Apr 23, 2024     Finished stick grips - (3 hours)       Category: Avionics

Marked and drilled the top of the left stick for the anchors holes for the infinity grips. New step drill bit and oil worked well to drill through the steel tubing. Installed grip and routed wires thru the grommet at the bottom of the stick. Reinstalled the left stick and grip in the fuselage and found that my static and antenna lines need to be moved to allow room for the aileron pushrod. One step forward, two steps back. Haha. Installed the right grip on the stick and routed the wires out the hole in the stick and installed the grommet to protect the wires. Reinstalled the right stick and grip in the fuselage. May have cocked the grip a little too far to the left, but that is what felt right.

  Apr 22, 2024     More stick grip work - (3 hours)       Category: Avionics

Sat in the left seat to determine stick height and orientation. Installed the side panel since there is an armrest pad to get a more accurate height. Marked the stick and cut to length. It should be almost exactly the same height as the right. Sat in the right seat and figured out orientation for that grip too. Marked the intersection of the tube and base for removal to the drill press. Taped the cut off portion of the left stick to the base of the right stick since they are the same diameter and used a straight piece of steel to mark the centerline of both sides. Started with a #30 bit and progressed to a bit and reamer fro an AN3 bolt per Vans SB. I may order a button pin fastener from McMaster-Carr to make removal easier. Marked the left stick for holes and slot for the left grip. While I was in the seat, I checked on a location for the parking brake bracket which hopefully won't interfere with my knee.

  Apr 20, 2024     Installed left seat - (.5 hour) Category: Interior Finish

Installed the left seat to determine left stick height and orientation.

  Apr 13, 2024     Pilot stick grip - (1 hour)       Category: Avionics

Spent time trying to determine the proper length of the pilot stick and grip orientation on the stick. Need to make sure the orientation is correct since it will not be adjustable after drilling the 7/16” holes for the stick grip. Tried to compare it to the copilot stick, but since it's not removable the lengths will be different to achieve the same height on the cockpit. Tested out my new step drill bit on some scrap tubing and it worked fairly well with some drilling oil. I plan to use a single or double leg spring pin to hold the copilot stick securely in place. As an added plus it came with a new center punch which I needed.

  Apr 10, 2024     Stick grips       Category: Avionics

Finished drilling second hole in copilot stick that is used to secure the Infinity grip. Marked and cut a slot for the wires to pass thru using the stick sleeve as a template. Used my hand grinder to cut the slot and finished up with a sanding drum on my dremel tool. Buffed off the powdercoat with the deburring wheel since the sleeve would not slide on with the powdercoat in place. Installed the copilot stick in weldment in the fuselage and checked for travel. Still interfered with the mixture knob when extended so I'll have to check the aileron travel later to determine if it's a player.

  Apr 09, 2024     Control sticks and grips - (5 hours)       Category: Avionics

Took a break from wiring to work on the stick grips. Marked and drilled both pilot and copilot sticks with 7/16” holes for a grommet where the grip wires will exit. Copilots is above the weldment to make removal easier. Pilot stick has a 7/16” hole in between the elevator weld and the aileron weld. Reasoning being the stick forces are higher for the elevator than the aileron so loss of strength in the stick is minimal. Didn't realize the sticks were different diameters so I don't need two sleeves to make the outer diameter of the stick 1” to fit in my Infinity grips. Pilot stick diameter is already 1” and copilot stick which needs the sleeve is 7/8”. Installed the panel and right seat to check for stick clearance of the panel and engine controls. Also wanted to check for a comfortable stick length. Cut copilot stick to length and had difficulty drilling the upper 29/64” holes for the grip. I think I'm trying to go too fast and the steel hardens. Will try again tomorrow. Also discovered that I mismounted the bracket for the Avidyne navigator so is about 1/2” short to the panel mount. Gonna have to remove the nav metal sleeve and drill out the bracket rivets in the fuse as I've already riveted a large portion of the subpanel in place.

  Apr 08, 2024     Hall sensor and red cube wires - (3 hours)       Category: Avionics

Used some butt splice crimp connectors and heat shrink to connect the hall sensor and red cube wires to the EMS-220 connector wires. Now just need to secure the extra length/service loops to the engine frame along with the engine sensor wires on the right side. Spent some time trying to figure out the mag rpm wires from the drawing. My ElectroAir start switch goes in place of a key switch so gonna need some more info/drawing to wire it up.

  Apr 07, 2024     Hall sensor wires - (1 hour)       Category: Avionics

Pulled the Hall sensor wires back to the firewall along with the orn/wht wire from the EMS-220 connector. I plan to splice these wires into the red cube wires forward of the firewall for easier access. Planning to use a red crimp butt splice unless I can find something better.

  Apr 01, 2024     Shunt wires and red cube wires - (3 hours)       Category: Avionics

Installed the 4-40 ring terminals on the ends of the alternator shunt wires from the EMS-220 harness. Added some heat shrink and installed on the shunt. Installed the OLC-1 connectors on the red cube wires after getting another set screw I lost earlier. There is some debate on the security of these connectors so I added some heat shrink and lacing cord to ensure the connection and strain relief. Rerouted the Hall sensor wire through the right firewall penetration and through the 3/4 snake skin to the EMS-220 connector. Did some research figuring out the connection between the Hall sensor and the EMS-220 wires. Strangely the white/orange wire from the connector connects to the white wire from the sensor and the white/orange wire from the sensor connects to the red wire from the red cube. (See dwg) Meanwhile the blue/white wire from the sensor connects to the black wire from the red cube. Seems like that could have been coordinated a little better. I just twisted the wires together until next work session after I determine the best way to splice the appropriate wires together.

