Mike Hostage's Pioneer Builders Log
1994
23 Jan 1.5 Rout right upper speedbrake bed (trailing edge). Trim opening for brake.
Measure for spray booth size.
0.3 Glue in trim at edges of upper right speedbrake to form lip for airseal.
6 Feb 0.5 Rout lower right spoiler box to fit spoiler.
0.3 Glue side strips to form seat for spoiler.
0.5 Drill bolt hole, pull rivnut to hold wingtip bolt. Scuff sand and tape tip for
fiberglass filling.
0.6 Fill lower right wingtip root edge to fair into end of wing. Also, filled left
blister for elevator horn and test section of canopy frame.
11 Feb 0.7 Sand right lower wingtip root (sand finer to meet wingtip). Sand left aileron
hump on fuselage, sand test spot on canopy rim.
0.5 Rout left upper spoiler opening fur proper clearance. Glued edge strips to seal
spoiler opening.
0.7 Fill top left wingtip surface, part of left canopy rim, and right fuselage elevator
hinge bump.
13 Feb 0.8 Begin sanding left upper filler surface of wingtip. Still not hard! (cold
basement) hung heat lamp 4' away. Add second layer of filler buildup.
0.4 Fill aft portion of canopy rim.
15 Feb 1.0 Sand top of left wingtip. Sand part of canopy rim (20%).
16 Feb 0.5 Drill and install bolt and rivnut to hold left wingtip on.
19 Feb 0.8 Sand canopy frame and top left wingtip.
20 Feb 2.5 Rout left lower spoiler opening, glue end pieces. Sand canopy frame edges
smooth. Fill final portion of canopy rim and left lower wingtip fairing.
21 Feb 2.3 Designed canopy latch on computer. (Ended up not using this idea.)
0.3 Sanded lower left wingtip root area.
22 Feb 1.6 Sand remainder of left wingtip. Sand remainder of canopy rim. Sand exterior
of canopy opening, cut glass to fill holes from original bridle locations and to
cover bolt heads. Tape over bolt heads. Cut glass for new double thickness
BRS cover, tape on wax paper.
23 Feb 1.5 Glass over 4 holes in fuselage (from 1st plan for BRS risers) glass new 2 layer
BRS cover. Glass small repair at lower fin edge. Glass over bolt heads for
spoiler arm guide.
0.6 Fill upper right wingtip root, left wing root edge (on fuselage) and rear holes
(glassed over this morning) for earlier BRS mod.
24 Feb 0.5 Trim BRS panel, glue in place.
25 Feb 0.5 Fit ply (.25 cherry) braces for underside of seat pan (near stick opening).
26 Feb 1.3 Sand right wingtip top, fuselage areas, trim rear lower fin area, trailing edge of
fuselage area, canopy rim area. Bondo ply supports for seat pan.
1.3 Glass in seat supports.
27 Feb 0.3 Flox fill top of seat pan braces to form seat for mating surface.
1.7 Lay out boards for spray booth. Tape perimeter of canopy fillet and rim of canopy.
0.7 Micro left rear canopy fillet.
28 Feb 1.2 Rough rasp first part of canopy fairing. Micro flowed away from rim, needs
another layer. Tape is good border, but should be cleared of excess prior to
setup. Laid fuselage on side for next step.
1 Mar 0.8 Micro layer on top of 1st layer of rear left canopy fairing. Used stiffer mixture.
2 Mar 0.8 Microed from leading edge of wing root to nearly forward midpoint of canopy
fillet left side. Used thick mixture, used small wire brad to make separation
from fillet to canopy rim, pulled tape while micro was wet, to get clean line.
3 Mar 1.4 Test sand left rear fillet. Micro fillet, right rear to just forward of release brace
bolt heads on right forward fuselage.
5 Mar 1.8 Drill holes both sides of canopy rim, forward of inner side flange. Countersink
and T-88 nuts inside, to mate with 1/4 bolts for opening canopy when nobody
is inside aircraft. Micro remaining forward fairing, micro all of BRS panel.
6 Mar 4.0 Cut 2" X 1/2" Velcro tabs, sewed to BRS risers. Testing contact cement to
attach to fuselage sides.
8 Mar 0.5 Hand sand left shoulder (over wing root) canopy fillet. Measure and cut
Velcro for holding BRS to fuselage walls.
9 Mar 0.7 5 minute epoxy 2 Velcro "hook" patches on right fuselage side. KTH sewed
canvas backing to all pieces to facilitate gluing.
10 Mar 0.5 Epoxy 6 more Velcro "hook" patches.
11 Mar 0.8 Epoxy remaining "hook" patches, left and right sides.
12 Mar 0.6 Epoxy "hook" patches for riser bag.
2.7 Sand fillet around canopy.
0.5 Complete fairing over back of turtle deck.
2.0 Finished framing spray booth, put up about 80% of plastic.
13 Mar 0.5 Glue 6 more hook patches. Needed 3 straps to cinch bag and lines up against
interior wall of fuselage.
