N727RT: Project Notebook
Intro: Build Sequence
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Intro: Build Sequence
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The Lancair ES build manual (that comes with the kit) implies a general construction progression. However, the manual does not prescribe a specific linear sequence, as many items can be done simultaneously and it does not cover all build tasks in detail (for example wiring, oxygen, and other selected items that are not part of the kit and/or left to the builders discretion). To facilitate an integrated approach, track progress,
and simplify communication, I've adopted the following high level build sequence
(e.g. phases) which was derived from the Lancair build manual and input from prior builders.
As a high-level sequence, it outlines the general construction approach (i.e. build phases), but is not 100% prescriptive. At the underlying component, sub-component, and item levels, there are exceptions to the high-level category sequence, based on logical dependencies and/or builder efficiency. These underlying exceptions/dependencies cause overlaps between the high-level sequence categories (phases). For example, while the Airframe is logically first, attaching the top and bottom of the fuselage (a airframe task/component) is one of the later tasks in the overall project. The rational for the high-level sequence and selected exceptions are summarized below.
Airframe: It should be obvious that fabrication of the general airframe components (wings, fuselage, tail, landing gear, etc) would come first, as these are the primary structures to which other items are attached. However, many of the final assembly tasks for these airframe parts are delayed until nearly the end of the project based on size/space and construction efficiency. Exceptions: Upper Shell (Top): The main fuselage is comprised of a lower and upper shell, which are bonded and fiberglassed together. This "fuselage closing" step is delayed until nearly the end of the construction sequence to facilitate working on the plane with the top off, rather than needing to work "in it". Main Door: The main door is fitted and bonded as part of the initial fuselage tasks. However, since the door frame is initially/permanently attached to the upper fuselage shell, final fitting/bonding, and bodywork are delayed until the fuselage is closed. Baggage Door: Likewise the baggage door spans the upper and lower fuselage shells and is thus delayed until after the fuselage closing. HStab: Once attached, the Horizontal Stabilizer becomes permanent. Since it is nearly 13 ft wide (and barely fits in a standard T hanger), attaching the Hstab is delayed as late as possible/reasonable - but must be done before the upper shell is attached (ref Vstab below). VStab: The Vertical Stab (and rudder) must be attached after the Hstab and before the upper fuselage shell, and is thus also delayed. Wings: The wings are finished, closed, attached and aligned with the fuselage as part of the airframe tasks. Additionally, they are used to help fabricate/match the wing fairings. However, following these tasks the wings are removed and set aside as they consume too much work space when attached. Additional tasks involving the wings (aileron weights, pitot/static plumbing, wiring, and initial finishing can be conducted with the wings removed. Main Gear: Likewise, the main gear legs, wheels, and tires are initially fitted with other primary airframe components. However, on the gear, the plane sits over 4' high, and they stick out the side 3-4' into the prime work space. For this reason, I fabricated a temporary set of "short legs", which will be used thought most of the construction process and then replaced with the actual landing gear closer to completion. Step: The step (as designed and supplied with the kit) is a bit of a Rupee-Goldberg eyesore. Following my initial failed attempts at designing/engineering an alternative step, I decided to delay the step - perhaps until after the initial flights/testing. Belly: Several prior builders have suggested that the belly (bottom) of the fuselage be body worked and primed (paint ready) early on, since the fuselage can be more easily rolled upside down prior to completing too much of the controls, systems, cabin, and/or firewallfwd work. I adopted this suggestion/approach and completed the finishign of the belly during the airframe phase.
Flight Controls: While work is progressing on the airframe components (wings, fuselage, etc), the flight controls surfaces are assembled and closed. Then, the control linkages are fabricated. Generally, the controls rods and mechanisms are installed first and everything else is then positioned around them (due in-part to their overall importance and the necessity for their correct movement, geometry, & clearance). Exceptions: Rudder Cables: The ends of the rudder cables are swaged on. Thus, once the rudder cables are installed they cannot be removed without cutting/destroying the cable. If the cables were installed early in the building process, they would be exposed to too much dust. Thus, the final rudder cables installation is delayed. Final installation: Most of the other control linkages are removable. Thus. after the initial fit and installation they are removed (to protect them) and, are only temporarily re-installed as needed. Final installation will be delayed until all other items are nearly complete. Systems: As the control mechanisms are being fabricated, and fit (installed), the surrounding systems are located and fit (i.e. fuel lines, brake lines, electrical, etc) Exceptions: Landing Light: if the landing light is to be fitted into the cowl, special consideration may be needed as the cowl can not be final fitted until the fuselage is closed. Built-in Fire Suppression: is a "nice-to-have" capability with several requirements and design unknowns. While I am planning on creating the opportunity for built-in fire suppression, actual installation will be completed after initial flight testing (if ever). A portable/hand held fire extinguisher will be included near the pilot seat. DeIce: DeIce systems available for the ES are still relative immature. While I am planning on create the opportunity for various DeIce equipment, actual installation (beyond a heated prop) will be completed after initial flight testing.
Cabin: Following design, placement, and initial installation of the control mechanisms and key system components, the internal cabin components (seats, instrument panel, etc). are fabricated and installed. Exceptions: Insulation: Sun Visors
Firewall Fwd:
Exceptions: Engine Probes: The placement and routing of the engine probes (CHT, EGT, TIT, RPM, MP, OilPsi, Oil Temp, FuelPsi, FuelFlow, etc) needs to be coordinated with placement of the Engine Mnitor (Avioncis). Cowl: The cowl can only be properly fitted after the fuselage has been closed (Top shell bonded on)
Avionics: Avionics equipment/options is an area experiencing rapid innovation and development. Thus, the intent is to wait as long as feasible to finalize design and purchase decisions on avionics equipment. Exceptions:
Finishing: One key consideration for finishing is whether the airplane will be painted before the first flight or initially flown in primer. I am targeting to fly in primer and paint afterwards. Exceptions:
Final Paint: To be done after flight testing
Testing:
Exceptions:
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Build Sequence Overview: