Chip's Sportsman

My First Flight

2010-02-16T09:42:00.000-08:00

Here is the first taxi:

http://www.youtube.com/watch?v=Zhyky9vYup0

Here's a video of my first flight. Quite a rush.

http://www.youtube.com/watch?v=5gJE14CDXek

More TWTT Photos

2010-02-16T09:41:00.001-08:00

http://picasaweb.google.com/haswett/TwoWeeksToTaxi#

The Two Weeks To Taxi Blitz

2010-02-16T09:37:00.001-08:00

This blog ended when I unloaded my wings and tail at the factory for the TWTT program. The following link is to photographs of every step done in the factory: http://picasaweb.google.com/haswett/TWTTGlasairPhotos#

Future Shock...

2007-03-18T14:56:00.000-07:00

After unloading the truck, the guys took me into the hangar where the magic happens. The is the latest 'Two Week" Sportsman. Be still my beating heart....

STAY TUNED....I'll have a whole bunch of new pictures in May when this thing becomes a real airplane.

Safe And Sound At The Factory

2007-03-18T14:51:00.000-07:00

I made the 3 hour trip to Arlington, WA without any trouble. I thought the truck was wider than the road going over Stevens Pass, but I made it without any trouble. I'm not sure how that Mercedes bumper snagged on the back corner of the truck...oh well. Meet Tim and Andy who are helping me unload. We will be getting to know each other pretty well during the 2 weeks to taxi final assembly beginning April 16th.

Time To Go Mother Trucker...

2007-03-18T14:49:00.000-07:00

Smooth Ride

2007-03-18T14:46:00.000-07:00

I am hoping for a smooth ride. I have the wings on top of some tires with straps securing them in place. The other parts are wrapped in plastic, or tarps and also tied into place.

Haulin Ass....

2007-03-18T14:44:00.000-07:00

Time to truck all of these goodies over to the factory. Man this is a big truck.

Ta Ta !!!!!!!!!!!!!!!

2007-03-18T14:39:00.000-07:00

Two years 3 months and 11 days after starting this project, I am done...with the garage phase of assembly anyway. One wing is on the rack and the other is on the floor in front of it. You also see 2 flaps, 2 ailerons, the horizontal stabilizer, the elevator, a trim tab, and the rudder.

Peeking...

2007-03-18T14:36:00.000-07:00

All of these pieces that I have been building look a little dingy because the aluminum is still covered with protective plastic. I couldn't resist removing the plastic from the ailerons. Jeez, they look beautiful!

Last Minute Fixes

2007-03-18T14:33:00.000-07:00

Now that I don't have anything more to build, I am going over every rivet and drilling out and replacing any that have 'smiles' on them. Some of the smiles I didn't even see until I put these goggles on.

Inspection

2007-03-18T14:26:00.000-07:00

Jerry made a few suggestions for things that I should fix, but said overall I did pretty good job for a 'first time builder'. Jerry has built 4 airplanes.

Jerry Dickson - EAA Technical Counselor

2007-03-18T14:11:00.000-07:00

Jerry used to repair airplanes for the Air Force. Now he likes to inspect homebuilt airplanes. Great guy...wish I had met him 2 years ago.

Getting The Parts Together

2007-03-18T13:56:00.000-07:00

Time to pull all those parts that I have been building for the last two years out of the various nooks and crannies where they have been stored...where was that other wing I built.

The Golden Spike

2007-03-18T13:37:00.000-07:00

Here it is, I'm preparing to drive...THE LAST RIVET...!!!!!! It's a hair raising experience.

On edge

2007-03-18T13:34:00.000-07:00

It's easier to rivet these things with the flap mounted vertically.

Wrist protection

2007-03-18T13:31:00.000-07:00

Reaching inside the flap to buck the rivets causes wrist chafing. A shop cloth wrapped with tape solves the problem.

2007-03-18T13:27:00.000-07:00

These flap assembly pictures are a little out of order. Here I am reaching inside the flap to rivet the skins to the spar

2007-03-18T12:03:00.000-07:00

Putting the flaps together really makes me feel like the end is in sight. I view the end of this process with mixed emotions. I have loved building this airplane and I'll miss not being able to go out into the garage at any time and have somthing to work on. On the other hand, I'm really glad I don't have another 2 or 3 years to go.

Trailing Edge Joggle

2007-01-22T20:49:00.000-08:00

This aileron is just about finished. I have clamped the trailing edge joggles together between two steel angle beams with some epoxy to make sure the trailing edge is straight. I then rivetted the trailing edge.

