Aug 19, 2023     Added VG's to Horizontal Stabalizer - (2 hours)       Category: Horiz S (IV)

Added VG's to the underside of HS. They were purchased from Stolspeed.com. I was amazed at how fast they arrived from down under! https://www.stolspeed.com/

I lightly sanded the bottoms since the surface is flat. I also painted them light gray to somewhat match the color of the plane.

  Apr 03, 2023     Paint Codes       Category: Paint / Decals

  Apr 03, 2023     Added new decals - (1 hour)       Category: Paint / Decals

  Jun 05, 2022     Silpruf all window gaps (exterior) - (10 hours)       Category: Final (X)

Now that paint is complete it's time to seal all the windows with Silpruf SCS2000. Cleaned all gaps from any overspray paint and loose silpruf from window installation. Taped both sides and back cut joggle. Applied Silpruf as needed and worked with a smoothing tool.

  May 29, 2022     Final Weight & Balance - (3 hours)       Category: Final (X)

After paint and tire swap was complete we reweighted 45HS and determined the following:

NLG = 442
LMG = 500
RMG = 513
Total = 1455

I will keep 10 lbs ballast in tail due to zero fuel weight FWD CG concern.

  May 07, 2022     Paint Begins!       Category: Paint / Decals

I made the decision a few months ago that I would outsource the painting to a professional as its one of those areas that I know I could do but it would take me a lot of time and possibly, a lot of rework. There is a paint booth across from my hangar and for the past 7 years, I've been watching the guy that paints in there get better and better. His prices have gone up but are still pretty reasonable, IMO. I was originally scheduled to have it painted in June but one of his customers was not ready so he called and asked if I wanted his slot...I jumped on it and we removed all the control surfaces on Monday and had the plane to him on Tuesday. He is really making good progress and I'm pleased with his level of detail.

  May 29, 2022     Paint is complete - (5 hours)       Category: Paint / Decals

Paint by Jake Buck @ KGJT.

  Apr 22, 2022     Installed Baja Design Cowl Lights - (3 hours)       Category: Lighting

Now that Phase 1 is done I'm hopeful that I'll be removing the cowling a little less so I decided to install the Baja Design Lights in the front cowl. I used the Baja Design S1

https://www.bajadesigns.com/products/s1-black-led-auxiliary-light-pod/

I created a mounting bracket, glassed it in, connected wires, and glassed them to the cowl to keep them free and clear of any other components.

The wiring that comes with the Baja Design S1 lights is way larger than it needs to be but I decided to keep the factory wiring as it's protected really well and weatherproof sealed. I'll splice in a quick disconnect where it's easy to work with near the firewall connection.

These will connect to a "landing light" switch protected by a 10 amp fuse in the cabin. The GAD 27 allows you to select Wig-Wag above a certain airspeed (programmed via the G3X) so they will wig and wag when in flight then go steady once you hit a certain airspeed. I don't recall what I set mine to but I think it was around 65 kts.

  Feb 12, 2022     First Flight - (4 hours)       Category: Phase 1

First Flight of N45HS! Watch the video here: https://www.youtube.com/watch?v=mtNFcgU7ctI

  Feb 07, 2022     Airworthiness Certification - (3 hours)       Category: Inspection

Airworthiness Certification achieved!

  Feb 03, 2022     8130-6 Paperwork - (10 hours)       Category: Inspection

I've been working on the paperwork for the Airworthiness Certificate with the DAR over the past week. I have everything entered and the DAR is scheduled for 2/7. This week I will work on cleaning up all the wiring zip ties, condition inspection, and all checklists for inspection.

The Step-by-Step Certification guide has been very helpful and I would recommend it to anyone at this stage.

  Jan 30, 2022     Weight and Balance - take 2 - (3 hours)       Category: Final (X)

Drained all the fuel from the wings and headers so no fuel was in the plane other than what was in the fuel lines. Put the MLG spaced under the weights instead of on top. Made sure the plane was leveled to the proper waterline measurement. The weights came out much better than last time and the NLG weight is more in alignment with what the factory was looking for.

  Jan 29, 2022     Fuel Sender calibration - (7 hours)       Category: Final (X)

I was able to borrow a large 50 gallon holding tank from a local A&P to store all the fuel I needed to calibrate the fuel flow testing. Apparently, I wired the main tank sensors backward so I had to fix the wiring on those two. This took some time but everything worked out well in the end. The float sensors seem to need some wiggling (wing rocking) to get them to read consistiently. Good thing the plane will moving the fuel some during flight.

  Jan 27, 2022     Pitot static test and Transponder check - (5 hours)       Category: Final (X)

Tested at DnT Avionics. Had a minor leak at the Pitot connection within the wing. Was fixed and all systems testing in accordance to Part 43, App E, App f

  Jan 28, 2022     Fuel Flow testing - (2 hours)       Category: Final (X)

Fuel Flow testing in accordance with EAA Phase 1 testing procedure. All test came out above minimums.

  Jan 25, 2022     Data plates - (1 hour)       Category: Final (X)

  Jan 25, 2022     High Speed Taxi and brake check - (2 hours) Category: Final (X)

I needed to move 45HS from the heated hangar that I had been borrowing this past week for the front windscreen install (which went great) back to my (cold) hangar so I took the opportunity to do a quick run-up, high-speed taxi (nose was getting light) and brake test. Everything felt great (I need to scoot my seat back).

