It has been a very interesting and rewarding experience.
This is the wooden jig that Van's recommends constructing from the packing crates to place the rudder pedals correctly for setting the cable length. These guys are so very clever.I have finished the rudder cables which required placing the fuselage on the bottom level of my work dolly to clear the low ceiling in my garage. This also enabled me to work on the canopy which is almost complete.
I also had an opportunity to sit in the cockpit, grab the joystick and make all sorts of airplane noises.
One part of the project that was unexpected required the construction of a fiberglass fairing at the base of the canopy aft of the front cowling. After some expert tutelage from Jeff Shutic, a master at resins and fiberglass, I came up with a pretty good result.
Another task is the assembly and sealing of the fuel tank. It is a smelly, sticky and unpredictable task. I would prefer to pay a couple of hundred bucks for a poly or welded aluminum tank. But it is what it is. So far I have everything but the top, vent tube, sight glass and sending unit plate sealed. That will take place soon.
Even the gas filler cap is slick!The day came when I had to bring the wings back from storage and fit them to the fuselage. This goes without saying that it is pretty important that the wings fit.
My helpful nephew, Terry, assisted me. The wings weigh about 88 pounds but they are impossible to move by oneself. I rented the stake truck that Home Depot has available and with a jury-rigged tailgate extender, we were able to to transfer the two wings, flaperons and wing cart in three trips. Luckily my storage facility is only about a mile away.
The wings do fit, the flaperons flap and ailerate too. The Jesus pins go in, sometimes with some force but having someone jiggle the wings helps.
All that remains of the finishing kit is installing the landing gear and brakes and tires.
The engine and avionics will arrive next week but the Rotax engine sensors are on back order.
As of Easter Sunday, there are sixteen weeks until Oshkosh.