0.3 Taped together filter door for booth.
0.8 Sand fillets.
14 Mar 1.0 Sand last portion (top of turtle deck) of fillets. Installed lap belts.
15 Mar 1.5 Glass 3 sets of bolt heads (seat belt bolts and stick bracket bolts). Cut 3/32 ply
panels for cockpit sidewalls.
16 Mar 1.2 Glue 4 side panel attach points to cockpit sides. Micro 3 bolt heads on
fuselage undersides.
19 Mar 0.5 Fill pin holes in canopy rim fillet, fill holes in 3 bumps on fuselage.
2.0 Tape spray booth, hooked up fan, tested booth. Seems to work OK
20 Mar 0.3 Repair ding in left lower trailing edge skin. cut Velcro for side panel attachments.
0.8 Fill seams and edges of fuselage with micro. Sand repair on left wing.
1.0 Varnish speedbrake wells, tip ribs and root ribs. Another coat for rudder blocks.
27 Mar 1.5 Micro top surfaces of both wingtips.
28 Mar 0.5 Glue Velcro to inside side panels.
0.8 Varnish canopy rails.
0.7 Micro bottom of both wingtip skins.
29 Mar 0.5 Sand fuselage areas.
30 Mar 0.8 Hung control surfaces in booth, for varnishing. Set right wing on horses.
31 Mar 0.7 Tape/mask all hinges as well as aileron pushrod (prior to spraying with varnish).
2 Apr 1.5 First brush coat varnish on bottom of right wing and all 5 control surfaces.
1.2 Second brush coat of varnish on bottom of right wing and 5 control surfaces.
3 Apr 1.5 First coat top of right wing. First coat on rest of bottom and top of left wing
(except for area touching wing saddle). Did right wing in booth on sawhorses,
did left wing nose down in saddles.
0.7 Second coat of varnish on both sides of left wing.
0.4 Second varnish coat on top of right wing.
4 Apr 0.4 First coat on saddle area of left wing.
0.2 Second coat on saddle area of left wing.
5 Apr 0.3 Cut piece for stopping leak in trailer door.
6 Apr 0.5 Sand (400 grit) top of right wing to remove fuzz from varnish
0.5 Cut fabric for top of right wing. cut pieces for rudder. Began gluing first
piece to left side of rudder.
0.6 Completed initial attachment of left side fabric of rudder.
1.0 Finish gluing edges of right side of rudder, used 200* to flatten bumps.
7 Apr 1.3 Cover left side of rudder. 200* sealed bumps and edges.
0.2 Final heat tauten (250 then 350*) rudder. Hang up until later.
0.8 Cut out remaining three wing pieces, pieces for elevators and ailerons.
0.3 Pre-cover file and sand right elevator.
1.5 Cover right elevator.
8 Apr 0.8 250/350* tauten right elevator. Precover file/sand left elevator, fit to wing to
ensure hinge positions, tighten hinges.
0.3 First coat 1/1 thinned Polybrush on top of right wing ply surfaces.
0.3 Second coat Polybrush.
9 Apr 0.8 Precover file and sand bottom of right wing. Wipe wing with tack rag.
1.6 Cover left elevator.
0.4 250/350 tauten left elevator.
0.6 First and second coats 1/1 of Polybrush on bottom of right wing.
1.0 Precover file and sand left aileron. Layout and trim aileron fabric. Test fit
both ailerons, tighten hinges.
10 Apr 2.5 Cover left aileron.
0.5 250/350 tauten left aileron.
0.8 Precover file and sand right aileron. Glue fabric to one side of aileron.
12 Apr 1.2 Install cable and pulley for spoiler in right wing. Install bolts and aileron
pushrod in right wing. Glue fabric to right aileron (second side).
13 Apr 1.2 Complete right aileron. Finished gluing fabric. 250/350* tautened fabric.
14 Apr 0.5 Sand aft topside of fuselage and fin.
16 Apr 0.5 Vacuum out interior of wing, lay out fabric on bottom of right wing.
0.4 Glue fabric to leading edge and forward part of open panels.
17 Apr 1.2 Finish initial gluing around perimeter of bottom right wing. Heat edges for creasing.
0.4 Cut open then glue edges of spoiler opening.
0.8 250* flatten bumps on glue areas of lower right wing.
0.4 Glue down rest of leading edge bottom skin on right wing.
1.3 Glue fabric edges around perimeter. 225* melt down bumps on leading edge,
right lower wing.
18 Apr 0.8 Fmished gluing and sealing all edges of lower right skin. Precoated rib
capstrips with 2 coats of Polytak.
19 Apr 1.4 Glue perimeter of top skin, right wing.
21 Apr 0.5 Trim edges of upper right wing fabric. Cut out and glue upper spoiler opening.
23 Apr 0.8 Trim remaining edges. Finish gluing upper spoiler opening and aileron pushrod exit.
250* crease an edges for final gluing. Flip wing.
24 Apr 0.8 Glue edges of top skim
0.7 Finished gluing all edges of top skin.
25 Apr 0.9 250* tauten tip and bottom ply areas and bottom open bays. Used MEK to
soften pre-glued Polytak on upper open bay spar caps, to stick fabric to reflexed airfoil.