  Mar 25, 2024     More engine sensor wires - (3 hours)       Category: Avionics

Spliced the remaining engine sensor wires to the fuel, oil and manifold pressure wires with heat shrink for support and stain relief. Finished the molex connector for the manifold pressure wires. These molex pins were larger than the ones I've installed before so had to use the “B” portion of the crimpers. Also added a ring terminal for the oil temp sensor wire and connected it to the oil temp sensor. Looked at the mag rpm wires and not sure about where to add the 30k resistors per the drawing and even if they are necessary. Also not sure how to wire up the ElectroAir mag. Gonna check the installation instructions.

  Mar 24, 2024     Unknown wires and Engine sensor ground wires - (2 hours)       Category: Avionics

Used the multimeter to find the pins for the 3 mystery wires. Marked the locations on the connector drawing and secured them to the other wires I don't need. As you can see in photo of the wires in my hand there are 3 ground wires, two aux fuel tank wires and the 3 extra wires. Not sure what to do with the extra wires so I'll give AFS a call for suggestions. Added a molex ground wire to the manifold pressure connector then soldered the fuel, oil and manifold pressure ground wires to the ground wire from the engine sensor connector. Added several pieces of heat shrink to secure the connection and add some strain relief.

  Mar 23, 2024     Engine sensor harness wires - (2 hours)       Category: Avionics

Continued to label the engine sensor wires. Pinned out the 6 ground (black) wires using the multimeter to determine which were which. Also labeled the trim sensor wires that will not be used since I'm using the ACM. Still have 3 wires that don't match the drawing that I'm not sure where they go. Looks like another email to Jonathan at Advanced.

  Mar 14, 2024     EGT/CHT connectors - (3 hours)       Category: Avionics

Installed the remaining EGT/CHT connectors to the SV-EMS-220 harness wires. Used my multimeter to verify the connection of all the connectors to the SV-EMS-220 dsub connector. Added some service loops and may have gone a little overboard, but I can always reduce the extra wire later. Now I just need to clean things up and secure the extra wire.

  Mar 13, 2024     More wire routing and Engine wires - (2.5 hours)       Category: Avionics

Ran the left and right fuel sensor wires from the SV-EMS-220 wire harness out to each wing. The only problem is they only reached as far as the wing spar through the corrugated tubing. White wire taped to the smaller fuel sensor wires is just a pull wire I used to get the fuel wires through the corrugated tubing. Gonna need to splice some wire to get out to the wings. Pulled some of the engine wire back to the SV-EMS-220 connector to provide a large service loop just in case I need to drop the platform the SV-EMS is mounted on for repair/replacement. It looks like a birds nest now, but I'll clean it up with some lacing cord or zip ties. Installed a couple spade connectors on the ends of the right side of the engine (CHT cylinders 1 and 3) along with more service loops. Also added two separate pieces of heat shrink to aid in strain relief. Maybe not needed, but sorta a belt and suspenders approach.

  Mar 12, 2024     More wire routing and TV upgrade - (2 hours)       Category: Avionics

Routed the SV-EMS harness red cube wires to the red cube. Also routed the two wires from the SV-EMS harness to the alternator amp shunt. Got a new TV from the misses as an early birthday gift and mounted it on the shop wall. As you can see from the photo it's a nice upgrade from the old one. Looks great and just in time for March Madness.

  Mar 11, 2024     Stick wiring harness - (2 hours)       Category: Avionics

Installed the stick grip harness for both pilot and copilot sticks. Routed the wires through the left side corrugated tubing with a pull wire. Had to pull left and right wires separately since there is very little room left in the tubing for wires. Was able to route the wires through existing pass throughs in the wing spar and to the vicinity of the bottom of the sticks. Plan to use 15 pin connectors and have the wires exit the stick about half way down (hidden by the stick boot) and into the area below the sticks. Will drill an exit hole in the stick on left or right side since the side loads on the stick will be less than the forward and aft loads. Photo of wires in my hand are the remaining wires from the wing that will have to get to the panel somehow. (Heated pitot controller, nav, taxi and landing light wires)

  Mar 07, 2024     Stick grips, wire routing, Engine sensor harnesses and alt static source - (4 hours)       Category: Avionics

Used some scrap throttle bracket to check the fit of my alt static switch and the protective cover. Seems like it will work well. Now to find some space on the panel to mount it. Received the spacers for the stick grips from Infinity that increase the OD of the stick to fit the ID (1”) of the stick grip. This looks like it will work well after I determine the proper length of the stick, but I need to install the panel to find that, so stick grip progress is on hold til then. Decided to install the engine sensor harness and EGT/CHT (brown wires) harness to the SV-EMS-220. The engine sensor harness connector thumb screws did not want to cooperate, but I was finally able to secure it after getting it exactly square to the opposing connector on the SV-EMS-220. Routed the associated wires from each harness to the appropriate firewall pass through and temporarily taped each wire to the corresponding engine sensor wire (EGT/CHT). Then began process of labeling and routing all the engine sensor wires in the correct portion of the aircraft. LOTS of wires to try and figure out the best and correct placement of each. Trying to not get overwhelmed by the myriad of wires and remember “one wire at a time”. :)

  Mar 02, 2024     Roll servo wires, new dessicant - (1 hour)       Category: Avionics

Installed dsub sockets on roll servo wires and inserted in 9 pin connector. Need to figure out a way to secure the connectors and prevent any interference with the aileron bell crank. Replaced the desiccant on #2 and #4 cylinders and both exhaust pipes.

