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Project: DaveBellairs -
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Categories

Show All Entries - (648)
Research
Workshop - (4)
Empennage - (14)
Fuselage - (54)
Firewall - (78)
Tail Feathers - (40)
Wings - (105)
Controls - (6)
Avionics - (145)
Lighting - (13)
Instrument Panel - (9)
Landing Gear - (4)
Engine - (159)
Propeller - (1)
Fuel System - (7)
Interior Finish - (3)
Paint / Decals - (6)
Inspection
Tools


Builder Name:	Dave Bellairs -

Project:	Vans - RV-7 - VIEW REPORTS
Total Hours:	1452.9
Total Flight Time:
Start/Last Date:	Jun 24, 2017 - No Finish Date
Engine:	Lycoming IO-360
Propeller:	Whirlwind 200RV
Panel:	Advanced Flight Systems Avionics

Friendly URL:	https://eaabuilderslog.org?s=DaveBellairs

Home or Last Project Picture

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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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)

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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”. :)

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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. :)

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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

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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.

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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.

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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

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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.

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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.

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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.

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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.

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

Category: Avionics

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

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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.

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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.

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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.

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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.

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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.

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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.

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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”

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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.

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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.

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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.

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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.

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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.

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Nov 06, 2023 Installed fuel pump and filter - (1 hour)

Category: Fuel System

Installed fuel pump and filter to verify the fuel line route to the firewall. Marked on fuse floor for some tie down points for the fuel line. Rerouted the elevator servo wires with a service loop. Think I've got a little too much extra wire, but better than not enough.

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Nov 06, 2023 Wire chafing prevention - (2 hours)

Category: Fuselage

Added some trim edge covering to the center and cover plate. (F-982C and E). Also RTV'd a cap to the nutplate on the fire wall to protect the corrugated tubing from chafing. Belt and suspenders. Reinstalled the snap bushings -6 and -7 at the firewall for the cable pass thru.

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Nov 06, 2023 Throttle cable cont'd - (1 hour)

Category: Controls

Reinstalled the throttle cable with a cotter pin, torque seal, and secured the cable bolts.

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Nov 05, 2023 Throttle cable - (1 hour)

Category: Avionics

Reinstalled the throttle cable thru the cover plate and with the appropriate sealers/covers that you can see in blue in the photo.

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Nov 03, 2023 Ammeter shunt and throttle cable - (2 hours)

Category: Avionics

Messed with a location for the ammeter shunt and decided the best place would be lower right on the firewall. Removed the throttle cable and drilled the cover plate for a cable pass thru. Made a rudimentary template and used a fuel line to verify Vans location for the hole would work for my cable. Needed to split the called out snap bushings (-6) to make them able to pass over the cable threads. Gonna be a miracle if I can assemble it all back together in the correct order

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Nov 02, 2023 Corrugated Tubing and Andair fuel valve - (2 hours)

Category: Avionics

Removed a nutplate on the F-782 fuel line cover that was chafing the corrugated tubing on the right side. Installed a new nutplate further to the left of the one removed. Secured the corrugated to the firewall stiffener with an Adel clamp. Installed nutplates to the Andair fuel selector valve.

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Nov 02, 2023 Nutplates for ElectroAir EIS controller and corrugated tubing - (2 hours)

Category: Avionics

Removed subpanel rib F-745R to aid in the installation of nutplates. Drilled, deburred and dimpled for nutplates to secure the the ElectroAir EIS controller on the subpanel rib. Worked on placement of the corrugated tubing up the firewall from the sit of the tunnel cover F-782C to prevent chafing.

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Oct 31, 2023 More subpanel nutplates - (1 hour)

Category: Avionics

Drilled, deburred and dimpled subpanel for nutplates to secure the B&C voltage regulator. Installed said nutplates.

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Oct 30, 2023 Nutplates on subpanel - (2 hours)

Category: Avionics

Removed the ElectroAir MAP sensor and the B&C voltage regulator from the subpanel to aid in the installation of the nutplates. Removed the subpanel rib F-745L and installed nutplates for the MAP sensor.

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Oct 29, 2023 Subpanel nutplates - (1 hour)

Category: Avionics

Decided to install some nutplates for the ElectroAir components on the subpanel since it is removed from the fuselage. Drilled the subpanel for nutplates for the MAP sensor.

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Oct 21, 2023 Foam supports and fuel selector - (2 hours)

Category: Fuel System

Cut and glued some extra foam tubing I had on hand. Sanded two sides flat and installed on the Swearingen fuel line from the filter to the firewall. Installed the Andair fuel selector and clecoed the support to the main spar. Opened up the center of the fuel line grommets to be able to slide over the end of the fuel line and inserted them into the opening on the fuselage skin. Gonna need to make a fairly serious bend in the lines to make them fit under the spar covers.

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Oct 19, 2023 Fuel lines - (3 hours)

Category: Fuel System

Began installing the fuel lines, fuel selector, fuel pump and filter to check for fit and any interference with the avionics wire runs. Installed Andair fuel selector after figuring out the correct orientation. Tried to modify some foam tubing I had on hand for the fuel line from the pump to the fire wall. Foam is sorta a stand-off between the floor and the tunnel cover.

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Oct 18, 2023 Bench panel assembly - (3 hours)

Category: Instrument Panel

Drilled out the four rivets holding the rear support angle to the subpanel. Reinstalled the angle on the correct side of the subpanel and secured to the Avidyne nav tray. Reassembled the subpanel on the bench and began routing the cables of the various components to the ACM. Temporarily installed the Avidyne navigator to the panel. It installs from the front using an Allen screw to move it forward into the connectors in the rear.

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Oct 17, 2023 Panel and subpanel removal - (3 hours)

Category: Instrument Panel

Routed the intercom cable to test for fit. Tried to install the Navigator and realized it needs to be installed from the rear. Installed the rear bracket/connectors to the navigator tray. Removed both the panel and subpanel to install the navigator tray. The rear tray angle mount was installed on the wrong side of the subpanel, so those rivets will have to be drilled out and reinstalled on the correct side. Lots of connectors and cables between the ACM and the rear of the PFD.

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Oct 16, 2023 More panel populating - (3 hours)

Category: Instrument Panel

Finished installing non ferrous fasteners to the ADHRS mounting bracket. Added some lightening hole trim to the subpanel to protect the avionics wires. Installed both EFIS screens plus the comm and AP controls to the panel. Did some tentative cable routing and installation of several cables to the ACM. Also removed and rerouted the flap position indicator wire through the wing spar, through the center floor and up the left corrugated tubing to the panel. Plan to remove the panel and clean up some of the wire bundles.

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Oct 09, 2023 Populated ACM - (1 hour)

Category: Avionics

Populated the ACM with connectors and cables of installed units. Swapped the location of the comm and transponder units to accommodate the cable length. Not much length for adjustments, but may be ok. I'll need to secure these cables and add some lightening hole trim protection if I leave the cable routing as is. Studied the rear connector drawing to try and finalize the wires to that connector.

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Oct 06, 2023 Pitot static tie down - (1 hour)

Category: Avionics

Added a cable tie down to the aft fuse stringer to support the pitot static lines.

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Oct 02, 2023 Coax connectors - (2.5 hours)

Category: Avionics

Trimmed the coax to length for the ADSB, Comm and transponder antennas. Installed two TNC right angle connectors and one BNC right angle connector to attach the coax cables to the main units on the subpanel. Tested all connections for shorts and found one cable that would not test ok. After much consternation, found that when the coax was connected to the antenna it would not test properly. Tested all cables unattached to their respective antenna and all tested ok. Soldering the connections proved to be challenging due to the tiny size and close quarters.

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Oct 01, 2023 Coax cable lebgth - (1 hour)

Category: Avionics

Worked on determining Adsb coax cable length with a service loop. Gonna use a right angle connectors for the connections at the subpanel. These connectors use a solder cup to make the connection to the coax wire, so I'll have to be super careful.

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Sep 21, 2023 ELT Antenna - (2 hours)

Category: Avionics

Match drilled, deburred and primed the ELT antenna tab. Riveted the tab to the aft bulkhead and installed the ELT antenna.

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Sep 17, 2023 AP Pitch servo wires - (2 hours)

Category: Avionics

Bit the bullet and cut the AP pitch servo wires to length. Added a service loop at each end, probably a little too much, but wanted to be safe on the length. Stripped and installed female D sub pins, remembered the the heat shrink and installed the connector with plastic cover.

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Sep 15, 2023 Edge trim and pitch servo wire length - (3 hours)

Category: Avionics

Installed some plastic edge trim to protect against chafing of wires in the aft fuselage (F-707 bulkhead), a lightening hole in the subpanel and one of the lightening holes in the seat rib. Installed the AP servo connector to the pitch servo wires and installed the ACM to determine pitch trim servo wire length. Tried to allow for a service loop without too much excess wire.

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Sep 14, 2023 New transponder coax and labeling. - (3 hours)

Category: Avionics

Replaced the transponder coax cable that turned out to be too short after I rerouted it to the panel through the center of the forward fuselage. Luckily I had some extra coax that was the perfect length. Removed all the coax cables and labeled them. Reinstalled same cables and rerouted the comm cable to the center of fuselage since I had some extra length. Added some heat shrink to the connection end of each cable for strain relief.

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Sep 08, 2023 Rerouting transponder wire, more tie downs and hardware - (2 hours)

Category: Avionics

Rerouted the transponder wire thru the corrugated tubing. May be a little short now. Secured the ELT speaker to the lower F-707 bulkhead. Added several more wire tie downs to the aft fuselage. Swapped out the silver screws on the ELT remote control on the panel with some new 4-40 screws and used a sharpie to blacken the head. Haven't been able to find black 4-40 screws.

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Sep 04, 2023 Antennae doublers and wire lengths - (4 hours)

Category: Avionics

Dimpled and riveted the transponder antenna doubler and installed the antenna. Torqued the nuts and applied torque seal. Was able to reach thru the large hole for the wing plumbing/aileron pushrod and get a bucking bar in place without any help. The ADSB antenna is a different story as the reach is too far for one person. Gonna have to recruit Rosy the riveter for some assistance. Used the Cleaveland close quarters dimple dies and my pull riveter to dimple the holes in the fuselage. Tried to finalize the length of the AP pitch servo wires. Struggled somewhat determining how much of a service loop is needed for these wires.

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Sep 03, 2023 Antennae doubler plates - (2 hours)

Category: Avionics

Match drilled, deburred, dimpled and primed antenna doubler plates for the transponder and ADSB antennae. Had to trim and redrill a couple mounting holes for the transponder antenna due to the proximity of the seat rib.

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Sep 01, 2023 Nutplates on subpanel - (2 hours)

Category: Avionics

Installed nut plates on the right subpanel for the remote ADSB and Comm units. Attached the mounting plate for the remote Comm and mounted the ADSB unit. Primed antennae backer plates.

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Aug 31, 2023 ADAHRS standoffs and wire routing - (7 hours)

Category: Avionics

Decided to try a different method to lower the ADAHRS unit using standoffs from fuel line tubing. Installed two to check for fit and decided this was the way to go. Sorta frustrating that. Spent two afternoons working on the other method, but feel this is better and WAY simpler. Now just need some ss or brass hardware to finish. Routed the SV cable and secured it to the F707 bulkhead. Drilled a hole in a firewall stiffener and installed an Adel clamp for the corrugated tubing. Secured a few more wires, coax,Elt and pitot tubes in aft fuselage. You can see where one of the cable tie downs failed to hold. It was the last of the clik bond glue I was trying to use up, so I'm not surprised. Still gonna need to ensure that the others are secure before flight. Decided to install nutplates on the subpanel for the Comm, Xpndr and ADS units. Drilled, deburred and dimpled subpanel for nut plates. Separated backer plates for two antennae deburred, and prepped for primer.

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Aug 30, 2023 ADAHRS bracket - (4 hours)

Category: Avionics

Fabbed another spacer to the z angles to increase the room at the rear of the ADAHRS bracket for the SV connector. Match drilled the new spacers, deburred and primed the left side. Also added a split fuel line to prevent chafing of the SV cable by the edge of the F-407 bulkhead. Not sure if this will be the final design, but is ok for now.

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Aug 29, 2023 ADAHRS bracket - (4 hours)

Category: Avionics

Removed the ADAHRS bracket and removed the SV-ADAHRS unit. Began fabbing a new bracket that will mount to the underside of the Vans bracket to allow easy access to the unit itself and make any removal/maintenance easier. This will also allow more room for the SV connector at the rear of the ADAHRS. Used some old fuel tank z angles, it they weren't quite thick enough to allow room for the unit. Fabbed some spacers out of some scrap angle I had to help with the height problem of the bracket. Need more room as the pitot connections interfere with the front of the bracket so I'll use some even thicker material tomorrow.

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Aug 28, 2023 SV cable and tie downs - (4 hours)

Category: Avionics

Began the day by drilling several in the mid rear bulkhead (F-704) to enable the installation of zip ties to secure the SV cable to the bulkhead. Adjusted the cable length for service loops and snugged down with zip ties. Installed the aft connector on the SV cable and plugged in to the ADHRS unit. Barely enough clearance to seat the connector, so I may move the ADHRS unit below the bracket where a second ADHRS unit would be. This would allow ease of access to the unit and connector for possible maintenance. Installed several more cable tie downs. Trying to secure all these wires is a PITA especially when instructions are minimal.

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Aug 26, 2023 More ELT wire routing and connections - (4 hours)

Category: Avionics

Installed the female end of the molex connector to the ELT data wire and routed it to the wire from the aircraft front. Installed two wire tie downs on the rear bulkheads for the ELT coax and the data wires using #6 screws. These new tie downs work great on the bulkheads. Rerouted the ADHRS cable and the ELT data wire. Replaced the snap bushing for the ADHRS cable to a larger size.

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Aug 16, 2023 ELT and OAT wiring - (3 hours)

Category: Avionics

Spliced the OAT wires to reach the ADHRS from the left wing and connected them to the ADHRS with plenty of extra if needed. Soldered some 22 AWG wires to the ELT data connector. This was probably some of my worst soldering ever. Super small solder pins and in close proximity. Secured the connection with some heat shrink and slathered in some RTV for strain relief. Forgot to put the connector cover on prior to make the solder joints. Had to cut the wire and install a molex connector. Always something.

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Aug 16, 2023 Epoxied tail light backer - (1 hour)

Category: Lighting

Mixed up some epoxy and glued the brass backer to the inside of the bottom rudder fairing. Took a little time to get the screws lined up due to the tight quarters.

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Aug 15, 2023 Tail light installation - (3 hours)

Category: Lighting

Added a pigtail to the FlyLeds tail light using some extra 18 AWG wire I had. Pulled out the bottom rudder fairing and installed the tail light. Super tight working quarters at the aft end of the bottom rudder fairing. Had to trim the interior of the fairing to allow installation of the aluminum backer. Not sure if I need the exterior aluminum plate or not. Sent an email to Paul at FlyLeds to determine a good course of action. Tested the light with a 9 volt battery and it worked great. Big warning about not using a 12 volt battery.

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Aug 14, 2023 Flap motor connectors - (2 hours)

Category: Avionics

Researched the installation of Faston connectors (ES 421-0107&-0108) and installed them on the flap motor wires. Used my new crimper for the first time. Have plenty of extra wire for a service loop, so need to figure out how to secure that.

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Aug 12, 2023 Trim wires - (2 hours)

Category: Avionics

Installed sockets on the roll trim wires and installed pins and sockets on the flap position sensor wires. Also installed pins on the pitch trim servo wires. Had to rerun the flap position wire due to a co flirt with one of the control cables. Hopefully done running and rerunning aft aircraft wires.

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Aug 11, 2023 Reran wires - (4 hours)

Category: Avionics

Spent the afternoon rerunning wires through the corrugated tubing on the firewall and attached pins to the roll trim servo. Plan to use the Stein technique of pins and sockets fastened with shrink tubing to make the connection. The other option is to use D-sub connectors. Finally able to start cleaning up some wires, especially to the rear of the airplane.

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Aug 08, 2023 Firewall corrugated tubing - (1 hour)

Category: Paint / Decals

Cut two lengths of the corrugated tubing and routed the available wires through it. Gonna need to unpin the aircraft rear connector and cut the ELT off the aft end to route those wires through the conduit. Not sure if that's the best option.

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Aug 07, 2023 Wire tie downs - (3 hours)

Category: Avionics

Cut a splice for the OAT wires. Used some extra black wire on hand since the polarity of the wires didn't matter and twisted the pair using my drill. Ran the wires thru the corrugated black tubing and ran it up to the ADHRS via the pitot lines. I'll connect the OAT at the wing root later. Installed the zip ties in the tie downs and loosely tightened the zip ties around the appropriate wires. Tried to figure out the rest of the wire routing on the firewall. Think I'm gonna install some more corrugated tubing and secure that per Vans drawing up the side of the firewall stiffeners.

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Aug 04, 2023 Connectors and tie downs - (4 hours)

Category: Avionics

Spent some time trying to figure out what I needed to connect the elevator and aileron trim wires to their respective harness. Found a Stein video that shows an easy way to make the connection with Dsub pins. Ordered some pins and coax connectors to try and finish off the some of the wiring to those components. Mixed up some Clik-bond and secured 11 tie downs for the wires going aft through the center channel. Had to work quickly as that stuff sets up fast.

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Aug 01, 2023 Pitot lines and flap sensor wires - (2 hours)

Category: Avionics

Cut the pitot line and ran it to the rear of the airplane through the corrugated tubing. Cut a slot in the corrugated tubing and ran the flap position sensor wire through it. Opened up a tooling hole for a snap bushing and routed the wire through it. Cut the static line and connected it to the ADHRS. Installed a snap bushing in the upper rib to route the static line to the ADHRS. Also connected the pitot and AOA lines to the ADHRS. Used removable zip ties that have rubber on the inside for now. Tried to secure the pitot lines, but need a couple more attach points. Installed the exhaust desiccant plugs I got from ACS last week that have been on back order forever. Spent 7/23-7/27 at OSH. Had a great time with Sam.

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Jul 20, 2023 Finished tubing runs - (2 hours)

Category: Avionics

Installed the two remaining brackets and ran the corrugated tubing to the aft fuselage. Cut a piece of the AOA tubing from the wing and ran it aft. Also ran the static line forward for the standby EFIS. On a side note, I dropped the manual pull riveter on the floor of the fuselage and left a nice dent. Hoping the paint shop can work that out.

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Jul 19, 2023 More corrugated tubing brackets - (4 hours)

Category: Avionics

Fabbed another set of brackets for the second tubing run. Deburred, scuffed and primed each bracket. Installed the two aft brackets. Decided the ones for the front were not the correct dimension from the floor rib so fabbed a couple more. Seems like it always takes a few tries before getting it right.

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Jul 18, 2023 Corrugated tubing runs - (3 hours)

Category: Avionics

Fabbed a couple new brackets for under the baggage floor for a little more length. Deburred, scuffed and primed brackets. Installed the brackets with pulled rivets due to lack of space and installed the corrugated tubing. Man that stuff is a PITA to pull thru the holes.

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Jul 17, 2023 Tubing angles - (1 hour)

Category: Avionics

Match drilled two of the angles Sam made to the baggage floor rib.

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Jul 16, 2023 Flap/trim connector and corrugated tubing brackets - (2 hours)

Category: Avionics

I installed the vinyl tape and plastic connector cover on the flap/trim wires. While Sam began fabricating brackets for the corrugated tubing to be installed in the floor of the baggage compartment and seat panels. I also began working on the pitot and AOA bracket to secure the connectors for the tubing and aluminum tubing from the pitot tube.

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Jul 15, 2023 Flap position wires - (1 hour)

Category: Avionics

Stripped the ends and installed pins on the flap position wires. Installed pins in the flap/trim connector.

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Jul 11, 2023 Corrugated tube mount - (1 hour)

Category: Avionics

Fabbed up a prototype bracket to hold the corrugated tube runs to the rear of the aircraft. Gonna need 8 of these for the two runs. Think it'll be a good project for Sam when he's home this weekend. One run will be to get the statictube forward and the pitot and AOA tubing aft. The other run will be for possible future wire needs. As you can see in the photo, a lot of nutplates were removed. Previous owner used the wrong type nutplates to secure the bottoms of the baggage panel. (K1100s) Plan to use leftover baffle scrap to make the brackets and pop rivet them to the seat and baggage floor ribs.

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Jul 10, 2023 Removing Floor panels - (3 hours)

Category: Avionics

Spoke with Vans tech support about getting the pitot and AOA tubing back to the ADHRS unit mounted in the upper portion of the rear fuselage. Decided the best route to go was to remove on set of floor panels to provide access to some tubing to run the pitot lines and possible future needed wires. Since the pitot lines come in from the left wing that's the side I removed. Removal went fairly smoothly with the exception of the rear nut plates. It was difficult to get the drill perpendicular to the rivets to prevent elongated holes. Nothing completely unacceptable, since the holes are just to keep the nutplate from rotating. All in all not as bad as I thought it was going to be.

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Jul 04, 2023 Finding room and a route - (2 hours)

Category: Avionics

Worked on trying to find space for all the cables going to the rear of the airplane. Decided the corrugated duct would not fit thru the holes made for the 5/8” snap bushings. I can get all the cables I need aft with the exception of the 1/4” SV cable that goes to the ADHRS. It fits in a 1/4” snap bushing perfectly, so I just need to find a route that will work to get past the bulkhead just past the baggage area.

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Jun 30, 2023 Empennage fairing and cowl touch up - (1 hour)

Category: Empennage

Sanded down the areas where I applied epoxy and micro to the lower cowl and empennage fairing. Both are going to need a little bit more touch up before paint.

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Jun 30, 2023 Pitot - (1 hour)

Category: Avionics

Tried to do some planning on how to attach the pitot lines to the pitot tube using some sort of bracket.

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Jun 29, 2023 Antenna coax connectors - (4 hours)

Category: Avionics

Practiced stripping coax for the xpndr, comm and adsb antennas. Watched Steins video and used my new jonrad tool. Took a few tries as you can see haha, but I finally found a technique that produced acceptable results. Installed male connectors on the end of each cable run and crimped in place. Crimper worked well for both the pin and connector. Used the voltmeter to check for shorts. Discovered the opposite ends required the screw on version so I'll need to order those. Always something. Spent some time trying to determine the best place for the GPS antennas. Not crazy about putting them under the cowl due to heat and vibration, but don't want to put them on the upper rear fuselage either. May try and get some ideas at OSH for those.

