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Off to build!

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pequeajim

Joined: 03 Sep 2006
Posts: 708
Location: New Holland, PA

Posted: Wed Jul 11, 2007 6:26 pm Post subject: Off to build!

The kit is in and I'm off to Green Landings for 5 days to start on my

Lightning.



I have to say that I am very excited and in spite of some delays in getting

the kit to WV, it all worked out and we are ready to rock and roll!



I will be taking a bunch of pictures and documenting everything that I am

doing.  I am also prepping for an article that may go in either Sport

Aviation or Sport Pilot.  In speaking with Mary at EAA today, we are going

to hold off and see what the focus of the article is going to be.  I want to

do something along the line of the builder's experience in the builder's

assist program with some focus on the Lightning.  This would allow me to put

the article in Sport Pilot because even though I am not going light sport, I

can talk about the Lightning and how is can be build as a light sport or

straight experimental aircraft.



I have a web site with nothing in it at this time, www.jimslightning.com



I will be updating it as I go.



Unless Ryan has wireless at Green Landings, I will not have internet access,

so I'll just say adios and will check back in next week.



Jim!

N730AL

Colin K.

Joined: 04 Sep 2006
Posts: 157
Location: Oklahoma

Posted: Wed Jul 11, 2007 6:48 pm Post subject: Off to build!

Good luck Jim - I can understand your excitement!   

A lot has been written on this forum about the Lightning's flying qualities, but relatively little about the build process. I am looking forward to your reports very much.  

Colin K.  

OK  [list] 

 --

_________________
Colin K.
OK

checkpoint2(at)comcast.ne
Guest

Posted: Thu Jul 12, 2007 10:16 am Post subject: Off to build!

Gentlemen; I have been tracking the Lightning on Matronics since S&F.  I have even been to “Podunk” by road   

from S.W. Florida! Where is this Greenfields? Is it like the mythical Camelot where all good Lightning’s are born?    

Bob  Haas, N380 BH.    

         

  

From: owner-lightning-list-server(at)matronics.com [mailto:owner-lightning-list-server(at)matronics.com] On Behalf Of Colin J. Kennedy

 Sent: Wednesday, July 11, 2007 10:48 PM

 To: lightning-list(at)matronics.com

 Subject: RE: Off to build!  

  

   

Good luck Jim - I can understand your excitement!   

A lot has been written on this forum about the Lightning's flying qualities, but relatively little about the build process. I am looking forward to your reports very much.  

Colin K. 

 OK   

 --

Kayberg(at)AOL.COM
Guest

Posted: Thu Jul 12, 2007 10:34 am Post subject: Off to build!

In a message dated 7/12/2007 2:18:23 PM Eastern Daylight Time,  checkpoint2(at)comcast.net writes:

  	  Quote: 	
		     

      Gentlemen; I have been tracking the Lightning on Matronics since    S&F.  I have even been to “Podunk” by road       

from S.W. Florida! Where is this    Greenfields? Is it like the mythical Camelot where all good Lightning’s are    born?     

Bob    Haas, N380 BH.        

 	


 

 Bob,

  

 Check www.greenstrip.com

  

 doug



Get a sneak peak of the all-new AOL.com.

pete(at)flylightning.net
Guest

Posted: Thu Jul 12, 2007 11:05 am Post subject: Off to build!

Better yet try www.greenlandings.com  

   

Pete  

         

  

From: owner-lightning-list-server(at)matronics.com [mailto:owner-lightning-list-server(at)matronics.com] On Behalf Of Kayberg(at)aol.com

 Sent: Thursday, July 12, 2007 1:27 PM

 To: lightning-list(at)matronics.com

 Subject: Re: Off to build!  

  

       

In a message dated 7/12/2007 2:18:23 PM Eastern Daylight Time, checkpoint2(at)comcast.net writes:  

   	  Quote: 	
		    

   Gentlemen; I have been tracking the Lightning on Matronics since S&F.  I have even been to “Podunk” by road   

from S.W. Florida! Where is this Greenfields? Is it like the mythical Camelot where all good Lightning’s are born?    

Bob Haas, N380 BH.    

   	
  

    

Bob,  

    

   

    

Check www.greenstrip.com  

    

   

    

doug  

  



 

         

  

Get a sneak peak of the all-new AOL.com.  

  

    [quote]



href="http://www.matronics.com/Navigator?Lightning-List">http://www.matronics.com/Navigator?Lightning-List

href="http://forums.matronics.com">http://forums.matronics.com



[b]

Kayberg(at)aol.com
Guest

Posted: Thu Jul 12, 2007 3:41 pm Post subject: Off to build!