The following are what I have left to complete prior to the DAR visit in a few weeks:

Pitot Test and Transponder check (Thursday)
Fuel Flow test (Saturday)
Calibrate fuel gauges in G3X (Saturday)
Condition Inspection (on-going next week)
Tentative DAR visit 2/10/22

Here is the video: https://www.youtube.com/watch?v=y5xwoOtO7XA

  Jan 18, 2022     First ENGINE start and taxi - (4 hours) Category: Final (X)

Big day at KB Stone Aviation! After weeks of slamming away the final 95% I felt ready to start the engine and finalize the calibration of the ADHARS and magnetometer. Everything went as planned and I had one of my favorite A&P/IA's help for the first engine start. I found a heated hangar that the owner is going to let me borrow for a week so today's plan is to install the front windscreen and allow it to cure for a while. I'm going to start the paper (computer) work for the DAR visit which I'm hoping can happen in about 2 weeks. My ‘day job' starts back up next week so the timing is about perfect!

The video of the first start can be seen here: https://www.youtube.com/watch?v=TNhTdleGtR4

  Jan 20, 2022     Weight and Balance - (3 hours)       Category: Final (X)

Since the amount of fuel in the wings was minimal I decided to work on the W&B while the plane was still in the heated hangar. The numbers don't make sense and after discussing with members on the GAOA and Coby at the factory, I decided to rework the W&B numbers. The weight on the NLG is too high. Note...the numbers shown in the picture below does not take into consideration the TAR weight (fuel, blocks).

  Feb 23, 2022     Front windscreen done - (2 hours)       Category: Final (X)

Front windscreen came out pretty good! I also injected some Silpruf into the cleco holes

  Jan 23, 2022     Installing EXPERIMENTAL decals - (2 hours)       Category: Final (X)

Went as planned....installed the stickers to comply with regulations

  Feb 05, 2022     Steps 152 - 175 Install Front Window - (30 hours)       Category: Final (X)

I was ready to install the front window after the first engine started and taxi. I'm sure right after I install the front window I'll need to get into the avioncs! I was able to borrow a fellow aviator's large heated hangar for a week so I took full advantage of having a warm shelter to complete a bunch of work.

  Jan 13, 2022     Transition Training - (10 hours)       Category: Final (X)

Flew to 91C and trained with Dan Dudley for transition training in his Sportsman Trike. What a great trip and very helpful. We spent over 3 hours flying around to various airports around the area and honed my skills with TO/Landings, stalls, steep turns, etc. I feel ready to fly 45HS.

BTW....the Sportsman does pretty well even without the elevator trim tab. The trim relay failed about 2.5 hours into the training so we removed the trim tab and continued on.

  Jan 06, 2022     Tensioned all control cables - (10 hours)       Category: Final (X)

Confirmed and set travel for ailerons…which took some time!

I was not happy with the original tension on the cables so I returned and set them all again. Had a local A&P review and confirm proper technique.

Flap Up = 45
Flap down = 40
Elevator = 40
Ailerons = 25 l

  Jan 07, 2022     Started to work on gathering information for programming of G3X and rest of avionics - (4 hours)       Category: Final (X)

N917X was very helpful

  Jan 05, 2022     Step #167 Install elevator counterweight - (4 hours)       Category: Final (X)

Installed counterweight as per Assy. manual

  Jan 04, 2022     Step #166 and 167 - (4 hours)       Category: Final (X)

9th day in a row working on 45HS…I'm going to take a break tomorrow and go skiing w/ Lori. But..before I do, the weights were installed for the Elevator. Had enough lead but not real happy with how the install looks. I'll pull it out and sand some to clean up the appearance…..I see now why others have poured their own lead,,,,,this will be a good project for the future!

I need to add a few grams as it just a little light.

  Jan 03, 2022     Step #164 - 165 - (6 hours)       Category: Final (X)

Continued work on fitting and installing all the HS and Elevator fairings today. Took tips fairing home and used mil fiber mix to lock in the bulkhead. Lots of nutplate installing! 30 total!

  Jan 02, 2022     Step #163 Install HS tip fairing - (6 hours)       Category: Final (X)

Moved on to the elevator balancing. Be sure to read the SB67 when completing this section.

Fit and installed HS tip fairing and began installation of the Elevator tip fairing. Lots of cutting and fitting today!

Checked out N917X install to be sure I was locating the faring nutplates in the correct location.

  Jan 01, 2022     Control Surface Balancing - Step #158 - 159 - (7 hours)       Category: Final (X)

Installed the aileron counterweight as per the assembly instructions. Had to grind off a lot of extra lead…seems like too much but they are now balanced. I checked 917X and they appear to be about the same size. BTW…be sure to follow the TWTT instructions with regards to measuring the distance forward and installing the counterweights.

Learned NOT to try to cut the lead with your bandsaw…it just gums up the blade! I used the 4” sanding disc (same one used to trim the windows) to trim down the lead. Face mask and full respirator for safety!

I did not have to bend the tube at all to maintain the proper clearance. Modifying the wingtip was pretty easy. I did not make a bulkhead inside of the wingtip as the wires for lighting is minimal and could not interfere with the aileron..

  Dec 31, 2021     Step #130 - 135 Install wing fold hatches - (9 hours)       Category: Final (X)

Continued the install of the wing fold hatches. Installed all the nutplates and am pretty happy with the final product. There is one nutplate I need to use the rivet gun on as I can't fit my hand crimper in the tight location. The curve of the fuselage lines came out real nice and the gaps are near perfect with the specifications in the assembly manual.

I also realized I put the flaps on the wrong side! I even labeled them nicely with Left Flap and Right Flap….moved them around w/o issue. Only damage was to my confidence!

