Gear Leg Fairings

Laid out some duct tape around the gear legs and fuselage, molded up some clay, and used 3 plies of BID to make some gear leg fairings.

Lower Cowl

Laid up some reenforcing tape for the lower cowl attachment points, made a shroud for the exhaust exit, and did the final fitting.

Cooling Scoops

Finished up the plenum cooling scoops with some nutplates and a coat of primer and paint.

Rigging

Finished rigging the right aileron, changed the right rudder attachment per plans, hung the wings, finished fabricating and rigging the firewall aft pushrods, and finished rigging the rudder control cables.  Also installed the navigation and strobe lights.

Aileron Rigging

Rigged up the left aileron after replacing the universal joint which was torn, as well as replacing the bellhorn with the beefed up version per CP-58, rod ends with -4 per CP-103, and torque tubes with steel per CP-49.

Hidden Bellhorn Attachment

Had to re-do the attachment for the rudder cable to the hidden bellhorn.  The original builder had permanently attached the cable using sheet aluminum with a bunch of pop-rivets.  I had to cut the cable when removing the rudders, and there was no way to attach a new one.  Plus it was binding, so I wanted to re-do it per plans.

Fabricated new steel tabs per plans, and cut the holes in the wings to line everything up without binding, then permanently attached with solid rivets.

Fixed a little hangar rash too while the wing was upside down. 

Fuel Line Support

The fuel lines needed a little more support between the sump and fuel selector valve, so I made quick bracket, flexed it in place, and secured the lines with adel clamps.

Avionics Installation

Finished installing all the avionics and wiring up all the indicator sensors.

ELT Installation

Got the ELT all mounted up.  Had to place it in between the legs of the back seat passenger.

Made a little aluminum mount for the antenna so I could attach copper tape underneath the plane where the belly brake is and create a decent ground plane.

Panel Overlay

Got the panel overlay laser cut and engraved by Martian Laser in San Diego.  It's made from a 1/8" reverse laser mark sheet of plastic made by Rowmark.  I used split electrode electroluminescent sheet from LuminousFilm to produce the backlighting.  I drafted everything up in autocad before getting all the pieces cut.

Gutted a cheap PWM dimmer I found on Amazon to provide dimming for the electroluminescent film.  This is what the vendor said to do to provide remote dimming with a rheostat.

Aileron Balancing

The left aileron was out of balance as well.  Added a strip of lead with adhesive spray and put a layer of glass over that, and some heavy sanding with a light coat of primer.  All in balance now.

Elevator Balancing

Found that the elevators were heavy and out of balance.  Had to sand it all down to bare glass and put on a light coat of primer to get them within weight and balance specs.

Rudder Pedal Return Springs

Made some aluminum tabs and hooked up the rudder pedal return springs.