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

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29mm spacers for aligning rudder pedalsflap pushrod clearance improvedrebate around tunnel slot for tie-bar
35mm film can spray gunflap pushrod clearance problemredundant cylinder shroud
3D Mouldings label in bonding areaflap pushrod hole in tunnel bulkheadRedux pre-bond thickness on port wing ribs
90mm spacer block for rudder pedal shaft alignmentFlap root extension inner layupsRedux spread ready for wing skin bond
A bad layupFlap root extension outer layupsRedux surplus after pre-bonding
Abrading for BID under FL18sflap slot damage insideRedux test piece
Access hole in cockpit module tunnelflaps stored in cockpitRedux test piece broken
Access hole positions transferred insideFlettner strips bonded to tabsRedux thickness on starboard rib flanges
access panel and support rib layupsfloxing vent pipe holesregulator mounted on firewall
Adjusting height of wing slingFlying but not in a EuropaRelease film for wing skin pre-bonding
aft baffleFoam supports carved to fit under footwell floorsRemoving a bad top-hat layup
Aft port wing pin socket pad shimmedForward socket heater clampRemoving another bad top-hat layup
Aft wing pin socket padsForward wing socket bolts - portremoving engine
Aft wing socket new hole - portForward wing socket bolts - starboardremoving engine mount fixings
aileron balance after paintingFuel elbow adjustedRemoving flap root extension former
aileron balance after painting with dimension linesfuel filler trial fittingremoving old connectors from fuel filler
aileron balance after sanding undersidesFuel gauge sender headremoving old connectors from fuel filler
aileron balance check after paint removalfuel hose clearance from engine mountResin pump calibration checks
aileron balance check after paint removalfuel hose firewall fitting mockupretract bungee re-fitted
aileron balancing after 2nd paintingfuel hose in tunnelretract bungee secured
Aileron drive bolt alignmentfuel hose marked for cutting at firewallRetract down-latch
aileron fillingfuel hose protection on aft baffleretract lever fitted
Aligning flap hinge plates FL1 FL2 FL3fuel hose protection on aft baffle - wrong sizeretract lever guide plate
alignment fixture for flap cross-tube guidefuel hose routing in tunnelRetract lever holes
alternator cable securedfuel hose with clip in tunnelRetract lever position
altimeter knob shaft extenderfuel hose, tunnel to firewallRetract lever slot cut
AN970-3 washers modifiedFuel level sensor amplifierRetract lever slot marking-out
anchor nuts for baffle fixingfuel level sensor cover fittedRig tailplanes
Arbour press ram modificationFuel level sensor tee-pieceRight-angle adaptor for wing-leveller servo
attaching Belleville washer to spar cupfuel line from flow sender to unionright-angle connector cover for wing leveller servo
axle bolt lockwirefuel line union at wheel wellRouting out brown foam
Bad and good airline connectorsfuel pipe from gascolator to pumpRowland with hammer
baffle clearance at oil tankfuel pipe from pump to flow senderrubber parts of rudder shaft seal
baffle clearance from oil hosesfuel pipe to gascolatorrubbing blocks on tower
baffle clearance from oil tank elbowFuel pipes from tank to selector valveRudder bellcrank split-pins
baffle clearance from water hoseFuel pump clearancerudder cable seal port
baffle edge sealsfuel return firewall fitting completedrudder cable seal starboard
baggage bay - first edge layupsfuel return line in cockpitRudder cable turnbuckles installed aft
battery boxfuel return restrictorrudder crank firewall relief marking
battery box mouldfuel systemrudder deflection 2nd check
battery isolator etc mountedFuel tank adaptorsrudder deflection first check
battery strap sewingfuel tank C adaptor fittedRudder flange damage
Beam balance fine adjusterFuel valve trial assemblyrudder hung on clecos
