NV WWA Highlander Build

Completed the last 4 flying wires for the tail. I'm pretty happy with how things turned out. One change from the manual was leaving the nicopress sleeves uncovered instead of putting shrinkwrap over them. I did this because I had read that the heatshrink has hidden corrosion which led to breaks in the past.  Next up in the manual was rigging the trimmer piano hinge. The trimmer is ready for covering now which is awesome. Hrs: 6 Total: 47

Checked on my primer-ed rudder petals and was very happy with how they turned out.  Checked the side and top stringers, cut a couple zip ties that were holding things in place, and I'm very happy with how they turned out. Re-leveled the frame a bunch to get the horizontal stab fixed into place with 1.6 degrees down on it's leading edge. Once that was drilled and secured I started the laborious process of squaring up the vertical and horizontal stabs and starting on the flying wires. I only got through making the first two for the leading edge top, but I have to say I'm really happy with how they turned out. Factory told me to do one washer for sizing, then because I have the stainless steel tabs I can remove them for the final install to make it tighten up. Hrs: 5 Total: 46

 Today I caught up on a few of the things that I started last week.  The left and right stringers went on after finishing trimming the spigots and deciding on the line. I figured I could just match the left stringer to the completed right one, but the welds were in different places so I ended up doing extra work to get the left one to fit. Once they both matched and looked the same I broke out the hysol which is kind of a pain to work with.  I then mounted the vertical stabilizer and finished its rivets and bolt so it's now fixed in place as well. Because I still had hysol in the baggie I worked quickly to finish the top stringer, drill, hysol, and rivet it in place. Next came the rivets to hold the rudder brackets in place for painting. The manual called for 3/32 rivets but didn't give a part number so after a bunch of tedious BS I had that done. Removed the rudder petals from the frame, degreased, and then hung for some etching primer.  Since that and all the hysol...

 I got frustrated with using the "kit plane builders Riv-Nut tool" and ordered a real one so I put the last two floor panels aside till I get that. I decided to go ahead and work through chapter 1 in the build manual to see what parts I could put together. I ended up doing a lot of reaming and fitting for parts. I also re-organized my parts table.  The vert stab has been giving me fits because it doesn't seem like it fits the rudder hinges appropriately. I have an email out to JA about it. They didn't answer the phones Friday. Other projects started: Started looking at the side stringer lines. Test fit the rudder petals, Paralleled up the control sticks in the mixer and started setting aside the installation parts for that. Test fit the horizontal stabs. Looking forward to more work on the stringers, and the back baggage walls sizing and cable run bracket cutouts. Much of the other things will have to wait for guidance from either Steve or JA.  Hrs: 12 Total: 34

I've spent a lot of time fitting, trimming, and de-burring aluminum sheet for the floor and baggage panels. Drilled the screw holes and opened up the frame attachment tabs for riv-nuts for the front footwell area so far. Working on the aft baggage floor panel attachment now.  There are chromoly fixtures coming through the floor in the forward baggage panel area, which I need to figure out how to make cutouts for, and what they're used for before I complete that one. Also have a lot of cutting and fitting to do on the aft baggage wall. I decided to use a slightly lighter weight aluminum panel, and cut it short for view access down the rear of the fuselage.  Hrs: 3 Total: 22

Last night I got started with the floor panel trimming and fitment, and also sanded down some of the powdercoating on the rear of the vertical stab so that it fits in its tubing.  I went through and buffed the edges of the aluminum floor panels to eliminate sharp corners, plus trimming the panels with sheers is new and exciting. Steve warned me about not trimming too much as the tubing of the frame should support some of the flooring, not just the welded tabs.  The plan for the rear panel of the baggage area is to cut it down to about half as high then use a netting to cover the top. I always liked seeing down the fuselage of aircraft, and it'll be my first step of saving a little weight.  Hrs: 3 Total: 19

Picked up all the metal parts from 6651 Customs in Vegas where they completed the powdercoating. Started reading ahead and locating parts for the floor panel install. Hrs: 2 Total: 16

Today I located a powdercoating place that agreed to lighty sandblast and apply RAL 7040 color powdercoat to the frame and all the metal parts. 6651 Customs will hopefully take good care of my kit and I'll be happy to get it back into the garage to start work. Hrs: 2 Total: 14

Worked with Ian to get the right engine harness components together to send off for cleanup from all the snowmobile quirks. Hrs: 1 Total: 12

+2hr unboxing and organizing workspace +1hr working with JA on kit details Amy is drop shipping Matco items direct from supplier. Need to find powdercoater in LV - emailed info for quote to one place and they turned me down, saying they can't work on planes because it takes a different type of powdercoat and their insurance won't cover it. They advised me to use a high temp rattle-can! hahaha... Onto the next place! +5 hours of inventory. Got through all 14 pages, next I need to rectify the items I didn't see with the items I have left over. Hrs: 8 Total: 11

My friends and I lifted, pushed and pulled in the sun for a while getting the kit off the delivery truck. Once it was on rollers we pushed up the driveway and broke it all down off and out of the crate. I've opened all the boxes and started reading through paperwork.  Hrs: 3 Total: 3

To kick off this blog, I have ordered a kit through Wild West Aircraft for a Just Aircraft Highlander with modifications designed and/or sourced by Steve Henry. The plan is to work hard on the project when I can. I'm a first time airplane builder, so I'm excited to learn everything it takes to piece it all together. Other than some tool deliveries, here's the beginning of the project. I received the engine, an 07 Apex with 4k miles from Jim Hensel. Chatted with Steve Henry about the wiring harness.