May to September 2022

May 20 2022 - 2.0hrs - 4420.5 total. Sanded down extra five minute epoxy at spar to #10 rib port joint. Made up ten shim and reinforcement strips. Received shipment of more cap strips and intercostal material.

May 21 2022 - 2.0hrs - 4422.0 total. Glued shim and reinforcement pieces onto rib #10 port around spar.

May 22 2022 - 2.5hrs - 4424.5 total. Glued all four cap strips onto one side of both #11 ribs.

May 23 2022 - 3.0hrs - 4427.5 total. Removed clamps, sanded down outer profiles on both ribs and prepped other side. Glued four remaining cap strips onto both #11 ribs.

May 25 2022 - 2.5hrs - 4430.0 total. Removed clamps from #11 ribs. Sanded down port rib, slid onto spar, re-aligned spar in jig, aligned #11port rib on spar and tacked in place with five minute epoxy.

May 26 2022 - 2.0hrs - 4432.0 total. Sanded down five minute epoxy joint on rib #11. Started making up shim and reinforcement strips. Finished four, still six more to go. Got out #12 ribs. Steamed eight more cap strips for #12 ribs. Modified one of the cap strip molds due to ribs getting smaller so needed cap strip shape is changing.

May 27 2022 - 5.5hrs - 4437.5 total. Finished making reinforcement strips for rib #11 and glued all ten pieces in place around rib #11 on spar. Removed cap strips from bend formers and cut to length. Glued four cap strips onto first side of both#12 ribs. Reviewed plans to start adding a few intercostals to stiffen things up.

May 29th 2022 - 4.0hrs - 4441.5 total. Located best position to start adding intercostals. Clamped large square to rib #5 to keep thing aligned. Cut and tacked in two intercostals with five minute epoxy without their gussets. Started on 1/4" ply stiffening wall that goes from rib 5 to 8 to strengthen that area when the wheel well gets cut out nearby. Pieces are dry fit, need lightening holes cut in them before getting glued in.

Rib #11 port tacked in place with 5 minute epoxy

First two intercostals glued in. Dry fitting 1/4" reinforcement wall

Rib #11 port tacked in place with 5 minute epoxy

Gluing cap strips to first side of #12 ribs

First two intercostals glued in. Dry fitting 1/4" reinforcement wall

Rib #11 port tacked in place with 5 minute epoxy

First two intercostals glued in. Dry fitting 1/4" reinforcement wall

May 30 2022 - 4.5hrs - 4446.0 total. Cut lightening holes in stiffening wall pieces, routed and sanded. Ready to be glued in. Glued remaining four cap strips onto other side of #12 ribs. While rolling around in my my chair I backed into the support holding the tip of rib#11 and snapped the tip of the rib off! It had already done its job of positioning the rib angle. Since I have to cut off the ribs aft of the rear spar later anyway, I'll just remake that section when the time comes. Also found a note on the plans saying that some of the intercostals are a different size than show in other areas. I'll need to order some more wood. Fortunately its not too expensive and is actually available!

June 1 2022 - 2.0hrs - 4448.0 total. Removed clamps from #12 ribs. Sanded down port rib and slid it into place on the spar. Re-leveled spar in jig. Aligned rib and tack glued in place with five minute epoxy.

June 2 2022 - 1.5hrs - 4449.5total. Made up reinforcement strips for first section of 1/4" wall. Also prepared some gussets for the intercostals that are already in place.

June 22 2022 -0.0hrs - 4449.5 total. Have been gone on a trip for the last couple of weeks. Hoping to get moving on this again now. Spent some time reviewing where I left off. Ordered the material for the wing upper side intercostals.

June 24 2022 - 2.0hrs - 4451.5 total. The final piece of metal tubing for the landing gear has finally come in at the supply shop. Will go pick it up on Monday. Cut some more reinforcement strips for the 1/4" wall section that goes behind the wheel well. Glued in two of the sections along with the eight reinforcement strips. Also glued in a little half gusset for one of the intercostals above a large lightening hole.

