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Categories

Show All Entries - (661)
Rudder (III) - (1)
Horiz S (IV) - (11)
Elevator (V) - (32)
Wing LH (VI) - (107)
Wing RH (VI) - (82)
Aileron(VII) - (38)
Flaps (VII) - (32)
Fuselage (VIII) - (67)
Systems (IX) - (113)
Avionics - (13)
Engine - (1)
Inspection - (2)
Interior Finish
Lighting - (1)
Paint / Decals - (5)
Propeller - (1)
Kit INVTRY - (5)
Research - (6)
Tools - (1)
Workshop - (13)
Wings
Final (X) - (126)
FWF (X) - (2)
Phase 1 - (2)


Builder Name:	Kyle Stone -

Project:	Glasair - Sportsman 2+2 - VIEW REPORTS
Total Hours:	1859.9
Start/Last Date:	Jul 03, 2019 - Jun 30, 2022
Engine:	Lycoming IO-390-EXP
Panel:	Garmin G3X w/ GNX375 IFR nav, GNC 255 NAV/COM

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

Home or Last Project Picture

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.

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Apr 03, 2023 Paint Codes

Category: Paint / Decals

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Apr 03, 2023 Added new decals - (1 hour)

Category: Paint / Decals

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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.

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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.

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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.

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May 29, 2022 Paint is complete - (5 hours)

Category: Paint / Decals

Paint by Jake Buck @ KGJT.

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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.

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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

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Feb 07, 2022 Airworthiness Certification - (3 hours)

Category: Inspection

Airworthiness Certification achieved!

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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.

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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.

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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.

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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

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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.

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Jan 25, 2022 Data plates - (1 hour)

Category: Final (X)

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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).

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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

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Jan 23, 2022 Installing EXPERIMENTAL decals - (2 hours)

Category: Final (X)

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

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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.

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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.

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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

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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

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Jan 05, 2022 Step #167 Install elevator counterweight - (4 hours)

Category: Final (X)

Installed counterweight as per Assy. manual

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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.

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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!

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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.

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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..

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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!

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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.

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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.

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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.

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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

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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.

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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.

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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.

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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

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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.

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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.

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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

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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!

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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!

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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.

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$gallery thumbnail$

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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

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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.

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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

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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.

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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!

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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

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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.

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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!

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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!

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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!

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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.

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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.

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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.

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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!

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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!

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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.

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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.

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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!

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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.

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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.

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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.

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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.

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Aug 10, 2021 Installed tabs for glare shield support - (1 hour)

Category: Final (X)

Installed support tabs for glare shield.

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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.

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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.

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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??

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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!

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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

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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.

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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!

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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!

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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.

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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.

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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.

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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.

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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!

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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!

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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.

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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.

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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.

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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!

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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!).

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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!

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Apr 06, 2021 Remote mount devices - (3 hours)

Category: Avionics

Finished up mounting the TWC battery back-up, GAD 27, and installed all connectors to look for any interference issues. Also mounted master and starter contactor and shunt. Had to move GAD 29 back a little as the clearance was too small with the connectors installed.

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Apr 03, 2021 Avionics Design and Install - (15 hours)

Category: Avionics

Lots of computer work this week with the design of the rest of the avionics. I made the final decision to NOT use ECB's and stick with the normal pull breakers. I had reviewed the ECB option (Vertical power) a while back but wanted to review it again to make sure I did not want to go that direction. Its tempting because it simplifies the install and wiring but I don't like how I am tied to a a system that is dependent on working with Avionics manufacturers to program the breakers. If VP should go out of business I would be stuck with a system that is not supported. Using pull breakers makes the install a little more complicated but the technology is proven.

I ordered all of the breakers, switches, and wire (most of it) this week from three different suppliers (ACS, DigiKey, and B&C). I double checked all of my amp draws and panel design prior to orders...which took a lot of time.

I'm also reading AeroConnections and Aircraft wiring books to help fill in the gaps. I'm trying to use the KISS approach and don't want to spent a ton of time building schematics within Autocad. I'm using ones that already exist as red-lining them. The circuits are pretty simple and the G3X manual has all the pinout data that i'll use when I start the actual wiring.

I also received the AutoPilot install kit from Glasair this week so I installed this kit sans the actual connection to the cables...which I'll wait until I mount the elevator and wings. This was a nice kit and saved me some design time and ordering parts from various suppliers.

I have all of the remote devices now and will finish up installing them this weekend, I plan to have the panel design and hopefully most devices mounted in the panel by the end of next week. Then...I can start wiring!

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Mar 25, 2021 Avionics design and install - (25 hours)

Category: Avionics

Another productive few weeks but more of the time was spent on design work vs. building. I created DXF files from CAD drawing obtained from another Sportsman Builder (Thanks Dan Lodge). My layout is going to be different so the outline of the center panel was correct and the G3X but I had to measure and redesign the other cutouts. I sent them to a company called ‘SendCutSend' and they turned them around very quickly. I made the inserts out of 6061 .063” and I'm really happy with the center one. The Left panel insert had holes here I thought I had deleted them but they must have been imbedded into another layer that I missed. I used the left panel as a patter then made my own. I also made my own Right insert panel. The 6061 is much more brittle than the other aluminum I've been working with so grinding took more effort.

Today I finished all the cut out for the panel and cut all the openings for the avionics. That Carbon is difficult to cut and makes a mess. I tried using my oscillating cutter but it was chipping the paint and leaving a jagged edge. Used the dremel cutting disc and it worked well but makes a mess.

I need to make some decisions on nutserts size. I don't like the smaller size included with the panel kit. 6-32. I'm going up to at least a #8.

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Mar 14, 2021 Avionics Install - (20 hours)

Category: Avionics

It's been a few weeks since I updated my build log! I have been finishing up little odds and ends with the engine install and have now moved on to the Avionics install. I've spent hours upon hours researching (since last year) the avionics package I want in the Highcountry Sportsman and finally decided on the following Avionics Package:

Garmin G3X with GNX375 GPS Navigator.
G5 Back-up
GTN 255 Comm/NAV
GTR200 COMM#2
507 Autopilot
GMA 245 Audio Panel

This seems pretty simple but there are so many decisions to make when designing the Avionics components. All items were ordered via ACS after talking with multiple sources. Avionics arrived over the past few weeks along with the Glasair Factory panel and glarisheild. I'm very pleased with the panel and glairsheild as these will help make the panel look very professional.

I've also been working on the various switches, breakers, and dimmers, etc. that all go into the panel. It can seem a bit overwhelming at times but just like building the wings....take it one step at a time!

I started to build the avionics trays and mounting the remote equipment this weekend so the install has begun. I need to order a few more small items but the majority of the $$ is done (at least I think so!).

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Mar 02, 2021 Exhaust System install - (4 hours)

Category: Final (X)

Installed exhaust system 4:1 Glasair with no issues. I did purchase Blo-Proof gaskets based on recommendations from the GAOA. Installed EGT probes and the only thing left is to install the scat tube for the heater.

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Feb 21, 2021 Baffling install - (3 hours)

Category: Final (X)

Finished u Garlock trimming and install with both LWR and UP Cowlings. Still need to tweak the LH plenum Garlock just a little but its 98% done! I am missing the Magneto ports and tubing....I'll see if I can add those to the order from GA prior to it shipping this week. Even though I am not using traditional Magnetos, I still need cooling tubes based on the installation instructions from E-Mag

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Feb 20, 2021 Baffling install - (2 hours)

Category: Final (X)

Worked on cutting and fitting Garlock to conform to LWR cowling. Instructions and pictures were good but should have cut my own slots in the Garlock where needed vs. looking at pictures in TWTT. All worked out good but trying to guess on exactly where the cut needs to happen just made it more complicated. Install the LWR cowling and slot as needed where the material binds.

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Feb 19, 2021 Baffling install - (2.5 hours)

Category: Final (X)

Continued to install Garlock around plenum. Measurements in TWTT instructions were pretty much spot on! Trim, drill, rivet...repeat.

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Feb 17, 2021 Baffling install - (1.5 hours)

Category: Final (X)

Trimmed front plenums to meet 3/8” - 1/2” clearance requirements. I'm getting better at taking on and off the cowling by myself!

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Feb 16, 2021 Cowling install - (5 hours)

Category: Final (X)

Finished the cowling install this afternoon. All went well with installing nutplates. I need to figure out the trick to installing the lower cowling by myself. Its a little tricky to manage everything. I'll fix the left intake opening when I get into the fiberglass work as there is a pretty big gap between the upper and lower cowl. Its a tight seal but just looks bad. Nothing a few layers of fiberglass cloth strips won't fix. Center line seems pretty good with the wooden spacer plate off. Maybe a 1/8” one way or the other but I don't see any interference issues.

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Feb 14, 2021 Cowling Install - (8 hours)

Category: Final (X)

I must have been blessed by the cowling fairies or something as the install went pretty easy! I installed the oil access cover yesterday (Saturday) and worked on aligning the cowlings. Mounted them together according to the TWTT instructions (not the installation instructions) and used a lever to push the cowling up against the joggle in accordance with the installation section (Step 4). You need to use both the TWTT and Cowl Installation instructions....IMO. I met all the criteria in Step 4 so I did not add any additional fiberglass. Set the spacing laterally and longitudinally from the spinner center line. Since I knew my spacer fixture is not really “round” I measured the centerline and worked off that for all measurements. Drilled, then upsized to 3/16” and countersunk all holes except as noted within instructions. All-in-all..I'm really happy with the fit. I have to holes one firewall that are too close to a rivet so I'll need to remove the rivet and set the nutplate....solvable issue.

I also need to cut the trike access slot a little bigger. TWTT = 5/8” Cowl instructions = 1/2”. The Cowl instructions are correct.

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Feb 12, 2021 Prop ordered - (1 hour) Category: Propeller

Prop is on order from Hartzell. Went with a 74” Blended Airfoil blade w/ constant speed. Due 5/13/2021

Feb 12, 2021 FWF Hose install - (2 hours)

Category: Final (X)

Finished up running the MAP sensor hose; fuel pressure hose, and started to figure out E-Mag MAP hoses from #4 cylinder. -3 Hose assembly went great.

