Drilled & tapped holes in LED light mount aluminum slugs, sanded the face of F0 smooth again.

Made fill blocks out of 1/4" thick many-layer fiberglass already laid up. Glued those into a foam blank then did a 2 ply UNI layup over same for a pitot tube mount bulkhead. Cut then glued into F-0 1/2" square aluminum pieces to mount the landing light.

Made delrin and foam parts for the pitot mount. Glued the delrin into the foam and did a 2 ply UNI layup on both sides of the pitot mount.

Cut and sanded F0 flat on the front face. Box tape protected the nose cone then floxed some areas disturbed by removing same. Taped on the nose cone to ensure the flox fixes were the right shape.

Drilled & tapped the delrin spacers for the rudder pedal pivots. Installed set screws, then installed the spacers into the assembly already mounted. Adjusted spacing of master cylinders from center.

Did a 1 ply BID layup over the nose cone.

Cut, carved, twisted, pulled and scraped the inside out of the nose cone.

Finished cutting the nose cone off of the airplane. Cleaned up the front face of F-0. Floxed the 'door' pieces cut out for weight and light access with Clecos.

Starting cutting the nose cone off of the airplane…. 7:^(

Made 4 Delrin donuts to serve as spacers / locaters, with set screws installed, to prevent the rudder pedals from moving side to side

Re-installed the rudder pedals into the airplane. Test fitted the left-most Delrin pivot and sanded the 'glass on the F-28 face until it was level. Re-installed the master cylinders and checked the fit and clearance of all parts and pieces.

Removed the pedals and master cylinders from the plane. Taper pin reamed the holes in the rudder pedal tubes and installed taper pins.

Drilled through the slugs and test installed the rudder pedals and master cylinders with real hardware.

Did a 2 ply BID layup over both sides of the F-22 slugs and did a 2 ply BID layup on the outside of the master cylinder mount pieces

Fitted the slugs into the holes. Sanded glass on both sides of F-22 for the layups to cover.

Drilled 5/8" holes in the back of F-22 for bolt hole filler slugs. Cut out the filler slugs from the fiberglass block I made the other day.

Made a second master cylinder mount bracket. Made spacers for the master cylinder mount brackets. Drilled holes in the glass pieces for nut install and access. Test fit the entire assembly together.

Cut scraps of UNI to size then made a 50-some layer UNI layup for rudder pedal pivot mounting bolt inserts. Weighted the layup down with spacers and cleaned up.

Made one aluminum channel for the master cylinder mount then test fitted the whole assembly together.

Finished cutting & sanding the master cylinder mounts to shape. Drilled 1/4" holes in them and the NG-30s then installed dowels and test fit them into the fuselage.

Removed the small foam piece between the NG-30s under the nose door. Carved, filed, sanded & planed the master cylinder mount pieces until they fit properly.

Used the Fein saw and sander and cut the master cylinder mounting bracket blanks to general size

Made a 3 ply BID and 1 ply UNI layup for the other side of the master cylinder mount blanks. Peel plied, vacuum bagged and cleaned up.

Cut donuts out of the 20+ ply solid layup. Drilled holes then removed foam from the back of the layup blank for the master cylinder mounts. Cleaned up the holes, the donuts, then floxed the donuts and some foam spacers into the holes in the blank. Cut glass for the next layup.

Made a 1/4" PVC blank. Added 3 ply BID and 1 ply UNI for the master cylinder mounts. Made 20-some ply 1/4" layup for inserts. Vacuum bagged the master cylinder mount piece.

Drilled holes and test installed the outboard rudder pedal pivots.

Marked holes for the rudder pedal pivots and test installed the center pieces into the airplane.

Made Delrin blocks for the rudder pedal pivots.

Did a 2 ply BID layup over the plywood fixture, floxed on the foot and the nose wheel pivot mount and cleaned up

Made a plywood fixture for the nose wheel pivot mount, epoxied it to the strut, sanded the strut for then made paper patterns for a layup to cover and affix same

Took the nose pivot off of the strut and starting making a fixture to correctly align and securely mount it

Heat molded yet another lexan window for the nose lights, this one turned out pretty darn good, good enough for a spare anyway. I'll make another one using parchment to prevent sticking and it should be near perfect

36-grit sanded the nose lights compartment insert then test fit it, enlarged the manual extension rod slot and drilled holes in the ballast compartment cover

Made a paper pattern for the backing plate for the lights space cover, then finishing cutting, sanding and drilling to size

Finished installing the manual extension rod for the nose lift by cutting appropriately sized and shaped holes in F-22 and the IP

Microed NG-31 then the sides of the taxi/landing light space then added a 1 ply BID layup to those same parts. Installed the nose lift, measured for the hole in F-22 and drilled it after laying out the manual retract rod's location.