June 26 2022 - 3.5hrs - 4455.0 total. Sanded down 5 min glue blobs from rib# 12 port. Made up the ten shim and reinforcement strips for it. Measured, cut and steam formed eight cap strip pieces for the #13 ribs.

oops! Broke off the end of port rib#11

Glued in two of the three 1/4" wall pieces and reinforcement strips

Ten shims and reinforcement strips for rib #12 port

Glued in two of the three 1/4" wall pieces and reinforcement strips

Ten shims and reinforcement strips for rib #12 port

June 26 2022 - 3.5hrs - 4455.0 total. Sanded down 5 min glue blobs from rib# 12 port. Made up the ten shim and reinforcement strips for it. Measured, cut and steam formed eight cap strip pieces for the #13 ribs.

June 27 2022 - 2.0hrs - 4457.0 total. Glued cap strips onto first side of both #13 ribs. I have to admit I'm getting pretty tired of gluing on cap strips! Fortunately each set of ribs is smaller and has less pronounced curves than the one before. So its getting easier. I'm past halfway now, at least.

June 29 2022 - 0.5hrs - 4457.5 total. Removed clamps. Trimmed off end of cap strips. Sanded down glue joint on outer edge.

July 14 2022 - 0.0hrs - 4457.5 total. Went on a trip to visit family and when I returned I tested positive for Covid. Have been pretty sick for a few days, but managed to spend some time puttering in the shop today. The intercostal material arrived from Aircraft Spruce - they do a great job of packaging this stuff. Have been coordinating with machinist who has started on the main gear construction. Researched requirements for wheels and brakes and job shopping for hard chroming and Rockwell heat treatment of parts.

July 15 & 16 2022 - 4.0hrs - 4461.5 total. Researched wheels and brakes and determined which ones I will use (Matco 600XP) although they are on backorder for 3 months. Made up reinforcement strips for last section of 1/4" wall. Glued in last section and strips and three more gussets. Glued ten shim and reinforcement strips around port rib #12. Glued cap strip onto second side of one of the #13 ribs.

July 18 2022 - 2.0hrs - 4463.5 total. Made up eight intercostal strips for bottom of wing and tacked them in place with 5 minute epoxy between ribs 8 to 12. Have found a shop that will due the hard chroming for the gear legs. Ordered the wheels and brakes directly from Matco. They should ship in 7 to 10 days.

July 20 2022 - 5.0hrs - 4468.5 total. Made up four more intercostal pieces. Used the table saw to cut notches in some of the gussets. Prepped and dry fit several gussets for existing intercostals. Glued remaining three cap strips onto second side of #13 ribs. With leftover glue, glued in a couple of the gussets. Glued in the four new intercostals.

July 21 2022 - 0.5hrs - 4469.0 total. Removed clamps from yesterday's glue jobs. Sanded down outer profile of both #13 ribs.

July 22 2022 - 3.5hrs - 4472.5 total. Got out both #14 ribs and setup on table for cap strips. Measured, cut and steamed eight cap strips for #14 ribs. Dry fit and marked 16 gussets for existing intercostals. Measured and marked location for intercostals on top side of wing, port side, ribs 8 to 12.

July 25 2022 - 1.0hrs - 4473.5 total. Made up four intercostals for top of wing from rib 8 to 12 port side. Picked up steel tubing from machinist and got it all boxed up to go off to the chrome shop in Pennsylvania.

July 27 2022 - 0.0hrs - 4473.5 total. Spent about an hour and a half looking at the alignment of the ribs already glued onto the spar. I noticed #13 was not perpendicular the full length. It was a good 1/2" skewed at the trailing edge. Was envisioning having to remove a bunch of the intercostals and remake them, but finally figured out the whole assembly of ribs was out of square, but still parallel to each other. Tried a bunch of things, then clamped a brace between the rib assembly and the jig that pushes everything into correct alignment without having to cut out or reinstall anything. It takes a bit of force to hold it in position, and I don't see a way to keep it there without the brace except to install some wing skin or maybe some temporary internal bracing? Will have to see...

