Aircraft Kit Builder

Construction log for Tornado II S

Report Date
6/12/2006

Randy Sill
24245 Tollgate Rd.
Cicero, IN 46034

Titan Aircraft
Tornado II S


Construction Log

Date

Category

Partner

Manual Ref #

Hours

3/12/2005

Fuselage

Randy Sill

5.00

Cut out skins from pattern, trim to fit, drill and cleco rear belly skin.




Initial sizing

The first drilled hole and Cleco!

First day complete

3/13/2005

Fuselage

Randy Sill

6.00

Continued the rear belly skin.


 

 

 

 

 

3/14/2005

Fuselage

Randy Sill

3.00

Completed cleco of rear belly skin, proceeded to front skin.




Laser sighting longeron tube rivets

Rear skin complete!

Starting front belly skin

3/15/2005

Fuselage

Randy Sill

3.00

Drill and cleco front belly skin



 

 

Front skin cleco complete, ready to overlap rear

 

3/16/2005

Fuselage

Randy Sill

2.50

Finished front belly skin drill and cleco, replaced rear over front skin to transfer overlap holes, drilled overlap holes, removed to debur.




Used ratchet strap and heat to stretch skins

 

Rear skin overlap matched and drilled

3/17/2005

Fuselage

Randy Sill

5.00

Final mating of the front and rear belly skins, trim overlap to 1/4" from edge of rivet holes. Sand blast and primer Panos nose forks.


 

 

Final fitting

 

 

3/17/2005

Fuselage

Dick Imel

2.00

Assist in final trim of belly skins.

 

 

 

 

 

 

3/19/2005

Fuselage

Randy Sill

4.00

Rivet nose fork bushings, mount nose wheel, assemble main axles/brakes, align and mount main wheels.




Nose wheel bushings

Laser sited axle alignment

Test wheel alignment and Panos nose fork

3/19/2005

Fuselage

Randy Sill

4.00

Mounted rudder controls and length adjuster. Reamed axle holes to 1/2" as well as polish axles to get them to move freely.




Length adjuster with rudder bushings

Left rear

Front

3/20/2005

Fuselage

Randy Sill

9.00

Installed contol torque tube bushings and control sticks. Drawing was hard to read and only installed one rear bushing instead of two. Fit is nice and tight though.




Rear bushing, added outer rudder cable bushings

 

 

3/21/2005

Empennage

Randy Sill

1.00

Sanded boom sockets and test fit boom. Mounted vertical stab with pre-drilled holes. Ready to level.




Double Sleeve

Test Fit

AeroBat!

3/24/2005

Empennage

Randy Sill

2.00

Level fusalage with SmartLevel, insure boom is fully inserted with ratchet straps, orient boom with smartlevel on vertical stabilizer. Drill and cleco boom tube through fusalage mounts.




Level the fusalage with Smart Level

Drilled and cleco Boom through fusalage mounts

 

3/26/2005

Empennage

Randy Sill

2.00

Debur all drilled holes, sand and scuff mating surfaces, mix uralane, apply to mating surfaces, install boom, rivet.



 

Front socket epoxied and riveted

Rear socket complete

 

3/27/2005

Empennage

Randy Sill

6.00

Drill and cleko vertical stab, align strake bottom edge with vertical bottom edge, then drill and cleko strake. Remove both, debur, sand, scuff, clean with acetone, epoxy, then rivet to boom tube.




Drill and Cleko vertical and strake

Bottoms aligned

Vertical complete!

3/31/2005

Empennage

Randy Sill

7.00

Assemble, drill, cleko stabilator and anti-servo tab.




Cleko Ribs in place

Fit skins. Using thin cardboard to slip rear under leading edge skin

Assembly complete, ready for debur, final assembly rivets

4/1/2005

Empennage

Randy Sill

8.00

Epoxy and rivet anti-servo tab, debur stab skin, fit and epoxy hinge doublers, epoxy and rivet stab skin to stab wing, rivet wing tips.




Hinge Doublers

Hinge installed on Anti-Servo Tab

Stabilator complete!

4/2/2005

Empennage

Randy Sill

2.00

Level aircraft, install stabilator collar, measure for alignment, drill and cleko




Wing Level

Looking good.

Drill and cleko and still level

4/3/2005

Empennage

Randy Sill

3.00

Sand, epoxy, rivet stab collar. Mount trim control rod and hinge system. Replace pilot heel brake rudders with correct toe brakes and adjust cable length of left rudder...re-nico press cable. Weather was too nice...took Sharon for a spin...