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Feb 12, 2021 Cowling Install - (1.5 hours)

Category: Final (X)

Finished making prop spacer fixture. Hard to get it perfecting round but it will work well for establishing the cowling distance.

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Feb 10, 2021 Cowling install - (2 hours)

Category: Final (X)

Unpacked the cowling and read installation instructions and GAOA for tips. Started to make fixture for prop hub to establish cowling spacing. Made my own restricted orifice using the tip from Kitplanes! Worked out great even without a lathe. Drill #60 orifice for manifold pressure sensor.

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Feb 08, 2021 FWF Hose install kit - (2 hours)

Category: Final (X)

About finished up all the hose installation for the FWF. Waiting on -3 mandrel so I can finish up the sensor hoses and I also need to figure out the manifold pressure set-up as I think I need pressure to the P-Mags as well. I am waiting to run these hoses until I do more research.

I am going to mount the cowling next!

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Feb 07, 2021 FWF Hose install - Cont'd - (4 hours)

Category: Final (X)

Good day of finishing up the baffle install and picking back up on the fuel line install. Fiddled with the Fuel Flow sensor install for a while and have it installed. Went to install the dipstick for the engine to check for any interference issues when I run the fuel line back up to the input of the injector distribution module and could not get the dipstick to screw in easily. Not sure if its just supposed to be really tight but it feels like I could easily strip the plastic threads on the holder. Going to wait and make sure I have the right dipstick with my engine.

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Feb 07, 2021 Install Baffling - (15 hours)

Category: Final (X)

I switched over to working on the Glasair Baffling kit and the install went pretty well. The kit was complete and instructions pretty clear (TWTT Step 3900). There are differences between the “Baffling kit” instructions and “TWTT” instructions so I chose to use the most recent version, which happened to be the TWTT. Keep in mind that these Baffle kits are made to work with a variety of engines so be sure to use the TWTT instructions that are for your engine (IO-390 in my case). The sequence of the TWTT instructions is the best sequence, IMO.

Lots of trimming and fitting as you go and the accessories you use will require different mods than shown. I am using a B&C Alternator and Skyteck Starter so it was pretty close to the TWTT. The LH Plenum part was a little tricky to figure out but I waited to cut it until I had temporarily mounted the upper part of that plenum.

I'm not 100% done with the baffling but am stopping at this point to tidy up the hoses and figure out the next steps on the Cowling install as I'm going to need the cowling installed to cut the seals....and I don't want the seals on while I try to install the cowling.

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Feb 07, 2021 FWF Hose Install - (8 hours) Category: Final (X)

Wow...I am getting behind in my Log updates! Once the engine was installed I started on the FWF hose kit install kit from Glasair. There were a couple of surprises. 1st, I thought that all the hoses would be assembled but nope...you need the -3, -4, -6 aeroquip mandrels to install these. Luckily, a local builder had a -4 and -6 that he let me borrow. I also discovered that the kit BOM and the kit TWTT and installation instructions are not correct. I spent time fixing the BOM issues and email Brian @ Glasair and he responded very quickly shipping the missing parts ASAP.. Here are the list of items that you'll need incase someone is reading this and wanting to use the Glasair FWF Hose kit:

I'm going to reference the Kit Instructions (063-09064-01) for the missing items listed below:

The kit instructions reference BOM 039-04660-01 but the BOM that was sent with my kit (and parts were picked from) is 039-07100-02. Not sure if this is the cause of the problem but wanted to note it just in case.
Step 3 (page 6) – I am missing P/N 320-0700-782. This was not included with the engine or the BOM.
Step 4 – (page 7) – I am missing P/N 320-0700-783. There is a -6 fitting in the outlet of the mechanical fuel pump but no “tee” in the kit.
Step 4 – (page 7) – “Remove the .017 diameter restricted orifice fitting from the flow divider “spider” on to of engine. Plug this hole with an AN932-25 plug. Install the restricted orifice fitting on the tee fitting on the left side of the mechanical fuel pump.” I cannot find any such fitting on the “spider”. All extra holes already have a plug and the any only fitting is the fuel inlet -4 hose on the “spider”. Maybe this is something old? Either way…..do I need to install a restricted orifice fitting? If so, I need one.
Step 9 (p. 16) – Missing 320-01400-02 Restricted orifice fitting .017
Step 9 (p. 17) BOM only calls out (1) 450-0190-004 SS clamp but it should be qty. 2. I received one. If you don't have any in stock, please don't worry about ordering as I can pick one up from the hardware store…just highlighting as a BOM error.
Step 10 (page 20) – AN840-4D is not in the BOM…thus it was not included in the parts…but is needed for the Vent line from the mechanical fuel pump.
Finally, the -12 fire sleeve quantity in the BOM is not correct. Assuming we don't put fire sleeve on the oil hoses or manifold hose, the kit needs at least 64” of -12 (3/4”) and the BOM is calling for 36.75”.

Parts received quickly and I'll finish up the hoses this week.

Jan 23, 2021 Engine install - (25 hours)

Category: Final (X)

Had a very productive week installing the engine and accessories. Once I completed the installation of the Firewall on Friday I was able to borrow an engine hoist from a local builder so it was time to install the engine. I spent considerable amount of time checking and double checking the firewall components to figure out what I was missing. I connected the fuel boost pump and all associated lines, oil cooler, and reinstalled the engine mount and nose gear.

Once I torqued all the engine mount bolts I realized the one thing I forgot was the grounding wire....dang. I'll have to replace the bolt when I take it out...

Engine install went pretty well but was a little tricky to get the last bolt in. I did not want to force anything so I just took my time and wiggled the engine a bunch, over a 2 hour period, and finally got them all in. I started to torque the bolts but noticed my torque wrench was not clicking.....so I kept torquing. After some investigation I realized my torque wrench is broken....darn. I bought a new one this week and sure enough..I over torqued two of the engine mount bolts. I ordered new ones on my weekly ACS order and will replace.

Installed the B&C Alternator, Avstar induction system, and started on the FWF hose kit from Glasair until I ran into a few errors with parts in the kit. I am missing a few fittings that I'll check with them on next week. I also need to track down mandrels to make my aeroquip hoses.

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Jan 15, 2021 Step 5 - Fasten FW to fuselage - (6 hours)

Category: Final (X)

Added Chafe tape to frame where it will potentially connect with FW as per Assy. instructions. Drilled all FW penetrations and heater holes. Installed Orcotek and taped with Orcotape. There is a kit from GA P/N 830-0102-017 that includes the Orcotek and tape needed and is much cheaper than ACS. Seam sealed everything with 3M Fire Barrier 2000+..which was most recommended on the Vans forum. Installed GA Firewall fitting p/n 101-00510-01 (three places) and sealed with 3M fire barrier. I'll let everything cure overnight then install in the morning.

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Jan 14, 2021 Prep for Firewall install - (3 hours)

Category: Final (X)

Finished all tasks that needed complete prior to installing FW. Rudder pedal brake pivot bolts needed to be longer AN3-7 instead of AN-6 as noted in assy. Manual. Ensured all routing of brake lines were correct. Tweaked covers a little more and installed boost pump plate. Also spent time measuring FW penetrations on N917X so I could drill prior to installing FW.

Large shipment arrived from Glasair so I can move forward with finalizing installation of FW.

Also received my tuned exhaust from GA along with resin materials.

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Jan 13, 2021 Fuel Line Tweaking (RH side) - (2 hours)

Category: Final (X)

Completed fuel lines on RH side of fuselage. The only fittings not tight are the ones going into the Newton control valve and into the boost pump..which will be secured once the Fire Wall is installed.

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Jan 12, 2021 Fuel Line Tweaking - (3 hours)

Category: Final (X)

I have been working on fine tuning (tweaking) the fuel line a they connect to the Newton fuel valve and the routing under the (and next to) the forward pulley cluster. Its tight and not much room to maintain the minimum 3/8” from any moving cables. BUT...with some perseverance and patience, I was able to get everything just right. I am really taking my time with these fuel line. Last thing I want to worry about when flying is a fuel leak in the cabin. I did rebend the tubing from the drain to the union on the LH side.

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Jan 05, 2021 Install Sportsman Latch kit - (3 hours)

Category: Final (X)

Finished installing latch kit on LH door and temporarily fit the doors. I will wait until the engine is hung to actually drill the door hinges.

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Jan 04, 2021 Install Sportsman Latch kit - (2 hours)

Category: Final (X)

Finished latch kit on RH door...turned out really nice.

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Jan 03, 2021 Install Sportsman Latch kiy - (2 hours)

Category: Final (X)

Started working on installing the latch kit on the main doors

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Jan 01, 2021 Chafe wrap brake lines - (1 hour) Category: Final (X)

Installed chafe wrap on brake lines. All of this minor stuff is much easier prior to mounting engine :-)

Jan 01, 2021 Safety wire gascoalator - (1 hour)

Category: Final (X)

This will only get easier and less bloody! Poked myself twice...ouch! After a couple of attempts and watching the EAA video: https://eaa.org/Videos/Hints-for-Homebuilders/Hardware-Cable-and-Safetying/6042446338001

...it was much better.

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Dec 31, 2020 Final trimming on Firewall - (1 hour) Category: Final (X)

Spent some time making final trimming adjustments on Firewall. Waiting on Insulation prior to installing....sort of held up at this point so I'm going to move forward with finishing up a few items in the cabin.

Dec 29, 2020 Moved wings to Hangar - (4 hours)

Category: Workshop

Borrowed trailer and moved wings to the hangar with the help of Lori. All went smooth and no road rash!

Made a bracket to keep them from moving side ways and denting the trailing edges

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Dec 30, 2020 Installed exit ramp on Firewall - (1 hour)

Category: Final (X)

If you use the TWTT Step 1700 instructions you'll see that you should install the exit ramp at this time. I pulled this piece from the Baffle kit and installed nut plates as instructed. This would be a PIA to install later!

