Unintended Adventures

Tag: Painting

Long time no update

The Spring 2018 semester is almost ready to start. This weekend I will be wrapping up some painting for my rudder, doors, and a few fairings around the tail area.

Not much work was done over the Fall mainly because of me taking on quite a few projects at school. Sort of depressing, but projects are good and they provide me with things to talk about during interviews when I’m not talking about the RANS :-).

The big task going on since the last update is painting. Although it has only taken place over two weekends, that is the big project for the last 4 months. I finally painted the landing gear and as mentioned above will have completed the rudder and doors. The bigger task before that was completing the door trim. That was a fussy task, but as with all other things, it has passed. If you have questions or want some tips, get in touch with me. I would like to write a detailed process, but it was messy haha.

Other little things were getting the tail brace wires installed, some hardware installed on the ailerons, attaching some interior fabric, and starting to fit up the wing tips.

In other big kit news, I ordered the firewall forward kit back in mid-November. I’m hoping that will keep me busy for a while. I will be out of town for 3 months over the summer, so I won’t have any airplane work going on although I do plan on working with some of my electronic projects.

On the electronics side, the Engine Monitor software is pretty much where I’d like it. It is really ready for some higher level testing. I’m preparing for this by working on some circuits to help protect the electronics from voltage surges and other things.

For some new ideas, I am beginning to toy with some components that would provide a means for an electronic circuit breaker and provide current monitoring for individual loads. My idea is to somewhat emulate other commercial offerings that provide electronic circuit breakers. I’m going to go slow with this one and test as much as I can. Even if I do put it in the airplane, I am planning on some standard fail safe circuit protection devices.

Here is an example of the circuit that I am going to play around with for the circuit breaker. The green line in the graph shows a simulated current draw. The system senses a voltage drop across a resistor. By changing the value of that resistor, the device will trip at the specified current. This example is using a resistor that should trip at 2A. The simulation shows it being tripped at 1.8A, which is caused by an additional resistor on on of the sensing pins of the chip. I need to do some researching on why they have used a resistor in that location.

Example current trip.PNG

Whirlwind

Summer is slowly coming to an end and things are getting crazier for us. Moving to a new place in a week so I can finish my engineer transformation, finishing an internship, starting classes again, and going to Oshkosh all in the next month.

The plane is painted (mostly)! There are still all the exit covers, inspection plates, boot cowl, and some trim colors on the doors and rudder, but all the major assemblies are painted. Covering and painting is about all we did on the plane this summer and it was a busy task. I don’t care for painting and am glad that it is mostly finished. The rest of it will be an exercise in finding the space and equipment to do so, but it shouldn’t be insurmountable.

The plane has also been moved. After 2.5 years of half living in a garage and the other half in storage, all the airplane parts are finally together again in a hangar. It looks much cooler in a hangar and it’s even neater to see everything together. The only annoying part is that there are no hangars available nearby where we are moving to, so it’s about 50 minutes away from the house. There is an airport 10 minutes from the house, but even after a year and a half on the wait list, I haven’t risen to the top. Looking forward to getting some things actually assembled this coming year and making it look more like an airplane finally.

That’s about all the airplane stuff for the past two months. I could write a small essay on painting issues, but nothing has to do with the paint I used. A lot of operator learning/error. If you want to hear more, let me know and we can discuss a few things.

As this is posted, we have completed the move. I’m still busy being an intern for another week and a half and then I’ll join back up to start the new semester.

Oshkosh was great. We saw a lot of cool things, got to play with some avionics, and visited with friends.

(80 h)

Plane’s new clothes

I never posted this draft of a post from a month ago, so here it is.

Finally it appears that the painting on the fuselage is mostly completely save for some touching up. We’ve learned a lot and it looks pretty awesome.

The colors are Insignia White, Battleship Gray, and Firethorn Red from Stewart Systems. The scheme came from RANS.

Few things from spraying EkoPoly Premium we found. The biggest one is make sure the booth is dry. It seems humidity played a large part in some of our more frustrating sessions. So make sure the air is dry in the line and in the booth. The nasty picture of a light coat of red below was what we ended up with in the beginning of putting the red on. A combination of drying the booth out more and increasing the tip pressure on the gun seemed to do the trick.

Next time I think I’ll try removing the tapes prior to the paint drying. Maybe that will allow me clean up the lines and make them better.

Either way, I’m a happy guy.

(10 h)

Sanding (Painting)

Took a while for an update, but Oshkosh and visiting family made for a pretty hectic end to July and beginning of August.

As of this writing, the fuselage has it’s white top coat complete. Now it’s time for masking and sanding in preparation for the second half that will be red. Not much else to report besides that.

The painting has been a learning curve, but it’s starting to come together. The biggest hurdle is the time between spraying products. Usually means waiting a day and when you’re just painting one part, it seems like eternity.

I haven’t tracked my hours very closely in this section of work, but I’ll make a guess about what it seems like it has been.

Hope to have pictures of the plane with red on it by the end of next week. Till then, here are some of the white. We did get orange peel in the finish, but I’m satisfied with how it turned out and I have a feeling it will fly just fine.

(30 h)

It’s getting serious

Last update prior to Oshkosh.

Fuselage is ready for a light sanding followed by the topcoat colors after I get back from my summer tour in a week and a half or so.


I’m also finishing up my wing rack build today and tomorrow so I can transport/store the wings more compactly.


See you at OSH!

(6 h)

Sanding

The painting process is in full swing at the moment. Between life obligations and other flying obligations, it takes forever to get anything done, but it is getting done.

Currently we have a horizontal stabilizer and fuselage that has all the coats of EkoFill on it and is ready for EkoPrime. Took a decent amount of trial and error to get everything working right and we did a good bit of sanding to get some runs out.

Brushing the EkoFill on the fuselage took a good 4 hours give or take 30 minutes.

The EkoPrime should be on this week and then we can start shooting color (EkoPoly) the next day. I’m not sure when this will happen. I’d like to say this week too, but we’re closing in on Oshkosh and I’ve got other things to take care of before the end of the week.

In somewhat unrelated news, I’m building a wing rack so I can transport my two wings and store them easier.

(20 h)

Almost building time

Te semester is drawing to a close with finals happening next week. I’ve planned a lot for the summer and hope that I can at least get half of it done. 

This past weekend I went to a three day course on the Stewart System. It reinforced some covering techniques and more importantly we went all the way through a topcoat on the frame. I learned a lot and found out that the painting thing probably won’t be so scary. It won’t be a showplane, but I figure it’s like a baby. It’ll never be ugly. 🙂

Plan for May is to start covering the fuselage and the small parts like flaps and rudder. When the fuselage is covered I’m going to get a coat of EkoFill on and then transport it up to the airport for paint. I’ll also try to get a few of the small pieces covered in EkoFill so I can have those ready if I’m able to get them going on color coats.

Finally, if that all goes well and by some miracle I still have some summer time left, I’ll try and start covering the wings. The idea is that having the fuselage covered and painted will keep me plenty busy getting things installed over the fall and winter. 

So stay tuned to see how much I actually get done haha. 

(15 h)

First picture – Frame covered with no tapes

Second picture – Frane with brushed cross coat of EkoFill

Third Picture – Two sprayed cross coats of EkoFill

Fourth Picture – Three cross coats of color

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