Items which are done have been moved to bottom of list. 1. buy/build wing a. Robby Grove ($11-12K) b. Craig Catto ($7.5-8K) Will be making with Craig along with new stabilizer c. Cassutt Parts Kit ($3500) X d. Gary Davis ($1000) Bought this at Reno 2001 3. rebuild engine (Dave Meyers @ CPE?) a. blueprint b. port c. polish d. lighten pistons e. lighten crank f. lighten case g. balance h. ceramic coat engine i. paint case j. anodize/chrome valve covers k. shape cam m. bake on dry lube and oil shedding coats n. seat/rethread spark plugs 9.5. strip frame and repaint w/ Zinc Chromate 10. make wheel pants & gear leg fairings b. FG-705 Gear Leg Fairings $75.00 11. connect brake system 19. buy/make fuel tank a. FS-100 Fuel Tank $450.00 b. FS-#1 Fuel System Kit $575.00 20. buy/make oil tank 21. make firewall a. SM-101 Firewall, Stainless .030 $105.00 23. buy seat parachute 27. buy tachometer (or use Kart system) 33. prime 34. Come up with paint scheme 35. paint 41. Sponsors 42. make instrument panel a. SM-110 Instrument Panel, Cut no holes, $75.00 45. duct tape around wing & stab 47. safety wire everybolt/nut/etc 49. form canopy frame 50. build latching mechanism & emergency escape system. 51. buy/make floorboard & seat pan & seat back a. SM-170 Aluminum Bulkhead Cockpit, Rear $65.00 b. SM-171 Aluminum Bulkhead for Racer $65.00 c. SM-175 Aluminum Floorboard $45.00 52. buy/make fuel sight gauge. a. HW-760 Fuel vent assembly $35.00 53. Build engine cooling boxes a. EN-350 Engine Baffle Kit, Cont. 0-200 for FG-200 $280.00 X b. Copy templates out of "Firewall Forward" by Tony Bingelis - $0.00 54. mount oil cooler 55. attach engine hoses & wires 56. Plumb instruments a. HW-750 Pitot tube assembly $35.00 499. Weight and balance 500. FAA Airworthiness Sign-off 501. test fly, checking incidence, cooling, speed, flutter, g-limitations, fuel system, oil system, engine, control effectiveness, etc. 502. set incidence 503. glass in horiz. stab and wing roots. 504. build trailer for plane and wing 800. Weight and balance (again) DONE: X0. buy builder's manual & plans X a. DOC-100 Builders Manual $15.00 b. DOC-105 Brochure/Info Pack $5.00 X c. DOC-110 Cassutt IIIM Plans $150.00 d. DOC-115 Newsletter (calendar year) $20.00 X 0.5 buy Scotty's Fuse ($1800) X a. fuselage X b. engine mount X c. ldg gear X d. wheels X e. brakes X f. fin & rudder X g. stab & elevator X h. control connections X i. turtledeck X2. buy engine a. Trade-a-plane runout $350 b. Trade-a-plane runout $900 c. new $10K X d. Bought from Dave Nicholas at Reno 2001 ($2500) X4. buy exhaust (short stacks, or tuned pipe?) a. EN-200 Exhaust Pipe Kit with flanges, short 0-200, set of four $110.00 Xb. EN-200W Exhaust Stack, welded (short) $180.00 (given to us by Scotty Crandlemire) c. EN-201 Exhaust Flanges, 0-200,set of four $40.00 d. EN-202 Exhaust Pipes, Short Stack set of four $80.00 e. EN-300 Oil Suction Adapter for Inverted Flight $95.00 f. EN-315 2 into 1 Exhaust Kit with crankcase augment system $420.00 g. Four into 1 exhaust (same as on Outrageous) ~$1800 X5. buy brake master cylinders a. GE-150 Hydraulic Master Cylinders, set $145.00 X b. Robbie Grove $200 X6. buy brake and rudder pedals a. CO-200 Rudder Cables, swaged $115.00 X b. CO-205 Pedal Kit (Rudder & Brake) $100.00 c. CO-205W Pedal Kit, welded $150.00 d. HW-500 Nylon Bushing, 7/8" Sleeve Rudder Cable, set of twelve $18.00 X7. weld elevator control tube back on x8. buy new tailwheel a. GE-540 Tail Wheel, Polyurethane $35.00 X9. buy new main wheels Xa. GE-101 5:00 x 5.6 6 ply tire $55.00 X 2 Xb. GE-102 Tube for GE-101 $50.00 X 2 x10. make wheel pants & gear leg fairings xa. FG-316 Wheel Pants, Brakes Faired In $215.00 X12. buy throttle and mixture vernier cables a. CO-220 Throttle Quadrant, 2 lever side mount $75.00 X b. bought throttle from David Hoover $40 X c. bought mixture cable from Aircraft Spruce $20.60 X13. buy airspeed indicator x14. buy altimeter x15. buy CHT/EGT indicator X16. buy rebuilt MAGS X a. bought from Dave Nicholas with engine X17. buy right angle plug wires X a. bought from Dave Nicholas with engine X18. buy spark plugs X22. make roll-over structure X24. buy flight helmet X25. buy nomex flightsuilt X26. buy nomex gloves & socks X28. install dummy engine, pipes, oil tank, prop extension, spinner, fuel tank X29. Make cowling and fuselage shape out of foam X30. make cowling and fuselage out of carbon & glass X31. hog out foam X32. sand & fill carbon X _. Buy engine mount parts X a. HW-700 Engine Mount Inserts, set of eight $50.00 X b. HW-701 Rubber Bushings for HW-700, 