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Builder Name:	Martin Guinn -

Project:	Vans - RV-14A - VIEW REPORTS
Total Hours:	1990.5
Total Flight Time:	36.1
Total Expense:	N/A
Start/Last Date:	Aug 30, 2019 - Dec 06, 2021
Engine:	Lycoming YIO-390-A3B6 Thunderbolt
Propeller:	Hartzell
Panel:	G3X Touch/GTN 650xi, SteinAir

Friendly URL:	https://eaabuilderslog.org?s=MartysRV14A

Home or Last Project Picture

Apr 23, 2023 A/C Leak Category: Maintenance

Refrigerant leaked over winter. Recharged system with R134a to 220/25 psi (ambient temp 76F) with engine running at 1300 rpm, A/C on, and condenser fan one high. Shut down and allowed to equilibrate overnight. Detected refrigerant leak in evaporator condensate drain. Removed and ship evaporator to John Strain for replacement. Also detected minor leaks in bulkhead fittings, perhaps due to over-tightening. Plan to replace all o-ring on reassembly.

Dec 24, 2022 Canopy Scrath Removal and Polishing Category: Maintenance

Experimented with approaches to remove canopy surface scratches, likely due to poor cleaning techniques. Using a 18"'X24"X0.22" sheet of plexiglass (Lowes 1AG2123A), lightly scoured 1/4 of the surface with red Scotch Brite pad in circular motion. Started linear sanding with a pre-wetted 1500 Micro-Mesh (KR-70) using moderate pressure for about 2 min. A good slurry forms indicating material removal. Wiped surface with moist microfiber cloth and checked that swirling scratches from red pad were gone or repeated sanding. Next, wiped surface clean with water and a damp cloth and continued linear sanding with 1800 Micro-Mesh at 90 degrees to the first sanding direction for about 2 min. Wiped surface and inspected that previous sanding marks were gone and moved on to 2400 Micro-Mesh and 3600 Micro-Mesh.

At this point, I switched to using 3M Perfect-It EX AC Rubbing Compound (36060) applied using a 3" yellow foam pad (Harbor-Freight 69335) attached to my cordless M-12 drill with 90 deg adapter. Applying moderate pressure, polished the surface at 1500 rpm for abut 2 min or until material disappeared. Wiped surface clean with water and a clean towel and applied Micro-gloss from the Micro-Mesh kit using the 3" white foam pad using moderate pressure at 1500 rpm for about 2 min. Finished cleaning with soap and water.

These final steps deviated from the Micro-Mesh but I felt they provided a superior finish in a shorter time. For these scratches, it was essential to start with the 1500 Micro-Mesh and work up to the 3600 before using the 3M rubbing compound. Deeper scratches will probably need an initial sanding with 400 grit sandpaper.

Dec 21, 2022 1st Annual Condition Inspection (202 hrs) - (20 hours) Category: Maintenance

Ran engine inflight to normal op temp, hangered, and drained oil. Removed oil filter. Submitted oil sample to Blackstone (46 hrs on oil). Cut open filter and found no debris. Removed and cleaned suction screen and also found no debris. Reinstalled and safety wired suction screen plug. Installed and safety wired new oil filter (Champion CH48110-1). Added 8L oil (Phillips 66 X/C, 20W-50). Removed spark plugs and cleaned plug adapters. No apparent plug fouling observed. Installed new Denso 5347 IKH27 Iridium Power spark plugs (0.030" gap) and copper gasket (Part# M674) using Tempest Anti-Seize (Part# T556) to required torque.

Ran engine at 1500 rpm until CHTs reached 300F. Removed upper plugs. Performed cylinders pressure test and obtained: 1 (78/80), 2 (78/80), 3 (78/80 ), 4 (79/80). Boroscoped each cylinder and stored photos. Nothing notable observed. Reinstalled spark plugs. EGT#1 giving erroneous readings. Replaced with new probe (Alcor #86255 EGT Probe Type K) and ran engine to verify operation.

Pulled prop using newly constructed wooden gantry. Installed new, larger Hartzell 70A alternator (Plane-Power Part No. AL12EI70/B, S No. H-S040586) and belt (Dayco Part No. 15350 ). Also installed 1" blast tube for new alternator. Replaced AC belt. Set belt tension and torqued all bolts to spec. Install new o-ring, reinstalled prop, torqued all bolts to 60 ft-lbs, and safety wired.. Torqued all bolts to specs. Installed new air filter. Inspected all engine compartment connections and components. Ran engine, cycled prop, and confirmed no leaks and normal operation. New W&B calculated.

Lubricated prop with 1oz (6 trigger pulls) of approved grease on each side of hub. Removed wing root fairing and inspected all bolts and harness connections. Removed fuel filters, disassembled, and inspected. No debris found in either one. Found evidence of fuel leak on left side likely due to loose compression fitting aft of the filter. Re-torqued fitting. Removed seat ramp covers and noticed light surface corrosion on floor, probably the result of water intrusion when canopy seal was leaking, since repaired. Re-primed all surfaces below the ramp cover. Removed entire tunnel cover from CB panel to baggage bulkhead and inspected area. Removed floor covers under seats and inspected area. Tightened headset jacks and added lock washer to prevent loosening and tested. Repaired O2 mount. Re-installed baggage area carpet and mounted O2 cylinder. Re-installed all floor plates and carpet.

Updated G3X and G5 software to latest version (9.14) to comply with Garmin Mandatory Service Bulletin 22112 Rev. B, 09Dec22. Re-installed all remaining fairings and cowlings. Test flew the airplane. Return to service.

Aug 03, 2022 Best Glide Speed - (1 hour)

Category: Performance

Measured best glide speed and sink rate.
Conditions:
- Full fuel
- No pass or baggage

Procedure
Climb to 7000 MSL. Set direct to KCRE, approx perpendicular to wind. Mix, Prop, Ram in, cut power, set IAS to desired and take picture every 30 sec to 3000 ft MSL. Climb and repeat at new airspeed. Continue on reciprocal course direct KSUT.

Results
Best glide speed (Vg) was 80 KIAS. Sink rate about 900 ft/min. Glide ratio 1.68 miles/1000 ft (8.8 ft//ft).

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Aug 02, 2022 Right Tank Fuel Level Sensor, A/C - (5 hours) Category: Maintenance

Right tank fuel level sensor showing wild swings during flight home from KOSH. Suspect bad ground. Removed upper fairing and noted lock washer missing on sensor cap screw. Confirmed open circuit. Removed and cleaned cap screw and surface and re-installed with washer. Measured 0.78V or ~ 15 gal. Reinstalled fairing.

A/C stopped working during trip to KOSH. On return, confirmed compressor operation so suspected freon loss. Using freon charge line on manifold, added 1/4 oz UV dye and attached 12 oz (340 g) of Freon 134a. Bled air out of line. With high and low pressure lines attached, started engine and fed freon through low side to 250 psig high side pressure. Added ~ 10 oz (283 g), so lost about 0.62 lbs of Freon of initial 1.2lb charge. System cooling. Ran 10 min and checked for leaks but unable to pinpoint source. Will continue to run and look for leaks.

Jul 19, 2022 Tires - (1 hour) Category: Maintenance

Checked tire pressures and set at 45 psi (all were around mid-20s). Required removing main front wheel fairings and entire nose wheel fairing. Re-installed fairings with new screws.

Jul 18, 2022 Garmin DBs - (1 hour) Category: Maintenance

Updated G3X and GTN databases.

Jul 15, 2022 Replace Canopy Seal. Grease Prop. Adjust K-factor - (3 hours) Category: Maintenance

Engine hours: 107.9, Total hours: 114.6
Replaced forward canopy seal and applied silicone sealant to prevent leakage occurring at hinges. Applied silicone sealant at upper aft rear canopy seam to prevent water leakage from rain. Added 5 pumps of NYCO grease to each prop lubrication fittings. Inspected prop pitch controller for leakage and damage. Added 19.6 gal 100LL. Used 17.8 gal flying from KRHP to KSUT. New K-factor = (17.8/19.6)*81488 = 74004

May 15, 2022 Cooling Test - (1 hour)

Category: Air Cond

Approximately 1 lb of R-134A refrigerant was charged to the previously evacuated system and with the engine running until the high side/low side pressures reached about 200/30 psig. Ambient conditions at the time of the test were 83.5 F and 75% RH. An Omega Engineering RH85 handle hygrometer was used for the measurements. With the compressor engaged and evaporator fan speed at medium, the following results were obtained:

Cooling performance test

May 14, 2022 Koger sunshade - (3 hours) Category: Finish

Fabricated and installed headset hangers for pilot/co-pilot from aluminum stock. Installed Koger Sunshade. Installed wire chain lanyards for Bogart bars support retaining pins. Checked oil, 7.5 qts.

Jan 14, 2022 Flight Day 10 - Phase 1 Complete! - (6 hours) Category: Flight

A windy and gusty day from the NW. Completed over 40 hrs as recorded by G3X.

Preflight
- Inspected roll trim servo and found a loose connection. Roll trim works now.
- Added 1 qt oil to 7.5 qts
- Changed pitch trim settings to reduce aggressiveness based on suggestions from VAF.

Flight Summary
Flew both RNAV approaches at KCPC. Control was good until full flaps, then got large drop in pitch and oscillation. Flew to KACZ, landed, refueled, and set additional intermediate flap position settings so have more step-downs. Flies much better with more gradual flap extension, essentially slowing rate of flap. extension. Flew RNAV 23 circle to 05 with strong 12 kt crosswind and gusts to 16 kts.

Jan 13, 2022 Flight Day 9 - (8 hours) Category: Flight

Another good flying day.

Inspected ram air inlet and found that y-valve had shaken free of the fuel controller. Removed the inlet air plenum and retourqued clamp.

Shot the VOR-A approach to KCTZ and confirmed navigation with the NAV radio (green lines). After a few attempts, learned that need to select NAV on the GFC 500 to track the VOR outbound.

Flew the RNAV 05 approach with and without auto pitch trim. Found the trim is overly sensitive resulting in large pitch oscillation when extending flaps. The approach with manual pitch trim was much more controlled. Since we're on a glide path, the nose up response of flaps seems to cause the pitch trim to overcorrect. With only me in the left seat and full fuel, a lot of nose up trim is needed on final. Hitting TOGA and going missed caused a large nose up pitch unless the pitch trim is simultaneously adjusted.

Flew several other approaches into KACZ and KSUT both with a fix transition and vectors-to-final to gain more practice.

Discovered on landing the the roll trim servo is not functioning.

Good values for flying the approach:
- 14 in/2700 RPM gives about 100 kts

Goals for next flight:
- Fly off another 5 hrs to complete 40 and Phase 1
- Investigate the roll trim motor issue

Jan 12, 2022 Flight Day 8 - (8 hours) Category: Flight

Fantastic day for flying. No clouds, lights winds. Goals today were to tune the AP without auto-trim and fly as many approaches as possible.

Morning Flight
- Flew to KCTZ and configured roll and pitch gains. Flew the VOR/DME A approach and landed for fuel. Very nice small airport.

Afternoon Flight
- Departed KCTZ, climbed to 5500 and recalibrated the AoA. Set-up and flew the LOC 06 approach.
- Flew the RNAV 24 approach at KCPC
- Flew the RNAV 23 into KLBT then did missed and entered hold. Left hold to do the ILS 06, but localizer was U/S.
- Flew direct to KSUT and did the RNAV 05 approach, broke off at 1000 and entered pattern for touch and go. Left pattern and flew the RNAV 23 approach and landed.

Summary
- A/P works well without auto-trim.
- Enter procedure at 90-100 kts. 50% power. 14 in/2700 rpm is good setting
- Maintain speed with power adjustment as pitch changes when capturing glide path
- Bring power into landing and cut power when at level pitch over runway. Come in faster.