  Feb 29, 2024     SV-EMS tray, Roll servo wires, Heated seat and Red cube wires - (4 hours)       Category: Avionics

Matched drilled, deburred, and primed the Z bracket to secure the SV-EMS tray. Installed the bracket with AN470 rivets and a nutplate on the tray. The tray is super secure now. Prob wasn't necessary and not the most elegant solution, but makes me feel better about wear and vibration over time. Belt and suspenders. Ran wires from the red cube to the SV-EMS unit, but this prob wasn't necessary since the SV-EMS harness has the wires for the Red cube already. Installed the right seat to try and figure out a good location for the heated seat control. Tried to position the controller between the seat and the side wall, but not sure there's enough room. Decided to install the rest of the right side interior just to see how it looked. Pretty happy with how it turned out. Interior is by Robert Lemke out of Germany. He was great to work with. Decide to pull the roll servo wires out of the right wing and install the sockets and connector on the opposite end so I won't have to try and do this after the wing is installed. Figured it would be easier to install the connector and dsub pins in the panel later. Gonna try and not use a connector at the wing/fuse intersection. Also marked on the stick where the boot reaches. Plan to drill a hole in the stick on the side for the wires to exit. Decided side loads would be less than forward and aft loads on the stick and further away from the bottom weld would be better too.

  Feb 28, 2024     Word from AFS on stick grips - (1 hour) Category: Avionics

Got word from AFS regarding the stick grips and how to utilize the extra two buttons that are not supported by the ACM. AFS sent a new schematic/wiring diagram to show the connections.

  Feb 28, 2024     Vans reply to front left gusset holes - (.5 hour)       Category: Fuselage

Got word from Vans that I can drill holes in the front left fuselage gusset to secure the SV-EMS-220 mount.

  Feb 28, 2024     Prop oil line grommet - (1 hour)       Category: Engine

Installed a rubber grommet around the oil line to the prop near the ring gear. Had to slice the grommet and force it in place. Did some trimming, but gonna need to add some sealant to make it secure.

  Feb 27, 2024     Final installed side subpanel, SV-EMS-220 support and ElectroAir MAP sensor - (2 hours)       Category: Fuselage

Riveted left outer subpanel (F7105B-L) to the fuselage rail gusset (F-721A-L). Was able to squeeze two rivets, but had to use the rivet gun on the two inboard rivets. Tried to connect the ElectroAir MAP sensor to the MAP line, but was unable to due to the size of the fuel vent tubing and the inner diameter of the MAP sensor tubing. (1/4”) Will try to find a 1/4” fitting tonight. Modified a Z angle to aid in support of the bracket for the AFS SV-EMS-220 (engine sensor module). Not sure if this is the best solution, since I have to drill two 1/8” holes in the forward left gusset. Probably give Vans a call or email.

  Feb 25, 2024     Stick grips and wire ties - (1 hour)       Category: Avionics

Spent some time comparing the AFS wire diagram for the stick grips versus the Infinity grip drawing. I've got two buttons on the grip that may not be functional due to lack of inputs on the stick grip connector. Need to contact AFS for some assistance. Installed some lacing cord on the pitot lines and wires coming into the fuse from the wing. Secured the wires coming forward from the rear of the aircraft thru the wing spar.

  Feb 24, 2024     Subpanel rib and manifold transducer - (2 hours)       Category: Fuselage

Removed the manifold transducer to rivet the subpanel rib (F-745-L) to the firewall. Used solid rivets, pulled rivets and AN3-5 bolts to secure the rib and manifold transducer to the firewall. Had to use the pulled rivets due to the inability to reach the two lower holes. Used both the hand squeezer and pneumatic squeezer to reach the other rivets.

  Feb 18, 2024     Tail light wire - (2 hours)       Category: Lighting

Found a way to route the tail light wire through the aft bulkheads F-711 and F-712. I used a gap in the F-711 longeron stiffener to route the wire and drilled a hole in the aft bulkhead per Dwg OP 56-2. Used pitot tubing to protect the wire from chafing on the bulkheads and also for strain relief. It was the perfect size

  Feb 17, 2024     Tail light wires and stick grip connector - (1 hour)       Category: Avionics

Marked the cabin heat and park brake brackets for holes for nutplates. Spent some time trying to figure out where to drill a hole in the aft bulkheads for the tail light wire. Previous owner drill the holes in the wrong place for the stinger bracket so now I have too many holes too close together for the correct #4 bolt locations. Gonna have to call Vans for recommendations on how to correct this. Thinking I may be able to just add some AN3 bolts in the aft bulkhead without sacrificing edge distance. Also spent time trying to figure out how to make the connection between the stick grip wires and the AFS wiring drawing.

  Feb 15, 2024     More wire security - (2 hours)       Category: Avionics

Added some more lacing cord to the wires in the center tunnel. Also tried to secure the wires in the flap motor tower. Not entirely happy with the extra wire length and loops, so I'll address this again later. Also ordered some more wire to connect the fuel flow transducer.

