Removing fabric for re-cover

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Removing fabric for re-cover

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Removing fabric for re-cover

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Removing fabric for re-cover

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Ready to re-cover

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Ready to re-cover

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Ready to cover

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Step built following factory plans

8 of 82 Retracted (above); Extended (below)

putting on fabric

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Fabric on, new cockpit door

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New windows in factory restroom

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Bill Baechler (Aeromarine Works) spraying silver

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Fuselage paint complete; Insignia Blue and Light Blue

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Todd Marrale (Aeromarine Works) dismantling old wing

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Original Gottingen 398 airfoil

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Don Ronda building ribs

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Detail of rib building

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First two new ribs

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Side view on April 3, 2002

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One of splicing the mahogony plywood for the facing on the box-spars

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Windows going in

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FAA Inspector Tony Accurso assesses the new alterations & improvements & approves. Standards are high for holders of Air Carrier Certificates.

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Final trim going on

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Restroom window and frame

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Pilot's door construction

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Clamping laminated spar

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Laminating spar caps

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FAA required data plate.
Makes it easier to track bootleggers?

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Building up front and rear box spars for wings

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"assembly"..." Laying in laminated blocks between spar caps

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"Clamping"...."putting on clamps for gluing pressure QUICK before glue sets up"

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these surfaces will be planed before plywood facing

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Laminations"..."Result; end view of laminations

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the laminated Spar ready for plywood facing

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New spar next to old spar; old spar has plywood facing

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New plywood ready to be glued and nailed

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Here's the spar completed except for cutting the ends to shape at the wing-tip

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Pencil lines show inner construction of laminates inside spar

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Wing going together at last

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Wing with one of the old wings against the wall behind it

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painting vertical fin

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Some pieces blue

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The wing as it looked on 5-14-02

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Some details of the wing construction.

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Details of the aileron spar area

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Wing fittings at wing root

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Wing fitting at strut attach point. All the fittings were sent to Oregon for magna-flux inspection and new cad plating.

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Installing the engine

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Engine installed

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The old and the new

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Orange elevator

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Wing trammelled and getting the final glued in blocks

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Detail

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Wing varnished, nav light fitting being glued in, aileron in foreground

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Installing fuel tank supports

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Installing fuel tank support straps inside fuel tank bay

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Details of spar, tank bay, and wing attach fitting

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Last step before covering, installing leading edge

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Trial installation. It takes a crew !!

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Left wing installed

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It fits perfectly!

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Unloading left wing at C & J Aircraft Services

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Left wing being covered

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Silver to protect the fabric from U.V.

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White goes on first to brighten, then -- ta-dah! -- orange at last

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Right wing after only five days, progressing fast

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Starting to come together. All we need now is the other wing

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Check the trick wing tip navigation lights!

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Interior with a new coat of varnish

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Doing the Weight and Balance

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Hanging from the roof during float installation...hold your breath!

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Getting close !! Got to the lake about midnight

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Getting the feet wet

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Free at Last!

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Back to Work

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