Squawk List:
- Fly VOR to confirm NAV radio working
- Fly ILS 06 approach into KILM to confirm LOC is active then break-off before entering airspace.
- Engage auto trim and tune
- Reload databases

Jan 11, 2022 Pre-Flight Preparation - (7 hours) Category: Flight

- Removed air control cable and discovered cable was bent aft of the bulkhead bracket fitting preventing full stroke. Straightened it out and re-attached cable, work as designed now.
- Leveled airplane and performed pitch/roll calibration for G3X and G5.
- Moved airplane outside to re-calibrate magnetometer and perform G5 vibration test.
- Configured G3X to show alternator alarms

Jan 08, 2022 Flight #8: GTN Practice - (8 hours)

Category: Flight

Flew with Carlos today as Additional Pilot. Shot the RNAV 06 approach into KCPC twice using GTN for first time to fly approach and missed. The AP performed as expected with the corrected trim motor direction configuration. Used TOGA button for first time. Landed and refueled.

Worked on pitch servo control settings to reduce oscillations on final with flaps deployed. CG was far aft with 100 lbs of sand in baggage area which was probably a contributing factor. Will try again with CG further forward.

Flew RVAV 15 approach at KEYF and landed to borrow the courtesy car for lunch at Cape Fear Vineyard. Adjusted stall vane to reduce nuisance alerts.

Flew flight plan that finished with full RNAV-05 approach, Carlos calling radio. Went missed and entered hold then repeated and landed.

Noticed G5 and G3X pitch offset. It's likely since I haven't performed pitch/roll calibration procedure on G5 yet.

Good setting for final approach:
- 15.7 in MAP, 50% power, no flaps,110 kts
- 13.2 in MAP, 40% power, full flaps, 83 kts

Post-Flight Squawk List:
1. Remove alternate air cable and find cause for reduced stroke.
2. Perform pitch/roll calibration of G5.
3. Email g3expert about pitch servo settings.
4. Email Stein and g3expert about alternator alert/alarm configuration one the G3X
5. Recalibrate AoA so it start displaying at a slower speed, say 90 kts.

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Jan 07, 2022 Flight #7 Pre-Flight - (4 hours) Category: Flight

Pre-Flight Prep:
- check angle of each flap relative to canopy longeron and neutral aileron. Make adjustments if possible to add differential lift in ccw direction
- adjust stall warning vane down slightly so that it actuates at a lower airspeed.
- read about the TOGA button and practice using it in the pattern

Trim Issue:
G3expert emailed that the AP roll trim behavior is a backward roll trim servo direction, which was in fact the case. The trim was be directed by the servo to move in the opposite direction. This should solve the problem.

Co-Pilot Stick
Installed the co-pilot stick.

Gust Lock
Installed the Anti-Splat gust lock.

Jan 06, 2022 Flight #6 - (4 hours) Category: Flight

Great weather today for flight testing. Calm winds and high ceilings.

Morning flight summary:
Loaded additional 100 lb ballast in baggage area in addition to the 150 lbs in co-pilot seat. Topped of tanks. With flight bag, total take-off weight 2135 lbs. CG calculated at 87.69 (91% aft). Disabled ESC. Flew 2.7 hours in practice area.

Pitch control
With aft CG had no issues with pitch authority at any flap setting.

Roll Gain
AP is doing better job handling small heading changes with aileron trim in center position, but has more trouble with large heading changes.

AoA
Was able to successfully calibrate AoA using AP in IAS mode with full flaps, starting at 90 kts for min visible, 75 kts, for caution yellow, and power off stall for stall red. Stalled at about 50 kts with full flaps.

Afternoon Flight Summary
Re-enabled ESC. Noticed I didn't have AP trim control selected which explains the observations before. Used values AP settings from Mike at Garmin for RV-14. The AP worked pretty well as long as roll trim was set manually first before engaging AP. This must be done often, otherwise, AP has tendency to pull and hold trim to extreme of range. Not sure why it's doing this. While hand flying, roll can be trimmed out with about 30% left trim, meaning plane has tendency to roll right with neutral ailerons. When trimmed, the AP handles heading changes well, but when untrimmed, the AP does not seem to be adjusting trim properly. Sent an email to g3xexpert about the issue.

Aileron rigging is correct since I checked both wings with the template. I also set the trim motor in the spring neutral position during calibration. So, if I require left trim for level flight, there is something causing differential lift, and causing a clockwise roll. Some possibilities are: offset flaps, wing twist, aileron twist. Only thing I can really adjust are the flaps.

-

Jan 05, 2022 Flight #6 Pre-Flight - (2 hours) Category: Flight

Rain today so no flying

Removed wing tips and confirmed aileron neutral position with template. Removed inspection plate holding trim motor. Set ailerons in neutral position and moved inspection plate with motor to neutral position and reinstalled plate. Calibrated as new neutral position.

Jan 04, 2022 Flight 5: Autopilot, Pitch, MP noise, AOA - (8 hours) Category: Flight

Flight 5 objectives:
- Evaluate performance following installation of snubber fitting and correction of ram air butterfly position
- Complete on-ground and in-flight set-up of autopilot on G3X
- Evaluate pitch control with heavy forward CG
- Calibrate the AOA and perform power-off stalls.

Flight Summary:
Flew two segments, morning and afternoon, with break for lunch, for total of 4.6 hrs. Confirmed correct operation of AP on ground. In flight, verified that snubber fitting and butterfly valve alignment resolved problem of MAP noise. Engage AP and performed in-air set-up to set desired roll and pitch gains. With roll trim centered and a roll gain of 1.0. after a left perturbation of 10deg, the AP rolled level after 10 deg. However, a right 10 deg perturbation required 127 deg before level. Suspecting the roll trim, moving the trim to just left of center, increased the right perturbation recovery speed to 30 deg. Need to reset roll trim neutral position. In afternoon segment added 150 lbs ballast in co-pilot seat and topped tanks. During flight, observed position pitch control at each flap setting and speed from 100 kts to 70 kts.

Performed a few power off stalls and attempted to calibrate the AOA. With full flaps and a heavy forward CG, the plane stalls at about 61 kts. Stall behavior is benign, lots of mushing then the nose drops. AOA calibration was unsuccessful, I think due to inability to maintain level flight. Will try again using the AP. Based on this, Vso of 75 kts is reasonable.

Used Lean Assist to find optimum cruise conditions:
- 23/2300 (66%), 9.2 gpm, 146 kts TAS, lean at peak
- 25/2500 (80%), 11.1 gpm, 155 kts TAS, lean at peak
- 25/2500 (80%). 12.8 gpm, 160 kts TAS, lean 50F ROP
CHTs were all comfortably under 400 F.

Spoke with Aircraft Spruce about ram air control cable. They confirmed stroke should be 3" not the 1.5" I'm seeing. There is likely a kink somewhere preventing full extension. The best option is to remove the cable and test on the bench. A replacement cable will take 4 wks to procure. Also look for a more direct routing with fewer bends.

Engine oil measure 6.8 at start of day and 6.2 at end of day, or 0.13 qts/hr.

Jan 02, 2022 Pre-Flight Maintenance: Continued - (3 hours) Category: Flight

Centered the y-valve control horn perpendicular to the valve body with both butterflies half-way open. Moved the cable back in the bracket. Was able to find a setting in which the ram air butterfly is centered in the ram air position and the filtered air butterfly is centered in the filtered air position. However, in each case the other butterfly is slightly open. This really shouldn't cause a serious issue. The only way to fix this is with a longer reach on the control cable, but these cable controls seem to have a fixed stroke length. Alternatively, could source a shorter control horn. Set best valve travel and torqued all nuts. Torqued clamps holding FM-200 and filter hose.

Installed snubber fitting (McMaster Carr, Part # 3820K42) on #3 cylinder and ran engine. The MAP responded within just a few seconds and appears very stable.

Re-installed cowlings.

Jan 01, 2022 Pre-Flight Maintenance - (3 hours) Category: Flight

Removed cowlings. Noticed butterfly y-adapter was loose. Also, the butterfly valve control rod was bending and preventing smooth operation. The butterfly is also not fully open in ram mode....could this be contributing to noise in the MAP reading at full throttle. Will need to rethink the linkage and install some support.

Measured 7.8 qts oil. Ran engine until oil temp reached 150F. Drained oil (dark black). Replace filter and safety wired. Added 7 qts Aeroshell 80. Ran engine and no leaks observed.

Oil consumption rate for 4th flight was 0.06 qts/hr.

Dec 31, 2021 Flight 4: Engine Performance, Altitude, Lean Assist - (6 hours) Category: Flight

Goals for Flight 4:
- Evaluate prop speed settings
- Experiment with Lean Assist
- Evaluate performance at various altitudes

Pre-Flight Prep:
- Added 2 qts oil to 8 qts total
- Tighten spinner backplate, torquing bolts to 170 in-lbs.

Flight Summary:
Flew total of 3.1 hours covering 390 NM in box. Flew at 3500, 5500, 7500, 9600, 10,500, 11,500, 12,500.

At 2700 RPM could only marginally lean engine limited by CHT1 and CHT2 reaching max imposed limit of 400F (fuel flow 20 gal/min). Decreasing prop speed to 2500 RPM, 25 in, permitted better leaning to 13.4 rpm (100% RAM air), although still limited by CHTs. Reducing prop speed to 2300 and 23 in, permitted full leaning while keeping CHTs below maximums. Best fuel consumption was between 10.5 and 11.5 gal/hr.

These results confirm:
- Use full rich at 2700 RPM
- Lower MAP to 25 and prop to 2500 for high power climb, don't lean yet
- Lower MAP To 23 and prop to 2300 for economy cruise. Use Lean Assist to lean mixture. Operate at max EGT
- Fly at high power cruise (25 in, 2500 RPM). Use Lean Assist. Operate 150F ROP.

Plan for 11 gph fuel consumption when properly leaned and 150-160 kts TAS.

Other observations:
- the airplane trims out very well. There is no offset in the turn coordinator, the ball is right in the middle. There's plenty of pitch authority with one passenger and full tanks (take off weight 1860 lbs, CG 84.3, 36% aft)
- steady MAP readings difficult to obtain with large variations difficult to explain. The engine appears to run well, so this is likely a sensor issue rather than a manifold leak issue. The snubber fitting should dampen out the pressure pulses.

Dec 30, 2021 Phase 1 Planning Category: Flight

Thursday, 12/30
- Grounded due to wind/rain
- Package up parts for return to Vans
Phase 1 hours, 7

Friday, 12/31
Weather forecast good.
- Continue engine break-in at full power for another 3-4 hours, for a total of 10-11 hour engine time and measure oil consumption
- Complete G3X on-ground configuration
- Re-torque spinner mount, appears loose
Phase 1 hours, 10

Saturday/Sunday, 1/1-1/2
Weather forecast, wind and rain.
- Remove cowlings.
- Change oil and filter. Inspect and clean screen.
- Inspect engine for leaks.
- Replace safety wire on alternator
- Install MAP snubber fitting and reconnect MAP line from transducer
- Install screws missing on inspection plates
- Install missing screw on baffle
- Install missing nut plate
- use solvent to remove tape residue on surfaces
- Install nose gear fairings. Epoxy tow bar hole guide to nose fairing
- Install main gear fairings. Continue with fabrication of transitions
- Test LED strip and repair/replace
- Install iPhone mount
- Install tow bar mounts
- Pick up sand bags

Monday, 1/3
Potential flying day...
- Pitch authority at various take-off weight and CGs.
Phase 1 hours, 13

Tuesday, 1/4
- Stall testing
- AoA calibration
Phase 1 hours, 16

Wednesday, 1/5
- Autopilot operation
Phase 1 hours, 20

Between 1/6 and 1/20 (14 days), need another 20 flight hours, or about 6-7 more good weather flight days.

Dec 29, 2021 Flight #3: More Engine Break-in Time - (8 hours)

Category: Flight

Today flew total of 4 hours, running hard at full throttle and 2700 rpm, >80% power. Covered the corners of my approved box for a total of 520 NM. Remained mainly at 5500 due to cloud layer and strong winds from the southwest. 8PP performed flawlessly.

