Europa #435 G-RODO Build Journal - list of photo pages

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Navigation & Acknowledgements
Navigation & Acknowledgements
29mm spacers for aligning rudder pedalsFitting fuselage rear bulkheadPropeller delivery
35mm film can spray gunFitting Mod 70 rubbing stripsRadio and intercom
3D Mouldings label in bonding areaFitting trailer floorradio panel instruments trial fit
90mm spacer block for rudder pedal shaft alignmentfitting vent hardware to F18radio panel populated
A bad layupFL15 paint removedradio panel trial fit
Abrading for BID under FL18sFL15 rubbing strip positionradio panel water-jet cut
Access hole in cockpit module tunnelFL15 rubbing stripsRe-bonding port wing TE
Access hole positions transferred insideFL15 rubbing strips bondedre-doing spar hole layups
access panel and support rib layupsFL18 hinge bracket alignment - first tryreaching into footwell
Adjusting height of wing slingFL18 hinge brackets on straight-edgeRear upper fuselage holes marked
aft baffleFL18s re-positionedrebate around tunnel slot for tie-bar
Aft port wing pin socket pad shimmedFL22 starboard alignmentredundant cylinder shroud
Aft wing pin socket padsFlapRedux pre-bond thickness on port wing ribs
Aft wing socket new hole - portFlap attachment bolt almost threadboundRedux spread ready for wing skin bond
Aileron drive bolt alignmentflap hinge arrangementsRedux surplus after pre-bonding
Aligning flap hinge plates FL1 FL2 FL3Flap hinge clampRedux test piece
alternator cable securedFlap hinge plate alignment toolsRedux test piece broken
altimeter knob shaft extenderFlap hinge plates FL1 FL2 FL3Redux thickness on starboard rib flanges
AN970-3 washers modifiedflap pushrod clearance improvedregulator mounted on firewall
Arbour press ram modificationflap pushrod clearance problemRelease film for wing skin pre-bonding
attaching Belleville washer to spar cupflap pushrod hole in tunnel bulkheadRemoving a bad top-hat layup
axle bolt lockwireFlap root extension inner layupsRemoving another bad top-hat layup
Bad and good airline connectorsFlap root extension outer layupsRemoving flap root extension former
baggage bay - first edge layupsflap slot damage insideResin pump calibration checks
battery boxfloxing vent pipe holesretract bungee re-fitted
battery box mouldFoam supports carved to fit under footwell floorsretract bungee secured
battery isolator etc mountedForward socket heater clampRetract down-latch
battery strap sewingForward wing socket bolts - portretract lever fitted
Beam balance fine adjusterForward wing socket bolts - starboardretract lever guide plate
blue foam for seat bases and battery box mouldfuel filler trial fittingRetract lever holes
blue foam side stiffenerFuel gauge sender headRetract lever position
Bonding clip for sight gauge tubingfuel hose routing in tunnelRetract lever slot cut
Bonding CS02 and CS03fuel hose with clip in tunnelRetract lever slot marking-out
Bonding CS05 to CS03Fuel level sensor amplifierRig tailplanes
bonding fin tipFuel level sensor tee-pieceRight-angle adaptor for wing-leveller servo
Bonding in FL18sfuel line from flow sender to unionright-angle connector cover for wing leveller servo
Bonding in port wing horn boxesfuel line union at wheel wellRouting out brown foam
Bonding on fuselage top mouldingfuel pipe from gascolator to pumpRowland with hammer
Bonding pitot/static tubing clipsfuel pipe from pump to flow senderrubbing blocks on tower
bonding shoot bolt guide in doorfuel pipe to gascolatorRudder bellcrank split-pins
bonding side stiffenersFuel pipes from tank to selector valveRudder cable turnbuckles installed aft
bonding studs to underside of tunnelFuel pump clearancerudder deflection 2nd check
bonding wing root fairingsfuel systemrudder deflection first check
Boring crank arm holeFuel tank adaptorsRudder flange damage
Both wings in garagefuel tank C adaptor fittedrudder hung on clecos
Bottom fuselage half upside-downFuel valve trial assemblyRudder jig for sanding
bracket for fuel line unionfuel ventRudder layup
bracket formers from blue foamfuselage centreline marksRudder port side filled
Bracket layups held in placefuselage damage at flap cross-tuberudder pulley access covers
brake bolt lockwireFuselage dollyRudder starboard side polished
Brake filler hole coverfuselage hard-points for wing pin socketsSagging filler
Bridge to hold down tubing clipsfuselage levelling jigSander for curved parts
brown foam cover for tie-bar tunnel slotFuselage on starboard sideSanding filler on rudder
BT Research Labs Martlesham HeathFuselage parked tail end inSandvik abrader
Bulkhead location on fuselage top mouldingFuselage spar hole layupSatisfactory Nicopress sleeve
card template for aft baffleFuselage spar hole repairScrew fouling rudder cable
card template for aft baffle unfoldedfuselage top propped upScrew spacers for stiffnuts