Electric Aileron Trim

2007-01-22T20:34:00.000-08:00

The actuator arm extends through this oval hole cut in the aileron.

Electric Aileron Trim

2007-01-22T20:33:00.000-08:00

Here is a closer look at the trim motor.

Electric Aileron Trim

2007-01-22T20:31:00.000-08:00

While I have been building parts of the wing, I have also been finishing the ailerons. I have decided to put in electric trim. In order to do this, part of the aileron is cut away to fit a trim tab. Here I have cut a circular hole in the aileron and installed a reinforcement ring which will be covered by a removable inspection cover. The motor can be seen through the hole.

Finishing The Wing

2007-01-22T20:16:00.000-08:00

John took to this riveting business like he'd been doing it all his life (he did work for Boing once, though not bucking rivets).

The Wing Is Finally Done. Thanks Greg. Thanks Pat. Thanks John. Your willingness to help has been one of the great parts of this project.

Finishing The Wing With John Newman

2007-01-22T20:01:00.000-08:00

There are only a handful of rivets left to buck on the right wing. This is John Newman...jack of all trades...experienced blue water sailor (he and his wife Sandy spend 6 years circumnavigating the Pacific)...and all around great guy.

Pat Bucking Rivets

2007-01-01T15:14:00.000-08:00

And this is the guy that made the final rivetting possible...Pat Wendt...here we are rivetting a hat section. Another half a day on this wing and it will be DONE!! Meantime I have almost finished the other aileron. One of the flaps is almost done...the other has been started...and it shouldn't take too long. I have to have all of these things done by 3-15-2007 when they need to go over to NewGlassair for inspection prior to the final "2 Weeks 2 Taxi" program. By the way, it was almost exactly 2 years ago, that I started building the Sportsman. Happy New Year.

Right Wing Nearing The Finish Line

2007-01-01T15:09:00.000-08:00

The right wing is almost done...just 2 months after Greg and I started it!!. The bottom skins have been riveted along the forward and aft spars...

2006-12-17T20:05:00.000-08:00

A lot of work went on between the last picture and this one. The leading edge skins were assembled and the leading edge ribs riveted inside. The whole assembly was placed on top of the wing. The ribs were riveted to the forward spar and then the skins were flush riveted to the spar. The lower skins have now been mounted ready to be riveted. At this point, you have reached the last page of the wing assebly manual....a few hundred rivets will finish the wing for now. I can easily finish it in a weekend if I can find a riveting partner...with Gregs help, I accomplished in 2 months what it took the better part of a year to do on the other wing.

2006-12-17T19:59:00.000-08:00

Now everything has been corosion proofed...time to start putting it all back together again.

2006-12-17T19:58:00.000-08:00

The wing skins layed out ready for alodine.

2006-12-17T19:57:00.000-08:00

Time for some real fun...acetone is used to remove Sharpie ink...the bottle with the blue label contains DX533 aluminum cleaner...the DX501 Alodine...and finally the two part primer DEFT.

2006-12-17T19:55:00.000-08:00

Another view of the relationship of these pulleys and the bell crank.

2006-12-17T19:54:00.000-08:00

Anoter set of pulleys is show here projecting to the left and the aileron bell crank is at the top of the picture.

2006-12-17T19:52:00.000-08:00

In the middle of the spar, one set of pulleys have been mounted that will route control cables to the ailerons.

2006-12-17T19:51:00.001-08:00

And at the far end of the aft spar, the aileron hinges have been mounted.

2006-12-17T19:51:00.000-08:00

Before the wing all goes back together again, there's a little more work to do. Here, the flap tracks are mounted to the aft spar.

2006-11-12T19:09:00.000-08:00

And here they are after I have sprayed them with 2 part primer...ready to go back together again.

Jeez...it really did fall apart

2006-11-12T19:08:00.000-08:00

Here are all those parts that Greg and I fitted, drilled, removed, and deburred. I have now treated them all with aluminum cleaner and Alodine. They are ready for priming.

So we did build a wing in a week...

2006-11-12T08:00:00.000-08:00

So we did build a wing in a week...sort of. At least the hard part is done. Now all I have to do is build some of the hinges, pulley and bell crank brackets...oh yeah...corrosion proof. Should actually be finished in no time. THANKS GREG FOR A GREAT WEEK!

2006-11-12T07:58:00.001-08:00

I get to play to.

There are only a few perfect heads in the world...the rest are covered with hair.

2006-11-12T07:58:00.000-08:00

I can't believe it fell apart...here Greg is countersinking holes for flush rivets.

2006-11-12T07:57:00.000-08:00

Wow...I mean totally WOW!