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Dec 28, 2020 Installed Gascoaltor - (2 hours)

Category: FWF (X)

Installed as per Oil Kit instructions

Will wait to RTV and mount bracket once Engine has been mounted.

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Dec 27, 2020 Sportsman Oil Cooler Installation - (3 hours)

Category: FWF (X)

Started the installation of the Sportsman Oil cooler system. Followed directions fro 063-09018-01; High Efficiency Cooler Shroud Kit 039-09010-01; TWTT Task 2400.

Everything went together nicely. I'm so glad that I purchased this accessory kit.

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Dec 26, 2020 FWF parts reserach - (5 hours) Category: Research

Spent time today sorting out all the parts I need to move forward on the engine installation.

Dec 25, 2020 Step #4 - Rivet firewall assembly together - (3 hours)

Category: Final (X)

Went as expected. I've been wondering where I use the stainless steel rivets! They actually riveted nicely. I had to trim some more off the FWD side of the Firewall when I checked the fit after everything was riveted.

Now I need to order the Firewall insulation so I'm going to set this aside for a bit and work on cleaning up all the brake lines and fuel lines....then its time to mount the engine!!!!

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Dec 24, 2020 Step #3 - Fit Firewall to Fuselage and drill Engine mount bolts - (1.5 hours) Category: Final (X)

Clean and deburr. This stainless steel is tough stuff! I had to trim some more off once I riveted the flanges. Not sure how this measurement was off but apparently I did not have the flanges pushed all the way into the cowl when I measured the amount I needed to trim off the front of the Firewall.

Dec 23, 2020 Step #3 - Fit Firewall to Fuselage and drill Engine mount bolts - (2.5 hours)

Category: Final (X)

Drilled all holes for side flange, upper and lower flange

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Dec 22, 2020 Step #3 - Fit Firewall to Fuselage and drill Engine mount bolts - (.7 hour)

Category: Final (X)

This seemed easy.....especially with a helper to drill the #19 holes on the lower part of the firewall.

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Dec 21, 2020 Step #2 - Fabricate FW components - (5 hours)

Category: Final (X)

Made template and cut firewall from stainless steel sheet provided in the kit. Lots of measuring, trimming, and fitting. Started making the flanges as well. Got sidetracked investigating the Orcotek material.....that stuff is expensive!! See TWTT Step 1700 for helpful examples of building the firewall.

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Dec 22, 2020 Step #2 - Fabricate FW components - (2 hours)

Category: Final (X)

Went as planned. SS is much more difficult to work with than aluminum! All side and top cut and ready for next step

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Dec 20, 2020 Step #2 - Fab firewall components - (1 hour) Category: Final (X)

Removed Trike gear and engine mount

Dec 20, 2020 Step #1 - Fab & install instrument panel brakets - (1 hour)

Category: Final (X)

Done as per instructions.

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Dec 20, 2020 Step #115 - Route fuselage pitot ine - (3 hours)

Category: Systems (IX)

Work on sorting out all the parts for the Pitot/static system options. Started this install yesterday and completed it today. Since my wings are not installed I am going to wait to install the pitot lines to the drain and forward. I also installed the static ports and will wait to install these until the avionics are installed.

Yea!!! Done with another section! I am going to wait to install the antenna and associated wiring once I determine panel and verify on N917X.

Now its on to the Final Assembly section (again) and start to mount the engine.

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Dec 19, 2020 Step 102 - route brake lines and install parking brake - (1 hour)

Category: Systems (IX)

Did not like the way the nylon line was running to the brakes. I checked out N917X and the reservoir is mounted on the LH side just aft of the Firewall. I like that installation so I made mine more permanent and used adel clam to finish the installation. Sometime the easier tasks take longer...but I like it now!

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Dec 18, 2020 Step 102 - route brake lines and install parking brake - (1 hour)

Category: Systems (IX)

Finished routing brake line to reservior

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Dec 17, 2020 Step 102 - route brake lines and install parking brake - (2 hours)

Category: Systems (IX)

Continued brake line install and worked on where to locate the brake line reservoir. The original one that came with the kit was already cracking so I ordered a new one. I finished up the install of the parking brake too.

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Dec 16, 2020 Parking Brake option install kit - (2 hours) Category: Systems (IX)

Installed parking brake option that I sources myself from Matco. This was not a huge deal and I followed the instructions provided by GA.

Dec 15, 2020 Step 101 - Route brake lines from calipers to Master cylinders - (2 hours)

Category: Systems (IX)

Parts from JEGs arrived so now I could return to the braided brake line install and finish this system up. All of the lines and fittings ordered worked out nicely. They were easy to assemble and quality seems good. I guess we'll find out when we charge the system and use the brakes! Started installation of the parking brake

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Dec 14, 2020 Theme

Category: Paint / Decals

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Dec 13, 2020 Step #108 - Route Fuel Lines to fuel selector valve - (4 hours)

Category: Systems (IX)

Continued to work on the fuel line routing and modifications needed for the Newton Fuel valve. I did confirm with GA that I have the correct boost pump. Brian sent me pictures of where they are currently locating the fuel selector valve (which is way far aft than the 19” described in the TWTT instructions). Some minor trimming and cutting still needed but almost done with this section. I need to order more adel clamps so I'll wait until I have them on all in to finish up the routing. Now on to the brake line install.

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Dec 12, 2020 Step #7 - Install Brake Master Cylinder - (2 hours)

Category: Systems (IX)

Returned this step since I got in the new Matco clevis connectors. I can't remember by I cut the ones short in the first place but they were too short and I needed to order new ones. Got them in and finalized the install of the master cylinders on both pilot and co-pilot side. Also installed fittings for flex hoses. I need more thin washers then will add cotter pins

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Dec 12, 2020 Step #107 + 108 - Run fuel lines from headers to shut off vlave - (4 hours)

Category: Systems (IX)

Worked on this off and on this week. Since I am using the Newton valve I have a few new issues. When I went to run the fuel line from the drain valve to the selector valve I found the Boost pump is not going to give enough clearance. Since I purchased the boost pump directly from GA I am guessing its the same as they use on the TWTT. I sent an email to GA engineering for clarification prior to engineering my own solution. Complete the RH fuel line routing from the header to the drain and the section directly after the drain. I'll have to wait to figure out next steps on boost pump prior to moving forward on my fuel lines:

Header - Drain = 35”
Drain - coupling = 38”
Coupling - Selector Valve = 39”???

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Dec 06, 2020 Step #106 - Mount header tanks and route fuel lines from drain - (2 hours)

Category: Systems (IX)

Purchased 3/8” copper to make templates with and I sure am glad I did. There are a lot of bends on the fuel lines. LH Header is plumbed from tank to drain.

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Dec 06, 2020 Step #106 - Mount header tanks - (1 hour)

Category: Systems (IX)

Installed as per instructions that were in the header tank kit. Since I will have the newer door hinges the install was a little cleaner than the assy. Manual shows.

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Dec 04, 2020 Step #105 - Install the drain valve - (.5 hour)

Category: Systems (IX)

I was able to install the pilot side drain valve but am waiting to finish the install of co-pilot as I needed a reducer bushing that is on its way from ACS. I purchased another swagelock tee as well for the co-pilot drain. Since I will have individual fuel lines (left and right) from each header tank I needed two drain valves instead of one.

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Dec 04, 2020 Step#104 - Drill drain valve holes in fuselage floor - (.2 hour)

Category: Systems (IX)

Did it pretty much the same but used a 7/8” hole saw because I did not have a 11/16” hole saw. Worked out fine

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Dec 04, 2020 Step #103 - reinforce drain valve mounting area - (.2 hour) Category: Systems (IX)

After inspecting N917X (TWTT) build they used a backing plate so I did the same thing.

Dec 03, 2020 Step #106 - Mount header tanks and route fuel lines from drain - (1 hour)

Category: Systems (IX)

Pressure tested both header tanks and no leaks.

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Dec 03, 2020 Step #103 - Reinforce drain valve mounting area - (2 hours) Category: Systems (IX)

Screech! Since I am installing a Newton fuel valve I'll need to have two fuel drains, one on the pilot and the other on the co-pilot side. I spent time determine which parts I need and working on the fuel line locations. This is where all these little details start to take more time!

Dec 03, 2020 Step 100 - install fittings in master cylinders - (1 hour) Category: Systems (IX)

These will come out when I get in the AN fittings

Dec 02, 2020 Step #99 - Install fittings in caliper assemblies - (3 hours) Category: Systems (IX)

I'm going to use all braided teflon tubing for the brakes and not the standard nylon tubing. Spent time calculating the necessary length, fitting. Placed order with JEGs for all parts. I'll return to this once the order arrives.

Dec 01, 2020 Step #86 - Check strut alignment - (.5 hour) Category: Systems (IX)

Meets spec in assy.manual. This will need to be rechecked once engine is mounted.

Dec 01, 2020 Step #85 - mount nose wheel axle to nose fork assy - (2 hours)

Category: Systems (IX)

Whoops...the Tundra fork that I received seems to have an issue with the two axle bolt bushings. They are not drilled perpendicular to the flange thus not allowing the bushing to sit flush on the outside fork flange. I put on the stock fork and I'll work with GA to resolve the issue. Still pretty cool to have the entire plane on its gear!

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Dec 01, 2020 Step #84 - Mount nose wheel fork to strut axle - (.5 hour) Category: Systems (IX)

Dec 01, 2020 Step #83 - Install shock bushings on truss - (.5 hour) Category: Systems (IX)

Nov 30, 2020 Step #82 - Mount Nose Strut to firewall - (.5 hour) Category: Systems (IX)

Went as expected

Nov 30, 2020 Step #81 - Mount shock truss to engine mount - (1 hour) Category: Systems (IX)

Had to mount the engine mount first. I am thoroughly impressed by the engineering and quality of this kit. The engine mount is near perfect and bolts slid right in.