  Feb 15, 2024     Cabin air and parking brake brackets - (1 hour)       Category: Instrument Panel

Finally got back out into the shop and the project after two weeks away due to a pinched nerve in my back. Cut the extra bracket I received from AFS for the parking brake and cabin heat cables. Not exactly sure where I'll locate them until I get a chance to sit in the cockpit and ensure leg clearance.

  Feb 01, 2024     Stick grips - (2 hours)       Category: Avionics

Pulled out the right stick grip and labeled the wires per the instructions. Added an additional tie down for the ELT wires. Removed the electric boost pump to determine a path for the pitot and static lines.

  Jan 31, 2024     Pitot and static line routing - (2 hours)       Category: Avionics

Cut and installed a T for the pitot line to slice it into the fuselage from the wing. It the will supply the ADHRS and the backup EFIS. Routed the static and pitot lines to the panel. Removed the fuel selector to ensure clearance under the electric boost pump. Will prob just route them on the outside of the left corrugated tubing thru the subpanel to the panel since I still need room in the corrugated tubing for wires from the wing lights and pitot heat controller.

  Jan 31, 2024     Fuel line routing - (1 hour)       Category: Fuel System

Spent time trying to get the fuel line routed from the fuel selector out to the wing without any interference with wiring and chafing the fuel line cover. The fabricated line has a metal braid and is flexible but does not conform well to the two 90 degree bends needed. Plan to email the manufacturer and see what can be done.

  Jan 31, 2024     Pitot tube routing and new wing spar penetration - (3 hours)       Category: Avionics

Added a few tie downs to the flap motor tower to secure the motor wires. Marked the extra throttle plate to cut for possible cabin heat and parking brake brackets. I'll install the panel, sit in the fuselage and try a few possible locations before committing to installing the brackets. Researched the Vans website to determine wing spar penetration locations to add a new pass thru for the pitot and static lines to the backup EFIS. Found a drawing on the Vans website for acceptable hole locations. Measured and measured and measured some more to figure out the best location of the new holes. Marked, drilled, deburred and installed 5/8” snap bushings. Fed the tubes thru and called it a day.

  Jan 29, 2024     Aileron trim wires and servo mount - (4 hours)       Category: Avionics

Finished up the service bulletin on the flap motor rod end. Already had the hole drilled and the wire run just needed to twist it and cut off. Continued to work on the center fuselage tunnel wires. Replaced a few zip ties and installed some lacing cord in between each tie down to further secure the wires. Reinstalled the flap motor wire connectors after removal of the previous ones for rerouting. Temporarily taped the wires in place on the flap motor mount. Need to add a few tie downs to secure the wires. Final installed the aileron trim servo and made the connection to the panel wire using some D sub pins and receptacles supported with heat shrink. Pinned out each wire to the ACM flap/trim connector to verify the wiring before securing the D sub pins. Placed heat shrink around each wire Dsub pin with a larger diameter piece of heat shrink to finish it off. Installation of the aileron trim servo was pretty difficult with the elevator pushrod installed. Required various tools and techniques.

  Jan 26, 2024     Mid fuselage wire runs - (2 hours)       Category: Avionics

Secured SV-EMS cable to tie down I installed the other day to prevent chafing on some rivet ends. Added some lacing cord to several more places in the mid fuselage. Connected the DSub pins for the aileron trim servo. Routed the flap motor wires to the flap motor. Will secure those next session.

  Jan 25, 2024     Defrost fans wire - (1 hour)       Category: Avionics

Installed a D sub pin on the defrost fan wire and inserted into the Aircraft aft ACM connector. Also played around with location of cabin air and park brake cables.

  Jan 24, 2024     Aircraft ACM forward connector - (3 hours)       Category: Avionics

Populated the aircraft ACM forward connector with alternator filed wires. Installed a nutplate to hold an Adel clamp for some wires going to the ACM.

  Jan 24, 2024     Reinstalled the baggage floor pan - (1 hour)       Category: Fuselage

Reinstalled the baggage floor pan with #8 screws. Also reinstalled the flap arm weldment with AN3 bolts and difficult to reach nuts and washers.

  Jan 23, 2024     Baggage floor pan - (3 hours)       Category: Fuselage

Removed the flap arm weldment to reinstall the baggage floor pan. Opened up and deburred all the rivet holes to allow installation of #8 screws

  Jan 23, 2024     Aft wires - (3 hours)       Category: Avionics

Spent a lot of time using lacing cord to replace some zip ties and secure the wiring in the aft fuselage. Added a couple tie downs to prevent chafing on some wires on rivets. Added a lot of lacing cord ties to the aft and center section wire runs.

  Jan 22, 2024     More flap position sensor work - (3 hours)       Category: Avionics

Secured the flap position sensor and mounting bracket with some #6 screws and nuts. Ran the flap motor and spent time adjusting the RC pushrod arm to ensure travel of the flap weldment arm didn't exceed the travel of the position sensor arm. Trimmed the pushrod to length and bent the end at a 90 to fit into the small bracket on the Adel clamp. Secured the sensor wires and connected to the panel wires with D sub pins and sockets. Used some heat shrink for added security and chafing prevention.

  Jan 17, 2024     Flap position sensor bracket - (6 hours)       Category: Fuselage

Reinstalled the flap actuator weldment (WD-613-EF) that was removed to install nutplates. Removed flap position sensor to fab new mounting bracket. Used a paper template to aid in fabbing a new bracket for the flap position sensor that would align it better with the travel of the flap actuator arm. Deburred and primed a new bracket. Removed the left seat belt anchors to allow room for my pneumatic squeezer and installed a one legged nutplate. (Knew I'd miss at least one). Installed an additional tie down for the flap position sensor wires to prevent chafing.

