Charles' Cozy Mark IV Project

Serial # 1394

Website last updated on: December 7, 2009

Page updated on: December   1, 2007
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

Chapter Status


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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 5:25

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 6:55

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 1:40

Step 1: Carving foam

Feb 10, 2008 Feb 11, 2008 7:43

Step 2: Fiberglassing

Feb 10, 2008 Feb 14, 2008 8:58

Step 3: Shoulder support

     

Step 4: Making headrests

Feb 10, 2008 Feb 10, 2008 1:53

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 9:10

Step 4: Spar Cap Layup

Jul 7, 2009 Jul 7, 2009 6:29

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 5:29

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 1:20

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 4:28

Step 3: Fitting elevators & torque tube to fuselage

Chapter hours

17:40

Chapter 13
Nose, Nose Gear
& Rudders
Sep 20, 2009 Oct 1, 2009 5:26

Step 1: Reinforcing the glass strut

Oct 16, 2009 Nov 13, 2009 23:01

Step 2: Fabrication of the NG-30s

     

Step 3: Installing the electric nose lift

     

Step 4: Installation of the nose box on fuselage

     

Step 5: Adding the nose floor and sides

     

Step 6: Installing the rudder pedals

     

Step 7: Installing the master brake cyclinders

     

Step 8: Completion of the nose gear

     

Step 9: Piping the pitot & static system

     

Step 10: Closing the top & finishing the outside

     

Step 11: Making the door for the nose compartment

Chapter hours

 

Chapter 14
Center Section Spar
     

   

     

   

Chapter hours

 

Chapter 15
Firewall
     

   

     

   

Chapter hours

 

Chapter 16
Control System
     

   

     

   

Chapter hours

 

Chapter 17
Trim System &
Center Console
     

   

     

   

Chapter hours

 

Chapter 18
Canopy
     

   

     

   

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

914:02