blue foam for seat bases and battery box mouldfuel ventRudder jig for sanding
blue foam side stiffenerfuselage centreline marksRudder layup
Bonding clip for sight gauge tubingfuselage damage at flap cross-tubeRudder port side filled
Bonding CS02 and CS03Fuselage dollyrudder pulley access covers
Bonding CS05 to CS03fuselage hard-points for wing pin socketsrudder shaft seal fixings
bonding fin tipfuselage in trailerrudder shaft seal fixings
bonding Flettner strips to tabsfuselage levelling jigrudder shaft seal fixings
Bonding in FL18sFuselage on starboard siderudder shaft seal fixings
bonding in flap cross-tube guideFuselage parked tail end inrudder shaft seal fixings
Bonding in port wing horn boxesfuselage ready to go into trailerrudder shaft seal fixings
Bonding on fuselage top mouldingFuselage spar hole layuprudder shaft seal fixings
Bonding pitot/static tubing clipsFuselage spar hole repairRudder shaft seals fitted
bonding shoot bolt guide in doorfuselage top propped upRudder starboard side polished
bonding side stiffenersfuselage top upside down in garageSagging filler
bonding studs to underside of tunnelFuselage trim linesanded through paint on starboard aiieron
bonding wing root fairingsFuselage upside-downSander for curved parts
Boring crank arm holeFuselage winched out of trailerSanding filler on rudder
Both wings in garagegap for upper bump stopsanding paint off stbd aileron upper surface
Bottom fuselage half upside-downgaps in duct around coolerssanding paint off underside of starboard aileron
Bowden cable protection on aft baffleGarden shedsanding port aileron underside
bracket for fuel line uniongascolator hatch splash mouldingsanding port aileron upper side
bracket formers from blue foamGel coat drips & runssanding through filler on starboard aileron
Bracket layups held in placeGel-coat trial finishSandvik abrader
brake bolt lockwireGel-coating rudderSatisfactory Nicopress sleeve
Brake filler hole covergetting ready to fill tailplaneScrew fouling rudder cable
Bridge to hold down tubing clipsGPO Research Station Dollis HillScrew spacers for stiffnuts
brown foam cover for tie-bar tunnel slotHandle for lifting forward end of fuselagescrewcutting AN840-6D boss
BT Research Labs Martlesham Heathheadrest hole brown foam routed outseat base foam proposals
Bulkhead location on fuselage top mouldingheadrest hole for wiresServo bellcrank relieved
bush for Dremel cutoff wheelheating resistors on aileron quick-connect bellcranksServo cable clips
carburettor Bowden cable fittingsHeating resistors on wing pin socketsServo link rod fouling
card template for aft baffleHolder for thinning FL11Servo link rod length
card template for aft baffle unfoldedhole in stick base socket for wiresServo mount bolts safetied
Carving flap root extension formerHoles in the wing skinSetup for first aileron hinge hole
Carving flap root extension formerHorn-box recess enlargedshaping door handles
Carving flap root extension formerhose cut for fitting endshelf cut out
carving foam for starboard seat recesshose end assembledshoot bolt alignment
Chamfer for tailwheel arm mounthose end damageshoot bolt guides bonded
check tailplane torque tube levelhose fitted to socketshoot bolt guides in door frame
check XTW06 lineup for XTW15 bondinghose insertion checkshort turnbuckle
Checking CS05 centre distancehose to fuel pump trial fitshortening FL15 cross-tube
Cleco sternpost in placehose to fuel pump trial fitSling for fuselage top moulding
clips retaining wires to fuel pump and flow sensorhub and brake lockwireslot for fuel hose on aft baffle
clips securing brake lineInitial fit of fuselage top mouldingsoft sanding block
Cockpit module bondingInstalling carb heat pipingspacing fuel hose from engine mount
Cockpit module pre-bond inspection rigInstrument module brackets.spanner jammed on firewall fuel elbow
Cockpit module spar bush bondingInstrument module cutout for radio panelSpar - bellcrank clearance
