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Tasklist

The manual that I'm working from is arranged by topic (wings, landing gear, fuel system, etc.). The plane is not built by starting a page one and working through the manual sequentially. There is a  "flow chart" that lists the tasks to be performed in the order they are supposed to be done in.

 

So to get an idea of what I'm doing, here it is. Some of the tasks are missing because they don't apply. For example, there's a fixed landing gear version which has tasks that I don't do. I've removed those steps. So if you notice some missing numbers, that's why. If it's red, it's done!

 

  1. Read chapter one of your manual and review the construction DVD's

  2. Cut out Doghouse

  3. Cut out and install premolded NACA scoops

  4. Install Overhead plenum NACA (do not install plenum until flipping airplane)

  5. Fit keel in airplane and then remove to install control system

  6. Install wood hardpoints for control system in keel

  7. Cut out and layup inspection covers in keel

  8. Install nut plates to hold inspection covers

  9. Cut out nose gear door hinges

  10. Install top Triax pad on firewall for Lycoming engine mount or the lower pads for a continental engine

  11. Complete fiberglass portion of nose gear door installation

  12. Install Heater flapper valve and aluminum outlet tubes in oil cooler exit

  13. Cut out oil cooer inlet and outlet ducts

  14. Install front oil cooler ducts

  15. Install rear aileron control bracket to keel rear section

  16. Install aileron torque tube and control stick in keel

  17. Mid bearing support installed in keel

  18. Install main gear and nose gear cylinder

  19. Install AN fittings into main and nose gear cylinders (tape over the ends)

  20. Install flexible hydraulic lines between nose and main gear cylinders

  21. Fit and install battery tray

  22. Fit and install Landing Light Assembly (not going to have a landing light in the nose)

  23. Structural Adhesive front of keel in place

  24. Install front keel stiffening layups

  25. Install nose gear bushing plates

  26. Glass edges of canard cutout to seal it

  27. Fit and fair in nose access cover

  28. Install nose gear gas spring and shock assembly

  29. Install nose gear door cylinder and assembly

  30. Install RG hydraulic power pack

  31. Install MG pulley and cable assembly

  32. Install rudder pedals

  33. Fit instrument panel into airplane ( Once the panel has been fitted it can have the instrument holes cut out be finished and sent out to be wired.)

