Top stringer fitted

Top rear stringer was cut, trimmed, and fitted. The back end was carefully filed so that it matched the profile of the tail fin tubing.  Two holes were drilled in stringer for the two center spigots that are welded to the frame.  The center spigots were also cut shorter to fit the shape of the stringer. Stringer was cleco'd to the tail fin, and will be epoxied in place later. (EJB, MHC)   Hours: 2

Installed Horizontal Stabilizer Front Attach Brack

The Horizontal Stabilizer front attach bracket (F-1020) was installed.  The AN4-12A bolt indicated in the manual was replaced with a AN4-13A for a correct fit, The AN3-12A bolt fit perfectly.  The Part originally had holes drilled on both sides which made it difficult to drill correctly.  Ed filled in one side of the holes with a TIG weld.  This allowed for a nice tight bolt fit. MHC & EJB.  Hours: 3

Tail Installation

Vertical fin fitted, leveled, and installed.  Some powdercoat had to be removed and tubing length trimmed slightly for fit. (MHC, EJB)  Hours: 4

Cockpit Floor Installation

The cockpit floor was trimmed to fit and then pilot drilled and cleco'd in place. (MHC)  Hours: 0.5

Flooring

Alum. sheets for flooring of front and rear baggage area were trimmed, fitted, and Cleco'd in place.  Two smaller side flooring pieces were also fitted (next to the seats). (MHC, EJB).  Hours: 4

Rotisserie jig strengthened

Added angle bracket on side of Rotisserie.  Also changed the angle steel piece to a square tubular piece for added strength.  These changes were made to eliminate some swaying of the fuselage from left to right when placed in the jig.  Jig was then repainted (brown and white) (EJB)  Hours: 3

Rear back baggage panel fitted, airplane on jig

Additional angle had been added at base of jigs for additional stabilization. Fuselage placed back up on jig.  Al sheet was trimmed and fitted for rear baggage panel. This was drilled and is currently held in place with clecos. (MHC, EJB).  Hours: 3

Completed Fuselage Jigs

The fuselage jigs were completed and fuselage frame was placed on the rotisserie.  We had to add adjusting feet to the legs of one of the jigs to allow for angle adjustment.  This required TIG welding 3 nuts to the jig legs.  We've also discovered that the garage will have to be re-organized to allow work room. EJB & MHC .  Hours: 4

Rotisserie jig bracket construction

Attached front jig spindle to fuselage.  Metal plate and round tubing cut and ground for rear jig spindle.  Metal plate welded to round tubing.   MHC, EJB.  Hours: 1.5

Jig bracket construction

Cut and welded steel plate to round tubing.  The tubing will insert into the rotisserie jig, and the plate will bolt to a cross bracket that connects to the front of the fuselage. MHC, EJB.  Hours: 1.5

Jig Bracket construction

Cut and welded square tubing to make a cross-bracket that attaches to the fuselage.  This bracket is needed to connect to the rotisserie jig. MHC, EJB.  Hours: 2

Fuselage transport

Hauled the fuselage from the hangar to the garage.  Hours: 1.0

Rotisserie jig cont.

Finished welding the jig stands, risers, and screw handles.  Painted vertical risers brown.  EJB, MHC. Hours: 1.0

Construction cont. for rotisserie jig

Welded long nuts to top (horizontal) pipes on the rotisserie jigs.  EJB.  Hours: 1.0

Rotisserie jig cont.

Finished and painted 2 bases for jigs. EJB/MHC.  Hours: 1.5

Rotisserie jig construcion

Continued construction of Rotisserie jigs.  Welded 6" pipe to top (moveable) shaft, and tacked nut to a T-handle.  EJB/MHC.  Hours: 1.0

Rotisserie jig construction

More work on rotisserie jigs, including welding nuts onto main shaft.  EJB,   Hours:1.5

Jig Welding

Grinded and welded on rotisserie jig.  EJB/MHC.   Hours: 1.0

Rotisserie Jigs

Welded up bases of rotisserie jigs (using TIG).  These jigs are used for holding/rotating the fuselage or wings.   Hours: 2.5,  EJB

Kit Pickup

Rented a Rider truck;  Traveled to Walhalla, SC to the Just Aircraft LLC factory to pick up the Highlander Kit.  EJB/MHC

Kit Loaded and Ready to Go

Demo Flight

Demo Flight