CS Spar Test Fit

CS Spar Test Fittings during “The Grand Mock-Up”

22 June 2013 — Today I pulled out all the stops . . . or should I say I pulled out all the pieces of the build so far.  Before I am separated from my project while I spend a year in the Middle East for Uncle Sam, I wanted to get an idea of what this thing looks like put all together.

So I pulled the fuselage out into the front yard, and kept it covered while I collected the other components.  Next up was the Centersection Spar which I placed into the fuselage for the first time since I completed it about 8 months ago.

Chap 14/15 - CS spar & firewall mockupChap 14/15 - CS spar & firewall mockup

You can see in the pic below that I got the measurements correct for running the rudder cable conduit through the fuselage sidewall, then through the CS Spar and positioned just off the edge of firewall (the curved metal conduit bracket that the Nylaflo will run through will get mounted to the firewall).

Chap 14/15 - CS spar & firewall mockup

I’m jumping ahead with the following pics below since they were at the tail end of the this grand mock-up as I was tearing it all apart, but I wanted to keep like pics together.

Chap 14/15 - CS spar & FirewallChap 14/15 - CS spar & Firewall

Chap 14/15 - CS spar & FirewallChap 14/15 - CS spar & Firewall

Chap 14/15 - CS spar & FirewallChap 9/14 - Main Gear & CS spar

After I got the CS spar & firewall in place, I added both of the wings next.  Again, besides the measurements provided to me in the plans, and of course a couple dozen confirmation measurements, I had not lined up either wing with the CS Spar to confirm that the hard points (aluminum extrusions) lined up with each other.  Obviously, I was very relieved to confirm I hadn’t jacked any of my measurements up!  Also, as you can see I had to throw on at least one winglet just to get an idea of how it would look.  Although it was a little awkward to get it on the end of the wing so it looked half-way normal, I think I got in the ballpark.  Well, and of course we can’t forget the canard… yes, it’s on there too!

Long-EZ Project Mock-upChap 14/15/19/20 - CS spar-firewall-wings-wingletLong-EZ Project Mock-upChap 14/19/20 - CS spar-wings-winglet

Once I got the pics above taken, now it was time to fill in what gaps I could to make it look at least a little like it had some mass to it.  Next came the engine cowlings.  The wind had picked up a little bit and I didn’t want to damage anything just to get some pictures, so I removed the Left winglet & put it inside the garage.

Chap 19/23 - Wing/spar & Cowling fit

Chap 19/23 - Wing/spar & Cowling fit

And then the following pics are more close-up shots of the upper cowling & CS spar-to-wing fit.

Chap 23 - Cowling Trial FittingChap 19/23 - Wing/spar & Cowling fit

Finally, after I broke everything down and got the wings, canard, cowling & firewall back inside out of the sun, I spent some time looking at the CS spar, taking some measurements and looking at how square it was to the fuselage (this was a quick mock up to keep all the parts in the sun as little as possible–about an hour total time . . . and if you actually look at the shadow of the house on the mock-up from start to finish, there’s not that much movement).  At this point the CS spar and the fuselage were in the shade provided by the sun going down on the other side of the house.

Chap 14 - CS spar trial fitChap 14 - CS spar trial fit

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Project Update

Hey Guys,

I left my last project update for a while so everyone would have a good chance to read it.  

So this is it folks!  I hope for this to be the final push from now until Rough River to get the main assembly of the aircraft completed.  That’s my goal.  Is it an aggressive timeline?!  Oh, yeah!  After Rough River, I then expect the next few months to be finalizing any leftover punch list items and the finishing & painting! 

Over the past few months I’ve had some unexpected scope creep in my build, which is all well and good because the build is THE project.  As you know I rewickered Marc Zeitlin’s new AEX system which took a fair amount of time to implement, then I had planned on knocking out a good dozen electrical related items so that I could close up the nose.  I got a bunch of those completed, but kept finding myself not being able to really close out wire runs, confirm install spacing configurations such as the pitch trim unit, etc. because I couldn’t sit in the airplane and confirm what I had dimensionally without the actual pilot’s seat in place.

This drove me to move my immediate project line of demarcation from the instrument panel, back one more bulkhead to the pilot’s seat.  I was then going to knock out the pilot’s seat area –including the thigh support & cover– but there was a glaring prerequisite to doing so: I couldn’t get the pilot’s thigh support configured & installed without the fuel lines in place!  Thus, I needed to move the project line of demarcation back one more bulkhead and knock out the thigh support sump tank to get the fuel lines run in reality without merely estimating some more with a fake, mocked up install.  

So the immediate order of battle right now is to finish the fuel sump (including configuring the majority of the back seat area), and then the pilot’s seat area. These, in turn, will allow me to finalize the configuration of the nose components. At which point I will focus on the building the nose while concurrently finalizing the wheel pants install (nope, haven’t forgot about those!). Then the canopy install will be after that.

Hang on to your hats folks, it’s about to get busy all up in here!

Cheers!

 

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