Charles' Cozy Mark IV Project

Serial # 1394

Website last updated on: December 10, 2011

Page udated on:

December 29, 2007
January 24, 2008
February 27, 2008
September 29, 2008
 		December 12, 2008
June 15, 2009
August 19, 2009
October   3, 2009
 		December   7, 2009
March   8, 2010
February   5, 2011
September   4, 2011
 		December   10, 2011

 

Chapter Status


Color coding
Completed: 
In process: 
Not completed: 

Chapter Start End Time Notes
Factory Oct, 2005 May, 2006   Includes:
  • Electrical
  • Insulation
  • Wallboard
  • Painting
  • 4x12 foot workbench
  • Exhaust fan
  • Epoxy hot box
  • Fiberglass rack
Chapter 3
Education		 Aug 15, 2006 Sep 25, 2006    
Chapter 4
Bulkheads		  Nov 19, 2006   Dec 25, 2006   14:00

Step 1: Front seat back
Dec 26, 2006 Dec 30, 2006 19:17

Step 2: Forward bulkhead
Jan 01, 2007 Jan 09, 2007 21:38

Step 3: Instrument panel
Jan 03, 2007 May 15, 2007 33:06

Step 4: Landing gear bulkheads
Jan 04, 2007 May 19, 2007 15:46

Step 5: Firewall

Chapter hours

103:47
Chapter 5
Fuselage Sides		 May 21, 2007 May 25, 2007 11:35

Step 1: Jigs & longerons
May 25, 2007 May 28, 2007 21:20

Step 2: Fuselage forms
May 30, 2007 May 31, 2007 05:25

Step 3: Shaping insides
Jun 1, 2007 Jun 11, 2007 13:25

Step 4: Longerons
Jun 10, 2007 Jun 16, 2007 12:40

Step 5: Lower longerons
Jun 15, 2007 Jun 18, 2007 13:42

Step 6: Fuselage sides

Chapter hours

78:57
Chapter 6
Fuselage Assembly		 June 20, 2007 Sep 13, 2007 44:09

Step 1: Fuselage build
Sep 14, 2007 Oct 17, 2007 36:49

Step 2: Keel & brace
Oct 17, 2007 Oct 30, 2007 37:57

Step 3: Fuselage bottom

Chapter hours

118:55
Chapter 7
Fuselage Exterior		 Oct 30, 2007 Nov   7, 2007 27:00

Step 1: NACA scoop
Nov   7, 2007 Dec 15, 2007 23:14

Step 2: Shaping bottom
Dec 15, 2007 Dec 23, 2007 13:34

Step 3: Fiberglassing
Dec 28, 2007 Jan 3, 2008 06:55

Step 4: Shaping sides
Jan 3, 2008 Jan 24, 2008 21:10

Step 5: Fiberglassing

Chapter hours

91:53
Chapter 8
Headrest & Seatbelts		 Feb 9, 2008 Feb 9, 2008 01:40

Step 1: Carving foam
Feb 10, 2008 Feb 11, 2008 07:43

Step 2: Fiberglassing
Feb 10, 2008 Feb 14, 2008 08:58

Step 3: Shoulder support
     

Step 4: Making headrests
Feb 10, 2008 Feb 10, 2008 01:53

Step 5: Shoulder harness
Feb 14, 2008 Feb 17, 2008 14:48

Step 6: Seatbelts & step
Feb 17, 2008 Feb 23, 2008 29:28

Step 7: Seatbelt attach

Chapter hours

64:28
Chapter 9
Landing Gear &
Landing Brake		 Feb 19, 2008 Feb 26, 2008 26:21

Step 1: Gear bulkhead
Mar 10, 2008 Mar 23, 2008 29:11

Step 2: Start strut install
Mar 23, 2008 Jul 15, 2008 78:48

Step 3: Attach tabs
Jul 17, 2008 Aug 2, 2008 32:41

Step 4: Landing gear cover
Aug 2, 2008 Oct 16, 2008 27:33

Step 5: Axles & brakes
Oct 10, 2008 Nov 1, 2008 47:29

Step 6: Landing brake

Chapter hours

242:03
Chapter 10
Canard		 Jan 23, 2009 Feb 10, 2009 10:25

Step 1: Cutting the Cores
Apr 15, 2009 May 5, 2009 31:30

Step 2; Lift Tabs & Shear Web
May 10, 2009 Jun 30, 2009 10:15

Step 3: Assemble Canard Sections
Jul 1, 2009 Jul 5, 2009 09:10

Step 4: Spar Cap Layup
Jul 7, 2009 Jul 7, 2009 06:29

Step 5: Apply Bottom Skin
Jul 9, 2009 Jul 24, 2009 35:42

Step 6: Hinges, Spar Cap & Top Skin

Chapter hours

103:31
Chapter 11
Elevators		 Jul 14, 2009 Aug 3, 2009 12:27

Step 1: Cutting foam cores & bonding to torque tubes
Aug 4, 2009 Aug 4, 2009 05:29

Step 2: Installation of the bottom skin
Aug 5, 2009 Aug 9, 2009 11:34;

Step 3: Installation of the top skin
Aug 6, 2009 Aug 22, 2009 19:25

Step 4: Installing the NC-6 inserts and the NC-3 hinges
Aug 11, 2009 Aug 27, 2009 22:59

