Builder's Log
Each chapter in the Lancair ES construction manual is represented below. This gives you an idea of the typical order of events in the construction process, the amount of time I have into each section, and what my progress is to date. Lancair estimates that the aircraft can be completed in 1300 to 1500 hours. To make it harder to estimate how much time will be needed to complete the project, I have gone with several Fastbuild options that should bring the required construction time down. We will just have to see...
Construction Tools
As I proceed through the project, I am learning some valuable lessons, and getting good tips from other builders on what is useful and what is not regarding tools. To share that information, I have created a page in this website that specifically discusses Construction Tools.
Time Totals
I have learned that some of the Fastbuild parts from Lancair actually have been taken to a greater level of completion than I had expected. This was a very nice surprise... Thank you Lancair!!!
Another nice surprise, Lancair had already removed peel ply from most of the larger parts. I only had to remove peel ply from the top and bottom cowling, the main gear fairings, and from the composite panel (Upholstry Panel Diviney Cell - Part # 1050A-38-86) that will be used to construct some of the interior. This was a huge improvement because removing peel ply is a time consuming, and difficult job. Thanks again Lancair!!! I have completed peel ply removal and have put those parts in storage. I wanted to remove the peel ply because I have been told that the job becomes more difficult as time passes.
| Chapter | Progress |
Hours To Date |
Start Date |
End Date |
|
|---|---|---|---|---|---|
| Kit Delivery Preparation | |||||
| Clean & Organize Garage | 100% |
NR |
8/18/01 |
10/21/01 |
|
| Build Heavy Duty Saw Horse | 100% |
7 |
9/11/01 |
9/22/01 |
|
| Build Heavy Duty Dollies ( 4 ) | 100% |
7 |
9/4/01 |
9/9/01 |
|
| Build Fiberglass Cutting Table | 100% |
25 |
11/18/01 |
2/17/02 |
|
| Kit Delivery Serial #: ES-166-FB | 100% |
NR |
9/28/01 |
10/10/01 |
|
| Kit Inventory | 100% |
NR |
10/11/01 |
10/20/01 |
|
| Remove Peel Ply | 100% |
FB + 4 |
10/18/01 |
10/18/01 |
|
| 1. | Introduction | 100% |
3 |
12/00 |
12/00 |
| 2. | Horizontal Stabilizer (HS) | ||||
| Building the HS Assembly Cradle | 0% |
* |
- |
- |
|
| Skin Trimming & Positioning | 0% |
0 |
- |
- |
|
| Aft Spar Installation | 98% |
FB |
- |
- |
|
| HS Hinge Brackets | 0% |
0 |
- |
- |
|
| Forward Spar Web & Ribs | 90% |
FB |
- |
- |
|
| Fitting Top HS Skin | 0% |
0 |
- |
- |
|
| Capstrip Fabrication | 98% |
FB |
- |
- |
|
| HS Closeout | 0% |
0 |
