Day 29 - November 14, 2015

TF4 is making great progress!  This week, work continued on the canopy, fuel tank, wing skins, and internal control systems.  As for the canopy, it has been riveted and mounted to the canopy frame, achieving the right fit.  The latch was also installed and fits great.  The fuel tank was also tested for leaks, and leaks have still been found.  This will call for more Pro-Seal in order to seal the tank. 

As for the left wing, the process of skinning has been started and the stall warning was tested and works well with the flip of the switch.  The majority of the skin has been riveted on and is coming together nicely.  The control systems are still undergoing assembly and the wiring was also worked on today. 

Check back soon for more updates!

Day 28 - November 6, 2015 & Day 27 - October 31, 2015

Over the past two weeks, many tasks have been worked on including the fuel tank, engine cowling, canopy frame, the wing skins and wiring.  As for the fuel tank, it has been continued to be sealed and tested for leaks.  The engine cowling has still been undergoing the tedious work of trimming and sanding for the proper fit.  The work has been paying off with a great fit between the upper and lower halves.  


As for the canopy frame, the holes in the plexiglass have been drilled and the canopy latch has been undergoing many intricate details.  The canopy is also starting to be mounted to the fuselage.  The wings are in the stage of being skinned which has been an exciting phase so far.  The internal wiring was continued, as well as the flight control systems.

Stay tuned!

Day 26 - October 24, 2015

Today was another productive day at the hangar with progress being made on the fuselage wiring, engine cowling, fuel tank, wing spar, and canopy frame.  As for the engine cowling, more trimming has been done in order to obtain the proper fit.  The fuel tank was also tested for leaks and was then sealed to stop the leaking. 
As for the wings, the left wing was further riveted and wired for lights and the stall warning.  Within the next week or two, we will probably be skinning the wing.  The canopy frame underwent more fitting to the fuselage and the wires in the fuselage were re-wired between the rudder pedals.
Also today, TeenFlight mentor, Mr. Dan Benua, gave a very informative presentation on electrical systems and wiring.  We all learned a lot! 
Stay tuned for next week!

Day 25 - October 17, 2015

TF4 accomplished many tasks at the hangar today which included work on the engine cowling, the canopy, and the wings.  As for the engine cowling, this was the first day of work on the fiberglass.  The work that was done included sanding, drilling and cutting to make the cowling the right size in order to eventually fit around the firewall. 

The wings underwent a lot of progress today.  Most of the ribs and plates on the left wing were final drilled and riveted.  They are coming together well and skinning is not too far away.  Also, the left rear spar assembly is being prepared for riveting and is currently in position.


Work on the canopy and frame was fairly tedious.  The plexi-glass canopy involved sanding and trimming in order to align with the frame that is in the process of being fitted to the fuselage.  This process is mainly trial and error until the canopy frame lines up to the fuselage within one eighth of an inch.      
Stay tuned for next week!

Day 24 - October 10, 2015

Today was another great day at the hangar.  Many tasks were worked on, including the fuel tank, the wings, the canopy frame, and the forward fuselage.  As for the wings, the rib doublers and the rest of the ribs were prepared for assembly.  Also, the hinge assemblies for the flaperon were riveted to the corresponding ribs. 

The fuel tank mainly underwent the somewhat messy job of using Pro-Seal.  The tank was double checked for finished work, Pro-Sealed, and then riveted together.  The fuel return line was also fabricated and prepared for installation. 
As for the wiring and upper fuselage, the headset audio jacks were installed and the panel attach strips were riveted to the forward upper fuselage skin.

Canopy preparation on the skins.

Stay tuned for next week!


Day 23 - October 3, 2015

Today was the first day back for TeenFlight 4 after the summer break.  It felt nice to be back at the hangar and we made a lot of progress on the airplane.
We mainly worked on the assembly of the wings, the canopy frame, wiring, and the fuel tank.  After planning the wing building, we dove into the project and started by clecoing and trimming the forward and aft ribs.  We then clecoed them and they were all a good fit. 

As for the canopy frame, the gas struts were drilled, the frame was filed down to allow clearance for the later-installed canopy, and the forward and aft attach angles were drilled and lined up on the frame. 
The fuel tank was also worked on and mainly involved an inspection to remember what had been done on it during the previous class.  Many wires and harnesses were routed through the fuselage from the forward end to the aft end in order for the avionics to function correctly. 
Overall, this was a great first day back at the hangar!

Summer 2015

The TF4 class has been on a summer break, but there have still been some great events going on. 

