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

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29mm spacers for aligning rudder pedalsflap cross-tube guide fittedRe-bonding port wing TE
35mm film can spray gunflap hinge arrangementsre-doing spar hole layups
3D Mouldings label in bonding areaFlap hinge clampre-hanging engine
90mm spacer block for rudder pedal shaft alignmentFlap hinge plate alignment toolsreaching into footwell
A bad layupFlap hinge plates FL1 FL2 FL3Rear upper fuselage holes marked
Abrading for BID under FL18sflap pushrod clearance improvedrebate around tunnel slot for tie-bar
abrasion hazards to C04 water hoseflap pushrod clearance problemredundant cylinder shroud
abrasion protection for C04 water hoseflap pushrod hole in tunnel bulkheadRedux pre-bond thickness on port wing ribs
abrasion protection for C04 water hoseFlap root extension inner layupsRedux spread ready for wing skin bond
Access hole in cockpit module tunnelFlap root extension outer layupsRedux surplus after pre-bonding
Access hole positions transferred insideflap slot damage insideRedux test piece
access panel and support rib layupsflaps stored in cockpitRedux test piece broken
Adjusting height of wing slingFlettner strips bonded to tabsRedux thickness on starboard rib flanges
aft bafflefloxing vent pipe holesregulator mounted on firewall
Aft baffle fuel hose slot changedFlying but not in a EuropaRelease film for wing skin pre-bonding
Aft port wing pin socket pad shimmedFoam supports carved to fit under footwell floorsRemoving a bad top-hat layup
Aft wing pin socket padsForward socket heater clampRemoving another bad top-hat layup
Aft wing socket new hole - portForward wing socket bolts - portremoving engine
aileron balance after paintingForward wing socket bolts - starboardremoving engine mount fixings
aileron balance after painting with dimension linesFuel elbow adjustedRemoving flap root extension former
aileron balance after sanding undersidesfuel filler trial fittingremoving old connectors from fuel filler
aileron balance check after paint removalFuel gauge sender headremoving old connectors from fuel filler
aileron balance check after paint removalfuel hose clearance from engine mountResin pump calibration checks
aileron balancing after 2nd paintingfuel hose firewall fitting mockupRestrictor hose with firesleeve
Aileron drive bolt alignmentfuel hose in tunnelretract bungee re-fitted
aileron fillingfuel hose marked for cutting at firewallretract bungee secured
Aligning flap hinge plates FL1 FL2 FL3fuel hose protection on aft baffleRetract down-latch
alignment fixture for flap cross-tube guidefuel hose protection on aft baffle - wrong sizeretract lever fitted
alternator cable securedfuel hose routing in tunnelretract lever guide plate
altimeter knob shaft extenderfuel hose with clip in tunnelRetract lever holes
AN970-3 washers modifiedfuel hose, tunnel to firewallRetract lever position
anchor nuts for baffle fixingfuel hoses with firesleeveRetract lever slot cut
anchor nuts for cooler bafflesFuel level sensor amplifierRetract lever slot marking-out
Arbour press ram modificationfuel level sensor cover fittedRig tailplanes
attaching Belleville washer to spar cupFuel level sensor tee-pieceRight-angle adaptor for wing-leveller servo
axle bolt lockwirefuel line from flow sender to unionright-angle connector cover for wing leveller servo
Bad and good airline connectorsfuel line union at wheel wellRouting out brown foam
baffle clearance at oil tankfuel pipe from gascolator to pumpRowland with hammer
baffle clearance from oil hosesfuel pipe from pump to flow senderRTV around firewall
baffle clearance from oil tank elbowfuel pipe to gascolatorRTV around firewall
baffle clearance from water hoseFuel pipes from tank to selector valverubber parts of rudder shaft seal
baffle edge sealsFuel pump clearancerubbing blocks on tower
baffle for gap between radiator and oil coolerFuel pump hoses with firesleeve re-alignedRudder bellcrank split-pins
baggage bay - first edge layupsfuel return firewall fitting completedrudder cable seal port
battery boxFuel return hose with firesleeverudder cable seal starboard