- |
- |
|
| 3. | Elevators | ||||
| Trimming Bottom Elevator Skins | 0% |
0 |
- |
- |
|
| Elevator Spars | 80% |
FB |
- |
- |
|
| Elevator Ribs | 90% |
FB |
- |
- |
|
| Elevator Capstrips | 98% |
FB |
- |
- |
|
| Trim Motor Inspection Panel | 100% |
FB |
NA |
NA |
|
| Closing the Elevators | 0% |
0 |
- |
- |
|
| Trim Tab Installation | 100% |
FB |
NA |
NA |
|
| Counterbalancing the Elevators | 0% |
0 |
- |
- |
|
| Elevator Travel Stops | 0% |
0 |
- |
- |
|
| 4. | Rudder | ||||
| Getting Organized | 0% |
0 |
- |
- |
|
| Rudder Spar Installation | 0% |
0 |
- |
- |
|
| Rudder Rib Installation | 100% |
FB |
NA |
NA |
|
| Forming Capstrips | 100% |
FB |
NA |
NA |
|
| Rudder Trim Tab | 0% |
0 |
- |
- |
|
| 5. | Wing Fixture Assembly | ||||
| Workbench Construction ( 4 ) | 100% |
~ 14 |
8/25/01 |
9/3/01 |
|
| Building the Wing Cradles | 60% |
15 |
11/04/01 |
- |
|
| 6. | Closeout & Shear Web Installation | ||||
| Positioning the Upper Wing Skins and Main Spar | 100% |
FB |
NA |
NA |
|
| Installing Main Spar Closeout | 100% |
FB |
NA |
NA |
|
| Installing the Forward Shear Web | 100% |
FB |
NA |
NA |
|
| Installing the Wing Attach Bracket | 100% |
FB |
NA |
NA |
|
| Trimming Top Wing Skin Trailing Edge (LW) | 0% |
0 |
- |
- |
|
| Trimming Top Wing Skin Trailing Edge (RW) | 0% |
0 |
- |
- |
|
| 7. | Wing Construction | ||||
| Wing Tubing Installation | 100% |
FB |
NA |
NA |
|
| Rib Installation | 100% |
FB |
NA |
NA |
|
| Sealing the Wing
Attach Bracket Bolt Holes (LW) |
100% |
5.5 |
5/7/02 |
5/31/02 |
|
| Sealing the
Wing Attach Bracket Bolt Holes (RW) |
100% |
10.5 |
11/03/01 |
04/05/02 |
|
| Fitting the Bottom Wing Skin (LW) | 75% |
FB |
- |
- |
|
| Fitting the Bottom Wing Skin (RW) | 75% |
FB |
- |
- |
|
| Core Removal Areas (LW) | 100% |
FB +3 |
5/14/02 |
5/16/02 |
|
| Core Removal Areas (RW) | 100% |
FB +3 |
4/7/02 |
4/13/02 |
|
| Fuel Cap Installation (LW) | 100% |
4 |
5/25/02 |
5/26/02 |
|
| Fuel Cap Installation (RW) | 100% |
4 |
5/26/02 |
5/27/02 |
|
| Fuel Vent Line Installation (LW) | 100% |
3.5 |
11/25/01 |
6/17/02 |
|
| Fuel Vent Line Installation (RW) | 100% |
3.5 |
11/25/01 |
6/11/02 |
|
| Fuel Drain Valve Installation (LW) | 100% |
3 |
4/29/02 |
5/2/02 |
|
| Fuel Drain Valve Installation (RW) | 100% |
5 |
10/23/01 |
4/21/02 |
|
| Nav Antenna Installation | 0% |
0 |
- |
- |
|
| Capstrip Installation | 100% |
FB |
NA |
NA |
|
| Fuel Probe Installation (LW) | 100% |
8 |
6/1/02 |
6/7/02 |
|
| Fuel Probe Installation (RW) | 100% |
4 |
6/4/02 |
6/18/02 |
|
| Fuel Pickup Installation (LW) | 100% |
3 |
5/16/20 |
5/19/02 |
|
| Fuel Pickup Installation(RW) | 100% |
6 |
4/7/02 |
4/21/02 |
|
| Fuel Return Line Installation (LW) | 100% |
