Builder's Log
DateAssemblyInstructionPartDescriptionLinks
05/13/2013 Gear L04 L04-01

L04-01 Tri-Gear Main Landing Gear Mount.
Today I worked on locating the holes for the main landing gear legs in the fuselage lower skin. I used tracing paper to copy the full size pattern in the plans. I then calculated reference lines for the inside of the fuselage. The reference line is 1 7/8" aft from the spar tunnel aft rivet line. The reference from the center line is 4 5/32" outboard from the 8th rivet hole in the spar tunnel aft rivet line. I marked the location of the holes. I placed the gear mounts in their locations to try to check the hole locations.

Photos
Shop-Video
05/14/2013 Gear L04 L04-01

L04-01 Tri-Gear Main Landing Gear Mount.
Today I made the actual holes for the gear legs. I used the method I saw on Bob Meyer's website. I drilled holes arround the inside of the hole outline I marked yesterday. I then updrilled the holes untill the center could be removed. I used the half round file to smooth and enlarge the hole. I used the file until I could insert the leg through the hole and into the gear mount. I will make final adjustments to the hole when I actually install the gear legs.
During this process I found that one of the gear legs would not go into the upper part of either gear mount. The other gear leg will go into either mount. I sent Kerry an email. I will see what he says. I won't need it for a while.

Photos
Shop-Video
05/17/2013 Gear L04 L04-01

L04-01 Tri-Gear Main Landing Gear Mount.
Kerry responded regarding the gear leg that did not seem to fit. He suggested sanding the gear leg and or the inside of the gear mount. So I wrapped some emery cloth around a dowel and removed the powder coating on the inside of the gear mount. Now the gear leg fits in the gear mount.

I also continued to try to find the correct location for the mounts. I want to be sure I get the correct location before I start drilling.

Photos
Shop-Video
05/18/2013 Gear L04 L04-01

L04-01 Tri-Gear Main Landing Gear Mount.
Today I decided that I had the left mount in the proper position so I started drilling holes.
I first drilled the 3 holes that go through the lower skin and the longeron to the #40 size.
I then drilled the 8 holes that go through the lower skin and spar tunnel to the #40 size.
Next I used the 90 degree drill to drill all but one of the holes that go through the angle on the side panel to the size #40. The lowest hole I could get the angle drill in position. I will remove the angle and the mount and drill this hole outside the fuselage. I will also updrill these holes to the #30 size outside the fuselage.
Then I drilled the holes that go into the aft side of the spar tunnel.
I then went back and up drilled all the holes to their final sizes except for the side panel angle holes.
When I started up drilling the holes going into the spar tunnel the drill did not want to go through the steel mount. After trying a few different things I realized the speed of the air drill was probablly heating the steel so the drill bit would not cut. So I got out the cordless drill which goes a lot slower and it work just fine. Lesson learned fast is not always better.

Photos
Shop-Video
05/19/2013 Gear L04 L04-01

L04-01 Tri-Gear Main Landing Gear Mount.
I removed the left mount and angle from the side panel. I updrilled the holes through the mount and side panel angle to #30 size. I deburred all the holes. I then clecoed the side angle back in place on the side panel. I also clecoed the left mount back in place.

I then started on the right hand mount.
I worked on getting it in the correct position. I enlarged the hole in the lower skin for the gear leg a little bit.
When I had the mount in the correct position I started drilling holes.
I first drilled the 3 holes that go through the lower skin and the longeron to the #40 size.
I then drilled the 8 holes that go through the lower skin and spar tunnel to the #40 size.
Then I drilled the holes that go into the aft side of the spar tunnel to the #30 size.
Next I used the 90 degree drill to drill all but one of the holes that go through the angle on the side panel to the size #40. The lowest hole I could not get the angle drill in position. I will remove the angle and the mount and drill this hole outside the fuselage. I will also updrill these holes to the #30 size outside the fuselage. Like I did for the left mount.

Photos
Shop-Video
05/22/2013 Gear L04 L04-01

L04-01 Tri-Gear Main Landing Gear Mount.
Right Hand Gear Mount. I up drilled all the holes to their final size. I removed the mount and side panel angle to up drill the holes in that location. Clecoed the gear mount back in location to be sure every thing fit. It did. I then removed both gear mounts and the angles and gussets from the side panels.
I then removed the aft spar tunnel as an assembly.
I also test fit the flap drive tube and assembly block. Before I start on the glare sheild and pannel I want to fit as much below them as possible.