Nov 30, 2020 Step #80 - mount tube and tire on nose wheel - (.5 hour) Category: Systems (IX)

I will only use this tire and wheel for building. Upgrading to Tundra fork prior to first flight

Nov 29, 2020 Step #79 - Mount the brake calipers - (2 hours)

Category: Systems (IX)

The technology is so simple on these disc brakes. After they were all mounted I spent some time removing the wing laydown work benches and taking them apart. I reorganized the workshop so I can work on the cabin and engine where there is good light and heat.

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Nov 29, 2020 Step #78 - Mount Wheel on Axles - (1 hour) Category: Systems (IX)

This was a HUGE milestone for me. It took minutes to mount the wheels but I spent a hour just looking at the plane on wheels ! So cool!

Nov 29, 2020 Step #76 Mount tubes and tires on main wheel - (1 hour) Category: Systems (IX)

I will not be using these tubes and tires for anything other than building as they are from 2006...too old for me to trust my life on. I'lll add bigger tires as I get closer to the test flight.

Nov 29, 2020 Step #75 Install brake torque plate and wheel pant mounting brakets - (.5 hour) Category: Systems (IX)

I will not be installing wheel pants so this step was pretty easy

Nov 29, 2020 Step #74 - Install Brake Mounting flanges - (2 hours)

Category: Systems (IX)

Wow...much less work and more accurate using the drill press. Took a little while to build a fixture to hold the gear but after about a 1/2 hour I had one figured out and it worked well.

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Nov 28, 2020 Step #74 - Install Brake Mounting flanges - (1.5 hours) Category: Systems (IX)

Finished drilling and mounting the brake bracket on this side. I think I'll give the drill press a try on the RH gear!

Nov 27, 2020 Step #74 - Install Brake Mounting flanges - (3.5 hours)

Category: Systems (IX)

I thought I was getting off easy with the drilling of these legs but I was wrong! The gear strut is hollow at the top where I drilled yesterday. The gear strut is solid hardend steel (1.25” diameter) and this was much more difficult drilling. This is where a second person would be helpful just to keep cutting fluid on the drill bit. I didn't want to remove the leg from the socket so I drilled the LH brake mounting brackets by hand. This was difficult drilling but not impossible.

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Nov 27, 2020 Step #73 - Drill and Bolt Main Gear legs - (4 hours)

Category: Systems (IX)

Purchased cobalt drill bits (3/16; 11/64; 5/16) and started to drill. I used my old corded Makita drill and it worked great. Went through lots of Majic Tap oil too. This was not too difficult but did take patience. I drilled these by myself and keeping an eye on the direction of the drill was not difficult. Total drill time as around 2 hours....the other 2 hours was buys drill bits!

I reviewed the SB# 8 about replacing the bolts with NAS. I will do this later as I'm guessing I'll be removing the legs again at some point for some reason!

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Nov 26, 2020 Step #72 - Insert and Position the Gear legs - (4 hours)

Category: Systems (IX)

Whew....these were really tight...which is what you want. I had to buy a small brush hone to clean out the sockets. I also spent some time polishing the gear strut a well. With some grease and lots of pushing, they are in and aligned as per the instructions.

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Nov 25, 2020 Step #71 - Support and level the fuselage - (2 hours) Category: Systems (IX)

I was able to level the fuselage on the stilts with plenty of room between the vertical fin and ceiling of the garage. I had at least 6 inches!

Nov 24, 2020 Moved wings...set-up workshop for Fuselage - (3 hours)

Category: Workshop

Moved the wings off the laydown table and put them in their holder. I'll move them out to the Hanger for storage at some point. Kept the laydown tables together and moved the Fuselage over the table. I was able to pick up the front myself but damn...that was heavy. Had to remove the rudder as I'm not 100% sure about how high this is going to be. Also worked on general cleaning and organizing in the workshop.

I made stilts for the mini legs so the Fuselage would not sit on the fiberglass for too long.

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Nov 23, 2020 Step #76 - install fuel caps - (1 hour) Category: Final (X)

Went as planned. Allowed to cure for 24 hours.

Stopped at Step #83 - install main fuel line fittings and hoses. I want to come back to this when I'm ready to mount on the plane.

Nov 22, 2020 Step #78 Rivet inspection hole doublers - (1.5 hours) Category: Final (X)

Why do I have a feeling I'm going to wish I would have waited to install these? That hole sure does get smaller once its installed. I have a feeling when I rig the flaps and ailerons I'm going to wish I had left those off until later!

Nov 22, 2020 Step #82 - Rivet the cove skins and trailer edge - (1.5 hours)

Category: Final (X)

After allowing a 24 hour cure I removed the clamps and angle and all looked good. Had some cleaning to do but nothing too major. Installed Flap to check for movement and it clears all brackets and rivets. There is about 1/8” on the inboard side that will seat in flap track when pulled tightly. I might need to work on the alignment a little when I install these on the plane. For now, its good to go!

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Nov 21, 2020 Step #82 - Rivet the cove skins and trailer edge - (4 hours)

Category: Final (X)

Once lower skins were riveted it was now time to glue the trailing edge with the Loctite H3151. My process was much smoother and I had more clamps so i could glue both the Flap and Aileron coves all at once.

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Nov 20, 2020 Step #82 - Rivet the cove skins and trailer edge - (2 hours) Category: Final (X)

Riveting all the lower skins to the cove skins

Nov 21, 2020 Step #82 - Rivet the cove skins and trailer edge - (3 hours) Category: Final (X)

Nov 20, 2020 Step #80 - Fit trailing edge doublers - (.5 hour) Category: Final (X)

Fit with less splices this time!

Nov 20, 2020 Step #79 - Cut cove skins to length - (1 hour)

Category: Final (X)

Learned my lesson on the RH wing! Much easier to cut these correctly PRIOR to installing

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Nov 19, 2020 Step #77 - connect fuel tank vent lines + aux vent lines - (3 hours) Category: Final (X)

Connected all internal fuel lines, cleaned and inspected each bay.

Nov 19, 2020 Step #75 - Install Fuel tanks and rivet root ribs - (3 hours) Category: Final (X)

Installed Main tank and root rib

Nov 18, 2020 Step #75 - Install Fuel tanks and rivet root ribs - (1.5 hours)

Category: Final (X)

Installed AUX tank and tip rib.

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Nov 17, 2020 Step #75 - Install Fuel tanks and rivet root ribs - (2 hours) Category: Final (X)

Riveted nutserts on access covers...that I forgot to do earlier in the build!

Nov 16, 2020 Swapped wings - (2 hours) Category: Final (X)

Moved the RH wing from laydown bench and put LH wing on laydown bench. Cleaned work area to get ready to complete LH wing

Nov 13, 2020 Glasair Firewall Forward parts arrived - (3 hours)

Category: Final (X)

Unloaded parts and inventoried. This should keep gong on the fire wall forward (FWF) for the winter!

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Nov 15, 2020 Step #76 - install fuel caps - (1 hour)

Category: Final (X)

Went well...I added RV roof rubber seal around the caps...this will provide a better seal between the outside elements and inside the wing.

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Nov 14, 2020 Step #75 - Install Fuel tanks and rivet root ribs - (1.5 hours) Category: Final (X)

Finished tank and root rib install.

Nov 11, 2020 Step #75 - Install fuel tanks - (2.5 hours)

Category: Final (X)

Stepped back in the assy. Steps to complete the fuel tank installs. On the next wing, I am just going to follow the assy. Manual in order. No need to complete coves prior to installing tanks.

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Nov 10, 2020 Step #82 - Rivet the cove skins and trailer edge Category: Final (X)

Wrapping up the clean-up from bonding process. All went well. Need to order another supply of Loctite HH3151

Nov 09, 2020 Step #82 - Rivet the cove skins and trailer edge - (1.5 hours)

Category: Final (X)

Flap coves came out great. Now on to the aileron cove bonding.

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Nov 08, 2020 Step #82 - Rivet the cove skins and trailer edge - (3 hours)

Category: Final (X)

Bonded flap coves....ran out of clamps and straight edge...so I'll bond the aileron coves tomorrow

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Nov 07, 2020 Step #82 - Rivet the cove skins and trailer edge - (1.5 hours) Category: Final (X)

Did not rivet the entire trailing edge....I only did this on each spar...similar to TWTT process. I am also going to bond w/ Loctite instead of rivet the trailing edge. Everything is fitted and ready for bonding tomorrow.

Nov 07, 2020 Step #81 - Fit and drill cove skins - (4 hours)

Category: Final (X)

Lots of measuring twice and drilling once. I took this step slooooow! All went well. Trying to follow the TWTT process along with the ANOR and Assembly manual then triangulate the best approach.

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Nov 04, 2020 Step #80 - Fit trailing edge doublers - (.5 hour) Category: Final (X)

Done

Nov 03, 2020 ANOR - Access covers - (1.5 hours)

Category: Final (X)

Made covers for inboard pulley covers per ANOR

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Nov 03, 2020 Loctite order - (1 hour) Category: Research

Tested out an alternative for gluing the trailing edges of the coves to the wings the other day but I was not happy with the outcome. I sourced and ordered all the Loctite product and equipment I need to glue the trailing edges as per the TWTT and ANOR instructions.

Loctite H3151 w/ gun and mixing nozzles = $80

Nov 01, 2020 Install nutserts on LH wing access panels - (3.5 hours)

Category: Systems (IX)

Got all nutserts installed. Not a huge deal but a little more difficult than with them out

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Oct 29, 2020 Step #79 - Cut cove skins to length - (6 hours)

Category: Systems (IX)

Prep coves for priming. Of all the parts in the Fuselage kit that I purchased these were the only ones that had some water damage on them. I had to use a DA sander to removed the water stains. This went on for a few days worth of work....cleaning and priming.

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Oct 29, 2020 Step #79 - Cut cove skins to length - (2 hours) Category: Systems (IX)

Cut coves to proper length. Cut access hole for pulley.