First of all, the awesome TeenFlight 3 Van's Aircraft RV-12 (N113TF) has been sold!  To a buyer who lives in Australia.

In July, the TF1 RV-12 and the TF4 RV-12 fuselage were on display at the Oregon Airshow.  It was a great way for people to hear about TeenFlight and Airway Science for Kids.  Also in July, TF3 flew all the way to Oshkosh, Wisconsin and back for the World's Largest Air Show, EAA AirVenture 2015!  TF3 was on display all week.  People from around the world were able to see the work we do at TeenFlight.

Check back soon for more updates!

Day 22 - June 13, 2015

Today was a very exciting day for TF4 before we break for the summer.
Our work session was followed by a tour with Hillsboro Aviation and Hillsboro Aero Academy, a TeenFlight 3 Graduation and Airway Science for Kids Celebration!

At the hangar, TF4 made a lot of progress and worked on the landing gear, fuel tank and wing parts.  As for the landing gear, the nose fork was partly primed and attached to the nose strut.  The fork was tightened and the main gear legs were also bolted into place.

The stub spar assemblies were clecoed, countersunk and riveted together.  Once the wings are further along, these assemblies will be ready for installation. 
The TF3 aircraft was also worked on today with the completion of the black pinstripes lining the paint lines.  This allows for a great visual effect on the freshly-painted plane.  TF3 looks stunning!

After class today, we had a great tour with Hillsboro Aviation and Hillsboro Aero Academy and awesome helicopter rides were given to the TeenFlight students!  At the end of the day, there was a TeenFlight 3 Graduation and Airway Science for Kids Celebration!

 A big thank you to Hillsboro Aviation, Hillsboro Aero Academy, Airway Science for Kids and TeenFlight.  Have a great summer!

Day 21 - June 6, 2015 & Day 20 - May 30, 2015

Over the past two weeks at the TF4 hangar, many tasks have been worked on, including the fuel tank and wing spars.  As for the fuel tank, it has been partially assembled with Pro-Seal and many rivets.  Students have been busy riveting on the wing spars and the results are looking good! 

Some work on the avionics has also been completed.  Due to the detail and importance of the wiring harnesses, this task takes some extra time and good progress is being made.  Other progress has been made on the control system components including the push-rods, the flap handle, and the flaperon arms.  The build is really moving along. 

  Stay tuned for next week!

Day 19 - May 23, 2015

A lot of progress was made at the TF4 hangar today!
The control stick pushrods were drilled and tapped, and the flap handle blocks were also cut.  The flap handle and the control rod were assembled along with the main push rods. 

The fuel tank was temporarily assembled to judge the fit in the plane.  Also, the rear spars in the wings were deburred and the flaperon spar was prepared.
The upper firewall and the left and right canopy ribs were riveted to the panel base.  Then, the engine mount brackets were attached to the panel base, and the cowl hinges were riveted to the side skins.  

As for TF3, prep work for the airplane's paint scheme was worked on today.  All of the masking was completed and the areas where paint will be applied were scuffed.  
TF3 is getting very close to being fully complete! 

Stay tuned for more progress soon!

Day 18 - May 16, 2015

Today was another great day at the hangar for TF4.  Many tasks were completed including the completion of the tires and wheels, progress on the fuel system, and more work on the map box.  As for the map box, the door hinge was riveted to the door and is almost ready to be attached to the map box.  The SkyView panel is also ready to be attached to the box. 

As for the main wheels and tires, the bearings were greased, and the wheel hubs, discs, and halves were also assembled. The main landing wheels are all ready to be balanced.  The seat backs were also worked on and are almost completed. 
Additionally, the fuel system return lines were installed in the fuselage.  This required many accurate bends and clamping.  We completed the return lines that extend from the engine to the back of the fuselage at the fuel tank.  The entire class went through a hands-on session on tube bending and flaring so all of the students had a chance to experience this.   
Check back soon for more progress!

Day 17 - May 9, 2015

TF4 worked on many tasks today including progress on the fuel system, the installation of the side vents and rudder pedals, as well as the assembling of the tires and wheels.  As for the fuel system, the gascolator was installed and most of the fuel lines were bent and put in place with the right torque. 

The rudder pedals were assembled and temporarily installed.  After a lot of adjusting and fitting, the side vents were riveted to the fuselage and they look great. 

As for the landing gear, the wheel halves, discs, and hubs were all assembled in the right order and they look great as well!  Work on the wing spars was also done.  The attach angles on the spar were riveted on, and they will later have the wing ribs assembled to them.

Stay tuned for next week!