Oil consumption rate has been steadily declining.

Oil Consumption
First flight (1.5 hrs)...................0.67 qts/hr
Second flight (1.5 hrs)..............0.33 qts/hr
Third flight (4.0 hrs)..................0.25 qts/hr

CHTs were well controlled and kept below 400F by adjusting the mixture. Fuel consumption was about 17 gal/hr for filtered air vs 16 gal/hr vs ram air at full power.

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Dec 28, 2021 Flight #3: Fogged In - (6 hours) Category: Flight

Flight #3 Plan:
Continue full power break-in. Plan to fly boundaries of box. Total distance 190 NM. Plan to refuel in Lumberton. Observe CHTs.

Flight #3 Summary
Grounded today due to fog rolling in around 11am so worked on squawk list. Oil volume 7.5 qts.

Squawks:
- Drained left tanks and removed 9 gal. Removed drain valve. Problem was over-torquing. Reinstalled and tighten to just before binding obtained. Fuel gauge read 0 when empty and 9 when recharged.
- Identified bad ELT remote battery. Purchased new one at Ace and replaced. ELT test successfully.
- Fixed stall warning switch by moving one wire to common.
- Sanded headset holder and fuselage, applied new tape and installed.

Other:
- Paired iPad with G3X. Live data download activated. Successfully uploaded flight plans to GTN.
- Started installing new glare shield that arrived today.
- Updated G3X software and all databases in G3X and GTN.

Dec 27, 2021 Flight #2: Engine Break-In - (5 hours)

Category: Flight

Watched great video by Mike Busch on new engine break-in which does the best job I've seen to explain the topic.
https://www.eaa.org/Videos/Aircraft-Building/6228066360001

He recommends in his video:
- run at highest power (full throttle) at lowest safe altitude.
- continue until oil consumption stabilizes and CHTs drop
- monitor CHTs, don't let any cylinder exceed 440F

Break-in should take 5 hours or so.

Flight #2 Summary:
Flew 1.4 hrs from KSUT to KACZ (Wallace) twice at 2500 ft and at 6500 ft at full power. TAS was 165 kts measured at each altitude and direction. Fully rich fuel flow was 19.4 mph at 2500 ft and 17.7 mph at 6500 ft. Added 1qt oil to 8 qts prior to departure. During flight measured about 1in additional MP when switching to RAM air. Tried leaning at full power, but CHTs rapidly hit imposed limits of 400F, so clearly will not be able to lean at full power. CHTs settled out during high power cruise with 1/2 reading higher than 3/4. MP signal is still noisy. G3X install manual suggests installing snubber fitting (Rev AN, 24-24). Purchased one from McMaster Carr.

Squaks:
- left tank fuel drain stuck....will drain tank and inspect. Ordered spare drains from AS
- ELT remote non-functioning....will check with back-up ELT
- Missing 6-32 pan head screws on aft empennage inspection panels....ordered from McC
- MP signal noisy...ordered snubber fitting from McC
- Stall warning switch not working
- Headset bracket still not secure.

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Dec 25, 2021 Post First-Flight Inspection - (2 hours) Category: Flight

Removed upper cowling to inspect engine. Didn't observe any leaks. Inspected the MAP line from #3 cylinder to the transducer and the compression nut may have been slightly loose. Retightened the nuts on both ends. Repaired a very small hole in duct to the oil exchanger. Used a heat gun to confirm #1 and #2 CHTs are properly configured. Will need to keep an eye on these.

Connected Garmin Pilot on iPAD via bluetooth to the GDL 51R to enable datalog downloads during operation.

Downloaded first flight data to on-line application called FlightData.com to better enable post-flight data analysis.
https://www.flightdata.com/flights/N818PP

Dec 24, 2021 First Flight - (3.0 hours)

Category: Flight

Successful first flight under ideal conditions at KSUT. Take-off run at gradual power increase to full was about 500 ft and climbed out at 1300 ft/min to 3000 ft. Performed three loops around the airport. Pitch trim is a bit sensitive, but was able to trim stable in pitch and roll. All engine readings in green. Performed two 360 turns at 30 deg in each direction. I didn't sense bias or heaviness in the controls. Climbed to 5000-7000 ft and flew NW to Clinton (CTZ). Practiced landing pattern at 4000 ft and returned to SUT. Max IAS at 154 kts and ground speed 180 kts. Switching from filtered to RAM air resulted in about 1in increase in MAP. Landed in less than 500 ft after 1.5 hrs.

CHTs were within range during entire flights, although they started to climb when flying at max power at end of flight. It's odd that cylinders 1 and 2 are reading higher and need to confirm they haven't been mis-assigned. MAP signal was quite noisy at high power which needs to be investigated further. Oil temps looked good as did oil pressure. Fuel pressure was well-regulated through flight and can clearly see increase when fuel pump turned on. Generally, vibrations were low and controls smooth.

Need to link Pilot to G3X to be able to download datalogs to Pilot.

IAS vs GS

CHTs

RPM vs MAP

Dec 23, 2021 Pre-First Flight Preparation - (3 hours)

Category: Pre-Flight

Performed power taxi tests. Plane tracked and steered easily. Confirmed pitot operation by comparing IAS with GPS ground speed (chart). Oil temp settled out at 180F (chart) within range. Oil pressure was in range. CHTs are within range. Oil pressure correlating with RPM.

IAS vs GS

Oil Temp

Oil Pressure

CHTs

EGTs

Oil Press vs RPM

Dec 22, 2021 Pre-First Flight Preparation - (4 hours) Category: Pre-Flight

Pre-first flight task completed today include:
- Configured EIS displays with appropriate color ranges
- Installed new cotter pins on right main wheel spindle nut.
- Reversed pitch trim control and confirmed pitch and roll trim.
- Removed cowling and inspected all fittings.
- Performed full power run-up. All readings looked good except for the fuel pressure, reading around 6 psig other not the expected 25 psig. Solved the issue by configuring the transducer range from 0-15 to 0-75 psig on the G3X.
- Confirmed no engine leaks after run-up. Resafety wired alt bracket. Reclamped edel clamp supporting fuel line to flow transducer using friction tape on the induction tube.
- Reinstalled cowling and wing root covers.

Printed checklists.

Dec 21, 2021 Pre-First Flight Preparation - (8 hours)

Category: Pre-Flight

Performed fuel flow test. Set pitch to 10 deg. Disconnected fuel line from fuel controller and placed in container. WIth fuel boost pump on, collected 1 gal in 1min24s (42.8 GPH) while fuel flow read 40 GPH. This represents 200% of the required flow rate for full power operation.

Recalibrated both fuel tanks by 2 gal additions. Both floats top out at 22-23 gal so will not see a change until reaching that value. 25 gal level is approximately 1 in below top of tank in level pitch.

Torqued main wheels spindle nuts to 141 in-lbs and installed new cotter pin on right wheel. Will do left wheel tomorrow.

Left Tank Calibration.pdf

Right Tank Calibration.pdf

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Dec 20, 2021 Pre-First Flight Preparation - (3 hours)

Category: Pre-Flight

Repacked nose wheel after having some concern for binding during low power taxi. Removed nose wheel and fork. Cleaned and sanded shaft and bearing with 320 grit. Applied blue marine grease to both bearing faces and reinstalled with new Belleville washers. Tightened nut until force of 26 lbs as measured with spring scale was required to move fork. Drilled new holes and installed Cotter pin.

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Dec 19, 2021 FAA Airworthiness Inspection - (1 hour)

Category: Inspection

Met the DAR at our airport near RDU to pick up airworthiness certificate and flight test program.

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Nov 25, 2021 Final Assembly - Day 4 - (3 hours) Category: Final Assemb

1. Installed N number on vert. stab.
2. Installed nameplate
3. Discovered and repaired loose wire to aileron trim servo. Roll trim position working correctly now.

Nov 24, 2021 Final Assembly - Day 3 - (6 hours)

Category: Final Assemb

Prepared airplane for weight and balance by deflating nose wheel to achieve 0.0 deg in lateral and transverse directions. Measured distance from leading edge to axel of each wheel. Kevin and Jim jacked the plane onto the scales and measured 1335 lb empty weight with left and right wheels within 3 lbs. The measured CG was 82.14 in specs and ideally located to make most use of useful load. Taxied plane and confirmed straight tracking and effective differential braking. Airspeed indicator appeared to respond to apparent increase in ground speed.

Verified operation of:
- landing lights
- wing tip strobe lights
- wing tip nav lights
- tail light
- pitot heater
- fuel pump
- defrost fans.....left fan is making noise, sounds like bad bearing, needs replacing

Roll trim position now working. Showing 0.012V and no change with position. Trims are working properly, so issues is likely a loose wire at the trim controller. Will check tomorrow.

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N818PP W&B.pdf

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Nov 23, 2021 Final Assembly - Day 2 - (4 hours) Category: Final Assemb

1. Installed VS front attach bolt and torqued to 70 in-lbs. Installed cotter pin.
2. Confirmed rudder hits both mechanical stops
3. Attached rudder cables. Torqued to 25 in-lbs, then backed-off slightly until clevis pin moved freely. Installed cotter pins.
4. Applied RTV to rudder system hole. Wrapped wiring with friction tape and secured with cable tie.
5. Ground the tail light to rudder bolt and re-torqued bolt.
6. Reconnected molex plug
7. Installed rudder bottom fairing and secured wiring.
8. Fished coax through VS and secured to NAV antenna.
9. Rivered VS top fairing to structure.
10. Installed edel clamp on coax.
11. Set ELT for ARM
12. Verified pitch and rudder control are free and clear with no binding.
13. Installed wings with Carlos and Markus help. All holes lined up extremely well. Technique was to use large drift pin for initial hole line-up, then insert a 3/8" hardware bolt and then wiggle the wing tip to help insert large bolts first, using light hammer taps. Neversiese was used to lubricate the bolts. The AN9 bolts were torqued to 75 ft-lbs each and the AN6 bolts to 14 ft-lbs. Aft bolts also installed with castle nut and cotter pin.
14. Set aileron deflection slightly up at neutral (1/16" up from trailing edge). Adjusted control rod end bearings to set stick in neutral position. Installed and torqued aileron control bolts and jam nut.
15. Reinstalled flaps. Adjusted full retract angle at 8 deg down relative to canopy rail - about 1 deg off of spec of 7 deg.

Nov 22, 2021 Final Assembly - Day 1 - (8 hours)

Category: Final Assemb

Picked up engraved nameplate. Started to reassemble the airplane:
1. Checked jam nut torques on elevator end bearings
2. Inspected rudder cables to ensure no binding/rubbing
3. Confirmed all electrical securely tied
4. Vacuumed aft empennage area to ensure no loose objects
5. Installed horizontal stab and torqued AN4 bolts to 70 in-lbs
6. Checked torque on all other HS bolts
7. Bolted aft elevator pushrod using two 0363P washers on each side of bearing. Torques to 25 in-lbs
8. Checked elevator travel. Measured 25.3 deg up and 26.5 deg down. Filed upper stop to increase up travel to 29.5 deg, so now in spec. In cabin, stick stops 1/2 in from panel and just presses into the seat.
9. Installed VS/rudder and torques all bolts to 25 in-lbs.
10. Checked torques on all elevator bearings and attachments.

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Nov 21, 2021 Leaving the Factory! - (6 hours)

Category: Transport

Transported my bird to the airport hanger. Beautiful Fall day. Hired flat bed tow truck and make two trips. Everything went great.

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Nov 19, 2021 Main Gear Fairings - (4 hours) Category: Finish

Fabricated both main gear fairings with slight change to instructions. Found it easier to drill rivet holes in hinges then clamp inside and shine light to pinpoint location to drill from outside.

Nov 17, 2021 Transition Training - (4 hours) Category: Training

Did 4 hours of RV-14A transition training with Zack in New Garden. Got logbook sign off.

Nov 15, 2021 Wing Removal - (2 hours) Category: Transport

With help from friends, removed wings and returned to cradle. Removed flaps, wing tips, and wing root fairings and transported to airport hanger.