Completed stab collar and trim control

Toe brakes

Downtown Cicero

4/4/2005

Fuselage

Randy Sill

3.00

Paint trim controls, align in fusalage, drill and rivet control bushings.



 

Front trim control

Rear trim control

 

4/5/2005

Fuselage

Randy Sill

2.00

Assemble, epoxy, bolt stab push pull tube into boom. Install tail wheel.



 

Bolted to front pivot

Extending out the back of the boom

 

4/6/2005

Fuselage

Randy Sill

2.00

Install brake cable sheathing and stainless cable to the toe brakes. Not installing rear brakes at this time until fusalage complete. May design a hand brake to keep passenger area clean.



 

Front brake and cables installed

Brake cables attached in rear

 

4/6/2005

Fuselage

Randy Sill

3.00

Adjust stabilator/control sticks for full deflection. Started kevlar test fit...dremel panels for installation.



 

Stabilator controls adjusted

Rear panels test fit

 

4/7/2005

Empennage

Randy Sill

3.00

Install Anti-servo hinge mount and cut stab skins for connecting rod access



 

Top - hinge mount

Bottom attachment

 

4/15/2005

Fuselage

Randy Sill

6.00

Fit nose cone to fusalage and installed fastenuts. Cut out fiberglass openings for air vents. Assembled air vent flaps. Install brake lines, added DOT5 brake fluid and bled air out of the system. Cut fuel tank holes for fuel fitting




Nose cone trimed for fiberglass install of air vents

Brake fluid resevoir

Fuel fitting ready for install

4/16/2005

Fuselage

Randy Sill

13.00

This was the hardest part of the construction to date. The Lexan was hard to "motivate" into the proper position. Installed the Left window, then the main door with Hinge




Clamps in place holding the Lexan in position

Left window complete

Front door complete

4/17/2005

Fuselage

Randy Sill

7.00

Custom build top hinged rear entry door. Created aluminum frame for lexan. Alumiweld additional support tube into stock door frame. Drill and Cleko to fit.




 

 

 

4/18/2005

Fuselage

Randy Sill

3.00

Trim rear door for top hinge, drill and cleko hinge to frame and rear door. While mounting front door to check match, the plastic hinge was stretched and tore out 3 holes. Replaced front door hinge with extruded aluminum hinge.




Doors are mounted

New aluminum hinge on front door

Loving the rear gull wing door!

4/21/2005

Fuselage

Randy Sill

2.00

Fiberglass nose vents into place




 

 

 

4/23/2005

Fuselage

Randy Sill

8.00

Fabricate hood and instument panel for EFIS Horizon I and AudioVox video screens.




Laser line to shape hood

Recessed video panel below with Lexan

Looking forward to the new view!

4/24/2005

Fuselage

Randy Sill

10.00

Size and trim to fit 1/2" foam insulation. This will allow the carpet to lay flat across all floor tubing with an added benefit of reducing cockpit noise. Found very nice black and tan Vinyl at Joanne Fabric and applied black to the instrument hood. Tan will be used on the upper side panels for contrast. Completed the nose cone fiberglass and pitot installation.




1/2" light foam insulation

Black Vinyl covering for the hood

Nose vents and pitot complete

4/25/2005

Fuselage

Randy Sill

9.00

Glued the Vinyl to the instument hood and riveted the hood to the fusalage. Started laying out the instument panel, mounted Mode C Transponder, Intercom, Flaps indicator. Trimmed doors to fit smoothly.




Instument Panel mounted with some instuments

Looking good with nose complete

Doors trimmed

4/27/2005

Fuselage

Randy Sill

3.00

Custom tray for electronics mounting under the engine. Strobe and relays can be mounted here.


 

 

Aluminum is wrapped around insulated tube and rivited to itself

 

 

4/27/2005

Fuselage

Dick Imel

3.00

Assist with the fabrication of the custom tray. Dick came up with the idea, Thanks!

 

 

 

 

 

 

4/28/2005

Fuselage

Randy Sill

5.00

Trim to fit and glue carpet to fusalage floor - right side. It was tough to get it cut around all the tubes, but turned out nice as expected with the foam which covered the floor frame tubes.



 

Glue setting, clamps keeping a nice edge

Cutting in around all the tubes was tough, but looks great

 

4/30/2005

Fuselage

Randy Sill

5.00

Finished the left side carpet. I used clamps to press the carpet to the sides and hundreds of clekos as well as chains to hold the carpet in place as the glue set.




Clekos and chains for weight as the glue dries

Looking great with no floor tubes showing!

