Mike Hostage's Pioneer building Log
1989
1 Jan 3.5 Draw cap layout on left shear web, scarf 3 more cap pieces. Sample 4. Glue
left rear lower cap splice. Lay out rudder shear web on 3/32" ply. Rough cut
out. Sample 5
Sample Glue Calculation using balance scale for measurement
(PartA) - cup 83% of (Part A - cup) = Part B Part B + (A+cup) = gross weight
6.8 - 1.7 = 5.1 .83 *5.1 = 4.233 4.233 + 6.8 = 11.033
Calculate weight of Part A by subtracting cup weight, multiply this weight by 83% to get needed
proportion, by weight, of Part B. Add this weight to total of Part A and cup to get gross weight.
Add Part B to achieve gross weight.
2 Jan 1.0 Glue up right rear upper and lower caps (outer splices). Sample 6
2.0 Cut rudder caps, glue to shear web. Sample 6
0.5 Make second rudder 3/32 shear web. (Didn't like glue job on first rudder web)
16 Jan 2.4 Draw out last side of shear web. set up shear web (right rear) for gluing on of
spar cap. Level out table. Calculate volume of glue required; did experiment
with baggie and .45" hole to lay out bead for 2 sample wood pieces, worked OK
1.5 Glue first cap, Sample 7. Slight bow in cap, need to re-level table. Cap glued
up OK. KTH helped.
18 Jan 0.3 Re-level short end of table
19 Jan 1.0 Cut vertical stiffener pieces + root filler piece for right rear spar
20 Jan 1.5 Glue vertical stiffeners and root filler block. Sample 8
0.5 Lay out aileron ribs on stock
21 Jan 2.0 Glued lower cap(no help). Sample 9
22 Jan 1.0 Lay out left rear lower cap
1.2 Glue left rear lower cap. Sample 10
23 Jan 1.0 Fabricate left rear root filler block
28 Jan $24.94 More spruce for second rudder caps, larger splice pieces for wing caps, extra
vertical stock. They sent 1/4 sq instead of 1/2 sq Must re-order
29 Jan 1.2 Splice two short wing caps. Left long rudder cap. Sample 11
0.5 Cut vertical stiffeners for left rear spar
31 Jan 2.0 Glue root filler, vertical stiffeners, and left rear spar. Sample 12
0.5 Glue rudder web members (other long one and opposite short one) Sample 13
1 Feb $31.79 Small block plane, to shape left rear root filler block
0.2 Shape root filler with new block plane
4 Feb 0.5 Set up clamps for next spar cap gluing. Started shaping down over-sized cap
splices (down to 1/2") but woke up KTH!
5 Feb 2.0 Glue upper cap on left rear web. Sample 4
9 Feb $5.50 (2) 1/2 sq X 5' for remaining sparcap splices
11 Feb 0.3 Remove clamps from left rear upper cap. Ready remaining two caps for
splicing
1.1 Glue spar scarfs (left front upper and lower). Glue 3 small vertical stiffeners
(left rear) glue last rudder spar cap. Sample 15
12 Feb 1.0 Left front upper cap too thin in 1 spot, must reorder. Layout right front upper
cap. Wedge under side so top is level.
1.5 Glue right front upper cap. Sample 16
16 Feb 1.0 Begin cutting right front vertical stiffeners (about half)
0.5 Finish stiffeners
1.4 Glue 1/2 stiffeners (right front) and root filler
17 Feb 0.3 Cut small vertical stiffeners for inside root filler. Glue remaining stiffeners
1.0 Glue remaining filler blocks, right front Sample 17
18 Feb 2.0 Glue right front lower cap. Sample l8
19 Feb 0.7 Remove clamps, practice planing at root for plywood outer faces
20 Feb 0.7 Set up right front lower cap
1.4 Glue right front lower spar. Sample 19
25 Feb 1.2 Shape root filler block left front, start vertical stiffeners
26 Feb 3.0 Shape remaining stiffeners. Glue root filler and all of the vertical stiffeners.
Sample 20
7 Mar $53.28 Wood (new spar cap) plus $91 shipping
11 Mar 0.8 Trim glue line for left front upper spar. Set up saw for spar cap cut (diagonal
rip to get two spar caps from one piece). Cut spar cap.