Oct 25, 2020 Step #75 - Install Fuel tanks and rivet root ribs - (4 hours)

Category: Systems (IX)

Installed tanks and connected lines from aux. pump. Checked location by temp. Installing fuel caps.
Also installed inboard inspection cover...then realized I had not installed any of the nut plates on ANY of the inspection covers....and they are all inside the wings. Luckily, I was able to removed the smaller ones but I had to figure out another plan for the larger ones

I also switched over to the TWTT instructions for this section...so I am not going to be following the steps a laid out in the manual.

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Oct 24, 2020 Step #75 - Install Fuel tanks and rivet root ribs - (4 hours)

Category: Systems (IX)

I never pressure tested my tanks so I spent the afternoon testing all four tank. Both Aux tanks has two minor pin hole on the top of the tank. Repaired with JB Weld

Removed wing from jig. Removed uprights from the jig so I can start the wing lay down steps.

Did I mention how good it feels knowing I'm done putting the wings back in the jig? Its a good milestone.

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Oct 23, 2020 Step #74 - Rivet Upper Wing Skins - (1.5 hours)

Category: Systems (IX)

Finished up all the riveting for the flap and aileron coves. Yeah!!!!! All the major riveting done on the wings. Now its time to remove it from the wing jig and install the fuel tanks.

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Oct 22, 2020 Step #74 - Rivet Upper Wing Skins - (1 hour) Category: Systems (IX)

All Rivets Matter

Oct 21, 2020 Step #74 - Rivet Upper Wing Skins - (1.5 hours) Category: Systems (IX)

Every rivet matters

Oct 20, 2020 Step #74 - Rivet Upper Wing Skins - (2.5 hours) Category: Systems (IX)

Continue to rivet inboard skin w/ Lori the Riveter.

Oct 18, 2020 Step #74 - Rivet Upper Wing Skins - (1.5 hours)

Category: Systems (IX)

Riveted inboard upper LH wing skin...not done yet...still a few more before I can start on the AFT spar riveting.

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Oct 17, 2020 Step #74 - Rivet Upper Wing Skins - (1 hour) Category: Systems (IX)

Started riveting no Inboard upper LH wing skin with Lori.

Oct 17, 2020 Step #74 - Rivet Upper Wing Skins - (1.5 hours) Category: Systems (IX)

Finished riveting Upper Center skin LH wing with Lori

Oct 15, 2020 Step #74 - Rivet Upper Wing Skins - (2 hours) Category: Systems (IX)

Continue riveting Center upper skin - LH wing. Lori is doing great running the Rivet gun

Oct 14, 2020 Step #74 - Rivet Upper Wing Skins - (1 hour)

Category: Systems (IX)

Started riveting Center skin - LH wing

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Oct 13, 2020 Step #74 - (2.7 hours)

Category: Systems (IX)

Finished riveting upper outboard skin LH wing

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Oct 12, 2020 Step #74 - Rivet Upper Wing Skins - (.5 hour) Category: Systems (IX)

Started riveting upper skins

Oct 11, 2020 Step #72 - Cleco upper hat section stiffeners to spars - (1 hour) Category: Systems (IX)

LH Wing - cleco hat sections and final audit of ALL bolts and connections..

Oct 11, 2020 Step #70 - Install wing lighting - (2 hours)

Category: Systems (IX)

Finished all wiring for LH wing. Much more in this wing with the addition of the Pitot / static lines and heater wiring. All of it fit through the flex conduit. Took pictures of each bay to document what was completed. I'll let the RTV setup then inspect everything one more time prior to riveting the upper skins on.

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Oct 11, 2020 Step #69 - Install pitot tube and line - (2 hours)

Category: Systems (IX)

Completed installation of Pitot / Static line and associated heater wiring. All went well. Used Swageloc fittings instead of flare fittings.

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Oct 08, 2020 Step #? Mount LH Wing in Fixture, level - (2 hours) Category: Final (X)

Leveled LH wing in fixture. Make punch list of final wiring that needs to be run prior to installing upper skins

Oct 08, 2020 Step #74 - Rivet Upper Wing Skins - (12.5 hours)

Category: Final (X)

Worked on riveting top skins on RH wings for the past few weeks. Lori was great on the rivet gun. Many of the rivets were pretty sporty and required some interesting solutions. Very happy with final product. We moved the RH wing out of the jig and replaced it with the LH wing. I'll return to the tank install once we get the LH wing done. Still on track to have both wings done by end of October.

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Sep 20, 2020 Step #72 - Cleco upper hat section stiffeners to spars - (1 hour) Category: Final (X)

Done...don't forget to install the stiffeners at this time too! There is nothing in the directions telling you to do this and it could easily be overlooked.

Sep 20, 2020 Step #73 - Drill Flap Track Rib Rivet holes Category: Final (X)

Already did this when I made the flap track brackets

Sep 20, 2020 Step #74 - Rivet Upper Wing Skins - (5 hours)

Category: Final (X)

Feels good to be back riveting the wings! Lots of inspecting prior to actual riveting as I want to make sure everything is completed and ready. I ALMOST forgot to tape the inspection plates on the inside of the LWR wings so I can rivet them in when I'm done. Not sure how one would fit them back in there if they forgot.

Had to experiment with different ways to keep the wing skin folded back to reach the FWR rivets. Worked pretty well but that is hard to reach. This is when I wish I had a 2x rivet gun instead of 3x.

Outboard RH skin is done.

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Sep 19, 2020 Step #70 - Install wing lighting - (2 hours)

Category: Systems (IX)

Received my flexible conduit and was able to finish installing the wing wiring. I was going to mount the Garmin GMU 11 in the RH wing but after consulting with experienced builders on the forum and checking in with Brian at GA, the consensus was to mount it behind bulkhead A 12 - 20” aft in the fuselage. I took the example from Vans builder forum for mounting the conduit and drilled a 7/8” hole in a few of the ribs and ran the conduit through them. Used RTV to lock them in place. Worked out well and looks professional and functional. I also a “pull string” in the conduit for future runs, if needed.

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Sep 18, 2020 Set-up wing jog - (2 hours) Category: Workshop

Worked on setting up wing jig to remount the wings for their final assembly. Lori helped me put the wings back in them. All went well.

Sep 15, 2020 Step #61 - Fit the Fuel lines - (1.5 hours) Category: Systems (IX)

Done..

Sep 15, 2020 Step #60 - Install vent & fuel line fittings - (1.5 hours)

Category: Systems (IX)

Completed for the RH wing. Followed same logic as TWTT venting and how I ran the lines on LH wing. I'm not sure why you would not go ahead and seat the Swageloc fittings now then reseat when you install the tanks. I went ahead and seated all fittings with the exception of the auxtank fittings. I guess I'll find out if this was a mistake!

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Sep 13, 2020 Step #67 - Drill the inspection hole doublers - (1 hour) Category: Systems (IX)

Drilled and taped together. I did not prime the doublers.

Sep 13, 2020 Step #64 - Route transfer pump wiring - (.5 hour)

Category: Systems (IX)

Done

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Sep 13, 2020 Step #63 - cut filler neck opening in upper outboard wing - (1 hour)

Category: Systems (IX)

Yea! Last hole to cut in the wings. This always makes me nervous cutting holes the skins. This was one of my best ones!

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Sep 12, 2020 Step #58 - install bumpers on tank perimeter - (.7 hour) Category: Systems (IX)

Done....I really like the thicker oil resistant bumper padding that I found. It works well with the black factory bumper too. I used HD double sided tape to secure instead of super glue. Seems to be just as strong.

Sep 12, 2020 Step #56 - Cut hole for Upper Wing skin fuel filler neck - (1 hour)

Category: Systems (IX)

Cut hole in upper skin for main tank

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Sep 11, 2020 Step #59 - Position, drill & rivet transfer pump doubler - (.5 hour)

Category: Systems (IX)

Mounted pump as instructed

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Sep 11, 2020 Step #57 - Position and drill Aux Tank Mounting Channels - (.5 hour) Category: Systems (IX)

Waited to do this step until I had the vent lines run so I only have to remove it once. All went as planned.

Sep 09, 2020 Step #56 - Cut hole for Upper Wing skin fuel filler neck - (1 hour)

Category: Systems (IX)

Measured three time....cut once. Cutting holes in the skins always makes me a little nervous!. Measurements were very similar to the LH wing. All went well with the hole..could have move it just a little bit but I'm happy with the final cut. Have a slight gap on the FWD side of maybe a 32”. Nothing a little RTV caulk cant fix on final assy.

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Sep 09, 2020 Step #66 - Install nut plate for wing support strut - (.5 hour) Category: Systems (IX)

Did this BEFORE installing tank. Saves one more step of removing the tank.

Sep 08, 2020 Step #53 - install bumpers around tank - (1 hour)

Category: Systems (IX)

I made sure that all the fittings and hat sections were all in their proper place prior to installing the bumpers. You will end up taking the tank out a bunch of times and each time the bumpers get a little banged up so I made sure all my mods were done to the outboard Rib #2 for the fittings prior to installing the padding. I'll use the thicker grey material I used on the LH wing for the big gap between the outboard end of the tank and rib #2. I'll let the glue cure prior to installing the tank.

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Sep 07, 2020 Step #55 - Drill holes in root rib for main & return line bosses - (1 hour) Category: Systems (IX)

Holes were already there but I opened them up as needed for proper clearance.

Sep 07, 2020 Step #51 - drill hole in LWR skin for tank sump. - (1 hour)

Category: Systems (IX)

Its always tedious work when drilling holes in the skins. I made sure I took what Learned on the LH to this hole. Get your tank set where you really want it first...then drill the hole. I went ahead and moved to step #55 prior to completing this step. The holes were already in the root rib but I needed to open them up. All went well and I'm happy with the hole locations. I need to clean up the main fuel hole to make it look better but the clearances are good...now I just need to make it round!

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Sep 07, 2020 Step #49 - apply chafe tape to hat sections - (.5 hour) Category: Systems (IX)

I'm going to run out of the anti chafe tape that came in the kit. I'm going to look for an alternative at Aircraft Depot.