Carving flap root extension formerfuselage top upside down in garagescrewcutting AN840-6D boss
Carving flap root extension formerFuselage trim lineseat base foam proposals
Carving flap root extension formerFuselage upside-downServo bellcrank relieved
carving foam for starboard seat recessgap for upper bump stopServo cable clips
Chamfer for tailwheel arm mountgaps in duct around coolersServo link rod fouling
check tailplane torque tube levelGarden shedServo link rod length
check XTW06 lineup for XTW15 bondinggascolator hatch splash mouldingServo mount bolts safetied
Checking CS05 centre distanceGel coat drips & runsSetup for first aileron hinge hole
Cleco sternpost in placeGel-coat trial finishshaping door handles
clips retaining wires to fuel pump and flow sensorGel-coating ruddershelf cut out
clips securing brake lineGPO Research Station Dollis Hillshoot bolt alignment
Cockpit module bondingHandle for lifting forward end of fuselageshoot bolt guides bonded
Cockpit module pre-bond inspection righeadrest hole for wiresshoot bolt guides in door frame
Cockpit module spar bush bondingheating resistors on aileron quick-connect bellcranksshort turnbuckle
Cockpit module trimmed and frettedHeating resistors on wing pin socketsshortening FL15 cross-tube
Cockpit module tunnel edges trimmedHolder for thinning FL11Sling for fuselage top moulding
conduit for VHF comms antenna cablehole in stick base socket for wiresSpar - bellcrank clearance
conduit hole in rear bulkheadHoles in the wing skinspar guides
conduit on baggage-bay roofHorn-box recess enlargedspar hole layups removed
Conduit sleeves and tube clipshub and brake lockwireSplash layup temporary bonding
Containment bulkhead clearanceInitial fit of fuselage top mouldingSplash moulding for top of containment bulkhead
Containment bulkhead sides bowedInstalling carb heat pipingSplash moulding on brackets
cooling duct final fittingInstrument module brackets.Spraying CS05 torque tubes
cooling duct fittedInstrument module cutout for radio panelstarboard aft baffle fitting
cooling duct marked for 2nd triminstrument module inner flangestarboard baffle fitting
cooling duct with first fit of sealsinstrument module ventilation holesstarboard baffle forward bend
cooling faninstrument panels black anodizedStarboard wing conduit tryout
cowl and propeller test assemblyInstrument sub-panelStarboard wing on car roof bars
cowl assembled with clecosIpswich airportStarter wiring in baffle location
Cowl first assemblyjig for thinning blue foamstick-top switch mount
cowl first trial fit on fuselageKeeping rudder pedals at neutralStraightedge on fin
cowl fit after trimmingkink in fin splash mouldingstrobe power supply mounted
cowl fittedKit partsstuds bonded to underside of tunnel
cowl fitted with clecosLanding gear mount corrosionTailplane alignment
cowl fitted with temporary screwslaser etched legendsTailplane outboard rib
cowl overlap on fuselagelayup covering tie-bar tunnel slotTailplane pip pin recesses
cowl trimming guide linelayup filed back to expose Belleville washerTailplane tips
cowl with propshaft holelayup for internal-corner conduit clipstailwheel arm mount pad ground down
Crank arm clamped to CS03 for drillinglayup on aft face of baggage bay bulkheadTailwheel arm mount plywood stack
crowbar etc mountedlayup on aft face of baggage bay bulkhead with peel-plytailwheel cables with turnbuckles
CS04 clamped in positionlevel fuselageTailwheel mount painted
CS04 shaped to fitLevelling fuselageTank spacer layup
CS10 pivot markingsLG02 propped up to check cable clearanceTank support layups
CS14 alignmentLG02A profilingtank vent assembly curing
Cupboards for glass and resinLumps on wing top skintank vent pipe to filler
Curing BID strips at rear of cockpit modulemachining vacuum adaptorTE support for sanding
Curing tent over inverted fuselagemagneto lead feedthroughTemporarily tensioning rudder cables - first method
Cutout for tailwheel arm mountMaking clips for stall-warner tubeTemporarily tensioning rudder cables - second method
Cutting away TE between aileron and flapMaking fuel tank adaptorsThin patches on rudder root
Cutting back FL18Smaking internal-corner conduit clipsThin spots on rudder hinge vee
Cutting out fuselage rear bulkheadMaking new top-hat layups between door framesthrottle lever handle
cutting semi-circular hole in bafflemaking replica of LG frame for fitting firewalltie-bar plywood brace bonding
Cutting trim slotsmaking stick-top switch mount (1)Tools
Dispenser bottle nozzlesmaking stick-top switch mount (2)Top of containment bulkhead trimmed
dolly hold-down nutplate locationsmaking stick-top switch mount (3)Torque tube support
door handle partsmaking stick-top switch mount (4)TP10 drill setup
door handle trial assemblyMaking support sleeves for wing conduitTP10 drill setup