battery box mouldfuel return line in cockpitRudder cable turnbuckles installed aft
battery isolator etc mountedfuel return restrictorrudder crank firewall relief marking
battery strap sewingfuel systemrudder deflection 2nd check
Beam balance fine adjusterFuel tank adaptorsrudder deflection first check
blue foam for seat bases and battery box mouldfuel tank C adaptor fittedRudder flange damage
blue foam side stiffenerFuel valve trial assemblyrudder hung on clecos
Bonding clip for sight gauge tubingfuel ventRudder jig for sanding
Bonding CS02 and CS03fuselage centreline marksRudder layup
Bonding CS05 to CS03fuselage damage at flap cross-tubeRudder port side filled
bonding fin tipFuselage dollyrudder pulley access covers
bonding Flettner strips to tabsfuselage hard-points for wing pin socketsrudder shaft seal fixings
Bonding in FL18sfuselage in trailerrudder shaft seal fixings
bonding in flap cross-tube guidefuselage levelling jigrudder shaft seal fixings
Bonding in port wing horn boxesFuselage on starboard siderudder shaft seal fixings
Bonding on fuselage top mouldingFuselage parked tail end inrudder shaft seal fixings
Bonding pitot/static tubing clipsfuselage ready to go into trailerrudder shaft seal fixings
bonding shoot bolt guide in doorFuselage spar hole layuprudder shaft seal fixings
bonding side stiffenersFuselage spar hole repairRudder shaft seals fitted
bonding studs to underside of tunnelfuselage top propped upRudder starboard side polished
bonding wing root fairingsfuselage top upside down in garageSagging filler
Boring crank arm holeFuselage trim linesanded through paint on starboard aiieron
Both wings in garageFuselage upside-downSander for curved parts
Bottom fuselage half upside-downFuselage winched out of trailerSanding filler on rudder
Bowden cable protectiongap at bottom of oil coolersanding paint off stbd aileron upper surface
Bowden cable protectiongap between cooling duct and cowlsanding paint off underside of starboard aileron
Bowden cable protection on aft bafflegap between radiator and oil coolersanding port aileron underside
bracket for fuel line uniongap for upper bump stopsanding port aileron upper side
bracket formers from blue foamgaps in duct around coolerssanding through filler on starboard aileron
Bracket layups held in placeGarden shedSandvik abrader
brake bolt lockwiregascolator hatch splash mouldingSatisfactory Nicopress sleeve
Brake filler hole coverGel coat drips & runsScrew fouling rudder cable
Bridge to hold down tubing clipsGel-coat trial finishScrew spacers for stiffnuts
brown foam cover for tie-bar tunnel slotGel-coating rudderscrewcutting AN840-6D boss
BT Research Labs Martlesham Heathgetting ready to fill tailplaneseals around oil hoses
Bulkhead location on fuselage top mouldingGPO Research Station Dollis Hillseat base foam proposals
bush for Dremel cutoff wheelHandle for lifting forward end of fuselageServo bellcrank relieved
C04 water hose and air filter foulingheadrest hole brown foam routed outServo cable clips
carburettor Bowden cable fittingsheadrest hole for wiresServo link rod fouling
carburettor heat hose routeheating resistors on aileron quick-connect bellcranksServo link rod length
card template for aft baffleHeating resistors on wing pin socketsServo mount bolts safetied
card template for aft baffle unfoldedHolder for thinning FL11Setup for first aileron hinge hole
Carving flap root extension formerhole in stick base socket for wiresshaping door handles
Carving flap root extension formerHoles in the wing skinshelf cut out
Carving flap root extension formerHorn-box recess enlargedshoot bolt alignment
carving foam for starboard seat recessHose braid flaringshoot bolt guides bonded
Chamfer for tailwheel arm mounthose cut for fitting endshoot bolt guides in door frame
check tailplane torque tube levelhose end assembledshort turnbuckle
Check where to cut C05 water hosehose end damageshortening FL15 cross-tube
check XTW06 lineup for XTW15 bondinghose fitted to socketside baffles for oil cooler
Checking CS05 centre distancehose insertion checkSling for fuselage top moulding
checking hose lengths into cooling ducthose to fuel pump trial fitslot for fuel hose on aft baffle