Photos
Shop-Video
05/23/2013 Gear L04 L04-01

L04-01 Tri-Gear Main Landing Gear Mount.
Today I counter sunk and dimpled the aft spar tunnel where the gear mounts will be attached by machine screws.
I first practiced on some scrap material.
I used the micro stop to get the proper depth for the counter sink. I do not have a dimple die for the 3/16th size so I used the a smaller size to get the dimple started. I then used the machine screws torqued to 25 in/lbs to get the finished dimple. That worked very well.
Bob Meyers said in his web site that he went ahead and riveted together most of the aft spar tunnel at this time.
I checked and I will be able to get it in and out OK. So I went ahead and riveted the vertical angles and the support angle to the aft tunnel angle. I did not rivet the ends where the shear plates will be attached. I did this while the gear mount were still bolted to the assembly.
Tomorrow I will remove the gear mounts and cleco this assembly back in the fuselage.

Photos
Shop-Video
05/25/2013 Gear L04 L04-01

L04-01 Tri-Gear Main Landing Gear Mount.
I removed the machine screws from the Mounts and aft spar tunnel. I removed the clecos from the mount also. I then clecoed the aft spar tunnel into the fuselage. I also clecoed the main gear mounts to the fuselage and the aft spar tunnel.
I located and drilled the 1/4in hole through the lower fuselage for the aft arm of each gear mount. I inserted a AN4-16A bolt in each hole to hold it in place. I place a nut on each bolt and only tightened it only finger tight just to keep the bolt from falling out.

Photos
Shop-Video
10/26/2013 Gear L02 L02

Firewall Cut Out.
I used the drill, nibbler and files to cut and shape the firewall cut out hole. This is where the rudder peddles will connect to the nose wheel for steering.

Photos
Shop-Video
11/07/2013 Gear L02 L02-01 L02-03

Nose Gear.
P32-01 Engine Mount. I removed the engine mount. I debured all the holes for the engine mount, shims and engine mount angles.
L02 SF 4048-20 bronze bearings. I filed and sanded the inside tube of the engine mount. I also sanded to out side of the bearings. I did this until I was able to insert the bearings into there location on the engine mount.
L02-02 Nose Gear Strut. I removed the powder coating where the strut will travel between the two bearings. I first used a propane torch and wire brush to remove the powder coating. I then used emery cloth to sand the strut smooth and remove any remaining powder coat.
L02-01 Nose Landing Gear Assembly. Trial Fit.
I placed the L02-13 Steel Washers and the L02-12 Spring on the Gear Strut. I then inserted the Gear strut into the bearings on the engine mount.

Photos
Shop-Video
11/08/2013 Gear L02 L02-01

L02-01 Nose Landing Gear Assembly.
Installed the two set screws holding the SF 4048-20 bronze bearings in place. I first practiced on a piece of scrap. Then I did the actual assembly. I drilled the two holes. First #40 then #30 and finally #21. I used the 10-32 tap to create the treads in the two holes. I used AN525-1032-R4 Machine Screws. They were a little too long. So I screwed each one into the practice scrap and used a file to shorten the screw. It took a couple times of trial fit to get them short enough. I used a piece of emery cloth attached to a wood dowel to smooth out the inside of the bearings. I then did another test fit of the nose gear strut. It fits great.
P32-01 Engine Mount.
I again attached the engine mount to the fuselage using the temporary bolts and nuts.

Photos
Shop-Video
12/12/2013 Gear L02 L02-01

L02-01 Nose Landing Gear Assembly.
I decided to remove the tape and paper wrapping the main gear axles. I know it is not on this plan page but I decided take a quick look at them.
I then decided to use a file to make sure that there wasn't any flashing or rough spots on the nose wheel halves.
I also looked to see that I have the parts and hardware I will need.

Photos
Shop-Video
12/13/2013 Gear L02 L02-01

L02-01 Nose Landing Gear Assembly.
I assembled the nose gear wheel.
I coated the inside of the tire and the outside of the inner tube with baby powder. I inserted the inner tube in the tire and assembled the two halves of the wheel. I tightened the bolts for the wheel. I partially inflated the tire and deflated it a couple of times to be sure the inner tube would not be twisted or pinched. I then re inflated the tire.
The nose gear fork.
The fork came with only one of the holes drilled. I located the other holes and used the drill press to drill that hole.
I attached the wheel to the gear fork.

Photos
Shop-Video
12/14/2013 Gear L02 L02-01

L02-01 Nose Landing Gear Assembly.
I decided to drill the holes that will hold the Nose wheel pants bracket to the Nose Gear Strut. The Nose Wheel Pant Brackets are provided with the kit as flat sheet parts that need to be bent. I bolted the flat brackets to the strut. I used the flat brackets to locate the holes for the AN3-5A bolts. I clamped every thing in place and drilled the 3/16th holes.
Since I had the bracket parts out I decided to go ahead and finish bending the brackets to their final shape.
Next I located and drilled the 1/8th In. pilot holes in the steering cap. I used the drill press to drill the pilot holes.