27 Apr $4.30 2.8 Took 1 gallon can of Polybrush to Hechingers and had it shaken for 8 min. Bought plastic
lids for gallon cans. Brushed 1/1 Polybrush on upper ply surfaces. 250/350* tautened
open bays of upper surface. Tumed wing over, 350* tautened open bays, brushed 1/1
Polybrush on ply surfaces.
0.8 Brushed 3/1 Polybrush on top and bottom open panels, and inside elevator and
aileron channels.
1.0 Masked upper surface for 3.5" spaced rib laces. Used 1.25" from lateral edge
of skin cutout to position first hole. Applied rib tape to both sides of wing.
28 Apr 1.0 Rib laced two ribs.
29 Apr 2.3 Finished rib stitching.
30 Apr 0.2 Cut finishing tapes for top of wing.
0.5 Trim ends of tapes to points with cardboard template.
0.7 Used 3/1 Polybrush to attach all rib stitch reinforcing tapes and root/tip scuff
tapes, on top side of wing.
0.9 225* iron all edges of tapes. Glue down root and tip edges of tapes.
1 May 0.8 250* iron edges of leading edge seam, prior to leading edge scuff tape.
0.7 Attach root (used 3" tape) and tip scuff tapes (lower side). Attach leading edge scuff tape.
0.5 Cut and trim lower reinforcing tapes for Stitching.
1.2 Polybrushed lower rib stitch tapes in place. Finished gluing down root and tip scuff tapes.
Cut, trimmed, and installed lower surface inspection rings, plus reinforcing patches
(aileron belcrank and spoiler pulley).
0.3 Attach trailing edge tape to lower middle section.
0.7 250t heat seal trailing edge, rib stitch and leading edge tapes.
1.0 Glued drain grommets in place 1.25" from trailing edge of elevator spar. Cut 45 "silver
dollar" patches to cover grommets.
2 May 0.7 Polybrusbed 3/1 drain grommet patches in place. Also patched tiedown and
wingtip bolt holes.
3 May 0.7 250* flatten edges of dollar patches.
0.5 Switch wings, left inside booth. Weighed right wing: 89-90 Ibs. Aileron/elevator/(2)
spoilers/wingtip: 13 lbs.
0.8 Sand top surface left wing, wipe with tack cloth.
4 May 0.5 Reload pouring cans, mix 1/1 batch of Polybrush, brush first coat on top of left wing.
0.3 Second coat applied.
5 May 0.5 Randy Bennet came to estimate spraying Zolatone on fuselage: $100. Said to prime
with BULLSEYE 123 first.
0.8 Sanded bottom of left wing.
7 May 0.7 Two coats 1/1 Polybrush on bottom of left wing.
8 May 1.2 Install bolts/nuts with spoiler pulley and aileron belcrank and pushrod. Glue
leading edge and main spar length of bottom left wing fabric.
0.8 Finish perimeter of wing bottom, cut and glued spoiler opening.
10 May 0.4 Trim excess fabric from lower left edges. Begin to flatten and crease rear edges.
0.2 Fmish 250* creasing and flattening glue edges on lower left wing.
14 May 1.2 Glue all edges, 250* flatten and smooth edges of lower left wing skin. Two
coats Polytak on top spar caps.
0.2 Glue down edges in spoiler opening, lay out upper left fabric.
15 May 1.8 Glue top fabric, cut and glue spoiler opening and aileron pushrod hole, trim all
edges to final size.
0.8 Glued all edges, sealed at 250*. 250* tautened lower surface, ply and open bays.
0.5 1/1 Polybrush on ply parts of lower left wing.
0.8 1/1 Polybrush on top of left wing after 250* tautening.
16 May 0.8 350* tauten both surfaces, open bays, left wing.
0.5 3/1 Polybrush on bottom open bays left wing. Test painted "ZINSSER'S
SHIELDZ" primer on underside of instrument panel.
0.6 3/1 Polybrush open bays top of left wing. Test brushed (doesn't brush well!!)
some ZOLATONE on the SHIELDZ primer.
0.3 Began sanding top of left wingtip.
19 May 1.1 Apply reinforcing tapes top and bottom, mark and punch rib stitch boles, stitch
first two inboard ribs
20 May 1.8 Finished left wing rib stitching.
21 May 0.5 Cut and trim finishing tapes for top of wing and leading edge.
1.2 Attach finishing tapes to top and leading edge of left wing. Also attached scuff
tapes (top) at root and tip.
0.8 Use 250* iron to flatten edges of tapes on upper surfaces of left wing. Finished
gluing scuff tapes at root and tip. Flipped wing, cut and trimmed tapes for
lower rib stitch reinforcement.
0.5 Polybrush tapes to bottom of wing.
0.2 Glue inspection rings and drain grommets.
0.5 Polybrush patches over rings and grommets.
22 May 1.0 Finish 250* flattening of tape edges, lower side left wing.
0.3 Sand left wingtip.
0.7 Tape spar caps of elevators and rudder. Paint 50/50 Polytak tbrough fabric to
attach to rib caps (recommended by Rich Horrigan) Removed tapes.