  Jan 16, 2024     More nutplates - (3 hours)       Category: Fuselage

Finished up the nutplates on the rear edge of the baggage floor pan. Added a couple more nutplates since I removed several rivets that used to secure the floor pan and found one not done on the right side as well. All done with nutplates; at least for now, I think. Match drilled the new (added) nutplates to the baggage area bulkhead (F-701). You can see in the photo the left side (bottom of photo) has 3 additional holes for #8 screws.

  Jan 15, 2024     More seat pan nutplates - (2 hours)       Category: Fuselage

Finished installing the one legged nutplates I got from AFS. Also installed several regular nutplates too. Just need to install a few more near the rear to finish up.

  Jan 09, 2024     Tail light and ELT wires - (2 hours)       Category: Avionics

Checked length of tail light and ELT wires. Labeled both ends and installed D sub pins on panel end of wires. Trying to finish up aft airplane wiring for the aircraft rear connector. This connector will be installed in the FlyLeds rear aircraft PWB and into the ACM as shown in the photo.

  Jan 03, 2024     Seat pan nutplates - (4 hours)       Category: Fuselage

Drilled, deburred and dimpled the seat pan ribs for nutplates. Installed all the #8 nutplates and the one legged nutplates I had. Need 11 more one legged ones to finish. Used the pneumatic squeezer for the ones closest to the fuse sides and tried to use it for all the others. Had limited success due to access so went back to using the manual squeezer which worked much better. At least I didn't have to drill out any rivets. Not sure it was worth the time and effort versus just reinstalling pulled rivets, but it's almost done now.

  Jan 02, 2024     Baggage and seat pans - (3 hours)       Category: Fuselage

Installed 15+ dimpled #8 rivets for the rear baggage area. Used my manual squeezer and two different yokes to reach all the rivets. Drilled and deburred for about 15 more nutplates that will secure the seat pan. I made both pans removable since I had already drilled out the pulled rivets to install some corrugated tubing underneath for rear aircraft wires. Used a long #40 drill bit to reach some awkward spots and the #8 nutplate installation tool (template) which sped things up.

  Jan 01, 2024     Mounted Hall sensor - (2 hours)       Category: Avionics

Installed nutplates to secure the Hall sensor PWB (for the backup alternator) to the firewall. Used standard rivets to secure the top nutplates and pulled rivets on the bottom two nutplates due to unavailability of space for the rivet gun. Installed the spacers and mounted the Hall sensor PWB to the firewall.

  Dec 31, 2023     Hall Sensor mount - (3 hours)       Category: Avionics

Riveted the seams of the Anti Splat heat shield to fix it in place and installed on the #1 exhaust. Determined the best location for the hall sensor and match drilled for nutplates on the upper firewall. Deburred and drilled center hole for #6 screws. Fabbed spacers out of fuel vent tubing to prevent the back of the hall sensor pwb to contact the firewall.

  Dec 30, 2023     Heat shield - (2 hours)       Category: Engine

Made good use of the front cover of an EAA Sport Aviation edition and constructed a paper template to determine where to cut the Anti Splat heat shield to match the bend of the exhaust. Needed about 115 to a 120 degree bend in the shield. Cut, deburred and riveted the shield to the exhaust to finalize the bends.

  Dec 19, 2023     Engine ground wire and voltage regulator wire - (3 hours)       Category: Avionics

Cut to final length the B&C voltage regulator #3 wire and connected it to power on the shunt. Had to change out the smaller snap bushing as it was too large to slide into the 1/2” #6 bushing. Connected the engine ground cable from the engine block to the firewall using a location for a through bolt near the oil filler tube.

  Dec 18, 2023     Secured pitot and AOA connections in wing - (2 hours)       Category: Wings

Took a break from wiring to address the issues with securing the pitot and AOA connections. Match drilled the bracket I made earlier to the wing rib with the pneumatic drill. Deburred the holes, clecoed the bracket and was barely and I mean barely able to get a rivet puller in through the access panel to be able to get to the rivet and actually pull it enough to get the mandrel to break off. I was then able to tighten down the Adel clamps to hold the connections in place. Connected the pitot and AOA tubes and called it a day. Glad to be done with this. Now to secure the wiring.

  Dec 18, 2023     Connected boost pump gnd wire - (1 hour)       Category: Avionics

Used some extra 14 AWG wire to connect the boost pump to ground. Installed the connectors and ran the wire to the firewall. Not sure where and how exactly I'm gonna make the connection to the aircraft frame.

  Dec 17, 2023     Flap position indicator arm - (2 hours)       Category: Avionics

Fabbed a bracket to connect the flap position sensor and the flap arm. Installed said bracket and connected the RC pushrod to the flap position sensor. Think I'm gonna need a bracket to align the sensor with the arm movement. Also rerouted the wire from the number 3 post on the backup alternator voltage regulator through the firewall with the rest of the power wires.

  Dec 16, 2023     Alternator #2 wiring - (2 hours)       Category: Avionics

Cut the #8 AWG wire to length for the backup alternator and attached a 5/16” eyelet to secure it to the 40A ANL. Added some heat shrink for strain relief. Ran a 18awg wire from the #3 post on the B&C voltage regulator to the post on the ammeter shunt. Will cut to length and attach to the shunt once I receive the 1/4” eyelet for that size wire.

