| Date | Tasks | Total Man Hours |
| 01/15/03 | Wings arrived via Roadway Express. 2 Wooden cartons. $192.32. | 2.00 |
| 01/17/03 | Started inventory of parts in Wing kit. Visit by Gordon Page to see kit. | 4.00 |
| 01/18/03 | Finished Inventory (questions on possible missing bags and skin components. | 4.00 |
| 01/19/03 | Began riveting tank attach nutplates to left main spar. Adjust countersink and test out procedures (there's 120 of them to do.) | 1.50 |
| 01/20/03 | Finished riveting on the platenuts (for tanks) on left main spar (x60). | 4.00 |
| 01/21/03 | Drilled, countersunk and riveted platenuts on right main spar (60 platenuts) | 2.00 |
| 01/23/03 | Drilled, countersunk and riveted access plate nutplates on both spars. | 1.50 |
| 01/24/03 | Talked to Vans Tech Support/Inventoried bags to identify items | 2.50 |
| 01/25/03 | Riveted 4 nutplates on end of spar. | 3.00 |
| 01/27/03 | Carefully re-adjusted the microstop countersink. Countersunk 90 of the 120 screw attach holes for tanks. | 3.00 |
| 01/28/03 | Countersank last 30 tank attach screw holes on spar. Set and countersank the 24 holes for attachnig the inspection plates to the spars. Roughted out the W726 spacesrs from aluminum bar stock. Located holes. | 2.25 |
| 01/29/03 | Smoothed the spacer edges with a scotchbrite wheel; match-drilled the tie-down bar to the left spar. | 4.00 |
| 01/30/03 | Worked on tie-down assembly for left wing. Started on right. | 1.50 |
| 01/31/03 | Milled tie-down spacer holes at Bob Niller's. Made 5 (including 1 extra). Tapped the threads on the tie-down bars using 3/8x16 tab. Cleaned up shop. | 2.00 |
| 02/01/03 | Match-drilled the tie-down assembly spacer bars. | 4.00 |
| 02/03/03 | Countersank platenut atttach rivet holes on tiedown spacers. Polished aluminum on wheel. | 0.50 |
| 02/04/03 | Trimmed ends of rear spar doubler plates, smoothed the rear spar reinforcement forks. | 3.00 |
| 02/06/03 | Began work on rear spar. Positioned and drilled bracket reinforcement plates and spars (left and right) | 5.00 |
| 02/07/03 | Drilled rear spar reinforcement plates. Trimmed the reinforcement forks to size. | 2.00 |
| 02/08/03 | Match-drilled the forks and rear spar reinforcement plates with the spar. Deburred all match-drill holes, deeburred the left rear spar on its long edges. | 3.00 |
| 02/08/03 | Drilled ou the aileron push-rod holes with a unibit and dremmel. | 0.50 |
| 02/20/03 | Finished polishing rear spar assemblies. Began fluting and finishing tank ribs. | 3.00 |
| 02/21/03 | Clecoed left tank skin ribs and baffle together. | 1.50 |
| 02/24/03 | Deburred rear spars and forks,deburred and poolished tank ribs. | 2.00 |
| 02/25/03 | Continued with fluting of tank ribs | 4.00 |
| 02/27/03 | Clecoed tank skin to ribs. | 0.75 |
| 03/02/04 | Finished smoothing the gas tank stiffeners (used a scotchbrite wheel and file) | 4.00 |
| 03/01/03 | Cut all gas tank stiffeners | 0.50 |
| 03/05/03 | Deburred and fluted 2 center ribs. | 0.75 |
| 03/12/03 | Deburred and fluted 6 ribs. | 1.50 |
| 03/14/03 | Deburred and fluted a half dozen ribs. | 2.75 |
| 03/22/03 | Deburred and fluted a half dozen ribs. | 2.00 |
| 03/23/03 | Deburred and fluted a half dozen ribs. | 1.75 |
| 03/29/03 | Deburred and fluted a half dozen ribs. | 1.00 |
| 03/30/03 | Deburred and fluted a half dozen ribs. | 0.75 |
| 04/09/03 | Deburred and sanded FL705 x 5 | 0.50 |
| 04/15/03 | Fluted Leading Edge Ribs | 1.50 |