1.2 Polybrush 3/1 all control surfaces.
0.8 Spray primer on instrument panel and seat pan.
25 May 0.6 Unbolt tow releases, rudder pedals and pedal bracket. Begin taping for spray
of cockpit interior.
26 May 0.7 Partial taping of cockpit.
28 May 2.5 Sprayed primer inside nose bowl and wing roots. Sprayed feather fill on left
wingtip, sanded, sprayed again.
29 May 0.6 Sanded left wingtip some more. Still trying to get rid of pinholes Began
sanding right wingtip.
0.5 Patch pinholes in bottom of left tip and fuselage turtle deck with micro.
30 May 3.0 Sanded right wingtip. Sprayed primer inside fuselage nose and wing roots,
again. Sprayed feather fill on right wingtip.
0.6 Sand right wingtip again. Sprayed more feather fill on it.
31 May 1.0 Sand fuselage areas that were patched with micro.
1 Jun 0.3 Sand right wingtip.
2 Jun 1.2 Spray featherfill on topside of fuselage and left wingtip. Sanded fuselage top
with 220 grit, when dry.
0.5 Tried Stitts MP-110 Micro Putty to patch pinholes.
3 Jun 0.7 Begin sanding Micro (mixed first batch too slowl). Mixed 5 more batches
(mixed much fasterl), filling holes on left side of fuselage.
1.5 Sand left side of fuselage. Micro right side. Sprayed "Stone Craft" (by
Krylon) textured surface material on underside of glare shield. Looks nice!
1.0 Sanded part of right side of fuselage.
1.0 Sprayed Stone Craft on instrument panel, seat pan, wing wells and inside of
nose bowl. Looks nicel
4 Jun 0.5 More sanding right side and left wing root.
1.2 More sanding. Fmished right side.
2.0 Finish sanding right side. Ready for second coat of featherfill. Mixed UV-550 to
spread over Stone Craft finish on seat, instrument panel and fuselage
interior. Brushed on.
0.3 Fill and trim plates for exterior opening of tow release area
5 Jun 1.5 Sanded 220 grit on top side of fuselage. Microed both wingtips top and bottom.
1.5 Cut ply and reinforcing pieces for saddle assembly dolly. Glued, screwed
"box" together.
2.5 Varnish remainder of textured surfaces inside cockpit. Put second coat on
instrument panel. If this makes panel smother, will do same for seat pan.
Sprayed featherfill on top side of fuselage. Fmished saddle dolly, by putting
on curved "seat" for wing, and feet.
7 Jun 1.2 Assembled left and right wings to fuselage. Dolly is too high. Leading edges
of wings extend beyond fuselage fillet areas by approximately 1/2". Both wing
are approximately l/2" above filled edge at trailing edges.
0.3 Spray rudder pedals and bracket black.
8 Jun 0.5 Sand left wingtip, top surface.
0.5 Install rudder pedals.
9 Jun 1.5 Assemble rear end stand, to boost fuselage height to match wing saddle stand.
10 Jun 0.3 Fit seat cushions, mark cutouts. Sand rear dolly.
11 Jun 1.3 Finish sanding Micro from left wingtip.
0.3 Cut felt for wing saddle dolly and rear dolly.
0.1 Trim seat cushions.
0.6 Finish sanding right wingtip.
0.8 Cover right wing (inside booth) and hung control surfaces for spraying.
1.3 Set up fuselage and wings, filled leading edges of wing roots to match wings.
Began filing to make smooth contours.
12 Jun 1.5 Inverted fuselage, sanded (scuffed gloss from surface) bottom half
1.2 Sanded new fillets on leading edges of wing roots.
1.0 Bondoed holes in lower fuselage half.
2.0 Finished aluminum plates for outer surface bearing plates, for releases. Drilled
then mounted to fuselage, without releases. Cut fiberglass cloth, 3 layers.
0.3 Glass 3 layers over release plates, with temporary screws in place. Must be
cut out at green staged
0.8 Sanded bondo off lower fuselage.
0.3 Countersunk six 3/16" 100 degree screw holes in plate for left tow release.
20 Jun 0.5 Lay out base of form for rudder gap seals.
2.5 Took 1 can of Polybrush and 1 can PolySpray to Builder's Square for shaking.
Sprayed Poly Brush on 5 control surfaces. Mixed 2 capfuls of blush retarder
into 1 gallon of Poly Spray. Sprayed 2 coats of Poly Spray on 5 control
surfaces. No significant pinhole areas noted. Prior to Poly Spray, used 225
degree iron to smooth down edges of tapes.
1.5 Cut down tail wheel bracket to fit roller blade wheel. Drilled out aluminum
spacers to center wheel on shaft. Drill out bracket for M-6 metric bolt. Cut,
screw, tape wax paper to jig for curved part of rudder gap seal. Sprayed
washers black, for instrument panel.