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Jun 23, 2023 Coax and ADSB antenna - (3 hours)

Category: Avionics

Figured out I can get more wires through vans corrugated tube than a snap bushing. Found I could get the SV cable and coax and elevator servo wires through the aft pass through hole near the baggage wall. Ran the antenna coax wires for the transponder, comm and Adsb antennas. Played around with a new coax wire stripping tool with limited success. Worked on a permanent location for the Adsb antenna.

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Jun 22, 2023 Tie down - (.5 hour)

Category: Wings

Tapped the hole in the tie down bar to 3/16x 24 one inch deep for the tie down. Hopefully won't interfere with the temp prob.

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Jun 22, 2023 Transponder and comm antennas - (3 hours)

Category: Avionics

Took the plunge and installed the transponder and comm antennas. Decided to mount them under the pilot's and copilot's seat pan. Makes for a short run to the panel. Also ran the SV cable to the ADHRS in the rear of the airplane . Not exactly sure how to route the cable, Checked to see if I can get the SV cable and two coax cables thru one snap bushing. May have to install Vans corrugated tubing after all since it has a larger inner diameter.

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Jun 19, 2023 Empennage fairing and cowl touch ups - (1 hour)

Category: Empennage

Mixed up some epoxy and micro balloons to fill in some low spots on the lower cowl near the spinner and on the empennage fairing.

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Jun 19, 2023 Pitot tube and bracket - (2 hours)

Category: Avionics

Countersunk to holes for additional rivets in the pitot mast and dimpled the holes in the skin for 426-3 rivets using the blind rivet puller and dimple dies from Cleaveland tool. Also trimmed the angle to fit under the lightening hole in the wing rib and for an adjacent rivet. This should finish up the pitot mast until it's time to final install.

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Jun 18, 2023 Pitot tube and support bracket - (2 hours)

Category: Avionics

Transferred the hike markings on the pitot mast to the lower right wing skin and match drilled the six additional holes for support. Fabbed an angle that Dynon suggests to provide additional support to the pitot tube. Dynon calls out to use a 1”x1” angle, but the hole in the mast I'm going to use for support is 1 1/4” away from the nearest rib so a custom support is needed.

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Jun 16, 2023 Marked pitot mast and coax cable routing - (1 hour)

Category: Avionics

Marked the pitot mast for additional supporting rivets and transferred to the lower right wing skin. Tried to figure out coax cable runs to antennas. There's limited space left for any more wires going through the aft pass through snap ring bushing.

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Jun 09, 2023 Pin removal tool and flap/trim connector - (1 hour)

Category: Avionics

Removed pins installed in error in flap/trim connector using the new removal tool I received. Tool worked well and reinstalled roll and pitch trim pins into flap/trim connector. Also did some rerouting of wires to get wire to connector aligned through the forward snap bushings. Pictures also include broken, cheap plastic removal tool.

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Jun 08, 2023 Antenna wire planning and pitot mast bracket - (2 hours)

Category: Avionics

Spent some time trying to determine the best locations for the 3 antenna I need to install and the routing of the associated cables. Fabbed a1x1 angle to help support the pitot per the Dynon instructions. 1” is too short to reach the pitot mast so I'll try and use some 1.25x1 angle I have on hand and see if that will provide sufficient edge distance. Also discovered the mast interferes with the adjacent rib flange. Will need to trim about 1/32” off of the inboard edge. Felt the interference with my finger and verified it with the borescope as you can see in the photos.

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Jun 07, 2023 More tie downs and labels - (5 hours)

Category: Avionics

Cleaned off the area in the center of the fuselage and forward of the wing spar to attach tie downs for forward wires. Masked off the center of the tie downs to prevent blocking of the channel that the zip ties pass through. Did not do this in rear fuselage and installing the zip ties there was difficult to say the least. Labeled pitch and roll trim wires and attempted to install them in the flap/trim connector. Had the connector upside down and inserted the pins in the wrong location. Broke the plastic removal, so new beefier one is one the way from Amazon. Installed OAT probe in the bottom of the right wing where Vans had a hole in the quick build wing for a pitot probe. Worked well and had just enough room left in the snap bushings to run the wires. Place some fuel line around the wires where they exit the OAT to prevent chafing with the pitot line.

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Jun 06, 2023 Pitch and roll trim pins, ELT wire - (5 hours)

Category: Avionics

Stripped and installed pins on pitch and roll trim 5 wires at fwd ends. Set up label maker and labeled bundles. Will label each individual wire too. Also installed pins on flap motor wires. Ran wire (phone type) to ELT. had to remove and remove and reinstall tail light and pitch trim wire bundles to allow the ELT wire room to pass through the snap bushings. Need to order larger diameter heat shrink tubing for wire bundles for printer. Need to figure out a good mounting location for the ELT speaker.

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Jun 05, 2023 Wire tie downs in aft fuselage - (5 hours)

Category: Avionics

Cleaned up locations for the farthest aft 3M wire tie downs. Mixed up some Clik Bond and secured tie downs to aft fuselage floor. Opened up tooling hole in aft fuselage bulkhead to accommodate the tail light wires and elevator trim wires. Installed a 5/8” snap bushing in said hole. Fabbed a bracket to attach to he aft bulkhead to secure the ELT antenna under the empennage fairing. By turning the antenna mount will provide adequate clearance over the HS spar. Will secure the wire part of antenna later. Used some old house wire to get a good length for the throttle cable. Looks like I need between 52-53”. Will call Vans later for new cable unless I can adjust the one I have to make it work.

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Jun 01, 2023 Forward engine control bracket - (5 hours)

Category: Engine

Completed installation of oil temp control cable and installed control arm to butterfly valve. Checked for full travel and applied torque seal to pass through bolts. Installed nut plates to F-746 fwd engine control bracket for adel clamps that will secure the engine control cables. Match drilled F-746 to lower portion of the subpanel and clecoed in place. I then installed the subpanel and adel clamps for the cables. Still not sure about the throttle cable as it is still too taught to reach an Adel clamp on the F-746 bracket. Called in to Vans to try and resolve and will update later. Installed the engine sensor wires to the SV-EMS to verify clearance with the connectors and it looks good.

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May 31, 2023 Secondary control cable support - (4 hours)

Category: Engine

Safety wired the two bolts that secure the throttle cable to the engine case. Super tight quarters to get the wire tight. Only took an hour and 3 tries. Installed the subpanel to finalize placement of control cables and location of adel clamps on F-746 fwd angle. Marked location of the cables and drilled, deburred and dimpled for nutplates on F-746 angle. Tweeted the routing of the mixture, prop and alt air cables and tightened the firewall pass throughs to secure the cables. Scuffed the F-746 bracket and primed. Trimmed right portion of subpanel to allow room for the fuel vent.

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May 29, 2023 Oil temp cable - (1 hour)

Category: Engine

Rough installed oil temp cable. Will finalize the length once I attach it to the subpanel.

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May 24, 2023 Secured Control cables - (2 hours)

Category: Engine

Installed cotter keys into mixture and throttle cable brackets and verified full and smooth operation. Torqued cable nuts to brackets and applied torque seal. Verified length of prop gov and mixture cables in fire wall pass through and secured both cables. Should be able to secure the cables next session with other structures/cables. Torqued rod end bearing nuts on mixture and throttle cables and applied torque seal.

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May 23, 2023 Roll servo safety wire - (1 hour)

Category: Avionics

What a difference a day makes. Safety wired the two lower bolts on the roll servo mount and was successful on the first try. Drilled a hole in the upper bracket using the pneumatic drill and safety wired the upper bolt as well. Went surprisingly well given the tight quarters of the access hole. Safety wire remains from previous tries.

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May 19, 2023 Roll servo range of motion limiting bracket - (2.5 hours)

Category: Avionics

Connected aileron pushrod to check aileron limit of travel to check full travel with limiting bracket. Had to trim range of motion limiting bracket to clear mounting bolt and rotate the limiting bracket slightly clockwise. This bracket prevents the servo arm from going over center and locking. Tried to safety wire the bottom bolts of the servo bracket, twice without much success, at least to my satisfaction. Will try a third time next session. Hard to get adequate access through the inspection hole. Not sure how I'm gonna be able to safety wire the 3rd bolt on the back of the servo bracket. Will check some other builder sites to see how they did it.

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May 16, 2023 Roll servo over center bracket - (1 hour)

Category: Avionics

Removed the auto pilot roll servo and began to install the roll servo over center bracket. Need to connect the aileron to ensure full travel. Ran out of time.

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May 13, 2023 Roll servo wires and throttle cable pass through - (1 hour)

Category: Avionics

Sealed the hole in the firewall at the throttle cable pass through with snap bushings and permatex gasket maker. Guess it is in the category of “the bigger the blob the better the job”. Ran the wires in the wing for the A/P roll servo. May have to disconnect the connector to run the wires in the fuse.

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May 12, 2023 Roll servo wiring - (3 hours)

Category: Wings

Spent some time cleaning up the shop. Spun the fuselage around with some help from the wife to keep me from running into anything. Opened up the tooling holes in the wing for a/p servo wiring. Opening up the tooling holes in the ribs near the root was a real challenge. Used a 12” bit and a step drill reaching in through the access holes.

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May 11, 2023 HS and Elevators painted - (3 hours)

Category: Empennage

Picked up the HS and elevators from the painter. Reinstalled and checked travel one more time. It was all good. Made a mount out of 2X6 to keep safe on the wall and for motivation. Installed a few cotter pins in throttle and mixture linkages.

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May 10, 2023 Brake lines - (4 hours)

Category: Fuselage

Finished leak test on right fuel tank. Tank pressure remained steady overnight so I feel this tank is leak free. Torqued and applied torque seal to all brake lines and fittings. Installed aftermarket vent line exit ports to bottom of fuselage and aligned with air flow. Torqued all fittings and applied torque seal. May have to go back and prime mating surfaces of aluminum washers.

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May 09, 2023 Fuel caps - (1 hour)

Category: Wings

Removed, disassembled, lubricated and reinstalled both fuel caps. This seemed to help the leaking around the caps. Thanks in large part to all the suggestions on VAF.

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May 04, 2023 Finished SV-EMS mounting tray - (1 hour)

Category: Avionics

Installed and torqued all fasteners for the SV-EMS 220, mount plate, ElectroAir MAP sensor and the BC backup alternator voltage regulator. Hopefully not asking the subpanel rib to support too much weight.

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May 03, 2023 SV-EMS 220 tray - (3 hours)

Category: Avionics

Removed left side of sub panel, F-745L, to match drill for the support angle. Located and match drilled angle to subpanel and mounting tray. Installed 3 nut plates to subpanel and match drilled all to mounting tray. Drilled and trimmed mounting tray plate for the SV-EMS 220 unit. Primed plate.

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Apr 29, 2023 SV-EMS bracket arm - (1 hour)

Category: Avionics

Primed the angle and riveted the reinforcements to the SV-EMS bracket arm.

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Apr 28, 2023 SV-EMS bracket - (1 hour)

Category: Avionics

Made some reinforcements for the SV-EMS bracket to support and strengthen the angle that will support the tray.

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Apr 27, 2023 Wiring and avionics mount - (3 hours)

Category: Avionics

Installed some zip ties loosely, in case I need to add more wires in the ties downs I glued down the other day. Began fabbing a mount on the subpanel for one of the avionics boxes that connects to the engine sensors and various other wires. Dynon calls it the SV-EMS-220. Only took me 3 tries to fab a support that didn't crack when I bent it. Amazing what a small relief hole can do.

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Apr 26, 2023 Throttle cable - (2 hours)

Category: Engine

Installed snap ring bushings per the plans for the throttle cable firewall pass through. Reinstalled throttle cable, adjusted for full throw at the fuel servo and installed heat shield tubing, minus the safety wire. All control cable have been adjusted for full throw when fully forward. You can see about 1/8” gap prior to hitting the cable bracket stop.

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Apr 22, 2023 Prop governor cable and Fw pass through - (3 hours)

Category: Engine

Got some advice from the fellow I bought the prop governor from and decided to cut off the bolt if I could reach it and reinstall the bolt the other direction. It all went fairly well and hardware was reinstalled. Checked the cable for full travel and installed the eyeball pass through.

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Apr 21, 2023 HS and elevator paint

Category: Paint / Decals

Ran over to my painters shop to check out the freshly painted HS and elevators. The photos don't do it justice. It looks awesome. I'm very pleased.

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Apr 21, 2023 Aft wire tie downs - (1 hour)

Category: Avionics

Mixed up some clickbond and set some wire tie downs in the aft fuse.

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Apr 20, 2023 Wire securing - (1 hour)

Category: Avionics

Placed the wire tie downs in some MEK to remove the foam backing in order to glue them in the fuselage. Also measured and marked several locations in the aft fuselage for placement to use for the rear fuse wires.

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Apr 20, 2023 Prop gov rod end bearing - (.3 hour)

Category: Engine

Tried to twist the prop gov cable per Vans tech help to screw the cable into the rod end bearing. Could only get a couple threads to engage. Not sure what to do. At this point I can't remove the rod end bearing due to interference with the prop gov housing and cable bracket. Will prob go on VAF to see what others have done

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Apr 19, 2023 More throttle, mixture and alt air cables - (4 hours)

Category: Instrument Panel

Began by shortening the throttle cable and rod end bearing by 1/4” inch. That seems to be enough to reduce the gap at the throttle bracket and mixture knob. Adjusted the arm throw at the fuel injector servo also. Checked mixture cable for full travel. Installed the cable for the alt air door and trimmed the excess. Installed both eyeball pass throughs for the mixture and alt air door cables. Tried to install the prop governor cable into the rod end bearing by spinning the entire cable without any luck. I called Vans and that is what they suggested also, so I'll try again.
Sealed up the left fuel tank cap and pressurized the tank for leak test. Seems to be holding for the time being, but that is what it's done before. I'll check on it again before bed.

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Apr 18, 2023 HS and elevators

Category: Paint / Decals

On a positive note, my painter got the HS and elevators done. They turned out great.

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Apr 18, 2023 More throttle cable bracket fitting - (4 hours)

Category: Engine

.Used the step drill to open up the holes on the throttle bracket for the prop, mixture and throttle cables. Installed the mixture and throttle cables for fit and length adjustments. Mixture cable is a little too long and throttle cable is a little too short, as you can see when installed on the throttle bracket. Instead the panel and subpanel to check for fit on the subpanel bracket. The throttle cable will not reach the secondary support on the subpanel, so I'm not sure how I'll fix that. Also removed and reinstalled the alt air door cable through the throttle cable bracket.

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Apr 13, 2023 New firewall pass thru and throttle bracket - (4 hours)

Category: Engine

Worked on attaching the throttle bracket to the instrument panel. Installed one nutplate before realizing that the throttle bracket I got from AFS was labeled on the opposite side of the RV plans. Nutplates needed to go on the upper surface of the bottom of the instrument panel. Had to remove the bottom set of switches on the panel to install the nutplates, but from there it went well.

Began installing the second new firewall pass through and match drilled to the firewall. Removed both the prop governor cable and mixture cable to pass through the throttle bracket. Made two 3/4” holes in the scrap throttle bracket to see how it would look. Will make holes in actual bracket next time. Last cable to upgrade would be the throttle cable and I may just use the plastic snap ring bushing and some high temp sealant, since that hole was previously drilled.

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Apr 11, 2023 Firewall pass throughs - (4 hours)

Category: Engine

Began upgrading the firewall pass throughs that were the aluminum screw type to the steel ones I just got. Photo shows the new pass through next to the old one. Tried to connect the prop cable to the prop governor and forgot to remove the inside aluminum ring from the cable. Removed the cable and tried to connect the cable again with no result. The rod end bearing bolt cannot be removed without disassembling the prop gov from the bracket. Spent WAY too much time trying to figure this out and researching on VAF. Decided at supper to try and twist the cable into the rod end bearing with some help from the wife and I think that is going to work. Stand by for further results.

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Mar 29, 2023 Finished SB-00036 - (3 hours)

Category: Empennage

Riveted the painted elevator brackets to the nested doubler, rear spar and forward repair doubler. Also riveted the HS skin, where I removed rivets, to the HS rear spar and nested doubler. This completes SB-00036. YAY!! Installed the HS and elevators on the fuse to check for interference with the elevators and HS upper skin where my painter said it may rub. Removed a small portion of the top aft edge of the HS skin. Will revisit this later at final assembly and modify the up stop if necessary. Used a couple new tools to help with installation and removal of the elevator to simulate the bolts and they worked great.

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Mar 28, 2023 And more SB-00036 - (3 hours)

Category: Empennage

Riveted the right side brackets to the rear HS spar and also riveted the HS skin to the nested doubler and rear spar where I removed rivets to complete the SB. Deburred and primed the repair doubler, nested doubler and new brackets for the left elevator outboard hinge. Dimpled the nested doubler with the squeezer which worked much better than my modified #40 vice grips. Installed/clecoed in place the repair doubler and nested doubler with the bent hanger tool. I used it to slide the repair doubler between the skin and rear spar and pulled it in behind the rear HS spar. That little tool worked great too to blindly install the repair doubler. Painted the brackets to install tomorrow and finish this SB.

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Mar 27, 2023 More SB-00036 - (4 hours)

Category: Empennage

Cut a coat hanger to make an attachment to the forward doubler to be able to insert the doubler into the HS and clecoed it to the HS rear spar. Found some scrap .040 and used it to simulate the nested spar double and be able to match drill the new bracket to the old. Also had to sand down the edges of the new bracket to be able to “nest” into the nested spar doubler. Primed and painted the right brackets. While waiting for the paint to dry I drilled out the left brackets and associated rivets on the skin in the rear spar. I then match drilled the right nested spar doubler, rear doubler and elevator brackets to the rear spar.

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Mar 23, 2023 SB-00036 HS doublers - (3 hours)

Category: Empennage

Started the SB-00036 for possible cracks in the rear spar of the HS at the outer elevator bracket rivets. Drilled out the right elevator brackets and several rivets along the upper and lower trailing edge of the HS. Match drilled, deburred, dimpled and primed the appropriate parts of the SB-00036 kit. Going to try and install the forward doubler even tho I don't have any cracks if I can figure out a way to get it inside the HS without drilling out any more rivets. The new brackets seem to be an exact copy of the old brackets, but by adding the rear .040 doubler the hole for the rod end bearing on the elevator will not match up. It's exactly .040 off. Hmmmmmm. Placed a call to Vans and they are going to research it.

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Mar 23, 2023 Brake lines - (2 hours)

Category: Fuselage

Fabbed a bracket to secure the Bonaco brake lines to the rudder pedal brace, since the Bonaco brake lines wouldn't fit thru the plastic snap ring bushings. Also attached the brake lines to the parking brake valve.

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Mar 21, 2023 SB-00036 HS elevator brackets - (1 hour)

Category: Empennage

Spent some time studying the SB kit and whether I want to do the full SB or just the part for rear spar with no cracks. Think I'll start and see how hard it's gonna be to install the forward doubler.

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Mar 17, 2023 Rudder pedals - (3 hours)

Category: Fuselage

Installed remaining rudder pedals and secured all castle nuts with cotter keys. Installed entire assembly into the fuselage. Very tight fit with NACA ducts and hinge pin tubing installed.

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Mar 14, 2023 Final choice

Category: Paint / Decals

Picked out the final choice of colors from paint shop with an overwhelming amount of colors. Thank goodness the wife helped with the selection.

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Mar 13, 2023 Rudder pedal anti skid paint - (1 hour)

Category: Fuselage

Decided to try some anti skid paint on the rudder pedals since they seemed a bit slippery after paint. Well see how this works.

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Mar 08, 2023 Tips primed

Category: Tail Feathers

My painter applied some primer to the tail tips. Looks great. Now I have to tear apart the trailing edge of the HS to do SB-00036 to replace the outer elevator brackets and add a doubler to prevent possible cracking of the rear HS spar.

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Feb 28, 2023 Throttle brackets

Category: Avionics

Received new throttle brackets from AFS. Going to try out both to see which one I prefer.

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Feb 24, 2023 Roll servo connector and tie down - (1 hour)

Category: Avionics

Installed the roll servo connector and tapped the hole near the access panel for the tie down to 3/16.

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Feb 23, 2023 Pitch servo wiring - (3 hours)

Category: Avionics

Thanks to YouTube I was able to figure out how to use the DMC crimper tool I got earlier this year. Used it to wire up the dsub connector to the AP pitch servo. Installed the pitch servo in the aft fuse on the bracket I installed a while ago and safety wired the attachment bolts. Had to drill a small hole in the bracket to secure one of the AN3 bolts. Used the extractor tool and removed the pins from the AP roll servo connector. Added pins to a couple wires per the wiring diagram and will install a new connector received from my avionics supplier . (AFS)

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Feb 22, 2023 Pitch servo wiring - (1 hour)

Category: Avionics

Spent some time trying to understand the wiring diagram for the pitch servo. Going to attach one d sub connector to the servo and then install the servo. Pulled out the DMC crimper and need to figure out how to use it.

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Feb 21, 2023 ELT antenna - (1 hour) Category: Avionics

Think I found a way to mount the ELT antenna under the empennage fairing. Just need to make a bracket.

Feb 21, 2023 Tip light wires - (1 hour)

Category: Wings

Finished the connector for the left wingtip lights and also completed the connector for the right wingtip.

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Feb 21, 2023 Sanding - (1 hour) Category: Tail Feathers

Sanded the areas on the HS tips where I filled pinholes. Still have pinholes. Not sure how to fix.

Feb 20, 2023 Rudder pedal paint - (.5 hour)

Category: Fuselage

Added another coat of paint to rudder pedals. Also searched for a good location for the ELT antenna without any luck. Will spend some time researching.

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Feb 20, 2023 Wingtip sanding and wiring - (1 hour)

Category: Wings

Sanded the left wingtip/wing transition and removed the wingtip. Stripped wires and installed the FlyLeds connector for the nav/strobe lights.

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Feb 20, 2023 HS tips - (1 hour)

Category: Empennage

Sanded HS tips and filled some pinholes I found.

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Feb 16, 2023 ElectroAir spark plug wire spacing - (.5 hour)

Category: Engine

Rerouted the ElectroAir spark plug wires to ensure adequate spacing required per the instructions and pointed out by a friend.

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Feb 16, 2023 Flap motor wire - (.5 hour)

Category: Avionics

Routed the black/ ground wire to the flap motor.

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Feb 16, 2023 Rudder pedals - (1 hour)

Category: Fuselage

Painted the rudder pedals.

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Feb 16, 2023 Wingtip transition - (1 hour)

Category: Wings

Sanded down the epoxy/micro I applied yesterday and added another layer to try and finish it off.