3 |
5/20/02 |
5/25/02 |
|
| Fuel Return Line Installation (RW) | 100% |
3.5 |
4/21/02 |
4/25/02 |
|
| Fuel Slosh Doors Installation (LW) | 100% |
4 |
4/25/02 |
5/1/02 |
|
| Fuel Slosh Doors Installation (RW) | 100% |
4 |
4/25/02 |
5/1/02 |
|
| Wing Tie Down Installation (LW) | 100% |
5 |
5/8/02 |
5/14/02 |
|
| Wing Tie Down Installation (RW) | 100% |
9 |
11/12/01 |
4/21/02 |
|
| Pitot Tube Installation | 90% |
4 |
6/20/02 |
- |
|
| Wing Vent Holes (LW) | 100% |
.5 |
5/14/02 |
5/14/02 |
|
| Wing Vent Holes (RW) | 100% |
1 |
11/12/01 |
11/12/01 |
|
| Implement Fuel Tank Extentions (LW) | 100% |
4 |
5/7/02 |
5/19/02 |
|
| Implement Fuel Tank Extentions (RW) | 100% |
3 |
11/10/01 |
11/25/01 |
|
| 8. | Flaps | ||||
| Flap Hinge Installation (LW) | 0% |
0 |
- |
- |
|
| Flap Hinge Installation (RW) | 0% |
0 |
- |
- |
|
| Flap Ribs & Spar Installation (LW) | 0% |
0 |
- |
- |
|
| Flap Ribs & Spar Installation (RW) | 0% |
0 |
- |
- |
|
| Optional Flap Access Panels (LW) | 0% |
0 |
- |
- |
|
| Optional Flap Access Panels (RW) | 0% |
0 |
- |
- |
|
| Flap Cap Strips (LW) | 0% |
0 |
- |
- |
|
| Flap Cap Strips (RW) | 0% |
0 |
- |
- |
|
| Closing the Flaps (LW) | 0% |
0 |
- |
- |
|
| Closing the Flaps (RW) | 0% |
0 |
- |
- |
|
| 9. | Ailerons | ||||
| Mounting Aileron Hinges (LW) | 0% |
0 |
- |
- |
|
| Mounting Aileron Hinges (RW) | 0% |
0 |
- |
- |
|
| Positioning Upper Aileron Skins (LW) | 0% |
0 |
- |
- |
|
| Positioning Upper Aileron Skins (RW) | 0% |
0 |
- |
- |
|
| Installing Aileron Spar (LW) | 0% |
0 |
- |
- |
|
| Installing Aileron Spar (RW) | 0% |
0 |
- |
- |
|
| Mounting Aileron Hinges and Actuator Arm (LW) | 0% |
0 |
- |
- |
|
| Mounting Aileron Hinges and Actuator Arm (RW) | 0% |
0 |
- |
- |
|
| Installing Aileron Ribs (LW) | 0% |
0 |
- |
- |
|
| Installing Aileron Ribs (RW) | 0% |
0 |
- |
- |
|
| Aileron Capstrip Installation (RW) | 0% |
0 |
- |
- |
|
| Aileron Capstrip Installation (LW) | 0% |
0 |
- |
- |
|
| Installing Roll Trim System (LW) | 0% |
0 |
- |
- |
|
| Installing Roll Trim System (RW) | 0% |
0 |
- |
- |
|
| Closing Aileron (LW) | 0% |
0 |
- |
- |
|
| Closing Aileron (RW) | 0% |
0 |
- |
- |
|
| Aileron Actuating Mechanism (LW) | 5% |
.5 |
11/11/01 |
- |
|
| Aileron Actuating Mechanism (RW) | 5% |
.5 |
11/11/01 |
- |
|
| Bellcrank & Idler Arm Inspection Panels (LW) | 60% |
FB +1 |
5/12/02 |
- |
|
| Bellcrank & Idler Arm Inspection Panels (RW) | 50% |
FB |
- |
- |
|
| Balancing Ailerons (LW) | 0% |
0 |
- |
- |
|
| Balancing Ailerons (RW) | 0% |
0 |
- |
- |
|
| 10. | Wing Closeout | ||||
| Sealing Fuel Tanks (LW) | 0% |
0 |
- |
- |
|
| Sealing Fuel Tanks (RW) | 0% |
0 |
- |
- |
|
| Closing the Wing (LW) | 0% |