0.3 Cut glass for curved part of rudder gap seal.
1.0 Glassed upper and lower jigs for rudder seals.
21 Jun 0.3 Removed glass parts from jigs, trimmed edges.
0.4 Put Micro filler on release plate areas.
22 Jun 0.8 Sand and feather Micro over release areas.
1.2 Wet sand both ailerons and rudder.
0.5 Wet sanded both elevators.
0.2 Re-countersunk release screw holes, filed release openings.
24 Jun 1.0 Cut and shape pieces for male mold of aileron guides. Cut foam for tail wheel fairing.
25 Jun 1.0 Mixed plaster of Paris for mold of aileron pushtube guide. Set up too fast! Ruined KTH's
9X9 Corning Ware pan! OOPS!!
0.5 Glass tail wheel failing.
0.5 Re-poured mold for aileron fairing. Pulled form, will have to fill some air-
voids, but looks usable.
0.8 Spray third coat PolySpray on 5 control surfaces.
1.0 Attempted color (white) coat on 1 aileron. Paint seemed to go on mottled, in
globby areas, and not smooth. Had to wash off with a sponge!
26 Jun 0.2 Microed tail skid
0.3 Bondoed voids in aileron guide mold. Bondo doesn't stitck well to plaster of Paris.
0.5 Lay glass (2 layers) in aileron guide mold. Used sandwich of wax paper, glass
and wax paper, weighted down, with collection of pens and pencils to fill
guide channel under weights.
0.2 PolyTak glued aileron guide to left wing.
0.2 Began sanding tail skid.
27 Jun 1.3 Tested different settings and thinness amounts on spray equipment and with
System Three LPU paint. Still not happy. Am at nearly 50% thinness yet, still
looks mottled when sprayed
28 Jun 0.5 Tried 109'o thinned and 20 up to 45 psi, with no appreciable improvement.
1.0 Finished sanding tail wheel failing. Cut wheel opening, installed four rivnuts
to hold in place.
29 Jun Drove to Howard Williamson's house. Borrowed his spray gun and the pressure pot.
30 Jun 0.8 Used Howard's gun and yellow paint. Carefully thinned approximately 10%
with distilled water. Sprayed beautifully! Tried same gun and some of white from 28 Jun.
Looked OK, but think I may have been thinning too much! Will have to try straight, unthinned.
1.0 Sprayed 1 side of second aileron, recoated first side of first aileron, sprayed
inspection covers and top side of left elevator.
0.3 Polybrushed one layer of fabric over left wing aileron pushtube guide.
4 Jul 1.5 Sprayed color coat on second side of ailerons, second side of left elevator.
Sprayed surfaces horizontal, seemed to run less. Also, strained paint through
panty hose = much less spitting.
0.3 Cut and trimmed right wing aileron pushtube guide.
1.5 Sprayed featherfill on bottom of fuselage, tail wheel fairing, and canopy rim.
5 Jul 0.2 PolyTaked right wing aileron push tube guide in place. Sanded part of primer
on fuselage.
0.5 Cut aluminum strips, glassed in place below wing root fitting holes, to brace
fiberglass area.
2.0 Sprayed color (white) on aileron edges, right side of rudder and top of right elevator.
0.1 Sprayed satin gloss black on aileron horns.
0.8 Sprayed white on left side of rudder, bottom of right aileron and bottom of both wingtips.
0.8 Strung ropes and suspended left wing from ceiling in paint booth.
6 Jul 1.5 Sprayed Polybrush 3/1 reducer on left wing. Prior to spraying, taped spoiler
openings and root opening.
0.5 Bondo filled wing attach area support laminations (glassed in metal supports
for wing root area).
1.3 First coat PolySpray on left wing.
0.3 Sanded Bondo over wing root support areas.
7 Jul 0.5 Finished sanding bondo over wing root support areas.
9 Jul 0.8 Sprayed second coat Poly Spray on left wing.
2.0 Wet sanded both sides of left wing.
10 Jul 0.3 Wipe both surfaces of left wing with tack rag.
0.8 Spray third coat of PolySpray.
0.8 Sand (400 grit) both sides of left wing.
11 Jul 1.6 Painted (white) underside of left wing. Used approximately 40 oz. paint.
13 Jul 1.6 Painted (white) upper side of left wing. Used approximately 32 oz. paint.
14 Jul 2.2 Marked off wing stripes, top and bottom. Masked off center yellow stripe,
painted yellow stripe, removed tape.
15 Jul 4.3 Painted blue and red stripes. Left wing painting complete! Painted tail wheel
fairing blue.
16 Jul 2.2 Removed left wing from booth, put right wing in. Vacuumed out booth.
Sprayed 3/1 PolyBrush on right wing.
2.0 Sprayed two coats PolySpray on right wing.
1.5 Wet sanded right wing. Wiped with tack rag. Ready for third coat PolySpray.
0.3 Used 225 degree iron and aluminum foil to smooth sand through areas. Works
well, but must use care not to let aluminum foil stick, or melt away the Poly Spray.
0.8 Dry sanded both sides of wing with 400 grit. Ready for color.
1.4 Spray white color coat on top of right wing.
17 Jul 1.5 Paint white coat on bottom of right wing.
1.0 Cut access holes in semi-circular fiberglass piece for sealing rudder. Test
fitted it to a board Seems to fit but is under much stress. Better idea might be
(drawing in notebook).
2.0 Mark stripes on right wing. Tape off center yellow stripe. Spray yellow stripe
top and bottom. Began marking off fuselage belly line.