2006-11-12T07:56:00.001-08:00

Are you sure the wing machine gun mounts here?

2006-11-12T07:56:00.000-08:00

You'd think I could remember how to do this, since I have already built the left wing.

2006-11-12T07:55:00.000-08:00

Got to label everything...because...dammit...we have to take it all apart again...and again.

2006-11-12T07:54:00.002-08:00

A hat section.

2006-11-12T07:54:00.001-08:00

Fitting hat sections.

2006-11-12T07:54:00.000-08:00

Man...are we making great progress or what? We have got all of the leading edge skins on and drilled and are well on our way to getting the main skins on and drilled. This really does look like a wing.

2006-11-12T07:53:00.000-08:00

Holes...holes...everywhere..and not nearly enough to drink.

2006-11-12T07:52:00.000-08:00

We put in 10+ hours a day for 5 days. Here Greg demonstrates the medically approved method of removing a booger from your nose.

2006-11-12T07:51:00.001-08:00

But we will try..

2006-11-12T07:51:00.000-08:00

It says here "Dont attempt to build a wing in a week"

2006-11-12T07:50:00.001-08:00

Contemplation....

2006-11-12T07:50:00.000-08:00

We begin by mounting the two wing spars and mounting ribs

2006-11-12T07:49:00.000-08:00

WING IN A WEEK! I'd like to introduce you to my old friend Greg Weltin. He has come all the way across the country from Maine. Our goal: to see how much of the right wing we can build in a week.

2006-09-30T18:24:00.000-07:00

Here is the forward and aft spar. Both ends are level and twist free. Notice the wooden post holding the aft spar up. Additonal posts will be added. Then when the ribs are placed between the two spars, it all turns out square...and level. I'll do a few other things to get this ready for Greg, but I won't actually start building the wing.

2006-09-30T18:21:00.000-07:00

Mounting the spars to these posts has to be done carefully to that the spars are level and don't have any twist.

2006-09-30T18:20:00.000-07:00

Two lines need to be drawn on each spar.

2006-09-30T18:19:00.000-07:00

My buddy Greg is coming out from Maine at the end of the October and we are going to do a marathon wing building week. I want to get everything ready...without actually starting so we can get as much done as possible. This is the forward spar of the right wing. I am marking lines which will be lined up under the rivet holes in the skins.

2006-09-30T18:17:00.000-07:00

I'm running out of clecos...I also have the ailerons half built...waiting for rivetting help...so I'm scratching the bottom of the barrel looking for clecos.

2006-09-30T18:16:00.001-07:00

Clecos...clecos everywhere...

2006-09-30T18:16:00.000-07:00

Here the flap skin is being fitted.

2006-09-30T18:15:00.000-07:00

Of course, the words that you hate so much...debur, and corrosion proof...

2006-09-30T18:14:00.002-07:00

and this.

2006-09-30T18:14:00.001-07:00

Like this...

2006-09-30T18:14:00.000-07:00

These are the flap hinges which are a combination of pieces which all get riveted together.

2006-09-30T18:12:00.001-07:00

More pieces...

2006-09-30T18:12:00.000-07:00

Time to start work on the flaps. These are the pieces.

2006-09-30T18:11:00.001-07:00

Here's the wing nestled in its cradle...out of the way.

2006-09-30T18:11:00.000-07:00

Some foam should help to cushion the wing.

2006-09-30T18:10:00.000-07:00

Now that the left wing is finished (for now), I've got to find a place to store it. The garage is filling up with parts. Looks likd there's room along the back wall. I built these blocks to hold it safely.

2006-08-21T21:17:00.000-07:00

The back side (with all those new rivets) is done. The skins on this side are put back with clecos and this wing will be put away for a while (where in the hell am I going to put this thing). Later on it will be attached to the fuselage and the cables, wires, gas tanks, fuel lines, etc. will be installed. Looking back in the old log book, it's taken the better part of a year to get this far. At this rate...well never mind. I usually get a lot done in the winter, but with both boys home this winter, we did other things. Time to finish the ailerons, and flaps...then the other wing. Should be a little easier this time.

2006-08-21T21:11:00.000-07:00

Look at all those magnificent rivets. They go on and on...forever. But they are good rivets. Mmmm...mmmm.

2006-08-21T21:10:00.000-07:00

This old wing has been hanging here for too many weeks waiting for final riveting. Pat Wendt (on the right) has become a hot trigger man on the uzi...and as usual, I'm on the other side...out of my bucking mind.