0 |
- |
- |
|
| Closing the Wing (RW) | 0% |
0 |
- |
- |
|
| Pressure Testing the Fuel Tanks (LW) | 0% |
0 |
- |
- |
|
| Pressure Testing the Fuel Tanks (RW) | 0% |
0 |
- |
- |
|
| 11. | Wing Tips | ||||
| Mounting Wing Tips (LW) | 0% |
0 |
- |
- |
|
| Mounting Wing Tips (RW) | 0% |
0 |
- |
- |
|
| Wing Tip Lighting (LW) | 0% |
0 |
- |
- |
|
| Wing Tip Lighting (RW) | 0% |
0 |
- |
- |
|
| Fuel Vent Completion (LW) | 0% |
0 |
- |
- |
|
| Fuel Vent Completion (RW) | 0% |
0 |
- |
- |
|
| 12. | Jigging Fuselage | ||||
| Cutting Fuselage Cradles | 0% |
0 |
- |
- |
|
| Building Fuselage Jig Stands | 0% |
0 |
- |
- |
|
| Positioning Fuselage in Cradles | 0% |
0 |
- |
- |
|
| 13. | Firewall & Bulkheads | ||||
| Fitting Top Fuselage Shell & VS | 100% |
FB |
NA |
NA |
|
| Installing Firewall | 0% |
0 |
- |
- |
|
| Exhaust Tunnel Installation | 100% |
FB |
NA |
NA |
|
| Engine Mount Reinforcements | 100% |
FB |
NA |
NA |
|
| Bulkhead Installation | 100% |
FB |
NA |
NA |
|
| Rear Tie Down Installation | 0% |
0 |
- |
- |
|
| VS Stern Post | 0% |
0 |
- |
- |
|
| 14. | Mounting Horizontal Stabilizer (HS) | ||||
| Forming HS Mounting Cradle | 100% |
FB |
NA |
NA |
|
| Mounting HS | 0% |
0 |
- |
- |
|
| 15. | Vertical Stabilizer Assembly (VS) | ||||
| Bonding Right VS Half | 0% |
0 |
- |
- |
|
| Installing Cabin Air Scoop | 0% |
0 |
- |
- |
|
| Installing Com Antenna | 0% |
0 |
- |
- |
|
| Installing VS Ribs & Webs | 100% |
FB |
NA |
NA |
|
| Forming VS Capstrips | 100% |
FB |
NA |
NA |
|
| Elev. Weld. Inspection Panels | 0% |
0 |
- |
- |
|
| Installing GPS Antenna | 0% |
0 |
- |
- |
|
| Installing Loran Antenna | NA |
NA |
NA |
NA |
|
| Closing VS | 0% |
0 |
- |
- |
|
| 16. | Rudder Installation | ||||
| Fitting Right Ridder Skin | 0% |
0 |
- |
- |
|
| Hinge Mounting | 0% |
0 |
- |
- |
|
| Tail Light Installation | 0% |
0 |
- |
- |
|
| Rudder Closeout | 0% |
0 |
- |
- |
|
| Balancing Rudder | 0% |
0 |
- |
- |
|
| Rudder Pedal Installation | 0% |
0 |
- |
- |
|
| Rudder Cable Installation | 0% |
0 |
- |
- |
|
| Rudder Stops Installation | 0% |
0 |
- |
- |
|
| 17. | Mating Wing to Fuselage | ||||
| Incidence Templates | 0% |
0 |
- |
- |
|
| Mating Wing to Fuselage | 0% |
0 |
- |
- |
|
| Shear Box Installation | 0% |
0 |
- |
- |
|
| Shear Box Cover | 0% |
0 |
- |
- |
|
| Wing Attachment Fitting | 0% |
0 |
- |
- |
|
| Center Seat Belt Reinforce | 0% |
0 |
- |
- |
|
| Forward Seat Mount | 0% |
0 |
- |
- |
|
| Wing Root Fairings | 0% |
0 |
- |
- |
|
| Wing Fairing Access Panels | 0% |
0 |
- |
- |
|
| Forward Seat Mount Close-Off | 0% |
0 |
- |
- |
|
| 18. | Aileron Controls | ||||
| Inboard Aileron Bellcranks | 0% |
0 |
- |
- |
|
