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

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tickgo to list of milestonestick Navigation & Acknowledgements
29mm spacers for aligning rudder pedalsfitting vent hardware to F18pulley mount trial
35mm film can spray gunFL15 paint removedRadio and intercom
3D Mouldings label in bonding areaFL15 rubbing strip positionradio panel instruments trial fit
90mm spacer block for rudder pedal shaft alignmentFL15 rubbing stripsradio panel populated
A bad layupFL15 rubbing strips bondedradio panel trial fit
Abrading for BID under FL18sFL18 hinge bracket alignment - first tryradio panel water-jet cut
Access hole in cockpit module tunnelFL18 hinge brackets on straight-edgeRe-bonding port wing TE
Access hole positions transferred insideFL18s re-positionedre-doing spar hole layups
access panel and support rib layupsFL22 starboard alignmentreaching into footwell
Adjusting height of wing slingFlapRear upper fuselage holes marked
aft baffleFlap attachment bolt almost threadboundrebate around tunnel slot for tie-bar
Aft port wing pin socket pad shimmedflap cross-tube guide fittedredundant cylinder shroud
Aft wing pin socket padsflap hinge arrangementsRedux pre-bond thickness on port wing ribs
Aft wing socket new hole - portFlap hinge clampRedux spread ready for wing skin bond
Aileron drive bolt alignmentFlap hinge plate alignment toolsRedux surplus after pre-bonding
aileron fillingFlap hinge plates FL1 FL2 FL3Redux test piece
Aligning flap hinge plates FL1 FL2 FL3flap pushrod clearance improvedRedux test piece broken
alignment fixture for flap cross-tube guideflap pushrod clearance problemRedux thickness on starboard rib flanges
alternator cable securedflap pushrod hole in tunnel bulkheadregulator mounted on firewall
altimeter knob shaft extenderFlap root extension inner layupsRelease film for wing skin pre-bonding
AN970-3 washers modifiedFlap root extension outer layupsRemoving a bad top-hat layup
Arbour press ram modificationflap slot damage insideRemoving another bad top-hat layup
attaching Belleville washer to spar cupfloxing vent pipe holesRemoving flap root extension former
axle bolt lockwireFlying but not in a EuropaResin pump calibration checks
Bad and good airline connectorsFoam supports carved to fit under footwell floorsretract bungee re-fitted
baggage bay - first edge layupsForward socket heater clampretract bungee secured
battery boxForward wing socket bolts - portRetract down-latch
battery box mouldForward wing socket bolts - starboardretract lever fitted
battery isolator etc mountedfuel filler trial fittingretract lever guide plate
battery strap sewingFuel gauge sender headRetract lever holes
Beam balance fine adjusterfuel hose routing in tunnelRetract lever position
blue foam for seat bases and battery box mouldfuel hose with clip in tunnelRetract lever slot cut
blue foam side stiffenerFuel level sensor amplifierRetract lever slot marking-out
Bonding clip for sight gauge tubingFuel level sensor tee-pieceRig tailplanes
Bonding CS02 and CS03fuel line from flow sender to unionRight-angle adaptor for wing-leveller servo
Bonding CS05 to CS03fuel line union at wheel wellright-angle connector cover for wing leveller servo
bonding fin tipfuel pipe from gascolator to pumpRouting out brown foam
Bonding in FL18sfuel pipe from pump to flow senderRowland with hammer
bonding in flap cross-tube guidefuel pipe to gascolatorrubbing blocks on tower
Bonding in port wing horn boxesFuel pipes from tank to selector valveRudder bellcrank split-pins
Bonding on fuselage top mouldingFuel pump clearanceRudder cable turnbuckles installed aft
Bonding pitot/static tubing clipsfuel systemrudder deflection 2nd check
bonding shoot bolt guide in doorFuel tank adaptorsrudder deflection first check
bonding side stiffenersfuel tank C adaptor fittedRudder flange damage
bonding studs to underside of tunnelFuel valve trial assemblyrudder hung on clecos
bonding wing root fairingsfuel ventRudder jig for sanding
Boring crank arm holefuselage centreline marksRudder layup
Both wings in garagefuselage damage at flap cross-tubeRudder port side filled
Bottom fuselage half upside-downFuselage dollyrudder pulley access covers
bracket for fuel line unionfuselage hard-points for wing pin socketsRudder starboard side polished
bracket formers from blue foamfuselage in trailerSagging filler
Bracket layups held in placefuselage levelling jigSander for curved parts
brake bolt lockwireFuselage on starboard sideSanding filler on rudder
Brake filler hole coverFuselage parked tail end inSandvik abrader
Bridge to hold down tubing clipsfuselage ready to go into trailerSatisfactory Nicopress sleeve
brown foam cover for tie-bar tunnel slotFuselage spar hole layupScrew fouling rudder cable
BT Research Labs Martlesham HeathFuselage spar hole repairScrew spacers for stiffnuts
Bulkhead location on fuselage top mouldingfuselage top propped upscrewcutting AN840-6D boss
card template for aft bafflefuselage top upside down in garageseat base foam proposals