  Dec 16, 2023     Installed new heat muff - (1 hour)       Category: Engine

Removed old heat muff and installed new turbo heat muff from Custom Welding Products. Temporarily attached the scat tube to get the orientation of the muff correct. Will trim the scat tube later when I get the heat shield from Anti Splat.

  Dec 15, 2023     New heat muff - (.5 hour)       Category: Engine

Received new heat muff from Custom Welding with new angled intake and clocked exhaust. Anxious to get it mounted on the exhaust and attach scat tubing to see how it looks.

  Dec 15, 2023     ANL limiters - (3 hours)       Category: Avionics

Cut, drilled and deburred the copper bar to connect both ANL 60A and 40A limiters to the ammeter shunt. Added some heat shrink for limited protection. Wire near 40A limiter is from the backup alternator and plan to connect it to the left post. Orientation/angle of the ANL brackets is to enable access to all fasteners through the motor mount.

  Dec 14, 2023     40A ANL and flap position arm - (2 hours)       Category: Avionics

Got some new items from Stein to finish the wiring from the backup alternator to the 40A ANL and mount the ANL block to the firewall. Test fit the ANL block and limiter in position. Marked up the copper bar I received for connecting the two ANLs to power. Found some scrap .063 to use for connecting the flap arm to the flap position indicator with an Adel clamp and RC aircraft pushrod. Marked it up also for cutting.

  Dec 13, 2023     Pitot tube bracket - (3 hours)       Category: Wings

Fabricated a bracket to secure the pitot lines in the wing. Installed a couple nutplates to hold the Adel clamps and attempted to install in the wing. Difficult if not impossible to tighten the Adel clamps with one hand. Will try and rivet the bracket to the rib then tighten the clamps. Still unsure if this is going to work.

  Dec 12, 2023     B&C voltage regulator wires - (1.5 hours)       Category: Avionics

Installed another ground wire and power wire to the B&C voltage regulator per the instructions. Not sure if power wire gets spliced into the field wire so I'll try and call them tomorrow. Added another tie down to the AP servo connectors for added security.

  Dec 12, 2023     Connected pitot and AOA - (1.5 hours)       Category: Wings

Trimmed AOA and pitot tubing and attached to pitot tube. Spent some time trying to figure out how to secure the tubing and wires. No great solution yet.

  Dec 11, 2023     Pitot tube and heat controller - (1 hour)       Category: Wings

Wires from the pitot heat controller were long enough to reach outside the pitot mast so I connected the spade connectors of the controller and pitot and installed the pitot tube. Now to figure out how to secure the wires and tubing inside the wing.

  Dec 10, 2023     Pitot mast installation - (4 hours)       Category: Wings

Installed the pitot mast on the left wing. Took some time to cleco the bracket in place inside the wing “in the blind”. Used some RTV to seal the mast to the skin and reached inside the access hole to rivet the mast and bracket to the wing skin and rib. Hard to find and buck the rivets from the access panel as well. All in all it turned out ok and didn't have to drill out any rivets. Used pull rivets to secure the bracket to the near rib. There was just enough room to get the rivet puller inside the wing to “pop” the rivets. Installed the pitot tube for fit and remembered I needed to tighten the fittings to the aluminum tubing. If I had to do it again I would not have placed the pitot so far outboard. It's been a pain trying to do the installation from the nearest access panel. Still need to figure out how to secure the wiring and tubing inside the wing. Tightened up some wiring zip ties in the back of the fuse in preparation to finish that up.

  Dec 09, 2023     ANL amp limiter locations - (3 hours)       Category: Avionics

Determined final locations of the two amp limiters for the alternator and backup alternator. The angle of the mounting brackets is for ease of access to the bracket mounting screws and fuse mounting screws around the motor mount. Secured the bracket for the main alternator with the 60 amp fuse and will install the bracket for the backup alternator when it is delivered next week. Used some gasket sealer to seal the holes to the cabin side. Also simulated the backup alternator wire and slipped the Hall effect sensor over it to try nd get some idea of how to mount the tiny circuit board securely. Not sure as of yet how I'm gonna handle that.

  Dec 09, 2023     Pitot heat controller installed - (1 hour)       Category: Wings

Reinstalled the pitot heat controller in the left wing on a rib next to the access panel. Super tight quarters trying to get both hands in and secure the controller to the rib. Once the wings are installed I may regret this location, but will go with it for now. I can always mount it to the back of the access panel cover later if needed. From here I plan to connect the pitot tube and and secure the tubing. Not sure how I'm going to do that though. Wish the previous builder had not closed up the wings prior to this, but I think I can come up with a plan eventually. Some of the photos have light reflecting which is from the LEDs on my borescope lens.

  Dec 08, 2023     Pitot heat controller and flap/trim connector - (2 hours)       Category: Avionics

Added heat shrink to flap/trim connector and installed plastic cover. Secured connector to the ACM. Added a pigtail to the pitot heat controller where the previous owner clipped the wires. Got the Hall effect sensor from Advanced Flight for the backup alternator now if I can just figure out where to mount it on the engine.

  Dec 08, 2023     Heat muff - (1 hour)       Category: Engine

Talked with Dave Edwards and tweaked the orientation of the lower duct 10 degrees plus angled the top duct 45 degrees forward.