  Dec 29, 2021     Step #130 - 135 - Install wing fold hatches - (9 hours)       Category: Final (X)

Started early so I could warm up the hangar and fuselage prior to Loctite. Wow...two heaters and the system in the fuselage worked out great. It was snowing and 25 degree's outside and inside the fuselage, it was 100 degrees. I actually turned down the heaters some!

After prepping the surfaces I applied the Loctite and hoped it would cure. While waiting for it to cure I continued with finishing up the LH wing wiring of the XFER pump and AUX fuel sensor. I also cleaned up all the wiring on the LH side as well.

After about 10 hours of cure time, I removed the hatches and carefully transported them home. The Loctite was cured but its pretty brittle and I did not want to run the risk of breaking the joint. Once home, I removed the clecos and applied a decent amount of Q-Cell mix to create a smooth fillet for the fiberglass layers that I would apply the next day. Took forever for the Q-Cell to get...40 minutes! Learned a lesson about adding more catalyst to the resin so the gel time would increase.

  Dec 28, 2021     Step #130 - 135 - Install wing fold hatches - (8 hours)       Category: Final (X)

Worked on fitting the wing fold hatches all day. Everything seemed to fit up well. The instructions in the Assy. Manual looks to be for the Glastar, not the Sportsman as the pictures are different. I found the TWTT Hatch Installation instructions to be more helpful. I tried out a few different scenarios trying to figure out how to set the conture of the fuselage and the flap then remove the hatch cover so I could bring it home to do the fiberglass work. I could never figure out a good system so I made the decision to glue the trailing edges and root seam together with Loctite H3151 to "set" them in place. I purchased more Kerosone and made a plan for gluing them the next day.

I bought another Brooding lamp and put it in the cabin and hope that along with the portable electric heater and my two job site heaters I can increase the temperature enough to allow the Loctite to cure.

  Dec 27, 2021     Installed WAT light system - (9 hours)       Category: Final (X)

Installed as per instructions. Mounting required #6 screws and nutplates, not #8. Really happy with the installation! Wired everything up and they worked perfectly! They sure are bright! I did not test the NAV antenna yet as I want to make sure everything is connected correctly prior to turning on the NAV radio. I used AMP connectors for the lights and created a grounding lug for the main ground.

  Dec 20, 2021     Installed NAV antenna - (3 hours)       Category: Final (X)

Installed NAV antenna per installation instructions. Will allow to cure while we are out of town for X-Mas

  Dec 19, 2021     Finished wingtip fiberglass work; WAT light install - (7 hours)       Category: Final (X)

Rotated the wings and started the installation of the WAT lighting system. I pulled the plane out of the hangar to test the tow set-up. Did not work...the bar I used was too light and bent. Plan B.

Removed wingtips and finished trailing edge fiberglass work.

  Dec 18, 2021     Step #181 and 182 - Install inboard and outboard delta wings - (2 hours)       Category: Final (X)

I decided to go ahead and install the delta wings as I will be test flying prior to paint. Install went as planned.

  Dec 18, 2021     Step 99 - Install wingtip fairing nutplates - (3 hours)       Category: Final (X)

Went as planned...installed nutplates and screws. This was pretty easy with the wings folded back.

  Dec 17, 2021     Step #97 - 98 - Bond wing tip fairings together - (4 hours)       Category: Final (X)

Had enough resin to bond these together but boy, did it gel quickly (13 minutes). I warmed up the garage to around 70 degree's and activated the resin according to my notes but it set-up too quickly and I had to throw away 50 grams. I mixed a new 50gram batch and it did the same thing. Maybe I had the resin too warm?

Anyhow...everything looks great with the seams and I cut out the aileron slots this evening after everything cured.

I also primed the Delta Wings while I was working on the Wing Tips

  Dec 17, 2021     Step #86 - 91 build and install Delta Wings - (6 hours)       Category: Final (X)

For some reason I was a little timid about building the Delta wings. I even considered buying them from NGA or Zach (composite) but after building them I'm glad I did! I had to purchase some new .035 6061-T6 aluminum as somewhere along the way I used what came in the kit for something else.

Fabrication went well as did locateing and drilling them. I'm going to go ahead and prime them then install as I'm going to wait to paint and want to have these on the wings for the test flight.

  Dec 14, 2021     Step #83 - Install main fuel lines fittings - (3 hours)       Category: Final (X)

Purchased new Swagelok PB-4 and PB-6 hose as my hose is from 2006 era and I'd rather not have any question if the hose is good or not! I'll use the old hose for chafe material.

Wired up fuel main fuel sender too.

  Dec 11, 2021     Antenna mount and Temp Probe - (4 hours)       Category: Final (X)

Finished install of both Comm 1 & Comm 2 antennas. Lew helped rivet double plates to wing skins.
Completed wiring of GP59 temp probe inside fuselage

  Dec 11, 2021     Misc. Final Assembly items - (15 hours)       Category: Final (X)

Seem like since Thanksgiving I've not had too much time to work on 45HS! I did manage to get the following completed:

- Set elevator travel in accordance with specifications: down = 20 degree; Up = 23 degree; +/- 1 degree.
- Started preliminary tension of cables. Set rudder and elevator
- Worked for hours on getting the travel correct on the aileron and flaps. I needed to step back a little bit to make sure I was doing this correctly. After much thinking and experimenting (and reading), I've realized the down setting on the aileron is the most critical and the 'up' travel will be where it is. I paused working on this so I could figure out what I was doing wrong with the aileron travel as I had it set correctly (or so I thought) when I mounted the wings the first time.
- Made a crossover cable guide template....checked everything...looked good. Made an actual crossover cable guide from Phelonic material and it worked out okay but I still have some cable rubbing so I need to make a new one. Ordered materials to fabricate a new guide.
- Started install of comm 1 and comm 2 antennas on wings. Made doubler plates
- Installed GMU 11 in RH wing access port
- Moved more stuff out to the hangar and purchased a 140,000 BTU heater!