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Feb 15, 2023 Flap motor wires - (.5 hour)

Category: Avionics

Measured, cut and routed the wires to the flap motor.

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Feb 15, 2023 Wingtip leading edge - (.5 hour)

Category: Wings

Sanded the epoxy filler and applied another layer.

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Feb 15, 2023 Sanding - (1 hour) Category: Tail Feathers

Sanded the primer I applied last week

Feb 09, 2023 Fuel tank leak and wingtip blending - (2 hours)

Category: Wings

Removed the sealant around the fuel pickup, loosened the nut and washer and resealed with proseal. Also added some epoxy filler to the wingtip to blend with the wing leading edge. Gonna need to prob touch up that area a couple more times.

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Feb 09, 2023 Primed - (2 hours)

Category: Tail Feathers

Filled some pinholes with epoxy and primed the outside ends of the elevators and HS. Also touched up the lower cowling with some leftover primer

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Feb 08, 2023 Priming and sanding - (3 hours)

Category: Tail Feathers

Primed the tail ends and found out from the painter that this primer will not work with the paint he's going to use. Ended up sanding all the primer off. One step forward, two steps back. Worked on routing the elevator trim wires with some tubing for added protection. Also put some RTV around the wires where they exit the trim motor for added strain relief. Leak tested the left tank again and still have a leak around the fuel pick up.

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Feb 06, 2023 Elevator trim wires - (3 hours)

Category: Tail Feathers

Worked on routing the elevator trim wires from the trim motor out to the elevator control horn. Removed the black heat shrink and used some clear to support the wires all the way from the trim motor. Drilled a hole near the elevator control horn to route the tubing for the wires. Installed a snap ring bushing and secured with RTV. Made sort of a mess with the RTV as it was pretty hard to reach. Still not sure how exactly I'll run the wires over or under the HS spar and into the fuselage.

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Feb 05, 2023 Sanding - (.5 hour)

Category: Tail Feathers

Sanded the area around the left elevator control horn where I added a little epoxy yesterday.

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Feb 05, 2023 Left wingtip leading edge - (.5 hour)

Category: Wings

Installed the left wingtip to check leading edge fit. Need to shore up with some epoxy/flox to even up wingtip to leading edge transition.

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Feb 04, 2023 Fuel tank touchup - (1 hour)

Category: Wings

Mixed up some proseal and touched up the fittings on both fuel tanks.

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Feb 04, 2023 Empennage fairing and priming - (2 hours)

Category: Tail Feathers

Removed empennage and trimmed and sanded area that I glassed and epoxied yesterday. Tried priming one of the elevator tips to see any imperfections. Applied some 5 minute epoxy to fill some voids on the elevator near the control horn where I epoxied in the foam yesterday.

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Feb 03, 2023 Empennage fairing trimming - (3 hours)

Category: Tail Feathers

Removed empennage and trimmed the epoxy and glass that I applied yesterday. Reinstalled the fairing and reinforced the underside curve around the leading edge of the fairing with a couple layers of glass and epoxy. Cut, trimmed and installed foam around the control horn of the left elevator. Will cut a hole for the elevator trim wires layer. Added another selfie.

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Feb 02, 2023 Empennage fit - (5 hours)

Category: Tail Feathers

Removed VS, HS, and left elevator from the fuselage. Installed rivets and nut plates in fuse to secure the lower empennage fairing. Messed around with the upper empennage fairing to check the fit with the lower fairing. Glassed and epoxied on the lower surface of the HS to extend the leading edge of the fairing that wraps around the leading edge of the HS. Also sanded the HS. Tried some new fiberglass and used the plastic to apply the layers.

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Feb 01, 2023 Empennage fairing trimming - (3 hours)

Category: Tail Feathers

Removed, trimmed and sanded the edges of the empennage fairing. The fit with the tail is way better than before. Decided to fill some of the mounting holes as I don't think they are needed now that the fairing fits better. The fairing still needs some work, but it's getting there. Installed the left elevator to be able to cut the elevator trim wire to length and used the remainder for the aileron trim. Used my new pin tools from Avery to temporarily install the elevator. Worked great. Ran that wire in the fuse.

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Jan 31, 2023 Fuel tank leak test - (1 hour)

Category: Wings

Resealed the left wing fuel cap to try another leak test. Pressurized the tank and found a small leak at the fuel pickup fitting. Not sure if I'll just apply more proseal or remove the fitting nut and reseal.

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Jan 31, 2023 Last epoxy and empennage fairing - (4 hours)

Category: Tail Feathers

Added one last layer of epoxy to the leading edge of the HS tip. Maneuvered the fuse around in the shop to access the tail area to attach the HS and VS. Marked the surfaces of both where the fairing meets and taped off with packing tape. Added a layer of automotive wax to ensure the epoxy would release from the HS and VS. Slathered up the fairing edges to fill any gaps and attached it to the tail. Wanted to get this done before sending the HS and elevators off to paint. EAA webinar on getting the airworthiness cert said to be sure and include pictures of yourself hence the goofy pic of yours truly.

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Jan 30, 2023 Left wing fuel tank leak test - (1 hour)

Category: Wings

Set up the manometer to test the left fuel tank for leaks.

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Jan 30, 2023 Finished sanding - (1 hour)

Category: Tail Feathers

Finished sanding the elevators and HS tip (I think). Orbital sander bit the dust (pun intended). Ordered a new belt to see if that will work.

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Jan 28, 2023 More sanding - (1.5 hours) Category: Tail Feathers

More HS and elevator sanding

Jan 27, 2023 More tip sanding - (2 hours) Category: Tail Feathers

Sanded and applied more epoxy to bad/low spots and pinholes. The never ending saga ……

Jan 26, 2023 More epoxy and foam - (2 hours)

Category: Tail Feathers

Applied some epoxy to the low spots on the HS and elevators. Filled in the forward section of the right elevator with foam and epoxy/flox. Want to do the same with the left elevator but not sure about routing of the elevator trim wire.

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Jan 25, 2023 Sanding the primer - (2 hours)

Category: Tail Feathers

Sanded down the Slick sand primer. Still have a few low spots.

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Jan 24, 2023 Sanding and priming - (2 hours)

Category: Tail Feathers

Sanded both HS tips. Mixed up some Evercoat quick sand primer and applied to all the tips and ends. Decide to try and just brush on since the the areas of application were so small.

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Jan 23, 2023 More sanding - (4 hours)

Category: Tail Feathers

Sanded all foam inserts, again. Also sanded the HS tips that I glassed yesterday and applied a feather coat to hopefully finish tomorrow.

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Jan 22, 2023 Left wingtip lens - (1 hour)

Category: Wings

Taped in place and drilled holes to attach the wingtip lens. Marked, drilled, countersunk and installed nut plates for lens attachment. Used new coarse bit to make countersinks for lens and wingtip.

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Jan 22, 2023 Still more epoxy and sanding - (2 hours)

Category: Tail Feathers

Sanded and add more epoxy to the low spots on all ends. Hope for this to be last time. Glassed and epoxied HS tips bottom surface at the tip/aluminum interface.

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Jan 21, 2023 HS tips edge glass epoxy - (1 hour)

Category: Empennage

Applied a strip of glass and epoxy to the HS tip/HS interface to both end of the top surface.

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Jan 21, 2023 Left wing fuel tank - (1 hour)

Category: Wings

Installed left wing fuel tank cover plate and sealed both screws and plate with proseal fuel tank sealant. Again used the plastic bag technique to apply the sealant.

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Jan 21, 2023 More epoxy filling ends - (2 hours)

Category: Tail Feathers

Began the day by sanding the ends of both the elevators and HS. I then mixed up some epoxy and micro to add another layer to all the ends. Ready to be done with the epoxy and sanding for a while.

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Jan 20, 2023 Right tank fuel sender - (1 hour)

Category: Wings

Installed the fuel float sender cap on the right tank fuel cover plate. Used proseal to complete the installation with a small plastic bag to apply the sealant. Made for a much cleaner application. Also applied some sealant to the left wing tank fuel pickup that I neglected earlier. Since I had some leftover sealant I decided to use it to seal the hole in the firewall where the horizontal cowl pins lead in tube penetrate. Used some folded up paper to try and center the tube in the hole.

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Jan 20, 2023 Epoxy filling - (2 hours)

Category: Tail Feathers

Added another layer of epoxy and micro balloons to the elevator ends to fill in some voids and level. Tired to secure the elevators to the bench to make for a level plane for the epoxy. Waited for the epoxy and micro to set up and added some to the lower portion that was angled down. Ended up pretty rough. Gonna take a few more tires.

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Jan 19, 2023 More foam filler - (3 hours)

Category: Tail Feathers

Sanded the HS foam fillers. Cut, trimmed and epoxied both ends of each elevator with foam.

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Jan 18, 2023 HS tips and foam filler - (5 hours)

Category: Tail Feathers

Pull riveted and epoxied the HS tips in place. Used flex epoxy and #40 CS pop rivets to secure the tips. Cut and epoxied in place foam filler to the HS. Also cut and trimmed more foam for the elevator inboard ribs.

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Jan 17, 2023 HS end rib fill in - (1.5 hours)

Category: Tail Feathers

Cut and trimmed foam to fill in end ribs of HS. Will epoxy these in place and fill later

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Jan 09, 2023 Finished elevator trim pigtail - (1 hour)

Category: Avionics

Completed soldering of elevator trim servo pigtail. These 26 AWG wires are delicate and hard to work with. Installed heat shrink on each wire and a larger one around them all.

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Jan 06, 2023 Elevator trim servo wires - (1 hour)

Category: Avionics

Added a pigtail to the elevator trim servo wires to extend them into the fuse, where I plan to add a connector. Used my new Santa gift to strip and solder the 26 AWG wires. Glad I had the new magnifying specs as these wires are TINY.

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Jan 06, 2023 Left fuel tank pick up - (1 hour)

Category: Wings

Temporary installed the fuel tank cover and fuel float. Amazing how much easier the task is the second time you do it. Plan to complete the installation once I have enough things that need proseal. That stuff is so messy and sticky I have to be in the right frame of mind to tackle those items.

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Jan 06, 2023 Sanding again …… - (2 hours)

Category: Tail Feathers

Sanded the elevator tips. Hoping this is the last time. May need just a little touch up on the forward end. Dimpled the right HS where the tip attaches. Added just a slight amount of epoxy and micro to the HS tips. Would have been able to install these had I not decided to fill in the outer rib. Waiting on foam and epoxy to arrive next week to finish these up. If you can ever say they are finished. Feels like the canopy fairing all over again.

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Jan 05, 2023 Left wing fuel float - (2 hours)

Category: Wings

Began assembly of left wing fuel float by,replacing stock fuel pick up with a screened version. Since my kit did not include the anti locking bracket, I drilled a hole in the tube nut and safety wired it to the bracket. Temporarily installed the fuel cover and adjusted the fuel pick up to avoid conflict with the fuel drain that I installed. Bent the float arm to recommended length and used a flashlight and mirror to view inside the fuel tank as you can see in the fuzzy picture. Assembled the fuel float using the plexiglass template I used on the right tank. It works great to adjust the range of the float via the access hole to the side.

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Jan 05, 2023 More sanding and epoxy - (2 hours) Category: Tail Feathers

No pics today. Just sanded down epoxy filler on elevator and HS from yesterday and applied a thin layer over some small blemishes. Removed elevator from the HS to ease filling of end ribs that I decided to do after watching Stu's YouTube video. Looks simple, but it always does.

Jan 04, 2023 Right wing fuel sender - (1 hour)

Category: Wings

Removed the fuel tank cover to prepare to install the fuel float sending unit.

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Jan 04, 2023 More epoxy and tip sanding - (3 hours)

Category: Tail Feathers

Sanded the bottom elevator tips and applied a thin coat of epoxy and filler to the edge seams. Also sanded the HS tips again. Ended up using the dremel tool with a scotchbrite wheel to smooth the contour. Not sure what to do about the gap between the aft end of the HS tip and the HS. Removed elevator trim motor in preparation for paint.

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Jan 03, 2023 More epoxy and filler - (3 hours)

Category: Tail Feathers

Mixed up some more epoxy and filler to apply to the bottom of both ends the elevator. One side I mixed up with a little too much filler as you can see in the photo, but I think it'll be ok. Used some extra to add to the HS tips again, which seems never ending. Also sanded down the edges of 3 nutplates of the elevator trim tab to make it easier to install and remove.

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Jan 02, 2023 Tip sanding - (1 hour)

Category: Tail Feathers

Sanded down right tip/elevator transition area

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Jan 02, 2023 Tail light - (1 hour)

Category: Lighting

Ran wire for tail light

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Dec 22, 2022 Sanding tips - (1 hour)

Category: Tail Feathers

Sanded the left HS and elevator tips. Still need a little more fairing filler.

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Dec 21, 2022 Elt shielded wire - (1 hour)

Category: Avionics

Ran some 22 AWG wire to the ELT for GPS information.

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Dec 21, 2022 Sanding and epoxy filler for HS and elevator - (2 hours)

Category: Tail Feathers

Sanded the HS tips where I added epoxying filler. Used the oscillating spindle sander, but was a little too aggressive. Hand sanding was better. Sam mixed up some fairing filler for the elevator/tip interface and applied same to the elevator tip.

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Dec 21, 2022 Pitot wiring - (1 hour)

Category: Wings

Sam ran wires for the pitot heat regulator.

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Dec 21, 2022 Wires for left wing lights - (1 hour)

Category: Lighting

Sam pulled/cut out old bulky wires for lights that came with the wing, circa 2005, and ran new ones for “The Works” LED lights from FlyLeds.

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Dec 20, 2022 Empennage tip sanding - (2 hours)

Category: Tail Feathers

Sam applied some glass and epoxy to the right elevator tip transition seam. Sanded the previously applied glass and epoxy on both tips. Also sanded the right HS tip area where I filled a void from the factory.

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Dec 19, 2022 Left wing flap hinge - (2 hours)

Category: Wings

Sam cut and bent the left flap hinge pin and hinge for center install and removal of hinge pin. Cut some scrap hinge to secure the pins to the wing with a couple eyelets and nutplate

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Dec 19, 2022 MoreElevator and HS tips - (4 hours)

Category: Tail Feathers

Added some fairing filler to the top of the right HS to to fill in a void from the factory. Reinforced the left HS tip after removing the foam with three strips of glass and epoxy per the instructions. Used a heat gun and wedge to spread the HS tips a little to match the profile of the HS. Sam added a strip of glass and epoxy to both elevator tips at the tip/elevator interface. Added some epoxy and fairing filler to the aft surface of the HS tips to sand down and contour with the elevator tips

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Dec 14, 2022 HS and elevator tips - (4 hours)

Category: Tail Feathers

Sam attached aluminum backer strips to right HS and elevator tips. Trimmed the left HS tip of excess fiberglass and epoxy. Also removed the foam insert in the left HS tip and added additional layers of fiberglass and epoxy to support the outer layer of glass. Laid up and epoxied a layer of glass on the left elevator transition betweeen the tip and aluminum edge. Used a strip of plastic to apply the epoxy soaked glass to the tip/elevator transition and to the left elevator tip.

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Dec 13, 2022 More tip work - (2 hours)

Category: Tail Feathers

Sam used pneumatic pull riveter to install the left elevator tip. Plan to glass and epoxy over the joint. Began foam insert technique per the plans on the left HS tip to fill in the aft portion. One layer of glass coated with epoxy on a contoured foam insert.

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Dec 12, 2022 Left flap hinge pin - (1 hour)

Category: Wings

Sam removed some hinge pin eyelets from the left wing and left flap to provide access for hinge pin installation. Will secure the pins in the same way as the right wing

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Dec 12, 2022 More tips - (5 hours)

Category: Tail Feathers

Sam continued to finish up the left HS and elevator tips by epoxying in aluminum bracket to both tips to support the factory end of the blind rivets. Edge distance is an issue that can't really be resolved, so we'll epoxy the elevator tips in as well. I started trimming the right HS and elevator tips. Match drilled the elevator tip to the elevator and deburred. Laid out the 4 upper and lower rivet lines for the HS stab tip, match drilled and deburred. Installed both right elevator and HS tips and trimmed for 1/8” spacing.

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Dec 11, 2022 Elevator tip - (2 hours)

Category: Tail Feathers

Sanded the left HS tip to provide clearance between the HS tip and elevator tip. Match drilled the elevator tip to the elevator.

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Dec 09, 2022 Empennage tips - (3 hours)

Category: Tail Feathers

Sam finished riveting the upper tip on the rudder. Will apply some glass and epoxy to smooth out the edges. Also finished safety wiring the brakes. Began trimming the HS and elevator tips for installation. Laid out the rivets for the HS tip, drilled deburred and match drilled to the tip. Need to trim the HS tip for 1/8” gap with the elevator tip then glass in the the end.

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Dec 08, 2022 Wheel pant brackets and rudder tip - (3 hours)

Category: Landing Gear

Jacked up the fuselage and reinstalled correctly the inboard wheel pant brackets and jack points. Fabricated an extension to the saw horse to support the gear while we completed the installation. Sam also epoxied the aluminum backer plate to the interior of the upper rudder tip and should be able to install rivets tomorrow.

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Dec 06, 2022 Wheel removal - (1 hour)

Category: Landing Gear

Sam and I began removing the wheel and tire on the right side to install the wheel pant bracket that was not previously installed.

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Dec 06, 2022 Rudder upppr tip - (2 hours)

Category: Tail Feathers

Sam helped me out while he was home and countersunk the upper rudder tip and match drilled it to a thin aluminum backer strip. Will epoxy and pull rivet the tip in later to fill in with fiberglass and epoxy. It's great to have his help on the project.

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Dec 06, 2022 Flap pins - (3 hours)

Category: Wings

Removed three eyelets from the right hinge pin to accommodate installation of the flap hinge pins. Cut and bent the hinge pin to secure it to the aft wing brace. Reinstalled the pins and placed the wing back in the cradle with Sam's help.

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Dec 01, 2022 ELT and wing wiring - (3 hours)

Category: Avionics

Studied and planned the ELT wiring. Determined location on the subpanel for the ELT mini speaker. Need to get some 4-40 screws to mount. Pulled the old wires out of the left wing with the exception of one. Used the last old wire to pull the new position, strobe and taxi light wires in the left wing.

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Nov 29, 2022 Elevator trim wires - (1 hour)

Category: Avionics

Installed several plastic snap in bushings in the aft bulkheads that were predrilled for wires. Ran a five strand 20 AWG wire to the tail for the elevator trim. Plan to install some wire tie downs on the floor of the fuse to secure the wires for the taillight, elevator servo and ELT.

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Nov 20, 2022 Avidyne Nav rear support - (3 hours)

Category: Avionics

Finished installation of angle to support the rear of the Avidyne Nav tray. Match drilled, deburred and primed angle prior to riveting to the subpanel. The angle attaches to the tray with #6 screws. Made some spacers to ensure an even gap around tray and subpanel. Also spent some time inventorying the cables and connectors from Advanced Flight to determine what wires I need to complete the avionics installation.

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Nov 19, 2022 More planning and avidyne tray mount - (4 hours)

Category: Avionics

Spent time trying to determine best way to mount the SV-220 box. May just use some rails between the subpanel ribs. Also fabbed an angle to support the aft of the Avidyne nav tray. Need to determine if I want to rivet it to either the tray or the subpanel. Lot of time in the shop with not much done. Watching too much foootball while trying to work. Haha

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Nov 19, 2022 More component placement - (1.5 hours)

Category: Avionics

Spent some more time trying to determine the location for the SV-EMS-220 box. This is the controller for the engine monitors (EGT and CHT). Connected the cables to the box for a better idea of the footprint needed to find a location. Connected the FlyLeds controller board I picked up at OSH that works with the ACM to the Advanced ACM and tried to figure out the wiring and connector needed.

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Nov 17, 2022 Filling the subpanel - (3 hours)

Category: Avionics

Located the final position of the ADSB transceiver, remote comm and transponder, backup battery and Advanced ACM. Marked, match drilled and deburred the subpanel for all said components.

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Nov 12, 2022 Panel attach angles - (6 hours)

Category: Avionics

Riveted vent angles to side of fuselage. Riveted small angles to side and top of fuse gusset. Could reach the outboard rivets with the squeezer, but not sure how I'll reach the inboard rivets as they are under the bent in portion of the gusset.

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Nov 11, 2022 Panel brackets and vents - (6 hours)

Category: Avionics

Secured the instrument panel in place and marked attachment brackets for rivets in fuse. Match drilled the brackets, deburred and riveted lower brackets in place. Match drilled and deburred the upper brackets, but did not rivet in place. Will rivet later. Fabbed two F-793 angles for the left and right vents from Advanced Flight. Match drilled to fuselage and vent bracket. Scuffed angles and primed.

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Nov 10, 2022 Subpanel cutout for Avidyne GPS - (4 hours)

Category: Avionics

Measured, remeasured and marked the lower center subpanel for a cutout. The Avidyne GPS tray extends forward past the center subpanel, a cutout had to be made to allow room for the tray to pass through the subpanel. Spent a lot of time ensuring I got the location correct. Gave myself about 1/8” gap around the tray and will attach the tray to the subpanel with an angle later.
Removed the comm and autopilot panels to make the process easier, but not before taking a couple photos to make sure they get reinstalled correctly.

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Nov 09, 2022 Vinyl stencils Category: Paint / Decals

Received vinyl stencils from Evoke paint schemers

Nov 08, 2022 More subpanel work - (3 hours)

Category: Avionics

Match drilled, deburred and dimpled the left subpanel rib. Riveted the angle to the subpanel ribs and attached both ribs to the instrument panel to locate the ribs on the subpanel. Glad I did this as my previous location was incorrect. Got the ribs in the proper location to ensure room for the avidyne navigator and marked the subpanel in order to match drill for rivets. Removed the instrument panel and subpanel from the fuse and match drilled the ribs to the subpanel. Should be able to mark and install components to the subpanel now that I know where the ribs will be.
On a side note, I missed one hole when dimpling the rib angle and ended up with two holes. Instead of replacing the rib I just added a rivet hole and rivet on each side, plus a rivet in the correct hole. Don't think this is a big deal, since I'm moving the ribs anyway. First time I've done that. Sorta like drilling through your finger; there are those that have and those that will. Haha

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Nov 07, 2022 Subpanel ribs - (1 hour)

Category: Avionics

Clamped the subpanel ribs I cut off to the actual ribs in order to get the placement correct on the center panel. These ribs had to be cut off and placed more inboard in order to make room for the EFIS screens. Marked the upper and lower locations of the cutoff ribs and match drilled and dimpled the new angle to the right rib.