In a message dated 7/12/2007 3:07:00 PM Eastern Daylight Time,  pete(at)flylightning.net writes:

  	  Quote: 	
		     

Better yet try www.greenlandings.com   

    

Pete 	


 

 

 

 wow, do I have egg on my face!

  

 Thanks Pete.

  

 Doug



Get a sneak peak of the all-new AOL.com.

pequeajim

Joined: 03 Sep 2006
Posts: 708
Location: New Holland, PA

Posted: Thu Jul 12, 2007 6:40 pm Post subject: Re: Off to build!

I arrived in the morning at Green Landings to find my Lightning in a cradle in the middle of the hangar waiting for me!



The guys here are pretty relaxed and willing to let me work at my own pace, (with help of course).



I had printed out the manual and brought my camera and notebook for taking notes.  I have also been adding notes to items in the manual for possible suggestions for improvements or additions.



One thing I should have done first thing is to separate all my stuff so it would be easy to find parts.  This slowed me down during the day as I found myself searching for things.  I will be sorting things out tomorrow.



Things accomplished today



- Cut out all openings

- Sanded the inside of fuse

- Cut out windows and prepped for gluing

- Glued right side window

- Prepped left window

- Cut holes in tail

- Installed brackets for horiz stab

- Started to assemble main gear.



I only ran into two issues today.



I can't seem to get the horizontal stab right.  I also noticed that when bolting the two halves together, there is a good 1/4"+ gap on both sides.  I assume that the the kid does not rely on the stab root being tight against the fuse half for support and this will be ok?  I will shoot a pic of it tomorrow after we fix my goof up and let you see what I mean.



The other thing I ran into was when drilling the bolt holes for mounting the main axle.  The instructions call for a two washer separation and as I was cutting, I noticed that the shaft had moved and mine was more like three.  I don't think this is an issue at all so I drilled the other side to match.  My wheels will stick out about 1/8th of an inch more than specified.



Kind of like a wide trac huh?



I having a great time.  I brought my motorhome and am camping out in their driveway.  Met some very frendly people at the airport and am looking forward to a productive day tomorrow.



"now where is that wheel?  I know I left it around somewhere..."

dashvii(at)hotmail.com
Guest

Posted: Thu Jul 12, 2007 6:51 pm Post subject: Off to build!

"I can't seem to get the horizontal stab right.  I also noticed that when 

bolting

the two halves together, there is a good 1/4"+ gap on both sides."



Jim,

  There were gaps in between the horizontal stabilizer.  I couldn't attest 

to the size from memory, but several people have added a layer of glass to 

seal this up once the horizontals are mounted.  It looks good once you get 

it all sealed up.  Whew, sounds like you got a lot done today.  You will be 

flying before you know it and look forward to hearing what you think of the 

plane.  Brian W.



From: "pequeajim" <pequeajim(at)gmail.com>

Reply-To: lightning-list(at)matronics.com

To: lightning-list(at)matronics.com

Subject: Re: Off to build!

Date: Thu, 12 Jul 2007 19:40:05 -0700






I arrived in the morning at Green Landings to find my Lightning in a cradle 

in the middle of the hangar waiting for me!



The guys here are pretty relaxed and willing to let me work at my own pace, 

(with help of course).



I had printed out the manual and brought my camera and notebook for taking 

notes.  I have also been adding notes to items in the manual for possible 

suggestions for improvements or additions.



One thing I should have done first thing is to separate all my stuff so it 

would be easy to find parts.  This slowed me down during the day as I found 

myself searching for things.  I will be sorting things out tomorrow.



Things accomplished today



- Cut out all openings

- Sande from the fuse side to the stab root.d down inside of fuse

- Cut out windows and prepped for gluing

- Glued right side window

- Prepped left window

- Cut holes in tail

- Installed brackets for horiz stab

- Started to assemble main gear.



I only ran into two issues today.



I can't seem to get the horizontal stab right.  I also noticed that when 

bolting the two halves together, there is a good 1/4"+ gap on both sides.  I 

assume that the the kid down not rely on the stab root being tight against 

the fuse half for support and this will be ok?  I will shoot a pic of it 

tomorrow after we fix my goof up and let you see what I mean.



The other thing I ran into was when drilling the bolt holes for mounting the 

main axle.  The instructions call for a two washer separation and as I was 

cutting, I noticed that the shaft had moved and mine was morelike three.  I 

don't think this is an issue at all so I drilled the other side to match.  