1.5 Tape and spray blue stripe. Tape technique: lay out markings, then tape paper
to within .2-.4 inches of desired line. Use Professional grade 1/2" tape for
actual line. put 1/2" tape on last. Rub edges well. Do the 400 grit sanding
and tack rag wiping after putting down the paper but before the 1/2", unless it
is next to a color border then you must put the 1/2" down to preserve the edge.
After spraying and the paint has begun to set (but before it is dry!) pull up the
1/2" to expose the edge. you can leave the paper in place until the paint is
dry. Cover everything that you want to keep clean, the over spray goes everywhere!
1.2 Mask and spray red stripes on right wing. Right wing completed.
0.3 Finished laying out line on fuselage.
23 Jul 1.5 Rearrange shop to put wings outside and fuselage inside spray booth. Begin
tightening screws on spoilers.
24 Jul 2.0 Finished tightening screws on spoilers. Wiped spoiler surfaces with MEK,
primed with All-Metal primer. Sprayed featherfill on reinforced areas on fuselage.
0.3 Begin taping yellow tine on fuselage belly.
0.3 Tape paper on belly of fuselage, ready for white paint.
25 Jul 1.2 Final sanding on lower fuselage area. Wiped upper wingtip surfaces, spoilers
and lower fuselage area with tack rag. Sprayed white color coat on all.
27 Jul 0.2 Sand edge areas where next white coat meets coat already sprayed.
0.8 Spray white around remainder of lower red border area. Spray inside of canopy rim.
28 Jul 0.6 Taped fuselage belly for yellow stripe.
0.5 Sprayed yellow stripe on belly.
0.7 Clean tape residue from fuselage. Scotch Brand 2090 "long mask" tape left
glue on fuselages. One area of white paint peeled away. Had to sand its edges.
29 Jul 1.1 Taped off peeled area, sanded exterior of canopy rim. Sprayed white on
peeled area and canopy rim.
30 Jul 0.5 Sand area of white that peeled and had to be repainted. Sanded well. Think
the System Three paint does not bond well with the feathercoat primer.
1.2 Sprayed red stripe on lower fuselage.
0.3 Installed instruments in panel. Painted 1/4" bolts black, to use to fasten air
valve to panel.
2.5 KTH and I peeleft off red, white, and yellow from fuselage. Will have to sand
down to fiberglass and try again, using correct primer!
0.3 Scraped more paint. Prepared test area of feathercoat and bare fiberglass, for
spraying with epoxy primer.
31 Jul 0.9 Spray test areas with LPU primer. Sprayed area of bare fiberglass, clean
feathercoat and mixed feathercoat, bare glass, and sanded white LPU topcoat.
4.0 Install ailerons and elevators on both wings. Installed upper right spoiler,
burned holes for all remaining spoiler attach bolts, installed bolts on both
lower spoilers.
0.5 Sanded and scraped right bottom side of fuselage. Primer stuck to both the
featherfill and the bare fiberglass. Stuck to the LPU, but LPU still peeled up.
1 Aug 0.6 Finish scraping and sanding paint from lower fuselage.
0.5 Finish bolting on lower right spoiler.
2 Aug 0.6 Fastened left lower spoiler, connected cables on right spoilers. Fit and began
installation of last spoiler, upper right
0.7 Completed assembly of both wings!
4 Aug 1.0 Sprayed epoxy primer (system 3) on lower half of fuselage.
5 Aug 0.8 Attempted to squeegee some primer into pinholes on lower right side of nose.
Removed outer paper cover from canopy.
0 7 Cleaned canopy with glass cleaner. Began polishing with #17 mirror glaze.
6 Aug 0.8 Attached air vent to panel. Hooked up heater fan inside spray booth to try to
speed up cure of primer.
7 Aug 1.0 Sprayed primer on top half of fuselage.
0.8 Sprayed second coat primer on top half of fuselage.
8 Aug 1.5 Flipped fuselage upside down. Sanded areas on right forward lower fuselage
where I used primer to fill pinholes. Seemed to work OK. Sprayed final coat
of primer on lower fuselage half.
10 Aug 4.5 Attach foam and fabric to side panels. Turned fuselage upright, installed
wheel, tailwheel, and tailwheel fairing. Installed canopy latches. Installed
instrument panel. Temporarily installed tow releases. Measured for tow rings,
Schweizer will work.
12-14 Aug Put Pioneer in trailer, went to SHA get-together at Kutztown, PA.
14 Aug 0.7 Put aircraft back in basement. Removed instrument panel, tailwheel, wheel, tow releases.
15 Aug 2.5 Took trailer back to Frederick. Sanded primer on upper fuselage. Taped color line for tip of fin
and rudder. Tack wiped fuselage; painted upper portion of fuselage white.
1.2 Sand lower fuselage. Mark off lower trim line. Shortened trailer chock stick.
16 Aug 1.2 Painted lower fuselage white.
17 Aug 0.3 Marked stripe lines on fuselage belly, rudder (top and bottom) and wingtips.
19 Aug 1.5 Masked and painted yellow stripe on lower fuselage. Made 3' sanding T bar
for profiling wings.