| Aileron Torque Tubes | 0% |
0 |
- |
- |
|
| Aileron Pushrod Completion | 0% |
0 |
- |
- |
|
| Control Stick Installation | 0% |
0 |
- |
- |
|
| Aileron Stops | 0% |
0 |
- |
- |
|
| 19. | Windows | ||||
| Prepare Upper Fuselage Shell | 0% |
0 |
- |
- |
|
| Prepare Windows | 0% |
0 |
- |
- |
|
| Window Installation | 0% |
0 |
- |
- |
|
| 20. | Main Gear Installation | ||||
| Gear Leg Mounts Installation | 0% |
0 |
- |
- |
|
| Main Gear Wheels & Tires | 100% |
2 |
6/02 |
6/02 |
|
| Axle Installation | 0% |
0 |
- |
- |
|
| Brake Installation | 0% |
0 |
- |
- |
|
| Main Gear Fairings | 0% |
0 |
- |
- |
|
| 21. | Nose Gear Installation | ||||
| Engine Mount Installation | 95% |
FB |
- |
- |
|
| Firewall Blanket Installation | 100% |
FB |
NA |
NA |
|
| Nose Wheel Strut Assembling | 100% |
FB |
NA |
NA |
|
| Nose Gear Strut Installation | 100% |
FB |
NA |
NA |
|
| Nose Gear Wheel Pant | 0% |
0 |
- |
- |
|
| 22. | Flap Controls | ||||
| Seat Support & Bulkhead Inst. | 0% |
0 |
- |
- |
|
| Torque Tube Installation | 0% |
0 |
- |
- |
|
| Flap Motor Installation | 0% |
0 |
- |
- |
|
| Flap Pushrod Installation | 0% |
0 |
- |
- |
|
| Flap Adjustments | 0% |
0 |
- |
- |
|
| 23. | Elevator Controls | ||||
| Elevator Idler Arm Assembly | 0% |
0 |
- |
- |
|
| Idler Mount Installation | 0% |
0 |
- |
- |
|
| Elevator Torque Tube Mounting | 0% |
0 |
- |
- |
|
| Elevator Pushrod Installation | 0% |
0 |
- |
- |
|
| 24. | Brake System / Rudder Controls | ||||
| Rudder Pedal Installation | 0% |
0 |
- |
- |
|
| Brake Master Cylinder Installation | 0% |
0 |
- |
- |
|
| Brake Reservoir Installation | 0% |
0 |
- |
- |
|
| Brake Lines Installation | 0% |
0 |
- |
- |
|
| 25. | Instrument Panel | ||||
| IP Installation | 0% |
0 |
- |
- |
|
| IP Dust Cover | 0% |
0 |
- |
- |
|
| IP Inserts | 0% |
0 |
- |
- |
|
| 26. | Seats | ||||
| Seat Pan Installation | 0% |
0 |
- |
- |
|
| Assembling Seat | 0% |
0 |
- |
- |
|
| Mounting Seats | 0% |
0 |
- |
- |
|
| Aft Seats | 0% |
0 |
- |
- |
|
| Seat Belt Installation | 0% |
0 |
- |
- |
|
| Elevator Pushrod Enclosure | 0% |
0 |
- |
- |
|
| 27. | Fuel System | ||||
| Wing to Fuselage Lines | 0% |
0 |
- |
- |
|
| Fuel Selector | 0% |
0 |
- |
- |
|
| Electric Fuel Pump Installation | 0% |
0 |
- |
- |
|
| Gascolator Installation | 100% |
FB |
- |
- |
|
| Fuel Return Line to Firewall | 0% |
0 |
- |
- |
|
| 28. | Door & Fuselage Closeout | ||||
| Lower Door Frame | 0% |
0 |
- |
- |
|
| Door Skin | 0% |
0 |
- |
- |
|
| Door Window | 0% |
0 |
- |
- |
|
| Door Stiffener | 0% |
0 |
- |
- |
|
| Door Hinges | 0% |
0 |
- |
- |
|
| Door Gas Strut | 0% |
0 |
- |
- |
|
| Fuselage Closeout | 0% |
0 |
- |
- |
|
| Door Latches | 0% |
0 |
- |