Sep 05, 2020 Moved LH wing and RH wing - (1 hour)

Category: Workshop

Determined I can finish the pitot install later so Lori and I moved the LH wing back into its cradle and moved RH wing on to the lay down table. I took a break from Sportsman Building on Sunday and cleaned the belly of 45GV as it was pretty dirty and needed a good scrubbing.

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Sep 05, 2020 Moved LH wing and RH wing - (1 hour) Category: Workshop

Sep 05, 2020 Step #69 - Install pitot tube and line - (3 hours) Category: Systems (IX)

I spent a lot of time sorting out the Garmin GAP 26 AOA/Pitot system. I ordered the GA Pitot option kit a while back and I wish I would have saved my $300. Most of the parts I've had to replace (pitot mast) because the Garmin is different. All of the pitot and static ports on the garmin are 3/16” and the fitting in the option kit are 1/8”. I also spent some time figuring out my wiring run and what type of wiring I'm going to need in the wing for Nav lights and possible wing mounted landing lights. This took some time and I placed and order with ACS for all the miscellaneous fittings, wire, and tubing I'll need to finish the Pitot install and wire runs.

Sep 04, 2020 Step #67 - Drill the inspection hole doublers - (1.5 hours) Category: Systems (IX)

I did not understand why the instructions suggested to drill these from the upper side. I was able to install all the doublers with the covers installed from inside the wing and then drill the holes for the doubler plate. All of my wing skins already had pilot holes drilled around the inspection hole opening so I'm guessing that when the instructions were written the pilot holes were not pre-punched in the skins? Either way...all holes drilled in LH wing. I left them in place until I complete the same step on the RH wing so I can remove them all and prime at the same time.

Sep 03, 2020 Fuel Tank padding - (1 hour)

Category: Systems (IX)

I was not pleased with the padding for the main tank. It could still move from side to side (not fwd & aft) so I added more padding to the double rib. Its secure now! I cut a strip from the flooring material I had laying around. Its oil resistant and pretty firm. I riveted it to the rib a few placed and now the tank is secure! I want to keep the tank as close to the root rib as possible and my drain hole is already cut so keeping it in the same location is critical.

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Sep 03, 2020 Step #66 - Install Nutplate for wing support strut eyebolt - (1 hour)

Category: Systems (IX)

Went easy once I figured out the secret! 1st....be sure to see ANOR for correct location. 2nd ....you will not be able to drill the holes from inside the FWD spar...the holes are too close to the web of the spar. Once you drill out the rivet from the bottom of the wing (outside), then mount the nutplate to the outside with a bolt then drill #40 holes from outside the wing. Move the nutplate to inside spar as shown in figure and mount. I used -6 rivets but -7 would work best.

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Sep 02, 2020 Step # 65 - Drill sump drain hole in lower skin Category: Systems (IX)

Not needed...my lower skins came with the holes already punched so I used them to locate the tank.

Sep 01, 2020 Step #63 - cut filler neck opening in upper outboard wing - (1 hour)

Category: Systems (IX)

Whew...these blind cuts are nerve racking! My measurements worked out well and the hole is pretty darn centered. I'm happy with the hole and flush cap setup.

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Aug 31, 2020 Step #61 - Fit the Fuel lines - (2 hours)

Category: Systems (IX)

Pretty straight forward. I think I'm going to be short some tubing for the next wing but I'm not 100% sure what all the other alumin tubing have in the kit goes to. Anyhow....sorted out the routing and installed according to assy. Manual.

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Aug 30, 2020 Step #4 - Fabricate Rudder Pedals - (5 hours)

Category: Systems (IX)

The fuselage kit I bought from Jory had the ACS Cast rudder pedals included in the kit. Since he had already bought the pedals and I had heard so many bad things about the standard rudder pedals that we fabricate from the kit parts....I plowed on with making my pedals. I had a template from Zach Chase on how to make the bracket...which turned out okay. The area I had issues with was drilling the mounting holes correctly. That is a big span to get just right...even when using a drill press. The castings are angled just enough so you can't drill straight without making a fixture....which I did but the holes are off just a little. I was able to purchase a “scratch and dent” set from GA that are used on the TWTT planes and I love them! Rudder and brake pedals are used a lot and I knew I would not be happy with the ACS ones in the long run. I've spent at LEAST 5 hours messing with the ACS rudder pedals....I spent 30 minutes bolting on my TWTT pedals.

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Aug 30, 2020 Step #60 - Install vent & fuel line fittings - (3 hours)

Category: Systems (IX)

Installed fittings a stated within instructions. Since I'm using the newer 2 vent line system I need to order additional fittings, tubing, and grommets for the RH wing.

Qty 12 - MS35489-6 Rubber Grommet 1/4” x 7/16”
Qty 2 - 320-0250-001 Connector nylon 1/4” x 1/8” NPT
Qty 25 feet - 830-0600-001 Tubing, Nylon, 1/4” OD Type T

Since I am building mine for both Trike and then TD, I need to add quick drains to the low points in the tanks. I'll need to order 4 more if I want to add them now rather than later.

Qty 4 - 320-0344-001 Saf-Air P/N CAV-110 1/8” NPT thread

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Aug 29, 2020 Step #58 - install bumpers on tank perimeter - (.7 hour)

Category: Systems (IX)

Done...I've used 1/2 of my bumper material so I should have enough for he RH tanks

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Aug 29, 2020 Step #57 - Position and drill Aux tank mounting channels - (1.5 hours)

Category: Systems (IX)

Installed correct channels for the FWD spar. Went as planned. BTW.....if you are going to run the vent line in the upper part of the spar you'll want to run it PRIOR to installing the FWD channel....or else you'll have to drill out the rivets to run the vent line....like I did :-(.

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Aug 24, 2020 Step #59 - Position, drill & rivet transfer pump doubler - (1.5 hours)

Category: Systems (IX)

Made both LH and RH doublers and installed LH one. Went as planned.

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Aug 23, 2020 Wing Wiring and vent line routing - (5 hours) Category: Research

Spent some time determining what this issue was and then sending email to Glasair for solution on the aux tank channels. They again solved the problem with out any hesitation. I had to pause on the build for a few days waiting for parts to come in. I also Spent a considerable amount of time trying to solve the VENT LINE Riddle. Geez people...how many ways are there to solve this? I read almost all the options in the GA Forum but many are retrofits to existing vent line issues. I read the SB68 but that was little help as I already knew to drill a small hole in the vent line. After a lot of research and head scratching I decided to go with the TWTT solution. I also spent time trying to figure out what wiring I'll need and also if I should run a conduit for wiring. I'm still not there yet but I have some ideas.....back to building!

Aug 22, 2020 Step #57 - Position and drill Aux Tank Mounting Channels - (2 hours)

Category: Systems (IX)

I've had a few issues with this step. 1st....I riveted the tip ribs onto the lower skin. Nothing was noted in the manual not too nor was there an ANOR for this. Rats....I had to drill out all the rivets (about 12) but since I'm a pro at drilling out rivets it was actually not too big of deal. Flipped the wing over and drilled out all the rivets and did not make any new work!

With the Tip Rib removed I also realized that I have an issue with the channel parts that came in my kit. I have 4 AFT channels and no FWD channels. I need two of each...the part numbers are correct but the parts are labeled wrong. Sent an email with pictures to GA with hopes they can replace them when they ship my rudder pedals....soon. I'll continue as far as I can w/o the channels...still lots to mount inside the wing.

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Aug 22, 2020 Step #56 - Cut hole for Upper Wing skin fuel filler neck - (2 hours)

Category: Systems (IX)

Took my time making sure the fuel tank was in snug and added more padding to the FWD side. Had to purchase a 3” hole saw and my fuel caps came in from ACS. After spending a lot of time measuring and triple checking the center of the hole...I cut and was happy with the fit. Yeah!! A little tweaking of the filler neck with a round wood dowel and everything was flush. I'm SOOOO glad I purchased the flush fuel caps rather than using the JOhn Deer ones.

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Aug 18, 2020 Step #55 - Drill holes in root rib for main & return line bosses - (2 hours)

Category: Systems (IX)

Holes were already in Root rib but needed some enlargement. I continued to work on getting all of the holes lined up and sized correctly. Making minor size adjustments. Also need to add more padding on FWD side of tank. Instructions don't indicate it but you need to temporarily install the upper stiffeners as this will lock the tank in place and Line up the bosses correctly.

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Aug 18, 2020 Step #54 - Make cutout in Root rib for fuel gauge mount - (.1 hour) Category: Systems (IX)

Not needed...holes are already in the root rib

Aug 16, 2020 Step #53 - install bumpers around tank - (.5 hour)

Category: Systems (IX)

Cut down neoprene material and located bumpers as shown in Figure 99. Glued them on with Gorilla Super Glue then taped them so they can cure for a while.

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Aug 16, 2020 Step #52 - test fit upper hat sections - (.1 hour) Category: Systems (IX)

Slide right in. My tanks must be made to spec.

Aug 16, 2020 Step #51 - drill hole in LWR skin for tank sump. - (.5 hour) Category: Systems (IX)

ANOR on this item. I forgot about the ANOR until after but I did exactly what was described. I marked my root rib outboard on the LWR and AFT flanges then located the hole. The measurement on Figure 97 were just about spot on. Hole drilled to 7/8” then opened up by 1/16”

Aug 16, 2020 Step #50 - fit test the main fuel tank - (.1 hour) Category: Systems (IX)

Slide right in! No issues with clearance.

Aug 16, 2020 Step #49 - apply chafe tape to hat sections - (.5 hour) Category: Systems (IX)

Back at it! I've really missed building over the past few weeks but I needed to take some time off to prep for my Commercial check ride..which paid off as I passed my check on Friday (8/14) in terribly smokey conditions as there is a huge forest fire just north of GJT.

Anyhow...above step went as describe. Chafe tape installed and ready for rubbing

Aug 04, 2020 Step #48- Fab and install control cable pulley guides. - (2.5 hours)

Category: Fuselage (VIII)

Took a little break from building to go play in the backcountry. Back at it this week but with school getting ready to start and my commercial check ride in a week, the progress will slow somewhat until the week of August 17th. I finished up installing the control cable pulley guards. I made a little fixture and the measurements came out nearly perfect according to the SB 63.