20 Aug 1.5 Sprayed red stripe on lower fuselage.
1.0 Sprayed blue on belly of fuselage.
21 Aug 0.5 Sanded (240/400) forward lower fuselage.
1.2 Sprayed clear coat on lower fuselage.
1.0 Installed skid, wheel, tail wheel and tail wheel fairing.
1.0 Replaced springs (tighter) on upper and lower spoilers, left wing.
1.5 Tumed fuselage upright, taped off for yellow stripe on fin tip, wing tips, and
both ends of rudder.
0.5 Drilled static ports, cut threads off of 90 degree tube fittings, epoxied to inner
fuselage walls over tip of static ports.
1.0 Sprayed yellow on fin tip, wing tips and rudder.
22 Aug 0.3 Mixed 1 oz yellow paint to repair spots on right wingtip where paint pulleft up
with tape. Need to pre-sand paint areas before spraying.
23 Aug 1.5 Sprayed red on wingtips, fin tip and rudder.
24 Aug 1.5 Sprayed final blue color on wing tips, fin tip, and rudder.
26 Aug 1.0 Sand upper white surfaces with 400. Apply N numbers, flags, and BRS decal.
0.8 Spray fuselage upper surfaces with clear coat. Attach ID plate.
27 Aug 1.5 Switch fuselage and left wing in spray booth. Apply test of Superlite epoxy
filler to depressions at about the 18' point of leading edge on left wing. Pre-sanded
these areas. Drilled and installed antenna in rudder. Ran tubing to Brunsweig tube.
28 Aug 1.3 Wet sanded upper leading edge left wing. Mark areas for filler.
0.6 Apply Superlite to upper leading edges.
0.8 Begin attaching releases.
0.4 Cut off aileron pushrod fairing, it was rubbing on pushrod. Enlarged exit hole.
1.0 Wet sanded bottom of leading edge of left wing.
0.5 Apply Superlite filler to bottom leading edge of left wing.
29 Aug 1.5 Wet sanded filler on bottom of wing. Flipped wing over.
31 Aug 0.5 Begin sanding upper surface of left wing.
1 Sep 0.7 Sanded remainder of top surface of left wing.
3 Sep 1.5 Taped off leading edge, upper and lower, of left wing. Sprayed one heavy coat
of system 3 primer.
4 Sep 2.0 Sanded down primer on leading edge. Sprayed second coat.
0.3 Began running pitot and static lines.
0.5 Finish running air lines, used plastic slip ties to hold in place.
0.5 Put EXPERIMENTAL decals on seat.
5 Sep 2.5 Sanded second coat of primer.
0.8 Made bracket and ply base for headrest. Attached to BRS canister.
0.5 Sand 1/2 lower left wing leading edge.
6 Sep 0.9 Finished sanding lower left leading edge.
8 Sep 1.2 Taped off left leading edge, painted white.
10 Sep 0.3 Partial sanding of paint edges on left wing.
11 Sep 0.5 Finished sanding top of left wing paint edges.
0.8 Made bracket for firing handle of BRS; removed headrest from canister.
0.5 Made form for next attempt at aileron push tube guides.
11 Sep 0.8 Finish sanding left wing lower sides. Swapped wings in spray booth.
0.3 Drilled out blind nuts for holding back of BRS shelf. Need to use wing nuts on
end of bolts as it is too hard to reach inside.
24 Sep 1.5 Sanded top of right wing leading edge, filled low spots with Superlite filler.
Put one coat paste wax on new aileron guide form.
25 Sep 0.3 Began sanding filler on top of right wing.
0.7 Finished two bridles.
0.9 Sanded part of upper right wing.
0.5 Laid up one aileron push tube fairing.
26 Sep 0.8 Finished sanding top of right wing. Relocated antenna bracket to lower
position, to accommodate 1/2 wave antenna. Cut fiberglass for second aileron
push tube fairing. Trimmed first fairing, fits greatl
28 Sep 0.3 Glassed aileron push rod fairing.
0.9 Presanded lower right wing leading edge. Filled low spots with Superlite filler.
30 Sep 0.8 Sanded part of bottom leading edge on right wing.
1 Oct 1.3 Finished sanding filler on bottom of right wing, masked off area for spraying.
0.7 Sprayed first coat primer on leading edge of right wing.
0.5 Installed antenna and coax cable at aft end of fin.
2 Oct 2.2 Began sanding primer coat on leading edge of right wing. Installed sensor unit
of magnetic compass. Worked on antenna mount at rear of fin.
2.0 Sprayed second coat of primer, after finishing sanding of first coat, on leading
edge of right wing. Soldered ground lead to antenna bracket, soldered ground
lead to frame.
1.0 Trouble shooting shorts in the antenna system Problem appears to be in the
connector where the RG58 cable meets the connector.
3 Oct 1.0 Flxed antenna, no more shorts. Began sanding runs on second coat of primer,
leading edge of right wing.
4 Oct 1.0 Cut filler panels for fin spar openings, from foam core board. Sanded primer
on lower leading edge of right wing.