Nov 13, 2021 A/C install - (4 hours)

Category: Air Cond

Installed cold air plenum. Drilled five #40 holes then match drilled into lateral roll bar support. Match drilled #27 and drilled #40 holes for K1006 nut plates. Dimpled and riveted nut plates to support.

Shorted length of canopy pull down handle to allow clearance for eyeball vent.

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Nov 12, 2021 A/C install - (2 hours)

Category: Air Cond

Fabricated and installed condensate drain.

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Nov 12, 2021 Insurance Quote - (1 hour) Category: Insurance

Requested insurance quote from AOPA.

Nov 12, 2021 Transition Training - (1 hour) Category: Training

Scheduled RV-14A transition training with Zack at New Garden for 11/17.

Nov 12, 2021 Flight Test Plan

Category: Inspection

Application resubmitted to new DAR-T. Proposed flight test plan.

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Nov 11, 2021 A/C install - (3 hours)

Category: Air Cond

Installed temp switch. Wired evaporator plug and attached. Confirmed evaporator fan operation. Installed relay mounts. Cleaned up wiring and bundled. Inserted new o-rings and torqued all fittings to 80 in-lbs.

Punch List:
1. Shorted left side condenser vent duct
2. Fab and install drain
3. Reverse low and med evaporator blower leads
4. Attach foam around supply and returns
5. Attach brackets to evaporator
6. Attach access panel.
7. Fit and attach cold air plenum
8. Finish and paint plenum

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Nov 10, 2021 A/C install - (4 hours)

Category: Air Cond

Fabricated and installed receiver/dryer mount. Cut and crimped all hoses.

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Nov 09, 2021 Tow Truck Search - (2 hours)

Category: Transport

Located tow truck that should work to transport plane to airport.

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Nov 09, 2021 A/C install - (3 hours) Category: Air Cond

Drilled and bolted forward condenser blower angle iron support to longerons. Located and installed evaporator supports and confirmed fit to access panel. Purchased parts from hardware store to fabricate holder for receiver/dryer.

Nov 08, 2021 A/C install - (5 hours)

Category: Air Cond

Fabricated aluminum flange for evaporator blower outlet and riveted to evaporator. Welded fiberglass hose flange to inside of plenum with flox. Installed aft condenser support angle to longerons with AN3 bolts. Bolted condenser to aft support member. John sending temp switch he forgot to install.

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Nov 07, 2021 A/C install - (5 hours)

Category: Air Cond

Mounted evaporator support bracket to access panel. Cut openings in access panel for supply and return vents. Test fit hoses.

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Nov 06, 2021 Evaporator Mock-Up - (5 hours)

Category: Air Cond

Erected a mock-up for the custom evaporator which arrived yesterday. Fabricated angle iron supports and access panel mounting plate.

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Nov 05, 2021 Compressor lubricant and hoses - (1 hour) Category: Air Cond

Added lubricant to compressor. Installed o-rings and tightened all refrigerant line fittings.

Nov 05, 2021 Autopilot Ground Test - (1 hour) Category: Avionics

Removed rubber grommets interfering with roll linkage at fuselage and confirmed correct autopilot operation of pitch and roll servos.

Nov 05, 2021 Firewall penetration fire seal - (1 hour) Category: Firewall Forward

Sealed both firewall penetrations as described in plans.

Nov 05, 2021 Nose Gear Fairing - (2 hours) Category: Finish

Finished installing nose gear fairing.

Nov 04, 2021 Nose Gear - (2 hours) Category: Finish

Completed riveting hinge. Removed cowling and installed fairing to nose gear. Had to curve hinge pin to clear bottom of fuselage.

Nov 04, 2021 Paint Scheme Design - Final - (1 hour)

Category: Painting

After many hours and revisions, approved the paint scheme design.

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Nov 03, 2021 Nose Gear Fairing - (3 hours) Category: Finish

Completed fabrication of nose gear fairing.

Nov 02, 2021 Nose Gear Fairing - (4 hours) Category: Finish

Started working on nose gear fairing. Completed all steps to drilling hinges.

Nov 01, 2021 Magnetometer Calibration - (2 hours) Category: Avionics

Recalibrated magnetometer by rotating plane cw in increments over 360 degrees following on-screen prompts. Continued working through post-install checkout. Reversed motor direction on pitch servo. Aileron and trim movement is sluggish and I suspect it's due to rubbing against the fuselage side rubber grommet.

Nov 01, 2021 Nose Wheel Fairing - (10 hours)

Category: Finish

Completed nose wheel fairing over a period of several days.

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Oct 28, 2021 Flaps and Vibration Test - (4 hours) Category: Avionics

Resolved problem with Flaps by reversing wires 18/19 on the GAD 27 J271 and wires 7/8 on the GAD 27 J273. Successfully ran the vibration test on the avionics by running engine at full RPM. It passed the second time.

Oct 26, 2021 Nose Wheel Fairing - (4 hours)

Category: Finish

Continued fabricating nose wheel fairing. Fabricated aluminum stand-offs.

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Oct 25, 2021 Main Wheel Fairings - (4 hours) Category: Finish

Completed fabrication and assembly of main gear wheel fairings.

Oct 22, 2021 Wheel Fairings - (3 hours)

Category: Finish

Continued working on right main wheel fairing up to point of installing brackets on wheels.

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Oct 16, 2021 Left Wheel Fairing - (2 hours)

Category: Finish

Pressured nose wheel to 30 psig and main gear to 40 psig. Installed left wheel fairing brackets. Fitted and sanded forward and aft fairings for 5/8" clearance around all sides of tire. Clecoed in place.

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Oct 14, 2021 Fuel Tank Calibration - (3 hours)

Category: Fuel System

Successfully calibrated left and right fuel tanks. Deflated nose wheel and propped up rear fuselage with saw horse until airplane in cruise attitude as measured by zero level reading (+/- 1 deg) at forward canopy longeron. Charged 5 gal 100LL in increments to 25 gal and created calibration curve following instruction on G3X. Saw no leaks and no mechanical or electrical issues. Note that voltage reading does not change above about 22-23 gal, approx.

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Oct 13, 2021 Relocate Left Wheel Hub - (2 hours)

Category: Finish

Jacked up left wing using new jack stand and removed wheel and hub. Rotated and reinstalled hub so that external bracket mount is parallel to airplane. Torqued all nuts to spec per Beringer instructions and fastened with safety wire.

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Oct 12, 2021 Wing Jack

Category: Finish

Upon attempting to fit the left wheel fairing, realized the hub was 90 degrees off, requiring removal of the tire. Picked up a tall bottle jack at HF and fabricated stand to lift plane at wing tie-down. Carlos welded cap to threaded stub to replace tiedown ring . Ordered remaining parts from McMaster but will return.

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Oct 11, 2021 Wheel Fairings - (4 hours)

Category: Finish

Assembled left wheel fairing following instructions up to mounting fairing bracket one wheel.

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Oct 08, 2021 GMU 22 Bracket - (2 hours)

Category: Avionics

Fabricated and installed bracket for GMU 22. Confirmed magnetometer functioning. Confirmed there's no interference with landing and nav lights. Re-installed inspection plates on each wing.

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Oct 07, 2021 Cowl Pin Covers - (4 hours)

Category: Firewall Forward

Modified cowlings for the Aerosport pin covers.

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Oct 04, 2021 Canopy - (2 hours) Category: Finish

Removed canopy and Installed new forward seal. Drilled hole in panel for canopy release and installed release handle. Removed plastic from canopy.

Oct 04, 2021 ADHS Calibration - (2 hours) Category: Avionics

Successfully calibrate magnetometer today. While still waiting on GMU 22 bracket from Vans, fabricated temporary support from used wing inspection plate. Initially was not getting GPS data to ADHR but after consulting with SteinAir, reconnected GPS coax from XM/GPS antenna from GDL 51 to GPS port on back of PFD display. Followed the steps directed by the ADHS configuration page and with Carlos' help, slowly rotated the airplane supported on auto Dollys, clockwise from North.

Oct 03, 2021 Wing Root Fairings - (3 hours) Category: Finish

Completed installation of left side wing root fairing and gas tank breather tube.

Sep 28, 2021 Wing Root Fairings - (3 hours) Category: Finish

Filed and deburred edges of wing root fairing pieces. Enlarged attachment holes to #17 and bent wing edges down slightly. Bent lower wing root fairings over 1.25" rod to form leading edge curve and temporarily attached with clecos. Clecoed upper fairing to confirm fit. Cut and deburred upper fairing stiffeners and dimpled. Dimpled flush outer surface of upper fairing where ribs attach.

Sep 28, 2021 Tail Light - (3 hours) Category: Finish

Re-attached vert. stab and rudder and routed control wire for tail strobe light. Ground wire, attached molex, and confirmed tail light strobe functions properly. Routed Nav coax through vert. stab. and attached antenna to custom made mount. Installed all aft fairings and inspection plates.

Sep 27, 2021 Wing Root Fuel Filters - (2 hours) Category: Finish

Installed elbow fittings that arrived from AS for the wing root Holly filter outlet and completed filter and shutoff valve installation on both sides. Began prepping wing root fairing covers.

Sep 26, 2021 Light Check-Out - (1 hour) Category: Finish

Confirmed operation of landing lights, nav lights, and wingtip strobe lights. Ordered GMU 22 mounting bracket from Vans. Also ordered replacement landing light lens for current one which is cracked and inspection plate cover to replace the one where the roll trim motor is attached. Ordered extra screws, nuts, etc since intention is to not reuse any surface mounting screws.

Sep 25, 2021 Wing Attachment - Wiring - (6 hours)

Category: Finish

Connected common harness to wing harness. Installed Molex for ground wires from wing to wire leading to firewall ground plate. Secured ground wires to fuselage and pre-installed nutplate grounds. Installed OAT on right wing near roll trim motor access plate. Had to drill out and some of the screws. Installed lightening hole trim near wiring harnesses and secured all harnesses with cable ties. Installed molex and reconnected wing tips. Attached aileron horn to actuator rods. Recalibrated flap travel with digital level. Flaps are still not progressing to next relative step as expected. Will check again after GMU 22 installed and ADHRS calibrated since my working theory is that the GAD 27 requires a valid air speed for the flaps to work properly.

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Sep 24, 2021 Wing Attachment - (4 hours)

Category: Finish

Attached left wing using temporary bolts. Process used was:
1. Set wing on padded sawhorses
2. Lubricated spar attachment surfaces with never seize.
3. Pushed in wing and raised tip to center holes. Used large drift pit to assist.
4. Installed lubricated 3/8" drift pins in smaller upper holes.
5. Installed 4 temporary bolts in spar and tightened nut
Repeated on right wing.

Noticed wing root fuel filter missing elbow on exit of filter. Spoke to Steve at Aircraft Specialties and he's having new ones sent. It was an item that was supposed to have been drop shipped from Spruce, but I never saw it.

Installed flaps actuator rods. Entered rough calibration into G3X configuration page, but flaps are not properly moving to next relative position up or down. Will diagnose tomorrow.

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Sep 22, 2021 Interior Close-Out - (3 hours)

Category: Interior

Installed new tunnel cover from Classic Aero to accommodate repositioned power outlet and audio jack. Replaced 12V power plug with 2X USB power ports. Installed new tunnel carpet which not extends to CB panel and attached black anodized trim pieces over power outlet and fuel selector. Removed right side floor carpet, cut channel for refrigerant hose, and installed. Finished by installed forward tunnel carpet and side pocket panel

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Sep 21, 2021 Condenser Vents - Close Out - (2 hours)

Category: Air Cond

Riveted right boot to flange. Clecoed left boot assembly to fuselage opening, match drilled #30, and demurred holes. Reclecoed and countersunk louver plate for BSC-44 pop rivets. Riveted boot assembly and louver plate to skin. Repeated on right side. Louvers are oriented forward on the intake side (right) and backward on the exhaust side (left)

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Aug 26, 2021 VOR Antenna

Category: Avionics

Fabricated fiberglass mount on vertical stabilizer for RAMI VOR antenna. Removed fiberglass cap from vert. stab.

