Charles' Cozy Mark IV Project

Serial # 1394

Website last updated on: January 24, 2021

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