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A few pics of what I have been able to get done over the past few days...
Pics 1 & 2 show the tailwheel area built up and shaped, the plywood plate around the boom will allow plenty of movement for "suspension" and give a good anchor for the covering. I had glued in a shaped 1/8" plywood plate for the stringers to butt up at about the mid point of the rear plate (just ahead of the tailgear boom) and I cut and glued in some 3/8" x 3/8" light balsa into the stringers at the corners and shaped them to give that transition smoother lines.
Next is the main landing gear mount, I used the aluminum angle supplied but I glued in some 1" wide 1/4" plywood blocks to the outside of the tunnel to give a bit more meat to bolt through and I also added two plywood strips across & inside the angle to give the blind nuts something to grab into. The runways I fly off are good but not perfect so I felt a bit more beef was needed. My TT Yak 54 had the same aluminum set up and it did tear out on what I felt was not that tough of a situation and when I rebuilt that area the tunnel sides were split out and the aluminum had hardly twisted so I tried to build this so the aluminum would let go before the sides did.
The hatch is done as far I can take it (until the t-deck is done), everything lined up very nicely and I may sand a very slight bevel to the bottom outside edges of the hatch tabs so they find their slots a bit easier but will wait until I am fitting the finished hatch. The laser cutting has been great and for any parts that need to mesh like this the tolerances are almost too tight!! (good issue to have!). I did use the hatch bolts as clamps as I was gluing them in, I had clamped and taped the hatch base down tight into place with wax paper sandwiched in at the tab locations (for any glue excess) and it worked out very well.
I also glued the fuel tank tray into place with Hysol as I had it mixed up to add in a bit more to the wing tube fillet.
I have this week off work and am hoping to get a bunch done in the next few days..... but my wife also has these days off and there as some things around the house "we" need to get done so I am trying to get them all done asap to give me some more time in the shop!
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) Great service!! I figured it would be way easier to do this now than to try to change these out in the future and as the DA100 is on the low range of displacement for this airframe and we fly at ~3400' ASL I wanted all the help it could get. So I ended up making new mounts for the smaller diameter pipes and again this took several attempts to get it to my liking. The ones I made are light and sturdy, I ended up laminating 1/32" plywood to both sides of 1/8" lite ply for the mounts and this seemed about right. 
Originally Posted by Trumpetman
