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September 2004
I've come a long way since I closed my wings a year and a half ago. Now the to-do list is getting the plane ready for inspection and first flight. Lots of little things still unfinished, but for the most part, my Legacy is nearing completion. The focus of September is cowling, baffling and little things on my list.

After getting the cowl fitted and the lower carbon piano hinge bonded in with Hysol, I installed the top hinge and placed the top cowl on. I then drilled clecos to hold it in position prior to bonding the top piano hinge in place. One thing I'll do to complete this will be to bond a two-bid strip on top the piano hinges for added strength. With everything in place, I wrapped the top edge with electrical tape and filled the low spots on the lower cowl. A typical release. Only difference here is I am mixing flox in with the micro. I found that 2 parts micro to 1 part flox works out pretty well. It gives the filler in this high maintenance area added strength and will guard against cracking/chipping.

So the body work on the cowl moves along including the installation of the oil door hinge and a fix of the lower firewall. When the lower cowl is fitted, there is a notch that I closed up with a scrap of carbon, flox and micro. A little sanding, a release and it now looks great! Easy fix!


Now for the little things. Installation of the battery boxes, body work the rear console and paint, installation of the aileron counter weights and fabrication of a instrument panel brace. I fitted a glare shield I purchased from Leighton Mangles. The one that shipped with my kit did not fit. Period. I understand the mold was corrected. In addition to the fitting, I came up with the idea of having my flexible ELT antenna glassed in RIGHT BEHIND the instrument panel. This will work great. I found this antenna at Dallas Avionics and it is an Artex 110-201.

Another little fix was the area under the trailing wing fillet. I wanted to close up the gap when the flap retracts. Pretty easy. I laid in a three-bid and filled with my new "micro-flox" mix. Sand and paint. Next was the installation the pitot-stact ports and lines. I body worked the ports in flush and did the rear quarter window inside lay-ups. I got a great idea on the LML to use a spackle knife with sandpaper to sand my wing gaps nice, straight and even. I installed my ELT, and strobe power box using click bond studs, then bonded-in the rear tunnel and baggage floor boards. Since I am using the Lancair battery boxes on the firewall, I needed a remote oil filter. I had Richard Ogg make up some custom lines to complete the installation.

Finally the last coat of primer. Finally. Everything is looking good and I'm leaving the fine tuning to Steve Green.


Baffling. The photo of the parts on the wing says it all. It's why I put this job off. I spent eight hours getting to the first eight images. I had some initial problems due to getting an older baffling kit that wasn't updated. You'll note the huge gap in the rear where I'll need to make a patch. The oil box didn't fit either and since it was so close to the cylinder, I cut a hole to allow air to circulate around the cylinder. This idea was from talking to Rob Logan and seeing his LML post. Rob has been a good friend throughout my build and been so kind and patient in taking my weekly calls for tech support. I can't say enough nice things about him, he also hosts this web site. Thanks Rob.

The rear "wings" had to be trimmed and bent in order to not rub on the cowling. It's a good idea to install the cowl and peek under to see how things look. You'll be surprised.

Once the rear wings were installed, everything moved right along pretty straight forward. I still needed to trim and adjust the front baffles to work around the electronic ignition. One note to make if you will be getting an Engine built by Performance Engines, The cylinders are not the tapered style and YOU WILL have to specify a baffling kit to fit a "G" model. Scott Decker at Lancair helped get me the correct parts, answer questions about the fitting and was a huge help. Thanks Scott. In addition, If you have a Performance Engine built, Lancair will do an "Engine Fastbuild" to it, completing the baffling and hoses for you. I would have had it done that in hindsight.



And now some highlights and visitors from September. I met a new Legacy driver who flew into RHV. John Nelson. He was upset about someone leaving his master switch on, so we (Ron Jones and I) hosted him while he got a charging and enjoyed his Legacy sitting on our ramp.

And off to the Air Races with my son Patrick. We had a great time and seeing Darryl's pass on Friday was worth the entire trip. Darryl cautioned Patrick to root for him and ONLY him. Way to go Darryl. It's exciting to see a Legacy fly so fast. His #33 built by Andy Chiavetta has new paint and a new engine (built by Performance Engines!) Click here for all of our pictures.

The true highlight of September was my check out training in the Legacy. I flew with Josh Brungardt and the best thing about training with Josh, is training with Josh. He is very low key, but highly competent. With 500+ hours in "his Legacy" he let's you fly, but he's always "on" so you don't go too far into an error. The check out went fine and I learned early on how this plane can get ahead of its pilot. Everything happens fast and the take-off can be best described as a "flow". It's power on, rotate, gear up, flaps in, prop back, turn downwind. It happens quick. Landings are fast and the stick forces are very light. The key is to keep everything smooth and fluid. After 10 hours in it, I was making perfect deadsticks and felt very safe and comfortable with this plane. I feel a proper check out is so important. In a clean configuration it will glide nice, but once dirty, your rate of decent will be 3000 FPM. It's a matter of holding onto the wheels until you have the field made. Thank you for the training Josh. I enjoyed every minute.

One last note, I can attest to this plane making nice, soft landings. It takes a bit of practice, but it lands as nice as an Arrow once you get the "picture" and can anticipate the sink in the roundout. I love this plane!

So October I will be moving my Legacy to AirCrafters in Watsonville for final assembly, checks and to ready for its inspection (and maybe first flight)! I need to balance the controls still, finish installing the hoses and check each bolt.







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Copyright © 2005. All rights reserved. This site is the builder's log of Don Barnes and for the purpose of sharing information and opinions related to building a Lancair Legacy. Any person using these images, ideas and tips does so at their own discretion and risk. No responsibility is expressed or implied and is without recourse against anyone related to this site. This site is not affiliated with Lancair International or Neico Aviation Inc., however, we love their aircraft.

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