  Nov 25, 2021     Mount Ailerons and Flaps - (6 hours)       Category: Final (X)

Mounted Flaps and Ailerons to the wings today. All went well. Spacing looks good and no interference between the ailerons, flaps, coves, etc. Rudder and Elevator go on tomorrow then everything will be reconnected to their respective cables.

Lets see how many times I can hit my head on these darn things!

  Nov 24, 2021     Mount wings to fuselage - (4 hours)       Category: Final (X)

Returned the next day and fixed the wire routing and ran the extra wires needed. Install went smooth and was able to accomplish the task by myself.

  Nov 23, 2021     Mount wings - (4 hours)       Category: Final (X)

Had a few helpers and started to mount the wings until I realized I made a mistake with the routing of the wiring into the wing struts. I needed to route the wiring between the wing strut attach arm as the wing strut will crimp everything the way I have it wired (below the arm). We mounted both wings and left them supported by ladders so i could work on solving the problem. I also realized that I was missing some wiring for the GMU11 (too short) and the OAT. I

  Nov 22, 2021     Moving Day to the Hangar - (5 hours)       Category: Final (X)

Big day! After thinking and researching a few options for moving 45HS to the airport I decided on hiring a tow truck flatbed to move it the 8 miles. The trailer was going to be $85 to rent and it was huge and my truck would struggle to haul it. I had a few folks offer their trailers but they were all a little narrow and I needed at least 7'6" width. I went with a local tow company that was highly recommended and he quoted $100. All went well with the move and the airplane is in its hangar and ready for the next phase.

I also spent a lot of time cleaning the garage and moving what I think I'll need to the hangar to keep working on 45HS.

  Nov 20, 2021     About ready to move! Final odds and ends - (6 hours)       Category: Final (X)

installed the fire extinguisher
Installed the engine heater
Installed heat shield on the lower cowling
Secured various wires
Secured castle nuts for travel
Cleaned garage

  Nov 15, 2021     Front Windshield prep and install - (10 hours)       Category: Final (X)

Started the prep and install of the Front Windshield on 11/15 and finished on Friday 11/19. There was a LOT of removal necessary so each evening I just kept working away with the big grinder and shaping to fit within the joggle. I think the dust must have been getting to me as I started to work on the gap between the joggle and the windscreen prior to putting in the stand-offs, as per Zach's videos. Luckily, I reached out to Zach w/ a question and he helped me with the sequence, which is a bit different than all the other windows. He mentions it w/n the video's but I did not pay close enough attention...which is funny because I watched them each time I started a new window...so 6 times!

Anyhow...the install went well and everything is ready for masking and silpruf once the start-up and avionics have been tested.

  Nov 15, 2021     Steps 152 - 156 - Window installation - (20 hours)       Category: Final (X)

This last week has been a productive week with learning l all about window install and finally getting the registration completed for N45HS!

I completely underestimated the bureaucracy involved with registering mine and have a new appreciation for proper ‘chain of custody' and Bill of Sales. I won't go into all details as I'm sure many have traveled similar journeys on their quest to register kits purchased from various owners. In general…be SURE you have a clean BoS from who you buy the kit from, who they bought it from, and then who the factory sold it to! I started my registration process on May 17, 2021, and just this past week, the FAA was finally pleased with all the chain of custody. The issue was compounded by the delay from the FAA in reviewing and providing feedback because they are about 2 months behind. I recently learned that for kits you can submit paperwork via email and not mail everything in (thank you to the very nice Legal Instrument Examiner at the FAA who suggested this route a few weeks ago). I wish they would have told me this about 3 months ago.

One of the last items I need to complete in the KB Stone Aviation factory Home Site was the installation of windows. I collected all my supplies and watched @ZachChase wonderful window tutorials and dove in last weekend. The process was pretty straight forward but I needed to start with the side windows instead of the skylight as I realized when I tried to take off the 15+year protectant on one of them it was baked on and was not removable. I ordered new ones from a local shop and even bought a darker tint for the skylights which I think I'll appreciate. I'll repurpose the old ones for inspection panels in the seat pans. All the other windows (with the exception of my windshield, which needed to be replaced) were fine and installed nicely. As usual with this airplane building, my process and quality improved greatly from the first window to the last but as Zach mentioned in his video…“don't worry about the inside clean Silpruf line as everyone will be looking at your cool avionics”! I sure hope so as I need to go back and lay another bead once I get close to complete. I plan to fly off the plane w/o paint then complete all the touch-up when I paint next Spring. My 2 cents is to buy more than the recommended 20 wing-nut cleco's if you want to install more than one window per day. I only bought 20 and would have liked to have about 10 more. So far, I've only used about 2 tubes of Silpruf but still have the windscreen to install which will probably take nearly one. Maybe I didn't use enough but everything was plenty messy and I was an “over Silprufer” as instructed by Zach.

I'm on track to move the Fuselage to the KB Stone Aviation Hangar site over T-Day break and mount the wings and start rigging this bird. I have the list from the DAR and plan on transition training with @DanDudley sometime over the next 8 weeks to check the insurance box. Everything is coming together nicely and I still anticipate the first taxi before the end of the year!