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Jul 28, 2020 Rearranged workshop for next section..installing fuel tanks in wings - (3 hours)

Category: Workshop

Got everything moved around and put back on dolly's. Even found a nice place to store the engine so I don't have to take it out to the hanger. I think bags of dirt will make nice cushy wing holders!

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Jul 27, 2020 Removed flaps, ailerons, and wings from fuselage - (3 hours)

Category: Fuselage (VIII)

Took off all of the flaps, ailerons, and then the wings. Bought a nice label maker so I could label all the cables for when I reinstall them. Its nice to have this step behind me. I was pretty nervous about setting the dihedral correctly and crimping all the cables. I'm happy with how everything turned out. Now I can set the workshop back up make the garage a little more useful and less crowded.

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Jul 26, 2020 Step #48- Fab and install control cable pulley guides. - (1.5 hours) Category: Fuselage (VIII)

There must be a better way to install these and maintain the tight tolerances per SB. .04 and .05 is pretty darn tight! I'm going to wait to install these when I have the wings off the fuselage. I made all the brackets but it will be easier to measure when there is no tension on the cables.

Jul 26, 2020 Step #47 - Install Cotter Pin cable retainers - (1 hour) Category: Fuselage (VIII)

Seems like this would be an easy task but a few of them needed their heads smashed or they were rubbing the aileron cable.

Jul 26, 2020 Step #46 - Secure Aileron cable guides - (.5 hour) Category: Fuselage (VIII)

Done..used #8 screws where I could not fit blind rivets

Jul 26, 2020 Step #45 - Make Aileron Travel Stop and set deflections - (3 hours)

Category: Fuselage (VIII)

Re-checked all angles and made a few more tweaks. Crimped all NicroPress fittings and finished cutting and shrink wrapping cables

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Jul 25, 2020 Step #45 - Make Aileron Travel Stop and set deflections - (3 hours)

Category: Fuselage (VIII)

This took some time to get everything just right. After lots of adjustments I have everything to spec...I think.

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Jul 25, 2020 Step #44 - Route Aileron Control Cables - (2 hours) Category: Fuselage (VIII)

I opted NOT to pre-cut all these cables as per one of the many SB's. I've been burned before on cut lengths (struts) and I want to actually measure everything. Its not that difficult to fit up and make them the proper length....of course..that's all before I attempt to tension them when I probably realize they are too long and I can't tighten them enough! I pulled them pretty taught prior to crimping.

Jul 24, 2020 Engine arrived!!!

Category: Engine

Yeah.. Lycoming YIO-390_EXP arrived safe and sound!

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Jul 24, 2020 Step #43 - Fabricate aileron cable guides - (.8 hour) Category: Fuselage (VIII)

Done...new band saw blade works much better

Jul 23, 2020 Step #42 - Complete the Flap Cables - (2.5 hours) Category: Fuselage (VIII)

Flaps work!

Jul 22, 2020 Step #41 - Route Flap Retraction cable - (1 hour) Category: Fuselage (VIII)

Jul 22, 2020 Step #40 - Route Flap deployment cable - (1 hour) Category: Fuselage (VIII)

Jul 22, 2020 Step #37 - Mount Aileron to Aileron hinges - (1 hour)

Category: Fuselage (VIII)

This is tedious work...I know I'll be taking it all off again but I want to make sure everything fits well.

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Jul 22, 2020 Step #36 - Install Flap pushrod - (.5 hour) Category: Fuselage (VIII)

Went as expected

Jul 21, 2020 Step #35 - Mount Flap to flap tracks - (.5 hour) Category: Fuselage (VIII)

Went as expected...need to order washer holding tool

Jul 21, 2020 Step #34 Bolt the wing strut to the wing - (3 hours) Category: Fuselage (VIII)

Once I was done with mounting the struts on the wings I noticed that my LH strut was about 5/8” longer than my RH strut. I went back through ALL the measurements to verify that I did not make a mistake. I sent an email to the engineers at GA to confirm my suspicion that the cage is not square thus causing the tolerance stack-up to result in the struts being different....they concurred that none of the frames will be perfectly square and the tolerance stack is normal. This is why you measure the dihedral from the waterline of the plane, not measurements from the frame itself. I was relieved to be over the hum of drilling the wing struts!

Jul 21, 2020 Step #34 Bolt the wing strut to the wing - (3 hours)

Category: Fuselage (VIII)

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Jul 20, 2020 Step #39 - Fab inboard cable guide - (.3 hour) Category: Fuselage (VIII)

Done..installed with #8 screws and stop nut

Jul 20, 2020 Step #38 - Install Aileron Pushrod - (.70 hour) Category: Fuselage (VIII)

Went as expected

Jul 20, 2020 Step #29 - 33 - Drill and cut the wing struts - (3.5 hours)

Category: Fuselage (VIII)

Used new style ‘Sportsman' jig for this one. While I think there is less room for error the set-up and measuring was not that difficult with the older style jig.

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Jul 20, 2020 Step #28 - Mount wings to fuselage - (1 hour)

Category: Fuselage (VIII)

Enlisted the help of another set of hands. My wife and I hung the RH wing but having a third person made it much safer.

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Jul 18, 2020 Step #39 - Fab inboard cable guide - (1 hour)

Category: Fuselage (VIII)

None of my normal cutting tools would cut the plastic material. I had to make a trip to HF and buy a small air grinder and bits. Spent around $20 for tool and bits and it made quick work of the cutting. I have a feeling this tool will become useful when working on the fiberglass.

I'm going to install #8 screws w/ lock nuts as its impossible to rivet these. There is no load on these at all. Double sided tape would probably work too!

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Jul 16, 2020 Step #38 - Install Aileron Pushrod - (.8 hour)

Category: Fuselage (VIII)

Went as planned. Pretty cool to see everything line up. The flaps and ailerons are coming back off once the cables are set so I'm not installing the cotter pins at this time. I am torque and setting all the pushrod components as I'm assuming these are staying on.

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Jul 16, 2020 Step #37 - Mount Aileron to Aileron hinges - (.7 hour) Category: Fuselage (VIII)

Went as planned. One of my holes was just a little off center which cause some difficult in mounting. Nothing major but the bolt did not slide right in and its tight quarters.

Jul 16, 2020 Step #36 - Install Flap pushrod - (.5 hour) Category: Fuselage (VIII)

No issues here.

Jul 16, 2020 Step #35 - Mount Flap to flap tracks - (.5 hour) Category: Fuselage (VIII)

Went as planned. This is where all of your holes that you drilled when fabricating many of these brackets on the wings and flaps need to line up. Mine did...so far!

Jul 15, 2020 Delay- wrong drill jig sent from Glasair - (1 hour) Category: Fuselage (VIII)

So....I sent an email to Glasair on Monday (July 13th) with a few clarification questions: Verify 2 degree dihedral and the correct jig P/N. I did not hear back from anyone so I moved ahead...I should have asked earlier or waited. There is another drill jig that will accomplish the same thing but apparently is easier to use and more accurate. I thought the one I used was pretty easy but they are shipping me the other one and will be here on Monday (July 20th) so I have decided to wait on mounting the LH wing and drilling the strut. I paused for a day and then started the next steps for the Flaps and Ailerons. I don't like delays!!!

Jul 14, 2020 Step #29 - 34 - Drill and cut the wing struts - (3 hours)

Category: Fuselage (VIII)

This was pretty tedious work. Measure three times and cut once! I measured 5 times...and cut once. I used a combination of the assembly manual and the TWTT wing strut drill fixture instructions. I like cutting the strut down PRIOR to installing and drilling. I cut the lengths in accordance with the TWTT instructions. Drilled the wing strut holes in accordance with the instructions and was able to maintain 2.0 dihedral. After it was all done and bolts installed I checked the dihedral with the weight 100% supported by the wing strut and realized the fuselage was tipping...which caused the dihedral to be off! With only one wing on its difficult to keep the fuselage level. I made a temporary support....re-leveled the fuselage and everything looks good. Once I mount the LH wing the plane should stay level. I'll mount the LH wing tomorrow!

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Jul 13, 2020 Step #29 - Set the Dihedral angle of the wings - (3 hours)

Category: Fuselage (VIII)

Was no happy with my original set for supporting the fuselage from the bottom and it was not very stable. I was concerned that the weight of the wings would tip the plane over! Can't have that at this point. I scratched my head for about a day and posted on the GAOA forum and received some great ideas. I took a few of them and merged them into my own and created stubby legs from the TD sockets. I feel MUCH better about the stability of the plane now and am ready to move forward with drilling the wing struts.

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Jul 11, 2020 Step #28 - Mount wings to fuselage - (2 hours)

Category: Fuselage (VIII)

Took it nice and slow on this step. I have reworked the support for the fuselage numerous times and I'm still not 100% happy with the support. I can't find pipe that will work in the main landing gear openings. I think what I have will work for not. I just need to be careful to check the level on a regular basis. Lori was a huge help lifting and holding the wing while I worked on installing the attach pins and bolt. The wing pretty much slid right in! Had to tap the pin a few times but it went in fine.

Now I need to wait for the wing strut drill jug to arrive...hopefully Monday or Tuesday.

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Jul 11, 2020 Step #27 - Trim openings in wing root area - (.5 hour) Category: Fuselage (VIII)

Used Dremel..had to make a few new passes when setting the wing

Jul 10, 2020 Rearranged workshop - (5 hours)

Category: Workshop

Took some time to figure out how to fit the fuselage AND the wings into the garage at the same time. With some mental gymnastics and a 25 foot measuring tape...I figure it out. Removed a few work benches and cabinets to the hangar and barn.

I think this will work just fine!

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Jul 10, 2020 Step #25 - Install wing strut fittings - (2.5 hours)

Category: Systems (IX)

Cut trimmed wing strut per ANOR and reviewed SB 54. Used band saw for these cuts and it worked fine. Not sure if my blade is getting dull or this was almost too much for the old bandsaw....took some time and wanted to slow down and stop a few times.

