tail: 61
308	04/09/2014			IIIe	4.0	Rob & Connie	Found bad connector in starter circuit and replaced along with master switch. Added co-pilot transmit switch. Verified out of useable fuel. Redid weight and balance both with and without doors. No noticable difference in no door weight. With Front Doors -- Left: 210, Right: 209.5, Tail: 59.5. With All Doors -- Left: 217, Right: 217, Tail: 58.5.
309	04/09/2014			IIIe	1.0	Rob	I certify this aircraft has been inspected in accordance with the scope and detail of Appendix D to Part 43 and has been found to be in a conditions for safe operation.