Knife trimmed the previous layup, glued in the aluminum slugs, sanded the landing and taxi light cavity then made a paper pattern for glassing it

36 grit sanded then installed with flox the ballast compartment door insert/mounting bracket, then sanded the bottom of the torsional stiffener, made a flox corner against F-22 and applied the 1 ply BID layup to its bottom

Finished making and fitting the aluminum slugs

Worked on making aluminum slugs for the lexan install bolts in the headlight area

Did the 1 ply BID layup on top of the torsional stiffener and surrounding areas

36 grit sanded the torsional piece, microed foam and floxed the corners

Floxed the torsional stiffener piece into the nose after drilling some nail holes. Peel plied the edges and weighted it into place.

Trimmed the torsional stiffener piece to a smaller size by cutting it into two pieces and trimming each piece; disassembled the nose wheel for shipping and truing

Made another form then cast another plaster of paris mold for the nose lights lexan

Started making another plaster of paris mold

Finished trimming and fitting the torsional piece, dull sanded where it would install and be taped, carved the canard cutout edges of the nose top to final shape and routed foam for a flox corner

Cut the holes in the torsional piece, trimmed it to fit tight against F-22, installed the canard to verify clearance, cut a slot in it, taped it into a bent position then glued it in that position

Unbagged the stiffener piece, then re-tapped the nose light holes and re-installed the nose door temporarily

Finished making the foam for the torsional stiffener, then, cut glass, microed it, did a 1 ply BID layup on both sides, vacuum bagged it and cleaned up

Started making a foam blank for a new/better torsional stiffening piece

Removed the last layup from the vacuum bag, then, baked another piece of lexan to mold it; stuck to the mold this time….

Trimmed & sanded the torsional stiffening piece edges and holes. Did a flox repair over the glass layups that didn't join and vacuum bagged it. Baked my plaster mold to get it completely dry.

Added a 1 ply BID layup to the bottom of the torsional stiffening brace, then vacuum bagged same. Mixed and poured plaster of paris into the nose lights lexan mold form.

Finished making the form for the plaster of paris mold

Started making a (second) mold form for a plaster cast of the nose to use to mold lexan for the lights

Cut holes in the stiffening piece between F-22 and the nose top, then routed a chamfer for glassing. Heat molded a piece of Lexan for the landing/taxi light cover and test fitted same. Didn't fit properly, need to make a new mold.

Cut the hole for the nose lights and dug out the foam, then, trimmed the backing plate to size and shape

Trimmed the excess glass from the inside of the ballast compartment and test fitted the door and door backing plate

Made a 3 ply BID layup on waxed paper, installed same over the foam blank on the inside of the nose door then vacuum bagged the assembly & cleaned up

Made a foam backing piece for the nose door

Made a 3 ply BID layup then applied it over the bottom of the nose.

Made a foam back for the ballast compartment door. Cut glass, then did a 2 ply BID layup on the inside of the ballast compartment, a 1 ply BID layup on the ballast compartment door, then vacuum bagged same & cleaned up.

Trimmed the blank for the ballast compartment door mount, then, glued on a printed sizing diagram, cut and sanded it to exact shape, drilled holes and test installed it. Made a foam backing piece for the nose ballast door then spray-glued it to the back of the door.

Made a 2 BID and 1 UNI ply layup blank for a ballast compartment mount, then, 'installed' it over the ballast compartment door, over plastic wrap, to cure in the correct shape

Cut a hole for the ballast compartment in the nose, removed the foam from below & sanded to shape, sanded the back of the door smooth

Removed peel ply, trimmed & sanded the previous layup, then laid out the door for the ballast compartment

Peel plied all the edges from the previous layup

Did the inside of the nose top - while still on the fuselage; one flox corner, micro, 1 ply BID, 2 ply BID tapes around the door and 1 ply BID tapes around the edges