Cleco sternpost in placehose to fuel pump trial fitslot in aft baffle for C04 water hose
clips retaining wires to fuel pump and flow sensorhub and brake lockwireslot in aft baffle for C04 water hose
clips securing brake lineInitial fit of fuselage top mouldingslot in aft baffle for C04 water hose
Cockpit module bondingInstalling carb heat pipingsoft sanding block
Cockpit module pre-bond inspection rigInstrument module brackets.spacing fuel hose from engine mount
Cockpit module spar bush bondingInstrument module cutout for radio panelspanner jammed on firewall fuel elbow
Cockpit module trimmed and frettedinstrument module inner flangeSpar - bellcrank clearance
Cockpit module tunnel edges trimmedinstrument module ventilation holesspar guides
conduit for VHF comms antenna cableinstrument panels black anodizedspar hole layups removed
conduit hole in rear bulkheadInstrument sub-panelSplash layup temporary bonding
conduit on baggage-bay roofIpswich airportSplash moulding for top of containment bulkhead
Conduit sleeves and tube clipsjig for thinning blue foamSplash moulding on brackets
confirming correct connectors for fuel fillerjoining baffle partsSpraying CS05 torque tubes
Containment bulkhead clearanceKeeping rudder pedals at neutralstainless steel firewall fitting problem
Containment bulkhead sides bowedkink in fin splash mouldingstainless steel firewall patch
cooling duct final fittingKit partsstainless steel firewall patch fitted
cooling duct fittedLanding gear mount corrosionstarboard aft baffle fitting
cooling duct marked for 2nd trimlaser etched legendsstarboard baffle fitting
cooling duct with first fit of sealslathe changewheels for threading bushstarboard baffle forward bend
cooling fanlayup covering tie-bar tunnel slotstarboard rudder crank and spring fitted
cowl and propeller test assemblylayup filed back to expose Belleville washerStarboard wing conduit tryout
cowl assembled with clecoslayup for internal-corner conduit clipsStarboard wing on car roof bars
Cowl first assemblylayup on aft face of baggage bay bulkheadstarter cable bush
cowl first trial fit on fuselagelayup on aft face of baggage bay bulkhead with peel-plystarter cable bush manufacture
cowl fit after trimminglevel fuselagestarter cable bush threading
cowl fittedLevelling fuselageStarter wiring in baffle location
cowl fitted with clecosLG02 propped up to check cable clearancesteel parts of rudder shaft seal
cowl fitted with temporary screwsLG02A profilingstick-top switch mount
cowl overlap on fuselagelower firewall panel fittedstorage of painted tailplanes
cowl positioning jigLumps on wing top skinStraightedge on fin
cowl trimming guide linemachining vacuum adaptorstrobe power supply mounted
cowl with propshaft holemagneto lead feedthroughstuds bonded to underside of tunnel
Crank arm clamped to CS03 for drillingMaking clips for stall-warner tubesupport for trim tabs
crowbar etc mountedMaking fuel tank adaptorsTailplane alignment
crowfoot spannersmaking internal-corner conduit clipstailplane holders in trailer
CS04 clamped in positionMaking new top-hat layups between door framesTailplane outboard rib
CS04 shaped to fitmaking oil cooler bottom baffleTailplane pip pin recesses
CS10 pivot markingsmaking protective cover for fuel level senderTailplane tips
CS14 alignmentmaking replica of LG frame for fitting firewalltailwheel arm mount pad ground down
Cupboards for glass and resinmaking stick-top switch mount (1)Tailwheel arm mount plywood stack
Curing BID strips at rear of cockpit modulemaking stick-top switch mount (2)tailwheel cables with turnbuckles
curing Flettner strip fillermaking stick-top switch mount (3)Tailwheel mount painted
Curing tent over inverted fuselagemaking stick-top switch mount (4)Tank spacer layup
custom hex drill bitMaking support sleeves for wing conduitTank support layups
Cutout for tailwheel arm mountmaking tailwheel towing devicetank vent assembly curing
Cutting away TE between aileron and flapmaking threading tool holdertank vent pipe to filler
Cutting back FL18Smaking throttle box custom washerTE support for sanding
cutting C05 water hosemaking up a hose endTEE in C05 water hose
Cutting out fuselage rear bulkheadMaking wooden handle for brake leverTemporarily tensioning rudder cables - first method