1 set (8 pieces) $22.00 X35.5. buy propeller X a. Sport prop from Catto Propellers $850.00 X b. Racing prop from Catto Propellers $850.00 X36. buy prop extension a. EN-500 4 " Propeller Extension, for 0-200 $290.00 b. EN-501 6" Propeller Extension $320.00 c. EN-502 8" Propeller Ext. for Racing Cowl $390.00 Xd. 10-3/4" Propeller Ext. for Racing Cowl by Saber Mfg. $900.00 Xe. EN-555 Crush Plate, propeller $27.50 X37. buy spinner bulkheads X a. FG-250 Propeller Spinner, Carbon fiber $225.00 X b. FG-251 Rear Bulkhead for FG-250 $40.00 X c. FG-252 Front Bulkhead for FG-250 $40.00 X38. buy oil cooler X a. EN-310 Oil Separator $95.00 X39. buy steel braided tubes and anodized pipe ends. X40. Come up with a name for the plane. X43. put wing on X a. HW-100 Attach Bolt Kit for Front Spar, Incl. Nuts, set of four $52.00 Xb. HW-120 Eye Bolts for Rear Spar, pair $22.00 Xc. HW-135 1/4" Pins for Control Hinges, (11pcs) $12.00 xd. HW-300 Attach Plates Front Wing Spar, pair $25.00 Xe. HW-310 Attach Plates Rear Wing Spar, (4pcs) $26.00 X f. HW-350 Tapered Aluminum Spacer for Main Wing Spar, set of two $40.00 X44. put horizontal stab on Xa. SM-200 Aluminum Cover Plates, Stabilizer Mount, set of two $25.00 X46. make tail dolly/towbar X48. buy canopy X57. Buy Racing Oil X a. NOT Aeroshell - wny not? did buy Aeroshell 100 Ashless dispersant oil X b. What does Scotty use? X300. learn how to hand-prop X301. Get checked out in tailwheel aircraft @ West Valley Flying Club X302. Get some time in a Pitts. X303. Get FAST signoff (Formation practice) x999. Transport Plane to Reno X1000. Pylon Racing Seminar X1200. practice X1201. qualify for racing x1202. get race insurance X2000. Sign up for Reno Air Races By July 31, 2002 X2200. Sign up Crew Members X2201. Buy T-shirts and Jackets and Hats for Crew X2202. Arrange Hotel Reservations for Crew Engine Race Prep article from Cassutt Newsletter: I will start a series of articles about how to prepare an O-200 for F1 racing. As I do not know every thing I may miss something but these are things I have done and they work. It will be limited for now to meet F1 specs since that what I am going to use it for, otherwise 200-250 hp would be well within reach. What about TBO is a frequently asked question, if you are going to race it who cares? If you are after 2000 hrs TBO don't touch it. You won't get that anyway however, a well built balanced blueprinted O-200 is a better engine than a stock engine out of the Continental factory. Why? Be-cause all the parts and I mean every part is measured and precisely fitted, and balanced to much tighter specs. Where do you start? Tear down the engine and clean all the parts. Then start with the crankcase. After checking for cracks and not having found any, I start to polish the inside of the walls, remove all rough casting surfaces. This facilitates oil scavenging and also removes crack in-ducers. Check that it is straight, use a good quality straight edge to visually check the 3 main bearing bosses for straightness also check the cam shaft bosses the same way. Now check the mating surfaces for flatness. And last check the deck height of all the 4 cylinder base sur-faces. On a high time engine these surfaces are going to be distorted. Use a dial indicator in a height gage on a surface plate and check that these 4 surfaces are the same height and that they are flat and parallel with the mating surfaces. If there are any distortion at all, send it to a shop and have it re-machined, to get rpm's it must be straight, if its not, some of the hp the engine produces get used up just to overcome internal friction drag by misaligned parts. Its better to send the hp to the prop. Check that the hy-draulic lifter bores are not excessively worn. I have sleeved bores that where worn and it works fine but I do not know if an FAA repair station will do this. Also care-fully check all threaded holes for damaged threads, if any just install a helicoil in the hole, if you are not familiar with this find a local machine shop and have them do it or send it to National Aeronautics, we will be happy to help you with this. I also use a Dremel tool and put some grooves in the camshaft bores to help increase lubrication, see photo. Later in the process after test assemblies has been done to determine oil clearances between the crankshaft and cam bearing surfaces I now start to bake on the dry lube and oil shedding coatings, more about that later. I know this may be a bit boring but building a good engine starts with this. Next time we will work on the crankshaft.