My wheels will stick out about 1/8th of an inch more than specified.



Kind of like a wide trac huh?



I having a great time.  I brought my motorhome and am camping out in their 

driveway.  Met some very frendly people at the airport and am looking 

forward to a productive day tomorrow.



"now where is that wheel?  I know I left it around somewhere..."





Read this topic online here:



http://forums.matronics.com/viewtopic.php?p=123521#123521

_________________________________________________________________

pequeajim

Joined: 03 Sep 2006
Posts: 708
Location: New Holland, PA

Posted: Fri Jul 13, 2007 6:05 pm Post subject: Re: Off to build! - Day Two

Just for fun, I thought I would keep a diary while I am down at Green Landings.  They are currently building two Lightnings, and finishing one.



It's kind of neat to walk in the hangar and see four Lightnings, (including Ryan's).  Mine is in the early stages, but I'm catching up!



The build process went slower today, but we still got a fair amount done.  Tomorrow we will do the controls, (no rigging), so that is out of the way before we paint; plus several misc. items to prepare the aircraft for painting.  I'm pretty happy so far.  I'm not sure how far the kits built in Shelbyville are along after two days, but we seem to be making good progress.



Worked on today.



- Fitted, refitted, refitted, and finally fitted wings!

- Corrected my horizontal stab problem from yesterday.  (Man, I love composites).

- Finished the brakes, and installed tubes and tires; they bounce!

- Installed the spar box

- Installed up front air vents

- Partially assembled the nose gear bracket, attached it to gear leg.

- Took several panel dimensions, including hinge placement.



I looks like we are going to finish over the stab gaps.  If I really had to take them off, I could hot cut the joints, but that's not going to happen.



It would be nice to see a little better tolerances for the wing and horizontal stab.  I'm not complaining, but just a thought.



BTW:  A nice surprise in my kit from the boys in Shelbyville.  Aileron hinge covers!  Very nice...  Unfortunatly, I think I only was shipped three.  I'm going to look through my kit contents again for the other three.



See you all tomorrow night.

rickss

Joined: 30 May 2007
Posts: 23
Location: Haymarket, VA

Posted: Sat Jul 14, 2007 4:25 pm Post subject: Re: Off to build!

Jim,



It sounds like you are having a blast. Thanks for keeping us posted. Having never built an airplane before, I find it fascinating to say the least. I am hoping to get up there soon to take a demo flight, but the gods of time have not been cooperating. Good luck on your project and thanks again for your running log.



Rick

_________________
Cherokee driver, but feeling the need for speed!

pequeajim

Joined: 03 Sep 2006
Posts: 708
Location: New Holland, PA

Posted: Sun Jul 15, 2007 6:19 pm Post subject: Re: Off to build!

I will combine day three and four into one post since not a lot what done today as there was a local EAA fly-in and LOTS of food an hangar flying.



I figured since I was pretty worn out after day three I would pretty much socalize today, so not a lot was done.  



Day 3:



- Installed tank vents and check valves

- Cut bottom wing inspection holes

- Installed wheel stop on nose wheel

- Installed flap and aileron brackets

- Installed flaps

- Installed control mixer

- Installed flap motor

- Installed elevator bellcrank

- Shaped Panel hoop for install

- Cut stab bottom inspection holes



No big suprises on this day except that I have to remember to cut all inspection holes a tiny bit larger as my hands are big and get cut if I don't make a litle bit more space.



Also, I am raising the panel and hoop about 1/2", so this required a little shaping to the hoop to get it to fit.  As it is, you need to shape the hoop anyway as it is too big for the fuse and forced in, will create a bend.  Easy to shape, but where a mask and turn on a good fan blowing the carbon fiber dust away from you.  



Day 4



Very tired today.  spending more time at the EAA fly-in than working on the aircraft, but I did get a few things done.



- Cut panel to size

- Cut out firewall

- Drilled main gear holes

- Rivited blind nuts so that I can screw the inspection hole covers in place.

- Installed aileron outboard pushrods, man!  tight space!



Tomorrow is my last day here for this trip.  I'm hoping to get most of the inside controls setup, including the pedels and other stuff that goes behind the firewall.  It would be great to get it up on the gear, but I think that is dreaming at this point.



One more report tomorrow night.



Jim!

pequeajim

Joined: 03 Sep 2006
Posts: 708
Location: New Holland, PA

Posted: Sun Jul 15, 2007 6:57 pm Post subject: Off to build!

Geez, what was I typing that last report with; rocks on my fingers!?!

  

 Sorry guys...

  [quote][b]

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