July 29 2022 - 2.0hrs - 4475.5 total. Spent about two more hours yesterday and another hour today - not counting that time - measuring and re-measuring the space between the ribs in four locations on each and determined the max variation was 1/16" on several locations, but they had a tendency to cancel each other out. Anyway, I'm satisfied that they are aligned well enough and I should just keep going. Made up eight deeper gussets for the upper wing intercostals. Glued in the remaining 21 gussets for the bottom intercostals and one of the upper intercostals and its two deeper gussets.

July 30 2022 - 3.5hrs - 4479.0 total. Made up eight more upper intercostals. Glued in all of the uppers and glued on gussets, but ran out of glue with four gussets left to go. The wheels arrived!

July 31 2022 - 1.5hrs - 4480.5 total. Sanded down rib # 13 port and slid it into position on the spar. Started aligning and clamping the rib in place in prep for gluing it in. Cleaned up the glue joints at the four remaining gusset locations and shaped and labeled the gussets for each position.

August 1 2022 - 1.0hrs - 4481.5 total. Made up five more intercostals for the bottom of the port wing between ribs 6 to 9.

August 6 2022 - 2.5hrs - 4484.0 total. Glued in several more intercostals and gussets. Final aligned rib #13 port and glued to spar.

August 10 2022 - 3.0hrs - 4487.0 total. Made up ten shim and reinforcement pieces for rib #13 port. Located and made two more intercostals for top of wing between ribs 5 to 7. Trying to stiffen this area as much as possible so the wheel well pieces can be cut from ribs 6 and 7. Another Tally-Ho builder, who is also an incredible machinist, made my throttle quadrant several years ago. He made a scale gear select lever for me, to replace the massive full sized one that I have now. This new scale one is perfect! And its made to work with the Tally-Ho incarnation of the pintal pin gear locking system. He even made up the distinctive pully covers that mount just where the pintal cables pass through the instrument panel bulkhead.

August 16 2022 - .5hrs - 4487.5 total. Made up four deep gussets for the upper intercostals from ribs 5 to 7.

August 17 2022 - 2.5hrs - 4490.0 total. Glued in the gussets I made yesterday along with the two intercostal pieces. Glued the ten shim and reinforcement pieces around rib #13 port to spar. Glued one cap strip onto one side of each of the two #14 ribs.

August 18 2022 - .5hrs - 4490.5 total. Made up three intercostals for upper side between ribs 12 & 13 port.

August 22 2022 - 2.0hrs - 4492.5 total. Glued in the three intercostals. Made up six deep gussets for them and glued them in also. Glued one more cap strip to one side of each of the #14 ribs.

Rib #13 port glued to spar

The new, accurately scaled gear select lever arrived - its perfect!

Ten shims and reinforcement strips for rib #13 port

The new, accurately scaled gear select lever arrived - its perfect!

Ten shims and reinforcement strips for rib #13 port

The new, accurately scaled gear select lever arrived - its perfect!

August 24 2022 - 1.0hrs - 4493.5 total. Removed clamps from #14ribs and sanded glue from outer profile in preparation for gluing caps strips to other side. Made up three intercostals then realized I used the wrong material, so made up three correct ones, and six gussets to go with them. Ready to be glued in place between ribs 12 and 13 port side bottom.

September 11 2022 - 2.0hrs - 4495.5 total. Its been several weeks since I've worked on the project as I had to get the vapor barrier finished on the new shop before winter sets in. I put it off last year and had lots of ice build up over the winter that turned to water inside the walls this spring. So the vapor barrier is finished now and I can get back to work on the project! I made a big mess doing the vapor barrier so I spent about 4 hours putting things back and cleaning the shop. Spent two hours gluing in the three intercostals and six gussets that I made up several weeks ago. Also glued the upper and lower cap strips onto the second side of one of the #14 ribs.

