Apr 29, 2024     Purchased Fuel Sender Wire       Category: Fuel System

Purchased 30 feet each of AWG18 Red Tefzel wire and AWG18 Black Tefzel wire for the wing fuel senders from Stein Air. I had them twist them together.

  Apr 28, 2024     R/H Wing Recognition Light and Nav/Strobe Light - (3.4 hours)       Category: Lighting

Used a unibit and drilled a 5/16" hole in the R/H wing leading edge for the recognition light. Installed a MS35489-4 grommets. Made two standoffs out of .032 6061-T6 to hold the recognition lights and nav/strobe lights from the bottom skin. One is for the left wing. Drilled two #40 holes for #3 rivets for attaching the standoff to the bottom skin L angle. Attached with #3 AD rivets. Drilled a 1/2" hole through the front spar and rear spar for where those wires will go through. Installed 3 SA-655 snap bushings that are from Stein Air. These bushings have a 3/8" inside diameter. Laid out where the wire standoffs from Zenith will go on the rear spar, P/N 11-03987. Spaced them one foot apart from each other. For the nav/strobe wires I'm using 20 AWG 4 conductor shielded wire. The recognition lights I'm using 18 AWG 4 conductor shielded wire.

  Apr 24, 2024     R/H Fuel Sender Access Cover - (1.0 hour)       Category: Fuel System

Drilled the screw holes in the R/H fuel sender access cover to a #19 for 6 each #8 Screws (MS24694C4 screws). Used the nutplate jig to drill the nutplate fastener holes. Dimpled the holes and installed 6 each MS21049L08 nutplates using #3 AD rivets.

  Apr 21, 2024     R/H Fuel Tank - (1.3 hours)       Category: Fuel System

Drilled the R/H fuel sender wire grommet hole to a 7/16”. Installed an AN931-4-7 grommet in that hole. Drilled the hole for the fuel vent line to a 1” hole so a socket could fit to install the fitting. Cleaned the chips and dust.

  Apr 20, 2024     R/H Wing Upper Skins - (1.7 hours)       Category: Wings

Started taping the areas on the R/H wing upper skins for primer. Removed the wing tip and skins.

  Apr 20, 2024     R/H Fuel Tank - (2.2 hours)       Category: Fuel System

Added cork to the sides of the R/H fuel tank. Drilled a pilot hole for the fuel vent line and fuel sender wires. Drilled 6 pilot holes in the fuel fill tube finishing ring. The grommets edging won't work because it will hit the welds. Once installed I'll put some sealant around the tube to finish it.

  Apr 10, 2024     Fuel Fill Tube Finishing Covers - (1.4 hours)       Category: Fuel System

Cut out the R/H fuel fill tube close out cover. Traced it and cut one out for the L/H fuel fill tube close out cover. Laid out 6 fastener holes one each. I'll use A4 rivets to attach them to the wing skin. I'm also going to put some grommet edging on the inside circle to protect the fill nozzle.

  Apr 07, 2024     R/H Fuel Tank - (7.0 hours)       Category: Fuel System

Marked where the R/H wing fuel sender is on the top skin. Cut a 3 1/8" hole and made a 5" cover from .040 aluminum for the fuel sender access. Drilled the fastener holes in the fuel sender access cover and matched drilled to the skin. Drilled the holes to a #19 on the cover and dimple for #8 screws. Made the L/H wing fuel sender access cover at the same time. Installed cork in the fuel tank bay. The fuel tank fits perfect, nice and tight. Put the top skin on to check the fit around the fuel fill tube. Needed to sand one side of the hole to get the skin to fit. Because of the gap decided to make a close out cover for around the fuel fill tube to finish it off. Laid out the cover from .040 aluminum.

  Apr 06, 2024     R/H Recognition Light - (.6 hour)       Category: Lighting

Put the R/H outboard slat on to mark where the recognition light wiring will go into the leading edge of the wing and marked it.

  Apr 03, 2024     R/H Wing Tip - (1.0 hour)       Category: Wings

Cleco the R/H wing tip into place and finished drilling the holes to a #30 for A4 rivets. I have two holes that are drilled to a #21. The very forward one on the leading edge. That hole is the one I started with and it got a little oblong from the cleco. The #21 bit did clean up the hole. The other hole is in line with the aft spar. I ended up drilling that one to a #21 as I was drilling the aft spar.