Peel Ply
Last layer is this peel ply layer. It helps to get a nice, non waxy surface.
Building Windshield Retainer
The retainer for the front of the windshield is built from fibreglass (GFK). 4 layers of fibre glued together by epoxy. With the experience in fibreglass work from the wing …
Preparing Retainer Epoxy Work
The windshield and other parts are coated with duct tape. On top if this tape the fibreglass retainer will be built. I used duct tape instead of wax paper. It …
Cockpit Ready To Fly
Instruments Panel has been installed this weekend. As you can see, there is an EFIS installed (TL-6624). This EFIS includes also motor control, so the panel is not so …
Top Retainer
The top retainer is from aluminum as well. It will be installed with 8-32 screws and additionally glued with PU.
Windshield Install
Picture shows the right retainer, fabricated from aluminum. The lower retainer will be created from fibreglass.
Windshield Paint Done
The paint is done. I am satisfied with the result, easier than expected.
Paint Booth Ready
Everything is ready for the spraying the paint.
Preparing for Paint
Before installing the windshield, the covered parts have to be painted. Since everything is installed, it’s necessary to do it in the garage. Therefore the garage need …
Cockpit Finish
Unpainted rivets on the painted cockpit parts give a nice finish. It looks really cool and will stay like this.
Instrument Panel Painted
Instrument panel is finished. All holes are done, all parts painted. The instruments itself will be installed later. We decided to build removable panels. This way with a lot of …
Epoxy System
The picture shows the epoxy system we used, all from R&G Faserverbundstoffe. Good stuff, probably much better than necessary for the simple, unstructural parts we had to make.
Painted Panel Parts
With the help of some friends the parts for the instrument panel were painted. 2K color from Mipa worked well and give a strong surface.
Strobe/Nav/Pos Lights
We acquired Nav/Strobe/Pos Lights from AveoEngineering. Great lights. No additional box required, no shielding of the cables necessary. The seem undestroyable and come with a lifetime warranty. With the epoxied …
Strobe Fixing Position
To fix the stobe/position/nav lights at the tips we need to do some epoxy work. Resin with micro-ballons worked well. After sanding a nice fixing plate for the lights is …
Wing tip end done
In the end we had a nice wing tip end. Ready for priming and painting. Since we will mount the tips with screws, it is possible to remove them, so …
Peel Off Fabric
Last layer of the fibre glass work is a special peel off fabric. It gives a nice finish and prevents from sanding the otherwise waxy surface.
Fibre Work at wing tip end
Second step is to lay fibre glass on the end. We used 3 layers of light fibre glass and gave special attention to get nice rounded corners.
Filling Wing Tip End
First step of the fibre work at the wing tip is filling the gap with epoxy mixed with micro-ballons.
Epoxying Wing Tip End
The lower end of the wing tip needs to be trimmed and glued together with epoxy resin. First picture shows the unglued end with a wooden stick inserted to get …
Wing Tip
Wing Tip is installed on right wing. The quality of the wing tip is much better compared to the rudder/elevator tips. Not much to rework. Only modifications I have …
Windshield Vents
I installed two computer fans for venting the windshield. A very easy installation. Seemed simpler to me than installing special ducting outlets. Below you can see the picture from the …
Brakes working
After the brakes were filled with fluid, I tested them. I put pressure on it and checked every connection. No leak occured. The parking brake is working well. Even after …
Bleeding Brakes
Filling the brakes with hydraulic fluid was a job I often thought of. Having done this never before, some consideration was made how to perform it. In the end …
Improving Tips
The tips delivered by Murphy were really of minor quality. They did not fit properly and putting them together left a big channel in the middle. I decided …
Modified Pedal Spring Mount
The manual says to insert the pedal return springs into a hole at the side of the motor mount. I did this first, but was absolutely unhappy with this. …
Parking Brake Position
The parking brake is installed behind the pedals.
Parking Brake
We installed a parking brake in the Rebel. There is a very good description available online from Roee Kalinsky (http://www.kalinskyconsulting.com/rvproj/parkingbrake.htm). I copied this design with some modifications.
Pedal Positions and Brake Cylinders Fixed
I decided to go with 4 brake cylinders. A lot of alignment work to get the pedals totally aligned. Although prepared before I had to wait for this step until …
Motor Mount Fixed
Finally the holes for the mount are done, the engine mounts in place. It was a lot of fiddling work. I wanted to be very precise here to have …