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Aug 24, 2021 Pitch servo - (3 hours)

Category: Avionics

Installed pitch servo stop bracket and torqued all bolts. This was quite a challenge requiring removal of the servo and mount assembly. Confirmed the stop bracket does not impede full movement of elevator (per. 18.5.2.2, G3X Touch Install Manual). Confirmed G3X recognizes the servo when A/P powered and that the CWS/Disconnect on the control stick is functioning (Open to Low when stick button below PTT trigger is pushed, also hear solenoid engage when releasing).

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Aug 21, 2021 Interior Install - (20 hours)

Category: Finish

Completed ClassicAero interior install over the past week, working about 4-6 hours a day. It started with laying out the carpet sections where I notified Classic that they send me the wrong tunnel carpet meant for the angled CB panel. Next, I used the supplied templates to locate and drill attachment holes. Installed the pilot side panels and the modified canopy idler assembly. Clearance for the JD latch is tight, but acceptable. Made adjustments to the eyebolt rod ends to ensure canopy closed switch engages. Removed seat bottom panel and installed crotch belt Hooker harness. Installed shoulder and waist belt harnesses. Removed joy stick cover and installed nutplates for attaching stick boot. Adjusted belt lengths and reassembled cover plates. Moved back rest support from seat back to seat. Installed seat back to existing hinge and seat bottom. Repeated installation for right side.

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Aug 16, 2021 Air Plenum - (2 hours) Category: Air Cond

Removed foam and sanded smooth. Applied flox and additional glass cloth to thin areas.

Aug 14, 2021 Air Plenum - (3 hours)

Category: Air Cond

Temporarily installed air plenum and marked areas the need. to be built-up to form a better fit. Used green closed-cell foam insulation from Lowes to creating backing for fiberglassing. Glued foam sections in place and taped faces with packing tape to ease release. Applied several layers of fiberglass extend and reinforce extensions. Allowed to cure overnight.

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Aug 14, 2021 Red/White LED lights - (3 hours) Category: Lighting

Troubleshot the red/white glare shield LEDs. Rebuilt molex and confirmed strip lights worked. Checked cabin light configuration in G3X and it turned out the function was not enabled for these lights. Enabled function and now they are working. Installed glareshield edging. Lightly sanded surface adjacent to edging, cleaned with alcohol and applied 3M VRM double-sided tape. Attached strip and secured wiring to underside of glare shield with RTV.

Aug 13, 2021 A/C install - (1 hour)

Category: Air Cond

Riveted boot to flange with LP4-4 and attached hose end. Fed assembly through aft fuselage and clecoed to louver cover and skin. Tested two options for flush pop riveting using a BSC-44 and an MK-319-BS through sandwiched layers totaling 0.1". The MK-319 requires a smaller countersink and leaves a better appearance.

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Aug 12, 2021 AC controls - (6 hours)

Category: Air Cond

Installed fan switch and connected to ac switch on panel. Installed a panel-mounted LED wired to ac switch. Ran two #14 wires for low and medium speed fan controls to aft of baggage bulkhead. Wired compressor and condenser relays and temporarily mounted. Turned on system and confirmed condenser fan operation with pretty good air flow. Confirmed with John that fan is pulling air through coil and discharging on pilot side. Match drilled #35 and countersunk left side louver cover. Installed boot and drilled #40 holes along all side for fastening. Disassembled and applied RTV and clecoed together overnight.

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Aug 11, 2021 A/C install - (2 hours) Category: Air Cond

Cut vent opening on right side.

Aug 09, 2021 A/C install - (1 hour) Category: Air Cond

Located right side vent and drilled mounting holes.

Aug 08, 2021 Plenum and Evaporator mock-up - (2 hours)

Category: Air Cond

Mocked-up plenum vent configuration and marked position of evaporator on aft face of bulkhead access panel. Evaporator will need rectangular stubs on both openings. Sketched planned flow diagram. Mocked-up evaporator mounting.

Flow Schematic

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Aug 07, 2021 Plenum, continued - (2 hours)

Category: Air Cond

Sanded plenum and dug-out the foam core. Removed fiberglass on forward and aft faces and test fit.

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Aug 06, 2021 Plenum, continued - (2 hours)

Category: Air Cond

Sanded plenum and applied coat of tinted epoxy and micro to fill voids. Allowed to dry overnight.

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Aug 06, 2021 Condenser Vents....continued - (4 hours)

Category: Air Cond

Completed riveting screens to front of vent flanges using thin aluminum strips on inside as hold-downs. Starting on left side, positioned louvers over fuselage at a panel location aft of the second bulkhead and aft and below the static port at an angle of 3.1 deg to match the angle of the main forward longeron. Taped louvers to fuselage side and match-drilled #40 all mounting holes. Marked online of cutout, removed louvers, and carefully cut the opening using a multitool. Filed opening to final size and deburred. Clecoed vent flange and louver cover to fuselage.

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Aug 05, 2021 Condenser Vents - (2 hours)

Category: Air Cond

Began planning condenser intake/exhaust plumbing. After careful consideration, decided to install fan intake on left fuselage side just aft of the static port. A hole will need to be cut for the intake flange oriented parallel to the main cabin longeron and a screen installed. Considered several options and decided best approach is to insert screen and secure with a flush-riveted band on the inside. Getting a bucking bar on conventional rivets will be nearly impossible, so plan to blind riveting the louver plate to the skin and flange with pop-rivets.

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Aug 05, 2021 Plenum, continued - (2 hours)

Category: Air Cond

Sanded plug and coated with release wax. Laid-up several layers of fiberglass and allowed to cure overnight.

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Aug 04, 2021 Condenser Install - (2 hours)

Category: Air Cond

Fabricated angle iron supports for condenser and rails to span main fuselage longeron.

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Aug 04, 2021 Plenum, continued - (1 hour)

Category: Air Cond

Sanded plenum and re-coated with tinted micro.

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Aug 03, 2021 Empennage Fairing - Part D - (2 hours) Category: Finish

Removed fairing and sanded excess flox. Cleaned then coated inside of fairing with epoxy resin. Re-installed after epoxy dried.

Aug 03, 2021 Plenum, continued - (2 hours)

Category: Air Cond

Built-up ends by gluing additional foam to better route scat tube. Sanded, shaped, and coated foam mold with micro slurry. Allowed to dry overnight.

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Aug 02, 2021 Plenum, continued - (3 hours)

Category: Air Cond

Used hot wire to carve foam to close to final desired shape. Applied micro along radius turns to strengthen and allowing shaping. In retrospect, micro may be too hard resulting in oversanding foam. May be better to use bondo. Allowed to dry overnight.

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Aug 01, 2021 Supply Plenum - (2 hours)

Category: Air Cond

Built form for air supply plenum and prepared polyurethane foam.

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Jul 30, 2021 Mock-Up, Continued - (2 hours)

Category: Air Cond

Unboxed additional parts received from John and continued mock-up in aft fuselage. Match drilled and clecoed condenser outlet fan shroud. Clamped SCAT tubing to each side and inlet boot. Mounted evaporator mock-up so it will eventually flange up to bulkhead door.

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Jul 30, 2021 Empennage Fairing - Part C - (3 hours) Category: Finish

Sanded edges to scribe lines. Reinstalled and noted gaps. Removed, applied packaging tape to vert and horizontal stabilizer, applied flox at gap areas and reinstalled with screws. Cleaned and allowed to harden.

Jul 29, 2021 Empennage Fairing - Part B - (3 hours)

Category: Finish

Removed vertical stabilizer and rudder to install fairing nutplates on each stabilizer. Installed the three nutplates on aft fuselage skin and the two on each side of the longeron. Replaced stabilizer and attached fairings.

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Jul 28, 2021 Empennage Fairing - Part A - (4 hours) Category: Finish

Started work on the empennage fairing by first trimming the fairing to 1/8" from scribe line and sanding. The fairing fit well enough to not require any signifiant sanding. The next step involved locating the nut plate holes through the fiberglass using backlighting which was a significant challenge. I securely taped down the fairing and located and drilled #40 the aft two holes using a flashlight for light. Then, Cate crawled into the aft fuselage and drilled the forward three holes from the inside which I clecoed. I then alternately removed the fairing, secured a small headlamp to each of the remaining holes, then reattached the fairing, located the hole, and drilled #40 until all were found. Each #40 was match drilled to #27 and then the fiberglass holes countersunk for a #6 screw. Finished the day be beginning to install nut plates realizing it will be easier to do this with the rudder and vert. stab. off.

Jul 27, 2021 Mount Tail Feathers - (3 hours)

Category: Finish

Mounted horizontal, vertical stabilizer, rudder and elevator to aft fuselage and connected harness and tail light. Connected rudder cables to rudder horn. Connected pitch torque tube eyebolt to elevator horns. Did not final torque. Confirmed elevator movement with stick was free with no binding. Confirmed rudder movement was free with no binding or interference. Confirmed roll trim on stick HAT control was functioning.

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Jul 25, 2021 Transport Stabilizers - (2 hours) Category: Fuselage

Transported tail feathers (horiz and vert stab) from hanger back to garage to begin working on fairing.

Jul 24, 2021 Ignition Light - (1 hour)

Category: Firewall Forward

Installed red LED ignition light on panel to confirm starter engage/disengage from flywheel during start-up. The light is connected to the 'I' terminal on the starter solenoid.

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Jul 24, 2021 Tach Cap - (1 hour)

Category: Firewall Forward

Installed and safety wired tack cap to reach or engine.

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Jul 24, 2021 Replace EGT - (1 hour) Category: Avionics

Replace #4 EGT probe that wasn't working with new probe. Working now.

Jul 22, 2021 Pilot Grip - (2 hours)

Category: Avionics

Moved grip back to shorter Tosten stick and crimped new terminals to the micro Molex connector. Drilled new mounting holes and installed. Confirmed that PTT is working, but can't really check out the trim functions until wing and tail assembly.

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Jul 22, 2021 Flap Position Sensor - (2 hours)

Category: Avionics

Installed Ray-Allen flap position sensor purchased from Vans. They included a 6 pos micro-fit rather than a 3 pos, but was still able to use. They also included the wrong manual section, but I was able to download the correct section 54 from my files. Followed instructions outlined in Sec. 54 with no other deviations. Confirmed full travel of sensor pushrod and flap linear actuator.

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Jul 20, 2021 Condenser Mock-Up - (2 hours)

Category: Air Cond

Started mocking-up location of condenser.

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Jul 20, 2021 Control Stick issues - (1 hour) Category: Avionics

I assembled the control stick with help from SteinAir for the initial engine start, but the PTT didn't work. There could be several reasons, most likely I ruined the micro Molex connectors when relocating the grip to my original stick, which turned out to be a bad decision given the much longer reach of the stock stick. I ordered micro Molex connectors and will return the grip to the Tosten stick and try again.

Jul 19, 2021 First Engine Start

Category: Engine

First engine start today a success. Had to replace starter solenoid and charge battery overnight, but otherwise it fired up after just a few revolutions. Engine data attached with and without cowlings on. One issue with EGT #4 and have replacement sensor on order. No leaks observed. Minor smoke from under cowling, probably just surface oil burning off. Added additional 1-1/2 its oil.

Initial Engine Data.pdf

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Jul 17, 2021 Day Before First Engine Start - (3 hours)

Category: Engine

Developed a start-up checklist.

Filled up a 5gal fuel can with Avgas. Disconnected fuel line before fuel controller and purged right and left fuel lines with electric fuel pump. Confirmed flowmeter working. Found minor leak at bulkhead fitting.

Added additional oil to sump. Measuring just under 8 qts.

Fabricated CAN jumper from SteinAir parts and installed on right wing harness. Everything seems ready for initial engine run tomorrow.