cutting semi-circular hole in bafflemanifold pressure restrictorTemporarily tensioning rudder cables - second method
Cutting trim slotsMark lower rear access hole positiontest alignment of rudder shaft seal
dipped firesleeve ends dryingMark Mod 77 bracket positiontest fit of AN nut on FRFF
dipping firesleeve endsMarking holes for LG01 top tube drillingtest fit of fuel line elbow on firewall
Dispenser bottle nozzlesMarking out for fuel gauge senderTest fit of NPT thread in end of FRFF
dolly hold-down nutplate locationsmarking out for tailwheel tracks in trailertesting stainless steel firewall fit
door handle partsmarking slot for flap actuator cross-tubeThin patches on rudder root
door handle trial assemblyMass-balance weights paintedThin spots on rudder hinge vee
door hinge gapMilling the slot in the rudder cable guidesthrottle box with custom washers
door hinge recesses maksedMinitool jigsaw blade clamp modificationthrottle lever handle
door hinges maskedModel aeroplanestie-bar plywood brace bonding
door latch fittingModified ironTools
door pushrod angle slotModify rear bulkhead for Mod 77Top of containment bulkhead trimmed
door pushrod tangsmount for Airbox Aware 5Torque tube support
door rebate impressionsmounting oil cooler in ductTP10 drill setup
doors fittedmoving fuselage to rigging dollyTP10 drill setup
doors hingedNeville Eyre's cowlTP12 - TP10 trial fit
Double marking of holes in cockpit moduleNew aft baffle fuel hose slot markedTP14 split pins
Double tube clip materialnew fuel filler connectors installedtrail assembly of cooling duct
Dowel roller for inside wing repairNew peel-ply roll mounttrail fit of water radiator
Drill CS17new resin balance placardtrailer floor rot
Drill TP10new shoot bolt holetrailer pulley adrift
Drilling pushrod ends using vee-blocksnutplates for dolly screwstrailer pulley repair
Drilling the torque tube hole in the seat faceodyssey batteryTrailer ramp gas springs
duct side puzzleoffering engine to fuselagetrailer spar clamp change
duct sides versus templateoil cooler bottom baffle fittedtrailer stuff moved out to get at wings
duct-tape masking for aileron bellcrank pad bondingoil cooler hoses fittedtrailer winch rope fairlead fitting
Dummy pitot-static mastoil hose at pump inlettrailer winch rope fairlead on frame
Dummy TS05oil hose return routingtrailer winch rope fairlead on spar support
Dynon D2 & Airbox Aware 5 mountedoil hose routingtrailer winch wire rope clamp
electrical items on firewalloil hose routing at tanktrailer winch wire rope route
electrical wiring on firewall itemsoil hoses passing rear starboard baffletrailer wing dolly restraints
Engine alignment checkoil pipe routing testtrailer wiring clear of winch rope
engine mount bolt split pinsoil return hose routetransponder installation
Engine mount re-fittedoil tank bracket screwtransponder loom lacing
engine on craneoil tank fittedtrial fit of all stainless steel firewall panels
engine removedold connectors on fuel fillertrial fit of assembled upper stainless steel firewall panels
engine sump banjo rotated and lockedold connectors removed from fuel fillertrial fit of cooling duct
engine without shroudOne-cup resin balancetrial fit of engine to fuselage
Enlarged gate for trailerOutriggertrial fit of oil cooler
Enlarging aft baffle cable slotsover-centre test bossestrial fit of port baffle
Enlarging aileron hinge screw holesoverflow bottle mountedtrial fit of rudder shaft seals
EURO29 bolt differencesoverflow bottle straptrial fit of silencer
EURO29 bolts lock-wiredoverhead panel bracket layuptrial fit of stainless steel firewall patch
exhaust hole in cowloverhead panel bracketstrial fit of stainless steel lower firewall panel
exhaust pipe nutsoverhead panel fittedtrial fit of starboard baffle
F18 filler neck BID strapsoverhead panel layuptrial fit of trimmed firewall panels
F18 filler neck fittedpainting flap hangerstrial fit of upper stainless steel firewall panel flange
F18 foam spacerpanel holes for warning lightstrial fit of upper stainless steel firewall panels
F18 foam spacer fittedparting off stepped washerTrial hole for transponder head