Cockpit module trimmed and frettedinstrument module inner flangespar guides
Cockpit module tunnel edges trimmedinstrument module ventilation holesspar hole layups removed
conduit for VHF comms antenna cableinstrument panels black anodizedSplash layup temporary bonding
conduit hole in rear bulkheadInstrument sub-panelSplash moulding for top of containment bulkhead
conduit on baggage-bay roofIpswich airportSplash moulding on brackets
Conduit sleeves and tube clipsjig for thinning blue foamSpraying CS05 torque tubes
confirming correct connectors for fuel fillerjoining baffle partsstainless steel firewall fitting problem
Containment bulkhead clearanceKeeping rudder pedals at neutralstainless steel firewall patch
Containment bulkhead sides bowedkink in fin splash mouldingstainless steel firewall patch fitted
cooling duct final fittingKit partsstarboard aft baffle fitting
cooling duct fittedLanding gear mount corrosionstarboard baffle fitting
cooling duct marked for 2nd trimlaser etched legendsstarboard baffle forward bend
cooling duct with first fit of sealslathe changewheels for threading bushstarboard rudder crank and spring fitted
cooling fanlayup covering tie-bar tunnel slotStarboard wing conduit tryout
cowl and propeller test assemblylayup filed back to expose Belleville washerStarboard wing on car roof bars
cowl assembled with clecoslayup for internal-corner conduit clipsstarter cable bush
Cowl first assemblylayup on aft face of baggage bay bulkheadstarter cable bush manufacture
cowl first trial fit on fuselagelayup on aft face of baggage bay bulkhead with peel-plystarter cable bush threading
cowl fit after trimminglevel fuselageStarter wiring in baffle location
cowl fittedLevelling fuselagesteel parts of rudder shaft seal
cowl fitted with clecosLG02 propped up to check cable clearancestick-top switch mount
cowl fitted with temporary screwsLG02A profilingstorage of painted tailplanes
cowl overlap on fuselagelower firewall panel fittedStraightedge on fin
cowl positioning jigLumps on wing top skinstrobe power supply mounted
cowl trimming guide linemachining vacuum adaptorstuds bonded to underside of tunnel
cowl with propshaft holemagneto lead feedthroughsupport for trim tabs
Crank arm clamped to CS03 for drillingMaking clips for stall-warner tubeTailplane alignment
crowbar etc mountedMaking fuel tank adaptorstailplane holders in trailer
crowfoot spannersmaking internal-corner conduit clipsTailplane outboard rib
CS04 clamped in positionMaking new top-hat layups between door framesTailplane pip pin recesses
CS04 shaped to fitmaking protective cover for fuel level senderTailplane tips
CS10 pivot markingsmaking replica of LG frame for fitting firewalltailwheel arm mount pad ground down
CS14 alignmentmaking stick-top switch mount (1)Tailwheel arm mount plywood stack
Cupboards for glass and resinmaking stick-top switch mount (2)tailwheel cables with turnbuckles
Curing BID strips at rear of cockpit modulemaking stick-top switch mount (3)Tailwheel mount painted
curing Flettner strip fillermaking stick-top switch mount (4)Tank spacer layup
Curing tent over inverted fuselageMaking support sleeves for wing conduitTank support layups
custom hex drill bitmaking tailwheel towing devicetank vent assembly curing
Cutout for tailwheel arm mountmaking threading tool holdertank vent pipe to filler
Cutting away TE between aileron and flapmaking throttle box custom washerTE support for sanding
Cutting back FL18Smaking up a hose endTemporarily tensioning rudder cables - first method
Cutting out fuselage rear bulkheadMaking wooden handle for brake leverTemporarily tensioning rudder cables - second method
cutting semi-circular hole in bafflemanifold pressure restrictortest alignment of rudder shaft seal
Cutting trim slotsMark lower rear access hole positiontest fit of AN nut on FRFF
Dispenser bottle nozzlesMark Mod 77 bracket positiontest fit of fuel line elbow on firewall
