Bill's Aircraft Factory

First Flight


Horizontal Stabilizer

Vertical Stabilizer


Trim Tab


Wings & Fuel Tank




  Page 1

  Page 2

  Page 3

  Page 4

Engine & FWF

  Page 1

  Page 2

  Page 3

Instrument Panel

Electrical System

Building in the Basement and Moving to the Airport

Dynon Autopilot Installation

Things to Consider



Tell me again

Helpful Links

Plane Pictures



bill (at)

Welcome to Bill's Aircraft Factory

Caution - Man running (with) power tools


E The goal became a reality on August 5th 2007.  (Picture taken by Robert Morrison)

Fly-O-Meter: 212 hours as of 1/31/09

1/31/09: Along with a bunch of other RV's and pilots Nora, Turner, and myself loaded up the RV-9 and flew out to 5NC3 for lunch.  The air was VERY bumpy and even though the destination was only 30 minutes away, Nora was not feeling very good by the end of each leg.  Thinking about how uncomfortable the flight was I downloaded the flight data from the Dynon EFIS and plotted the G's and compared that graph to one of the same data acquired from a flight I took a week earlier.  Looking at the two plots really helped me understand her discomfort.  For those non-pilots out there; yes, we do tend to get desensitized to turbulence but that doesn't mean it doesn't bother us or that we don't recognize the discomfort of our passengers.  Check out the new trip report.

1/22/08: How to make a transition for a 4" round SCAT tube to a rectangular firewall mounted oil cooler.  See the "Things to Consider" page.

1/16/08: I haven't been doing much flying as of late, the new addition to the family has been keeping me away from the airport.  However, I did manage to make up an inexpensive engine pre-heater.  Check out the last entry in the "Things to Consider" page.

11/12/08: Added two entries to the bottom of the 4th fuselage page.  One for a fuel sampler cup holder and the other for the tie downs I'm installing in my baggage compartment.

11/4/08: Updated the trips page by adding pictures from the trip to OSH and added one more item to the bottom of the instrument panel page.

10/29/08: It has been a long summer with lots of flying.  Dynon was gracious enough to select me to Beta test their Autopilot, which meant a good bit of flying.  I defined a good bit of flying as 50+ hours.  As is typical with any new system, there were bugs to be worked out, improved functionality defined, implemented, and tested.  It was a great experience and one for which I am very grateful for the opportunity to participate in.

Details on my autopilot installation can be found here.

I just had to add this audio clip as I found it too funny.  Probably because somewhere in my distant past I actually picked up an engineering degree.

7/1/08: Since April I've been slowly working to balance my CHT"s.  Although they were not out of line, I would like to get them balanced and provide for more cooling air.  Read about my trials and tribulations on Engine Page 3.

6/28/08: A bunch of us flew North of Roanoke, VA to Hop-Along field to visit Stormy and his lovely wife!  Check out the pictures on the Trips page

5/28/08: More work on the lower intersection fairings.  I've been working on other things but need to get these done before my next flight.

Added a diagram detailing the P-mag preflight check sequence to the electrical page.

5/15/08: The lower intersections fairings are under construction and are looking good.  Pictures are on the 4th Fuselage page.

The other challenge I have is getting the cylinder cooling under control.  A little bit of fiberglass AKA micro-balloons work is under way in an effort to give the airseal fabric a smooth surface to seal against.

Not much is going with the -9.  I still need to make the gear leg intersection fairings.  That may happen next week, we will see.

I did add two new pictures to the engine page depicting the size of the holes required for the MA-3 Carburator.

A friend and RV-7 builder took my paint scheme and using painted up this 3D model for me:

Check out the latest trip report, flying through cold and snow.

Every new builder goes through the frustration phase.  This is when you do something to a part and realize it no longer meets your exacting quality standards.  In the building of N941WR a lot of former beer cans gave up their lives only to find themselves in my dead parts pile, waiting to be recycled back into beer cans.  Tonight while cleaning out the 'ol Basement Aircraft Factory I finally piled up all the dead parts and took a picture.  Just remember when you damage something, it is not the end of the world.  Order a new part from Van's and move on.  Besides, as you can see from this picture, you can use those parts to make other things, such as doors to cover your ELT and strobe power pack, if you mount them under your baggage compartment floor.

Every once in a while you run across a really great deal on an airplane and even though you can't take it home you want to help the owners find a new home for their prized possession.  Such is the case with N5745E.  This pretty little C-150 is owned by some good friends and it has been lovingly cared for by them for over 10 years.  Click on the picture below to read more about it.

If you like what you see, contact Andy or Mike, I have nothing to do with the sale or plane other than getting the word out for them.

Not much flying going on but lots of work.  My first attempt at modifying RV-7 intersection fairings didn't work out so well.  Bummer as it now looks like I will do it the way Van's calls for in the plans.  Jack the plane up, align the gear leg fairings and then get some molding clay and fiberglass out to make the intersection fairings.  Not a big deal, it is just finding the time to do it with the holidays coming up fast.