Cut glass for the next layup

Prepared for the next layup inside the nose top; routed for flox corners, trimmed previous layups, measured & made wax paper templates for tapes & sanded & vacuumed foam

Sanded the edges in preparation for the BID layup that goes on the inside of the nose top, then, made a paper pattern for the fiberglass

Did the 2 ply BID layup on the aft face of the nose door opening

Finished sanding and carving the inside of the nose top, then drilled holes for the nut plates

Made a sanding jig for the inside of the nose top and started sanding the foam behind the flanges to shape

Removed the peel ply from the nose top layup, cut the hole for the nose door, started carving for same and did a 1 ply BID layup for the F-22 torsional brace

Did the 2 ply BID layup on the outside of the nose top; micro, 2 layers, peel ply & clean up

Sanded foam from the previous fix, cleaned up, then cut glass for the next layup

Made a paper template for the nose covering 2 ply BID layup, then made the foam piece for the brace between F-22 and the nose top

Sanded the recess for the nose door and did some foam repair work on the nose

Did the 3 ply BID tapes layup on the inside of the nose door

Made a pattern for then did the 3 ply BID layup for the nose door

Finished carving the nose top and sanded the .2" slot for the canard cover overlap

Started carving the rest of the top of the nose, sanded the .1" deep slots etc.

Made a hockey puck into a nose bumper by drilling it and beveling one edge

Removed the nose strut from the fuselage, sanded the urethane foam spacer and did the 1 ply BID layup over that

Made another plaster of paris mold for the lexan

Made a form for then cast a plaster of paris mold for the nose light lexan

Did a couple of experimental heat molds of Lexan sheet for the landing and taxi light covers

Cut the nosewheel glass over the strut loose, did some trimming and fitting around the nosewheel doors and cleaned up

Did the 2 ply BID, 3 over the strut layup, peel plied and cleaned up

Rebuilt the hardener side of the pump with SS parts and a new reservoir; made a test batch for a scratch test

Floxed in the plywood for the nose puck

Sanded the piece of foam to match the fuselage bottom, then, wax-filled the aluminum slug holes

Cleaned up then cut and fitted a piece of foam to fill in above the nose strut; epoxied it in

Finished installing the nose lift, then, tested the fit of the strut cover and enlarged the slot in F-22

Re-installed nose strut and started re-installing nose lift assembly

Removed the nose strut and noselift assemblies. Sanded the inside of the NG-30s and strut cover flanges with 36 grit. 5 minute epoxied the strut cover in its corret location then floxed it in permanently.

Made some guards then mixed & poured some pour foam to fill where some of the foam had shrunk; marked the strut cover outline on the NG-30s for sanding in preparation for floxing

Finished carving the nose pour foam to shape. I have some voids and some foam that shrank that will need to be re-foamed

Started carving the nose after the pour foam had cured

Made a bunch of pour foam batches and covered the nose so I can re-carve it

Made a couple batches of pour foam and filled some divots in the front of the nose

Removed the strut cover from the vacuum bag, removed the peel ply then trimmed it to shape and cut the hole in for the nose lift

Made an aluminum, adjustable, hard stop for the nose wheel strut to prevent it binding on the the forward rudder pedal tube

Did a 3 ply BID layup over the mold, then peel ply and vacuum bagged it

Finished making mods to the strut cover mold & covered it with tape

Started making mods to the strut cover and a new mold for, hopefully, the last one

Continued fitting the slider to the nose strut cover and decided to abandon the slider idea

Started fitting slider to strut cover

Finished assembling the slider

Cut fiberglass parts out from the blanks I did yesterday and also made aluminum parts for the slider

Made some 2 ply layups for the slider, 3 ply for the slider cover plate

Cut out the slider parts, then, measured & designed a new slider for the nose strut cover

Finished trimming & fitting the strut cover rev 3

Started fitting & trimming the strut cover rev 3

Cut holes and installed some aluminum slugs in the nose puck plywood plate, made some foam pieces for nose carving repair

Did the rev 3 strut cover layup, also, layups for my slider pieces & cover, vacuum bagged

Made a rev 3 strut cover mold, covered it with tape and cleaned up

Worked on the rubber insert for the nose strut cover insert

Worked on the strut cover metal, 'glass and rubber inserts; have a small issue, will have to make a revision 2

Started making an aluminum backing plate for the strut cover

Drilled holes for nut plates in the strut cover

Continued trimming & fitting the strut cover

Made the 1/4" ply nose bumper mount, trimmed & started fitting the strut cover

Did a 3-ply layup over the mold I just made, then vacuum bagged it & cleaned up

Finished making the 'mold' for the rev 2 strut cover, cleaned up, and cut glass and peel ply for the layup

Started making a mold, after drawing a new design, for a nose strut cover revision 2

Continued carving the nose. It's pretty much done, I need to fix a couple spots that didn't turn out well.

