Back to the ER tank grind


Man the number of operations for each bracket to mount the ER tanks in insane. The middle bracket is the most time consuming. On the left tank I thought it took four hours to fabricate. But today on the left I took nearly six hours (for one bracket). Sheesh. And I’m sure I was faster today… So all that is…

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Left ER Tank Bolted On


Damn, what a frustrating day, it wasn’t that anything went horribly wrong. Just one of those days. On the positive side, I did manage to get the left ER tank 100% bolted on, all that remains is running the fuel lines and tank vent. I keep going back to how much effort it was for the mid bracket (4 hours).…

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ER Mounting Day 2


Started the day installing the end ER tank brackets which went pretty smooth. Next was a bigger challenge getting the outboard tank mounts positioned. This seriously took way longer than I would expect but it has to be tilted so gravity moves the fuel to the inboard side of the tank, the wing tips have to fit, and there has…

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ER Tanks have fuel pumps!


Started with making a vacuum adapter for sucking the metal flakes when drilling the holes for the main fuel tank bung. Drilling went well but I did spend about 45 minutes deburring, vacuuming, and cleaning the tanks. I think and hope I got everything. Then it was on to installing the ER tank fuel pumps, once I deciphered how everything…

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Full steam ahead


With three of us working I bounced around a bit but my main focus was finishing the Vertical Stabilizer. I had some rivets on the rear spar before I could assemble and start the not so fun riveting which involved reaching way up inside the cavity for a number of hours. I also helped with the fuel valve/lines installation only…

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More Vertical Stabilizer fun before an exciting end of the day.


Finished up the deburring of the holes, counter sinking spar holes, cleaning the parts, and finally priming them. Cue the riveting, today I seemed to not have my head on straight. Half the rivets had to be drilled out either due to incorrect assembly or crappy rivet setting. Ugh, one of those day. But I did get the rear spar…

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Finally back to the Vertical Stabilizer


Well almost, first I had to build a new stand for the wings for the install of the ER fuel tanks. The current stand supports the wings from the ends which obviously won’t work when sliding a tank on the outboard side. A couple hours later I feel good about the stability of what I built. Then the final bit…

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Fun steps assembling the Trim and Autopilot systems


I started by finishing up fabrication of the two brackets for the Elevator trim. Then on to cleaning and priming all of the parts. Queue the fun, assembling the pitch trim. This went smoothly until testing, the servo hit metal before reaching the internal stop. Need to think a bit about how to correct this, I can’t see any possible…

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Almost forgot something important


Laying in bed last night what pops into my mind but that I forgot to pull the wire through the wings for my extended range fuel tank pumps. Ugh, that could have been a pain. So guess what I started my day doing… Reading through the instructions and reviewing the excellent builders log by Robert Lussow I decided the tanks…

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Wire up those wings!


With the tail is good shape, my plan had been to bang out the Vertical Stabilizer but plans changes… Instead I ran the wires through the wings, mounted the Garmin Pitot tube regulator, and wired the Autopilot Roll servo connector. I got the cutouts finished for the rear air vents too. A productive day and now the wings are ready…

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Closing out the tail, by working on the tail


There is a lot going on at the end of the Tail section. Today was spend getting all the pieces prep’d, fitted together in the correct order, and preparing for riveting. Oh and riveting too. Too focused on riveting to snap any pictures. Shame. Shame. Shame.

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