Photos
Shop-Video
12/16/2013 Gear L02 L02-01

L02-01 Nose Landing Gear Assembly.
I drilled and up drilled to 5/16th the hole through the steering cap and gear strut. I used the drill press and self centering jig to start the holes trough the gear strut. I then used the jig to hold the gear strut while I used the hand drill to up drill the hole to the final 5/16th.
I applied white lithium grease to the bushings, washers and gear strut. I then assembled the gear strut to the motor mount. I used a harbor freight ratchet strap to compress the spring enough to get the bolt through the holes of the steering cap and gear strut.

Photos
Shop-Video
12/18/2013 Gear L02 L02-01

L02-01 Nose Landing Gear Assembly.
I shaped the travel stop plate to fit on the motor mount. I drilled a hole in the corner and then used the band saw to cut out the corner. I then used the scotch brite wheel to trim and shape the cut out to fit around the weld on the motor mount. I located and drilled the holes in the motor mount. I then installed the bolts to hold the travel stop plate.
I also attached the nut holding the 5/16th bolt through the steering cap and gear strut.
I also started looking at the boot for the control push rod for the steering. I decided I should prepare the steering push rod so I can be sure the boot will fit correctly.

Photos
Shop-Video
12/19/2013 Gear L02 L02-01

L02 Push Rod Boot.
I cut down the Cessna 150 boot to the size of the firewall opening. I drilled the holes in the firewall for the rivets. I applied Red RTV to the mating surfaces. I then installed the rivets.

Photos
Shop-Video
12/21/2013 Gear L02 L02

L02 Push Rod Boot.
I turned the boot inside out and applied Red RTV to completely coat the inside surface.

L01 Main Gear Leg.
I used the drill press to drill one pilot hole in one of the gear legs. I did not have a Cobalt 1/4 drill bit so I tried a normal one. It started to smoke so I stopped. I went and bought a couple of 1/4 in Colbalt bits and another 1/8 in Colbalt bit.
I highly recommend watching the Sonex video on drilling the gear legs. I followed the video instructions for the pilot hole and it worked great.

Photos
Shop-Video
12/22/2013 Gear L01 L01-04

L01-04 Main Gear Legs.
I continued drilling the upper holes in the gear legs. I finished up drilling the first one to the 1/4 size using a new Cobalt drill bit.
I then drilled the pilot hole and final 1/4 size in the other leg.

I also bolted the engine mount back in position.

Photos
Shop-Video
12/23/2013 Gear L01 L01-05

L01 Gear Mounts.
The kit supplied gear mounts did not have the pilot hole drilled. I used a bent coat hanger to locate the top and bottom of the doubler in the gear mount. I then measured the 1/2 inch location for the pilot hole per the plans. I drilled a 1/8th inch pilot hole and up drilled to the 1/4 inch. I inserted the gear legs. I used the hole in the gear leg to locate and drill the 1/4 inch hole on the other side of the gear mount. I put the gear mounts back in the fuselage using clecos to hold them in place. I then inserted the gear legs and installed the bolts holding them.

L01-05 Axles.
The kit supplied axles did not have the 3/16th pilot holes drilled. I located the position of the pilot holes. I used the drill press to drill the pilot holes on one side of the axles. I drilled the hole on the side that will be on the up side when placed on the gear legs.

Photos
Shop-Video
12/26/2013 Gear L01 L01-05

L01-05 Axles.
I used a 6ft piece of aluminum angle and 2 short scrap pieces of angle to position the axles on the gear legs. I put the toe in alignment tools on the axles. I clamped the short angles to the axles. I clamped the 6 ft angle to the 2 short scrap angles. There was a place on each on the axle welded part that interfered with the 6ft angle. So I filed away enough of the angle so that they did not touch. I used two large carpenter squares clamped to the 6ft angle to hold the axles the 14 3/8 inches from the bottom of the fuselage. I used visegrips to hold the axles to the gear legs. I then used the hand drill to drill a starting position through the pilot hole in the axle and onto the gear legs. I removed the right gear leg from the fuselage with the axle still held in place by the visegrip. I setup the drill press with the self centering jig and gear leg / axle. I then drilled a pilot hole through both the axle and the gear leg. I up drilled the hole to the final 1/4 in size. I put the AN4-17 bolt through the gear leg and axle. I bolted the gear leg back in the fuselage. I clamped the angles back to the axle. The position and measurements were still correct.