| 04/29/03 | Connie took home parts for sanding: FL-704-L x 4, FL-705 x 3, 1 pen, 1 edge deburring tool | 0.00 |
| 05/06/03 | Parts listed above returned and sanded. Sanded Control surface brace. | 1.25 |
| 05/13/03 | Sanded more ribs, snaded more stiffeners | 2.00 |
| 06/01/04 | Etched and alodined all wing ribs. | 6.00 |
| 07/12/03 | Etched and alodined rear spar components and some wing skins | 6.00 |
| 07/13/03 | Primed parts alodined yesterday. | 3.00 |
| 07/14/03 | Primed main spar countersinks. Attached (not torqued) tie-down brackets. | 2.00 |
| 07/16/03 | Riveted rear spar members. Rough cut aileron stiffeners. Began deburring remaining wing parts. | 3.00 |
| 07/18/03 | Deburred and polished miscellaneous pieces. | 1.50 |
| 07/19/03 | Finished deburring and dimpling the aileron stiffeners. | 2.00 |
| 07/20/03 | Torqued the tie-down brackets and aileron brackets (using torque wrench.) Verified all work donw with the directions. | 3.00 |
| 07/21/03 | Fabricated tank bracket. Deburred braces. Dimpled aileron skins. | 4.80 |
| 07/25/03 | Polished miscellaneous items. Sutdied tank bracket assembly. | 1.50 |
| 07/27/03 | Worked on tank brackets. | 3.00 |
| 07/28/03 | Worked on tank brackets. Finished 12 of 14. | 2.00 |
| 07/29/03 | Drilled holes in anti-rotation brackets. | 1.50 |
| 07/30/03 | Primed miscellaneous wing parts. | 3.00 |
| 07/31/03 | Attached 12 tank-spar attach brackets to main spar. Torqued all bolts. | 2.00 |
| 08/02/03 | Fitted tank baffle to z-spacers (tank); fastened on inboard z-spacers to spar. | 6.00 |
| 08/03/03 | Fabricated left aileron parts. Clecoed together. | 1.50 |
| 08/04/03 | Back-riveted stiffeners to aileron. | 2.25 |
| 08/04/03 | Miscellaneous reading. Roughly assembled flaps. | 2.00 |
| 08/05/03 | End rib of tank - riveted interior ring. Cut hole in rib. | 2.00 |
| 08/07/03 | Worked on Tank fitting and tubing. | 2.00 |
| 08/09/03 | Double checked the fitting of the baffle with the z-plate spacers, ribs and tank skins. Reinforced center holes (fit was improved after this.) Match drilled the tank ribs, z-plate spacers and baffle together. | 4.00 |
| 08/10/03 | Dimpled tank stiffeners, all leading edge ribs and began work on center ribs. | 2.00 |
| 08/11/03 | Dimpled center ribs. | 0.50 |
| 08/17/03 | Dimpled center ribs. | 1.00 |
| 08/17/03 | Dimpled more ribs and dimpled leading edge skins. Began fitting leading edge skins with ribs. | 3.00 |
| 08/22/03 | Fitted tank joint plate W423 to left wing. | 2.50 |
| 08/24/03 | Primed contact surfaces on spars, wing walk doublers, miscellaneous control surface parts. Finished left tank joint plate. Positioned right tank joint plate. | 6.50 |
| 09/01/03 | Finished deburring and dimpling ribs for right leading edge (outboard part) | 1.50 |
| 09/01/03 | Began installing landing light in left leading edge (outboard part); drilled out opening for the light, cut the plexiglass cover for the light. | 5.50 |
| 09/06/03 | Drilled Z brackets on right wing for tank attachment. Drilled plate nut holes in tank joint plate. | 1.50 |
| 09/07/03 | Fitted plexiglass in left leading edge for taxi light (dirlled and deburred screw holes.) | 2.00 |
| 09/09/03 | Fitted tank skin against leading edge skin in left wing. Drilled screw holes on attach strip. | 2.00 |
| 09/13/03 | Match-drilled tank joint plate with platenuts. Countersunk plate nut attach holes. Riveted on plate nuts. | 2.50 |
| 09/13/03 | Resized the landing light lens (left) | 2.50 |