  34. Install seat hardpoints

  35. Use Velocipoxy and micro to fair in back of windows

  36. Construct sump tank

  37. Glass side of canard bulkhead opposite the flange

  38. Install sequence valve assembly

  39. Install Dump Valve

  40. Install nose gear guides

  41. Install hydraulic power pack

  42. Install hard lines for RG system

  43. Install Center Spar

  44. Install all Triax reinforcements on the forward side of the firewall between the center spar and the gear bulkhead.

  45. Place airplane on jacks and remove main gear

  46. Cut out fuselage to allow main gear retract and complete transverse bulkhead installation

  47. Install main gear bushings

  48. Triax over main gear bushings

  49. Permanently install steel bushings in gear legs and make aluminum spacers

  50. Install straws on MG for brake lines

  51. Install canard attachment reinforcements (triax)

  52. Install Canard bushings

  53. Complete all canard Triax reinforcements

  54. Install hinges on elevators

  55. Install hinge arms in canard

  56. Attach canard tips

  57. Install concentric torque tube

  58. Install counterweights

  59. Check balance of elevators

  60. Install elevator pitch trim actuator

  61. Install main gear

  62. Install main wings prep for strake install

  63. Temporarily install doors (hinges do not have to be completed yet)

  64. Fit lower strake

  65. Cut out baggage access opening

  66. Install lower strake bottom

  67. Fit top strake

  68. After bottom strake is attached permanently you can remove wings to provide more space

  69. Glass dyvinicel sheet to make fuel tank baffles

  70. Cut out opening for gear and wheel well

  71. Fit gear and wheel well

  72. Cut out baffles a little larger than templates

  73. Glass top flange on wheel well

  74. Fit baffle bottoms to bottom strake

  75. Fit baffle tops to top strake

  76. Reposition all baffles in bottom strake and tack in place

  77. Glass bulkheads and baffles to lower strake

  78. Install hardpoint for fuel vent and main fuel line

  79. install sight tubes

  80. Install fuel caps in strake top

  81. Plug fuel lines and remove senders and coat tank to seal with 2 coats of Jeffco or EZ-poxy

  82. Coat strake top with Jeffco or EZ-poxy in fuel tank area

  83. Cut wing access bolt hole

  84. Practice fuel strake top installation with partner

  85. Install strake top

  86. Cut wing from strake

  87. Remove wings

  88. Cut leading edge from strake that will go on the door (or is already attached to the door)

  89. Install door and glass leading edge of strake to it

  90. Install outboard end stake reinforcement

  91. Finish glassing on exterior of fuel tank bottom seams and back of spar to strake top and bottom

  92. Pressure check each main fuel tank

  93. Complete finish work between strake top and fuselage and leading edge of strake

  94. Reinstall wings

  95. Complete finish work between strake top and wing (recut line between wing and strake)

  96. Remove wings

  97. Flip airplane

  98. Finish glassing on exterior of fuel tank top seams

  99. Complete finish work between strake bottom and wing (recut line between wing and strake)

  100. Complete glass work between strake top and inside of baggage well

  101. Install overhead fresh air plenum

  102. Fit main gear doors and install attach brackets onto gear legs

  103. Fill sand and prep gear legs for primer (RG's may be easier to remove legs from plane for this)

  104. Complete all finish work on bottom of airplane including all bolts that protrude through the floor and around the oil cooler exit

  105. When completed with all bottom finish work the bottom of the airplane can be primed to prep it for paint

  106. Remove wings

  107. Flip airplane back onto it's gear

  108. Install sump tank

  109. Install fuel plumbing between main tanks and sump tank and sump tank and firewall fitting (RG's make sure you cycle your gear to make sure your gear clears your fuel lines)

  110. Install Fiberfrax and stainless steel on firewall

  111. Install oil lines to forward oil cooler ( make sure to cover them at the firewall until the flexible oil lines are installed)

  112. Install rudder cable nylaflow in airplane from pedals to the firewall

  113. Bond in rear keel (whale tail) section and install rear aileron bellcrank in keel

  114. Install Aileron push/pull cables through firewall

  115. Install Aileron torque tube

  116. Install Aileron bellcrank and bearing brackets in wing root

  117. Install Rudder hinges

  118. Install rudder horn

  119. Install rudder return spring

  120. Install Aileron hinges

  121. Install rudder cable in airplane and wing nylaflow

  122. Install rudder pulley and cable adjuster between firewall and wing root

  123. Install winglet bottom

  124. Fit top and bottom cowling and flange

  125. Install Door hinges

  126. Install secondary lock in door

  127. Install key lock

  128. Fit door trim panels

  129. Install door gas springs

  130. Assemble seat backs to bases with seat hinges

  131. Install seat belt hardpoints

  132. Remove wings

  133. You will now progress into engine installation. Before installing the engine it is easier to finish as much component installation onto the firewall as you can.

  134. Fit fiberfrax and stainless to firewall and install

  135. Install front oil cooler lines and bracket on firewall

  136. Install secondary oil cooler

  137. Install electric fuel pump

  138. Plumb aluminum lines between firewall bulkhead fitting and fuel pump

  139. If using a prewired harness you can begin routing the main harness and installing the terminal blocks on the firewall and in the rear of the airplane Harness instruction

  140. Mount the engine mount on the engine

  141. Mount the engine on the firewall

  142. Fabricate oil access door

  143. install oil and fuel line plumbing from the airframe to the engine

  144. Install engine senders on firewall and wire

  145. Plumb flexible lines between engine and senders

  146. Jack airplane up and fit brakes to gear legs

  147. Check for toe in and camber. Shim axle to correct

  148. Installed prewired panel

  149. Connect panel wiring to premade harness Harness instruction

  150. Install Throttle , Mixture and Prop control cables

  151. Install pitot tube

  152. Install Static port

  153. Install vacuum system and static system

  154. Install engine cooling plenum and runners to NACA scoops

  155. Cut exhaust exit in cowling

  156. Trim exhaust tubes and permanently install on engine

  157. Install prop as per manufacturers recommendations and trim or modify rear cowling as necessary to fair in

  158. Install canard

  159. complete control stick to concentric torque tube installation