Built all the seat belt brackets. These are made from .125 4130. I put some bends in them to line-up better with the belt angle. The two aft side brackets didn't have the bend in the plans , but I think this is better. Tacked in the top forward bracket. To make the bends, I heated with a torch and tapped the fitting over with a ball peen hammer , on the cool part.
11/10/07 - 4.0 hours - Total Time 742.0 hours.
Did a little clean up on the seat belt brackets, then tacked them all in. Cut, fit and tacked the tubing for the aft storage bay. Built the fairlead supports for the rudder cables and tacked them in as well.
11/11/07 - 1.0 hours - Total Time 743.0 hours.
Did some work on the rudder cables. I tried out a swaging tool I bought some time ago. I'll have to cut this one out, and do it again now that I have the hang of it. I'm thinking about putting the turnbuckles in the tail, just aft of the baggage compartment?
11/12/07 - 3.0 hours - Total Time 746.0 hours.
Fabricated the rudder cables. I'm thinking about adding another fairlead in the tail? I decided to put the turnbuckles just forward of the trim. There will be an access panel there, that will allow inspection and adjustment. Need to trim down the rudder horn to keep the cable from contacting.
11/17/07 - 4.0 hours - Total Time 750.0 hours.
Fabricated the rudder tension spring tabs. Installed springs I picked-up at ACE Hardware. After quite a bit of thought, I installed two diagonal 3/8" .035 tubes in the rudder. I studied the Citabria tail structure and decided on this design. I can already tell it's much more solid. Trimmed down the rudder horn quite a bit, but still have some contact with the cable at full deflection?
11/20/07 - 5.0 hours - Total Time 755.0 hours.
Modified the rudder horn connection to fix the clearance problem. I also had to shorten the cable. I'll have to build new cables when I'm done. Tacked in the aft storage tubing, and started to mock-up the tray. Built a tool to install tabs. I used an old rib that I cut wrong, and riveted it to a scrap piece of aluminum. I can just clamp this wherever I need, and with a tab installed, tack the tab in place. Trimmed down, and tacked in the flap mechanism mounting bracket.
11/21/07 - 2.0 hours - Total Time 757.0 hours.
Built 8 tabs with Monadnack 8-32 clip nuts, and welded them in. I used an Olfa knife to cut out the .032 2024-T3 Aluminum floor once I had the pattern final. You simply score with this about 20 times, and it makes a very clean break. It's a great way to make accurate and inboard cuts without a shear. Still need to add some more tabs and clips, but it's a start.
11/24/07 - 5.0 hours - Total Time 762.0 hours.
Built the floor just aft of the front pedals. I used 3 pieces of aluminum for this. I will have to build a fiberglass channel to provide more clearance under the front stick. Added a bearing to the aft stick. This gave me some more clearance.
11/25/07 - 3.0 hours - Total Time 765.0 hours.
Built a new trim wheel out of a recycled plastic board. It has just the right texture and make-up for this. I used a router to round out the edges and lightened it up with four holes. Looks pretty cool, and works well. Too bad no one will ever see it, and admire my last three hours?!
12/3/07 - 1.0 hours - Total Time 766.0 hours.
Big day for the project, as I purchased an engine. It's an O-235-C2C. (Similar to the one pictured to the right) It has 1800 hours since a Mattituck overhaul, with a 2400 hour TBO. So, 600 hours left. It was still flying last month. No mags, but it has the carb, starter and flywheel. It's a certified engine that I could bolt on and fly with if I was ready. 115 max HP. But really about a 100 HP continuous at 2400 rpm. $2500. I also received some throttle quadrants, tail wheel springs, and a couple of new air tools the other day, along with some aluminum and tube. This will be a big step toward the firewall forward completion!
