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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

N917X was very helpful

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

Installed counterweight as per Assy. manual

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Removed wingtips and finished trailing edge fiberglass work.

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

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

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

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

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

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

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

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

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

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

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

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

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

Wired up fuel main fuel sender too.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Safety wire all prop bolts

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

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

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

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

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

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

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


-

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

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

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

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

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

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

5. Installed sniffer valve

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

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

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

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

Accomplished a number of items over the past few weeks:

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Installed support tabs for glare shield.

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

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

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

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

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

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

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

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

  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.

  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

  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.

  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.

  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!

  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.

  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.

  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.

  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.

  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.

  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!

  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.

  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.

  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.

  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.

  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.

  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.

  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.

  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.

  Jan 04, 2021     Install Sportsman Latch kit - (2 hours)       Category: Final (X)

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

  Jan 03, 2021     Install Sportsman Latch kiy - (2 hours)       Category: Final (X)

Started working on installing the latch kit on the main doors

  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.

  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 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!

  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!!!!

  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

  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.

  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.

  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

  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.

  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!

  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.

  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

  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.

  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!

  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.

  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.