I prepared the fairings per the plans (this was a lot of work with many iterations—lining up rounded parts is tricky, and I wanted to get these well aligned with the airstream). I used jack stands to raise the airplane… Read More »Gear Leg and Wheel Fairings
Lifting the fuselage to install the landing gear was the primary challenge in completing this step. The fuselage accumulates a lot of weight by this stage in the build. We removed the tail feathers to make it more manageable. After… Read More »Landing Gear Installed
I made two jack stands to raise the airplane for the installation of the gear leg fairings. I plan to use these jacks for future maintenance. I purchased two 3-ton long ram flat-bottom hydraulic jacks from Harbor Freight. I made… Read More »Jack Stands
I followed the Van’s fiberglass fairing how-to video series to bond the windscreen to the aluminum skin and build up the fairing. I started by marking the upper edge of the windshield fairing. I 3d printed a template with the… Read More »Windshield Fairing
I opted to use Cee Bailey windows when I ordered my finish kit. I have nothing to compare it to, but the overall fit of the Cee Bailey windshield was poor and required a lot of trimming. The lower left… Read More »Windshield Installed
I used the Silpruf method for installing the windows. I used Cee Bailey windows and black Silpruf SCS2000. I started by trimming the windows to a 5/32″ gap. The Cee Bailey windows fit well on the left side, but needed… Read More »Windows Installed
Finally. The doors feel like a neverending part of the project. After multiple iterations of micro and sanding, the doors smoothly transition to the cabin top. I gapped the doors to a gap of just under 1/8″. A lot of… Read More »Doors Complete
I ordered my finish kit in August 2021 and the front seats finally arrived. The seat foams are still on back order but at least I have the frames. Unlike the old seats, these require assembly. The box had unfortunately… Read More »Front Seats
I chose to delete the Van’s Grove wheels and brakes from the kit and upgrade to Matco I Series wheels and brakes. I also deleted the tires and tubes and purchased Desser retreads. The complete list of parts that were… Read More »Matco Wheels
I am using McMaster door seals which require that the hinge attachment areas in the door be covered to complete the seal. I didn’t like the idea of burying nutplates here (as used by one after-market option) but I liked… Read More »Door Hinge Pockets