At first it was very inefficient - having to move tools back in forth (keeping them in my car trunk) and trying to get things I needed to the airport when I needed them.
The airport is 20 minutes away from my house on a good day, and with traffic it's often 30 minutes. Getting there and finding I didn't have some necessary part or tool was very frustrating.
It didn't take me long to get some shelving set up so I had somewhere to put things, as well as a portable camp table to use as a temporary desk.
The other thing I didn't realize is how much time can be spent by talking to people that come by (which is a blessing, but can be a bit time waster). We are fortunate to have a very active building and flying community in our local chapter. There are probably a dozen guys with either projects or flying aircraft at CPK, so there is a lot of help and eyes to make sure you aren't doing something stupid.
At any rate I decided I had to have a schedule I could depend on, so I worked out a deal with my wife. Tues and an Thurs evenings I go straight to the airport from work and don't get home til 9, and Saturdays I'm there all day until 6. That way she can plan when we do go out and know I'll be home if she needs something. That was one of the best decisions I've made so far after moving. I can spend my lunch hour planning work sessions and getting my punch/finish lists down pat, and when I get out to the airport I can hit the ground running.
Ironically week nights are by far the most productive. All the builders pretty much leave each other alone and we work away. If we do need help it's literally next door. Pretty great.
The first thing I did was install the empennage - horizontal stab first, then vertical stab, then rudder, then elevators.
I finally installed the cable fairings I made so long ago on a rainy day.
And pulled the manual trim cable through the holes. What a bear. Hopefully that was the last time.
Once that was done I got my kids to come out Sunday afternoon after church and lunch and we installed the wings so I could lay out the flap holes, root fairings, drill the rear spar, etc.
Becca did the honors inside with the bolts. Greg and I wiggled, aligned and cajoled. I used hardware store bolts that I had ground down considerably, so they went in reasonably easily. I also lubed up the bolts and spar fairly liberally to prevent galling and to make it slide together more easily.
Both wings done. Only took us about an hour, and cost me a couple of Blizzards. Well worth it! Finally looks like an airplane. :)
Now it's time to start working on all the stuff I need to do before I install the wings permanently.
First order of business - check the sweep. Ended up being 1/8" forward on both wings.
Check the rear spar edge distance. Looks good.
Start enlarging the flap pushrod exit holes.
At this point I noticed there was no way to get the bolts through the flap actuator weldment from outboard (which is what the plans showed). I started to shorten some up, then changed my mind - leaving them like that would drive me nuts. I just removed the weldment and installed them properly.
After twiddling with the sweep (really hard to get 1/8" out - turned out to be hard to move the tip just enough - very easy to blow right past the distance. 1/8" over 12 feet isn't much.
As good as I can get it.
After setting the incidence on both wings, drilled a #40 hole. Then remeasured about a million times. :)
Fabricated the forward fuselage fuel tank attach points, then match drilled them to the fuse.
And to each other.
Clecoed on the inboard fairings so I could match drill them. Need to drill them to size so I can install nut plates. Also may have to trim them at the inboard side a bit (at least forward) to allow the gap seal to fit.
June 3 & 4. Among other things, I final drilled the rear spar to size.
Doing the left side my drill bit broke, so I had to drive it out with a pin punch. Fun times.
Left side drilled to size. Big sigh of relief. Glad to have this done.
Pretty good progress in the last month. Get some more stuff wrapped up and I can start thinking about first engine run and fuel tests.
My friend Tim helped me finish the riveting on the forward skins on Wed afternoon. (I forgot to take pictures of that) Now that that is done I can start reinstalling the avionics and get all the lines reinstalled. That also opens the door to reinstall the panel and engine cabling. :)