RV-14A Checklist.pdf

Jul 16, 2021 Engine Pre-Oil; Firing Order Check; Brake Fluid Charging - (4 hours) Category: Engine

Added approx 2 qt of oil about to engine using fabricated PVC tank over about an hour. Pulled top plugs and manually turned prop to pump oil through engine and accessories. Tied battery to main bus and turned engine over with starter to circulate oil. Pressure increased to 50 psig. Reading 6 quarts in sump.

Confirmed cylinder firing order 1-3-2-4 by removing all spark plugs, reconnecting to leads, and grounding to the engine case. Ungrounded p-mags and slowly turned prop and observed plugs sparking in the correct order.

Charged brake fluid to master cylinder and purged brake lines.

Received interior from Classic Aero today. Unboxed and checked inventory. Called to get installation instructions.

Jul 15, 2021 First Electrical Power-Up Category: Engine

Confirmed both p-Mags have jumpers between terminals 2 and 3. Realigned the cooling tubes to focus air on the fins.

Fabricated new seat hinges and installed on floor. Installed seat backs.

Tied the battery. When switching to BATT on panel, smelled burning, so immediately turned off. I suspected it's coming from CB panel touching side of housing. Untied battery and installed plastic edging along right side along bus bar. Re-tied battery and this solved the problem. PFD, MFD, G5, and rocker switches all lit up. Confirmed correct operation and display on PFD for canopy latch. Confirmed fuel pump and flap motor control from panel. Confirmed GTN650 powers up. Confirmed light dimmer switches work. Confirmed operation of the defrost fan from the panel. The LED does not function.

Went through the procedure for timing the p-mags. Removed Cyl #1 spark-plug and turned the prop CW until at TC and confirmed this aligns with TC mark on rear of flywheel at engine centerline. Rotated prop CW 2 teeth (~4 deg after TC). With p-mag OFF, set BATT and observed red lights one each p-mag. Disconnected MAP line to sensor and blew into line until red light flashed. Blew a second time until light flashed green. Cycled battery OFF/ON and LED was solid green on both p-mags. Turned prop slightly to confirm light turned from red to green to red as prop passed through TC. Couldn't be easier.

Jul 14, 2021 Check List Prior to Interior Install - (4 hours) Category: Finish

Complete the following before installing interior:
- run additional ground wires to wing harnesses
- tighten and torque brake line fittings
- tighten and torque brake frame hold-down blocks
- thoroughly clean tunnel
- fabricate and install seat back hinges
- tie-down harnesses as needed to reduce potential chaffing
- complete left and right center harness terminations into molex.
- install stop on pitch servo
- confirm all bolts under floor are properly torqued
- re-install rear canopy

Tightened and torqued banjo fitting on brake lines to 12 ft-lbs. Tightened and torqued bolts holding pedal mechanism to fuselage. Cleaned tunnel and installed all floor panels including over flap motor.

Spoke with Tim and SteinAir to understand what I need to power up G3X without roll servo plugged in. He sent instructions along with parts to assemble plug to terminate CAN bus.

Spoke with Brad at eMag to confirm method for identifying TC and setting the pmag timing.

Jul 13, 2021 Brake and Rudder; A/C harness; grounds - (5 hours) Category: Avionics

Re-assembled brake and rudder system and reinstalled in forward fuselage. Decided not to wait on Risse to deliver the needed parts as he promised and will consider whether to install them or return them.

SteinAir parts were delivered and finished fabrication of A/C harness. Ran harness through lightening holes under co-pilot side and then down tunnel to aft of baggage bulkhead. Terminated all grounds and coiled up power wires for later termination.

Ran 14 ga ground wires to left and right side of fuselage at wing attachment. Ran ground wire from fuel pump.

Installed new 6V battery in ELT remote.

Organized coax cable and wire bundles behind CB panel.

Cabin is nearly ready for installation of interior being delivered on Friday.

Jul 10, 2021 Sniffle Line - (2 hours)

Category: Firewall Forward

Fabricated and installed sniffle line. Couldn't find the bracket anywhere, so fabricated a new one.

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Jul 09, 2021 Flap Motor; A/C; Interior: Brake Pedals

Category: Finish

Connected flap motor to mount. Drilled and safety wired lower end of shaft as described in plans. Connected black and red power leads to corresponding wires in common harness using molex.

Spoke with Show Planes who made flap position sensor that Carlos gave me and confirmed it would not be the best option for G3X with the GAD 27. It's best to use Van's position sensor so that I can have flap position displayed on the PFD. Ordered position sensor from Vans (W21-070916704).

Spoke with John to confirm wiring schematic and parts shipment. Based on the discussion, drew up a plan-style schematic showing the needed wire runs. Ordered wire from SteinAir.

Paid balance on interior from Classic Aero estimated to arrive next Thursday.

After repeated threats, Kevin finally agreed to finish my pedal order and said he'll ship out the missing parts on Monday...we'll see. Not getting a good review from me.

Guinn, RV-14 AC wiring.pdf

Jul 08, 2021 Grounding; NAV antenna cabling

Category: Avionics

Evaluated grounding with plan to run all grounds to firewall rather than to structure, were possible. This is what I come up with:

LEFT WING
- Pitot Heat (14)
- Landing/Nav Light (14)...Spliced to P2176 on common harness
- L2188 on fuse side and L420 on wing side
- Spare (16)

RIGHT WING
- Roll Servo (16)
- Landing/Nav Light (14)...Spliced to P2176 on common harness
- L2188 on fuse side and L420 on wing side
- Spare (16)

FUSELAGE
- Pitch Servo (16)
- Power outlet (16)
- Tail Light (16)

Ordered additional wire from SteinAir. Installed second ground bus to firewall.

Installed BNC connector to one end of coax and snaked through tunnel to the aft fuselage. Connected BNC end to NAV connection on rear of GTN 650xi. This should be the last antenna.

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Jul 07, 2021 Canopy Harness Close-Out; Pitot/Static/AoA Install - (6 hours)

Category: Avionics

Coiled up and secured remaining unused wires including: Voltage Regulator, DC spares (2), PMW spare, and discrete spare. Connected loose AML wires to back of A/C switch. Modified thermocouple harness to shorted longer leads so that they are all approximately the same length.

Ran Pitot (red) and AoA (green) tubing through left fuselage side to sub-panel behind the GSU 25C and G5. Protected from potential chafing with edging on the lightening holes use to thread the pneumatic lines. Connected tubing to back of GSU 25C and G5 and cable-tied securely.

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Jul 06, 2021 Canopy, Defrost Fan, LED Cabin Lights Wiring - (6 hours)

Category: Avionics

Ran two 22 ga wires, green and black, through the wire access holes on the lower left side of the canopy using safety wire. On one end, formed a small loop and fed the safety wire through the forward end and retrieving it using needle nose pliers from the aft hole. Formed another loop on the forward end and twisted stripped ends of each wire through the loop, using duck bill pliers to compress the joint. Crimped spade plugs and shrink-wrapped aft ends. Applied RTV to the aft hole. Adjusted switch and confirmed zero ohms when latch fully closed and infinite ohms with latch partially to fully open. Located purple and green Canopy Open wire and temporarily tied it to green canopy wire. The purple/green wire terminates on pin 42, Discrete #3 in, on the GEA 24 J244 jack.

Located red Defrost Fan wire and routed to left sub panel side. Ran red and black 22 ga wires along canopy frame and connected to red and black wires on defrost fans using a butt splice and shrink tubing.

Installed the red/white LED strip light 1" below the edge of the glare shield. Used a power supply to confirm positive is black wire while red and white are corresponding grounds. Located red and white ground leads from Stein harness.

Connected all canopy, fan, and cabin light wiring to 12 pin molex. Fabricated harness with matching molex from existing loose wires from Stein harness, including two additional ground wires for canopy and fan. Red and white LED grounds already exist from the Stein harness.

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Jul 05, 2021 ELT Installation - (4 hours)

Category: Avionics

Back from a week off for vacation. Scoured the bottom side of the antenna mount and Installed the whip antenna. Mounted the ELT battery mounting tray and clamps on aft fuselage as described in Sect. 53. Secured audio alarm temporarily on side of battery. Fabricated DIN connector as described in Sect 53 and the ACK Mode E-04 ELT installation manual, pg.8. Ordered a Duracell PX28L battery for remote already installed on panel. Registered the new ELT on the NOAA website https://beaconregistration.noaa.gov/RGDB/index.xhtml. User name RViator62. Battery expiration date is July 29 2025. Need to reregister in two years.

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Jun 26, 2021 Transponder and COM Antenna Install - (6 hours)

Category: Avionics

Installed a Comant CI-105 (SN #98177) transponder antenna in the pre-drilled holes on the lower rear side of the aft fuselage. Connected existing BNC coax previously installed on page 10-23 to the antenna and the other to the XPDR plug on the GTX-45R transponder. The GTX-45R contains both a mode C and ADS-B transmitter and uses the common antenna. The separate pre-drilled hole in the fuselage floor installed on 26-11 will not be used. GPS position data for the GTX-45R is coming from the GTN-650Xi so no separate GPS antenna connection is required.

Installed a Comant CI-122(SN# 647962 ) VHF communications antenna on the right side fuselage outside bottom. Drilled out four rivets holding antenna doubler with a #12 bit, removed the doubler, and attached the antenna with cork gasket and four #8-26 flat head screws and lock nuts. Fabricated coax cable with BNC connection and inserted into COM plug on back of GTN-650XI. Repeated for left side COM antenna, Comant CI-122 (SN# 647956) and inserted coax on the COM plug of the GTR-20 remote radio.

Labled and cleaned-up cable and wire routing in center chase, not an easy chore given the tight clearances.

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Jun 25, 2021 GA-57X Antenna Install - (6 hours)

Category: Avionics

Fabricated doubler and mounted Garmin 57X GPS/XM antenna to top of aft fuselage. Fabricated coax from RBG-400 for both GPS antennas and connected to associated LRUs; the GA-57X GPS and XM cables to the GDL-51R data link and the GPS/WAAS cable from the teardrop antenna to the back of the GTN-650Xi.

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Jun 24, 2021 GA-35 Antenna Install - (3 hours)

Category: Avionics

Fabricated a fuselage doubler for the GA-35 GPS/WAAS antenna. Match drilled doubler holes onto the upper aft fuselage just off-center behind the baggage bulkhead. Dimpled and riveted nut plates on the doubler. After removing rear canopy, dimpled #40 match-drilled holes in fuselage and riveted doubler to fuselage. Installed a GA-35 antenna (part no. 013-00235-00, SN# 196335) using 4 screws provided.

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Jun 23, 2021 Wiring Clean-Up - (3 hours)

Category: Firewall Forward

Relocated CHT probes wires so they are further away from exhaust piping and wrapped with spiral nylon wrap. Wrapped all remaining wire bundles. Wrapped thermocouple and sensor wire bundles to plugs.

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Jun 22, 2021 A/C install - Cabin Close-Out - (4 hours)

Category: Air Cond

Installed left and right side bulkhead fittings using SS washers (NAS 1149-C1490R, NAS 1149-C1290R) on each side. Applied bead of pro seal on fwd side and torqued nut on aft side. Installed and torqued left and right side torque tube pushrods. Secured refrigerant lines under pushrods with cable tie and confirmed sufficient clearance under pushrods. Cut each hose to length and crimped a 45 degree RB fitting.

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Jun 21, 2021 Cabin Heat Controls - (3 hours) Category: Finish

Back inside the cabin again. Installed left and right side cabin heat control cables.

Jun 20, 2021 Firewall penetration fire seal - (4 hours)

Category: Firewall Forward

Installed firesleeve in both firewall penetrations. The upper wire bundle is large but I was just able to push the firesleeve through the opening, although I see little chance of filling the cavities between the wires effectively with sealant. Will hold off until last moment, before first flight, to seal. Torqued and installed cotter pin on prop governor control cable. Installed adel clamp on suction refrigerant line. Checked and tightened all adel clamps. Re-installed cowlings and ram intake plenum.

