2011    updated 13/01/2012

December 2011 - Last week of December and the workshop is "still running hot". Part of the catching up while Bill has been away working.

More balance weights, getting good at casting these things now.

Hardware for linkages in and hooked up and working.

Wing sections and elevators in various stages of putting together. The balance weights need to be finished off, before mounting on the elevators.
See the model Cozy Pieter has carved out of foam and has covered in micro. He needs to sand it smooth so it can be painted. The model plane is made it to scale and will be mounted on a base as a desk model.

Wing sections glued and clamped while the resin is curing.

Taking the wing in its jig outside in the bright light on a good sunny spring day.

Bill checking clearances and finishes before the elevator can be assembled.

Bill has been away working in Joburg. He is back, so the "fun work" has started again.

The left wing nearly there. It is sitting in its jig, as it is becoming quite heavy to move around by an individual. Also, so it can be pushed outside for some workshop space. The dark green part, is the main spar section, made up of many layers of cloth and is extremely strong.

The control linkages are assembled        Bill demonstrating where the flap will fit in.
and in mounted in place.

Pieter and Bill cutting this front section off the foam core of the right wing with the "hot knife".

It requires a steady hand and accurate co-ordination following the jig cutting line,
which has been screwed the the foam.

Going well......                                                             .......3/4 the way through.

....and this is the cut face left after removing this front section of the wing core foam.

Man that hot knife works well!!

Buttering the surfaces to be join with "micro". Cling film is used on the table  to make
sure the "micro" does not stick to the table surface.

Joining the surfaces and using weighted bags to hold the section on the right against the other section.

Bill and Pieter nailing a straight edge to the table to keep the foam cores aligned. They have been checked for alignment and straightness.

Mean while, Pieter had started setting up the jig supports and has mixed the "micro" to glue these right hand  wing sections together.

Pieter has buttered the joint surfaces with "micro".  Bill is clamping the plank straight edges, to hold the wing
                                                                           sections in alignment.

October 2011 - Both Bill and Pieter are multitasking these past months.

Bill squeezing out the excess resin through the peel ply after
laying up the underside of the left wing.

Pieter helping wet out the peel ply with resin.

July 2011 - Both Bill and Pieter have been busy.

The metal plate has been roughed out and is still in progress.  The underside of the engine for measuring the mounting and cutting profiles.

The engine mount stand has been made and is portable for future moving and testing.

Bill is busy with the winglets seen on the bench.

February 2011 - Its been a busy time during January and February. The main spar has many layers to put down, and is now completed. Then the decision for an engine has been made, so other ideas and decisions can be made and the budgets planned.
Another Cozy builder from Polokwane (Pietersburg, north of Pretoria) has been to visit, and stayed 2 days to discuss as many issues and ideas with Bill and Pieter as he could. His name is Pieter Erasmus.

photograph by Pieter Saayman

The spar coming along. On the right is Pieters canard coming along. 

photograph by Pieter Saayman

Pieter was also busy with his canard and has finished the layers and started the filling.

photograph by Pieter Saayman

Some of the fibres are visible which will be bonded to the ends.

photograph by Pieter Saayman

Nearly there.

The spar completed and Bill is happy with the outcome.

The wings are next and this one is being set up in the jig and held in position for joining.

photograph by Pieter Saayman

Bill has decided this is the engine for his plane and is busy loading up after purchasing it.

What on earth is it?

A 13B Mazda rotary, which is fuel injected and turbo charged.

There are a lot of parts which come standard for a motorcar which are not needed.
So Bill is stripping down to check and see the wear on the motor, it looks very good so far.
The clutch has not even worn in, the general condition of the bolts, nuts, pulleys, hoses, 
indicates the motor has hardly been run in.
Those are the inlet ports with the blue gasket surrounding them and the 2 exhaust ports
the darker roundish holes.

The side with the spark plugs.

This is a wooden template for the plate which will become part of 
the engine bracket for the engine mounting. The engine mounting 
fastens to the firewall and this bracket.

Bill has been busy cleaning the starter.

The standard injector body with part of the inlet manifold.

The cast iron exhaust manifold which the turbo bolts too.

The turbo and wastegate body.

The standard alternator which comes with the engine.

The inspection and stripping process will take some time. The wings
are next to do, while the engine is been worked on.