Photos
Shop-Video
12/27/2013 Gear L01 L01-05

L01-05 Axles.
I removed the Left gear leg from the fuselage with the axle still held in place by the visegrip. I setup the drill press with the self centering jig and gear leg / axle. I then drilled a pilot hole through both the axle and the gear leg. I up drilled the hole to the final 1/4 in size. I put the AN4-17 bolt through the gear leg and axle. I bolted the gear leg back in the fuselage. I clamped the angles back to the axle. The position and measurements were still correct.

Photos
Shop-Video
12/28/2013 Gear L01 L01-05

L01 Gear Leg and L01-05 Axle.
Rework left gear leg holes.
After closer inspection I found that the holes drilled through the left gear leg, gear mount and axles were not as good as they should be. The problem was in the welded parts. I decided that I would up drill the holes to AN5 (5/16th) hardware. Today I up drilled the hole through the gear mount and gear leg. The new hole came out great. Tomorrow I will re work the hole on the axle end of the gear.

Photos
Shop-Video
12/29/2013 Gear L01 L01-05

L01 Gear Leg and L01-05 Axle.
Rework left gear leg holes.
Today I will re worked the hole on the axle end of the gear leg. I up drilled the hole for AN5 (5/16th) hardware.

Photos
Shop-Video
02/07/2014 Gear L01 L01

L01 Main Landing Gear.
I placed the gear legs in the gear mounts in the fuselage. I installed the bolts, washers and nuts. I torqued the nuts and installed the cotter pins. I tapped the hole on the end of the axle with a #10-32 tap as called out in the plans. I also started the -09 wheel assemblies. I don't have any hex wrenches at the hangar so I'll will finish that tomorrow.

Photos
Shop-Video
02/08/2014 Gear L01 L01

L01 Landing Gear Installation.
L07 Optional Hydraulic Brakes.
Finished assembling the wheels and tires. Inflated the tires to 50 psi.
Installed the nut plates on the wheel pant mount plates. Threaded the 90 degree compression fitting and the bleed valves into the main brake body. I also inserted the pistons, o-rings and pucks into the main bodies. I put the wheel pant mount plates and brake main bodies on the axles. I packed the wheel bearing with grease. I assembled the wheels and bearings on the axles.

C08 and C09 Optional Center Controls.
I cut out the notch in the seat pan required for the center controls. I put the seat pan back into the fuselage and riveted the hinge halves to the spar tunnel.

Photos
Shop-Video
02/09/2015 Gear L01 L01

L07 Hydraulic Brakes.
L07-11R&L Master Cylinder Mount Angle.
L07-13 Master Cylinder Spacers. Fabricated from angle and bar stock. Drilled pilot holes.

Photos
Shop-Video
02/12/2015 Gear L01 L01

L07 Hydraulic Brakes.
Drilled, debured and rivets to installed L07-11R&L Master Cylinder Mount Angles and L07-13 Master Cylinder Spacers. Up drilled holes and installed hardware and the master cylinder.

Photos
Shop-Video
02/26/2015 Gear L01 L01

L07 Hydraulic Brakes.
Ran and connected the brake lines. Add DOT 5 Brake Fluid. Bleed the lines.

Photos
Shop-Video
02/28/2015 Gear L01 L01

L07 Hydraulic Brakes.
Replaces one of the compression fittings on the master cylinder that was leakinging.
Bleed the brale lines again.
Located and drilled the holes for the brake handle.

Photos
Shop-Video
05/19/2015 Gear L01 L01

Finished installing the screws for the canopy. Installed the canopy restraint cable.
Worked on trimming and fitting the nose wheel pant. I had to remove the nose gear in order to slide on the nose wheel pant. Installed the nut plates to hold the nose wheel pant. Still need more trimming to provide proper wheel clearance.

Photos
Shop-Video
05/20/2015 Gear L01 L01

Finished installing the nose wheel pant. Started work on the landing gear fairings. Cut out the sheet metal shapes.

Photos
Shop-Video
05/21/2015 Gear L01 L01

Made the hinges for the fairings. Drilled and up drilled the holes for the fairing assemblies. Riveted and shaped the nose gear fairing.

Photos
Shop-Video
05/22/2015 Gear L01 L01

Installed the nose gear fairing. Trimmed the cowl for the fairing. Re installed the prop hub lugs. Made a tracing of the spacing of the prop hub lugs. Using the bolts for the prop matched up the prop spinner and prop hub to be sure the holes match.

Photos
Shop-Video