Day 62 (TF3) & Day 7 (TF4) - February 28, 2015

Today was a very exciting day as we near the finish of TF3 and keep digging into the new project of TF4.  On TF3, we worked on the fine tunings and adjustments that will be checked in the upcoming inspection possibly occurring in two weeks.  The magnetometer or compass was calibrated, and the brakes worked a lot better than before due to the bleeding of the brakes that occurred last week.  Work on the stall warning kept progressing and areas on the horizontal stabilator were trimmed in order to fit the empennage cowling correctly. 
As for TF4, they worked on the baggage bulkhead, the forward lower fuselage, main bulkhead, and the seat ribs.  The baggage bulkhead and ribs were deburred and the small rear spar receptacles were riveted to the baggage bulkhead. 

The forward lower fuselage was riveted together involving the tunnel ribs between the pilot and the passenger, as well as the firewall bottom, side fuse skins, and center fuse skin.

The main center section assembly was riveted together and drilled.  This is what the baggage bulkhead will be riveted to in the future.  

The seat ribs were deburred and prepared for future assembly with the seatbelt attach lugs installed. 
The flaperon mixer arm was also finished which is used for moving the control surfaces.
Tune in for more next week!   

Day 61 (TF3) & Day 6 (TF4) - February 21, 2015

Today was yet another productive day at the hangar!  On TF3, we worked on many fine tunings and adjustments.  These tasks involved re-routing hoses on the engine, checking the screws in the empennage fairing, bleeding the brakes, and bending the stall warning switch arm.  The hoses on the engine needed to be re-routed due to interference with other hoses to prevent chafing. 

During the bleeding of the brakes, the goal was to remove air bubbles in the brake lines by compressing the air and moving them out through the fluid reservoir.  We had to bend the stall warning switch to ensure that the switch activates when the vane is moved up so the warning will be accurate. 
It was an exciting day for TF4 as they started to work on the actual airplane.  First, the entire fuselage kit was inventoried to ensure that all of the parts that were included in the kit were there. 
Then, the students were divided equally into four different groups working on different sections of the airplane.  Tasks that were being worked on today included firewall work, work on the main bulkhead and details in the rudder pedal area.   

Tune in next week for more TF3 and TF4 progress!  

Day 60 (TF3) & Day 5 (TF4) - February 14, 2015

It was a noisy day at the hangar.  As for TF3, we rolled the plane out and started the engine.  We performed tests including flaperon clearance, stabilator tuning, and the balancing of the carburetors.  Overall, the tests went smoothly and the carburetors were balanced, creating the necessary same fuel- to-air mixture.  The wings were installed to the fuselage and they still fit great. 

Inside the hangar, the TF4 students kept progressing toward completing their toolboxes.  Most of the students had the chance to work with a new tool called the "C Frame" which can be used to dimple and rivet using taps from a hammer.

Most of the students finished their toolboxes after more deburring, riveting, drilling, and dimpling.  This is an example of a completed toolbox.  Nice job! 

Tune in for more progress next week.  See you then. 

Day 59 (TF3) & Day 4 (TF4) - February 7, 2015

Today at the hangar, we underwent tests on TF3 and more toolbox construction on TF4. 
On the toolbox, the students are close to finishing.  We worked on more deburring, riveting, drilling, dimpling, as well as some layout work for the complicated hinge components.  The hinge involved switching of the parts, cutting, and alignment.  Some students made it to bending the toolbox handle and installing the latch.  In those steps it is very crucial for proper alignment, otherwise the toolbox will not close properly.  