Rear carpet

5/1/2005

Fuselage

Randy Sill

6.00

Trim kevlar panels to fit, then drill and fasten. Cut top and bottom panels to match and fit in place. Right panel is mounted with screw fasteners and is removable.




Left panel will be riveted in place

Right panel is removable with screws every 3"

View from inside.

5/2/2005

Fuselage

Randy Sill

4.00

Finished fuel tank fittings after flushing clean with fuel, riveted door skins in place leaving windows attached with Clekos, finished rivnuts on right kevlar panel, fiberglassed one more layer in nose cone for strength.




Fuel tank "thunker" with filter, rubber seal

Front door riveted

Tank installed

5/4/2005

Fuselage

Randy Sill

1.50

Install carpet in nose cone and paint the remainder of the uncovered areas flat black.


 

 

Carpet complete and nose cone installed for test fit

 

 

5/7/2005

Fuselage

Randy Sill

3.00

Install wiring for strobe and camera in the tail. Set wires in silicone for insulation. Camera is .67x.67x1" 12v 480 scan line color from SuperCircuts.com




Air hose holding wires down as silicone sets

camera is tiny!

Camera glassed into tail tip

5/8/2005

Fuselage

Randy Sill

5.00

Design hing mounts and install lift struts for front and rear doors. Install handles and locks




Front door lift strut

Rear gull wing door with strut

Front door handle with lock

5/9/2005

Fuselage

Randy Sill

2.00

Test lcd display from camera and other sources


 

 

Video working!

 

 

5/10/2005

Fuselage

Randy Sill

2.00

Bleed brakes and test.

 

 

 

 

 

 

5/22/2005

Wing

Randy Sill

1.00

Moved fusalage and Shopsmith to make room for wing. Located wing components and lay out to organize.


 

 

Ready to start wing!

 

 

5/27/2005

Wing

Randy Sill

5.00

Measure and mark wing for Hat locations, Rib locations, etc. Drill hat strengtheners.



 

Wing measurements

Checking rib locations

 

5/28/2005

Wing

Randy Sill

7.00

Install Ribs, spars, control assemblies, and stiffeners




Using D-Cell flap to transfer centerlines to spar cap

Lines transferred

Ribs, aft spar, stiffeners in place

5/29/2005

Wing

Randy Sill

12.00

Install fuel tank bays and nutplates




Bays complete

Fabricate fuel tank template

Test template for fit

5/30/2005

Wing

Randy Sill

12.00

Drill 5/8" fuel line routing holes through ribs as well as 3/8 fuel vent lines at the top of the ribs. Bond and rivet end spar cap.




Left fuel line hole, right dual air vent holes with bushings

Nutplates in place

Bonded and riveted! Taking great shape for 4 days!

6/1/2005

Wing

Randy Sill

2.00

Join intermediate rib spar sections, prep, epoxy, and rivet.


 

 

Intermediate rib spar

 

 

6/2/2005

Wing

Randy Sill

3.00

Fit, dril, debur, epoxy, and rivet intermediate spar webs. Epoxy and rivet intermediate cap.




Spar cap in narow section next to center section

Spar caps in wide rib section

Intermediate spar cap

6/3/2005

Wing

Randy Sill

2.00

Remove all clekos from ribs, debur, scuff, epoxy, and rivet ribs to D-Cell. Shim 2 outer ribs to set washout to 2.1 degrees.



 

Ribs permanantly riveted

 

 

6/5/2005

Wing

Randy Sill

6.00

Create flap and aileron alignment templates. Align and rivet flap bushings. Drill and rivet flap controls. Drill and rivet aileron controls. Align, epoxy and rivet aileron horns.




Aileron linkage to rear of wing

Rear wing controls

Aileron with tamplate setting proper height

6/6/2005

Wing

Randy Sill

3.00

Fit, drill, and cleko wing tank access panels to wing bottom. Dril D-Cell spar skin to match spar pre-drilled holes.




Skins fit with clekos, nut plates to be added next

View from the top

Fuel line access section

6/10/2005

Wing

Randy Sill

3.00

Starting from the outside wing tips, fit wing skins, use rib template set hole locations, then drill and cleko.



 

Template used to locate rib drill holes

Bottom skins

 

6/11/2005

Wing

Randy Sill

12.00

Complete bottom skins fit and drill, then dimple skins with rivet dimple die set. My wing will use flush steel and aluminum rivets.



 

Dimple Die Set in rivet gun

Dimpled skins

 

6/12/2005

Wing

Randy Sill

12.00

Repeat skins install for the top side. After full install and dimple on the bottom skins, I got the system down pat and did an even smoother job on top, which is where I wanted it the smoothest.




 

 

Best rivet gun in the world!