- |
|
| Door Handle | 0% |
0 |
- |
||
| Door Lock | 0% |
0 |
- |
- |
|
| Handle Cover Panel | 0% |
0 |
- |
- |
|
| Door Seal | 0% |
0 |
- |
- |
|
| Air Duct | 0% |
0 |
- |
- |
|
| 29. | Interior Panels | ||||
| Hat Rack | 0% |
0 |
- |
- |
|
| Arm Rests | 0% |
0 |
- |
- |
|
| Side Panels | 0% |
0 |
- |
- |
|
| Rear Passenger Foot Rest | 0% |
0 |
- |
- |
|
| Forward Floorboard | 0% |
0 |
- |
- |
|
| Air Duct | 0% |
0 |
- |
- |
|
| 30. | Baggage Door | ||||
| Fitting & Hinging Baggage Door | 0% |
0 |
- |
- |
|
| Baggage Door Locks | 0% |
0 |
- |
- |
|
| Weather Seal Installation | 0% |
0 |
- |
- |
|
| 31. | Firewall Forward | ||||
| Mounting Engine | 0% |
0 |
- |
- |
|
| Engine Exhaust Installation | 0% |
0 |
- |
- |
|
| Baffling | 0% |
0 |
- |
- |
|
| Engine Primary Control Systems | 0% |
0 |
- |
- |
|
| Fuel Systems | 0% |
0 |
- |
- |
|
| Engine Oil Systems | 0% |
0 |
- |
- |
|
| Propeller & Spinner | 0% |
0 |
- |
- |
|
| Cowling | 0% |
0 |
- |
- |
|
| Landing Light Installation | 0% |
0 |
- |
- |
|
| Air Filter Installation | 0% |
0 |
- |
- |
|
| Vacuum System | 0% |
0 |
- |
- |
|
| 32. | General Wiring | ||||
| Battery Box Options | 0% |
0 |
- |
- |
|
| Basic Wiring | 0% |
0 |
- |
- |
|
| Flap Wiring | 0% |
0 |
- |
- |
|
| Lights | 0% |
0 |
- |
- |
|
| Fuel Pump / Primer Wiring | 0% |
0 |
- |
- |
|
| Trim System Wiring | 0% |
0 |
- |
- |
|
| Antenna Placement | 0% |
0 |
- |
- |
|
| Automatic Door Seal Pump Wiring | 0% |
0 |
- |
- |
|
| 33. | Odds & Ends | ||||
| Wing Electrical Holes | 0% |
0 |
- |
- |
|
| Pitot Static System Completion | 0% |
0 |
- |
- |
|
| Door Seal Pump | 0% |
0 |
- |
- |
|
| Sound Proofing | 0% |
0 |
- |
- |
|
| Painting & Interiors | 0% |
0 |
- |
- |
|
| Bid Tapes | 0% |
0 |
- |
- |
|
| Mixing Micro | 0% |
0 |
- |
- |
|
| General Surface Preparation | 0% |
0 |
- |
- |
|
| Primary Materials | 0% |
0 |
- |
- |
|
| Painting | 0% |
0 |
- |
- |
|
| Paint Preparation | 0% |
0 |
- |
- |
|
| Base Colors | 0% |
0 |
- |
- |
|
| Trim Colors | 0% |
0 |
- |
- |
|
| Interiors | 0% |
0 |
- |
- |
|
| Upholstery | 0% |
0 |
- |
- |
|
| Weight & Balances | 0% |
0 |
- |
- |
|
| Flight Testing | 0% |
0 |
- |
- |
|
|
Table Key |
|
|
FB |
Section that was completed or partially completed as a result of a Fastbuild option. |
|
NR |
Not Recorded |
|
|
Left Wing |
|
|
Right Wing |
|
( n ) |
n Represents the quantity of the item that has to be built. |
|
* |
I may be able to get this item from an ES builder that has completed this step. |
|
|
Wing Related Section |
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© 2001 -2006 Don Parsons
Send Questions and Suggestions to DAP@Lancair-ES.com
Page Last Updated: May 16, 2006