More Detail Work

Here are some more of the many finish details I've been trying to wrap up. Above is the pilot side sight gauge. I've applied the vinyl level markings and reinstalled the trim. This really turned out well and looks great. As you can see, the fuel level will be clearly visible. These Vance Atkinson gauges are even lighted. The light goes on with the Nav lights. I'll see if I can get a good shot at night.

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Here are some pictures of the modified Infinity stick grip. You can see the rectangular area Dremeled out in the forward portion of the base. The wires come out there, go down a channel in the spacer and will then be affixed in the chanel in the spacer and protected by tie wraps, then concealed by the leather bootie.

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Here is the new placard for the dimmer switches. It's a small change, but it makes a noticeable improvement and more custom look over the shiny plastic placards that came with the switches. Click on the picture for a better look.

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Here is the dip stick epoxy coated to protect the vinyl markings then scuffed with 400 grit to give it a matte finish. With it shiny, the fuel didn't leave a mark and it was too hard to read.

I have to admit, I even enjoyed making a little doodad like this. Part of what is so enjoyable about building is taking some nothing piece of wood or fiberglass and making it into something good looking and functional. It's fun to put your own spin on each part with little innovations.

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The DAR wouldn't let me slide with 3 inch numbers for my fly off. He insisted on 12 inch numbers, so I had them made and will apply them this weekend. (Then laboriously remove them before final paint) Oh well, more education and recreation to enjoy!

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We got 3 feet of snow and were snowbound for 3 days. Luckily, I ran out to the hangar when I saw the forecast and brought home my doors for some much needed final touch up work. Redoing working parts can set you back in terms of your completion date. The problem is, you get better as you work on the project and will want to improve details as you go on. The doors work fine and look great on casual inspection, but I can make them better. I'm trying to go for "Best" instead of "Good enough" on each part.

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My nice, warm basement shop. Most of the tools are out at the hangar these days, but it is a nice bright (warm) place to work. The plexi is taped off, sanding done and ready to fill and paint.

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This is the kind of thing I want to fix. There are missed spots, scratches, dry areas and scrapes from my ill fated attempt to use machine screws to hold the door pin receiving plates in place.
This stuff would bug me and be embarrassing at Oshkosh.

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For touching up small holes, scratches and pinholes, you can't beat a product called Icing available at auto paint specialty stores. It goes on easily and is ready to sand in 10 minutes.

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Now it's time to touch up the paint with my handy air brush. It took only 1 1/2 of these tiny bottles and gives fine control.

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Can you believe the wife laughed at my high tech painting garb? I'm building an airplane here, woman!

Seriously, you will track dust onto the hardwood, furniture,etc. unless you take precautions. The best bet is a set of coveralls and easily removable shoes that stay in the basement/workshop. This means less laundry too, especially during the dreaded fill and sand phase.

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Here are the refinished door hinges. I did several upgrades here. One thing to remember with all the hinges you make is to fix them so that the hinge pin can't fall out. You can do this by slightly shortening the pin, beveling the ends with your belt sander, then using a nail set around the opening on each side of the hinge to bend the inner edge of the hole in slightly so the pin can't slide out.

In addition, the interior guy painted them a nice matching color with laquer - without priming the aluminum. It was already flaking off. I stripped them with thinner, primed them with metal primer and will hit them with matching lacquer tonight for a nice, durable matching finish.

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Here is the repainted pilot side door with the "Experimental" vinyl lettering applied. I went with a dark navy blue to complement the interior and the blue trim on the exterior (once I get the final paint and get rid of this awful green).

Since I have the doors off and apart, I'm going to take off the door handles and refinish them. I'm going to put nice rounded edges on them, both for aesthetic reasons and because the sharp edges hurt my hands. The doors on a new Velocity are typically hard to shut for the first few months until they get worn in. The outer door handle is painted, but is made of stainless steel. This feels to me like the idea paint on finished hardwood. I'm going to strip them and buff them to a high shine.

Out to the hangar tomorrow to shovel my way in and install the emergency fuel shutoff and 12 inch numbers.

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