It has been almost two years since I picked up my parially completed kit. And the learning curve has been quite steep. In no particluar order, I will post some of my "Aha" moments here.
On Getting Started
Being a complete novice, you may have a general reluctance to do anything permanent. And that's OK for the first few months, but eventually you have to start cutting metal, drilling holes, and placing rivets.
One thing that made it easier for me was to just assemble as much of the project, fuselage in my case, with clamps and other connections that require no permanence. And eventually things start fitting together and looking like the structure you envision and then you begin to develop confidence needed to move forward.
As I studied the plans, read the manual, looked at other builder sites, I gained more confidence in the process and was able to move forward, albiet slowly at first.
On having the right tools
One of the benefits of the project I acquired was having a great set of tools included. You can do alot of things with a hacksaw and file, but you can do them much faster and with greater accuracy using a high speed electric cutoff wheel and electric disc/plane sander.
You can probably acheive similar results, but if your goal is to eventually fly, rather than perpetually build, invest in the necessary tools.
On priming the parts
Much has been written about this subject, so I state my opinion from the perspective of least time spent balanced with acceptable results. According to Van's, unclad aluminum components should be primed. And while I have seen alot of RV's that were bare metal inside, I am following the manufacturers advice.
I am not, however, willing to do a 3 step, highly toxic priming process. My method is pretty simple and quite inexpensive. Once a piece of aluminum is completed - cut, drilled, bent, deburred, etc. Then I sand it with medium, then fine grit material, wash it thoroughly with Bar Keepers Friend, which has Oxalic Acid as a main ingredient (removes oxidation and etches the metal) then I allow it to dry, then spray it lightly with Rust-Oleum Aluminum primer sold at Lowes.
When all the pieces are completely white, I am ready for skins. IT is visually encouraging, and simple. Just be sure you are actually DONE, with the piece to be painted. Handling it a great deal after priming will turn it varius shades of fingerprint grey.
On keeping it close to home as long as possible
At some point, I recognize there will be a hanger required for my project. But with my garage just 30 seconds away, I cannot overemphasize how much more efficient it is to build at home. For me, the time it takes to drive to the airport, get out and then stow the needed tools is an hour I simply don't have.
If you faithfully spend a few minutes each and every day, you will accomplish more than spending large chunks of time on occaision. There is a reason why some projects are 10 plus years and a long way from being finished.
If you are creative, there is a great deal you can do in a two car garage, and even leave room for your wifes car (on most days)!
On recording the building process
Heck if I know! If I spent the time building instead of writing this silly builders log, I would be way down the road. I honestly don't know how you other builders do it.
The only thing I have found is that by keeping my Smart Phone handy (one with a decent camera helps) , I can take photo's that are date stamped. By going back and assembling the photos by date, I can at least have some remembrance of the process in the general order it occured.
But as for writing lengthly explanations, I am so far behind that I doubt I will ever catch up on my builders log. And it is quite apparent that the thing is amatuer built, so isn't that the whole point?
On quick build vs. regular kits
I have a good buddy who apologizes to me because he bought a quick build kit. I apologize to others because I bought a partially completed kit. You might apologize for something else. Let's all get over our worries about what others might think about our particular approach and just enjoy the experience.
If you compare buying a quick build to a regular kit, of course it is going to go faster. It's time or money, you make the call. I have learned a great deal by drilling, deburring, dimpling or countersinking each hole. Not to mention fitting, modifying, and even manufacturing some pieces.
Build and let build!
On firewall forward options
OK, it's time to come out of the closet. I'm a alternative powerplant guy, rotary power to be exact. I have flown turbine engines all of my professional life, never had a problem in over twenty thousand plus hours. Yet I belong to a local flying club that has had to replace 3 out of 4 piston engines in the three years I have been a member (each with a special assessment).
I am using a Mazda rotary as a poor mans turbine engine. It is nearly indestructible and very inexpensive by comparison. I will spend less that 10% of the cost of a similarly powered certified engine up front, about 1/2 of 1% on my overhauls, burn mogas, and produce more power per weight.
It's not perfect and I understand there will be large challenges doing the installation, possible resale value ramifications, and limited support for maintenance. Got it. But I for one am really tired of paying a 900% markup on 1940's technology just to pay the multimillion dollar legal judgements that have destroyed the GA business.
On the RV Community
From a world-wide view, it appears to be phenomenal. Locally, I have had real difficulty connecting with other builders who will offer to spend even 10 minutes providing assistance. Building is a difficult task under any circumstances, doing all by yourself is even more so. I recommend checking out your local EAA Chapter first and getting a sense of the community in your local area.
All EAA chapters are not created equally! And if you live in Northern Utah and need a hand, call me anytime and I'll be happy to do what I can to help.
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