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Nov 03, 2022 Subpanel ribs - (2 hours)

Category: Avionics

Spent some time trying to find the new location for the subpanel ribs. Decided to remove the EFIS screens to make the process a little easier. Needed five hands to keep the panel in place, so I clamped some wood blocks to the fuse to keep the panel from sliding off the fuse rails. Was able to get pretty close approximation of where the ribs needed to be.

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Oct 31, 2022 Panel Attach angles - (1 hour)

Category: Avionics

Screwed attach angles to the panel in order to secure panel to the fuselage. This will also enable me to locate the holes for the modified subpanel ribs that had to be removed to avoid interference with the EFIS displays. Had to rivet a nutplate to one angle that I neglected to install before. Made some initial layout markings for the remote comm, transponder and backup battery locations.

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Oct 27, 2022 Trimmed subpanel and avionics layout - (2 hours)

Category: Avionics

Trimmed F-786Bs, subpanel outside pieces, for interference with the fuel vent lines. Tried to layout some components on the subpanel for mounting. Avidyne GPS navigator interferes with the middle section of the subpanel. Not sure how to address that at this time. May have to cut out a portion of the lower section to allow room for the GPS tray. But it will still interfere with the canopy release mechanism. Think I'll use a suggestion from AFS regarding placement of the remote comm and transponder along with the ADSB transceiver. ACM will be mounted on the left section of the subpanel.

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Oct 25, 2022 Panel delivered - (1 hour)

Category: Avionics

Panel from Advanced Flight Systems arrived today. Unpacked the panel, but left the rest of the boxes in tact until I get some time to sort them out. The large hole above the switches is where the Avidyne nav unit will go and the square blank is for the backup EFIS that I will get later.

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Oct 20, 2022 Coil pack relocated - (2 hours)

Category: Engine

Been trying to figure out how to secure all four corners of the coil pack to the engine mount. Reviewed the suggestions I was able to get on VAF and saw one I thought would work. Moved the coil pack down to the next lower engine mount brace and by moving the coil pack left and right was able to find the sweet spot where the lower holes on the coil pack aligned to enable the use of both lower Adel clamps. Was fortunate the spark plug wires were still able to reach the new location of the coil pack.

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Oct 19, 2022 Fuel tank leak test again - (1 hour)

Category: Wings

Was finally able to seal the fuel tank cap with some RTV and a trimmed plastic lid plus lots of packing tape. Pressurized the tank and let it sit overnight. Checked the manometer this morning and the water level had actually risen. This was due to a drop in the barometric pressure, so I'm considering this a positive leak test (finally); especially since the tank stayed pressurized overnight.

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Oct 12, 2022 Rudder bottom - (3 hours)

Category: Empennage

Trimmed and sanded bottom rubber tip for fit. Got it as best I could which should be fine. I'm going to use #6 screws and nutplates instead of rivets for securing the rudder bottom so I can access the taillight if necessary. Marked, match drilled, deburred and dimpled for nutplates.

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Oct 11, 2022 Rudder tips - (3 hours)

Category: Empennage

Made a new long sanding block to get the edges of both tips even. Trimmed a little more off both tips and fit seems good. Previous builder drilled and dimpled the top of the rudder for CS4-4 pull rivets. I flattened the dimples with my squeezer and laid out a row of holes for CS3-3 rivets, since I'm going to use these CS rivets and some west systems flexible epoxy. I plan to lay down some epoxy filler between the tip and rudder for a smooth transition. Had to cut a couple slots in the leading edge of the top tip so it would fit in place. I'll use some epoxy and glass this in later. Also laid out a row of holes for #6 screws and nutplates on the lower rudder fiberglass tip to be able to remove it if needed.

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Oct 07, 2022 Bottom rudder fairing - (1 hour)

Category: Empennage

Worked on the bottom rudder fairing fit. I feel it's pretty close, but needs a lot more tweaking.

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Oct 05, 2022 Upper cowl - (2 hours)

Category: Engine

Sanded upper cowl and riveted oil door hinge to cowling.

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Oct 04, 2022 Upper cowl and oil door - (2 hours)

Category: Engine

Applied sandable primer to upper cowl. Also riveted the hinge half to the oil door. Began trying to figure out a way to secure the ElectroAir coil pack more securely. Spent more time sanding lower cowl.

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Oct 03, 2022 Lower cowling - (1 hour)

Category: Engine

Sanded and sanded the lower cowl

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Sep 29, 2022 Lower cowl primed - (1 hour)

Category: Engine

Been putting off spray priming the lower cowl, but the actual application wasn't too bad. Sorta feel like lots of sanding ahead though.

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Sep 27, 2022 Oil dipstick - (1 hour)

Category: Engine

Torqued the oil dipstick in place then safety wired it to the engine.

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Sep 26, 2022 Left seat back adjustment - (2 hours)

Category: Interior Finish

Drilled out the -4 rivets on the left seat back hinge to be able to move it slightly inboard to remove interference with the roll bar. Cut new hinge, match drilled and installed new rivets.

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Sep 25, 2022 Right Seat back - (3 hours)

Category: Fuselage

Drilled out hinge half from bottom of right seat back. Match drilled and installed new hinge to prevent interference with the roll bar. Started out using the manual squeezer and quickly switched to the pneumatic one as the -4 rivets proved more than my post Covid hands were ready for.

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Sep 24, 2022 Wingtip lens - (.5 hour)

Category: Wings

After a busy few weeks at work and a positive Covid test finally got back into the shop. Match drilled and installed a nutplate on the bottom of the right wing to secure the wingtip lens.

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Sep 24, 2022 Coil pack reposition - (.5 hour)

Category: Engine

After a busy few weeks at work and a Covid positive test, finally got back into the shop to finish repositioning the coil pack to avoid interference with the oil dipstick.

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Sep 01, 2022 Interior - (.5 hour)

Category: Interior Finish

Received the interior today from Robert Lemke interiors. Had to put it in the fuse for a quick fit check.

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Aug 19, 2022 Wingtip lens - (.5 hour)

Category: Engine

Drilled the right wingtip for nutplate for the light lens.

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Aug 18, 2022 Cowl hinge pin stop - (.1 hour)

Category: Engine

Installed #4 stainless steel screws into side cowl hinge to act as pin stops.

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Aug 11, 2022 Oil door and dipstick/coil pack interference - (2 hours)

Category: Firewall

Clecoed oil door in place on upper cowl and not super happy about the fit. Gonna need some adjustment there. Set upper cowl in place on the airplane and found I mounted the ElectroAir coil pack on the engine mount that interferes with the dipstick. Spent a bit of time trying to move the coil pack but ended up removing it and reinstalling. Can only secure the coil pack to the engine mount with 3 bolts and adel clamps. Need to find a way to secure the last corner. Always something.

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Aug 06, 2022 New removable zips ties and brake lines - (.5 hour)

Category: Firewall

Replaced standard zip ties with new rubber backed new zip ties purchased at Airventure. These are to secure the brake lines to the lower motor mount near the firewall. Added another coat of paint to the oil door hinge.

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Aug 06, 2022 Sanded down wingtip - (1 hour)

Category: Wings

Sanded down wingtip again and found wingtip lens installation instructions.

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Aug 05, 2022 Oil door hinge paint and wingtips lens - (1 hour)

Category: Wings

Painted the oil door hinge and drilled #40 holes in the wingtip lens for #6 screws and nutplates.

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Aug 05, 2022 Leak test again and wingtip sandin - (1 hour)

Category: Wings

Installed new 3” wide tape over fuel cap and reinforced it with more tape. Tested for leaks again using the manometer with a 27” difference in water height in the tube per Vans instructions. Water actually rose in the open end of tube indicating a drop in air pressure, which according to my weather app, it dropped all day. Feeling pretty good that I don't have any leaks in the right tank.
Sanded down the wingtip to remove the “bad” West systems 410 fairing filler that could blister the paint on a hot day per the expert at the OSH RV fiberglass forum. Reapplied 407 fairing filler that supposedly will not cause blisters.

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Aug 01, 2022 Oil door hinge paint - (1 hour)

Category: Engine

Scuffed and primed the oil door hinge.

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Aug 01, 2022 Fuel tank test cont'd - (2 hours)

Category: Wings

Removed the balloon from the fuel tank vent and installed some plastic tubing to try the manometer test. Secured the tubing to a piece of 1/4” aluminum tubing with a couple safety wires. Pressurized the tank to get the 27” difference between the water line inlet and outlet. Still getting leaks around the fuel cap so ordered some 3” wide packing tape to try and get the entire cap covered with one piece of tape. To be cont'd.

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Jul 24, 2022 Left side firewall rivets - (1 hour)

Category: Firewall

Completed riveting the left side fuselage skin to firewall and skybolt fasteners. On rivet hole was pretty wallered out, so I decided to drill it for a 426-4 rivet and riveted in place.

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Jul 24, 2022 Rt wing fuel leak test cont'd - (1 hour)

Category: Wings

Flipped the right wing over and discovered a leak at the fuel cap. Also tightened the valve stem at the fuel drain. Secured new packing tape to fuel cap and tested for leaks again. No leaks on any rivets and so far none at the fittings. We'll see what the balloon looks like in the morning.

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Jul 23, 2022 Firewall side rivets - (1 hour)

Category: Firewall

Riveted the right side skybolt brackets to the firewall and fuselage skin. Really gave it a finished look.

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Jul 23, 2022 Wingtip leading edge - (1 hour)

Category: Wings

Sanded down the wingtip leading edge and removed it from the wing. Wingtip seems way more solid now.

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Jul 23, 2022 Fuel tank test - (2 hours)

Category: Wings

Installed the Vans fuel tank test kit. Taped off the fuel cap and capped the fuel line from the tank. Installed the needle valve into the fuel drain and attached a balloon to the vent line. Initial attempt did not work as I had leaks around the vent line exit where I had trouble sealing off the balloon. Installed the small length of vent line and taped another balloon to the end. I pressurized the tank ever so slightly and began to spray a light coating of soapy water on the entire tank, or at least where I could reach. The balloon again indicated a leak so back to the soapy water test. Discovered the vent line and the capped fuel line were both leaking. Tightened up both fittings and balloon seems to be holding. We'll see what the morning brings.

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Jul 21, 2022 Flap rods - (1 hour)

Category: Wings

Measured and replaced the flap rods I made about 2years ago with hex ones from Cleaveland tool. These are way more substantial. We'll see how close I got to the correct length when I put the wings on the fuse again some day. Added a third coat of epoxy/filler to wingtip leading edge. Think this one should do it.

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Jul 21, 2022 Flyboy Jack Pionts - (1 hour)

Category: Landing Gear

Used the Flyboy Jack point I bought a while ago to jack up the gear and rotate the tires to prevent getting flat spots. It worked great on the left wheel, but I was unable to remove it from the right wheel due to interference between the bolt on the jack point and the rotor of the brake.

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Jul 21, 2022 Alternator bolts - (2 hours)

Category: Engine

Spent some time removing the alternator to reach some bolts that needed safety wires. Drilled a small hole in one of the support arms to secure one bolt, but used the standard “z” pattern to secure the main bracket bolts. Left the last two bolts loose to be able to set the tension on the belt later. Torqued backup alternator nuts to 100” lbs. Had to estimate on one nut that was impossible to reach with a torque wrench. Had to use a crows foot on the others.

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Jul 21, 2022 More fuel float - (3 hours)

Category: Wings

Messed around again today adjusting the fuel float arm to hit just short of full and empty. Flipped the float around in the wire so it sits more aft and that seemed to help getting it just right. It's not perfect, but comes in very close once installed at 30 ohms resistance, which the instructions say is what it's supposed to be at full fuel. Since my quick build wings are vintage, ie 2005, the tanks did not have the anti rotation bracket for the pick up line. I drilled a very small hole in the hex of the fitting and safety wired the it in place. Mixed up some proseal and installed the cover plate and the fuel float. Proseal is the messiest, stickiest stuff ever and gets all over. Guess that's why it works so well. Plan to leak test the tank soon so I can get started on the next one. Sanded and applied more filler to the wingtip leading edge. It's close, but needs a few divots filled.

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Jul 20, 2022 Fuel float template - (2 hours)

Category: Wings

Made a template of the fuel float cover plate to be able to see into the fuel tank to adjust the float itself and be able to see the range of motion. Also made a large access hole to be able to move the float up and down. Several iterations of insert, test, bend wire and repeat. Think I have it where I want it to be able to proseal the tank shut tomorrow.

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Jul 19, 2022 Wingtip leading edge - (1 hour)

Category: Wings

Filled in the leading edge of the wingtip with epoxy fairing filler to match the wing.

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Jul 18, 2022 Fuel float - (2 hours)

Category: Wings

Made a wire template of the fuel float wire with bends. Got the correct fuel float assembly for the right wing and bent wire of float to fit and ensure full range of motion. Decided the wire template was not needed especially since I found a Vans drawing for the floats in one of the float boxes. Oh, well.

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Jul 17, 2022 Fuel floats - (2 hours)

Category: Wings

Installed the Ray Allen flap sensor in aft fuselage near flap arm. Moved the left wing to the table (Sam helped) to begin installation of the fuel floats and seal up the fuel tanks. Removed quick build fuel pick up and installed the screened version.

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Jul 17, 2022 Wingtip wing side hing - (2 hours)

Category: Wings

Sam was home for a couple days from doing his two week summer drill in SUX. He riveted the hinges to the end of the wings for attaching the wingtips. Had to dimple one side before riveting that Dad forgot. Oops. Only had to drill out a couple rivets.

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Jul 15, 2022 Spark plug wires - (2 hours)

Category: Engine

Got my new 7/8” crows foot and torqued the ElectroAir spark plug wires on the right bottom side of engine. Tightened up the zip ties on the right side as well. Began rerouting the spark plug wires on the left side. Not sure the best route for the mag wires yet. Worked on chafing issue between oil cooler scat tube and oil cooler line. Not sure how to solve this either.

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Jul 14, 2022 ELT and B&C voltage regulator - (3 hours)

Category: Avionics

Match drilled ACK ELT mount to aft fuselage support (F-729A), bellcrank support and installed. Decided this location was way better than using the Van's ELT bracket that was designed for an older ELT with difficult to reach rivets and possible rudder cable chafing. Match drilled B&C voltage regulator to subpanel rib. Instructions say you can mount it on the firewall, but sticker on the regulator itself says to mount in cabin away from heat and vibration close to the panel. So subpanel it is.

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Jul 13, 2022 Engine plumbing - (3 hours)

Category: Engine

Tried to figure out proper routing of spark plug wires, control cables and oil cooler lines. Got completely frustrated with spacing and the use of Adel clamps. I despise those things. Hard to install and get in the proper space. Decided to do some mind numbing sanding on the left wingtip and touch up the trailing edges of both wingtips. Should probably route the mag wires from #2 and #4 cylinders over the top for length and security. Means I have to undo all the work I did the other day. One step forward two steps back.

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Jul 12, 2022 Left side engine probe wires - (3 hours)

Category: Engine

Worked on routing the left side engine probe wires and spark plug wires. Left them fairly loose so as to make adjustments later. Installed and torqued the ElectroAir spark lugs on the lower right side. Couldn't torque the spark plug wires since I didn't have the correct size crows foot. Ordered a 7/8” one off Amazon. Lots of extra spark plug wire length from the slick mag. Not sure how I'm going to address that.

Also reinstalled the cowl side hinge pin guides in the fuselage with the correct size Adel clamps (-3G). Need to trim the fuselage ends and proseal the cowling ends.

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Jul 11, 2022 Evoke design

Category: Paint / Decals

Think this may be the final paint scheme from Evoke

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Jul 11, 2022 Elt mount - (2 hours)

Category: Avionics

Spent time trying to figure out how to install the Van's Elt mount. Bind/pull rivets are gonna be difficult to reach and looks like chafing with the rudder cable is a definite possibility. Researched VAF for ideas. Also need to drill new holes for mount as the ones predrilled will not work.

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Jul 07, 2022 Engine probe and spark plug wire routing - (3 hours)

Category: Engine

Researched, planned and secured the left side engine probe wires and spark plug wires. Researched required torques for the valve cover screws (30 in-lbs) and spark plug wires nuts (90 in-lbs). Secured the left spark plug wires with adel clamps to the bottom screw of the valve covers and used those to secure the engine probe wires with the “pitot tubing zip tie technique. Fabbed a small aluminum extension to the bottom of the rear baffle to prevent spark plug wire chafing. Left some slack in the spark plug wires for strain relief and to aid in spark plug removal. Seemed to work pretty well, but may still need some additional ties. Very happy to have this done as I was unsure of how this was all supposed to work.

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Jul 06, 2022 Completed SL-00014 tail brace - (2.5 hours)

Category: Fuselage

Primed angles, dimpled tail cone and riveted angles to tail of fuse per SL-00014. Used the squeezer to dimple and rivet the top 3 holes. Had to use the rivet puller to reach the bottom two. Same with the rivets. Squeezed the top three rivets and was able to buck the bottom two without the need to drill any out. Service letter 00014 is officially done.

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Jul 05, 2022 SL-00014 tail brace - (1 hour)

Category: Fuselage

Marked and match drilled the angle for the right side. Deburred, dimpled and primed both angles. Used my trusty compass from my old engineering days to mark the two end hole locations. Rivet fan works great to speed up the spacing of rivet holes

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Jul 04, 2022 SL-00014 tail brace - (4 hours)

Category: Fuselage

Began the SL for the tail brace. Researched on VAF. Decided to not order the two angles and just fab up my own. Used .032 instead of the .025 that Vans used since that is what I had on hand. Took some time to get the exact hole locations from the drawing.

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Jul 04, 2022 Alt air door cable - (1 hour)

Category: Controls

Secured the alt air door cable to the bottom of the engine with an Adel clamp. Seems to work ok in the rare event I need to use it.

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Jul 03, 2022 Wingtip sanding - (2 hours)

Category: Wings

Sanded right wingtip with 220 in preparation for paint, per Al Mullenbach who will hopefully be painting parts starting this winter. Can't really tell I did much.

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Jul 03, 2022 Man pressure line - (3 hours)

Category: Engine

Installed additional Adel clamps (DG7) to support the manifold pressure line to transducer manifold. Sanded lower cowl with 220 grit. Gonna need to spray on remaining areas for better coverage. Made foam block to simulate battery to test ease of installation and removal.

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Jul 02, 2022 Oil door primed, oil temp sensor and mag duct - (3 hours)

Category: Engine

Primed oil door and part of lower cowl with Evercoat slick sand, sandable primer. Torqued oil temp sensor. Lycoming says finger tight and then 135 degrees more. Didn't seem like enough, but stopped and torque sealed. Drilled hole in aft baffle to 11/16” and installed mag cooling duct. Sealed with high temp RTV. Sanded oil door with 320 grit then 400. Felt like I sanded off most of the primer, but we'll see.

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Jul 01, 2022 ADHRS - (.5 hour)

Category: Avionics

Spent a lot of time reading installation instructions for the Advanced Flight boxes I received. Got some good input from the folks on VAF and installed the ADHRS on the bracket I had previously installed at one of the rear bulkheads. Got a draft from Evoke/plane schemers that I feel is pretty close to final. Spent a short amount of time sanding down the spots where I filled the forward holes on the cowling for the hinge pins.

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Jun 27, 2022 Avionics - (.5 hour)

Category: Avionics

Received a big box of avionics to include the ELT and antennas.

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Jun 27, 2022 Oil door - (.5 hour)

Category: Engine

Applied the pin hole filler to the oil door. Will try the sandable primer on it to see before I use it on the cowlings.

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Jun 27, 2022 Scat tube and CHT probes - (2 hours)

Category: Engine

Secured scat tube with stainless strap to engine mount. Still need to figure out some chafing issues with the lower baffle straps. Installed the remaining CHT probes. The one for cylinder #3 was a PITA to secure

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Jun 26, 2022 cabin heat scat tube - (2 hours)

Category: Engine

Cut to length and installed cabin heat scat tube to heat muff and cabin duct. Began fabbing some support angles and stainless clamps to secure scat tube in place. May be some chafing issues in a couple places I'll need to address.

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Jun 25, 2022 ElectroAir EIS Controller - (1 hour)

Category: Engine

Match drilled ElectroAir EIS controller to the right subpanel rib. Needed to be mounted on cabin side of firewall. May need to add stiffeners to the rib for more strength.

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Jun 25, 2022 Red cube wires - (1 hour)

Category: Engine

Installed Adel clamps to route wires from the fuel transducer (red cube). Used handy little tool from HFS mfg to get clamps installed in tight quarters

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Jun 20, 2022 Right inlet diffuser and spark plug wires - (1 hour)

Category: Engine

Reinstalled right inlet diffuser and attached scat tube to lower heat muff outlet for fit. Checked continuity on all spark plug wires. All good, I think. Checking with Darrell at smooth power to be sure.

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Jun 20, 2022 Cable control bracket - (1 hour)

Category: Controls

Trimmed and opened up the lower control bracket for the added cables. Left room on both edges for heated seat control knobs. Now to ship of to Advanced flight for power coat and labeling.

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Jun 14, 2022 Throttle bracket - (1 hour)

Category: Controls

Drilled holes and trimmed lower throttle bracket.

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Jun 08, 2022 Cowling pin hole filler sanding - (3 hours)

Category: Engine

Sanded both upper and lower cowls after the pin hole filler dried. Much like sanding drywall which I feel I put on too thick.

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Jun 08, 2022 ElectroAir spark plugs - (2 hours)

Category: Engine

Tried a suggestion from mfg and put the wire in the freezer overnight to help with the installation of the ferrule on the wire. I was able to get it installed, but freezing it wasn't much help. Watched a different video pulling on the center wire and that seemed to work the best. However is was still a major PITA to install the ferrule on the wire. Pulled so hard to get it one a couple of the wires that I'll be lucky if there's no damage to the interior of the wire itself. Poor design of exterior of the wire for this application. The wire is super flexible, but the outer material is way to soft for this method of installation. Actually used the table vise so I could pull on the wire with both hands. Used some wire cutters to bevel the end to aid in feeding the wire into the ferrule. Sorta like pushing a rope.

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Jun 06, 2022 Heated seat switches - (1 hour)

Category: Avionics

Spent some time trying to decide if the heated seat switches would fit on the lower throttle bracket I plan to install

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Jun 06, 2022 Cowl pin guide interference - (2 hours)

Category: Firewall

Removed cowl pin guides to enable riveting of skybolt barckets. Riveted associated skybolt brackets to the firewall and rechecked the spacing of the affected rivet for interference with the cowl pin guide.