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Jun 19, 2021 A/C install - FWF Close-Out - (3 hours)

Category: Firewall Forward

Ran power wiring to compressor. Step-drilled holes in lower left and right sides of firewall and inserted bulkheads. Ordered ss washers for doublers and to better seal the opening. Cut and crimped hoses to reduced barrier fittings. Secured hoses to engine mount.

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Jun 18, 2021 Cowling Close Out - (2 hours)

Category: Firewall Forward

Fabricated and riveted lower cowling close out flange. Installed heat reflective tape on lower cowl. Sealed edges with epoxy.

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Jun 17, 2021 V-Belt saga ends. Installed and torqued prop. - (3 hours)

Category: Firewall Forward

Received and installed a Gates XL 9405 (1/2" X 40-7/8") v-belt which fit the narrow range required for the a/c compressor. Reinstalled the compressor, tensioned the belt, and torqued and safety wired the tensioner bolt. Re-installed the left side baffle sections that needed to be removed to access the compressor. Tensioned and torqued the alt belt tensioner bolt.

Removed the expansion plug by drilling a 1/4" hole in center then hammering a 3/8" drive extension in the center until it was loose enough to pull out. Probably the hole wasn't necessary. Using a hoist, re-installed the prop and torqued in two steps to 40 ft-lbs, then 65 ft-lbs following the Hartzell install manual and pattern for R-flanges. Safety wired pairs of adjacent bolts with 0.031" wire. Noticed slight dings on one blade edge so covered with paper. These composite blades are definitely easier to damage.

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Jun 15, 2021 Cowling - (2 hours)

Category: Firewall Forward

Prepped and epoxied inside of top and bottom cowls.

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Jun 14, 2021 FM-200A Install - (4 hours)

Category: Firewall Forward

Cleaned and installed FM-200A flange with new gasket. Picked-up FM-200A fuel controller from Airflow Performance last Friday and got tour of facility in Spartanburg. Don reversed mixture operation so that it's standard cockpit action with full rich forward. Applied Loctite 648 and torqued 5/16-18 socket head screws to 120 in-lbs. Cleaned flange face and installed modified FM-200A with new gasket and tightened 5/16-24 stop nuts. Connected mixture cable to mixture control arm as shown in picture. Torqued control arm to 40 in-lbs, the castle nut on the AN3 bolt to 40 in-lbs, the stop nuts on the cable coupling to 30 in-lbs, and the nuts on the cable bracket to 100 in-lbs. Connected throttle linkage and torques to specs. Installed y-adapter and connected alt air cable and linkages. Torqued all nuts.

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Jun 13, 2021 Oil Cooler Wrap-Up and V-Belt Saga continued - (2 hours)

Category: Firewall Forward

Finally installed oil cooler duct and 5" SCAT tube that were long back-ordered from Van's.

Ordered and tried smaller v-belt, Gates 9412, but still just a hair too long. Ordered 9403 and 9405 arriving Tuesday.

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Jun 12, 2021 V-Belt saga - (1 hour)

Category: Air Cond

Back from a week on vacation. Pulled prop. Installed Gates XL 9400 v-belt arrived for A/C, but it's a bit too short. Ordered 1" and 2" longer belt from O'Reilly.

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Jun 06, 2021 STATUS AND UPDATE - (1 hour)

Category: Firewall Forward

Here is a summary of work in progress and completed along with punch list items:

Firewall Forward
Cowling is nearing completion. In last week, finished flox and sanding around air inlets, and installed last of baffle seal on right side only. Fabricated and installed new aft top cowling hinge pins. All that remains is:
- installation of foam seal around prop gov.
- installation of heat shielding to inside top cowling
- any modification to lower cowling to accommodate controls

Fuel Controller will be picked up from Airflow next week and re-installed along with the alt air and all controls the week of June 13. That will complete these mods.

Vans should be shipping the back-ordered parts to complete installation of the oil cooler ducting so I expect to complete that the week of June 13 as well.

Ordered the a/c v-belt recommended by John and should arrive next week. Will have to pull prop. I may have to order alternate size if this one isn't correct.

Other FWF items to complete include:
- installing firewall seal on all penetrations
- install bulkhead fitting and connect hoses to a/c
- run power to a/c compressor

Cockpit and Cabin
Classic Aero interior is due mid-July. Thing to get done before that include:
- Install the new toe brakes and foot pedals and connect to rudder cables
- Install heater vent cables (part of back-ordered parts)
- Install aileron control links
- connect refrigerant lines to bulkhead fittings
- run a/c wiring to aft of baggage bulkhead
- install flap position switch
- install antennas including coax
- run AoA and pitot tubing

RV-14A Punch List 061421.numbers

Jun 02, 2021 FM-200 Return - (1 hour)

Category: Firewall Forward

Returned FM-200 to Airflow Performance to have Don change out mixture action so that in my configuration its normal (forward control is fully rich).

Began working on air inlet mods for the lower cowling.

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May 28, 2021 Oil Access Door - (4 hours)

Category: Firewall Forward

Installed oil access door in top cowling.

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May 24, 2021 Lower Cowling Mods - (4 hours)

Category: Firewall Forward

Finally completed intake air plenum. Applied micro to lower cowling and installed plenum protected with shipping tape with clecos in order to fill gaps. Sanded and installed nutplates. Also sanded micro applied to air diverters in upper cowling.

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May 22, 2021 Lower Cowling Mods - (2 hours)

Category: Firewall Forward

Sanded around inlet nozzle and applied second coat of micro. Applied micro on forward side of new lower cowling flange groove to fill the honeycombs. Test fit lower cowling and opened up existing hole to accommodate alt air controls. Installed inlet air ramps into top cowl with flox, clecoed, and installed onto lower cowl to set and cure.

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May 21, 2021 Lower Cowling Mods - (6 hours)

Category: Firewall Forward

Sanded flat plenum flange bottom. Secured plenum to cowling with tape and drilled #40 about every 3-4 inches. Removed plenum and applied two courses of fabric to inside of cowling to strengthen area where I removed material on front side and provide a good surface for attaching nut plates. Installed intake flange to plenum with micro. Installed alt air cable that just arrived from AS and it fit well. Secured all three cables with nylon spiral wrap. Installed second insulation blanket between exhaust and cables. Connected alt air cable to y-adapter.

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May 20, 2021 Lower Cowling Mods - (4 hours)

Category: Firewall Forward

Removed peel-ply and sanded to level ridges formed by the underlying tape. Covered surface with layer of grey-dyed epoxy and cured. Pried part from mold and cleaned surface of lower cowling. Cut a flange evenly around part and sanded. Traced part onto lower cowling and used drum sander to remove a band of fiberglass to the honeycomb to permit attaching the intake plenum flush with the cowling surface.

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May 19, 2021 Lower Cowling Mods - (6 hours)

Category: Firewall Forward

Decided to redo part by first sealing foam with epoxy to ensure tape adheres completely, which was the problem encountered on first attempt. Did some additional fairing to improve overall appearance. Covered tape surface with release wax and layer-up four sheets of cloth using grey-dyed resin on last two layers.

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May 17, 2021 Lower Cowling Mods - (6 hours)

Category: Firewall Forward

Dug-out foam on aft face to allow room for intake elbow and installed lower cowling. Continued sanding monitoring thickness with graduated wooden skewers. Set-up for second pour to build-up entrance nozzle. After curing, shaped and sanded plug to final desired shape. Filled large holes with bonds and sanded. Covered plug with black duct tape and applied a wax release agent. Covered with two layers on fiberglass cloth and West System resin.

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May 15, 2021 Lower Cowling Mods - (2 hours)

Category: Firewall Forward

Pulled off cardboard, made much easier having taped the box inside. Started carving toward a desired final shape.

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May 14, 2021 Lower Cowling Mods - (3 hours)

Category: Firewall Forward

Reached out to Hartzell tech support for high pitch clearances and established forward inlet flange face 1" aft and marked location. Built box for foam mold on lower cowling. Removed cowling, inserted CEET tubing and inlet flange to mark and formed mold using two-part polyurethane. I had several leaks which created quite a mess for sure. Let cure overnight.

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Scan May 18, 2021 Scan.pdf

May 13, 2021 Induction Air and Cowling Mods - (1 hour)

Category: Firewall Forward

Cut larger opening in lower cowl to make room for induction air pipe and filter. Cut and installed CEET hose and inlet flange to alt air y-adapter. Need to confirm required clearance from prop before settling on forward flange position.

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May 12, 2021 Inlet Air Deflectors and spiral wrap - (2 hours)

Category: Firewall Forward

Fabricated and installed inlet air deflectors on right and left sides. Riveted right side and screwed in left side to be able to remove to service compressor. Wrapped thermocouple leads with nylon spiral wrap to provide better protection and rigidity.

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May 11, 2021 Left Side Baffle and AC - (6 hours)

Category: Firewall Forward

Completed modification of left side baffle, fabricating and installing removable ramp for compressor access and forward right mount to ac bracket. Installed baffle seal around prop governor and installed baffle assembly. Mounted and final torqued compressor bracket to pad. Removed paint and Installed grounding wire and confirmed continuity. Installed all baffles and completed riveting. Removed ramp to allow access to install compressor. Installed new bushing on tensioner arm and torqued all bolts.

Test fit intake air 90 degree adapter and positioned filter in gap behind compressor. Gaps around compressor should provide fresh air to filtered intake area although impact on pressure differentials not know yet. Plan to test on ground with leaf blower.

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May 10, 2021 Fabricating inlet ramp - (4 hours)

Category: Firewall Forward

Built box on left side air inlet for pour mold. Poured two-part urethane and it turned into quite a mess and not really what I hoped. Two key learnings: need to use some kind of release method on the parts, and second, can't have any holes or major gaps in the box. Disassembled with difficulty, will need to spend some time later with detailed clean-up. Decided to go with original idea of aluminum ramp. Mocked ramp with cardboard, then cut out and shaped a piece of aluminum sheet to act as a ramp. Also started working on ramps mounted to inside of top cowling.

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May 09, 2021 Baffle Mods - (1 hour)

Category: Firewall Forward

Started designing left side baffle modifications. Mocked idea with cardboard. Plan to fabricate fiberglass inlet ramp.

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May 08, 2021 Baffle Seals - (2 hours) Category: Firewall Forward

Completed fitting of baffle seals and riveted to baffles except for left intake which needs a different solution.

May 07, 2021 Ordered parts - (1 hour) Category: Firewall Forward

Ordered CEET-14 ducting from AS for alternate connection of inlet flange to y-adapter. Also ordered hardware from McMaster to complete compressor assemble. Followed-up with John on parts requested for A/C.

May 06, 2021 Baffling and A/C continued - (4 hours)

Category: Firewall Forward

Ordered 3.5" inlet air hose for fuel controller from Advanced Auto to arrive this afternoon, pretty sweet. Temporarily installed rubber baffling. Cut refrigerant hose outlets in rear baffle and installed snap bushings. Routed refrigerant hoses and crimped on reduced barrier fittings. Covered and secured refrigerant lines with firesleeve. Inserted inlet flange on hose and installed on y-adapter. Clearance from the prop is damn close. Not sure if prop blades are fully rotated under no hydraulic pressure but I assume not, so shorter inlet air hose may be needed.

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May 05, 2021 Cowling Mod Design, Baffle, A/C Compressor - (4 hours)

Category: Firewall Forward

Had helpful PM discussion with Dan Horton the VAF fiberglass expert and am beginning to formulate a strategy for the cowling mods using expanded polyurethane foam following his write-up on a similar project. Ordered needed materials from US Composites.
https://vansairforce.net/community/showthread.php?t=41375

Returned to the baffle mod to accommodate the A/C compressor. Riveted a short angle to mate the two parts and test fit on engine. Compressor fits snuggly with just enough clearance. Bought firesleeve to cover the refrigerant line the pass over the left side cylinders.