In addition to all this, a few weeks ago I sold (sale pending) my Cessna R172K 3 Hawk XP to a young local couple who will be hangared right next door. Needless to say…its been a busy last few weeks but now that my plane is pretty much sold, I am super motivated to get N45HS in the air!

  Nov 02, 2021     FAA Registration issues - (3 hours) Category: Final (X)

I started the registration process for 45GV in May once the N-Number reservation was confirmed in May 2021. Since then I have been dealing with Chain of Custody issues since I have three different "parts" for my kit. Today I spent more time resolving what is hopefully the final issue. I have never experienced anything so ridiculous in my entire life! I'm aware the FAA is a government agency and expected some hoops to jump through but its just been amazing at the level of bureaucracy and a process that seems to be pretty straightforward but is anything but. Oh well..lesson learned.

Update 11/12/21 - N-Number appears to be fully registered on the FAA website....I'll believe it when I receive my actual registration in the mail!

I did locate the DAR today and he is actually based in Rifle and had a nice chat with him about the process. He wants 2 weeks' notice and will send me a check list to follow. $500 bucks seem like a bargain at this point!

  Nov 03, 2021     Prop Safety Wire - (1 hour)       Category: Final (X)

Safety wire all prop bolts

  Nov 02, 2021     Torque Prop bolts - (.5 hour)       Category: Final (X)

Reviewed TWTT installation instructions and Hartzell Prop install manual. Initial torque = 50 ftlbs, final torque 65 ftlbs. Adjusted for extension used.

  Oct 31, 2021     Step 188 - Inspect Landing Gear, Wheels and Brake System - (2 hours) Category: Final (X)

Added brake fluid (Aeroshell 41) to all brake lines as per Assy Manual. All went well however, the RH, co-pilot brake line is leaking at the hose end when pressure is applied. Drained fluid from RH line and attempted to reseat fitting. No joy so I ordered new ones from Jegs. They should be here later in the week then I'll fix the issue. I'm sure this is just the start of fixing leaking lines!

  Oct 29, 2021     Misc. Final Assembly items - (30 hours)       Category: Final (X)

Productive few weeks with installing the prop and fitting the front nose gear strut:

-Installed Spinner on the backing plate
-Trimmed spinner to fit..again..and again..and again.
- happy with spinner fit but stopped trimming until after prop is mounted and cowling mounted to ensure clearance is correct
- Mounted Prop, twice...once to check spinner fit and backplate...second time because there was still a little interference between the backplate and prop when rotated to the full stops.
- Also forgot to remove oil feed cap so this was more difficult than needed to be. I was able to remove w/o any damage but it took a while!


-

  Oct 16, 2021     Final Assembly items - (35 hours)       Category: Final (X)

I conquered the MG fairing this past few weeks and found the process to be pretty fun…aside from the stinky resin! We had a cold snap hit us this past week so I felt pressure to get the majority of the fiberglass work done prior to winter setting in. Here is a list of items completed:

1. Left and Right Main Gear fairing fabricated and installed. I still need to do some more body work on them but they are structurally all done. I experimented with using a tick Q-Cell coating for the body work and it seemed to work fine. I got it too think one batch and it was a pain to sand off. I'm learning the balance between too thick and too thin.

2. Installed 4-point seatbelt from Wicks….its too short so I'll return it and order the Glasair ones. I really like the 4-point set-up.

3. Installed Tundra Trike nose gear and everything went well. The original nose fork was not made correctly so NGA sent a replacement under warranty. Then I had an issue with the Grove wheel because I ordered the magnesium one instead of the aluminum one. The one ordered is heavier duty and lighter but the seals are a little different. Grove helped solve the problem and it worked out great. I increased the height to 14” prop clearance and a much wider tire that will provide more floatation on the dirt strips.

4. Installed the cooling enhancer modification from NGA. All went well and the part fit nicely.

5. Installed sniffer valve

6. Installed quick oil drain P5000 (ACS #07-00879)

7. Prior to installing these, I drained the remainder of the preservation oil and installed 8 quarts of 80w mineral oil.

8. Built front gear fairing. All went well so far!

  Oct 03, 2021     Misc. Final Assembly items - (25 hours)       Category: Final (X)

Accomplished a number of items over the past few weeks:

- Cover glair shield w/ vinyl. Tried the Gorilla spray first but was not happy with the outcome. Bought 3M 77 spray adhesive
- Fitted rudder fairing..a couple of times! When I glassed it together I must have pulled it apart a little too much and when the part cured, it was too wide. I cut it apart and did it again. Made a better jig this time and it came out better.
- Worked on fitting the Tundra Trike wheel set-up. I discovered that the wheel I ordered from Grove was a different part than what Glasair designed the Tundra Fork. I worked with Grove and ordered the correct bearing seal rings that will hopefully allow my wheel to work.
- Received a replacement Garmin GPS antenna under warranty and replaced it. Worked fine and everything is working correctly now.
- Found grey vinyl locally and completed the covering of the bulk head cover. The 3M 77 spray adhesive worked well.
- Started the fabrication of the LH MGL fairing. I was able to wrap the gear leg and create the foam core. I'm happy with the outcome. I applied Q-cell and filled in the gap between the gear leg and foam core. I'll start wrapping with fiberglass this week. The fiberglass really shrinks when its wetted out!