6/13/2005

Wing

Randy Sill

3.00

Fit and install 1/4" fuel vent lines and 1/2" fuel lines. Install nylon snap grommets in ribs for fuel line to run through.



 

Nylon snap grommets for insulation

Lines running through grommets

 

6/13/2005

Wing

Norm Sill

3.00

Assist in fuel line installation. Helped make decision on location of fuel exit and how to flair tubing.

 

 

 

 

 

 

6/14/2005

Wing

Randy Sill

2.00

Finish and tighten fuel fittings. Install nuts and washers on aileron and flap controls. Applied medium thread lock on internal nuts and collar locks.



 

Wing fittings all installed

 

 

6/15/2005

Wing

Randy Sill

2.00

Bond and rivet bottom left wing skins. Flush rivets looking good.




Rear spar line, SK42BS 120 degree steel flush rivets

AK42BS aluminum flush rivets on intermediate spar

First panels bonded and in place

6/17/2005

Wing

Randy Sill

2.00

Bottom right epoxy and rivet

 

 

 

 

 

 

6/18/2005

Wing

Randy Sill

4.00

Continue inward with bottom wing skins. Design mount for Rey Allan flaps indicator to properly slide with flap arm.




Bottom wing skinned except for center section

Rey Allan flaps indicator extended

Indicator retracted

6/19/2005

Wing

Randy Sill

3.00

Begin installing skins on the top of the wing. Rivet and epoxy outer skins first.


 

 

Outer skins installed

 

 

6/22/2005

Wing

Randy Sill

2.00

Run wires through intermediate spar to wing tips for landing lights, marker lights, and left camera. Black=Ground, Blue=Marker, Yellow=Landing, White is 2 pair tef shielded for camera




 

Snap grommets for insulation from aluminum

 

6/23/2005

Wing

Randy Sill

1.00

Look over Eagle Fuel cells and dry fit to determine fittings required.




Molded fuel tank (filled with bubble pack for shape)

Only one tank will need the filler neck

Side port that will join the tank next to it.

7/1/2005

Wing

Randy Sill

1.00

Install Fuel Fittings with fuel seal tape. 3/8 FPT to 1/2" Barb. Mount fuel vent line into access panel cover.




Left tank

T connection on inside tanks

Fuel vent line pressure tube

7/2/2005

Wing

Randy Sill

5.00

Install final bottom wing skins and drill inspection plate holes and mount covers




Center section with covers for ailerons and flaps

Aileron inspection left

Aileron inspection right

7/3/2005

Wing

Randy Sill

4.00

Design and install fuel filler caps and flanges




Flange plate will attach to fuel cell

 

 

7/4/2005

Wing

Randy Sill

5.00

Install and rivet wing top surface skins except final center section (wiring needs to be complete first). Cover all sharp edges inside fuel tanks with Seal All fuel coating.




Seal All fuel coating in any abrasive spots

Right wing top surface

Left wing top surface

7/8/2005

Wing

Randy Sill

3.00

Created flanges from 16ga steel to help seal the tank lids. The flange mounts on top of the .040 aluminum caps.



 

Outer tank that will mount to the wing skin with velcro

Inner tank that will mount to the wing skin with the fuel cap

 

7/9/2005

Wing

Randy Sill

3.00

Mounted the final top .040 wing skin.



 

 

 

 

7/10/2005

Wing

Randy Sill

6.00

Mounted full hinges to ailerons, mounted counter balance to ailerons, mounted hinges to the flaps. Aligned and mounted flaps to the wing.




Full length hinges on ailerons

Flaps mounted to wing

Getting close!

7/11/2005

Wing

Randy Sill

3.00

Install ailerons temporary with 2 aluminum rivets. mount and drill wing tips.




Left wing tip cleko in place before trimming

Right wing tip.

1/16 gap between AN4 bolt head and flap

7/12/2005

Wing

Randy Sill

1.00

Determin trim areas and cut to fit. Install right wing tip rib.




Right wing with rib held in place with cleko

View from the top of the wing

Left wing trimmed

7/18/2005

Wing

Randy Sill

4.00

Install MSD waterproof electrical connectors. Insulate fuel cells for outboard tanks and permently install fuel cells in outer auxilery locations. Install wing tip marker lights and landing lights.




Left wing tip with lights

MSD sealed connectors

Outboard tank installed.

7/20/2005

Wing

Dick Imel

3.00

Assist mounting of wing on fusalage. Assist removing wing. Trim oil sump resevoir access on inside of firewall. Drill hole for aileron control rod in firewall. Tim Fisher also assist in wing mounting.