card template for aft baffle unfoldedFuselage trim lineServo bellcrank relieved
Carving flap root extension formerFuselage upside-downServo cable clips
Carving flap root extension formergap for upper bump stopServo link rod fouling
Carving flap root extension formergaps in duct around coolersServo link rod length
carving foam for starboard seat recessGarden shedServo mount bolts safetied
Chamfer for tailwheel arm mountgascolator hatch splash mouldingSetup for first aileron hinge hole
check tailplane torque tube levelGel coat drips & runsshaping door handles
check XTW06 lineup for XTW15 bondingGel-coat trial finishshelf cut out
Checking CS05 centre distanceGel-coating ruddershoot bolt alignment
Cleco sternpost in placeGPO Research Station Dollis Hillshoot bolt guides bonded
clips retaining wires to fuel pump and flow sensorHandle for lifting forward end of fuselageshoot bolt guides in door frame
clips securing brake lineheadrest hole for wiresshort turnbuckle
Cockpit module bondingheating resistors on aileron quick-connect bellcranksshortening FL15 cross-tube
Cockpit module pre-bond inspection rigHeating resistors on wing pin socketsSling for fuselage top moulding
Cockpit module spar bush bondingHolder for thinning FL11Spar - bellcrank clearance
Cockpit module trimmed and frettedhole in stick base socket for wiresspar guides
Cockpit module tunnel edges trimmedHoles in the wing skinspar hole layups removed
conduit for VHF comms antenna cableHorn-box recess enlargedSplash layup temporary bonding
conduit hole in rear bulkheadhub and brake lockwireSplash moulding for top of containment bulkhead
conduit on baggage-bay roofInitial fit of fuselage top mouldingSplash moulding on brackets
Conduit sleeves and tube clipsInstalling carb heat pipingSpraying CS05 torque tubes
Containment bulkhead clearanceInstrument module brackets.starboard aft baffle fitting
Containment bulkhead sides bowedInstrument module cutout for radio panelstarboard baffle fitting
cooling duct final fittinginstrument module inner flangestarboard baffle forward bend
cooling duct fittedinstrument module ventilation holesStarboard wing conduit tryout
cooling duct marked for 2nd triminstrument panels black anodizedStarboard wing on car roof bars
cooling duct with first fit of sealsInstrument sub-panelStarter wiring in baffle location
cooling fanIpswich airportstick-top switch mount
cowl and propeller test assemblyjig for thinning blue foamStraightedge on fin
cowl assembled with clecosKeeping rudder pedals at neutralstrobe power supply mounted
Cowl first assemblykink in fin splash mouldingstuds bonded to underside of tunnel
cowl first trial fit on fuselageKit partsTailplane alignment
cowl fit after trimmingLanding gear mount corrosionTailplane outboard rib
cowl fittedlaser etched legendsTailplane pip pin recesses
cowl fitted with clecoslayup covering tie-bar tunnel slotTailplane tips
cowl fitted with temporary screwslayup filed back to expose Belleville washertailwheel arm mount pad ground down
cowl overlap on fuselagelayup for internal-corner conduit clipsTailwheel arm mount plywood stack
cowl trimming guide linelayup on aft face of baggage bay bulkheadtailwheel cables with turnbuckles
cowl with propshaft holelayup on aft face of baggage bay bulkhead with peel-plyTailwheel mount painted
Crank arm clamped to CS03 for drillinglevel fuselageTank spacer layup
crowbar etc mountedLevelling fuselageTank support layups
CS04 clamped in positionLG02 propped up to check cable clearancetank vent assembly curing
CS04 shaped to fitLG02A profilingtank vent pipe to filler
CS10 pivot markingsLumps on wing top skinTE support for sanding
CS14 alignmentmachining vacuum adaptorTemporarily tensioning rudder cables - first method
Cupboards for glass and resinmagneto lead feedthroughTemporarily tensioning rudder cables - second method
Curing BID strips at rear of cockpit moduleMaking clips for stall-warner tubeThin patches on rudder root
Curing tent over inverted fuselageMaking fuel tank adaptorsThin spots on rudder hinge vee
Cutout for tailwheel arm mountmaking internal-corner conduit clipsthrottle lever handle
Cutting away TE between aileron and flapMaking new top-hat layups between door framestie-bar plywood brace bonding
Cutting back FL18Smaking replica of LG frame for fitting firewallTools
Cutting out fuselage rear bulkheadmaking stick-top switch mount (1)Top of containment bulkhead trimmed
cutting semi-circular hole in bafflemaking stick-top switch mount (2)Torque tube support
Cutting trim slotsmaking stick-top switch mount (3)TP10 drill setup
Dispenser bottle nozzlesmaking stick-top switch mount (4)TP10 drill setup
dolly hold-down nutplate locationsMaking support sleeves for wing conduitTP12 - TP10 trial fit
door handle partsmaking tailwheel towing deviceTP14 split pins
door handle trial assemblyMaking wooden handle for brake levertrail assembly of cooling duct
door hinge gapmanifold pressure restrictortrail fit of water radiator
door hinge recesses maksedMark lower rear access hole positiontrailer pulley adrift
