Charles' Cozy Mark IV Project

Serial # 1394

Website last updated on: March 8, 2016

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 June    6, 2012 December 3, 2012December 15, 2012
March    5, 2013June    3, 2013June    6, 2014 June    1, 2015
July 21, 2015March  8, 2016

 

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 Dec 11, 2011 6:48

Step 8: Hardpoint reinforcements

Dec 13, 2012 Dec 24, 2012 17:17

Step 9: Access for wing attach and end layup

     

Step 10: Installing in the fuselage

Chapter hours

117:48

Chapter 15
Firewall
     

Step 1: Rudder cable brackets

     

Step 2: Firewall insulation & liner

Chapter hours

 

Chapter 16
Control System
Jan 3, 2012 Jan 3, 2012 1:53

Step 1: Pivot mounts

Jan 3, 2012 Jan 3, 2012 2:07

Step 2: Fabrication of pitch & roll parts

Jan 21, 2012 Jan 21, 2012 1:29

Step 3: Assembly of pitch & roll parts

Jan 21, 2012 April 5, 2012 20:17

Step 4: Installation of pitch & roll assembly

April 5, 2012 April 11, 2012 18:27

Step 5: Routing & rigging the rudder cables

April 21, 2012 Nov 13, 2012; 10:35

Step 6: Rudder stop and brakes

Chapter hours

54:48

Chapter 17
Trim System &
Center Console
May 1, 2012 June 12, 2012 15:23

Step 1: Roll trim

April 21, 2012 Oct 30, 2012; 16:54

Step 2: Pitch trim

July 10, 2012 Nov 13, 2012 77:20

Step 3 & 4: Landing brake, center console, throttle quadrant;

     

Step 4: Throttle quadrant; completed during step 3

     

Step 5: Landing light (Completed in Chap 13; Step 10A.)

Chapter hours

109:37

Chapter 18
Turtleback and Canopy
Dec 12, 2012 Dec 25, 2012 25:39

Step   1: Building the turtleback form

Dec 25, 2012 Dec 28, 2012 17:52

Step   2: Construction of turtleback & inside layup

Jan   2, 2013 Jan   9, 2013 29:48

Step   3: Turtleback bulkhead & rib

Jan 10, 2013 Jan 17, 2013 9:15

Step   4: Contouring & glassing outside of turtleback

Jan 17, 2013; Feb 18, 2013 20:15

Step   5: Installing the windows

     

Step   6: Installing hinges on longerons (skipped (Front Hinged Canopy))

Feb 12, 2013 Feb 13, 2013 5:00

Step   7: Installing upper half of firewall

     

Step   8: Installing the turtleback (waiting for spar installation)

     

Step   9: Engine mount reinforcements (waiting for spar installation)

Feb 19, 2013 Apr   7, 2013 15:32

Step 10: Installing the canopy

Apr   8, 2013 Oct 23, 2013 34:37

Step 11: Building the canopy frame

Oct 22, 2013 Feb 25, 2014 36:00

Step 12: Carving the inside foam

Apr   2, 2014 Apr   8, 2014 26:18

Step 13: Canopy hardware reinforcements & inside skin

     

Step 14: Provision for removable fuselage top (to be skipped)

Mar 13, 2013 Feb 10, 2015 43:19

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

     

Step 16: Installing fuselage top (not needed due FHC design)

Mar 24, 2015 Apr 14, 2015 18:00

Step 17: Canopy lip and instrument cover

     

Step 18: Installing access door (will not be installed)

Dec 23, 2014 Nov  4, 2014 54:20

Step 19: Installation of canopy latches

     

Step 20: Safety catch (skipped, front hinge canopy)

Jan 20, 2015 Jan 20, 2015 1:30

Step 21: Canopy handle

     

Step 22: Canopy stop

Nov   5, 2013 Jan 20, 2015 60:23

Step 23: Cockpit ventilation

Chapter hours

397:48

Chapter 19
Wings & Ailerons
July 5, 2015 July 7, 2015 5:46

Step 1: Building the wing jigs

     

Step 2: Setting up the jigs

May 19, 2015 July 14, 2015 41:47

Step 3: Cutting foam cores

     

Step 4: Assembly of foam cores & lay up of shear web

     

Step 5: Bottom spar cap

     

Step 6: Bottom skin

     

Step 7: Top spar cap

     

Step 8: Top skin

     

Step 9: Wing ribs

     

Step 10: Ailerons

     

Step 11: Controls

     

Step 12: Attachment, wing to center section spar

Chapter hours

 

Chapter 20
Winglets & Rudders
July 20, 2015 July 21, 2015 14:15

Step 1: Cutting the cores

     

Step 2: Glassing the skins

     

Step 3: Jigging upper winglet to wing

     

Step 4: Inside layups

     

Step 5: Outside layers

     

Step 6: Lower winglet attach

     

Step 7: Rudder

Chapter hours

 

Chapter 21
Strakes &
Fuel Tanks
     

Step 1: Fabrication of parts

     

Step 2: Jigging and assembly of parts

     

Step 3: Inside layups

     

Step 4: Vent, screen and drain

     

Step 5: Top skin cores

     

Step 6: End rib and outlet piping

     

Step 7: Bottom outside skin and sump

     

Step 8: Top skin

     

Step 9: Pressure check

     

Step 10: Leading edge and outboard fairing blocks

     

Step 11: Fuel valve, electric pump and gascolator

Chapter hours

 

Chapter 22
Electrical
     

   

     

   

Chapter hours

 

Chapter 23
Engine
     

   

     

   

Chapter hours

 

Chapter 24
Covers & Fairings
Jan 13, 2015 Jan 19, 2015 7:47

Step 1: Map pockets

Apr 14, 2015 Feb 9, 2016 36:42

Step 2: Front armrests

Feb 16, 2016    

Step 3: Front seat thigh supports

Feb 16, 2016    

Step 4: Rear seat armrests

     

Step 5: Heat duct cover

     

Step 6: Back seats

     

Step 7: Landing brake & battery cover

     

Step 8: Canard cover

     

Step 9: Strake fairings

     

Step 10: Wing centerspar seal

     

Step 11 Optional ice shields

Chapter hours

 

Chapter 25
Finishing
     

   

     

   

Chapter hours

 

Chapter 26
Upholstery
     

   

     

   

Chapter hours

 

Phase 1 Flight Testing      

   

     

   

Chapter hours

 

Total Hours

1,866:08