| 09/16/03 | Cut landing light hole in right leading edge. | 1.50 |
| 09/18/03 | Flared tubing for both fuel tanks. | 1.00 |
| 09/19/03 | Etched, alodined, and primed the landing light retainer strips, housing and wing skin (inside only). | 6.00 |
| 09/20/03 | Primed landing light parts and top skins. Fitted/riveted plate nuts for 2nd landing light. | 4.50 |
| 09/27/03 | Screwed in the taxi/landing light mounts into the leading edges. Apoxied the lens for the right wing and regitted it. Attached retaining strips to the lens (left) using double-stick tape. Placed and screwed in the landing light (left.) | 4.00 |
| 09/28/03 | Started 1st and 2nd row of rib/skin rivets on the right outboard leading edge. Removed plastic from inside of tank (using soldering iron.) | 1.50 |
| 10/01/03 | Riveted 2/3 of all skin/rib rivets on right outbard leading edge. | 1.50 |
| 10/06/03 | Riveted 1/2 of all skin/rib rivets on left outboard leading edge. | 1.50 |
| 10/12/03 | Riveted the rest of the skin/rib rivets on both the left and right leading edges (outboard.) | 3.00 |
| 10/18/03 | Prepared fuel tanks (dimple, scored, trimmed vinyl coating. | 9.00 |
| 10/19/03 | Sealed and riveted stiffeners into both tanks. | 6.00 |
| 10/23/03 | Fitted fuel metering plates. Riveted nutplates to sender plates on one set. | 2.00 |
| 10/26/03 | Took off vinyl from the inside of the gas tanks. Countersunk all holes on the outer edges of the tank skins (for rivets connecting skins to baffle.) | 6.00 |
| 10/28/03 | Soldered wires to connections for fuel senders. | 1.00 |
| 11/01/03 | Scored tank drain pieces, fuel cap flanges and adjoining parts of the tank skins. Fitted the reinforcement pieces for tank ribs. | 3.00 |
| 11/02/03 | Sealed the tank drain flanges, fuel cap flanges (riveted all four pieces to the tank skins.) Sealed and riveted on the reinforcement plates for all the tank ribs. Added sealant to all shop heads fo these rivets. Drilled out and replaced a few tank stiffener rivets with "Oops" rivets. | 6.00 |
| 11/06/03 | Sealed and riveted in tank ribs (2 ribs), cleaned off all parts. | 8.00 |
| 11/08/03 | Scored/scratched up all 14 gas tank ribs' flanges with a paint-stripping wheel, and then a piece of carborundum (ruby.) | 3.00 |
| 11/25/03 | Selaed and riveted 2 tank ribs. | 6.00 |
| 11/29/03 | Clecoed all ribs to the skin on the left tank. Started match-drilling the flap ribs to the spar. Deburred these parts after drilling. | 3.00 |
| 11/30/03 | Sealed and riveted 2 tank ribs (one left and one right.) | 6.00 |
| 12/06/03 | Sealed and riveted 2 tank ribs. | 5.00 |
| 12/12/03 | Worked on fabricating angle bracket. | 1.00 |
| 12/13/03 | Worked on support for flaps. | 1.00 |
| 12/18/03 | Drilled flap brackets. Began fitting brackets. | 2.00 |
| 12/19/03 | Continued work on flap brackets and skins. | 3.00 |
| 12/20/03 | Sealed and riveted 2 tank ribs. | 6.00 |
| 12/20/03 | Notched snap bushings, trimmed insulators for capacitive fuel senders. | 1.00 |
| 12/23/03 | Covered rivet heads in tank (with sealant). Began installation of fuel metering system. | 2.50 |
| 12/27/03 | Match-drilled the flap ribs to the bottom skin. Match drilled hinges to the spars on flaps. Began assembling the vent line and fuel metering sysstem in the left tank. | 5.50 |
| 12/29/03 | Installed second sender plate in the left tank. | 1.00 |
| 01/02/04 | Attached fittings to the right tank. | 1.50 |