dolly hold-down nutplate locationsMarking holes for LG01 top tube drillingTest fit of NPT thread in end of FRFF
door handle partsMarking out for fuel gauge sendertesting stainless steel firewall fit
door handle trial assemblymarking out for tailwheel tracks in trailerThin patches on rudder root
door hinge gapmarking slot for flap actuator cross-tubeThin spots on rudder hinge vee
door hinge recesses maksedMass-balance weights paintedthrottle box with custom washers
door hinges maskedMilling the slot in the rudder cable guidesthrottle lever handle
door latch fittingMinitool jigsaw blade clamp modificationtie-bar plywood brace bonding
door pushrod angle slotModel aeroplanesTools
door pushrod tangsModified ironTop of containment bulkhead trimmed
door rebate impressionsModify rear bulkhead for Mod 77Torque tube support
doors fittedmount for Airbox Aware 5TP10 drill setup
doors hingedmoving fuselage to rigging dollyTP10 drill setup
Double marking of holes in cockpit moduleNeville Eyre's cowlTP12 - TP10 trial fit
Double tube clip materialnew fuel filler connectors installedTP14 split pins
Dowel roller for inside wing repairNew peel-ply roll mounttrail assembly of cooling duct
Drill CS17new resin balance placardtrail fit of water radiator
Drill TP10new shoot bolt holetrailer floor rot
Drilling pushrod ends using vee-blocksnutplates for dolly screwstrailer pulley adrift
Drilling the torque tube hole in the seat faceodyssey batterytrailer pulley repair
duct side puzzleoffering engine to fuselageTrailer ramp gas springs
duct sides versus templateoil hose return routingtrailer spar clamp change
duct-tape masking for aileron bellcrank pad bondingoil hose routingtrailer stuff moved out to get at wings
Dummy pitot-static mastoil hose routing at tanktrailer winch rope fairlead fitting
Dummy TS05oil hoses passing rear starboard baffletrailer winch rope fairlead on frame
Dynon D2 & Airbox Aware 5 mountedoil pipe routing testtrailer winch rope fairlead on spar support
electrical items on firewalloil tank bracket screwtrailer winch wire rope clamp
electrical wiring on firewall itemsoil tank fittedtrailer winch wire rope route
Engine alignment checkold connectors on fuel fillertrailer wing dolly restraints
engine mount bolt split pinsold connectors removed from fuel fillertrailer wiring clear of winch rope
Engine mount re-fittedOne-cup resin balancetransponder installation
engine on craneOutriggertransponder loom lacing
engine removedover-centre test bossestrial fit of all stainless steel firewall panels
engine sump banjo rotated and lockedoverflow bottle mountedtrial fit of assembled upper stainless steel firewall panels
engine without shroudoverflow bottle straptrial fit of cooling duct
Enlarged gate for traileroverhead panel bracket layuptrial fit of engine to fuselage
Enlarging aileron hinge screw holesoverhead panel bracketstrial fit of oil cooler
EURO29 bolt differencesoverhead panel fittedtrial fit of port baffle
EURO29 bolts lock-wiredoverhead panel layuptrial fit of rudder shaft seals
exhaust hole in cowlpainting flap hangerstrial fit of silencer
exhaust pipe nutspanel holes for warning lightstrial fit of stainless steel firewall patch
F18 filler neck BID strapsparting off stepped washertrial fit of stainless steel lower firewall panel
F18 filler neck fittedparts sprayed whitetrial fit of starboard baffle
F18 foam spacerParts spread out on lawntrial fit of trimmed firewall panels
F18 foam spacer fittedPitot-static mast connexiontrial fit of upper stainless steel firewall panel flange
F33 door latch cover trimmingpitot-static systemtrial fit of upper stainless steel firewall panels
Failed bond on flap root extensionPitot-static tubing connectorsTrial hole for transponder head
failed funnel flatteningPlastic bottlestrial of seal on duct side
failed rivet replacedplastic conduit through baggage baytrial setting of wing incidence