  Sep 19, 2021     Misc. Final Assembly items - (15 hours)       Category: Final (X)

Great week of wrapping up a bunch of odd jobs on the plane. I received my order from Glasair so I was able to continue with fiberglass work and install many of the items I had on order from them. Here's what I accomplished this week:

Installed elevator trim motor, wired, and configured G3X system to show correct elevator trim position.
Installed baggage door socket in the fuselage with Resin and Cabosil
Installed Hickman Headset hanger in cockpit
Installed four-point seat bar harness kit in fuselage
Installed Trike Tail strike wheel kit
Returned to baggage door install to finish door install. I was able to get my handle to work since I made an error a few weeks ago cutting off the wrong part! This door actually came out really nice and I'm pleased with the fit and finish. I want to make a handle out of something different from what is provided in the kit as it looks pretty cheap. Otherwise, the baggage door is nearly done.

  Sep 11, 2021     Step #30 - 34 - Install Strakes - (15 hours)       Category: Final (X)

Whew...strakes are installed! I'm getting better at managing the gel time of the resin (the cooler temps also help) so the single layer of fiberglass cloth between the strake and fuselage did not seem so rushed. Once I did the lay up I allowed it cure then went back over everything with Q-cell and sanded it down smooth. A little more body work and it will be ready for painting.

I also installed the rudder fairing and tail cone fairing. Installed the elevator with ease and finished checking the fit of everything..which I'm happy with.

  Aug 29, 2021     Step #21 - Mount Seat Tracks to cage (again) - (1 hour)       Category: Final (X)

Used Click Bond nuts to ease removal of seat tracks in the future....one less thing to worry about dropping when assembling! See pictures for details.

  Aug 27, 2021     Step #30 - 34 - Install Strakes - (10 hours)       Category: Final (X)

Yeah! The Strakes are bonded to the fuselage! I am still figuring out what I can and cannot do with fiberglass / bonding and I learned this week that you need to allow ample time for the bonds to set up completely for certain steps. I was a little impatient after I bonded the ribs in the strake to double-check the fit again and mounted them to the fuselage before they were completely done curing. I broke the bond on Rib D when I pulled the strake a little too wide when adjusting the fit. Opps...lesson learned. I rebonded the rib and let it cure 24 hours!

I'm happy with how everything came out. I have a nice tight fit between the HS and the Strake with the anti-chafe material installed. The -1.4 degree incedent angle from the waterline was maintained and the bond appears to be very solid with the fuselage. Next week I'll finish up the body work around the strake and fuselage but overall, the installation is done!

  Jul 17, 2021     Avionics - continued - (45 hours)       Category: Avionics

I took about 1.5 weeks off from the build so I could run a race and visit family in KCMO. It was a nice break but missed building! Since my last post in June I've completed the following:

- Configured G3X system along with all other devices
- Mounted panel permanently
- Fitted glare shield
- located and ran all wiring to antenna's (except ones that will be mounted on wing)
- Wired all headset and mics (crossover console)
- Ran wiring for battery charge system w/n cockpit
- Connected autopilot cables to capstans (need to wait to tighten cables prior to final adjustments)
- wired XFER pump discrete to G3x
- Finished connecting static and pitot lines to avionics
- ordered throttle, prop, and throttle cables from McFarland
- mounted ELT system
- mount fresh air vents (sure wish I had mounted these PRIOR to install the firewall!

  Aug 22, 2021     Step #27 - #29 Install Strakes - (6 hours)       Category: Final (X)

The RH Strakes fit pretty well and did not require much sanding and trimming. The LH Strakes needed a lot of sanding and trimming to get them flush against the fuselage and HS. After fussing with them yesterday and today I was finally happy with the fit so I fiberglasses them together. They need to cure for 24 hours before I install them. Sanding the Gelcoat off the fuselage in the meantime.

I'm getting better at managing the resin time and was able to apply 3 strips with 100grams of resin. I mixed a 50gram batch to fhinish off the last fiberglass strip and cleaned everything up.

  Aug 21, 2021     Fuselage Fairing Installation - (2 hours)       Category: Final (X)

Cleaned up the workshop and rearranged the airplane so I could start to work on the Strake installaion. Needed to mount the rudder and horizontal stabalizer.

  Aug 16, 2021     Label Panel - (2 hours)       Category: Avionics

Not sure if I'll keep these labels permanently but for now they will do. They came out pretty good and are functional...and look better than my green tape!

  Aug 17, 2021     Step #101 - ? Baggage Door Install - (6 hours)       Category: Final (X)

Continue to work on installing the baggage door. Trimmed and sanded to as close and I can w/o mounting door. I need to wait until the door seal arrives prior to bolting the door to the fuselage then I can work on the final sanding for the door and set the door pin.

  Aug 14, 2021     Step #? - Install baggage door - (4 hours)       Category: Final (X)

It was late and I was tired.....I realized that I needed to modify the baggage door handle that came with my kit as there is a pin facing outboard that is not needed and interferes with the exterior door handle socket. I took it over to the workbench and cut off the pin but soon realized I cut off the wrong one! Bummer. I cut off the correct one then tried to drill out the remaining pin so I could install a bolt. No joy...the pin is hardened steel and after three different drilling attempts I drilled a new hole about 1/4" away from the 'old pin'. I think this will still work but need to Cabosil in the door inserts...which is what I did this morning....and now they are curing.

  Aug 14, 2021     Install forward tunnel covers - (2 hours)       Category: Final (X)

Nut plates came in from ACS so I spent a few hours drilling and installing all the nut plates and finishing the install of the tunnel covers. I'll paint the heads of the screws black at some point. I also installed the floorboards with longer screws and fender washers to distribute some of the load. I need to source floor mats that will be placed over the floorboards and also paint these.