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Jun 02, 2022 ElectroAir spark plugs - (2 hours)

Category: Engine

Worked on ElectroAir spark plug wires without much success. Couldn't seem to be able to fit the grommet on the wire no matter what I tried. Watched the YouTube video for more instructions, but did not help. Will contact Darrell Pool at Smooth Power for help.

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Jun 02, 2022 Alternate Air Grommet - (3 hours)

Category: Firewall

Installed alternate air grommet and attached cable to engine mount with Adel clamps. Will have to remove and reinstall when panel arrives for final cable length.

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Jun 01, 2022 Lower cowl sanding - (1 hour)

Category: Engine

Spent some time sanding the lower cowl in preparation for painting with primer.

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Jun 01, 2022 Alt air firewall pass through - (1 hour)

Category: Firewall

Located and drilled/punched hole for alt air cable in firewall. Started with the step drill and finished up final size with the hole punch.

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May 27, 2022 Throttle bracket - (1 hour)

Category: Instrument Panel

Spent some time trying to layout my throttle bracket(s). Advanced flight is going to fabricate the upper one, but I'm sending the lower one for the noted cables.

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May 26, 2022 Modified subpanel - (2 hours)

Category: Fuselage

Trimmed the aft portion of the subpanel ribs (F-745) to accommodate the Advanced avionics EFIS screens. Fabbed some flanges to attach to new location on subpanel. Won't install these until avionics panel arrives.

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May 26, 2022 Wingtip trailing edges - (1 hour)

Category: Wings

Sanded trailing edge of both wingtips after applying epoxy filler yesterday. Came out pretty well with a few voids I'll need to fill. Match the ailerons well

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May 25, 2022 Wingtip ribs and trailing edge - (3 hours)

Category: Wings

Installed the rivets to attach the wingtip ribs to the flanges. Also sanded the trailing edge of the wingtips. Mixed up some epoxy filet filler and filled the voids from when I cut the trailing edge to match the ailerons. Will sand again to match.

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May 24, 2022 Wingtip rib installation - (4 hours)

Category: Wings

Scuffed, primed and installed both left and right wingtip ribs plus flanges. Should have riveted the flanges to the wingtips first. Not sure how I'm gonna reach them now. May try and run out after supper and remove the ribs and reinstall. Was able to separate the pieces and reinstall. Riveted the wingtip ribs in place. Whew!

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May 22, 2022 Left wingtip hinge - (4 hours)

Category: Wings

Installed, prosealed and riveted left wingtip -3 hinge in the wingtip. Also trimmed both upper and lower hinges at the trailing edge

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May 21, 2022 Wingtip trailing edge glass - (2 hours)

Category: Wings

Installed fiberglass and epoxy inside wingtip at the trailing edge to reinforce the area I trimmed to match the aileron. Will fill the outside trailing edge with flox to sand and match the ailerons.

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May 21, 2022 Fluid hoses - (2 hours)

Category: Engine

Used permatex #2 to seal tapered threaded fittings for the manifold pressure line at the engine and manifold transducer. Torqued brake lines to the brakes and the NPT fittings from the firewall to the engine driven fuel pump. Marked each with torque seal.

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May 20, 2022 Bonaco fluid lines - (2 hours)

Category: Engine

Received and installed new fuel line, brake lines and manifold pressure line from Bonaco. Fuel line is perfect, brake lines now have the correct fittings and the manifold pressure line fits. The MP line should prob have a 90 fitting at the engine port, but current setup should work. Now to route the lines and torque the fittings. Marked and drilled 7/32” holes in both wingtip ribs for proseal “rivets”. Oh yeah, Happy 25th Birthday Sam.

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May 19, 2022 Wingtip rib flange - (3 hours)

Category: Wings

Fabbed a small flange for the bottom of the left wingtip rib for support where I removed material that interfered with the lower hinge. Drilled, deburred and match drilled flange to the left wingtip. Trimmed the wingtip at the leading edge to aid in installation. Countersunk the new holes drilled in the wingtip for AN426 rivets. Marked and drilled hole in plastic anchor block for bottom pin in left wingtip.

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May 18, 2022 Left wingtip bottom hinge - (5 hours)

Category: Wings

Drilled, deburred and match drilled the -3 half of the left wingtip bottom hinge using the -4 half as a guide for the -3 hinge location. Countersunk the holes in the wingtip for AN426-3 rivets and clecoed hinge in place for a test fit. Trimmed the wingtip to remove the “spacer” section and installed on the wing. Unfortunately it has the same play/movement as the right wingtip at the trailing edge. Not sure how I'm going to correct this, but will work on it some more once I get the wings out of the cradles. Trimmed the bottom of the left wingtip rib where it interferes with the hinge and match drilled it to the wingtip with the blind hole tool aligning it with the rivet line.

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May 17, 2022 Left wingtip bottom hinge - (4 hours)

Category: Wings

Decided to install a hinge on the bottom of the left wingtip that will hopefully be somewhat more secure than the right. Used my rivet fan to lay out holes in between the ones already in the bottom of the wing. Match drilled the wider -4 half of the hinge to the wing, then drilled out the additional holes once the hinge half was secure with clecoes. Removed the hinge half and installed it into the left bottom wingtip and match drilled the additional holes to the wingtip. Marked the centerline of the narrower -3 hinge half and used the -4 hinge half once again to mark the -3 half for rivet holes.

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May 16, 2022 Left wingtip rib flange - (2 hours)

Category: Wings

Drilled and deburred the top half of the left wingtip flange. Match drilled to left top wingtip.

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May 16, 2022 More Wingtip rib flange work - (2 hours)

Category: Wings

Match drilled wingtip flanges to the tops of both wingtips. Used my right angle, which worked quite well. Fabbed another wingtip rib flange for the bottom of the right wingtip rib. Drilled, deburred, and match drilled to the wingtip.

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May 14, 2022 Wingtip rib flanges - (3 hours)

Category: Wings

Fabbed two small angles to replace the ones I removed from the wingtip rib to prevent interference with the hinges. Got the fit wrong on the first, but was able to use it for the other wingtip and made the second correctly. Marked, drilled, deburred and match drilled to each wingtip rib. Gonna have to use the right angle drill to match drill the flanges to the wingtips in tight quarters. We'll see how that goes.

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May 13, 2022 Wingtip ribs - (3 hours)

Category: Wings

Laid out, marked and match drilled the right wingtip rib to the wingtip using a blind hole guide. It worked really well for this task. Di same for the top of the left wingtip and rib. Still undecided if I'm going to install a hinge on the left wingtip bottom due to movement of the right wingtip.

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May 12, 2022 Wingtip and cabin heat duct proseal - (6 hours)

Category: Wings

Installed, riveted and prosealed cabin air duct to inlet diffuser, oil door frame, top of left wingtip and top and bottom of right wingtip. Had some trouble riveting one corner of the cabin inlet duct so decided to use a #6 screw. Pneumatic squeezer was a life saver on the wingtip hinges. And BTW I hate working with proseal.

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May 10, 2022 More wingtip backer rod - (4 hours)

Category: Wings

Glassed in more backer rod in the top of both wingtips. Glad this is done. Not my favorite mini project. Created lots of fiberglass scraps and used lots of latex gloves.

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May 09, 2022 Wingtip backer rod - (3 hours)

Category: Wings

Marked wingtip and installed door sealant backer rod with fiberglass and epoxy in bottom of wingtips to prevent “oil canning” of wingtip when pressed.

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May 03, 2022 More wingtip work - (3.5 hours)

Category: Wings

Marked, drilled and deburred wingtip hinges to 7/32” holes. This is to aid in the adhesion of the proseal to the hinge and security to the wingtip. Made a new fiberglass countersink tool from a worn dremel bit. Seemed to work well after trimming down on the grinder. Countersunk all the wingtip holes for -3 rivets.

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May 02, 2022 Wingtip reinforcement - (2 hours)

Category: Wings

Determined location of wingtip “oil canning”, laid out and epoxied in backer rod from Lowes to prevent this flexing of the wingtip. Other builders have noted that their paint has cracked from someone leaning or pressing on their wingtip. Some have also seen vibration of the wingtip in flight. Decided the 1/2” rod is too large so will get the 3/8” for the rest of the installation.

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Apr 29, 2022 Pitot and AOA line connectors - (1 hour)

Category: Wings

Installed the AN fittings on the pitot and AOA lines. Staggered the fittings to fit thru the pitot mast. Tested fit in wing. It's tight but should work as is a lot of things on this project.

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Apr 29, 2022 Alternator lock plate - (1 hour)

Category: Engine

Installed and torqued alternator mounting screws lock plate. Not sure if I need to safety wire these screws, but if I do they will be tough to reach.

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Apr 28, 2022 Wire pass throughs - (7.5 hours)

Category: Firewall

Located, drilled and deburred two pass throughs for electrical and oil cooler butterfly valve. Used safety wire through the wire nut to find a good location for cable pass thru. Also safety wired the fostener screws in the back plate of the FAB. Not my best work, but hard to get into that area.

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Apr 27, 2022 Map sensor plumbing - (3 hours)

Category: Engine

Fabbed/bent 1/4” tubing to connect ElectroAir MAP sensor to the manifold transducer. Measured, installed the connectors, flared the ends and drilled through hole in firewall to connect to the MAP sensor on cabin side. Also mapped out location for the Advanced Flight MAP sensor and fabbed up some aluminum washers to support the plumbing. Made a little stub of 1/4” tubing to connect to the ElectroAir MAP.

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Apr 26, 2022 ElectroAir MAP sensor - (2 hours)

Category: Engine

Determined location for the ElectroAir MAP sensor on the cabin side of the firewall. Match drilled the MAP to a sub panel rib and installed. Still need to figure out plumbing and location for the Advanced Flight MAP sensor that will also have to be plumed to the same line.

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Apr 25, 2022 Manifold pressure line - (1.5 hours) Category: Engine

Measured and ordered a manifold pressure line from Bonaco. 40 1/4”.

Apr 19, 2022 Pitot tube inlet tubes bent wrong - (1 hour)

Category: Wings

Discovered that I had bent the pitot tube supply lines in the wrong direction. Carefully bent the lines in the correct orientation and test fit connectors.

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Apr 16, 2022 Pitot line Adel clamps - (1 hour)

Category: Wings

Installed a couple -4 Adel clamps to prevent chafing with the bolts on the aileron bell crank.

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Apr 14, 2022 Pitot controller - (2 hours)

Category: Wings

Drilled and countersunk holes in the pitot controller for nut plates, since I was not able to install the controller with screws and nuts. Temporarily installed the controller in the wing via the access panel. Very tight quarters, but the nut plates worked as hoped.

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Apr 06, 2022 Park brake valve - (2 hours)

Category: Fuselage

Finished riveting park brake mounting bracket to firewall. Would have been a lot easier to do before mounting oil cooler. Used my smallest bucking bar to back rivet bracket. Installed park brake valve and connected to interior brake lines. Rubber washers seemed to get smashed out of place so need to check on proper torque of AN3 bolts.

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Mar 23, 2022 Park brake valve bracket - (2 hours)

Category: Engine

Was able to remove and reinstall the park brake valve bracket with this little close quarters ratcheting tool. Had to use a flat head screwdriver to apply enough pressure to the back of the ratchet to turn the screw. Decided to try to rivet the bracket in place using a small bucking bar and back rivet set. Practiced on a few and then tried the technique on one. So far so good.

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Mar 22, 2022 Top cowl sanding and ElectroAir coil pack - (3 hours)

Category: Engine

Secured 4th corner of ElectroAir coil pack to engine mount. Ended up using an AN3 bolt to make things fit and special tool from HFS Mfg to secure the last corner of the coil pack . Adel clamp tool works great in tight places. Sanded the top cowl some more and found some places I need to fill. Looked into finishing up the parking brake valve install. Should have riveted it in place before mounting the oil cooler to the firewall. No access without removing a LOT of stuff. Gonna have to think on this.

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Mar 17, 2022 Bonaco Brake lines - (1 hour)

Category: Engine

Installed Bonaco brake lines that I received yesterday. Fitting at the brake calipers was a -3 and needed to be a -4, so Bonaco is going to send me a two new NPT 90 fittings with a -3 at one end to fit the brake lines.

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Mar 17, 2022 AOA and pitot lines - (2 hours)

Category: Wings

Opened up the tooling holes to 3/8” at the root of the wing for the AOA tubing. Used the 12” bit I got yesterday and a step bit to reach the inside rib. Installed plastic grommets and inserted both tubes with some extra on each end.

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Mar 16, 2022 Top cowling and canopy fairing - (1 hour)

Category: Engine

Sanded and primed canopy fairing. Actually looks pretty good gonna leave it for now. Began sanding top cowling with #80 grit paper on orbital sander.

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Mar 15, 2022 Pitot controller - (3 hours)

Category: Wings

Installed template for pitot controller in left wing and match drilled for #8 screws to rib adjacent to pitot. Made for tough drilling and deburring with very limited access to backside. Tried to install controller but it's going to be darn near impossible to get to hardware on back of rib. Even tried my washer tools to access the backside without success. Can't install controller on facing side of rib due to raised portion of rib around lightening holes. Bent AOA and pitot aluminum tubes to fit in wing and through pitot mast. May have to cut one short to get mating hardware to fit through the pitot mast. Applied another thin coat of epoxy and fairing filler to canopy fairing.

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Mar 14, 2022 Pitot tubing - (4 hours)

Category: Wings

Changed gears a bit today and started working on the pitot tube tubing and AOA tubing. Previous builder had already sealed up the bottom skins of the wing so working inside the wing through the access panels was a bit challenging say the least. Opened up the upper tooling hole to 3/8” to accommodate the AOA tubing. Ran into a little roadblock a the root of the wing where the ribs are to close together to get a drill inside. Had to order a 12” drill bit to finish the tube routing. Made a template to mount the heat controller to a rib for the pitot. Clamped in place for now. Controller will have to go on the outboard side of the rib to avoid the bump out of the lightening holes. Sanded down the canopy fairing again..

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Mar 13, 2022 Stick grip and canopy fairing - (2 hours)

Category: Avionics

Removed push button in #3 position on left stick grip. Installed and soldered toggle switch in same position for flap control after hearing from JD I did the right grip correctly. Sanded the never ending canopy fairing and reprimed.

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Mar 12, 2022 Coil pack install - (2 hours)

Category: Engine

Finally received the AN4 bolts I needed to attach the ElectroAir coil pack to the engine mount. Getting the Adel clamps to match up and install was a real PITA. Could not get the last hole in the coil pack to match up with an Adel clamp, so I either go with 3 clamps or figure out a way to secure the fourth mounting hole. Sanded off the 5 min epoxy on the canopy fairing ( don't use the 5 min stuff) and reapplied another coat of west systems epoxy and fairing filler.

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Mar 12, 2022 Infinty stick grip - (2 hours)

Category: Avionics

With the Advanced avionics I'm using the flap position indicator will not work. Need to order a different type and also needed to change a push button on the Infinity stick grips to a toggle. Ordered the toggle switches and began changing them out. Opened up the stick grip to find a mass of wires and several buttons to choose from for removal. I decided to go with the manufacturer recommendation to put the flap toggle switch in the #3 position. (Upper left on right grip and vice versa on the left grip). Removed the button and clipped the wires. Stripped and resoldered the wires to the toggle. Soldered the connections per the wiring diagram in the instructions, but not sure of correct orientation. Will wait to do the other grip until I hear from the manufacturer.

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Mar 11, 2022 EGT probes, oil and fuel transducers - (3 hours)

Category: Engine

Drilled exhaust locations and installed the remaining EGT probes. Installed fuel and oil pressure transducers on transducer manifold. Had some interference between the fuel restrictor and oil cooler line. Had to remove all to adjust fuel restrictor. Resealed and retorqued all fittings with fuel sealer and #2 gasket sealer for oil cooler line.

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Mar 10, 2022 EGT probes - (1 hour)

Category: Engine

Installed the lower cowling to check for interference with EGT probes, double checked location and center punched marks for drilling #30 holes. Drilled into #1exhaust and installed probe.

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Mar 05, 2022 Engine probes - (4 hours)

Category: Engine

Sanded down the canopy fairing again. Just a few spots that may need a little touch up with epoxy/sandable primer. Installed FAB back plate with new gasket and fostener screws. Will wait to install safety wire until I finish cable and wire runs. Installed the oil temp probe to finger tight for now. Probe has a one time use crushable washer that I didn't want to tighten just yet. Installed the CHT probe inserts into the threaded wells on the engine near the spark plugs. Torqued to 30 inch pounds with blue locktight. Marked the exhaust for EGT probe locations. Installed a couple spark plug wires to check for possible interference.

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Mar 04, 2022 Canopy fairing - (1 hour)

Category: Fuselage

Sprayed some primer filler on the canopy fairing. A few minor blemishes but overall it's looking pretty good. Gonna sand a little more and then leave for paint.

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Mar 04, 2022 Pitot mast - (1 hour)

Category: Wings

Countersunk the holes I drilled earlier in the pitot mast for the 6-40 mounting holes.

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Mar 04, 2022 Backup Alternator - (1 hour)

Category: Engine

Installed backup alternator on accessory pad. There is one mounting nut that is nearly impossible to access, but I managed to get it on. Not sure how I'm going to torque it. May just use the “Gootentiet” method.

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Mar 03, 2022 Wingtip hinge pin anchors and pitot tube screws - (4 hours)

Category: Wings

Fabbed the hinge pin anchors that secure the hinge pins from vibrating aft/out of the wingtip. Drilled the cutting board block (1/2”) for the pins and the #10 screw that will hold it secure it to the wingtip rib. Riveted the nutplate in place on the wingtip rib.
Received some #6-40 stainless screws from Mike Bullock that he used on his pitot tube as he had a lot extra per his build site. Tapped the pitot tube for 6-40 screws without damaging the pitot lines or the electrical wires, at least I think. Thanks a bunch for the screws Mike.

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Mar 02, 2022 Cowl hinge pins and firewall pass thru - (4 hours)

Category: Firewall

Secured cowling side hinge pin guides using smaller Adel clamps and some RTV sealer at the firewall. Only had a dg2 and 3 Adel clamps. The dg3 is the perfect size for the stainless tubing and I made the dg2 work, but need to order some dg3 clamps for the Bowden cables as well so I'll replace the 2 when I get those. Made a hole for one of two firewall pass throughs using a step drill and finishing with a hole punch. Used a location from an existing hole I covered. The previous owner mislocated the hole for the brake reservoir which was not supported by an aluminum angle, so after putting the reservoir in the proper location I had an extra hole in the firewall. There may be a problem with it interfering with removing or installation of the battery, but I'll deal with that when I get my battery. May have to trim the battery tray.

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Feb 28, 2022 TE Wingtip trimming - (3 hours)

Category: Wings

Trimmed the trailing edge of each wingtip to match the trailing edge of the ailerons. Installed, marked and cut the left wingtip hinge pin for installation in the anchor block. Did some planning on the alternate air door control cable. Think I found a good spot for the firewall pass through. You can just barely make out my mark on the firewall in the photo. Gonna use the tab on the engine sump for an Adel clamp to route it to the alt air door.

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Feb 27, 2022 Wingtip rib nutplates - (3 hours)

Category: Wings

Fabbed a wooden hinge pin stop. The final product will be a delrin or plastic block that will secure the aft end of the pins to keep the pin from vibrating out. Fit check the right wingtip rib into the wingtip to check and trim the hinge pins. Finalized location of hinge pin anchor block and marked for screw and nutplate. Drilled both ribs for #10 nutplates. Will wait to drill hole to final size and match drill to anchor block.

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Feb 26, 2022 Right wingtip rib - (3 hours)

Category: Wings

Trimmed right wingtip rib where it interferes with the hinge. Fitted rib to wingtip and trimmed the hinge ends that interfered with the stop screws installed earlier. Fabbed a flange to replace the one that was trimmed. I'll use it to attach to outboard side of the rib to the wingtip. At least that's my plan.

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Feb 25, 2022 Wingtip ribs - (3 hours)

Category: Wings

Spent more time on the wingtip ribs. Measured and drilled rivet holes for the left rib. New rivet spacer tool worth every bit of the cost; worked great. Fabbed a new flange for the portion removed that conflicted with the hinge. Planning to attach it to the outboard side of the rib to support the forward part of the rib. Struggled a bit with the location on the rib and hinge for the new flange. Began work on the placement of the right wingtip rib. Seems the sweet spot is right where the rib meets the fiberglass edge near the trailing edgeinside the wingtip.

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Feb 24, 2022 More wingtip rib work and coil pack Adel clamps - (3 hours)

Category: Wings

Fabbed up a wooden aileron profile to help with placement of the wingtip rib. Clamped the rib in place and moved forward and aft until it matched the wooden aileron. Just to be more accurate I made two inch tic marks on both the wooden rib and wingtip on both top and bottom. Measured the distance at each tic mark and compared the two. Came in very close so I match drilled a hole from the wingtip to the rib. This is as close as I can get until I mount it on the wing and trim the trailing edge.
Also drilled out the remaining 3 Adel clamps for AN4 bolts (1/4”) to mount the ElectroAir coil pack to the engine mount.

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Feb 23, 2022 Wing tips and pitot tube - (3 hours)

Category: Wings

Fiddled around some more with the wingtip rib location. Thinking of removing the rib flange where it interferes with the hinge and riveting a new flange to the rib to compensate for the hinge. That would give the tip the full support of the rib without removing a large portion. Also match drilled, with a drill stop to prevent damage to the pitot tube plumbing, the pitot tube mast to the pitot tube after much measuring and marking. Always stressful drilling into new high dollar parts. All went as well as could be expected. Not sure if I'm going to use 6-32 screws or 6-40. Don't really think it makes much difference.

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Feb 22, 2022 Alternate air door and wingtip - (3 hours)

Category: Engine

Final riveted the alternate air door to the backplate of the Sam James FAB. Tried to figure out how to fit the wingtip rib to the wingtip without distorting the wingtip and matching the profile of the aileron. No great epiphany yet.

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Feb 21, 2022 Baffles - (3 hours)

Category: Engine

Final installed baffles. Installed tension rods on left side and opened up #30 holes on aft corners to #28 for installation of #6 screws and lock nuts. Decided to deviate from the plans and use screws instead of rivets to ease disassembly if needed. Tension rods were a pistol to secure but finally got er done. Added some pvc tape to tubing on outer tension rods that may rub slightly on oil return lines.

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Feb 20, 2022 ElectroAir install - (1 hour) Category: Engine

More ElectroAir installation planning.