1.0 Cut splices. Trim and glue cap splice
12 Mar 0.7 Prepare left upper cap for gluing. Lay out clamps, shims, clean and sand, etc.
1 Apr 1.4 Glue on upper front left cap. Sample 21
2 Apr 0.3 Remove clamps. Start clean-up
0.6 Re-hang doors
MOVED TO TABB, VA
4 Sep 1.3 Trim vertical stiffeners, rear face right spar. (dovetail saw, then plane)
6 Sep 0.4 Trim vertical stiffeners right front face
7 Sep 1.0 Finish trimming front and rear faces of right spar
9 Sep 1.0 Repair two vertical stiffeners (tried chisel to trim, didn't work). Lay out ply
face plates for spar root and filler blocks for tie down fittings
1.5 Trim vertical stiffeners, both faces of left spar. cut root ply (3/32) pieces and
tie down blocks
0.7 Glue right front spar ply face and both tie down blocks
1.4 Trim rear vertical stiffeners, left spar, glue 3/32 root ply on rear face
10 Sep 1.8 Trim vertical stiffeners, front face right side, trim tie down blocks. Glue both
front face root 3/32 ply faces
16 Sep 0.5 make jig to hold power planer at 90 for working spar edges.
17 Sep 1.0 Trim lower edge of both spars
1.8 Mark all leading edge ribs with numbers. Mark rib positions and top trim line
on spars
19 Sep 1.0 Mark top line on spars (both sides)
22 Sep 3.8 Mark then plane top edges of both spars
23 Sep 0.8 Unpack metal parts
1.0 Grind butt ends of both spars
24 Sep 2.0 Build fuselage dolly. Hang canopy from ceiling
$1.50 4' plastic tubing to level wings
26 Sep 1.5 Drill left lower spar attach fittings, first two holes
27 Sep 3.0 Drill 2 holes each in left upper and both right spar fittings. Jig spars up with
carry through structure. Dihedral is good, but root fittings off by as much as
3/32. Need another 3/32 ply face on spar.
28 Sep 2.0 Cut and glue extra 3/32 ply faces on front face of both Spars. Re-cbeck
alignment of root spar fittings and carry through structure.
29 Sep 2.0 Drill remaining 3/8 holes for spar attach fittings
30 Sep 0.3 Cut rib corner fillers for front ribs
1.5 Cut bracing strips for gluing wing ribs to spar. Partial lay-out of aileron
pattern on 1/16 ply. Glue rib 3 and 20 onto right front spar
1 Oct 1.3 Glue 5 nose ribs to right front. Had to stop. Staple gun not enough pressure to
hold stops down. Need brads.
1.5 Glue nose ribs 6-10
1.0 Glue ribs 10A-15
2 Oct 0.6 Glue ribs 15A-20 to right front spar
8 Oct 0.5 Look at how to proceed with attaching the leading edge spar and the last 3 root
ribs.
9 Oct 1.0 Scarf leading edge basswood for right wing. Trim ribs to straight line upper
and lower edge (stretched string)
0.8 Varnish root spar attach area and bolt holes
11 Oct 0.5 Attach lower right spar fitting
13 Oct 1.0 Attach upper right spar fitting. Attach last 3 leading edge ribs on right spar
15 Oct 0.6 Attach upper and lower attach fittings to left spar root
19 Oct 0.5 Glue on left front ribs 3 and 20A
21 Oct 0.8 Pre-nail leading edge rib root filler pieces
25 Oct 1.0 Glue ribs 3A - 6A, left front
28 Oct 1.0 Glue ribs 7-12A, left front
30 Oct $6 Latex gloves (50)
31 Oct 1.0 Glue ribs 13-20
BRIGHT STAR + TILE KITCHEN TABLE
25 Nov 0.5 Glue ribs 1,2,2A onto left front spar. Nose ribs all glued on!
8 Dec 0.5 Suspend wing from table, leading edge upside down