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Project: DaveBellairs -
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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)
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Inspection
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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

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

Category: Engine

Scuffed and primed the oil door hinge.

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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 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 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 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 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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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 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 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 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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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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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 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”.

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 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 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 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 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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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 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 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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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 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 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 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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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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May 20, 2020 Hung the engine - (3 hours)

Category: Engine

Hung the engine finally

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