Feb 19, 2022 ElectroAir coil pack location - (2 hours)

Category: Engine

Finished sanding canopy fairing one last time. Gonna try some primer and see how it looks once the big side shop warms up. Messed with trying find a location for the ElectroAir coil pack. Think I have settled on securing it to the motor mount with Adel clamps per the ElectroAir guys. At least for now.

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Feb 18, 2022 Baffle rods and more canopy work - (2 hours)

Category: Engine

Installed the left side baffle rods with the metal locking nuts. Sanded and epoxied more spots on canopy fairing.

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Feb 17, 2022 Baffles, inlet diffusers and oil cooler scat tube - (4 hours)

Category: Engine

Installed rear baffle AN3 bolts the rear bracket on engine. Sanded canopy fairing. Getting close to final prep for primer paint. Installed both inlet diffuser ducts. Also temp installed some extra rubber tube on engine mount to prevent chafing of oil cooler scat tube on engine mount as per a suggestion on VAF. Installed plenum just for fun

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Feb 16, 2022 Final baffle install - (3 hours)

Category: Engine

Used torque wrench and torque seal to tighten and mark baffle screws. Drooped a screw bit into engine near the red cube. Had to use a telescoping wand and duct tape to retrieve. Needed extra long extensions on torque wrench for one screw. Pretty sure I'll need to remove the baffles later since they are all torqued now. Murphy's law. Haha

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Feb 15, 2022 Front Cowling fasteners - (1 hour)

Category: Engine

Installed newly received longer Skybolt studs. Inventoried items from ACS firewall pass thru kit. Marked location on firewall for 1” hole. Right side will be a little lower since I'm going to modify existing hole for pass thru

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Feb 10, 2022 More canopy fairing work - (1 hour)

Category: Fuselage

Sanded some epoxy I added to the canopy fairing a while ago. Used the pneumatic sander which was too aggressive and had to add more epoxy to fill in the divots I made with the sander. Oops

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Feb 10, 2022 Adel clamps and oil cooler tube - (1 hour)

Category: Engine

Added a couple Adel clamps to fuel line to prevent chafing on motor mount and installed the oil cooler scat tube. Lots of rubbing with oil cooler lines and engine control cables that I'll need to address.

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Feb 10, 2022 Hinge wingtip Screw stops - (1 hour)

Category: Wings

Installed wingtip hinge screw stops to both wing hinges using #4 stainless sheet metal screws. Added another coat of paint to inlet diffusers.

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Feb 09, 2022 Oil cooler line connection - (3 hours)

Category: Engine

Spent some time ordering some parts. Needed longer Skybolt stud screws for the two forward fasteners on the cowl that have deeper grommets. Also ordered another firewall pass thru kit. So now have two pass thru kits for each side of the firewall. Added another coat of epoxy paint to inlet diffusers. Installed and connected oil cooler lines to oil cooler. Tight quarters, but was able to get everything snug. Wasn't able to use my torque wrench since I didn't have a crows foot big enough for oil cooler lines.
Countersunk and riveted the Skybolt receptacles to the brackets at the front of the cowl. Had to bend the tabs, as shown, a little to ensure the center was flush as possible with the bracket.

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Feb 08, 2022 Front Skybolt cowling receptacles - (2 hours)

Category: Engine

Added another coat of paint to inlet diffusers and recessed Skybolt receptacles on cowling front.

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Feb 03, 2022 Diffuser paint and fuel line - (2 hours)

Category: Engine

Put a coat of white epoxy paint on inlet diffusers. Little too much on one and it ran. Rats. Gonna have to sand and repaint. Installed fuel line from engine driven pump to fuel servo. Adel clamps were a pain to install. Wouldn't have been able to install without the clamp tools shown.

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Jan 19, 2022 Left wingtip - (1 hour)

Category: Wings

Countersunk the wingtip spacer that was trimmed off earlier and dimpled the end of the wing for the spacer. Clecoed the hinge and spacer back in place.

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Jan 18, 2022 Wingtip hinge trimmed - (1 hour) Category: Wings

Removed right wingtip lower -4 hinge to trim the leading edge flange I left in place to be sure it was long enough. Measure twice, cut once, throw out the part and order another. Haha. No pics today. Spent some time making a to-do list.

Jan 11, 2022 Wingtip nav PCB nutplates - (1 hour)

Category: Wings

Riveted a one legged #6 nutplate at the tip of the wingtip to secure the nav light PCB. Regular two legged nutplate just wouldn't fit with the curve of the tip. Marked the left wingtip for trimming of the trailing edge and removed from the left wing. Installed the same one legged nutplate on the left wingtip.

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Jan 05, 2022 Left wingtip - (1.5 hours)

Category: Wings

Trimmed the top of the left wingtip for hinge. Installed the wider half of hinge on the wing with the trimmed piece as a spacer. Installed the left wingtip to the wing leaving the bottom untrimmed to utilize #6 screws. Clecoed wingtip in place using the top hinge and bottom edge of wingtip. Trailing edge of wingtip is rock solid with this type of configuration versus using hinges on top and bottom.

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Jan 04, 2022 Riveted angle - (2.5 hours)

Category: Instrument Panel

Riveted angle to back of instrument panel in preparation for shipping to Advanced Flight Systems. Also riveted both small angles to the outside edge of the panel. Used AN426-5 rivets since the -6 rivets called out on the drawing seemed a bit long. The -5s worked well along with the pneumatic squeezer. Also used the fat bottomed squeezer heads so I wouldn't have to be so “dead eye dick” with the squeezer. Took a selfie with the instrument panel clamped to the bench. Don't pay attention to the position of the squeezer, I'm a rookie selfie taker. Placed some rivets into some misdrilled holes that I thought I needed for nutplates. Filed the backside flush with the panel to accommodate the angle the panel attaches to.

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Jan 03, 2022 More left wingtip hinge - (2 hours)

Category: Wings

Finished match drilling -4 wide hinge half to wing and assembled with -3 narrow hinge half for match drilling-3 hinge to wingtip.

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Jan 02, 2022 Left tip hinge - (2 hours) Category: Wings

Marked and began match drilling wider -4 hinge to left wing.

Dec 29, 2021 Angle attachment - (2 hours)

Category: Instrument Panel

Continued prep of instrument panel for attachment of support angle. Scuffed, masked and primed area on back of panel where angle attaches. Countersunk holes on front of panel for rivets. Painted oil door frame.

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Dec 22, 2021 Instrument panel - (2 hours)

Category: Instrument Panel

Removed angle (F703-B) from instrument panel (F-703) to deburr and prep for assembly. Need to get it ready to ship to Advanced Avionics for panel build. Drawing says to use 426-6 rivets, but they seem way too long. Gonna try -5s and see how it goes. Also sanded down bad paint on oil door frame and primed with the standard grey rattle can paint from Napa.

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Dec 19, 2021 Landing lights and oil door - (2 hours)

Category: Wings

Reassembled landing light that I damaged after getting repair from Aeroleds. Attempted to paint the oil door support bracket with some white epoxy paint, but the paint ran and spotted. Gonna try again with primer.

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Dec 18, 2021 Wingtip hinge - (2 hours)

Category: Wings

Started to trim the top of the left wingtip and realized I needed to match drill the other side of the hinge on the wingtip before going further. Oops. Only affects about 4 rivets, so hopefully won't have much of an impact.
Match drilled the left top, narrow -3 hinge half using the -3 top hinge from the right side.

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Dec 17, 2021 Nav light nut plates - (2 hours)

Category: Wings

Installed a couple nutplates for each nav light PCB. Need the one legged nutplates for the screws that are near the very tip as the fiberglass curves and won't support a regular nutplate

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Dec 16, 2021 Wingtips and lights - (2 hours)

Category: Wings

Finished match drilling the top of left wingtip to wing. Decided to secure the nav lights to the tips with screws instead of double sided tape as suggested in the instructions. Didn't want to have to try and peal the PCB off if needed. Drilled to #40 for now. Will install nut plates for #6 screws

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Dec 14, 2021 Left wingtip - (2 hours)

Category: Wings

Aligned left wingtip with the left aileron using the tooling holes and alignment tool per dwg 12. Secured the wingtip and match drilled to the wing.

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Dec 13, 2021 wingtips - (2 hours)

Category: Wings

Marked right wingtip for trimming the trailing edge to match the trailing edge of the aileron. Used the top hinge from the right wing to match drill the extra holes in the top left wing for the left wing hinge.

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Dec 08, 2021 Wingtip fit and trimming - (3 hours)

Category: Wings

Tried to firm up the trailing edge of the right wingtip. Put some tape around the leading edge with no change. Also tried a couple different straps to secure the trailing edge of the hinge. Installed both with no better result. Decide to begin work on the left wingtip with the idea of using screws on the bottom of the wing and see if this keeps the trailing edge from moving. Began trimming the edge of the left wingtip to fit the left wing. Installed left wingtip to check fit and align with aileron. All geared up for flying fiberglass dust.

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Dec 07, 2021 Installed wingtip - (1 hour)

Category: Wings

Installed wingtip to wing to check fit. It all looks good, but have about an 1/8” wiggle at the trailing edge. Gonna check on line to see if others have had a similar issue.

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Dec 05, 2021 Wingtip trimming - (3 hours)

Category: Wings

Trimmed and sanded edge of right wingtip. This trimmed edge will be used as a spacer for the wider wing side hinge. Countersunk the trimmed portion using a deburring tool. Worked better than countersink tool. Just had to use consistent pressure and a short pull on the trigger. Installed on wing to check fit.

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Dec 04, 2021 Wing tip match drilled top hinge - (1 hour)

Category: Wings

March drilled the holes on the -3 side of the top hinge to the wing tip. Think I'll use this technique on the left wingtip as well

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Dec 03, 2021 Top right wingtip - (2 hours)

Category: Wings

Laid out hole pattern for -3 hinge for top right wingtip. Decided to drill hinge first then match drill to wingtip. I'll see how this works using my right angle drill taking care not to push too hard preventing break out on outside of fiberglass wingtip. Set up a jig on the drill press to ease drilling and ensure hole edge distance.

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Nov 28, 2021 Wingtips - (2 hours)

Category: Wings

Marked hinge and match drilled wide side of hinge (-4) to end of right top wing.

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Nov 22, 2021 Wingtip hinge - (1 hour)

Category: Wings

Finished match drilling narrow side of hinge to bottom of right wingtip.

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Nov 21, 2021 Wingtip work continued - (3 hours)

Category: Wings

Matched drilled wider half (-4) of hinge to bottom of right wing. Wider half of hinge used to cover any gap between wing and wingtip joint. Lots of measuring and marking. Began match drilling narrower half (-3) of hinge to wingtip.

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Nov 20, 2021 Wingtip match drilling - (1 hour)

Category: Wings

Match drilled wing extra holes to wingtip for hinge attach.

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Nov 19, 2021 More wingtip work - (2.5 hours)

Category: Wings

Continued work on wingtips. Aligned right wingtip with aileron and attached it to the wing. Matched drilled the wingtip to wing and removed. Made a jig to drill additional holes in between predrilled holes on the wing to support the hinge. Drilled said holes.

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Nov 12, 2021 Wing tip alignment - (1 hour)

Category: Wings

Made tool for wingtip to aileron alignment per dwg 12A. Installed wingtip and matched drilled a few holes to secure right wingtip to end of wing in preparation for hinge installation. What you see in the photo that looks misaligned is the wing flap.

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Nov 11, 2021 Wing tip - (2 hours)

Category: Wings

Began trimming right wing tip to fit wing flange in preparation for hinge installation.

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Nov 09, 2021 Top Dead Center - (2 hours)

Category: Engine

Redetermined TDC on the #1 cylinder again with false prop (1x3) in place to aid in finding top dead center. Was sorta hard to turn the starter ring gear by itself yesterday. Removed and reinstalled MTH with pin, then removed pin. Hopefully that's all done.

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Nov 08, 2021 Wingtip light lens - (1 hour)

Category: Lighting

Tried to install last collimator lens into lens holder, but just wouldn't seat down far enough to engage hooks on lens holder. Emailed FlyLeds and said to return for new parts from Flyboys Accessories. All the other lens installed without a problem.

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Nov 08, 2021 Finding TDC on #1 cylinder and MTH installation - (2 hours)

Category: Engine

Installed ElectroAir MTH gear, torqued nut and installed cotter pin. Determined top dead center of #1 cylinder using a piston stop and my cell phone compass app. Also referenced the small hole on the starter and indication on the starter ring gear plus indicator at top of ring gear to engine case centerline. Installed MTH back onto right mag pad and removed timing pin from MTH.

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Oct 22, 2021 Right wingtip leds - (4 hours)

Category: Lighting

Match drilled right forward facing PCB to right wingtip cove for nut plates. Installed 4 nut plates since the 5th on on top of the left wingtip was difficult to install and seemed excessive. Stripped and soldered wire ribbons that connect the two PCBs. Installed wire ribbons on outboard facing PCBs. Installed taxi/landing for fit. Installation was a PITA.

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Oct 22, 2021 FlyLeds taxi and lndg lights - (6 hours)

Category: Lighting

Started part 3 of FlyLeds build. Riveted nut plates to boards. Single leg nut plate was a PITA due to the rivets being so close together made it difficult to squeeze separately. Damaged one of the Leds. Ordered some clear glue to cover bulb per instructions. Installed heat sinks and lens covers. Installed all lens but the one damaged led. Trimmed left (red) wingtip to allow room for backside components. Drilled nut plates on fwd facing wingtip cove. Trimmed right wingtip cove for PCBs. Left a little more material than the left side.

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Oct 20, 2021 FlyLeds right tip lights and controller board - (4 hours)

Category: Lighting

Finished right side forward facing and outboard facing PCBs. Soldered all resistors and connectors to back of both boards. Installed strobe light heat sinks. Tested both boards with 9V battery to check lights and all functioned as advertised. Populated and prepped all components for the controller PCB. Soldered all components and connectors. Tested controller board indicator lights and seems to function well.

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Oct 19, 2021 FlyLeds Finished left light CBs and started right - (4 hours)

Category: Lighting

Prepped and installed left resistors and green connectors. Bent and cut leads, used a spacer to lift the resistors off the PCB for heat dissipation and soldered in place on back of PCB. Installed heat sinks opposite the strobe lights on the back side of PCBs. Soldered green connectors and tested lights with 9V battery. All worked as advertised. Began working on right ( green) lights. Trimmed PCBs to right wing tip and marked cutouts for both PCBs on wingtip cove. Prepped right strobe lights and green nav light and attached with thermal grease, being careful of orientation.

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Oct 18, 2021 Strobes and red nav Led lights - (2 hours)

Category: Lighting

Prepped more strobe light legs. Applied thermal grease to strobes and red Leds. Mounted and soldered all. Used template and cut out wing tip for forward facing lights.

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Oct 17, 2021 Wing tip lights - (2 hours)

Category: Lighting

Used FlyLeds template to make make cutouts for both the forward facing and outboard facing circuit boards. Trimmed the forward facing circuit board circuit board to fit the left wingtip light cove. Also beveled the aft edge of the outboard facing PCB to sit flush against the forward facing PCB.

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Oct 16, 2021 Wing tip lights - (2 hours)

Category: Lighting

Trimmed outboard facing circuit board to match wingtip light cove. Began prepping LEDs for solder installation and cut out template for wing tip trimming.

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Oct 15, 2021 Fuel injector servo gasket, breather tube, wing tip lights - (3 hours)

Category: Engine

Removed and reinstalled fuel injector servo to install the gasket. Used permatex gasket sealer, torqued nuts to 65 inlbs and applied torque seal. Secured oil breather tube to angle of oil cooler mount. Epoxy primed inlet diffusers and FAB parts. Started planning FlyLeds “The Works” wing tip lights install.

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Oct 14, 2021 Left side baffle spark plug wire pass through - (2 hours)

Category: Engine

Made an opening in the #4 baffle for the spark plug wire seal. Drilled and dimpled for nut plates and installed. Had to drill out the plug seal to 5/16 inch to accommodate the larger ElectroAir spark plug wires.

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Oct 13, 2021 Baffle spark plug wire seal - (2 hours)

Category: Engine

Dimpled and installed nut plates on baffle #3 for the spark plug wire seal. Also marked up #4 baffle for spark plug wire seal pass through. Actually used the DRD2 dimpler to reach the lower nut plates.

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Oct 11, 2021 Spark plug baffle pass thru - (2 hours)

Category: Engine

Worked on top right spark plug wire pass through hole location. Installed the oil filler tube to check for interference with spark plug wires. Looks like somebody decided to be funny on dipstick packing. Haha Found some good pics from RV-14 plans and drilled oblong hole for spark plug wire pass through grommet. Also drilled for #8 nut plates to secure.

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Oct 10, 2021 Oil cooler installed and scat tube - (1 hour)

Category: Engine

Reinstalled the oil cooler to firewall and temporarily attached the scat tube to oil cooler duct and cylinder #4 baffle. Appears as though the stock oil cooler lines will work.

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Oct 09, 2021 Oil cooler duct - (.5 hour)

Category: Engine

Riveted oil cooler butterfly valve to oil cooler duct.

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Oct 08, 2021 Oil cooler sealing and butterfly valve - (2 hours)

Category: Engine

After all the time it took to install I had to remove the oil cooler to goop the edges with RTv and match drill for pull rivets to the butterfly valve. Hint: always a good idea to double check the directions.

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Oct 07, 2021 Oil cooler installation - (5 hours)

Category: Engine

Assembled and installed oil cooler to the firewall. One mounting bolt was impossible to install due to limited access. Just couldn't get it to engage in the nut plate. Ended up removing the nut plate to be able to use a standard nut on the backside. Struggled with hole alignment and nut plate engagement on all holes. Hope I never have to take the oil cooler off. Added an angle from the firewall to the forward edge of the oil cooler to ensure support.

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Sep 22, 2021 Plenum paint prep - (2 hours)

Category: Engine

Mixed up some epoxy and applied to plenum mod in preparation for paint. Reinstalled left rear baffle. Drilled out a couple rivers on the lower cowling brackets and replaced with 426-4s

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Sep 21, 2021 Baffle tension rods - (4 hours)

Category: Engine

Installed full brake line sleeves on baffle tension rods. Removed and modified pipe clamps on oil return lines to prevent interference with the baffle tension rods. Clipped the tails on the pipe clamps and reoriented screw to belong the oil return lines. Riveted oil cooler scat tube duct to the back of the #4 cylinder baffle. Reinstalled the fuel line from the fuel spider that was removed to install the red cube bracket.

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Sep 20, 2021 AC specialties flightlines bracket - (3 hours)

Category: Engine

Finished the installation of the AC Specialties Flightlines bracket. Modified one of my cheap 7/16” open end wrenches to reach the mounting bolt per the instructions. It's a tight little space to torque a 1/4” bolt. Couldn't get a torque wrench in there so had to rely on my calibrated wrist to set the torque. Gritted my teeth and drilled a hole in my brand new red bracket to secure a safety wire after loosening the 90 degree fuel feed. Struggled safety wiring the bolt since it's such a small space and trying to figure out the correct technique. Eventually got everything back together and torqued the last two AN3 bolts that hold the fuel transducer to the bracket. Hopefully there won't be any fuel leaks during the fuel test as it will be a PITA to troubleshoot.

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Sep 13, 2021 Red cube installation and oil door frame paint - (4 hours)

Category: Engine

Installed the red cube and Aircraft Specialty Flightlines mounting bracket. Had to remove the fuel spider line to the #1 cylinder to have access to torque the bolt on mounting bracket.
Painted the aluminum oil door frame.

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Sep 12, 2021 Top cowling paint and lower cowl brackets - (6 hours)

Category: Engine

Sanded, primed and painted the inside of the top cowling. Riveted the forward bottom cowling brackets after having to rework some. Sorta difficult squeezing the rivets on the curved surface of the lower cowl. They aren't perfect, but will suffice for their intended use. Primed the outside of the left inlet diffuser. Painted the inside of the oil door.

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Aug 31, 2021 Clogged rattle can and cowling angles - (1 hour)

Category: Engine

Spent time prepping left inlet diffuser for paint only to struggle with a clogged spray can nozzle. Ended up ordering new bottles from a different vendor. Scuffed and primed the small aluminum pieces that go on the lower cowl to reinforce the top and bottom cowl edges between the spinner and air inlets.

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Aug 26, 2021 Inlet diffusers and and paint - (1 hour)

Category: Engine

Sanded down epoxy filler on outside of inlet diffusers for paint and painted right diffuser.

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Aug 26, 2021 Cowling heat shield, inlet diffuser paint prep - (4 hours)

Category: Engine

Installed remaining lower cowling heat shield. Split it into several sections to avoid as many wrinkles as possible. Used the wallpaper seam roller to “iron” out as much as I could, but no way to avoid all the wrinkles in the heat shield foil. Filled some voids on the outside of the inlet diffusers to prepare for paint. Reinstalled camlocks on lower cowl.

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Aug 25, 2021 Cowling heat shield and baffle corner - (2 hours)

Category: Engine

Replaced a nut plate on the lower right corner of the forward right baffle with an angle and rivet. One less screw. Started lining lower cowl with heat shield. Wallpaper tool worked well to smooth out the wrinkles. Think it's gonna take two more sections per side.

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Aug 23, 2021 Painting inlet diffusers - (3 hours)

Category: Engine

Match drilled large hole in right inlet diffuser for scat tube mount to heat muff. Sanded, masked off and painted interior of inlet diffusers. Attached heat shield to exhaust to protect the throttle cable. Test fit stainless steel screen to diffuser cabin heat inlet.

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Aug 09, 2021 Breather tube - (2 hours)

Category: Firewall

Finalized position of breather tube and fastened with Adel clamps. Cut a whistle hole in tube to prevent freezing up. Drilled out a couple rivets on the right front inlet baffle that may not have needed to do. Oh well

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Aug 08, 2021 Engine breather tube - (2 hours)

Category: Engine

Continued work on new breather tube. Removed the oil cooler for better access. Messed with some bends to fit, but was marginally successful. Need to secure the bottom with some adel clamps. Lots of on and off and small bends to get end of tube to exit over exhaust pipe. May need to add a whistle hole to prevent freezing up. Marked an initial location for cabin hot air inlet on right inlet duct

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Aug 05, 2021 Engine mount bolts, hinge pin tubing, cabin heat scat tube and breather tube - (3 hours)

Category: Engine

Received new stainless tubing to replace cowling side hinge pin aluminum lead in tubing that deformed when I tried to open it up. Bent to shape and installed. Need to figure out how to properly secure it and cut to final length. Sam retorqued firewall to engine mount bolts and secured with cotter pins. Began fitting cabin heat scat tube from inlet duct to heat muff. Removed inlet ducts to prep for paint and determine location of scat tube cutout. Started bending of new breather tube since old one interfered with oil cooler on firewall. Photo of tools used to connect two Adel clamps together to secure breather tube to engine mount.