| 01/04/04 | Deburred and dimpled flap skins (bottom), hinges and spars. | 4.00 |
| 01/12/04 | Finished fuel sender installation. | 1.00 |
| 01/13/04 | Began assembling flaps. | 1.00 |
| 01/14/04 | Continued riveting right flap. | 2.00 |
| 01/15/04 | Finishing up right flap. | 2.00 |
| 01/16/04 | Finished up right flap. | 2.00 |
| 01/18/04 | Began assembling left flap (riveting). | 5.00 |
| 01/19/04 | Continued assembly (riveting) of left flap. | 4.00 |
| 02/03/04 | Sealed and riveted (squeezed) last outboard tank rib on both tanks. | 4.00 |
| 02/07/03 | Installed (sealed and riveted) the final outboard ribs for both gas tanks. Also installed tank supports. | 6.00 |
| 02/08/04 | Began assembling aileron. | 2.00 |
| 02/17/04 | Match-drilled spar reinforcement brackets to spar on right aileron; riveted the inside column of rivets on these pieces. | 3.00 |
| 02/20/04 | Assembled (riveted) aileron skins, spar and ribs. | 3.50 |
| 02/21/04 | Match-drilled spar, skins and ribs. | 2.50 |
| 02/22/04 | Deburred spar, skin and ribs; Jim Branche here to put in some spar rivets. | 1.00 |
| 02/27/04 | Dimpled spar, skin and ribs. | 0.50 |
| 02/27/04 | Drilled the #30 holes in the steel counterweight for aileron using a drill press; pop-riveted it to the nose ribs; clecoed the tops fo the leading edge and trailing edge skins to the spar. Note: to pop-rivet the weight, we had to drill out a few rivets first, then re-rivet the spar-to-nose-ribs junctions. | 3.00 |
| 02/28/04 | Worked on aileron push-rods and aileron. | 2.00 |
| 02/29/04 | Worked on right aileron. | 4.00 |
| 03/02/04 | Finished riveting the right aileron. Ailerons now finished!!! Cut a push rod, polished ends for fit with the end piece (rod end mount.) | 3.00 |
| 03/05/04 | Riveted one aileron control rod; sealed capacitive sender wires to the vent tube in both tanks. | 2.00 |
| 03/06/04 | Finished assembling the aileron push-rods (2 large, 2 small.) | 4.50 |
| 03/13/04 | EAA TECH INSPECTION - Inspected by EAA Tech Counselor, Doug Sykes. | 0.00 |
| 03/13/04 | Drilled out bad rivets in the flaps and control rod, re-riveted (based on tech-counselor advice.) | 2.00 |
| 03/14/04 | Worked on fuel pickup assemblies; layed out work for closing tanks. | 2.00 |
| 03/16/04 | Scored baffle mating surfaces for ribs and brackets. Finished fuel pickups. | 6.00 |
| 03/17/04 | Transferred Z-brackets from spar to baffles (both sets.) | 3.00 |
| 03/17/04 | Sealed the fuel pickup couplings. | 2.00 |
| 03/20/04 | Tested both tanks with water; sealed the rear baffle on one tank. | 14.00 |
| 03/21/04 | Replaced bad rivets in the tanks (47!) | 2.00 |
| 03/27/04 | Sealed rear baffle on right tank; cleaned clecoes | 15.00 |
| 04/03/04 | Cleaned clecoes from baffle sealing and covered all pop-rivets, etc. on baffles. | 6.00 |
| 04/04/04 | Screwed on the tank closure plates; ready to leak-test the tanks (air test will be required.) | 2.00 |
| 04/06/04 | Removed closure plates to coat fuel pickup tube connections to avoid loosening over time. | 1.00 |
| 04/08/04 | Re-sealed closure plates. | 1.00 |
| 04/16/04 | Measured/driled holes in the ribs for electrical conduit. | 2.00 |
| 05/01/04 | Inserted the lens into the right leading edge. Started to drill and countersink the right spar-skin attach holes on the main spar. | 4.50 |
| 05/04/04 | Countersunk skin attach points on spar (402 on each spar.) | 1.50 |
| 05/07/04 | Drilled spar holes with a #40 drill. | 1.00 |
| 05/14/04 | Countersunk skin attach points on main spar. | 3.00 |