door hinge gapmaking tailwheel towing deviceTP12 - TP10 trial fit
door hinge recesses maksedMaking wooden handle for brake leverTP14 split pins
door hinges maskedmanifold pressure restrictortrail assembly of cooling duct
door latch fittingMark lower rear access hole positiontrail fit of water radiator
door pushrod angle slotMark Mod 77 bracket positionTrailer ramp gas springs
door pushrod tangsMarking holes for LG01 top tube drillingtrailer spar clamp change
door rebate impressionsMarking out for fuel gauge sendertrailer stuff moved out to get at wings
doors fittedmarking slot for flap actuator cross-tubetrailer wing dolly restraints
doors hingedMass-balance weights paintedtransponder installation
Double marking of holes in cockpit moduleMilling the slot in the rudder cable guidestransponder loom lacing
Double tube clip materialMinitool jigsaw blade clamp modificationtrial fit of cooling duct
Dowel roller for inside wing repairModel aeroplanestrial fit of engine to fuselage
Drill CS17Modified irontrial fit of oil cooler
Drill TP10Modify rear bulkhead for Mod 77trial fit of silencer
Drilling pushrod ends using vee-blocksmount for Airbox Aware 5Trial hole for transponder head
Drilling the torque tube hole in the seat facemoving fuselage to rigging dollytrial of seal on duct side
duct side puzzleNeville Eyre's cowltrial setting of wing incidence
duct sides versus templateNew peel-ply roll mounttrial setting of wing incidence 2
duct-tape masking for aileron bellcrank pad bondingnew shoot bolt holeTrim and anti-servo tab
Dummy pitot-static mastnutplates for dolly screwsTubing clip bond failure
Dummy TS05odyssey batterytunnel slot for tie-bar
Dynon D2 & Airbox Aware 5 mountedoffering engine to fuselageTurnbuckles fitted forward and rubbing on floor
electrical items on firewalloil pipe routing testturning down AN840-6D boss
electrical wiring on firewall itemsOne-cup resin balancetyre clearance
Engine alignment checkOutriggerUnidentified objects in fuel tank
engine on craneover-centre test bossesUnsatisfactory Nicopress sleeve
engine without shroudoverflow bottle mountedupper bump stop
Enlarged gate for traileroverflow bottle strapUSB outlet on main panel
Enlarging aileron hinge screw holesoverhead panel bracket layupvacuum port adaptors
EURO29 bolt differencesoverhead panel bracketsvacuum pump pad cover
EURO29 bolts lock-wiredoverhead panel fittedvacuum system
exhaust hole in cowloverhead panel layupvent hardware trial fitting
F18 filler neck BID strapspanel holes for warning lightsVoid between rib and bottom skin
F18 filler neck fittedparting off stepped washerW35 gussets on tie-bar
F18 foam spacerparts sprayed whitewater pipe routing test
F18 foam spacer fittedParts spread out on lawnwater trap adaptors
F33 door latch cover trimmingPitot-static mast connexionWeekend Workshop
Failed bond on flap root extensionpitot-static systemWeights for wing skin bonding
failed funnel flatteningPitot-static tubing connectorsWet sanding with guide coat
Filing CS09APlastic bottlesWing conduit installation
Filing down CS07/CS08plastic conduit through baggage bayWing fairing protector
filing engine mount weld filletplenum chamberWing leveller servo mounted
filling trim link slotplotting trim link rod pathWing on table for pin fitting
fin splash moulding taped in placepoor sewing on battery strapWing pin fitting
fin tip flanges trimmedPort aileron bellcrank mountWing rear closeout spacer
Fin wedged openPort flap aligned with aileronWing repair completed
final fit of cooling ductPort flap clamped to templateWing skin bonded
Finger strainers and tank adaptorsPort tip flange misalignmentWing skin cut away for repair
Finishing rudder port sidePort wing aileron bellcrankWing slings
Finishing rudder tipPort wing aileron closeout cutawaywing socket hardpoint layups 1
fire extinguisher mountedPort wing on flap templateWing TE aileron closeout trimming
fire extinguisher re-fitPort wing skin pre-bondingWing tip support
firesleeve on firewall feed-throughPort wing skin slotted to clear tip flange misalignmentWings first pinned together
firewall pass-through from M8 boltPort wing tilted onto LEwingtip to wingtip string test
firewall pass-through made from jam funnelPosition sternpost holewingtip to wingtip string test 2
firewall templatesPositioning CS09wirebook
firewall wire bundle testPotential control restrictionWitness marks on CS22 & CS23
first plan of items on firewallpower distribution terminalsWooden block for rudder hinge vee
first successful wing rigPreparing for spar bush bondingXTW06 alignment
first trim of cooling ductprop drive dowels safety-wiredXTW06 alignment template
Fit trim servoprop stored in garageXTW15 magnetic retainer
Fitting fuel valve mounting platepropeller brush bracket check

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