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Jul 09, 2020 Step #25 - Install wing strut fittings - (.5 hour) Category: Systems (IX)

Pressed in using vice.

Jul 08, 2020 Step #24 - Install elevator control cables - (3 hours) Category: Systems (IX)

Went as planned...no surprises

Jul 08, 2020 Step #24 - Install Elevator Control Cables - (2.5 hours)

Category: Systems (IX)

This is the fun part! Double checked to ensure all cables were routed properly and Fuselage was leveled so the yoke netural position could be found. Made minor hole enlargements for the Bulkhead A pulleys and opened up the Bulkhead E hole for the control rod. I'll fine tune the openings once all the cables are tensioned.

I now have a functional rudder and elevator! I'm good to go fly as long as I don't need to stay coordinated.

Now its time to HANG THE WINGS! I need to build some wing stands and I'mm waiting on the strut drill jig from GA. I'm also considering putting the fuselage on its main gear so it will be more stable during the wing installation.

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Jul 08, 2020 Step #23 - Install Elevator pushrod - (.5 hour) Category: Systems (IX)

Installed as expected.

Jul 07, 2020 Step #22 - Fabricate Elevator Pushrod - (3 hours)

Category: Systems (IX)

Went as planned. Its difficult to drill 6 holes on a round tube...evenly. Did the best I could w/o creating a fancy drill jig. Primed and painted unit.

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Jul 05, 2020 Step #21 - Complete Rudder cable installation - (3 hours)

Category: Systems (IX)

This went as planned but I was a little perplexed by the NicroPress crimping tool that I borrowed from a local builder. At first, I thought it had the wrong dies in to but after watching a couple of YouTube videos I realized I had the correct crimper. After a few trial runs I ensured everything was aligned correctly and crimps went as planned. All crimps checked out to the go-no-go gauge. Cut the cables with the Dremel then heat shrinked the ends to make it tidy. I did not have to add the extension for the Rudder pedal springs as I was able to connect them without too much effort.

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Jul 05, 2020 Step #20 - Install FWD rudder cables - (.5 hour) Category: Systems (IX)

Went as planned

Jul 04, 2020 Step #19 - Install cable fairleads - (.5 hour) Category: Systems (IX)

Installed per assy manual

Jul 04, 2020 Step #18 - Fab and install bulkhead A pulley brakets - (2 hours)

Category: Systems (IX)

Install per instructions. Went as expected and I have a feeling this won't be the last time I am working in tight places within the fuselage. BL1 Latern works great as work light!

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Jul 03, 2020 Step #18 - Fab and install bulkhead A pulley brakets - (3.5 hours)

Category: Systems (IX)

Made the brackets per assy. Instructions. Another exercise in measure 3x, cut once!

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Jul 02, 2020 Step #13 - 17 Install various pulleys - (3.5 hours)

Category: Systems (IX)

Installed most of the aileron, rudder, and flap pulleys. This was motivational as I was stalled out on the FWD pulley cluster for a few days. I also realized that the Assy. Manual that came with my QB fuselage was dated 3/29/04 and the most recent is 12/29/04....which I had been using for the wings (Assy. Manual #1). I am switching back to the one that came with my elevator kit as they are newer. No biggie an I'm glad I noticed it early in the systems section.

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Jun 30, 2020 Step 12 - Install forward pulleys - (8 hours)

Category: Systems (IX)

Wow....such a simple task but for some reason this was pretty difficult. Read ANOR (which is mandatory) and marked up drawing accordingly. This is where I am missing working in manufacturing. I could have drawn a CAD drawing and cut these out in way less time than hand cutting these on my band saw. Oh well....just part of the 51% build. Trying to hold .00 tolerances is difficult with using a band saw, files, and hand tools. I worked on these for a couple of days and finally finished the install today (July 2). They turned out very nice and I'm happy with the finish product....but 8 hours of work!

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Jun 29, 2020 Step #3 - 7 Rudder and brake mods - (1.5 hours)

Category: Systems (IX)

Drilled all ACS brakes for mounting and brake lever. Not sure if the mounting holes are parallel enough. Very difficult to drill perpendicular with the odd shape of the pedals. Installed bushings....but I think they might need to be rotated 180 degree's. Shoot...these are turning out to be a pain. Waiting on longer bolts to mount correctly then I'll work on any adjustments needed.

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Jun 28, 2020 Step #3 - 7 Rudder & Brake mod - (1 hour)

Category: Systems (IX)

Continued to work on modifying the aluminum ACS rudder pedals in lieu of stock ones. Installed the co-pilot master cylinders.

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Jun 23, 2020 Step #11 - install flap handle - (.5 hour) Category: Systems (IX)

Done

Jun 23, 2020 Step #10 - Assy flap handle - (1.5 hours)

Category: Systems (IX)

Finally found a use for.my old trekking poles for use as the spacer within the flap handle

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Jun 23, 2020 Step #9 - Install control yoke assy - (1.5 hours) Category: Systems (IX)

This is starting to feel like a real airplane!

Jun 23, 2020 Step #8 - Assy Elevator / aileron controls - (1 hour) Category: Systems (IX)

Went together as described. Made sure to capture the ANOR update.

Jun 22, 2020 Step #3 - 5- Make rudder pedals - (3 hours)

Category: Systems (IX)

Based on what I've read on the GAOA the worst part of the Sportsman is the rudder pedals. Jory had already purchased the ACS Rudder pedals but needed to be modified. I also needed to make 2 more because I am installing brakes on the RH side too. Thus, the modification begins. Went well on the first two but I need longer bolts and bushings so these were ordered and I'll finish the brakes when they arrive along with the extra brake cylinders and parking brake.

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Jun 21, 2020 Step #2 - Mount Rudder control brackets - (.5 hour)

Category: Systems (IX)

Done

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Jun 21, 2020 Step #1 - Drill Rudder control brackets - (.5 hour) Category: Systems (IX)

Done

Jun 20, 2020 Steps #49 - 94 - (5 hours)

Category: Fuselage (VIII)

Completed audit of each step and finished a few steps that needed completed. Audit did not reveal any issues and I was able to better understand the assembly thus far. The SB-74A was completed by the previous builder and the tailcone is reinforced for TW install.

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Jun 20, 2020 Steps #47 - 48 - Factory QB - (.5 hour) Category: Fuselage (VIII)

Verified installation is correct

Jun 20, 2020 Steps #39 - 46 - mounting rudder assembly - (1 hour)

Category: Fuselage (VIII)

Verified installation is correct

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Nov 30, 2019 Step 52- Fabricate Inboard Pulley - (1.2 hours)

Category: Wing LH (VI)

Fabricated LH & RH Inboard pulleys....need to prime

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Jun 20, 2020 Step #74 - 82 - Various steps install shearweb & HS FWD attach bracket - (.5 hour)

Category: Fuselage (VIII)

Verified all steps completed correctly and installed HS FWD Attach bracket

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Jun 19, 2020 Step #38 - install bulkheads completed by factory Category: Fuselage (VIII)

Verified correct installation

Jun 19, 2020 Step #37 - Align and cleco Vertical fin half - (.5 hour)

Category: Fuselage (VIII)

Verified work completed correctly. Used Plumb line to check vertical fin alignment and it's near perfect!

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Jun 19, 2020 Step #36 - completed by factory Category: Fuselage (VIII)

bulkheads already installed. Inspected for proper installation and not signs of cracks or issues.

Jun 19, 2020 Step #35 - Level fuselage longitudinaly Category: Fuselage (VIII)

Verified correct via waterline marks

Jun 19, 2020 Step #32 - 34 - Various steps completed by factory Category: Fuselage (VIII)

Verified correct as per assy. Manual and QB instructions.

Jun 19, 2020 Step #31 - cut-out vertical fin rib Category: Fuselage (VIII)

Verified complete - the rudder has been installed therefore, the vertical fin rib was already installed.

Jun 19, 2020 Step #30 - Mark the fuselage Waterline - (.5 hour) Category: Fuselage (VIII)

I found the marking on the fuselage on the LH side of the Fuselage (fwd & aft). But did not see any fwd markings on the RH side. I'll need to investigate this a little closer to verify that its correct. I will check with Jory to see how he set the waterline.

Jun 19, 2020 Step #29 - Install FWD shell attach fittings - (.2 hour) Category: Fuselage (VIII)

Verified correct installation and checked for proper torque

Jun 19, 2020 Step #28 - Install the upper, LWR, and AFT shell attach fittings - (.5 hour)

Category: Fuselage (VIII)

Verified all screws and nuts were tight. One has an interference issue that will be addressed later.

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Jun 19, 2020 Step #27 - Position and drill AFT shell attach fittings - (.5 hour) Category: Fuselage (VIII)

Verified step completed correctly. There is one nut that cannot be tightened due to the support wood that is supporting the fuselage. This needs to be fixed when the fuselage is put on the gear.

Jun 19, 2020 Step #26 - Position and drill the LWR shell attach fittings Category: Fuselage (VIII)

Verified work completed correctly and checked torque of screws / nuts

Jun 19, 2020 Step #25 - Position and drill the upper shell attach fittings - (.5 hour) Category: Fuselage (VIII)

Verified installation was correct. Also verified that I have the 'new��yle doors that do not require the bushing as noted in this step. It was not installed and noted within the build manual but I also confirmed this to be true.

Jun 19, 2020 Steps 13 - 24 - Various steps completed at factory Category: Fuselage (VIII)

Reviewed Assy. Manual and verified work completed correctly.

Tightened all cage attach screws and installed one lock nut that was missing.

I am so glad I did not have to buy a slow build kit and do all of this work myself.

Jun 19, 2020 Step #12 - install wing pivots - (.5 hour)

Category: Fuselage (VIII)

Yeah! My first parts installed on the fuselage. Went as planned. Greased and set castle nut propoerly.

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Jun 19, 2020 Step #11 - Press bushings into wing pivot joints Category: Fuselage (VIII)