Well, as of October 21, we passed the one year mark. A few thoughts from the builders seem appropriate. Overall, the experience has been really enjoyable and fun. I think we have made good progress; I've seen some builders of kit planes that are years into their project for various reasons. I know I don't have that much patience. At one point during some aggravating times with a wing fuel tank, I was ready to go out and buy a plane! Really. In fact, the last time I sealed that tank I told myself that if it leaked I was going to buy a plane! Originally I predicted we'd fly within 18 months. I now know that this was newby "optimistic" thinking. While I'm still quite optimistic I can tell that it will take longer. I'm officially extending the fly time to 24 months!!
The actual building was new to us for the most part. As a woodworker, there have been some skills that have been useful such as measuring/marking. Many of the needed tools were already in the shop and I got/get to buy some new different ones! I do like tools. The builder's manual has been an ongoing source of frustration. Since our kit was actually made in 1993, I had to order a current manual and I go back and forth comparing and referencing the two. The builder's group I belong to has been a tremendous source of help, support, and information. I don't think I'd want to build without them. Also very helpful are the builders that have sent photos and tips. (Thanks Charlie, Ben, Ted, and Roger) The tech guy at Murphy has also been a load of help. In July while in Canada, I got to fly in a rebel courtesy of a fellow builder. What a shot in the arm that was! We flew out and landed on a lake (yes, he was on floats!). He let me have the controls on the way back and it was awesome to know that our plane would be very similar to his.
My wife Deb enjoys riveting the most and drilling next. Unfortunately for me, she hates deburiing! We have used close to half of the rivets supplied with the kit--22,000! That's alot of deburring. The control surfaces were fun to build (except when I ruined parts and had to order new ones) and it was great to see a real airplane part come out of it. The wings were more of a challenge but also gave more of a visual reward. We need those visual rewards. We built the second wing in half the time as the first and then had trouble sealing it. It ended up taking about the same amount of time. One cool part for me was running tubing and wire for lights, pitot, etc. One not so cool part was always needing to call someone to help flip the wing.... again. We live in the sticks and there aren't many people around. I never did come up with a safe reliable way to do it on my own.
Now we have started the fuselage and have been working on the tailcone. Again it's a quick visual reward. I need to stay focused on not only interpreting the manual (grrr) but remembering to add certain strengthening modifications in various areas. Luckily, this plane's been around for almost 20 years and there are many people with valuable experience flying it. For instance, over the years they've discovered that float operations will challenge the structure in places-thus the builder mods in those areas. Another thing to think about is that the fuselage is the area where we'll spend our time; there are things that will make flying easier and more fun that we need to think about. Panel layout, nav/com equipment, interior comfort stuff, cowling design...these and more are all on my mind as we build.
So...would I reccomend this journey? If you like building things then this would probably be for you. Heck, I've met guys who just build and sell! Although I like building, I also have a need to get in the air. As a newer pilot I fly twice a month or so to make sure I don't forget how. But I'm ready to stop renting. I know when our rebel's finished I'll fly alot more. Onward!!