2006-05-27T08:05:00.000-07:00

Zach, my rivetting buddy, is getting real good at bucking these rivets. We are rivetting the bottom skins on the wing. Zach is holding a bucking bar on his side of the wing and I am pounding the rivet with the rivet gun on the other side. Only 5000 more rivets to go...on this wing.

2006-05-27T08:03:00.000-07:00

This is the right aileron. These orange straps make it easier to get the skins to fit properly. There is no servo tab on this side.

2006-05-27T07:57:00.000-07:00

I have constructed the servo tab...which looks likea mini-aileron...and put it temporarily in place. One of the great things about this project is figuring out how all this stuff works. I havn't yet figured out how this works...but I will.

2006-05-27T07:53:00.001-07:00

I have inserted a small spar between the layers of aluminum and attached a hinge.

2006-05-27T07:53:00.000-07:00

For the left aileron, a servo tab is needed. Here, I have cut out a section of the aileron.

2006-05-27T07:52:00.000-07:00

Now the bottom side of the aileron has been drilled...now it's time to repeat the process on the top side. It takes a lot of side grip clamps to get everything to fit just right.

2006-05-27T07:50:00.000-07:00

Ed Carter...ace mechanic...stops by to offer advice, wisdom, and a lot of ribbing.

2006-05-27T07:48:00.000-07:00

I have positioned the skin of the left aileron...the pre-punched holes in the skin have to be lined up with centerlines which I have drawn on all of the spars and ribs...once everything is lined up, holes are drilled and clecos placed to line everything up.

2006-05-18T22:02:00.000-07:00

Here, I have mounted a sturdy hinge bracket between the ribs. Another hinge bracket is shown above before it is mounted.

2006-05-18T22:01:00.000-07:00

Some of the nose ribs are doubled where they will attach to the hinges. The double nose rib at the outboard end of this aileron will hold a lead counterweight.

2006-05-18T22:00:00.000-07:00

There are nose ribs on the ailerons.

2006-05-18T21:59:00.000-07:00

While I am waiting for the compressor to be repaired, I'll start on the ailerons. These ribs are attached to a spar. (Temp is in the 90's...I can't keep that glass full).

2006-05-18T21:57:00.000-07:00

Here is a look at these flush head rivets after they have been set. Now I'm ready to rivet the lower skins on the assembly and then the wing will be done...for now. I will put it aside (for a year or so) and bring it back out again when they will be mounted to the fuselage. Then the fuel tanks are installed, and the plumbing and wiring is done...BUT, my compressor just sprung a leak so I am going to have to wait to finish the wing until I get it repaired.

2006-05-18T21:54:00.000-07:00

Now it's time to rivet the leading edge assembly to the forward spar. I am using a rivet squeezer which is nice when you can use it because you don't need two people to set the rivets. It takes a pretty hefty squeeze to make it work. My tendons were screaming by the time I finished all of these rivets.

2006-05-18T21:52:00.000-07:00

The flap track bracket reinforcement angles attach through the skin to the spar.

2006-05-18T21:51:00.000-07:00

Notice the string attached to the tip of the track. It is holding it straight while I secure it to the top skin and to the flap track brackets.

2006-05-18T21:50:00.000-07:00

I am obsessing about getting the two flap tracks straight...and parallel to each other. Otherwise the flaps may bind in the track. My laser level has the bracket in the crosshairs. The spar is straight and level so this should work.

2006-05-08T22:09:00.000-07:00

The angle is attached to the bottom flange of the aft spar...and to the flap track. I am spending a fair amount of time with my laser level to make sure that the spar is exactly horizontal...and that the flap tracks are perfectly vertical.

2006-05-08T22:08:00.000-07:00

This is a closer look at one of these angles.

2006-05-08T22:07:00.000-07:00

The 2 flap tracks have to be stable and strictly parallel to each other so that when the flap moves in the flap track, it doesn't bind. To help fix it into place, small flap track reinforcement angles are attached. The clecos in this picture hold these angles prior to drilling.

2006-05-08T22:04:00.000-07:00

The ribs inside the leading edge assemblies are rivetted to the forward spar. Then the skins are rivetted to the spar.

2006-05-08T22:03:00.001-07:00

And the stringers (the horizontal channels)

2006-05-08T22:03:00.000-07:00

The 'hat sections' go back in.

2006-05-08T22:02:00.000-07:00

Now the assembly is attached to the wing structure...for the last time. Wow...this is really beginning to look like an airplane wing.

2006-05-08T22:00:00.001-07:00

I have taken the leading edge assemblies and clecoed them together.

2006-05-08T22:00:00.000-07:00

All of the ribs are now rivetted into place. They have come in and out so many times...it's kind of exciting to put them in for the last time.