door hinges maskedMark Mod 77 bracket positionTrailer ramp gas springs
door latch fittingMarking holes for LG01 top tube drillingtrailer spar clamp change
door pushrod angle slotMarking out for fuel gauge sendertrailer stuff moved out to get at wings
door pushrod tangsmarking out for tailwheel tracks in trailertrailer winch rope fairlead fitting
door rebate impressionsmarking slot for flap actuator cross-tubetrailer winch rope fairlead on frame
doors fittedMass-balance weights paintedtrailer winch rope fairlead on spar support
doors hingedMilling the slot in the rudder cable guidestrailer winch wire rope clamp
Double marking of holes in cockpit moduleMinitool jigsaw blade clamp modificationtrailer winch wire rope route
Double tube clip materialModel aeroplanestrailer wing dolly restraints
Dowel roller for inside wing repairModified irontrailer wiring clear of winch rope
Drill CS17Modify rear bulkhead for Mod 77transponder installation
Drill TP10mount for Airbox Aware 5transponder loom lacing
Drilling pushrod ends using vee-blocksmoving fuselage to rigging dollytrial fit of cooling duct
Drilling the torque tube hole in the seat faceNeville Eyre's cowltrial fit of engine to fuselage
duct side puzzleNew peel-ply roll mounttrial fit of oil cooler
duct sides versus templatenew shoot bolt holetrial fit of silencer
duct-tape masking for aileron bellcrank pad bondingnutplates for dolly screwsTrial hole for transponder head
Dummy pitot-static mastodyssey batterytrial of seal on duct side
Dummy TS05offering engine to fuselagetrial setting of wing incidence
Dynon D2 & Airbox Aware 5 mountedoil pipe routing testtrial setting of wing incidence 2
electrical items on firewallOne-cup resin balanceTrim and anti-servo tab
electrical wiring on firewall itemsOutriggerTubing clip bond failure
Engine alignment checkover-centre test bossestunnel slot for tie-bar
engine on craneoverflow bottle mountedTurnbuckles fitted forward and rubbing on floor
engine without shroudoverflow bottle strapturning down AN840-6D boss
Enlarged gate for traileroverhead panel bracket layuptyre clearance
Enlarging aileron hinge screw holesoverhead panel bracketsUnidentified objects in fuel tank
EURO29 bolt differencesoverhead panel fittedUnsatisfactory Nicopress sleeve
EURO29 bolts lock-wiredoverhead panel layupupper bump stop
exhaust hole in cowlpainting flap hangersUSB outlet on main panel
F18 filler neck BID strapspanel holes for warning lightsvacuum port adaptors
F18 filler neck fittedparting off stepped washervacuum pump pad cover
F18 foam spacerparts sprayed whitevacuum system
F18 foam spacer fittedParts spread out on lawnvent hardware trial fitting
F33 door latch cover trimmingPitot-static mast connexionVoid between rib and bottom skin
Failed bond on flap root extensionpitot-static systemW35 gussets on tie-bar
failed funnel flatteningPitot-static tubing connectorswater pipe routing test
Filing CS09APlastic bottleswater trap adaptors
Filing down CS07/CS08plastic conduit through baggage bayWeekend Workshop
filing engine mount weld filletplastic tub for flap cross-tube guideWeights for wing skin bonding
filling trim link slotplenum chamberWet sanding with guide coat
fin splash moulding taped in placeplotting trim link rod pathWing conduit installation
fin tip flanges trimmedpoor sewing on battery strapWing fairing protector
Fin wedged openPort aileron bellcrank mountWing leveller servo mounted
final fit of cooling ductPort flap aligned with aileronWing on table for pin fitting
Finger strainers and tank adaptorsport flap BID patchWing pin fitting
Finishing rudder port sidePort flap clamped to templateWing rear closeout spacer
Finishing rudder tipport flap filledWing repair completed
fire extinguisher mountedPort tip flange misalignmentWing skin bonded
fire extinguisher re-fitPort wing aileron bellcrankWing skin cut away for repair
firesleeve on firewall feed-throughPort wing aileron closeout cutawayWing slings
firewall pass-through from M8 boltPort wing on flap templatewing socket hardpoint layups 1
firewall pass-through made from jam funnelPort wing skin pre-bondingWing TE aileron closeout trimming
firewall templatesPort wing skin slotted to clear tip flange misalignmentWing tip support
firewall wire bundle testPort wing tilted onto LEWings first pinned together
first plan of items on firewallPosition sternpost holewingtip to wingtip string test
first successful wing rigPositioning CS09wingtip to wingtip string test 2
first trim of cooling ductPotential control restrictionwirebook
Fit trim servopower distribution terminalsWitness marks on CS22 & CS23
Fitting fuel valve mounting platePreparing for spar bush bondingWooden block for rudder hinge vee
Fitting fuselage rear bulkheadprop drive dowels safety-wiredXTW06 alignment
Fitting Mod 70 rubbing stripsprop stored in garageXTW06 alignment template
fitting tailwheel tracks in trailerpropeller brush bracket checkXTW15 magnetic retainer
Fitting trailer floorPropeller delivery

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