|This photo is of the prototype during the
earlier phases of construction.
March 19 2017 2.0hrs - 3163.0 total. Removed fiberglass from windscreen and trimmed back a little. Put it back in
place and marked final trim lines. Removed it again, trimmed some more, put it back and checked trim lines, made a
few adjustments, removed and trimmed some more. Not done trimming yet. Then it will need fill and at least three
more 6 oz layers of fiberglass.
March 20 2017 2.5hrs - 3165.5 total. Sanded entire outer surface of frame. Set up laser lever to shoot a line down the
top of the fuselage to verify centerline on windscreen. Measured, marked, and trimmed back top center section for
flange and location for mirror mount bracket.
|3rd trim, top flange cutout,
and all outside sanded.
March 21 2017 2.0hrs - 3167.5 total. Mixed up a batch of micro in thickened epoxy and spread over all outer surfaces of frame.
Built up areas in front of canopy rails. While that started to dry, cut out some foam to start building up the form for the bullet proof
glass frame. Glued it together into one large plug.
March 24 2017 1.5hrs - 3169.0 total. Sanded down filler. Cleaned up all surfaces in prep for another coat of glass. Started carving
March 25 2017 3.0hrs - 3172.0 total. Measured, cut and applied another layer of fiberglass (3 layers of 6 oz cloth) on top of the
sanded filler. All of the corners and most of the top of the frame are overlapped meaning there are 12 layers at those locations.
March 26 2017 5.5hrs - 3177.5 total. Removed frame, rough trimmed with tin snips. Trimmed back further with band saw and
Dremmel. Final sanded. Clamped onto windscreen and worked on the foam plug for the bullet proof glass section. Got it down to
final shape that looks good. The plans call for it to be very narrow at the top and wide at the bottom, but photos of actual early Mks
as well as Terry's original prototype screen show a more consistent thickness. I've opted to deviate from the plans here and go with
what looks more authentic. Clamped completed plug to bench and applied 3 layers of 6 oz cloth.
|Coat of thickened micro over all.
|Starting on foam core for
front glass frame.
|Three more layers of 6 oz glass
on top of the fill.
|Cleaned up after 2nd glass
|Foam core finished, clamped
in place to check how it looks.
|Forward frame (with foam still inside)
glued onto windscreen frame
March 27 2017 2.0hrs - 3179.5 total. Trimmed and sanded down forward frame section - while leaving the foam plug in place. It
cleaned up very nice. I'm worried it will be too flimsy and not keep its shape if I remove the foam at this point. Went ahead and glued
it onto the windscreen frame. Will need to add another layer of glass over the forward frame section before cutting out the foam.
March 29 2017 3.0hrs - 3182.5 total. Sanded back glue joint on sides flush with existing frame. Sanded rest of glue joint on outside
surfaces in prep for next layer of glass. Spent some time looking at photos of original Mk1 and IIs to convince myself the shape is
correct. Also researched how wide the outer lip on the forward frame will need to be. Marked and cut out several pieces of fiberglass,
pre-glued, then applied them to the forward frame. To get the top area I cut the glass on the bias - works very well like that. After
glass was in place and still wet, trimmed some larger extra pieces off and applied them to the top area where the mirror base will go.
Might be overkill, but it will make it much stronger and it needs to look thicker here anyway. Also printed out a full size template,
from the plans, of the bulkhead where the instrument panel will go. Glued to piece of cardboard. Starting to plan the layout for the
March 30 2017 3.5hrs - 3186.0 total. Trimmed back the raw edges of glass, then cut out foam mold. Had to dig it out of the frame
with a screw driver, then sand and use wire brush to get all the foam out. Marked and cut back edges of forward frame as indicated
on plans. Ground and sanded back to final profile. Sanded all surfaces in prep for final cot of fill.
March 31 2017 2.0hrs - 3188.0 total. Trimmed back area around mirror base all the way to original shape. Touched up sanding and
shaping a little more. Cut off lower corners where they will butt against canopy frame. Mixed up batch of thickened epoxy and
micro. Covered all surfaces with thin layer, to fill in all the fiber texture and minor imperfections.
April 1 2017 3.5hrs - 3191.5 total. Sanded down all surfaces of the windscreen frame, inside and out with 80 grit, then 120 grit by
hand. Took forever! Put two coats of primer on all surfaces. Worked on laying out the control panel a little more. Made up list of all
needed instruments and switches/controls. Its a pretty long list and I know its not done yet. Made up a bunch of 3 1/8" and 2 1/4"
paper discs to use to position everything.