As for TF3, the static system, used for showing altitude by measuring air pressure, was tested for any leaks and accuracy.  We used a syringe and putty to create a vacuum by decreasing air pressure to simulate around 1,000 feet in altitude.  A decrease in pressure indicates an increased altitude reading.The test involved analyzing the amount of time this system could hold this altitude.  
We also performed a similar test on the pitot tube, a tube used for measuring airspeed.  Unlike the static system, an increase in pressure increases the airspeed reading.  We used a tube connected to the syringe to increase the air pressure until the pitot system shows 130 knots.  We also had to check for leaks and examine how well this airspeed could be held. 
Most of the exterior of TF3 was cleaned with alcohol to remove the pen and plastic marks.  The interior upholstery is very close to being finished with the nice, grey seats.  
Next week is sure to be even more exciting with the possibility of starting the Teen Flight 4 RV-12! 

Day 58 (TF3) & Day 3 (TF4) - January 31, 2015

This Saturday, TF3 & TF4 continued to accomplish many tasks. 
TF4 completed the OP-51 project.  In order to finish, the students had to rivet three different kinds of rivets, dimple and countersink a few holes and install nut plates.  This took about half of the class period and then the students dove into the toolbox project which involved a lot of deburring.  Most students made it to the point of match-drilling holes for the rivets and some of the students even installed the hinge for the lid.

As for TF3, we have been working on the fitting of the engine cowling due to interference with the engine.  We made a lot of progress.  We are also close to finishing the installation of the interior upholstery and carpet which is looking great.   

Stay tuned for next week as TF3 keeps progressing toward the finish and as the TF4 toolboxes near completion.


Day 57 (TF3) & Day 2 (TF4) - January 24, 2015

This Saturday, the TF4 students dove into the OP-51 project, a project that incorporates crucial knowledge of many important sheet metal basics.  The students learned how to use the deburring wheel and how to lay out markings for holes and spacing.  After their first use of a power tool, they started drilling multiple holes which will later be used for installing rivets.  Students also started to learn how to dimple holes and some students even made it to countersinking and riveting.

As for TF3, more testing of the fuel pump continued and the interior upholstery was temporarily installed.  The interior color will be a nice light grey. 
Later in class, TF3 was weighted and balanced with the wings, fairings and all of the parts installed for accurate balancing.  The actual weight registered at 756 pounds. 

Today was another productive session.  Tune in next week as TF3 nears the finish and TF4 nears the finish of the OP-51 project. 

Also, here's a great photo from last week with the students of TF3 and TF4.


Day 56 (TF3) & Day 1 (TF4) - January 17, 2015

This Saturday, we passed another major milestone; the beginning of the next class-build, TeenFlight 4 (TF4).  Today was mostly a class full of learning and starting the first project of the name tag.  For the first hour, we went over guidelines and expectations that the students have to agree to in order to be successful.  Topics covered in the class were different types of rivets and riveting, countersinking and dimpling holes, drill bit sizes and the deburring process.

After this learning session, we broke into the first project.  Each of the TF4 students were paired with one student from TF3 to mentor them.  The first project was the name tag which may sound simple, but it involves precise details of deburring, drilling, counter-sinking and setting two rivets.  After this initial project of TF4 was completed, it was back to the board for some more instruction.  

At the very end of class, the TF4 students gathered in front of the TF3 airplane for some pictures.  It was a great day! Check back next week for more progress.


Day 55 - January 10, 2015

Today at the hangar, we kept pushing on toward the finish.  One of the tasks that was worked on was the interior decals.  They were adhered to the avionics panel to label and identify what certain controls are in the cockpit.  The main things that they label are the throttle, the choke and the cabin heat.  

The plastic on the canopy and rear window was also peeled off and it produced some strong static electricity as you can see.  However, despite the fact that it was pretty funny, it also looks great!

Near the end of class, the fuel pump was tested to check the pumping rate.  The pumping rate had to be about 1 gallon of fuel in 180 seconds, or three minutes.  After the test, the pump pumped out one gallon in about 130 seconds, or two minutes and ten seconds. 

All of the wheel fairings, besides the nose fairing, have been painted silver to match the color of the aluminum and they also look great! 

The trim and attitude controls were calibrated with the Garmin G3X EFIS system to ensure the right attitude was being displayed on the screen.  Near the very end of class, we also started the EFIS continuity check.  
Stay tuned for more next week!