Project: Sportsman   -  
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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

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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.


 
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!


 
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.


 
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


 
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.


 
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


 
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”???


 
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.


 
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.


 
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.


 
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


 
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.


 
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!


 
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.


 
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 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.


 
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!


 
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.


 
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 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


 
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.


 
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.


 
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.


 
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.


 
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


 
Oct 13, 2020     Step #74 - (2.7 hours)       Category: Systems (IX)
Finished riveting upper outboard skin LH wing


 
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.


 
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.


 
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.


 
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!


 
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 #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!


 
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 11, 2020     Step #59 - Position, drill & rivet transfer pump doubler - (.5 hour)       Category: Systems (IX)
Mounted pump as instructed


 
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.


 
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.


 
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!


 
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     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.


 
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.


 
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.


 
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.


 
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.


 
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


 
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


 
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 :-(.


 
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.


 
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.


 
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.


 
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.


 
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.


 
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
 
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.


 
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.


 
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.


 
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.


 
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!


 
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!


 
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.


 
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!


 
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.


 
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.


 
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


 
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.


 
Jun 21, 2020     Step #2 - Mount Rudder control brackets - (.5 hour)       Category: Systems (IX)
Done


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


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