| 05/19/04 | Touched up spars and ribs with primer. | 3.00 |
| 05/21/04 | Moved spars and ribs to garage. Clecoed left wing spars and ribs together. Covered desk to use as a work table. | 2.00 |
| 05/22/04 | Clecoed together right wing. Trimmed and positioned both wing-walk doubler plates. Made them 26 3/4" rather than 25" to allow for 1" overhang. | 2.00 |
| 05/22/04 | match-drilled wing-walk doublers to skins. | 2.00 |
| 05/25/04 | Riveted ribs on right wing to rear spar. | 4.00 |
| 07/08/04 | Match-drilled right side top skins to ribs/spar. | 4.00 |
| 07/10/04 | Match-driled right side bottom skins to ribs/spar. Removed vinyl (as necessary) from skins. | 5.00 |
| 07/17/04 | Started to tived the leading edge rib flanges to the main spar. Brian Butler squeezed a few rivets on the leading edge skin to the spar. | 4.00 |
| 07/18/04 | Deburred the outside skins for the top of the right wing (both sides of the skins.) | 1.50 |
| 07/18/04 | Finished riveting the leading edge rib flanges to the main spar. | 3.00 |
| 07/22/04 | Dimpled wing skins. | 1.00 |
| 07/21/04 | Deburred more of the skins. | 1.50 |
| 07/23/04 | Dimpled the outer holes on the bottom side right skins. | 0.75 |
| 07/24/04 | Dimpled all the rest of the holes in the two bottom right wing skins. Tested all holes with a 3-4 rivet for "flushness." | 2.00 |
| 07/24/04 | Dimpled the top right wing skins. | 1.50 |
| 8/9/2004-8/13/2004 | Pressure tested tanks. 42" water column held for over 24 hours. Primed tanks (outside) and lower skins. Fastened right tank to wing spar. Primed aileron push rods. | 10.00 |
| 08/16/04 | Riveted on the right top inboard skin (3 rows donw.) Had to remove more vinyl so the rivet gun and rivets seat a little better. | 4.00 |
| 08/17/04 | Started riveting the top right outside skins on the wing. | 3.00 |
| 08/19/04 | Finished riveting the top skins onto the right wing. | 3.00 |
| 08/28/04 | Rivet session with the following folks: Bill Bower, Joe Cress, Paul Cress, Don Long, John Holst, Gordon Page, Krista Socash | 0.00 |
| 08/30/04 | Finished riveting leading edge (bottom). Torqued all tank bolts. Installed aileron bell crank. Moved the wing off the stand. | 3.00 |
| 09/01/04 | Started riveting the main ribs (712) to the rear spar. | 2.00 |
| 09/15/04 | Finished riveting the rear spar to the ribs for the left wing. Attached the jig bracket to the left wing. | 2.00 |
| 09/18/04 | Match-drilled all holes for the left wing top skins. | 2.00 |
| 09/19/04 | Match-drilled the left bottom inboard wing skin. | 1.00 |
| 09/22/04 | Deburred outside of the top left inboard, outboard and bottom left outboard skins. Match-drilled the lower outer left wing skins to the leading edge. | 1.50 |
| 10/05/04 | Deburred the outside left top outbard wing skin on primed side. | 0.25 |
| 10/11/04 | Riveted the leading edge ribs to the spar (left wing.) | 2.00 |
| 10/16/04 | Deburred left bottom outboard training edge skin; drilled and deburred left tank screw holes. | 2.00 |
| 10/15/04 | Riveted the outboard leading edge. | 1.00 |
| 10/16/04 | Dimpled all holes on both top skins and the inboard bottom skin (left wing) that could only be dimpled with a C-frame. | 2.50 |
| 10/22/04 | Dimpled the left wing skins. | 1.00 |
| 10/23/04 | Riveted ribs under Tank overlap. | 1.00 |
| 10/24/05 | Removed vinyl from the left wing's bottom outboard trailing edge skin. Fastened on fuel tank. | 3.00 |