Continued carving the nose

Finished trimming & sanding the nose side for the nose top foam to fit, epoxied on same and started carving the whole nose

Shaped the nose top foam and sides to install same

Cut foam for the nose top, then, made foam pieces for the front of F-0, trimmed them around the pitot tube and microed them into place

Worked on the proper (distance) retraction of the nose wheel, fit of the nose wheel doors and slot for the foot

Changed the position of the nose light mount hardpoints and microed in urethane foam below NG-31

5 minute epoxied on the nose ballast floor/light mounting piece of foam

Did a bunch of small layups - some fixes to the nose floor, behind F-0, a small protective piece for the pitot tube piping and the heat duct splitter behind the nosewheel box

Worked on the nose wheel door mounts; they're pretty much done

Started installing foam pieces on lower side of NG-31 for the lights install

Made & drilled & tapped aluminum slugs for nose light mounts

Designed a nose light install and made foam parts for same

5 minute epoxied in the pitot tube piping, microed in (finally) the nose wheel door mounts

Started running the pitot tube line from the nose to F-22

Removed one of the plywood pieces from in front of F-0 and drilled it for a pitot tube fitting

Cut fiberglass layup blank into pieces for nosewheel doors

Did a 3 ply layup for edges around the nose wheel doors

Installed the foot on the nose gear and fitted the nosewheel doors around it

Continued making hinges, then test fitted the nosewheel doors

Made hinges for the nose wheel doors

Trimmed the fuselage bottom to match the newly installed nose gear box; cleaned up

Removed the wheels and brakes

Finished making the static port tube, microed and glassed in same & peel plied

Started on the static port by cutting & bending tubing, marking the side, cutting a slot, etc.

Installed the second master cylinder reservoir

Made a second aluminum plate for mounting the master cylinder reservoirs

Made aluminum plates to mount the master cylinders, alodined, added nut plates, installed some brake line tubing

Finished drilling holes for rudder pedals & test mounted same, started on the master cylinder install

Made 2 CS-13 spacers from 1/4" OD tube, then, began drilling rudder pedals for tube joining AN-4 bolts

Installed the nose wheel box into the fuselage with 2 ply BID tapes

Finished trimming the nose wheel box & sanded its and the floor dull for the next layup & trimmed the end of the strut cover

Applied protective tape to the nose wheel box, trimmed the edges and started fitting it into the fuselage

Opened the hole in the front of the heat duct

Test fitted the nose wheel box in the fuselage

Cut the hole in the strut cover and removed the mold from the nose wheel box

Did a 2 ply BID layup over the Lexan windows, peel plied & vacuum bagged same and cleaned up

Cut film from & sanded the edges of the Lexan pieces and double-stick taped them to the outside of the nose wheel box

Made Lexan windows for the nose gear wheel box

Worked on the nose gear door hinges

Trimmed the nose wheel box from the previous layup & cut holes for windows in same

Made hinge pieces and started fitting the nose wheel doors

Drilled & tapped holes in the nose gear door mounting brackets

Did the 3 ply BID layup over the nose wheel box mold, peel plied & cleaned up

Put another coat of micro on the nose wheel box mold, covered with tape & cut glass

Sanded micro on the nose wheel box mold

Marked the strut cover; for the hole that will allow the nose lift actuator to pass

Microed the outside of the nose wheel box foam plug mold

Opened the slots in the nose gear doors for the hinge brackets

Started trimming pieces from the last layup

Microed the nose gear door pivot mounts and doors, added a 2 ply BID layup then vacuum bagged same

Prepared for the nose gear door layups

More of same & fitted aluminum slugs

Carved and sanded foam for one side nose gear door hinge mounts

Sanded the foam between the inside and outside layups around the nose wheel cutout for hinge mounting hard points

Made a sanding block for the next steps

Cut foam pieces for the nose gear doors; epoxied same to the bottom fuselage cutout piece