Three new intercostals (and three from wrong stock) and gussets ready to be glued in place

Three intercostals and six gussets glued in place between ribs 12 and 13 port bottom

Three new intercostals (and three from wrong stock) and gussets ready to be glued in place

Top and bottom caps glued to 2nd side of #14 SB rib

Three new intercostals (and three from wrong stock) and gussets ready to be glued in place

Top and bottom caps glued to 2nd side of #14 SB rib

September 12 2022 - 1.0hrs - 4496.5 total. Sanded down glue on SB rib # 14 and re-labeled it port. (they're the same) Slid onto spar and relevelled and aligned spar in jig. Aligned rib on spar and tacked in place with 5 min epoxy.

September 14 2022 - 1.5hrs - 4498.0 total. Made up ten shim and reinforcement strips for rib #14 port.

September 17 2022 - 3.5hrs - 4501.5 total. Glued the ten pieces around rib # 14. Glued one of the remaining cap strips to rib #14 SB and accidentally applied glue to the wrong side of the last cap strip, so had to quickly pull one of the #15 ribs out and glue it to that. Made up three upper intercostals and six gussets to go between ribs 13 and 14. Tried to glue them in with some of the leftover glue from the cap strips, but it was getting too thick so only managed to get one of them and its gussets glued in.

September 19 2022 - 2.0hrs - 4503.5 total. Determined I have rib #14 in about 1/8" out of perpendicular with centerline on spar. Am able to tweak the alignment using the intercostals. Had to remake the upper ones that I hadn't glued in yet and make up three for the bottom. Also made up six gussets for the lower ones. Ready to be glued.

September 23 2022 - 2.0hrs - 4505.5 total. Measured, cut and steamed eight more cap strips for #15 ribs. Marked locations for intercostals on ribs in front of spar. Made up five upper intercostal pieces for in front of spar from ribs 5 to 10.

September 24 2022 - 4.0hrs - 4509.5 total. Made up remaining upper intercostals for in front of spar to reach existing rib #14. Made up 18 gussets for them. Glued in three upper intercostals and four lower including 14 gussets between ribs 13 and 14 aft of the spar. Glued in two intercostals and four gussets between ribs 5 and 7 in front of the spar. Glued last spar cap onto rib #14 SB and one more onto one of the #15 ribs.

September 25 2022 - 4.0hrs - 4513.5 total. Removed clamps from cap strips, trimmed and sanded down rib #14SB and put in the stack. Cleaned up the rib 15 that was glued yesterday and glued remaining two cap strips to other side. Its finished now. Glued one cap strip to other rib #15 - three more to go on that one. Glued in two more upper intercostals and four gussets in front of spar from ribs 7 to 9. I've been stacking the SB ribs without sanding them for a while, so while waiting for new glue to dry, spent some time sanding a few of them down. The SB side of the wing will go very quickly compared to the port because I'll have all the ribs ready, and I'll know what I'm doing!

September 26 2022 - 1.5hrs - 4515.0 total. Triple checked vertical alignment line for rib #15 on spar, then slid rib in place, aligned and clamped in place. Its such a tight fit on the spar, I don't think tacking it with 5 minute epoxy will work. Going to try gluing a couple of the reinforcement strips on. Made up two of the larger vertical ones. Ran out of time to glue today. Also, as I was measuring, Steve Foley called and we talked about his goal to start selling plans again! Exciting news! I don't think I'm giving anything away to say that he's planning to start slowly while working out a mechanism to pass on all the little tweaks and changes that the current builders - me included - have discovered as we've gone.

BUILDERS LOG - may TO september 2022

Ribs # 1 and 5 to 10 port glued in place. Starting to look like a wing!