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Aug 04, 2021 Wing tip lens - (2 hours)

Category: Wings

Sam cut and fit remaining wing tip lens.

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Jul 30, 2021 Cowling paint and heat shield layout - (4 hours)

Category: Firewall

Sam sanded, painted and laid out the pattern for the cowling heat shield.

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Jul 19, 2021 New magneto gear - (1 hour) Category: Engine

Installed new magneto gear on the Electro Air MTH ignition. Temporarily installed MTH on right mag port.

Jul 18, 2021 Interior cowl hinge pin - (3 hours)

Category: Engine

Fabbed spacer and match drilled to F-109 bulkhead. Used #10 screw to mount spacer and 7/16 hole for hinge pin guide tubing. Tubing directs side cowl hinge pin to the first grommet on lower cowl hinge. From there push to insert from inside the airplane. Still hard to install one pins into cowling, but will try some Boelube and open up some sticky grommets to ease installation.

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Jul 09, 2021 Oil cooler finished

Category: Engine

Installed vent duct to rear baffle at #4 cylinder. Assembled oil cooler duct system. Tight but think it'll work.

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Jul 08, 2021 Cowl side hinge pins - (2 hours)

Category: Engine

Flattened scrap hinge pin to open up aluminum tubing that will feed the pin from the cockpit to the first eyelet of the cowling hinge. Opened up hole through the firewall for the tubing to pass and checked for interference with the fuel vent tube.

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Jul 07, 2021 Oil cooler duct - (2 hours)

Category: Engine

Match drilled duct inlet to the back of rear left baffle that is the attach point for the scat tube to the oil cooler. Used a fly cutter to make the large hole in the baffle.

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Jul 06, 2021 Cowl sanding, baffle tension rods and oil cooler mount - (6 hours)

Category: Engine

Dave - Match drilled lower oil cooler mount to firewall and oil cooler. Fabbed lower support to firewall and oil cooler.
Sam - Sanded inside of lower cowl for epoxy paint. Bent tension rods and installed on bottom of baffles

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Jul 04, 2021 Oil cooler mounts - (2 hours)

Category: Engine

Match drilled actual oil cooler mounts to the firewall. Performed test fit with scat tube and butterfly fly valve. Trying to avoid space conflict with valve cable, prop Gov cable, mixture cable, fuel pressure line and oil lines to cooler. Too much stuff in small space.

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Jun 30, 2021 Baffle tie rods - (2 hours) Category: Engine

Sam threaded the rods connecting the baffles below the engine.

Jun 26, 2021 Oil cooler mount - (2.5 hours)

Category: Engine

Began installation of oil cooler mounts. Drilled out 2 firewall rivets and made one new hole for oil cooler mounts. Marked scrap angle for holes and match drilled from fire wall. Time spent earlier on oil cooler placement paid off making hole location fairly easy. Marked new angle for drilling.

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Jun 25, 2021 Cowling hinge pins and MTH gear - (2 hours) Category: Engine

Drilled second hole in fire wall for the right side cowl pin. Goes in about as well as the left side which is almost impossible. Screws in with a drill attached, but need to make it easier to install. Determined I have the wrong gear for the MTH need a direct drive gear so will try and order that next week. Dropped the oil cooler and put a dent in the back side. @#$&* Don't think it is damaged, but will try and test for leaks on the bench. Removed the cowls and top forward skin to begin oil cooler mounting and prep for wiring. Not a real productive day.

Jun 24, 2021 Nut plate Electro Air MTH and cowl pins - (3 hours)

Category: Engine

Installed nut plates on cowling tabs. Received my Electroair ignition kit and temp installed MTH in right mag port. Drilled the firewall for rear inserted cowling hinge pins. Need to improve ease of installation of pins. Lots of friction.

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Jun 22, 2021 Cowling tabs - (2 hours)

Category: Engine

Separated top and bottom cowls to finish up inner fiberglass tabs by the spinner. Trimmed, match drilled for #6 screws and drilled for nut plates. Countersunk top cowling for screws and tinnerman washers.

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Jun 18, 2021 Cowling tabs - (3 hours)

Category: Engine

Mixed up epoxy and fiberglass to make tabs to secure outside edge of cowling near spinner. Test fit of scat tube for heater box. Tried to determine final location of oil cooler scat tube on back of baffle near #4 cylinder.

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Jun 06, 2021 Neoprene sleeves and hose clamps - (2 hours)

Category: Engine

Glued and installed neoprene transition sleeves on aluminum inlets and FAB inlet. Installed hose clamps on oil cooler duct

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May 31, 2021 Oil collar duct and alt air door control arm - (2 hours)

Category: Engine

Riveted oil cooler duct to mounting angles and secured to oil cooler for placement of oil cooler on firewall and air duct to aft left baffle. Determined placement of butterfly valve on oil cooler duct.

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May 30, 2021 Oil cooler duct mount and alt air door - (2.5 hours)

Category: Engine

Marked, match drilled and deburred duct and oil cooler mounts for oil cooler. Primed mating surfaces. Riveted oil cooler door to control arm. Final drilled oil cooler mounts for AN3 bolts.

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May 28, 2021 Neoprene sleeves and oil cooler mount - (1 hour)

Category: Engine

Trimmed neoprene sleeves to final length and drilled pilot holes in oil cooler mounts.

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May 24, 2021 Inlet neoprene - (.5 hour)

Category: Engine

Measured and cut the neoprene for the inlet diffusers.

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May 20, 2021 Front cowling fasteners - (6 hours)

Category: Engine

Fabbed new fastener brackets for front of cowling between the spinner and air inlets. Decided to try and use Skybolt fasteners instead of #8 screws. Installed cowling back on airplane to get exact placement of camlocks. May add #8 screw to sides near spinner. Used the extended fastener rings, but still need to sand down the area around rings to get the proper length to engage the securing rings. Marked the left aft baffle for air exit to scat tube to oil cooler.

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May 19, 2021 Nut plates on plenum mod - (6 hours)

Category: Engine

Located and match drilled plenum mod for nut plates and installed. Sand voids I filled in on plenum mod

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May 18, 2021 Plenum mod voids and oil cooler scat tube - (2 hours)

Category: Engine

Mixed up some quick set epoxy to fill some voids on plenum mod and messed with oil cooler scat tube and butterfly valve for placement

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May 13, 2021 Plenum mod results - (.5 hour)

Category: Engine

Removed the mold support for the plenum mod. Turned out fairly well minus a few voids that I can fill in.

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May 12, 2021 Plenum mod - (2 hours)

Category: Engine

Cut out a section of a plastic jug to support the fiberglass on the inside of the plenum mod and clamped the foam piece over it for support. This should hopefully give it some stiffness and a nice smooth transition to the plenum. Used some extra epoxy to fill in some voids on the FAB transit duct. Found an initial location for the oil cooler butterfly valve. Gonna be a tight squeeze.

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May 11, 2021 Plenum corner mod - (1 hour)

Category: Engine

Began forming a mold for the aft left corner of plenum. Found a piece of foam that matched the curve of the plenum, but needs some support to keep the foam from deforming into the interior of the plenum.

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May 10, 2021 Plenum, transit duct and oil cooler - (3 hours)

Category: Engine

Trimmed and sanded both plenum and transit duct for fit and additional glass work on plenum. Spent a bit of time on transit duct and think I've finally got the fit I need to back plate on the SJ FAB. Nice and snug to rubber gasket on air filter and a smooth transition to through the back plate. Received the oil cooler kit to mount on firewall and butterfly valve to control cold air to oil cooler. Also received a couple cans of epoxy paint for the interior of lower cowl. Continued working on the oil cooler placement with a scrap piece of angle to hold the oil cooler and to check fit of oil lines and scat tube to firewall.

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May 07, 2021 Plenum and transit duct fill in - (1 hour)

Category: Engine

Mixed up some epoxy and filler to fill in some vacant spots on the plenum and transit duct that didn't fill in very well the first time. Still may have to add more, but will sand those areas and see.

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May 03, 2021 Plenum mod and transit duct repair - (1 hour)

Category: Engine

Disassembled and trimmed the plenum and transit duct from fiberglass mod done last week

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Apr 28, 2021 Plenum extension and transit duct mod - (5 hours)

Category: Engine

Applied epoxy and fiberglass to left rear of plenum to create a new back wall of plenum to replace the baffle oil cooler brace since I'm mounting my oil cooler to the firewall. Opened up the transit duct inlet to align with the injector servo inlet. This created avoid in the inner wall of the transit duct that had to be repaired with fiberglass and epoxy. Used a aerosol can that had the exact size diameter to act as a mold for the fiberglass. Primed a couple parts of the alternate air door on the Sam James FAB. Also firmed up the location of the oil cooler on the firewall. Should be able to use an existing hole for an adel clamp and some rivet holes for attaching the oil cooler mounts.

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Apr 27, 2021 Plenum extension - (2 hours)

Category: Engine

Began working on extending the plenum at the left rear. Match drilled the left aft baffle to the left side rear baffle to #40 and will use #6 screws here for ease of removing the baffles if necessary. Prepped for fiberglass extension by cutting glass strips and masking off the aft area where the epoxy resin will meet the left rear baffle.

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Apr 27, 2021 Oil cooler mount - (1 hour)

Category: Engine

Decided to mount the oil cooler to the firewall. Spent some time researching for parts, scat tube, butterfly valve and tubing mounts. Made a wooden mock-up of oil cooler to use to determine position on firewall with damaging oil cooler or engine mount. Marked aft baffle at 1 inch intervals for #40 holes to be later opened up for #6 screws

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Apr 25, 2021 Trimmed plenum - (1 hour)

Category: Engine

Trimmed the aft left corner of plenum to extend it aft. This will allow me to attach it to the aft left baffle and eliminate the oil cooler brace, since I plan to mount the oil cooler to the firewall.

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Apr 24, 2021 Oil cooler mount planning - (2 hours)

Category: Engine

Began mapping out plan to mount the oil cooler to the firewall. Removed the fuel pressure hose and oil breather tube to allow acces to the firewall.

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Apr 23, 2021 Sanded cowl - (1 hour)

Category: Engine

Sanded the cowling around the inlet rings and the spinner flange

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Apr 21, 2021 Cowling hinges - (4 hours)

Category: Engine

Finished riveting the lower cowling hinges. Proseal had set up more making it much easier to remove from the clecos. Removed and replaced some bad rivets on the upper cowl. Installed the inlets, plenum and cowling on the airplane to check fit. It all looks good, thankfully.

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Apr 20, 2021 Cowl hinges and diffuser rivets - (3 hours)

Category: Engine

Riveted the nut plate backers onto the inside of the inlet diffusers and riveted the hinges to the top cowl with the pneumatic squeezer. Soaked and cleaned the clecos that had some proseal residue on them.

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Apr 19, 2021 Pro seal cowl hinges - (3 hours)

Category: Engine

Prepped and applied proseal to cowl hinges and inlet diffuser nut plate backers.

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Apr 15, 2021 Cowling hinges - (3 hours)

Category: Engine

Flattened ou the end of a hinge pin to try and drill out the left hinge that is tough to install. Worked somewhat, but not perfect. Drilled 1/4” holes in hinges to allow spots for the proseal to adhere and scuffed up back side. Stated to countersink rivet holes in cowl to attach hinges.

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Apr 14, 2021 Inlet repair - (1 hour)

Category: Engine

Repaired and redrilled with countersink a few counter sinks on bottom of right inlet diffuser that were too deep.

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Apr 13, 2021 More nut plate backers - (3 hours)

Category: Engine

Fabbed, match drilled and primed two more nut plate backers for the inlet diffusers.

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Apr 11, 2021 Baffle cooling mod bracket and nut plate backers - (3 hours)

Category: Engine

Finished riveting cooling mod bracket to right rear baffle. Used back rivet set which I haven't done for a long time. May have over smashed a couple rivets , but not bad enough to replace. Began fabbing nut plate supports to bottom of both inlet diffusers. Countersunk for rivets and will install with pro seal as well when I rivet the hinges to the cowling that will also need pro seal.

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Apr 10, 2021 Right rear baffle mod - (4 hours)

Category: Engine

Fabricated, match drilled, dimpled and primed a cooling mod to the right rear baffle to allow better air flow at the rear of the #3 cylinder. Made a template from card stock to make the mod cover. Cut out a portion of the baffle that the mod will be riveted over. Began riveting in place said mod.

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Apr 08, 2021 Plenum nut plates - (3 hours)

Category: Engine

Installed 33 nut plates around the edge of the plenum to hold #6 screws for attachment to the baffles. Spent some time trying to determine best vertical location for the #4 baffle support. Van's directions are very vague other than locating the oil cooler as high as possible. Thinking of mounting the oil cooler to the firewall if able, so this may be a non factor. Also thinking of fabbing a fiberglass extension to the plenum to fill the gap. We'll see.

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Apr 06, 2021 Plenum nut plates - (2 hours)

Category: Engine

Match drilled baffles to plenum for #6 screw. Countersunk plenum for nut plate rivets.

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Apr 03, 2021 More nut plates - (3 hours)

Category: Engine

Drilled for and installed nut plates on top side of both inlet diffusers.

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Apr 02, 2021 Nut plates - (5 hours)

Category: Engine

Continued installing nut plates on the sides of the inlet diffusers. Also installed nut plates on the bottom of the right side inlet baffle to hold the right inlet diffuser.

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Apr 01, 2021 Inlet diffuser nut plates - (5 hours)

Category: Engine

Match drilled and installed nut plates on left diffuser inlet sides. Made nut plate backers for sides of diffusers. Started nut plate installation on right inlet diffuser.

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Mar 30, 2021 Baffle and inlet nut plates - (4 hours)

Category: Engine

Installed inlet diffusers and plenum to match drill sides and bottoms of inlets where I filled in previous holes. Match drilled all the holes that I could and then removed plenum to match drill right side of left inlet. Drilled and installed nut plates on bottom of left inlet baffle. Started drilling for nut plates on side of forward center baffle.

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Mar 29, 2021 More inlet diffuser trimming and hole filling - (2 hours)

Category: Engine

Trimmed both inlet diffuser sides and top for the 1” plenum overlap. Also trimmed the front of the left diffuser for a 1/4” gap to the aluminum inlet ring. Mixed up some epoxy flox to fill the holes in the sides and bottom of the inlet diffusers for redrilling after final positioning with inlet rings. Filled in some holes in the top of the plenum that were incorrectly drilled for nut plates. Used the leftover epoxy to fix a table knife.

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Mar 22, 2021 Plenum nut plates - (3 hours)

Category: Engine

Installed plenum, baffles and inlets on engine for final position prior to drilling for nut plates. Aligned inlets to ensure location of side and bottom nut plates. Drilled plenum for #6 nut plates plus a few extra. Oops. Gonna need to fill some holes at the front of the plenum that overlaps the inlet diffusers.

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Mar 19, 2021 Front baffles - (4 hours)

Category: Engine

Deburred, match drilled, primed and assembled both front baffle assemblies and installed on the engine. Made a slight notch in left front baffle for extra space near the prop oil line.

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Mar 18, 2021 Left inlet baffle - (5 hours)

Category: Engine

Match drilled and riveted modified left inlet baffle. Installed nut plates for center baffle attachment. Primed and set aside for final inlet diffuser installation. Began working on right inlet baffle. Drilled J bracket for nut plates. Trimmed right inlet diffuser. Struggled a bit with a couple 470-4 pan head rivets that were difficult to access. Ended up drilling one out, but settled with a couple not so perfect rivets

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Mar 16, 2021 Fabbing baffle angles - (5 hours)

Category: Engine

Riveted nut plates to the left forward support brackets. Fabbed new angles to support left center baffle to left forward baffle and j bracket. Matched drilled from #30 to #40 and primed for assembly.

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Mar 14, 2021 Plenum trimming fwd and aft supports - (6 hours)

Category: Engine

Trimmed the edges of the plenum to fit inside the baffle forward and aft supports. Refabbed aft support angle due to edge distance issues. Trimmed plenum where the forward and aft support brackets interfered as seen in photos taken with bore scope camera. Installed nut plates on one forward support bracket. Determined location for aft support angle and riveted in place. Primed both parts.

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Mar 10, 2021 Front center baffles and brackets - (4 hours)

Category: Engine

Drilled and trimmed front center baffles to plenum. Drilled plenum to top of inlet diffusers and reinstalled top cowling to check alignment. All looked good. Began fabbing front and aft plenum supports. Match drilled front brackets for nut plates and to secure position of aft support. Sam modified aft support to adjust for baffle mounting holes and plenum.

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Mar 09, 2021 Baffle trimming and plenum drilling - (3 hours)

Category: Engine

Secured side baffles to plenum and drilled for nut plates. Had some great help today with son Sam home. Gots lots done. Secured and drilled back baffles to plenum for nut plates. Final trimmed side and back baffles to plenum. Looks good. Had to reposition left diffuser inlet again to aluminum inlet rings. Plenum and top cowling on and off numerous times.

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Mar 08, 2021 Plenum - (2 hours)

Category: Engine

Spent today trying to nail down the plenum placement. Clamp plenum in place and used some molding clay cones on top to determine gap to top cowling. Clamped and readjusted plenum numerous times to get the 3/8 to 1/2 inch gap necessary. Got it as close as I could and drilled a hole for #40 clecos at each corner. Edges are pretty well locked in. Need to secure and drill holes to lock down center aft and forward section of plenum to baffles. Left inlet diffuser still wants to drop down from alignment. Will try and improve that with holes and clecos in plenum.

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Mar 07, 2021 Left center baffle and left inlet diffuser - (4 hours)

Category: Engine

Began trimming left center baffle and plenum for fit. Several iterations to ensure little gap at the top where they meet. Trimmed left center baffle where it interfered with the front of engine. Lots of moving parts. Worked on lateral error of left diffuser by removing diffuser and and front lower baffle to redrill holes. Finalized position of left center baffle, plenum and left inlet diffuser. Drilled vertical holes between left center baffle and left diffuser. Struggled clamping and locating holes due to angle and location of fasteners.

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Mar 06, 2021 Left plenum and baffle trimming - (5 hours)

Category: Engine

Drilled left diffuser to left side baffle to secure diffuser vertically. Need to Agustin left diffuser laterally and right diffuser vertically after result of installing top cowl.
Fabbed small angle to support lower left corner of left side baffle and left inlet angle. Trimmed left forward inlet baffle. Worked on lateral error on left diffuser. Drilled a new lateral hole at bottom of left diffuser. Began trimming plenum to left diffuser interface.

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Mar 02, 2021 Left inlet diffuser - (5 hours)

Category: Firewall

Fabbed nut plate backer for left side of right diffuser to right center baffle. Started fitting left diffuser inlet to left inlet baffle and left side baffle. Lots of measuring and trimming to get correct fit to inlet baffle angle. Finally secured left inlet diffuser laterally to cowl aluminum inlet ring with a 1/4” gap between. Styrofoam insert really helps to establish concentric lines between aluminum inlet ring and diffuser inlet.

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Mar 01, 2021 Forward center baffles - (5 hours)

Category: Firewall

Trimmed plenum and right center baffle for fit. Fabbed angle to secure right center baffle base. Many trips to band saw and sander to get a good fit between baffle and angle and engine. Made a scrap angle piece for fit and practice. Installed lower cowling and aluminum inlet ring. Secured right center baffle side to right inlet diffuser. Right diffuser is now set in place. Yay!!

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Feb 28, 2021 Right center baffle - (3 hours)

Category: Firewall

Made a couple 0.020 backers for the side and bottom of the right inlet diffuser. Began fitting the right center baffle to right diffuser and plenum. Trimmed a little area a the bottom to allow baffle to seat against cylinder fins. Had to “rebend” baffle to fit. May have to replace the right center baffle, but for now will use it to get the correct fit with diffuser and plenum. Marked plenum for trimming.

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Feb 27, 2021 Right inlet diffuser - (5 hours)

Category: Firewall

Continued working on right inlet diffuser. Began by setting the vertical position of the right inlet diffuser with respect to the aluminum inlet ring. Used Bill Lanes recommendation of using styrofoam to align the ring and diffuser. Clamped and match drilled hole from inside diffuser. Removed the diffuser and drilled remaining holes for vertical support, then match drilled the last two vertical holes to the diffuser. Alignment looks good so far. Match drilled remaining holes form diffuser to horizontal angle on the front right baffle. Trimmed the last of the ramp on the right baffle that is covered by the inlet diffuser. Fabbed an 0.32 backer for the inside of the diffuser on the right side to support nut. Match drilled it to side wall of right diffuser. Fabbed and match drilled an 0.63 angle to bottom corner of baffle/diffuser.

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Feb 26, 2021 Right inlet/diffuser - (3 hours)

Category: Firewall

Spent time today trimming the right fiberglass inlet/diffuser. Made an initial trim mark at front of diffuser and installed on the cowling for final trim. Used Bills suggestion of making a styrofoam circular ring to fix the relative position of the aluminum inlet ring to diffuser. Match drilled an additional hole on bottom of diffuser to lower right baffle angle and side of diffuser to right side baffle.

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Feb 22, 2021 Baffle bracket and diffusers - (4 hours)

Category: Firewall

Installed and match drilled left forward baffle j bracket to left forward. Riveted j bracket to Van's stock bracket baffle support. Began fitting and trimming right air inlet diffuser. Drilled hole in center of diffuser to enable adjustment laterally to cowling aluminum air inlet rings.

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Feb 21, 2021 Left forward baffle j bracket - (4 hours)

Category: Firewall

Fabricated another j bracket for the left forward baffle since I'm going with Bill Lanes plenum. His design requires modifications to the forward inlet baffles and supporting structures. Made paper template first, followed by a 0.32 pattern and finally an 0.50 bracket. A slow and methodical process with lots of trimming iterations.

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Feb 17, 2021 Baffle J bracket - (3.5 hours)

Category: Firewall

Continued working on baffles. Made several attempts to fabricate the J bracket needed for the front right center baffle. Spent way too much time on this, but think I finally got something that will work.(top right bracket). Lots of trial and error to get angle and bend correct. Pics of installation. Also began planning process for fabrication of support bracket on left side front baffle.