  Aug 12, 2021     Step #101 - Install Cabin Doors - (6 hours)       Category: Final (X)

Followed TWTT Instructions instead of Assy. Manual instructions since my kit #7069 has the newer style Sportsman doors. Had a heck of a time getting the doors to lay flush but after some research and trial and error, I figured out the issues. It was a combination of pushing the fuselage door opening out by adding nylon spacers and also trimming the door seal joggle to 9/16" all the way around so the seal would install completely. They are still pretty tight but I also need to lube the parts and allow the seal to set. Lori helped push on the hinges while I drilled them.

  Aug 10, 2021     Installed tabs for glare shield support - (1 hour)       Category: Final (X)

Installed support tabs for glare shield.

  Aug 10, 2021     Finish installing cabin heat - (2 hours)       Category: Final (X)

Finished installing the cabin heat control cable and duct. All went well and it's ready for heat! I'm going to wait to run the actual aeroduct within the cabin so I can get a feel for where it needs to be routed.

  Aug 10, 2021     Installed oiler cooler aeroduct - (.5 hour)       Category: Final (X)

I've been waiting to complete all the aeroduct as I knew it would just get in my way while completing the FWF wiring and hoses. I think I'm about done with all the FWF but still have some wire management to complete so I needed to install all the aeroduct.

  Aug 08, 2021     Installed Front pulley and cable covers - (2 hours)       Category: Final (X)

Installed the factory front pulley, cable, and boost pump cover as per the TWTT instructions. I need to order the Tinnerman nut plates but everything else is drilled, cleco'd and ready to install nut plates. Due to the Newton selector valve the fuel lines are packed in there really tight so getting the cover to fit properly was an exercise in compromise. Once I take off the green tape everything will look better. I'm still not sure if I'm going to leave them black or paint them gray to match the rest of the interior. I kind-off like the black as it matches the panel??

  Aug 08, 2021     Step #17 - Fit floorboards - (3 hours)       Category: Final (X)

Fit floorboards, drilled holes, installed screws (need to get 5/8" screws, not 1/2"). Used birch 1/4" plywood as per instructions. I'll seal with poly and paint w/ epoxy paint at a later date. Pleased with the install and the ole skill saw worked great!

  Aug 07, 2021     Install Cabin light - (3 hours)       Category: Avionics

Installed LED Red/White cabin light in crossover cable cover and made it dimmable via the G3x system using the GAD27 PWM option. Pretty cool! I don't think I'm going to need dash lights as everything is lit pretty well.

I purchased the 754 Series LED Light from ACS: https://www.aircraftspruce.com/catalog/pspages/754cockpitlights.php?clickkey=7189
The SPDT three-position switch came from Amazon: https://www.amazon.com/dp/B07LBMTWB6?psc=1&ref=ppx_yo2_dt_b_product_details

  Aug 07, 2021     Step #25 - Install Control sticks - (2 hours)       Category: Fuselage (VIII)

Finished installing and wiring both control sticks. Check operations and both seem to be working correctly.

  Aug 07, 2021     Step #25 - Install Control sticks - (1 hour)       Category: Fuselage (VIII)

Finished installing RH control stick....now I need to finish wiring these!

  Jul 28, 2021     Install Vents - (4 hours)       Category: Fuselage (VIII)

Painted vents and side of fuselage today. All went well except I got a little carried away with the "spackle" spray and put it on too heavy and it sagged....a lot. So....had to let it dry, sand off, and spray again the next day. Lesson learned...don't over spray the texture product!

  Aug 06, 2021     Step #25 - Install Control sticks - (3 hours)       Category: Fuselage (VIII)

Started the install of control sticks. Drilling went well and measurements seem correct. I borrowed 917X control stick jig (2x4 w/ two holes), which was helpful.

  Aug 04, 2021     Step #8 - Fit the seat pans through Step #25 install seat tracks - (7 hours)       Category: Fuselage (VIII)

Started work on trimming and fitting the seat pans. LIke building the wings, this is a process of "parts on, parts off". Trimming went well and everything fit nicely. Eventually, I'll install a plexiglass bottom in the seat pan so I can see all the controls easily.

It was fun to actually sit in the seats and get a feel for the visibility.

  Jul 30, 2021     Install engine control cables - (6 hours)       Category: Fuselage (VIII)

Fabricated insert and installed Throttle, Mixture, and Prop engine control cables. Used the nut tool from GAOA and it worked great! Had some minor issues with the fit but with the help of Coby and members of the GAOA the problem was quickly solved.

Had to reposition all of the control arms (Throttle, Mixture, and Governor). Not a huge deal but I did not realize this on the Prop Governor until AFTER I had safety wired all the screws from mounting the bracket.....good practice for safety wire tying.

  Jul 29, 2021     Step #8 Close out bulkhead - (3 hours)       Category: Fuselage (VIII)

Cut bulkhead cover as per instructions and installed. I'll cover with the same type of vinyl cover as dash will have.

  Jul 25, 2021     Install Vents - (3 hours)       Category: Fuselage (VIII)

Sanded Q-cell today and pretty happy with the flaring of edges. The NACA intakes look nice. Now I have to mask everything and paint the inside. It may not look pretty in these pictures but its smooooth!

  Jul 24, 2021     Install Vents - (3 hours)       Category: Fuselage (VIII)

Applied Q-Cell today to the edges of the NACA intakes and also inside the cabin to smooth the edge transition. Lots of sanding in my future!