| 10/27/04 | Dimpled and countersunk rear spar. Finished riveting the top fo the leading edge to main spar. | 1.50 |
| 10/29/04 | Started riveting the inboard top skin of the left wing. | 3.00 |
| 11/07/04 | Finished riveting the top left outboard skins. | 4.00 |
| 11/08/05 | Riveted the Top skins (bottom row to rear spar.) | 1.00 |
| 11/10/04 | Removed tank on left wing for better fitting. | 2.00 |
| 11/14/04 | Began fitting lights, braces, ..etc. | 2.00 |
| 11/14/04 | Attached the aileron brackets; deburred, dimpled and riveted on the aileron gap fairing and flap brace (left wing.) | 4.00 |
| 11/19/04 | Match-drilled, deburred the aileron gap fairing and flap brace (right wing) | 1.50 |
| 11/20/04 | Riveted fairings on the right wing. Attached ground point for lights. Getting ready to mount the bottom skins. | 2.50 |
| 11/27/04 | Began riveting on the skin on the lower (bottom) right inboard skin on the right wing. | 4.00 |
| 12/04/04 | Shaped/filed down the navigation/strobe light covers. | 4.00 |
| 12/05/04 | Finished riveting on the bottom inboard skin of the right wing. Riveted on (squeezed) the platenuts for the inspection port of the bototm outboard skin of the right wing. | 4.00 |
| 12/06/04 | Started riveting on the bottom outboard skin fo the right wing. | 2.00 |
| 12/11/04 | Worked on the right wingtip and additional riveting on the lower outbard right wing. | 4.00 |
| 12/17/04 | Riveted the bottom outbards skin fo the right wing (finished the rib-attach rivets.) | 3.00 |
| 12/22/04 | Finished riveting the bottom outboard skin of the right wing. | 5.00 |
| 12/27/04 | Right wing: fitted (match-drilled) the flap piano hinge to the wing. Fitted the fiberglass wingtip to the wing. | 8.00 |
| 01/04/05 | Finished riveting the flap hinge. Drilled holes for Tip platenuts. Measured/fitted tip cutouts. | 3.00 |
| 01/10/05 | Installed pitot tube inside left wing. | 2.00 |
| 01/15/05 | Started to rivet on the left wing's bottom inboard skin (Steelers win today! First Playoff!) | 4.00 |
| 01/17/05 | Continued to rivet on the left wing's bottom inboard skin. | 3.00 |
| 01/18/05 | Finished inspection port platenuts and lower skin dimpling. | 0.20 |
| 01/24/05 | Finished riveting on the left wing's bottom inboard skin (with th exception of the ones on the root end that can be squeezed.) | 2.00 |
| 01/29/05 | Started riveting on the left wing's bottom outboard skin. | 3.00 |
| 02/04/05 | Continued match drilling the left wing's main bottom outboard skin. Match-drilled the fiberglass tip to the wing. | 2.50 |
| 02/11/05 | Continued rivetingon the left wing's bottom skin (the row matching the spar.) | 3.00 |
| 02/18/05 | Finished shooting/bucking wing skins. | 2.00 |
| 02/20/05 | Fitted left wing flap hinge. Fabricated spacers for aileron. | 4.00 |
| 02/24/05 | Countersunk the left wing's aileron piano hinge. | 0.00 |
| 02/27/05 | Adjusted the aileron push-rods for both the left and right wings. | 3.00 |
| 02/28/05 | Drilled, deburred and dimpled the tip attached screw holes for the left wing's tip. | 0.50 |
| 03/06/05 | Drilled, deburred and dimpled the tip-attach screw holes for the right wing's tip. | 0.50 |
| 03/06/05 | Drilled out 6 incorrect rivets in the root-end of the right wing. | 0.25 |
| 04/17/06 | Attached aileron stops - left wing and right wing. | 6.00 |
| 04/26/05 | Deburred fuselage parts (already have the kit!) | 3.00 |
| 04/27/05 | Finished wings! | 1.00 |
| Total Man-hours: | 606.75 |