02Jan00, 5 hours - Trimmed inboard end of both elevators.  Used body putty on the bench & block sanded to get dead straight section for elevator trailing edge.  Finish fit elevators, sanded all bonding surfaces.  Inspected all bonds, nutplate rivets & threads prior to close.  Bonded elevator skins with milled fiber.  Straight sanded bottom right horizontal leading edge, added milled fiber to 6” long low spot @ B rib.  Sanded wheel pant seams, added a bit of milled fiber in spots.

03Jan00, 3.5 hours - Promoted 1 gallon resin, 5cc cobalt, 3 cc dma.  Gel test 25 minutes.  Trimmed elevator hinge clearance slot, widened leading edge slots in preparation for leading edge layup.  Q-celled leading edge seams, leaving one seam incomplete.

05Jan00, 1.5 hours – Completed elevator Q-cell.  Fabricated inboard end caps.

06Jan00, 2.5 hours – Applied leading edge laminated, using glass/resin prepared in advance on aluminum foil.  Applied root rib laminates.

08Jan00, 5.0 hours – Assembled elevators to horizontal.  Trimmed for 30deg up, 22 deg down, and end clearance.  More sanding…continued forming stabilizer leading edge.

09Jan00, 5 hours – More sanding…trimmed elevator, capped elevator inboard ends, seamed c/w arms, formed and applied outer laminates to c/w leading edge.  Elected to save horizontal tip installation till last, since it is a transition piece that must be formed to match the horizontal (it’s fits poorly as delivered.)

10Jan00, 3 hours – Completed layup of c/w end caps, installed c/w shearweb, cleaned up trailing edge mismatch on left elevator.  Filled miscellaneous bits on elevator edges, capped gaps behind torque tubes with milled fiber.

11Jan00, 2.5 hours – Bondoed and formed c/w arms, laminated c/w shearweb.

12Jan00, 2 hours – Completed final forming, used bondoe to level inboard closeouts, touched up trailing edge.  Balanced elevators using 2-7/8 oz. weight on trailing edge to simulate paint.  Used 3 lb. piston pin as c/w to mark & calculate c/w needed. 

Left side marked at 6.8 inches x 3 lbs. = 20.40 in-lb. 

Right side marked at 6.625 inches x 3 lbs. = 19.88 in-lb.

Total moment = 40.28 in-lb.

Center c/w balances 60%, .6 x 40.28 = 24.17 in-lb.

Center c/w station @ 9.5”, 24.17/9.5 = 2.54 lb., 40.64 oz.

Each tip balances 12.5%, 12.5% x 40.28 = 5.04 in-lb.

Tip c/w station @ 7”, 5.04/7 = .72 lb., 11.52 oz.

The manual suggests cutting the tip weights as small pucks running spanwise.  This makes it difficult to put the c/w c.g. at the 7” station.  Instead, I cut them as 2.32 long trapezoid, 1” tall at front, 1.66” tall at back.  

13Jan00, 2 hours - Completed c/w laminates, capped c/w arms.  Fabricated center weight, 40.60 oz. using 13 sheets lead, 1-1/2 x 5 x 1/16".  Supplied AN4-12A mounting screws were 1/4" too short.

15Jan00, 2 hours - Fit stabilizer tips, bonded left.  Fabbed taillight support. 

16Jan00, 1.5 hours - Bonded right tip, capped left horizontal end.

17Jan00 - Completed airport website.  http://www.bakalar.org.  Sent $$$ to Stoddard Hamilton, full kit now one month away!

18Jan00, 1.5 hours - Capped right horizontal.  Completed taillight block layup with one layer of glass.

21Jan00, 1.5 hours - Completed center c/w, ended up with 40.35 oz. lead.  Filled & smoothed endcaps.

22Jan00, 6.4 hours - Smoothed ends of horizontal & elevators, shaped tips, redrilled all drain holes & inspected all for clear flow.  Finish shaped horizontal leading edge.  Assembled actuator arm & c/w.  Inspected entire assembly, compared all steps in manual (B1-B80).  Red tagged all pages with fasteners & drain holes to assist in final assembly & inspection.  Reconfirmed control system clearances at 30deg up, 22deg down, end c/w clearances, center c/w clearance & actuator clearance.  Crated horizontal, elevator & wheelpants.  Touched-up rudder & prepped to install light.

24Jan00 - Shop is looking awfully empty...

Elevator & horizontal tip details:

January 2000 - 46.4 hours

Total 164.5 hours