 

 

 

 

 

 

7/20/2005

Wing

Randy Sill

3.00

Place wing on fusalage to align and mount rear attachment brackets. Align, drill, scuff, epoxy and rivet rear wing attach points. Mark aileron arm location and fuel connection location on engine firewall. Remove wing. Mark location of oil sump resevoir on inside of firewall, then trim to fit sump. Drill hole for aileron control rod in firewall.




Wing mounted

Rear attach points epoxied and riveted.

Looking like a plane now!

7/22/2005

Wing

Randy Sill

2.00

Fill rivet dimples with metal glaze

 

 

 

 

 

 

7/23/2005

Wing

Randy Sill

5.00

Finish metal glaze and wet sand smooth.

 

 

 

 

 

 

7/24/2005

Wing

Randy Sill

4.00

Finish wing tip lighting mounts and rivet tips to wing with several aluminum rivets to be drilled out to access final light assembly. Mask lights and wiring, then spray primer on bottom side. G.B.P Self Etching primer from Sherwin Williams.

 

 

 

 

 

 

7/25/2005

Wing

Randy Sill

4.00

Turn wing over and primer top side.

 

 

 

 

 

 

7/26/2005

Wing

Randy Sill

6.00

Mask pattern to wing and spray yellow paint. Sherwin Williams Ultra 7000 base coat. Remove mask and apply new mask to the yellow paint following first mask lines. Spray blue metalic to center section.


 

 

 

 

 

7/27/2005

Wing

Randy Sill

5.00

Mask blue paint to protect and spray orange. Mask orange and spray Victory Red. Mask red and spray metalic green to wing tips.




 

 

 

7/28/2005

Wing

Randy Sill

5.00

Turn wing over and mask matching pattern on bottom of wing. Mask all areas that could cause overspray on wing top. Spray yellow, then blue.

 

 

 

 

 

 

7/29/2005

Wing

Randy Sill

5.00

Spray orange, then red, then green tips. Remove all masking paper to prepare for clear coat.

 

 

 

 

 

 

7/30/2005

Wing

Randy Sill

4.00

Spray Ultra 7000 139 Super Glamor clear coat to bottom of wing.

 

 

 

 

 

 

7/31/2005

Wing

Randy Sill

3.00

Flip wing over, airbrush small areas of overspray, then clear coat top of wing blending to bottom.




Prior to clear coat

Center blue

Wing complete!

8/4/2005

Fuselage

Randy Sill

1.00

Create fiberglass mold for wheel pant skirt from original plastic part.

 

 

 

 

 

 

8/5/2005

Fuselage

Randy Sill

3.00

Prep fusalage for painting, apply masking tape to any areas that may enter fusalage, scuff all shiny surfaces.

 

 

 

 

 

 

8/5/2005

Fuselage

Randy Sill

2.00

Clean and scuff fusalage skins to prepare for painting. Complete molds for wheel pant skirts.

 

 

 

 

 

 

8/6/2005

Fuselage

Randy Sill

6.00

Mask all areas not to be painted, mask doors so they can still be opened, but covered when open. Primer fusalage with 2 coats.



 

 

 

 

8/17/2005

Fuselage

Randy Sill

4.00

Finish green and blue base coats, then clear coat.




 

 

 

8/21/2005

Fuselage

Randy Sill

2.00

Size and pre-punch rubber weatherstrip on main door and left window. Install lexan in main door. Even with 090 lexan plus weatherstrip, AD42 rivets still had a good grip on the backing plate. Install Left window.




Left Window

Weatherstrip

Interior Vinyl

8/21/2005

Fuselage

Sharon Sill

1.00

Sharon operated rivet gun as Randy placed rivet washer on the inside.

 

 

 

 

 

 

8/28/2005

Fuselage

Randy Sill

3.00

Paint aluminum hinges, assemble and rivet rear door, rivet hinge to front door, rivet front door to fusalage.




Full hinge for front door

Light tinted lexan

 

5/27/2006

Avionics

Randy Sill

8.00

Wire EIS, EFIS, Radio, Intercom, etc.



 

 

 

 

5/28/2006

Avionics

Randy Sill

4.00

 

 

 

 

 

 

6/3/2006

Avionics

Randy Sill

6.00

 

 

 

 

 

 

6/11/2006

Miscellaneous

Randy Sill

2.00

Assemble aircraft as it will be flown for W&B. Left main tire 313#, Right main tire 313#, Tail wheel 21#.


 

 

 

 

 

6/11/2006

Avionics

Randy Sill

7.00

 

 

 

 

 

 

Total Hours

420.00