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Big Steve

Steve Harmons Future ride

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Well it has been a while since my last update. I started the project Nov.11, 2006 I have invested 1238 hours in it so far. I use a timer in my watch to track the time. I have built all the big pieces except for the wings and the strakes. I have not yet put it together so that in itself will take some time. I have been building seats and arm rest and doing all the little things to the fuselage that need to be done. I guess I am 70% done with 80% left to do here are some pictures of the seats and arm rests. STeve build on

 

 

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http://websites.expercraft.com/bigsteve/images/1895146712495467178bb56.jpg

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Time for another update. After building a spar for another builder I am back to working on my own plane again. I have started on the wings. I borrowed a really nice set of templates from a fellow builder. They were so nice I decided I needed my own set so I traced them up and cut them out. I cut my first core tonight. The bottom turned out really good the top well I am glad it can be repaired easily. I bought out a varieze project and the foam cores are probably 20 plus years old but they look great on the inside. They are larger than the cores that spruce now sells. I will have to buy a couple more cores from spruce to finish. The Varieze had smaller wings than a Cozy IV. I will post some pics when I get them all cut out and jigged up. Steve build on

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It has been a while since my last update. I am working 4 10 hour days this summer so it gives me all of friday to work on the plane. I have finished my winglets and am slugging away on my wings. The picture shows the finished winglets I glassed them all together I will cut the bottoms off when I go to install them to the wings. Behind the winglets is my right wing which just got its top spar cap installed this morning. Behind the winglets under the table is my motor covered by a box. My shop is starting to get really tight. I cant wait to start doing the duck walk when I build my strakes. STeve build on

 

 

 

 

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I had a big weekend this week on the plane. Got my wings mated to the center section spar. It was a tight fit in my shop and took 13 hours to get it all done. I am up to 1570 hours working on the project now. The weather is starting to cool will have to start running the heater to cure the epoxy.

 

Build on STeve

 

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Thanks Waiter.

 

If this Cozy turns out as good and as fun as the Longeze was I am going to be a very happy camper. Steve

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As far as this phase of the construction goes:

 

Is it possible to drill a .25 inch pilot hole though the CS Spar the aft side to the forward face ..... mate the surfaces and the drill from the front face through the wing hardpoints.

 

At this point: It would be Ideal if you could finish the 5/8ths cut with one of the carbide tipped counterborers available. The problem seems to be the shaft is too short.

 

Could the cut be finished via a horizontal borer or the like using the established pilot hole?

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i think thats what i did. i had my spar in the plane and needed to invent a way to drill it. :P

BIG STEVE, any chance you could slow down a bit, we cant see a thing in all this dust !

(looking good buddy)

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Well I guess it is time for another update. I find it amazing how in one short afternoon My plane can grow so big and my shop can shrink so small. I mounted the center section spar yesterday afternoon and my shop will never be the same. Until I get rid of the table I will be walking around to get to the other side of the plane and the shop. I think after the strakes are done I can hang the table in the rafters. Steve building on

 

 

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good time to replace the striped out bolts in the fire wall with click bonds;)

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Those bolts are not stripped out and will not be replaced with clickbonds. I have had those bolts covered since day one. I also welded welding rod onto the heads of the bolts and then floxed them in. They wont turn either. STeve

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Those bolts are not stripped out and will not be replaced with clickbonds. I have had those bolts covered since day one. I also welded welding rod onto the heads of the bolts and then floxed them in. They wont turn either. STeve

i wish i had :sad:

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Steve:

 

The reason I knew to make it so the heads would not turn is that the ones on my Longeze did. I had to take a hack saw and cut slots in the ends of the screws so I could put a small screw driver on them when I tightend the bolts It was a pain but it worked. STeve building on

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Well today is Thanksgiving. Was able to work on the plane a good portion of the day. I have something new to be thankfull for. I have a wing hanging on the plane. Only took a little over 3 years to get to this point. The shop has really gotten a lot smaller. Going to start on the strakes now. Then all the big pieces will be done except for cowlings.

The wing makes a big table to put stuff on. I will be getting rid of my big 12' table after I build the strakes. STeve building on

 

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STeve:

 

What are those 'lift eyes' at the aft end of the top longeron for?

 

Rick

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Rick:

 

Good eyes I did not think anyone would notice those. They are temparary plywood pieces that are bondoed on. They locate my turtle back in the right position. There is also one on the back of the front seat. When I put the turtle back on I put the pins in and everything fits like it was made to. I am trying to put off installing the turtle back until the bitter end. It is hard for me to get my old large body in the back when it is on. Steve

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wow, it sure looks big !

i have my last wing on the floor doing the rear spar in the am and the aileron in the pm. soon i will be as you and mount them:D

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Rick:

 

Good eyes I did not think anyone would notice those.

On a clear day I can see the sun, and that's 93 million miles away.

 

I'm always looking (snooping?) for stuff to make my build easier :)

 

Rick

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Once again it is time for an update. I have something new to show and tell. I just saved myself a pile of money by building my own motor mount. It is my first attempt and it turned out pretty good. I got better at fitting the tubes as I went. My heliarc ran like a champ. Now I have to install it to the fuselage. But first I have to finish my oil heat under the right passenger thy rest and install the back seatback and cover up those ugly holes in the center section spar. The first picture is the mount in the jig. The second picture is the finished mount. My thanks go out to the Cozy girls for some tech help and The late Tony Bingalis's book firewall forward.

 

 

STeve building on

 

 

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Simple and stout looking. That looks like it would be really hard to bend under G's! Looks nice and wait 'til you start installing stuff on the engine and all that extra room makes a difference.

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