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Feb 16, 2021 Front center baffles - (5 hours)

Category: Firewall

Worked on fabrication of left front center baffle from template supplied by Bill Lane. Bend is not exactly correct, but going to wait for inlet duct installation and placement before redoing. Cut away a portion of the front right baffle assembly to accommodate J bracket and new center baffle. Rebent right front center baffle. Fit is ok, but bend is sorta rough. Began fabbing J bracket per Bill Lanes photos. Made a paper sample to test fit and then attempted making the bracket out of .063. Fit was not good so making a new one from .063 sheet. Lots of trial and error. A template would have really helped

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Feb 15, 2021 More baffle trimming - (3 hours)

Category: Firewall

Continued trimming side and rear baffles to 1/2” mark from paper clip technique. Also trimmed off extra material from side baffles that aren't needed with the Bill Lane plenum. Test fit plenum again and marked left rear oil cooler baffle for trimming and trimmed. Everything is looking pretty good, but need to reinstall the top cowl and use the mini clay cone technique to ensure plenum to upper cowl 1/2” gap.

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Feb 14, 2021 More baffle trimming - (3 hours)

Category: Firewall

Continued with baffle trimming. Used the paper clip method to get a more accurate spacing (1/2”) between the top of the baffles and underside of top cowling. Also used a sharpie to mark baffles around valve cover gaskets where the baffles interfered. Removed baffles and trimmed to fit.

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Feb 10, 2021 More baffle trimming - (3 hours)

Category: Firewall

Continued trimming baffles to get the 1/2” gap between the upper cowling and baffles. Think I've finally got them trimmed correctly. Test fit plenum again and actually looks ok. Had to remove rear baffle support bracket as it pushes the rear baffles too far aft. Will trim off angle on bracket and reposition a new .063 angle as several other builders have done

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Feb 09, 2021 Forward center baffles and trimming - (5 hours)

Category: Firewall

Began fabbing of forward center baffles using the templates from Bill Lane. I'm using the Sam James cowl with Bills plenum so I tried to modify the center left baffle from the Van's baffle kit. Had to bend the side of the baffle backward so I may have to make a new one out of 0.032 sheet, but this was good practice. Traced the template for the center left side too. Began the iterative process of trimming the rear and side baffles for the 1/2” spacing to the top cowl. Must've had the top cowl off and on 50 times trying to work my way down to the 1/2” spacing. Finished the day with the cowling on and no interference, so now it just needs the 1/2” spacing. Photos are shots through the cooling inlets and rear shot of right baffle through the oil door.

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Feb 08, 2021 Baffles and plenum - (4 hours)

Category: Firewall

Clecoed and match drilled some parts for the left forward baffle. Primed and then riveted together the baffle stiffener and air dam part. Placed plenum on engine inside the baffles for initial placement. Spent time poring over the Bill Lane plenum and air inlet instructions. Made contact with Bill and cleared up a LOT of questions

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Feb 07, 2021 Baffles - (5 hours)

Category: Firewall

Installed rear baffles and side baffles. Made a 1/2” marking tool with a wood block and sharpie pen. Installed the upper cowl and made 1/2 inch mark from upper cowling. Matched drilled and clecoed forward baffles. Also drilled right forward baffle for prop oil line - the rubber grommet you can see in photo.

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Feb 06, 2021 Camlock repair, Baffles and alt air door control arm - (5 hours)

Category: Firewall

Installed lower cowl to check alt air door arm and needed more trimming. Prob should have tried harder to place it on the vertical, but committed to bottom of FAB for now. Match drilled the last camlock hole that needed repair on bottom of lower cowl. Installed the floating receptacle and fits well now. Spent a lot of time trying to figure the engine baffles and modifications needed for Bill Lane plenum. Installed the aft baffles for number 3 and 4 cylinders after digging thru several hardware bags in firewall forward kit.

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Feb 05, 2021 FAB back plate and transfer duct fit - (1 hour)

Category: Firewall

Separated transfer duct from back plate and sanded down transition to ensure a smooth air flow between the two. Trimmed alternate air door control arm due to lower cowl interference and reinstalled entire FAB assembly to check for clearance. Also ground down a back plate mounting screw more that still protruded too high and interfered with the transit duct seating fully down inside the back plate.

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Feb 01, 2021 More FAB work - (3 hours)

Category: Firewall

Spent the day continuing to work on FAB. Match drilled the remaining two holes from the back plate to the fuel servo using the gasket supplied in the injector kit. Also drilled out the center of the back plate to match the transit duct flow thru hole. Needed some more epoxy flox to seal the gap between the two. Made a dummy Skybolt bracket to drill a new hole in the bottom of the cowl to get a better fit on one hole and mounted the aft baffle support bracket. Used some surplus epoxy to beef up the small fiberglass area near the alt air door.

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Jan 30, 2021 FAB transit duct wall and nut plates - (3 hours)

Category: Firewall

Cleaned up the inner wall of the transit duct and sanded down the outside edge for a better fit with the back plate. Fits very snuggly inside the back plate so I'm not sure if I need to secure it or not. Match drilled the #40 holes in the outer wall of the filter housing to the back plate to #21 for nut plates and #8 screws. Installed the nut plates and temp installed on the fuel servo. All seems well except securing of top screw on filter housing due to close access. Need to get a shorty #15 Torx bit reach the top screw

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Jan 29, 2021 FAB transit duct inner wall - (3 hours)

Category: Firewall

Masked off the bottom of the FAB back plate so I could build up the inner wall of the transit duct. I used some plastic washers to simulate the thickness of the the bolt heads and installed the transit duct. Mixed up some epoxy with cotton flox and filled in the gap. I'll trim down the edges once dry. Used some of the leftover to fill in a gap I have at the front of the cowling

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Jan 25, 2021 FAB fitting - (2 hours)

Category: Firewall

Removed the tape from back plate of FAB. Sanded down the edge to fit with the filter housing. Installed on fuel injector to fit with the air inlet duct. Marked the intersection and drilled thru both back plate and filter housing to #40 for nut plates later. Reinstalled on the injector to check fit with aluminum inlet duct on lower cowl. Lined up well finally. Bottom right pic is shot of filter housing inside the lower cowl. Bottom left pic is front shot of lower cowl air inlet

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Jan 24, 2021 FAB back plate wall

Category: Firewall

Built up FAB back plate outer wall to fit into filter housing. Used thick pvc tape to support fiberglass and epoxy. Ground down the top of the fillister screws to fit under the transit duct under the back plate.

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Jan 23, 2021 FAB filter housing trimming - (2 hours)

Category: Firewall

Began trimming the extended filter housing outer wall that I built up the other day with some epoxy and fiberglass. Turned out ok after some trimming down to make it easier to mate with the transit duct. Began prepping the transit duct for extending its outer wall as well. Al this is being done to ensure proper edge distance on the nut plate fasteners.

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Jan 22, 2021 Glassing FAB transit duct - (2 hours)

Category: Firewall

Spent today glassing outer aft wall of FAB transit duct. Also glassed over “bad” camlock hole on lower cowl. Used 3 layers of fiberglass on FAB and small patch for hole. Installed camlocks on oil door flange.

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Jan 18, 2021 Floating Skybolt camlocks - (2 hours)

Category: Firewall

Drilled out 4 camlocks from brackets on lower cowl that did not align with screw holes well enough to “lock”. Installed floating camlocks to see if that would help. All but one now lock lower cowl to bottom of firewall fairly easily. May need to redrill hole if it becomes a constant problem. Primed oil door flange.

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Jan 12, 2021 Cowl, FAB and pins - (2 hours) Category: Firewall

Finished match drilling the forward brackets on the lower cowl. Reinstalled the cowling and FAB to work on alt air door arm that interferes with lower cowl. Gonna need to trim the door arm. Adjusted the cam locks on upper cowl and removed the locking pins

Jan 11, 2021 Cowling front brackets - (2 hours)

Category: Firewall

Spent time today refabbing the brackets at the front of the cowling between the air inlets and the spinner. Used the thicker .050 material for strength. Going use 4 -3 rivets on the bottom and two #6 screws on top

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Jan 10, 2021 FAB installation - (2 hours)

Category: Firewall

Worked on FAB fit with lower cowling. In order to ensure a smooth transition from the lower cowling inlet to the FAB transit duct the transit duct had to be adjusted down and to the left. Drilled 5 #40 holes in the edge of transit duct and into the back plate. Fit again with lower cowl and match drilled to #30. Need to do something about a couple holes that have edge distance issues.

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Jan 04, 2021 More Skybolt cam locks and baffles - (4 hours)

Category: Firewall

Continued to install cam lock receptacles, sleeves and match drilling holes from brackets. Sam continued his work on the baffles priming mating parts and riveting the doubler plates. Began match drilling holes in bottom of bottom cowling. Also pushed cowling up to get 1/8” engine predroop dimension. Installed both cowls, hinge pins, and inlet rings to confirm fit. Pic of front of cowl looks BADASS. IMHO haha

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Jan 03, 2021 Cowling cam locks - (2.5 hours)

Category: Firewall

Continued to install Skybolt/cam lock receptacles while Sam continued his work on the baffles. Installed two too many receptacles and had to drill them out in order to match drill the 15/32” holes for the cam lock inserts. Ended up wallowing out one bracket. Luckily had a couple extra brackets for just such an occasion.

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Jan 02, 2021 More cam lock installation - (2.5 hours) Category: Firewall

Kept working on cam lock/Skybolt installation on upper cowl. Top cowl drooped a little too low (1/4”). Need to get it to at most 3/16” for engine droop. Going to try and adjust bottom cowl bottom cam locks to push cowl up a smidgen.

Dec 31, 2020 More cam lock inserts - (4 hours)

Category: Firewall

Continued installing cam lock inserts. Riveted some lower cam lock mechanisms for lower cowling alignment. Actually seemed to fit well. Installed some on upper cowling to finish off left side of upper cowl.

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Dec 30, 2020 More cam locks - (2 hours)

Category: Firewall

Continued drilling holes for cam lock fasteners on lower cowling.

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Dec 29, 2020 Skybolt cam locks - (2 hours)

Category: Firewall

Positioned cowling in final best position with a 3/16 spinner to cowl gap and below top of spinner by 1/8” for engine droop. Began final drilling of Skybolt fasteners in top cowl near oil door for access. Used the back light method to line up holes in brackets with mixed results.

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Dec 21, 2020 Cowl trimming - (2 hours) Category: Firewall

Spent more time trimming about 1/16” material off the aft of cowling for more spacing between cowl and spinner. Appears it will result in about 3/16” gap between spinner and cowl. Need to figure out how to hold it in that position as I drill out final holes for cam locks.

Dec 16, 2020 Cowl spinner spacing - (1 hour)

Category: Firewall

Started removing material from aft of cowling to increase spacing between cowl and spinner. Pics are of cowling/spinner gap before adjustment.

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Dec 15, 2020 Cowl fitting - (2 hours)

Category: Firewall

Spent today fitting the cowl some more. Initial gap between spinner and cowl is supposed to be between 1/8-3/8” with 1/4” as the sweet spot. We have 1/8”, so going to try to trim off about 1/16” for final fit. Also trimmed cowl for engine droop of about 1/8” and that turned out to be about 1/4”. Going to try and retrim that to get the 1/8” predroop space.

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Dec 13, 2020 Test fit of spinner and prop - (3 hours)

Category: Propeller

Test fit cowling, spinner and prop with son Sam's help. Also did some more deburring and dimpling of baffles. Really like the look of the Sam James cowl and the aluminum inlet rings

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Dec 09, 2020 Engine Baffling - (2 hours)

Category: Firewall

Deburred and match drilled several baffle parts. Studied the drawings and plenum instructions to avoid errors. Waiting to make big hole in aft baffle new cylinder #4 since I'm not sure of location of oil cooler

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Dec 08, 2020 Alternate air door - (2 hours)

Category: Firewall

Installed alternate air door, masked off edge of door with tape and wax and sealed the edge of door with RTV. Began working on engine baffles by separating parts from Van's baffle kit

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Dec 06, 2020 Alt Air door control arm - (2 hours)

Category: Firewall

Fabbed a new alternate air control arm for the SJ FAB. Decided to use .050 material to beef up the arm a bit.

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Dec 01, 2020 FAB alternate air door - (2 hours)

Category: Firewall

Think I finally figured out the profile needed for the FAB alternate air door control arm after numerous iterations. I also added a small cutout in the back plate to allow for additional throw of the control arm. Sorta hard to see in the photo.

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Nov 20, 2020 FAB alt air door - (3 hours)

Category: Firewall

Continued working on FAB alternate air door. Finally figured out door swing and spring orientation. Trimmed hinge for fit and avoid interference with transit duct. Fabbed first try on actuator arm and trimmed opening for a better fit. Matched drilled swing arm to lower hinge. Need to refab actuator arm for longer swing action.

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Nov 19, 2020 FAB alternate air door - (4 hours)

Category: Firewall

Struggled with the Sam James FAB and installing the alternate air door. Decided I need to build up the aft side of the back plate to ensure alignment with the injector ring. Also made initial cutout for the alt air door. Spent too much time trying to decipher the poorly written instructions on door spring installation and operation. Think I have a plan now to reconstruct to door above the lower hinge and seal with RTV.

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Nov 18, 2020 FAB - (4 hours)

Category: Firewall

Continued work on the Sam James FAB. Decided on orientation of alternate door. Looks like the door facing down will make for the least interference with engine accessories. Sanded mating surfaces of filter housing and back plate for easier fit. Match drilled back plate using injector gasket as a template and hand reamed holes for accuracy. Only need slight adjustment of FAB to ensure smooth transition from inlet ring.

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Nov 16, 2020 Sam James FAB - (4 hours)

Category: Firewall

Began assembly of the Sam James filtered air box. Trimmed both the filter housing and back plate to fit together. Also trimmed the transit duct to fit inside the back plate. Ran into a problem the transit duct not fitting with the 1/4” nut spacers placed inside the FAB. You can see in the photos that causes the transit duct to protrude above the rim of the back plate. Also received and installed the 1/8” fuel plug into the extra hole in the the fuel spider.

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Nov 14, 2020 Injector ring installation - (4 hours)

Category: Firewall

Cleaned up injector ring on cowling from extra epoxy/flox mix and worked on cowling side hinge pins for easier installation. Tried drilling out hinge with a flattened pin tip.

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Nov 13, 2020 Injector ring install - (2 hours)

Category: Firewall

Trimmed hole for injector ring and epoxied/floxed in place in lower cowl.

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Nov 12, 2020 Inlet rings - (4 hours)

Category: Firewall

Trimmed inlet ring holes. Taped and waxed rings to aid installation and removal. Placed cowling nose down and epoxied/floxed inlet rings in place.

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Oct 23, 2020 Oil door - (3 hours)

Category: Firewall

Trimmed oil door and marked location on cowling

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Sep 30, 2020 Cowling - (2 hours) Category: Firewall

Continued fit of cowling. Began working on fit between upper and lower sections of cowl near air inlets prior to installation of cam locks or nut plates.

Sep 08, 2020 New workshop

Category: Workshop

Built a new shed during Covid. Partitioned into two parts, one side 54x40 to store large items. (Trailers, mower, car and misc stuff. The other part 24x40 is new airplane/woodworking shop. Insulated and heated both with larger side cool storage in winter. Love the new digs. A long time coming. Old pole building succumbed to the elements and excavator. Moved project out of garage and into new shop/hangar. Had a Higher Power door installed at the west end of the building to allow easy exit/entrance for up to a 35' wingspan.

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Aug 27, 2020 Brake lines - (2 hours)

Category: Fuselage

Installed new Bonaco brake lines

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Aug 04, 2020 Engine Controls - (5 hours)

Category: Controls

Installed mixture and throttle cable brackets and connected cable end bearings to ensure full throw and no interference with surrounding structures.

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Jul 24, 2020 Mixture and prop Gov cable FW penetration points - (3 hours)

Category: Firewall

Finally located proper locations for the mixture a prop Gov penetration points based on my parking brake valve location. Made some slight mod from Van's location , but should work well with park brake cable too. Used new harbor freight punch out tool and worked great except for the deep cut on my thumb from trying to remove the metal scrap

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Jul 23, 2020 Breather tube and fuel pump overflow - (5 hours)

Category: Firewall

Replaced Breather tube with a new tube and whistle hole. Drilled hole for fuel pump overflow line in firewall flange and Skybolt locking flanges.

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Jul 14, 2020 Skybolt cowling fasteners - (3 hours)

Category: Firewall

Began spacing and match drilling Skybolt fasteners to the firewall.

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Jul 11, 2020 Cowl trimming - (3 hours)

Category: Firewall

More cowl trimming. Trimmed front of cowl for level line on both upper and lower cowls. Trimmed edges of inlet rings to prepare for side trimming

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Jun 28, 2020 Lower cowl fitting - (3 hours)

Category: Firewall

Continued trimming lower cowl gear leg openings. Used aluminum inlet as a guide to make trim line on front of lower cowl. Installed with strap on fuse with upper cowl. Gonna need some more trimming on both cowls.

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Jun 26, 2020 Lower cowl trimming - (2 hours)

Category: Firewall

Began trimming lower cowl for gear legs

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Jun 17, 2020 Upper cowl marked for trimming - (1 hour)

Category: Firewall

Marked cowl for trimming. Not sure about this mark. Looks like too much cowl removal. Gonna check with SJ about cut on long cowl with forward facing inducted IO-360 Lycoming

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Jun 11, 2020 Upper cowl initial fit. - (2 hours)

Category: Firewall

Initial test fit of upper cowl. My son Sam horsing around. Haha

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Jun 03, 2020 Park brake valve - (3 hours)

Category: Firewall

Installed parking brake valve on firewall. Only used one small 40 size screw on the bracket in case it interferes with other firewall items. Used some plastic sleeving to protect against any chafing with firewall stiffener.

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May 31, 2020 Fuel overflow line - (2 hours)

Category: Firewall

Fabbed drain line for fuel overflow valve. Need to secure with some Adel clamps and safety wire

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May 25, 2020 Primed parts - (2 hours)

Category: Firewall

Favorable wind and humidity made for good conditions to prime a bunch of parts.

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May 25, 2020 Exhaust security - (3 hours)

Category: Firewall

Installed both vertical and horizontal tailpipe supports. Had to trim the horizontal metal supports

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May 23, 2020 Hung the exhaust

Category: Firewall

Hung and temporarily fit the vetterman exhaust

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May 20, 2020 Hung the engine - (3 hours)

Category: Engine

Hung the engine finally

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Feb 12, 2020 Pitot tube mast - (3 hours)

Category: Wings

Marked and cut lower wing skin for pitot tube mast.. very scary cutting lower wing skin. 😳

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Oct 31, 2019 Canopy glued on - (4 hours)

Category: Fuselage

Canopy cured and struts installed

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Aug 11, 2019 More tip up skin pics - (1 hour)

Category: Fuselage

Checked fit of cabin frame attach brackets and left side pic of new tip up aft fuse skin

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Jul 30, 2019 Clamped cabin frame supports

Category: Fuselage

Clamped cabin frame supports to cabin frame to locate positions for ��old together��rivets

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Aug 11, 2018 Tip up skin - (3 hours)

Category: Fuselage

Slider skin removed and tip up aft skin clecoed in place

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Aug 09, 2018 Drilling out lots of rivets - (4 hours)

Category: Fuselage

Drilling out the rivets in slider skin to replace with tip up fuselage skin

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Aug 05, 2018 Aft fuse rudder support holes - (3 hours) Category: Fuselage

Marked location of rear bulkhead holes

Jul 29, 2018 Photo of fuse

Category: Fuselage

Quick photo of project with slider skin on forward part of aft fuse. Will replace it with the appropriate skin for a tip up canopy. QB wings in cradle.

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Jul 29, 2018 Cabin frame - (2 hours)

Category: Fuselage

Finished riveting cabin frame

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Jul 29, 2018 Cabin frame assembly - (2 hours)

Category: Fuselage

Began final riveting cabin frame by using my pneumatic rivet puller. Worked like a champ. Can understand how popular the RV-12 is for just that reason.

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Jul 28, 2018 Cabin frame angles

Category: Fuselage

Began fabbing large angle for cabin frame bottom supports

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Jul 27, 2018 Cabin frame assembly - (1 hour)

Category: Fuselage

Began assembly of cabin frame by enlarging holes to #30

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Jul 22, 2018 Cabin frame splice plate - (2 hours)

Category: Fuselage

Riveted splice plate onto aft cabin frame channels and opposite side with angle at the top

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Jun 28, 2018 Cabin frame paint - (1 hour)

Category: Fuselage

Painted interior of cabin frame to test color. Think I'm going to go with something darker.

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Jun 26, 2018 Jdair rudder stop - (1 hour)

Category: Fuselage

Installed delrin internal rudder stop. Had to do some trimming, but eventually got a good fit.

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Jun 26, 2018 Elevator upstop - (4 hours)

Category: Fuselage

Installed elevator up stop. Clecoed for now.

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Jun 25, 2018 Antisplat vertical stab reinforcement - (2 hours)

Category: Fuselage

Installed the antisplat vertical stab reinforcement mod

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Jun 25, 2018 Elevator control horn - (1 hour)

Category: Empennage

Had a friend repair/weld hole in elevator control horn that I messed up. After drilling thru from opposing horn hole edge distance was insufficient.

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Jun 25, 2018 Cabin frame - (2 hours)

Category: Fuselage

Began working on cabin frame first by using a hole cutter to make the two access holes that face aft at the bottom of the frame. Beware using the tooling hole to center your drill. As you can see from the scrap it is not colocated to the center of access hole.

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Jun 16, 2018 Trimming longeron top plate - (.5 hour)

Category: Fuselage

Trimmed top plate to allow cabin frame anchor braces to sit flush on longeron and F-757 brace. F-757 installed is for the slider canopy so I'll need to replace it with the correct one for a tip up.

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Jul 14, 2017 More Wing mating - (3 hours) Category: Fuselage

Mated the wings with Sams help

Jul 03, 2017 Wing mate prep Category: Fuselage

Attempted to install the wings with Sams help the and couldn't understand why it was so difficult to get them to fit properly. Turns out that QB wings do not have the tab trimmed on the aft spar. Removed material from the tab per the drawing and wings fit well.

Jun 24, 2017 Temporary wing bolt prep - (1 hour) Category: Fuselage

Modified temporary wing bolts to use as pins to mate the wings to fuse

Jun 24, 2017 Wing mating prep - (1 hour) Category: Fuselage

Began marking the wing for the wing root fairing

Jul 27, 2016 Metal working class at Oshkos - (1 hour)

Category: Workshop

My son Sam working on the project at the metal working class at Oshkosh.

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Jun 29, 2016 Set up shop - (5 hours)

Category: Workshop

Set up shop in third stall our garage. My son Sam made the EAA workbenches. Bought a used kit with the empennage complete so got it up and out of the way.

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