Filing CS09Aplastic tub for flap cross-tube guidetrial setting of wing incidence 2
Filing down CS07/CS08plenum chamberTrim and anti-servo tab
filing engine mount weld filletplotting trim link rod pathtrim tabs rubbed down
filling tailplanepoor sewing on battery straptrimming stainless steel sheet with power nibbler
filling trim link slotport aileron balance after sanding undersideTubing clip bond failure
fin splash moulding taped in placePort aileron bellcrank mounttunnel slot for tie-bar
fin tip flanges trimmedPort flap aligned with aileronTurnbuckles fitted forward and rubbing on floor
Fin wedged openport flap BID patchturning down AN840-6D boss
final fit of cooling ductPort flap clamped to templateturning down hex aluminium bar for FRFF
Finger strainers and tank adaptorsport flap filledtyre clearance
Finishing rudder port sideport rudder crank and spring fittedunderside of starboard aileron with paint and filler sanded off
Finishing rudder tipPort tip flange misalignmentUnidentified objects in fuel tank
fire extinguisher mountedPort wing aileron bellcrankUnsatisfactory Nicopress sleeve
fire extinguisher re-fitPort wing aileron closeout cutawayupper bump stop
firesleeve on firewall feed-throughPort wing on flap templateUSB outlet on main panel
firewall clearance with port rudderPort wing skin pre-bondingvacuum port adaptors
firewall clearance with starboard rudderPort wing skin slotted to clear tip flange misalignmentvacuum pump pad cover
firewall fuel elbowPort wing tilted onto LEvacuum system
firewall panels trimmed to clear rudder systemPosition sternpost holevent hardware trial fitting
firewall pass-through from M8 boltPositioning CS09Void between rib and bottom skin
firewall pass-through made from jam funnelPotential control restrictionW35 gussets on tie-bar
firewall templatespower distribution terminalswater hose routing
firewall wire bundle testPreparing for spar bush bondingwater pipe routing test
first plan of items on firewallpreparing to fill tailplanewater trap adaptors
first successful wing rigpreparing to sand starboard aileronWeekend Workshop
first trim of cooling ductprofiling tailplaneWeights for wing skin bonding
Fit trim servoprofiling tailplaneWet sanding with guide coat
fitting baffle edge sealsprofiling tailplaneWing conduit installation
Fitting fuel valve mounting plateprofiling tailplaneWing fairing protector
Fitting fuselage rear bulkheadprofiling tailplaneWing leveller servo mounted
Fitting Mod 70 rubbing stripsprofiling tailplaneWing on table for pin fitting
fitting tailwheel tracks in trailerprofiling tailplaneWing pin fitting
Fitting trailer floorprofiling tailplaneWing rear closeout spacer
fitting vent hardware to F18prop drive dowels safety-wiredWing repair completed
FL15 paint removedprop stored in garageWing skin bonded
FL15 rubbing strip positionpropeller brush bracket checkWing skin cut away for repair
FL15 rubbing stripsPropeller deliveryWing slings
FL15 rubbing strips bondedpulley mount trialwing socket hardpoint layups 1
FL18 hinge bracket alignment - first tryRadio and intercomWing TE aileron closeout trimming
FL18 hinge brackets on straight-edgeradio panel instruments trial fitWing tip support
FL18s re-positionedradio panel populatedWings first pinned together
FL22 starboard alignmentradio panel trial fitwingtip to wingtip string test
Flapradio panel water-jet cutwingtip to wingtip string test 2
Flap attachment bolt almost threadboundre-align firewall fuel elbowwirebook
flap cross-tube guide fittedRe-bonding port wing TEWitness marks on CS22 & CS23
flap hinge arrangementsre-doing spar hole layupsWooden block for rudder hinge vee
Flap hinge clampre-hanging engineXTW06 alignment
Flap hinge plate alignment toolsreaching into footwellXTW06 alignment template
Flap hinge plates FL1 FL2 FL3Rear upper fuselage holes markedXTW15 magnetic retainer

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