J.D. Stewart's C-II
Owner, UltraFun AirSports,  Norfolk, NE

steakrun6.jpg (33033 bytes)

Be patient.  Lots of pics in here.  Click on Thumbnails to Enlarge

10/02.  Miss Tress has been sold and went to NY.

juststrt.jpg (26288 bytes) Getting started.  Built a table to lay out everything.  Whatever size you build it, it's never big enough :>)  Dan from the factory sent the tail feathers ahead to keep me busy while the plane was being built.
vertstab.jpg (21226 bytes) Gluing the perimeter of the vertical stabilizer.
tailcvrd.jpg (17809 bytes) Tail feathers completed.
ontrailr.jpg (28153 bytes) Picking my C-II up at the factory.  Looks like a submarine project!
vanfctry.jpg (22303 bytes) Ready to leave the factory.
unboxn.jpg (32787 bytes) I've never seen so much cardboard in one place!  3 hours later, it, and all the tape holding it together is finally gone.  It's not an optical illusion.   My garage is actually that big.  I used to own a limousine service and kept the limos in the 54' deep garage.  Makes a dandy aircraft factory!
boxtip.jpg (16336 bytes) Inboard and boxed wing tip detail.  In order to have the sheet lay flat over the rivet holding the rib on, I drilled a hole in the sheet.
buildwng.jpg (31300 bytes) Installing the ribs.  A 4X8 table seems really dinky when you lay a wing on it. 
gluailrn.jpg (31735 bytes) Gluing the perimeter of the aileron.
ribinstl.jpg (31883 bytes) Finishing both ends and running construction string back and forth keeps the ribs all the same height.
sawblade.jpg (13647 bytes) No, it's not there to cut the grass when I'm taxiing, or to scare big iron away.  It's the beginning of my manual disk brake project.  A pair of the calipers were $25, and the rotors will be made out of circular saw blades.  Yes, I have since ground the teeth off of the blade :>)
brakes1.jpg (41263 bytes) And here's the final product.  UPDATE:  The brakes never did hold really well, so I've upgraded to Tracy O'Brien hydraulic disc brakes.  They work so well, I can lock up the wheels at full throttle and skid the tires on the grass.  :>)
tkbreak.jpg (35668 bytes) Taking a break.  Haven't got the wheels on yet, so I can't sit in it and make airplane noises :>(
wingend.jpg (20960 bytes) Covering the bottom of the left wing.
winbotm.jpg (20415 bytes) I have taken the wingtip bows off, as I did with my last plane.  The tips apparently don't provide much lift, and increase drag.  The roll rate will be better.  Wingspan will be 28'.  Kinda like a hybrid between the long wing and a CWS.
porcupin.tif (674643 bytes) All the rib rivets in, ready to pull.  Looks like a porcupine.   These were spaced 5" apart, but I easily had enough left over for 4" spacing.
drillrib.tif (674643 bytes) The easy way to get a hole in the ribs.  Turn them upside down and drill from the inside.  Naturally centers itself.
markline.tif (674643 bytes) Marking a centerline.  On stuff that exceeds the length of the carpenter's square, I clamped on a board to keep it at a right angle.  Hard to see, but those plastic clamps are lifesavers.  Get a couple of the big ones and about 4 of the little ones.  You'll use them a lot when covering.
assyline.tif (674643 bytes) A couple of friends came over one night to check up on me and I put them to work :>)  Here Bryan, Norm and I are installing ribs "assembly line" style.  I would drill, Norm would put in the rivets, and Bryan would pop them.   We did the whole wing in a hour.
pipewrap.tif (674643 bytes) After hearing about the pipe wrap idea, I decided to do it.  Cost, $7, and virtually no weight.
paintcge.tif (674643 bytes) On to the Fuselage.  I painted the tubes that everyone will see.   Didn't paint the root tube, since it would involve a lot of masking or removing of parts.  The contrast looks good.  See the motor mount pic later.
mtrmount.tif (674643 bytes) I painted the motor mounts also.  Looks great.  Notice the fingernail polish on the nuts to confirm if they have loosened.
frontsuspension.jpg (37173 bytes) Custom front suspension, made by Brad Stiefvater.  Plans are on his page in the photo gallery.  One of the best mods ever.
nosecone.tif (674643 bytes) Nose Cone on.  Now we're getting somewhere!
fueltank.tif (679347 bytes) I wish I would have thought of this on my previous plane.  You can never see how many gallons you have.  With the lines marked and moved to the side, I can see all the way down to a gallon (when I'm not flying, or 4 gallons when I am).
sndrclmp.tif (674643 bytes) Putting in the fuel gauge sender.  This was one of the hardest things to do.  I ended up cutting the ring out at its widest point to get it through the cap hole.  I still had to put a slight notch on the filler and force it in.  Be sure you put the sender close enough to reach in there with your fingers to hold it for the bolts.  The string works enough to get it close.
Instruments.jpg (49359 bytes) The completed Instrument Panel.  I love the simple layout possible because of the EIS.  I am a dealer for them and can get good prices on the system.
fusebatt.tif (674643 bytes) Padding the bumpy parts with cotton batting.  A great idea I learned from Oshkosh.  Double up on the piece where the 2 tubes meet the longeron in the middle of the picture.
throttle.tif (674643 bytes) Throttle and Choke cable setup.  I didn't measure according to the instructions (actually I found the measurements after I already drilled).  I sat in the seat and marked where my hand would go.  Worked better.
fuelpump.tif (679347 bytes) Facet pump mounted in series.  Since this picture was taken, I've added the starter solenoid and rectifier to the plate.  Made a neat installation.   Everything is routed through a hole that is buffered by a rubber grommet I made out of a Ford brake reservoir diaphragm.  Works perfect.
plumbing1.jpg (47969 bytes) Completed.  
cbintrcm.tif (674643 bytes) CB antenna and intercom mounted.  All wires route through the down tubes.  The little white piece next the CB coax on the front tube is my outside air temp sender for the EIS.  UPDATE:  I've since gone to a "Real" radio and aircraft antenna.  It was fun to talk to truckers, but nobody else really used CBs.
pitot1.tif (674643 bytes) I don't get brilliant ideas very often, but I got to admit, this is one of my better ones.  After drilling a hole in the front of the nose cone and mounting the pitot tube, 3 pilots in one night knocked up against it!  So I filled the hole and moved it right out to the tip of the nose.  The pitot hose mates to a spark plug boot.  The tube is left over from the fuel tank sender that I had to cut to fit.
pitot2.tif (674643 bytes) The hose and boot were slipped in from the back, and a grommet was made by cutting off the bottom of another boot, and then siliconed to the nose.  Now I can remove the pitot when the plane is parked.  Even if I forget, it is still somewhat flexible if someone bumps against it..

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