F33 door latch cover trimmingparts sprayed whitetrial of seal on duct side
Failed bond on flap root extensionParts spread out on lawntrial setting of wing incidence
failed funnel flatteningPatch for aft baffle fuel hose slottrial setting of wing incidence 2
failed rivet replacedPitot-static mast connexionTrim and anti-servo tab
Filing CS09Apitot-static systemtrim tabs rubbed down
Filing down CS07/CS08Pitot-static tubing connectorstrimming stainless steel sheet with power nibbler
filing engine mount weld filletPlastic bottlesTubing clip bond failure
filling tailplaneplastic conduit through baggage baytunnel slot for tie-bar
filling trim link slotplastic tub for flap cross-tube guideTurnbuckles fitted forward and rubbing on floor
fin splash moulding taped in placeplenum chamberturning down AN840-6D boss
fin tip flanges trimmedplotting trim link rod pathturning down hex aluminium bar for FRFF
Fin wedged openpoor sewing on battery straptyre clearance
final fit of cooling ductport aileron balance after sanding undersideunderside of starboard aileron with paint and filler sanded off
Finger strainers and tank adaptorsPort aileron bellcrank mountUnidentified objects in fuel tank
Finishing rudder port sidePort flap aligned with aileronUnsatisfactory Nicopress sleeve
Finishing rudder tipport flap BID patchupper bump stop
fire extinguisher mountedPort flap clamped to templateUSB outlet on main panel
fire extinguisher re-fitport flap filledvacuum port adaptors
firesleeve dip penetration testport rudder crank and spring fittedvacuum pump pad cover
firesleeve dip penetration testPort tip flange misalignmentvacuum system
firesleeve ends dippedPort wing aileron bellcrankvent hardware trial fitting
firesleeve on firewall feed-throughPort wing aileron closeout cutawayVoid between rib and bottom skin
Firesleeve on fuel pump hosePort wing on flap templateW35 gussets on tie-bar
firewall clearance with port rudderPort wing skin pre-bondingwater hose routing
firewall clearance with starboard rudderPort wing skin slotted to clear tip flange misalignmentwater pipe routing test
firewall fuel elbowPort wing tilted onto LEwater trap adaptors
firewall panels trimmed to clear rudder systemPosition sternpost holeWeekend Workshop
firewall pass-through from M8 boltPositioning CS09Weights for wing skin bonding
firewall pass-through made from jam funnelPotential control restrictionWet sanding with guide coat
firewall templatespower distribution terminalsWing conduit installation
firewall wire bundle testPreparing for spar bush bondingWing fairing protector
first plan of items on firewallpreparing to fill tailplaneWing leveller servo mounted
first successful wing rigpreparing to sand starboard aileronWing on table for pin fitting
first trim of cooling ductprofiling tailplaneWing pin fitting
Fit trim servoprofiling tailplaneWing rear closeout spacer
fitting baffle edge sealsprofiling tailplaneWing repair completed
Fitting fuel valve mounting plateprofiling tailplaneWing skin bonded
Fitting fuselage rear bulkheadprofiling tailplaneWing skin cut away for repair
Fitting Mod 70 rubbing stripsprofiling tailplaneWing slings
Fitting rubber to new aft baffle fuel hose slotprofiling tailplanewing socket hardpoint layups 1
fitting tailwheel tracks in trailerprofiling tailplaneWing TE aileron closeout trimming
Fitting trailer floorprop drive dowels safety-wiredWing tip support
fitting vent hardware to F18prop stored in garageWings first pinned together
FL15 paint removedpropeller brush bracket checkwingtip to wingtip string test
FL15 rubbing strip positionPropeller deliverywingtip to wingtip string test 2
FL15 rubbing stripspulley mount trialwirebook
FL15 rubbing strips bondedradiator to oil cooler gaps not sealedWitness marks on CS22 & CS23
FL18 hinge bracket alignment - first tryRadio and intercomWooden block for rudder hinge vee
FL18 hinge brackets on straight-edgeradio panel instruments trial fitXTW06 alignment
FL18s re-positionedradio panel populatedXTW06 alignment template
FL22 starboard alignmentradio panel trial fitXTW15 magnetic retainer
Flapradio panel water-jet cut
Flap attachment bolt almost threadboundre-align firewall fuel elbow

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