Ten shim and reinforcement strips for #10 rib port

Intercostal material and more cap strips arrived

Intercostal material and more cap strips arrived

Rib #11 port tacked in place with 5 minute epoxy

First two intercostals glued in. Dry fitting 1/4" reinforcement wall

Rib #11 port tacked in place with 5 minute epoxy

Gluing cap strips to first side of #12 ribs

First two intercostals glued in. Dry fitting 1/4" reinforcement wall

Rib #11 port tacked in place with 5 minute epoxy

First two intercostals glued in. Dry fitting 1/4" reinforcement wall

First two intercostals glued in. Dry fitting 1/4" reinforcement wall

First two intercostals glued in. Dry fitting 1/4" reinforcement wall

oops! Broke off the end of port rib#11

Glued in two of the three 1/4" wall pieces and reinforcement strips

Glued in two of the three 1/4" wall pieces and reinforcement strips

Glued in two of the three 1/4" wall pieces and reinforcement strips

Glued in two of the three 1/4" wall pieces and reinforcement strips

Glued in two of the three 1/4" wall pieces and reinforcement strips

Ten shims and reinforcement strips for rib #12 port

Glued in two of the three 1/4" wall pieces and reinforcement strips

Ten shims and reinforcement strips for rib #12 port

Gluing cap strips to first side of #13 ribs

Last section of 1/4" wall and reinforcement strips glued in place

Last section of 1/4" wall and reinforcement strips glued in place

Last section of 1/4" wall and reinforcement strips glued in place

Reinforcement strips glued around port rib #12

Reinforcement strips glued around port rib #12

Eight intercostal pieces tacked in place with 5 minute epoxy

Using the table saw and cross cut sled to cut notches in gussets

Four more intercostals and a couple of gussets glued in. More gussets ready to go

Four more intercostals and a couple of gussets glued in. More gussets ready to go

25 gussets glued in and four upper intercostals

Rib # 13 port on the spar

Wheels and brakes arrived from Matco - so shiny!

Wheels and brakes arrived from Matco - so shiny!

Rib #13 port glued to spar

The new, accurately scaled gear select lever arrived - its perfect!

Ten shims and reinforcement strips for rib #13 port

Ten shims and reinforcement strips for rib #13 port

The new, accurately scaled gear select lever arrived - its perfect!

Ten shims and reinforcement strips for rib #13 port

The new, accurately scaled gear select lever arrived - its perfect!

The new, accurately scaled gear select lever arrived - its perfect!

The new, accurately scaled gear select lever arrived - its perfect!

Three new intercostals (and three from wrong stock) and gussets ready to be glued in place

Three new intercostals (and three from wrong stock) and gussets ready to be glued in place

Three new intercostals (and three from wrong stock) and gussets ready to be glued in place

Three intercostals and six gussets glued in place between ribs 12 and 13 port bottom

Three new intercostals (and three from wrong stock) and gussets ready to be glued in place

Three new intercostals (and three from wrong stock) and gussets ready to be glued in place

Top and bottom caps glued to 2nd side of #14 SB rib

Three new intercostals (and three from wrong stock) and gussets ready to be glued in place

Top and bottom caps glued to 2nd side of #14 SB rib

Rib #14 port tacked into place with 5 minute epoxy

Three new lower intercostals and two remade uppers, with gussets, ready to be glued in place

Ten shim and reinforcement strips ready to be glued to rib#14 port

Ten shim and reinforcement strips ready to be glued to rib#14 port

Three new lower intercostals and two remade uppers, with gussets, ready to be glued in place

Ten shim and reinforcement strips ready to be glued to rib#14 port

Three new lower intercostals and two remade uppers, with gussets, ready to be glued in place

Three new lower intercostals and two remade uppers, with gussets, ready to be glued in place

Three new lower intercostals and two remade uppers, with gussets, ready to be glued in place

Eight more cap strips steamed to shape (four in each clamp)

Rib #15 port on the spar, aligned, clamped in place and ready to be glued in

Five upper intercostal pieces being dry fit in front of spar

Five upper intercostal pieces being dry fit in front of spar

Rib #15 port on the spar, aligned, clamped in place and ready to be glued in

Five upper intercostal pieces being dry fit in front of spar

Rib #15 port on the spar, aligned, clamped in place and ready to be glued in

Rib #15 port on the spar, aligned, clamped in place and ready to be glued in

Rib #15 port on the spar, aligned, clamped in place and ready to be glued in