Germany I (Mar-Oct 2012)

I arrived in Germany in late July 2011.  I spent the first 5 weeks looking for a place to live and then was deployed shortly afterwards to Vicenza, Italy for another 5 weeks.  By the time I moved into my place in October 2011, the weather was getting much cooler and my garage was unheated and had no power.  So I decided to hold off on the build and enjoy the holidays build-free.

I shipped most of my shop to Germany thinking that I would add more weight to the project and to my return household goods shipment by building the airplane bits ‘n pieces (epoxy adds weight), and then getting rid of a bunch of shop stuff.  By ridding myself of all the shop table frames, foldaway glass-cutting table, raw particle board (for center section spar jig), etc., I hope it all would equalize out as a zero sum weight gain.  We’ll see!

I spent March & April 2012 prepping the garage and a utility room as the two primary workshops.  I had to outfit (read: buy) the shops with 220V lights and extension cords.  For the garage, I ran extensions cords from the back of the house and my front kitchen window.  Also, any specialized US-spec tool had to be run through a transformer… as you can see, a lot of plugging/unplugging just to finish the simplest tasks.  And since Germany is cold/cool most of the year, I had 2-3 heaters that I ran A LOT (electric bill was HIGH!).

In Germany I, the chapter build order does NOT follow the plans since I was prioritizing the build based on which sections would use the most epoxy (more on that in the posts).

• Feather Lite Order – Inventory

• Shop Preparation – “Chapter 3 Prep Round 2”

• Chapter 6 Part 2 – Fuselage Repair & Assembly

• Chapter 7 – Fuselage Exterior

• Chapter 8 – Rollover Structure & Seat Belts

• Section VI – Landing Brake

• Chapter 9 – Main Gear

• Chapter 16 & 24 – Covers, Fairings & Consoles

• Chapter 19 – Wings Build Prep

.                        Right Wing Build

.                        Left Wing Build

• Chapter 20 – Winglets

• Chapter 14 – Center Section Spar: Spar Box

.                        Center Section Spar: Shear Web & Spar Caps

.                        Center Section Spar: Final Steps

 

 

 

 

 

 

Recent Posts

Project Update

Hi Folks,

Months ago I made a goal to try my best to get this bird done before the Rough River fly-in.  Yes, a crazy goal… but I knew it would keep me working on the plane full bore.  So much of these builds are like running a marathon… mental motivation.  As in staying motivated.  

When it was clearly obvious that I wasn’t going to make Rough River, I took a break for almost a week to head back up to the DC area to simply relax and visit friends.  Upon my return I’ve been getting some personal things done and am really just getting back into the build.

With the fuselage still inverted I’ve knocked out nearly all of the “micro” (West 410 + micro) finishing on the bottom surfaces of the airplane and the subsequent epoxy wipes ala the Corey Bird finishing method.

Within days I expect to be be diving into knocking out the main gear leg-to-fuselage interface fairings as well.

Concurrent with completing the gear fairings I plan on doing a fair amount of priming and painting on the bottom side of the bird as well.

Yep, I expect this bird to be inverted for another 2-3 weeks (ha!) before it gets flipped back upright to close out the strakes with the top skin install.

After the top strakes it will be on to the winglet/rudder install (Chapter 20).  Then engine and top cowling install, topside finish and prime/paint.

 

  1. Chapter 25 – Post epoxy wipe refits Leave a reply
  2. Chapter 13/25 – Nose gear actuator out Leave a reply
  3. Chapter 25 – Bottom cowl micro Leave a reply
  4. Chapter 25 – Bottom cowl final fit Leave a reply
  5. Chapter 23/25 – Flox & Primer! Leave a reply
  6. Chapter 23/25 – Cowl CAMLOC holes Leave a reply
  7. Chapter 25 – Bottom plane epoxy wipes Leave a reply
  8. Chapter 24/25 – Aft fuselage junction Leave a reply
  9. Chapter 25 – Wing bottom epoxy wipes Leave a reply