Today I finally installed the center tunnel cover and carpeting.  I didn't have the camera, so no pictures.  Completing that task sure makes the plane look like a production aircraft.

A friend up in Alaska who is building a big footed RV-9 asked if I couldn't take some pictures of my engine installation.  Thus the new FWF page.  Mike, I sure hope that helps.

Check out the TRIPS page for pictures.

Build-O-Meter: 2832 hours as of 10/17/07.  (Updated page 2 of the engine page - How I fitted the spinner.)

It flies, and it flies great!

 Click here to go to the 1st. Flight Page.  This page has been updated with the first installment of my speed testing.


New Trips Page Page.  Now that N941WR is finished and flying, I will document some of the adventures she takes us on.

Blog section moved to below these pictures.

Empennage:  (265 hours, Updated 7/18/06)
Wings:  (605 hours, Updated 7/15/07)    
Fuselage  (1274 hours, Updated 5/27/07)
Engine and Firewall Forward (400 hours, Updated 10/17/07)
Instrument Panel  (176 hours, Updated 4/6/07)
Electrical System (115 hours, Updated 6/17/07)
Things to Consider (Updated 10/14/06)
Building in the Basement and Moving to the Airport (Updated 6/30/07)
Tools (Updated 3/1/07)
Tell me again how I got into this?
Helpful Links (Updated 3/28/05)
Plane Pictures (Updated 8/22/06)

8/5/07 - It flies!  See the First Flight Page for details.

7/22/07 - Weighed it and performed the weight & balance calculations.  990 lbs empty with a CG of 78.82".  This means that two 220 lb passengers and 60 lbs of luggage can fly it and land with 10 gallons of fuel and remain within CG.  Here is a spreadsheet of my W&B.

7/15/07 - Updated the wing page with the new pitot tube connection.  The AN fittings just didn't cut it.

6/30/07 - Giving birth!  It is now at the airport.

6/17/07 - We are getting down the wire and I haven't spent much time updating the web site.  The wings and tail are now at the airport awaiting the fuselage, which will follow in a few weeks.  The canopy needed some work as did the P-mag wiring.  If you follows my suggesting for wiring the P-mags, check out the electrical page.

5/27/07 - Three different Tech Inspectors checked out my engine installation over the past week.  There were some minor items to clean up.  Check the issue section on the first page of the O-290 engine section for details.

5/18/07 - Working on a bunch of the little things such as installing the trim cable bracket, fitting the TW springs, and riveting on the forward top skin.

5/6/07 - Making progress.  The EFIS-D100 from Dynon was sent back for the screen upgrade.  This will make the unit much brighter!  I continue to work on the engine installation.  Although simple and I don't have much left to do, work is getting in the way of me completing the plane and moving it to the airport.

4/14/07 - The FAB is done, or almost so!

3/20/07 - Added issue #10 - Fitting the Inter-cylinder baffles

3/8/07 - Moved the Blog down here based on the input from a site visitor.  Not much going on right now.  Most of my time has been spent doing 101 little things that are required prior to moving it to the airport.

3/6/07 - Posted pictures of the completed panel.  I've been busy working on the engine baffles and will post some pictures soon.

1/22/07 - Updated the Engine page by adding some comments on fitting the baffling.


Work has slowed down and I have more time at home, which means there is extra time for me to update the web site.

The brake line dilemma has been resolved.  I elected to switch to stainless steel brake lines from the firewall bulkhead fitting all the way down to the brake calipers.  Not a big deal and the total cost was around $45.  One advantage of living the heart of NASCAR country is that I had the things made up by a local speed shop.

When I first created this site I mentioned that I might use some type of red, white, and blue paint scheme.  Nice thought but not what I'm going to do.  Here is what my current thinking is.  Just let it be known, that I reserve the right to change my mind at any time.

One thing that I have made up my mind about is that the plane will fly for a year or so before it gets painted so there is a VERY good chance this design might just change.

If you have been following my lead on installing the brake lines, check out the fuselage page.  My ideas may not work out.

When I stared this project back in 2003 I thought it might take between 2,000 and 2,200 hours to complete.  Based on those numbers I should be finished soon.  In reality I now think it will take me around 2,500 hours to complete.  This is mostly due to the amount of rework I have done because of dumb mistakes and changes (improvements, if you wish to call them that.) I have made.

Few builders have the engine issues I have caused myself due to the engine I have elected to install.  In addition, the throttle quadrant added some time as did the custom work on the Affordable Panel required because of the throttle, etc., etc., etc.  Every little change adds time.  Maybe not for that change but it might impact something down the road.

Do not take this as complaining.  I would make the same improvements again, if I were to start over today.