April 2 2017 2.0hrs - 3193.5 total. Spent a couple of hours digging through various instrument supplier and reseller websites. Also
spent a good deal of time studying photos of early Mk instrument panels, as well as the two Tally-Ho panel layouts. Used some tacky
spray and temp positioned all the instruments I'm planning to have - in place on the panel template. One problem is that I've never
flow an aircraft with a liquid cooled engine, so I'm not actually sure what I'll need? I know I'll need a coolant temp, but do I need a
coolant pressure? Do I still need EGT/CHT? I need to call the guy at Titan (where I'm planning to buy the engine) and get his
April 5 2017 1.5hrs - 3195.0 total. Hand sanded down the primer on all surfaces of the windscreen frame. Clamped back into place
on the fuselage and started working on making the form for the front fairing.
April 8 2017 3.0hrs - 3198.0 total. Trimmed up the cardboard fairing template a little then covered it, and all contact areas on
windscreen, with clear packing tape. Made up a 3 layer/6 oz epoxy fiberglass layup and applied over form. There's a 90 degree corner
on the forward edges of the fairing that the glass doesn't like to go around. After epoxy had partially set and got pretty stiff, but still
sticky, pressed these areas down by hand then clamped some pieces of aluminum angle over them to see if they will set with the glass
|Another layer of 3 X 6 oz cloth. 3 on
each side, 3 across the top (bias)
and 6 more at the mirror base area.
|Starting to layout instrument panel.
|Windscreen frame, fully trimmed,
ready for final fill coat.
|Set in place on fuselage to
see how it looks.
|Thin layer of micro overall to
fill in fiber weave.
|After 1st coat of primer.
|Hard to see, but I've got pretty
much everything on there.
|Starting on the front fairing form.
|First glass layup, just off the form.
|2nd Coat of glass on inside,
micro overall to fill in weave.
April 9 2017 3.0hrs - 3201.0 total. Popped yesterdays fiberglass layup off the cardboard form. Rough trimmed piece to shape, then
sanded to final shape, then sanded all surfaces inside and out. Applied 3 more layers of 6 oz cloth to the inside of the fairing. Put
some thickened micro on all inside surfaces first especially in the 90 degree corner area, creating fillets. Then placed the still wet piece
back in place on the windscreen frame - after removing the cardboard form, and pressed into place. Added a couple of strips of glass
(3 X 6 oz) on the side tab areas for strength and thickness. Spread the extra micro over the outer surface of the fairing to fill in the
April 10 2017 2.5hrs - 3203.5 total. Removed fairing from form. Rough trimmed with bandsaw and tin snips. Final shaped with
sander. Had to put it back in place few times to make measurements and finalize the shape. Sanded all surfaces inside and out.
Cleaned it up then applied 1st coat of primer. Got out instrument panel template and started making a shopping list of tools, templates
and exactly which instruments I plan to buy. Stopped by parts store earlier today and ordered a piece of .065 aluminum large enough
to make instrument panel.
April 15 2017 3.0hrs - 3206.5 total. Picked up the .065 aluminum sheet and a set of hole punches loaned by a fellow EAA member.
Picked up some 4-40 screws and nuts for attaching the windscreen, plexi and frame tubing together. Also got a couple of 4-40 taps.
Made a very accurate paper template of the area inside the fuselage where the instrument panel will go and compared it to the template
I've been using to plan the layout, which came directly from the plans. Turned about to be some significant differences in overall
width, as well as the location of the longerons and stringers. Transferred the dimensions from the paper template onto the cardboard
one and trimmed it to match. Tried it in the fuselage, but it took about an hour of sitting in there with scissors and a box knife to get it
in place. But that left some large gaps on some of the notches and in spaces around the perimeter. Messed around for quite a while
trying to mark the gaps with tape, shims, etc. then struck on the idea of trying to use modeling clay. Went and bought some very nice
clay for only $5 and worked it into all the notches and gaps around the edge of the template - after coating all contact areas with
packing tape first. Will let it cool and harden up a bit and then see if I can get it out of there in one piece.
April 16 2017 5.5hrs - 3212.0 total. Pulled out the cardboard template with the clay attached. Worked pretty well. Traced onto
aluminum, rough cut with jig saw, then trimmed to near final with band saw. Was having a very tough time with the band saw, only
getting a couple of inches with a lot of effort and the blade would grab and come off the saw. Went and got a new metal cutting blade
and it was like cutting butter. Makes a huge difference to have the right tools, and to keep them sharp. It took almost three hours of
fitting, grinding, fitting, grinding, etc. to get the metal piece to fit in place, but finally got it in there. Once it was final shaped, removed
it and spent about an hour sanding the glue joints on the inside of the skin pieces and the instrument panel bulkhead. Due to the size of
the epoxy fillets and the longeron to bulkhead joints, the metal doesn't sit flush against the bulkhead. Thinking of putting in filler strips
or maybe standoffs. Marked the line to cut off the bottom as needed, but haven't cut it yet. Started to layout the position of the "blind
April 17 2017 2.0hrs - 3214.0 total. Cut off the bottom of the instrument panel and sanded to final shape. Researched vibration
isolation standoff hardware. Went to a couple local hardware stores, but no luck. Looks like I'll need to order something. Removed
all the masking, plastic sheeting and various tape from the windscreen frame and tubing. Working up the courage to drill the frame and
tubing! Measured, marked then triple checked the location of where the top fuselage skin will need to be trimmed back over the
instrument panel. Started looking at plans to verify how fuel tank cover skin piece is attached at the instrument panel bulkhead.