  Dec 07, 2023     Ordered new heat muff - (1 hour)       Category: Engine

Wasn't happy with the orientation of the scat tube coming out of the stock heat muff so I ordered a custom muff from Custom Welding Products via ACS that orients the exit duct at 135 degrees from the intake duct. This will provide a much better way to route the scat tube to the cabin air duct around instead of through the engine. Made a rough sketch of what I needed for the manufacturer Dave Edwards. Gotta like a guy that has my same first name uses my middle name as his last name. :)

  Dec 07, 2023     Alternator wire and rear aircraft connector - (3 hours)       Category: Avionics

Cut ACM wire to final length and connected to the cold side of starter relay. Used some extra heat shrink for strain relief. Installed an eyelet on the end of the 8 AWG alternator wire. Will wait for the backup alternator ANL 40A limiter to arrive before mounting the 60A limiter on the firewall and connecting this wire. Removed the wires from the rear aircraft connector to add a large heat shrink for strain relief. Cut the flap trim position sensor wires to final length and installed in the aircraft rear connector. Marked the connector with a sharpie for easy identification of the pin numbers and the name of the connector.

  Dec 06, 2023     ACM power cable - (2 hours)       Category: Avionics

Rerouted the ACM power cable per Vans OP-30 drawing. Decided to use the hole in the firewall that I ran in the first place. Drilled a 1/2” hole in the subpanel to accommodate a #6 snap bushing and ran the power to the ACM through it. Attached an eyelet to the opposite end with some heat shrink strain relief and a rubber boot. Not sure how to attach it to the master relay since I'm out of length on he post. May connect it to the starter relay post. Played around with the 60 amp power limiter location on the firewall.

  Dec 03, 2023     Pitot mast support - (2 hours)       Category: Wings

Clecoed pitot in mast in place to try and figure out placement and how to match drill the mast support. Decided to use the right angle drill through the hole in the wing to try and access the rib to drill into. Cut a small piece of scrap to simulate the thickness of the pitot tube. Match drilled the support to the wing rib with the right angle drill (barely reached the rib) and used my new cogsdil deburring bits to deburr the rib holes.

  Dec 02, 2023     More wire routing to ACM aircraft fwd connector - (6 hours)       Category: Engine

Installed ElectroAir MAP sensor and attached the ground wire from the B&C voltage regulator to grounded corner of the MAP. Installed Alt field 2 wire from voltage regulator to the ACM A/C front connector. Drilled, deburred and dimpled the subpanel for AN3 nutplates after I incorrectly installed AN4 nutplates earlier. Installed the ACM. Cut to length Alt 1 & 2 wires and boost pump wire. Installed D sub pins on to each wire. Added a pigtail to the electric boost pump AWG 14 wire. Ran snake skin shielding over said wires and added edge trim to a subpanel lightening hole. Also added some fuel tubing to connect the manifold pressure to the Advanced Avionics MAP sensor.

  Dec 01, 2023     Backup Alternator wires and ELT - (3 hours)       Category: Engine

Removed and replaced ELT “phone” wire connector to pass wire through a snap bushing near the ELT. Now I just need a new male to male connector. Ran the backup alternator ALT field wire and ground wires. Connected Alt field and ground wires to the B&C voltage regulator. Redrew the ACM aircraft forward connector drawing to include the B&C backup alternator.

  Nov 30, 2023     More wire runs - (4 hours)       Category: Engine

Ran three more wires (master relay to master panel, starter relay to start switch and electric boost pump to panel). Added connections (eyelets and spades) on one end of each wire and attached two to the starter relay. Installed some heat shrink for added protection and wire support. I'll install the ACM later and finalize wire lengths. Added a pigtail to the end of the alt field wire for the A/C forward connector.

  Nov 28, 2023     Alternator wires and shunt - (3 hours)       Category: Engine

Finalized installation of the ammeter shunt using some #10 screws in the 1/4” holes which actually gave me a little slop on the ability to locate the screw holes and assemble the shunt to the starter relay. Installed the alternator wire to the ammeter shunt, but couldn't finish since I didn't have a 5/16” eyelet. Tried drilling out the 1/4” eyelet but was unhappy with the edge margin since it is a pretty important connection. I'll order the correct eyelet and install that later. Ran some #18 wire for the alternator field and the wire between the master solenoid to the master panel. Attached eyelets to one end of each and installed, but will wait until I know how I'm going to run the wires before making the final cuts. Need to call AFS since I have some questions regarding their drawing which didn't include my backup alternator.

  Nov 26, 2023     Elevator pushrods - (2 hours)       Category: Fuselage

Sam reinstalled the elevator push rods and the aileron connecting rod with some help from the washer tool. Tight quarters

  Nov 26, 2023     ACM power cord - (2 hours)       Category: Avionics

Cut ACM power cord to length and attached 1/4” eyelet. Master solenoid eyelet bolt is 5/16” so tried to drill out the eyelet with limited success. Gonna prob need to order a replacement with the correct eyelet diameter as important as this connection is.

  Nov 20, 2023     ACM nutplates and ground cables - (1 hour)       Category: Avionics

Cut and installed eyelets on the #10 wire for the ACM ground connection. Drilled and installed nutplates on the subpanel to install AN4 bolts to secure the ACM to the subpanel. ACM only needs AN3 bolts for mounting so drilled out AN4 nutplates. Ugh! Dumb mistake, so will drill subpanel for AN3 nutplates next session. Note to self, put on rubber boots before installing eyelets.