  Jul 17, 2021     Install Vents - (4 hours)       Category: Fuselage (VIII)

First time with working with the Resin and took some time to learn the process. It was a pretty warm day (90 degree's) so the pot life was really short (10 minutes). I did one at a time and followed the directions in the Assy. manual and all worked out pretty well. I SURE wish I would have installed these prior to the Firewall being installed...but it all worked out okay. The speckly paint worked out well too. I'll let them cure a while then return to finish the body work around the edges.

  Jun 24, 2021     Avionics Wiring - (50 hours)       Category: Avionics

Yeah....I'm nearly done with all the wiring for the Avionics...whew..did I ever underestimate "building your own panel". I've sort of lost track of the hours I have in this part but it's a lot. This past two weeks I've spent at least 50+ hours on the panel. I learned so much through this process and while it was frustrating at times, it was also fun to overcome the challenges. When the panel powers up and everything is working there is a high amount of satisfaction. I know I still have lots to figure out and configure but at least most of the devices are connected and reading correctly in the G3x.

  Jun 06, 2021     Avionics Wiring - (30 hours)       Category: Avionics

Great week of solid work wiring the panel. I was able to get in the flow and make great progress and I'm happy to report that ALL LRU's have been wired with their CANBUS, RS232 wires in addition to various other connections. This weekend I spent much of it troubleshooting a few devices that were not communicating correctly (GSA28, GEA24). I had three wires that needed to be switched and one bad crimp on a PWR wire to the GSA28. Otherwise, after I worked through the configuration process via the G3x manual, everything is communicating now with the exception of the GAD27 and the NAV 1 on the GNC255. I've spent hours trying to figure them out but finally stopped and sent an email to G3xpert for assistance. I have plenty to move forward on such as the lighting bus and wiring the GMA245 heard set / PTT switches in the control sticks. Excellent week of progress and I'm looking forward to another productive week.

  May 30, 2021     Avionics Wiring - (30 hours)       Category: Avionics

I continue to make progress on the wiring and FINALLY have a good mental model in my brain on how this system works. It took me a few times to get it straight in my head but now I can see the systems and how they all interconnect. I have all the PWR circuits done to the main avionics and everything tested out perfect and no smoke was seen or smelled during the first power up.

Now that school is over for the summer I can dedicate nearly unlimited time to the wiring and I've found it much easier to get in the flow of wiring w/o stopping. I have my CAN BUS system designed and love the simplicity of the system. I've read and figured out all the “non-G3x” equipment manuals such as GNX375; GNC255; and GMA245.

As of today (Sunday May 30th) I have the GMU11; GSA28 (roll) GSA 28 (pitch); GAD29 all completely wired. I have the CAN bus and PWR to the GTR20 but need to return to this device later when I wire-up the GMA245.

Only 7 more devices to wire into the CAN Bus system!

  May 09, 2021     Avionics Wiring - (5 hours) Category: Avionics

Finished wiring the Alternator circuit, alt switch, Master switch, and then started in on the Avionics master switch. Waiting on diodes that are on order. Since Radio Shack closed down years ago you just can't find any small resistors and diodes locally any more!

  May 08, 2021     Panel Build and Wiring - (25 hours)       Category: Avionics

OMG....I cannot believe that it has been 3 weeks since my last update. I've been making forward progress with lots of design issues almost overcome and ordering small parts here and there. I have most of the wiring, connectors, relays, circuit breakers, grounding buss, and other minor items either on the way or already here. I kept going back and forth on the Avionics master relay and finally decided to keep the switch and associated relay. Reading AeroConnection is very helpful but there are some ideas put forth that were conflicting with what I was seeing in other builds. I think I've mentioned this before but the quick evolution of newer technology has outpaced some of the suggests made in older avionics examples. Another example is the TWC battery back-up system, which included all the diodes and circuitry that protects devices from being backfeed when in use. The Garmin avionics also have connections for primary power and back-up power so they know when you are on ‘main' vs. ‘back up' power.

You can see below the modifications made to my circuit breaker and I worked through the ‘E-Bus', Avionics bus, and main bus. I think I now have it all figured out!

I have all the CHT/EGT wires run through the FW along with ALT and Starter wires. I missed ordering butt splices and male spade connectors to connect to the fuel pressure, oil pressure, and oil temp sensors and I don't want to use ‘automotive' grade so i'm waiting for those to come in from ACS. I'll continue with finalizing the grounding strip and various other items when finish up all the FWF wiring this next week.

I'm getting a feel of the Garmin G3X manual and once I have the FWF devices through the FW I am optimistic that progress will speed up!

Prop should ship this next week and I'm working on my FAA 8050-3 Registration paperwork for N45HS (reserved number took 12 weeks for approval!).

  Apr 17, 2021     Panel Build - (15 hours)       Category: Avionics

Lots of work on the panel build over the past few weeks and I'm very happy with the final product. I was going back and forth on the Aera 760 but went ahead and cut the hold and installed the AirGizmo panel mount. Its not as clean of an install as the other components but all the other homemade options I considered would have been worse. The faux carbon overlay turned out very nice. I put some on a test piece a while back and its been doing really well with 409 cleaning and general handling. It will still tear if sharp edges come in contact but that's to be expected.

98% of holes are cut in the panel. The only remaining items (I think) are the EFIS battery switch,....which I ordered this weekend.

The buss bar material all came in today so I can start building the buss bar systems and begin to wire!