5 Oct 0.5 Began sanding upper surface of right wing leading edge.
8 Oct 1.8 Finished sanding leading edge of right wing. Painted two coats of white on
leading edge. KTH finished sewing headrest cover.
0.6 Epoxied aileron pushtube fairing on left wing. Began wet sanding right wing.
0.5 Hot glued covering on ply former for headrest.
9 Oct 1.5 Finished sanding top of right wing. Began working opening for right wing
aileron push tube, still binds at full down aileron movement. Hot glued first of
four panel closures in fin spar.
2.0 Fmished reaming exit holes for right aileron push tube fairing. Epoxied
fairing in place. Cut mylar seals for rudder. Did test cut of aileron seals.
Taped tail wheel failing.
0.7 Spread Superlite filler on aileron pushtube fairings, after sanding them.
10 Oct 3.2 Sanded and painted aileron pushtube fairings. Made pattern for forward
cockpit floor. Rough cut ply pieces for floor.
2.5 Make filler blocks for inboard ends of ailerons and elevator of right wing.
Made floor board support structure and floor. Epoxied support frame together.
Had to remake filler blocks out of balsa because foam kept ripping apart.
1.5 Epoxied side and front faces of filler blocks, then epoxied to wings. Microed
top and bottom of filler blocks. Cut all mylar strips for aileron and elevator
seals. Cut to length.
11 Oct 0.7 Sanded top surface of filler blocks. Flipped wings to get at bottom surfaces.
12 Oct 1.2 Finished trimming floor board for nose bowl. cut and installed scuff panels,
taped them over, and sprayed Stone Craft texturing on floorboard. Installed
mounting bracket on fuselage former. Drilled and installed rivnuts for 3/8"
bolts to hold floorboard in place. Finished sanding filler blocks at control
surface root areas. Painted filler blocks white.
13 Oct 0.7 Hot glued corner dots of Velcro on headrest. Greased hinges on ailerons and
elevators. May have to pull aileron bolts to get best lube coverage.
15 Oct 1.8 Assembleft A/C in backyard. Left wing spoiler cable is too short, right
wing cable is too long! Need to reverse bolt on bottom of aileron belcrank.
Cracked tailwheel fairing! Attempted to weigh ship, but broke Medcalf's scale
and broke ours too. Sat in A/C with all parts on, but no battery or canopy, and
it sat nose down. KTH lifted nose, had to hold in level flight.
16 Oct 1.5 Reversed aileron belcrank bolt. Installed new springs in right wing ailerons.
Reversed cables to fix length problem from yesterday. Had to open inspection
ports for aileron pulleys.
0.6 Used 7/16x20 thread/inch tap to clean threads on spar taperpins. Polished,
greased and put in a baggie.
2.2 Removed both ailerons, greased hinges, and replaced. Greased main aileron
belcrank. Cut holes for spoiler cables. Installed 5 rivnuts to hold instrument
panel in place.
17 Oct 1.5 Soldered wiring for compass and vario. Left bare wires for radio hookup.
Soldered plug for gel-cel battery. Tested hook-up, works OK.
21 Oct 9.5 Fit radio to panel, made supporting bracket. Trimmed antenna, installed sealing panels
at fin spar. Installed instrument panel. Fashioned battery box, installed on floor board.
Attached right side rudder seal, after bolting on rudder. Attached aileron seals. Weighed
at about 388 lbs., all up. Wings are 109 lbs, fuselage 148, and BRS is 22. Ready for inspection.
22 Oct 2.5 Set up A/C in backyard. Pop riveted (3/16") trim tabs on elevators. Safety wired spoiler
turnbuckles and aileron end rods. Bart Crotty inspected it, found lower rudder bolt too short,
3 nuts needed torqueing on lower right spoiler, nut needed tightening on release knob, and
needed slight relief of fiberglass near right elevator torque tube to prevent rubbing.
Otherwise, A/C passed inspection!
23 Oct 1.0 Glassed over cracks in tail wheel fairing.
1.7 Put Superlite filler on outer surface of tail wheel faring. Cut new feet for wing
saddle. Raised front of saddle 4.5" (based on measurements taken 23 Oct).
Will now support wing at proper angle for fuselage, in tail wheel-down attitude. Attached
new saddle feet after removing old ones.
1.5 KTH sewed up stick boot. Fastened 12 snaps to stick boot, pop riveted other halves
to seat pan. Stick boot now in place.
25 Oct 1.0 Sanded Superlite filler on fairing, sprayed blue color coats.
2.5 Hooked up radio to battery. Works OK. Attached fairing to fuselage, taped
edges. Glued 6 velcro strips to hold seat pad in place.
29 Oct 2.2 With Phil Burgess, attempted weight and balance. Scale was not too good,
seemed to get empty gross weight of 404. Balance was good, measured
empirically by sitting in it and seeing whether the nose dropped.
0.7 FIRST FLIGHT! I Flew 0.2 for first flight, released at 400' after tow got too slow,
accomplished 2 360 degree turns, a 270, and landed. Second flight, using 65 mph for
tow to up to 5000 AGL, lasted .5 hours.
Total Hrs: 1059.8
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