Step 5: Checking the elevator travel & installing tip farings
Aug 27, 2009 Sep 13, 2009 15:28

Step 6: Install pitch trim belcrank & balance weights

Chapter hours

87:22
Chapter 12
Canard Installation		 Aug 31, 2009 Aug 31, 2009 01:20

Step 1: Fitting the alignment pins
Aug 31, 2009 Sep 4, 2009 11:52

Step 2: Aligning the canard
Sep 13, 2009 Sep 16, 2009 04:28

Step 3: Fitting elevators & torque tube to fuselage

Chapter hours

17:40
Chapter 13
Nose, Nose Gear
& Rudder pedals		 Sep 20, 2009 Oct  1, 2009 05:26

Step 1: Reinforcing the glass strut
Oct 16, 2009 Nov 13, 2009 23:01

Step 2: Fabrication of the NG-30s
Dec 27, 2009 Dec 28, 2009 11:10

Step 3: Installing the electric nose lift
Dec 29, 2009 Dec 30, 2009 06:54

Step 4: Installation of the nose box on fuselage
Jan  9, 2010 Jan 25, 2010 48:08

Step 5: Adding the nose floor and sides
Jan 24, 2010 Jan 26, 2010 06:24

Step 6: Installing the rudder pedals
Jan 30, 2010 Mar 30, 2010 24:02

Step 7: Installing the master brake cyclinders
Apr  6, 2010 Jan 18, 2011 30:49

Step 8: Completion of the nose gear
Nov 16, 2010 Nov 16, 2010 03:12

Step 9: Piping the pitot & static system
Jan 20, 2011 Aug  5, 2011 78:22

Step 10: Closing the top & finishing the outside
Aug  5, 2011   18:47

Step 11: Making the door for the nose compartment

Chapter hours

256:15
Chapter 14
Center Section Spar		 Aug 15, 2011 Aug 18, 2011 10:35

Step 1: Center section jig
Aug 18, 2011 Aug 20, 2011  3:15

Step 2: Assembly of foam parts
Aug 17, 2011 Aug 29, 2011 23:40

Step 3: Interior layups
Aug 23, 2011 Oct 24, 2011 25:46

Step 4: Install the forward face
Oct 25, 2011 Oct 29, 2011 19:49

Step 5: Outside hard points
Nov 11, 2011 Nov 19, 2011 13:14

Step 6: Spar cap layup
Nov 24, 2011 Nov 28, 2011 28:10

Step 7: Shoulder harness & outside layups
Nov 29, 2011    

Step 8: Hardpoint reinforcements
     

Step 9: Access for wing attach and end layup
     

Step 10: Installing in the fuselage

Chapter hours

94:49
Chapter 15
Firewall		      

Step 1: Rudder cable brackets
     

Step 2: Firewall insulation & liner

Chapter hours

 
Chapter 16
Control System		      

Step 1: Pivot mounts
     

Step 2: Fabrication of pitch & roll parts
     

Step 3: Assembly of pitch & roll parts
     

Step 4: Installation of pitch & roll assembly
     

Step 5: Routing & rigging the rudder cables
     

Step 6: Rudder stop and brakes

Chapter hours

 
Chapter 17
Trim System &
Center Console		      

Step 1: Roll trim
     

Step 2: Pitch trim
     

Step 3: Landing brake and center console;
     

Step 4: Throttle quadrant
     

Step 5: Landing light

Chapter hours

 
Chapter 18
Canopy		      

Step   1: Building the turtleback form
     

Step   2: Construction of turtleback & inside layup
     

Step   3: Turtleback bulkhead & rib
     

Step   4: Contouring & glassing outside of turtleback
     

Step   5: Installing the windows
     

Step   6: Installing hinges on longerons
     

Step   7: Installing upper half of firewall
     

Step   8: Installing the turtleback
     

Step   9: Engine mount reinforcements
     

Step 10: Installing the canopy
     

Step 11: Building the canopy frame
     

Step 12: Unknown (can't find in the instruction manual)
     

Step 13: Canopy hardware reinforcements & inside skin
     

Step 14: Provision for removable fuselage top
     

Step 15: Canopy hinges; cutting out frame; install drip rail
     

Step 16: Installing fuselage top
     

Step 17: Canopy lip and instrument cover
     

Step 18: Installing access door
     

Step 19: Installation of canopy latches
     

Step 20: Safety catch
     

Step 21: Canopy handle
     

Step 22: Canopy stop
     

Step 23: Cockpit ventilation

Chapter hours

 
Chapter 19
Wings & Ailerons		      

   
     

   

Chapter hours

 
Chapter 20
Winglets & Rudders		      

   
     

   

Chapter hours

 
Chapter 21
Strakes &
Fuel Tanks		      

   
     

   

Chapter hours

 
Chapter 22
Electrical		      

   
     

   

Chapter hours

 
Chapter 23
Engine		      

   
     

   

Chapter hours

 
Chapter 24
Covers & Fairings		      

   
     

   

Chapter hours

 
Chapter 25
Finishing		      

   
     

   

Chapter hours

 
Chapter 26
Upholstery		      

   
     

   

Chapter hours

 
Phase 1 Flight Testing      

   
     

   

Chapter hours

 

Total Hours

1,259:40