  Nov 20, 2023     Ran the cable for the ACM power - (1 hour)       Category: Avionics

Ran the cable for the ACM power thru the firewall snap bushings

  Nov 20, 2023     Sam installed nutplates - (2 hours)       Category: Fuselage

Sam installed all the #8 nutplates for the bag floor I had on hand and drilled for more.

  Nov 19, 2023     Power cable pass through - (.5 hour)       Category: Engine

Drilled out the power cable firewall pass through to enable the installation of #4 and #6 snap bushings. Installed, crimped and insulated a ring terminal for the end connecting to the ACM. Routed the cable from the master solenoid to the ACM.

  Nov 19, 2023     Stater cable wrap and power cable pass thru - (1 hour)       Category: Engine

Installed some spiral wrap on the starter cable to prevent chafing on the engine sump.

  Nov 19, 2023     Baggage area nutplates - (1 hour)       Category: Fuselage

Sam drilled for nutplates where I removed the floor pan to install some corrugated tubing for wiring.

  Nov 19, 2023     ADSB antenna - (.5 hour)       Category: Avionics

Sam helped rivet the backer plate in the rear fuselage for the ADSB antenna.

  Nov 16, 2023     MAP line and starter to starter solenoid wire - (3 hours)       Category: Engine

Installed two more Adel clamps to secure the manifold pressure line to the engine mount. Installed the #2 AWG cable to the starter solenoid and the starter. Secured the cable at three locations with Adel clamps and standoffs to prevent chafing with the engine sump. Used both of my Adel clamp installation tools which proved invaluable. May need to figure out one more spot that has the potential for chafing.

  Nov 15, 2023     MAP line adel clamp - (2 hours)       Category: Firewall

Drilled out a rivet on the firewall to make a location for an Adel clamp to secure the manifold pressure line. Drilled for a nutplate on the backside. Used a location with a stiffener which proved to be a challenging spot. Ended up mounting the nutplate with pulled rivets since there was no room for a rivet gun.

  Nov 14, 2023     Needed wires - (1 hour) Category: Avionics

Spent some time determining last of the wires I need to complete the wiring.

  Nov 14, 2023     Torqued rudder pedal mounts - (1 hour)       Category: Fuselage

Torqued and marked with torque seal the rudder pedal mounting bolts. Used my new digital torque wrench for the first time. Very easy to get the proper torque.

  Nov 14, 2023     Dynon MAP Sensor - (2 hours)       Category: Firewall

Determined the location for the MAP sensor on the firewall near the transducer manifold. Match drilled, deburred and dimpled for nutplates. Finished installing the MAP sensor. Always a challenge to drill into stainless steel.

  Nov 13, 2023     Subpanel mod - (3 hours)       Category: Fuselage

Trimmed the canopy release tunnel to make room for the Avidyne navigator that extends past the subpanel. Removed the four rivets that support the rear of the nav tray to allow room for the control bracket and reriveted it to the subpanel. Realized later that there was no interference and the rework wasn't necessary. Oh well, at least no harm done. Trying to decide if I want a cable mechanism for the canopy release or forget it and just bolt the canopy hinge in place.

  Nov 11, 2023     Subpanel riveting - (2 hours)       Category: Fuselage

Dimpled and riveted the F-745L to the center panel F-768A using a couple countersunk rivets to prevent interference with the back of the ACM.

  Nov 09, 2023     Cleaned - (1 hour) Category: Workshop

Cleaned the shop for a couple RV builders that are stopping by on Saturday.

  Nov 09, 2023     Andair screws - (1 hour)       Category: Fuel System

Installed the last 4 screws into the Andair fuel selector and “stagged” (used a punch) the screws to the housing once I figured out what that meant. (Thanks VAF) Added some blue 242 loctite for good measure. “Belt and suspenders”

  Nov 09, 2023     Cabin air and parking brake cables - (1 hour)       Category: Controls

Fit cabin air and parking brake cables to the firewall in preparation of cutting to length once I get the panel back in. Plan to cut the plate from AFS to install it on the outside edges of the panel. Sat in the cockpit to see if I had knee room with those in place.

  Nov 09, 2023     Heat shrink to cover bar and battery cable - (1 hour)       Category: Firewall

Added a couple layers of heat shrink to copper bar between master and starter relays and ammeter shunt. Attached #2 AWG cable to the master solenoid with the opposite end going to the battery.

  Nov 08, 2023     Ammeter shunt - (2 hours)       Category: Firewall

Determined location of the ammeter shunt based on proximity to the starter solenoid. Used some leftover copper strip to make the connection. Match drilled the firewall and shunt for AN 4 screws and connected it to the starter solenoid. Added some heat shrink for electrical protection.

  Nov 08, 2023     AFP pump and filter adjustment - (2 hours)       Category: Fuel System

Adjusted the AFP electric pump, fuel lines and filter to avoid interference with the forward edge pump cover (doghouse) F-7115C. Laid out the fuel selector label and knob to see how it looked. This took more time than expected as most things do. Also safety wired the fire sleeve on the throttle cable where it comes close to the exhaust.

  Nov 07, 2023     AFP fuel pump and filter interference - (2 hours)       Category: Fuel System

Installed the AFP fuel pump and filter to check for any interference with the center floor panel. Adjusted the fuel lines and secured the fuel selector valve to to prevent interference with the fuel line between the pump and filter. Installed a tie down for the elevator servo service loop. May need to add the protective trim for the edges of the center panel to prevent chafing of the wires running underneath.