April 26 2017 1.0 hrs - 3215.0 total. Measured, marked, cut out, and sanded to final shape the "blind flying panel" that contains the
instrument "six pack" and is mounted forward of the rest of the panel by vibration dampeners. Also have ordered several parts over
the last couple of days including a very nice replica gear position indicator, an original start button with cover, the airspeed indicator
and some vibration dampeners.
April 27 2017 1.0hrs - 3216.0 total. Removed plastic covering from one side of the blind flying panel, sanded edges with emery cloth
and lightly scuffed surface as well. Applied 2 lite coats of self etching primer and a coat of satin black rattle can paint. Also purchased
a rough cast flap lever on e-bay.
April 28 2017 1.0hrs - 3217.0 total. Found out the airspeed indicator I had ordered was on back order for at least 4 months, so
cancelled and ordered the altimeter instead. Re-aligned and clamped windscreen frame in place over plexi and maneuvered into position
to start drilling the holes through the frame and into the metal frame tubing. Measured and marked location for holes.
April 29 2017 2.5hrs - 3219.5 total. The black paint I had applied to the blind flying panel was not drying, even after several days so I
removed it. After fiddling with a problem with the spray nozzle, finally got a nice coat on there. This time it appears to be drying
properly. Re-checked the plans as well as printed out some of the photos of Terry's windscreen I took a few years ago, then
repositioned the marks for drilling the frame. Went ahead and drilled the fiberglass frame, then made up a jig to help me center the
holes over the tubing for the frame. Marked plexi-glass and drilled it - one of the most frightening things I've done yet! Used the jig to
align frame and plexi on tubing then used drilled holes as a guide to mark the tubing. Removed frame and glass, drilled and tapped
holes in tubing.
April 30 2017 5.5hrs - 3225.0 total. Attempted to put screws in place through fiberglass frame and plexi and into threaded holes in
tubing. Had to enlarge plexi holes and stretch them out in specific directions. With that done, it still required a little tweaking on the
fiberglass frame to get it all to line up without any stress on the plexi-glass. Also, am leaving allowance for some butal putty to go
between the frame and the plexi for water barrier once its ready for final assembly. Removed the structure from the fuselage to make
it easier to work on. Cut screws to needed length and temp mounted everything together. Marked location of all remaining drill holes.
Drilled plexi and frame at rear of bullet proof section and drilled frame around front of bullet proof section. Still need to drill sides for
plexi and mounting to fuselage.
May 1 2017 2.5hrs - 3227.5 total. Removed plexi from tubing and frame. Drilled all remaining holes in plexi and cut out front section.
Used de-burring tool and chamfered both sides of all holes and outside edges of plexi. Still need to final shape the area cut out in front.
Also need to drill remaining holes in fiberglass frame.
May 2 2017 1.0hrs - 3228.5 total. Picked up a piece of lexan for the forward bullet-proof glass section. Traced pattern from
windscreen and cut to shape. Sanded to final shape and started dressing the edges.
May 5 2017 4.5hrs - 3233.0 total. Received altimeter yesterday. Marked locations for instrument holes on blind flying panel. Drilled
pilot holes for all six instruments, then used hole punch tool to knock out holes. Used dremel tool to grind out notch for altimeter
adjustment knob. Marked and drilled three holes then trial fit altimeter.
|Trimmed and sanded to final shape.
|Piece of .065 aluminum that will be
the instrument panel.
|Cardboard template with clay
shoved in around the edges.
|Took almost three hours of fitting
to get it in there - but there it is!
|"Blind Flying Panel"
cut out and shaped.
|"Blind Flying Panel" primed
and painted - on one side.
|Holes drilled in frame, plexi, and
starting on holes in tubing.
|Windscreen frame and plexi screwed
to tubing. Holes done in front flanges.
|Finished drilling all holes in plexi.
Cut out front section.
|Punching the instrument holes. Metal
is so thick I had to use a long
"cheater bar" on the wrench.
|All six holes punched and
de-burred. Paint got pretty messed
up. Will have redo paint.
|Altimeter temp mounted in place.