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May 04, 2021 Lower Cowling Mod and A/C Bracket - (4 hours)

Category: Firewall Forward

Finished riveting hinges to upper cowling. Consulted with Don who confirmed Y must go forward. He sent pictures of several cowling mods to give me some ideas. Enlarged the opening in the lower cowling to allow hinges to mate. Began to explore how to design mold. Reamed 3/8" holes in bracket to 13/32" and test fit bracket onto engine pad.

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May 03, 2021 Cowling and A/C - (5 hours)

Category: Firewall Forward

Installed 3/8 and 1/4 studs on compressor bracket mount. Ordered 13/32 reamer to open up holes in bracket to fit. Riveted lower cowling hinges. Marked intake air cutout using wooden sticks. Cut out hole and experimented with various possible positions for y adapter. I noted the opening is oddly not centered on cowling and the best orientation for the y is backward with the side tee pointing backward.

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May 01, 2021 Cowling - (4.5 hours)

Category: Firewall Forward

Continued assembly of cowling

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Apr 30, 2021 Cowling - (4 hours)

Category: Firewall Forward

Continuing installation of cowling.

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Apr 29, 2021 Cowling - (4 hours) Category: Firewall Forward

Completed cutting and sanding both cowling halves.

Apr 28, 2021 Electrical and Cowling - (4 hours)

Category: Firewall Forward

Completed grounding of all wires to grounding block. Mounted prop using engine hoist. Started on cowling

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Apr 24, 2021 Engine Systems: Electrical - (5 hours)

Category: Engine

Completed FWF wiring including mounting the avionics relay on the aft FW and shunt on the forward FW. Connected alternator to shunt and then to master solenoid on side connecting master and starter solenoids. What remains is running power to A/C compressor and grounding all wires to FW.

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Apr 23, 2021 Engine Systems: Electrical - (4 hours) Category: Engine

Continued connecting wiring including oil and fuel pressure sensors, manifold pressure, and oil temp. Connected master and starter field wires. Ordered 8 ga wire from AS to complete alternator shunt install. Also ordered 16 ga wire for a/c compressor clutch field power.

Apr 23, 2021 Engine Systems: Sensors - (4 hours) Category: Engine

Completed connecting EGT and CHT sensors to leads using overlap connectors. Covered connectors and wiring with shrink wrap and used safety wire to secure mesh sleeves. Confirmed continuity of each sensor.

Apr 21, 2021 Engine Systems: Sensors - (2 hours)

Category: Engine

Connected manifold pressure ports on P-mags to manifold pressure sensor using modified fittings. Secured manifold pressure sensor with additional adel clamp. Connected oil pressure sensor with Molex connector. Routed ground wire behind brake fluid reservoir to keep out of way.

What I did was replace the F-4 DTX-S on the Garmin firewall-mounted transducer with a 4-MTX-3 tee and 4-G6X-S adapter to 1/4" NPT where I connected a 90 deg 1/4" pneumatic swivel fitting. I ran 1/4" tubing to an insert tee then ran the rubber tubing supplied by E-Mag to each p-mag with the supplied pulse dampener in each line. On the RV-14A, the manifold pressure is taken off the #3 cylinder with a braided hose supplied by Vans which connects to the other side of the 4-MTX-3 tee.

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Apr 20, 2021 Engine Systems: Air Conditioning - (2 hours) Category: Engine

Began modifying left side baffling to accommodate a/c compressor. Will have to get creative with this. Decided it makes sense to start on cowling to better see how the baffling needs to be modified to ensure air flow over top of cylinders on that side. First the prop needs to be installed. Fitted spinner backplate to hub and positioned prop to prepare to lift it with shop hoist. Reversed the bracket side arms to original orientation.

Discussed a/c install with John. He will send alternate belt that is wider for better traction in compressor pully. Need to remove paint on bracket to ensure good ground to engine. He will send fan switch and relay.

Apr 20, 2021 Engine Systems: Air Conditioning - (2 hours)

Category: Engine

Measured for v-belt using rope. Calculated outside circumference using equation C2=C1+ 2pi(belt thickness) as reasonable estimate for effective length. Purchase 40" Dayco top cog belt (15400) and mounted compressor to check alignment. It's not bad, but any forward adjustment will not be possible without modification to bracket. Discharge and suction are oriented upward so best hose routing will be across top of cylinders, but don't see an issue here. Manual states these need to be oriented upward no greater than 45deg from vertical, so downward installation is not permissible. Probable good to fire sleeve these. Tension adjustment arm needs to come forward so additional washers and longer bolts required. Otherwise, there's sufficient separation from #2 cylinder, oil return line, and starter, actually a very nice fit.

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Apr 18, 2021 Engine Systems: Air Conditioning - (1 hour)

Category: Engine

Unpacked compressor (Valeo 103-52070) and test fit onto mounting plate to check alignment with the forward dual pulley. Removed baffle sections of left side. Was able to move into better alignment by repositioning bracket side arms with the compressor fully forward on the bracket. The alignment is close but it's at the fully forward limit. The only other possibilities would be to elongate the bracket mounting holes, not simple to do in steel, or reduce the thickness of the forward bracket side arm. Ordered Lycoming studs from AS based on what's required on the IO-390-C which uses the same mount for a compressor bracket.

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Apr 17, 2021 Engine Systems: Controls - (4 hours)

Category: Engine

Installed new turnbuckles from Don and connected mixture and throttle controls. Ordered parts from AS. Installed Thermo Tec clamp-on heat shield between exhaust and controls. Ordered second one. Connected EGT2 to thermocouple wire using overlap clamp to see how well that works. Waiting on more to arrive. Connected fuel flow transmitter with Molex.

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Apr 16, 2021 Engine Systems: P-Mags - (6 hours)

Category: Engine

Wired p-mags starting from left side to include tach pick-up and ground. Ran and secured plug wires per Lycoming instructions, Left: 2T/4T/1B/3B; Right 1T/3T/2B/4B.

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Apr 15, 2021 Engine Systems: Exhaust - (2 hours)

Category: Engine

Replaced exhaust pipe gaskets with copper #77611 gaskets and torqued to 190 in-lbs.

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Apr 13, 2021 Engine Systems: Controls - (4 hours)

Category: Engine

Installed bracket and routed control cables using prop cable in place of alt air cable not yet arrived. Confirmed with Don Rivera that phenolic spacer not required for FM-200 and ordered links and rod ends. Ordered custom push-button control cable from ACS for alternate air. Ordered exhaust pipe shield https://www.thermotec.com/products/clamp-on-heat-shield . Ordered inlet transition https://www.merlinmotorsport.co.uk/p/aluminium-air-inlet-polished-ai?pn=15767 . Installed and secured prop cable to governor. Installed control bracket under panel.

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Apr 11, 2021 Engine Systems: Controls - (2 hours)

Category: Engine

Mocked up options for controls and think I found the best option. Will need to order a few parts.

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Apr 10, 2021 Engine Systems: Controls - (2 hours)

Category: Engine

Build a stand to evaluate best configuration for installing mixture, throttle, and alternate air cables.

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Apr 09, 2021 Engine Systems: Baffling - (5 hours)

Category: Engine

Continued working on installing baffle except for left side until compressor and bracket arrive.

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Apr 08, 2021 Engine System: Air Induction

Category: Engine

The FM-200 alternate air duct and filter arrived from Airflow Performance.

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Mar 30, 2021 Engine Systems: Baffling - (8 hours)

Category: Engine

Started installing baffling.

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Mar 29, 2021 Engine Systems: Oil Cooler - (3 hours)

Category: Engine

Primed and installed oil cooler bracket and cooler and will complete vent assembly when back-ordered parts arrive.

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Mar 27, 2021 Engine Systems: Heat muffs and scat ducting - (2 hours)

Category: Engine

Finished installing scat ducting between heat muffs and to vent flanges on firewall.

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Mar 26, 2021 Engine Systems: Fuel xpdr and heat muffs - (2 hours)

Category: Engine

Modified Vans red cube install to move further away from exhaust pipes and mount on hose rather than cube. Was able to use existing hose to connect to FM200A inlet.

Made heater muffs using alternate end caps purchased from Rick and Robin Wings. They fit snug to exhaust pipes and are eccentric to permit more position flexibility. They replaced Vans parts that are known to prematurely wear out and potentially damage the exhaust. Realized I had to relocate my quick drain oil valve to the left side due to interference with the connecting scat hose. Drain oil sump, moved valve, and recharged with same oil.

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Mar 25, 2021 Engine Systems: Fuel and Oil Category: Engine

Installed fuel line from firewall to fuel pump inlet after reinstalling bulkhead fitting removed to enable installation of exhaust pipe.

Removed cover over induction air port and temporarily fit FM-200A. Discussed install with Kyle at Airflow Performance and ordered their throttle/mixture bracket that mounts under the oil sump, a cleaner design than that provided by Van's. Rotating the FM-200 to place the control arms below the sump will move the fuel inlet and outlet fitting and require new hoses.

Measured and ordered a new AN4 outlet hose with integrated fire sleeve to fuel divider from Aircraft Specialty Products.

Also ordered cable bracket, alt air tee and filter for test fitting to FM-200A. Reached out to James Aviation for advice/support on cowl modifications. Also to Bauer Aviation for info on his airbox if I decide to use filtered ram air. Ordered extra cable bracket for alt air control and researched push/pull cable to mate with linkage.

Spoke with John and he is shipping ac compressor and bracket. This all should give me all I need to assess required cowl modifications.

Mar 24, 2021 Engine Systems: Exhaust

Category: Engine

Completed installation of EGT and CHT probes.

Identified and temporarily routed all FWF wiring.

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Mar 23, 2021 Engine Systems: Exhaust - (6 hours)

Category: Engine

Finished main exhaust install, but waiting on head muff end caps from Rick to complete. Installed support from engine case. Included directions were a bit confusing. Installed heat deflectors. Began installing EGT probes.

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Mar 22, 2021 Engine Systems - (6 hours)

Category: Engine

Installed alternator and power cable. Measured for new v-belt required for smaller dual pulley. Had long chat with John about A/C and followed up with emails on compressor bracket and hose fittings. Requested he send main components to begin install. Started exhaust system install.

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Mar 20, 2021 Engine Install - (4 hours)

Category: Engine

Big day....installed the engine with help from a couple of pilot neighbors. Took about an hour with only a little difficulty. Installed red cube, clamps, and cables to starter.

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Mar 19, 2021 Crimper practice - (1 hour)

Category: Air Cond

Tested out crimper and discovered beadlock fitting need to be reduced barrier type other than standard. Ordered new fittings from TBI Products.

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Mar 18, 2021 Engine Prep - Oil Fill - (2 hours) Category: Engine

Installed Saf-Air drain valve on right side drain. Installed four new spark plugs to match four existing. Confirmed gap at 0.030. Charged 6 quarts of AeroShell 80.

Mar 16, 2021 Engine Prep - Uninhibiting Engine - (4 hours)

Category: Engine

Removed all lower spark plugs and temporary plastic plugs. Inserted 5/8" plastic tubing to each and routed to trash can. Turned engine over four times by hand and observed oil flowing out of #1 and #2 cylinders only. Drained perhaps 1/2 qt of oil from sump by removed both oil drain plugs. Moved engine on hoist to prepare for mounting.

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Mar 15, 2021 Various Engine Items - (4 hours) Category: Engine

Installed boots ordered from AS onto master/starter relay. Ordered Saf-Air P5000 oil drain valve and spare o-rings from AS to be installed prior to first fill. Spend some time researching a/c hose crimpers. Realized installed hoses are reduced barrier type which require corresponding die. All affordable beadlock hose crimpers made in China. Decided on Mastercool copycat unit which comes with needed dies and a separate hydraulic pump to better allow field crimping. A few day earlier ordered bulkhead a/c fittings and 90 deg hose ends from Summit Racing.

Reviewed options for induction air from Airflow Performance manual which avoids installing fiberglass plenum where a/c compressor will ultimately mount. Best option seems to be the alternate air duct and filter https://airflowperformance.com/index.php/product/fm-200-alternate-air-duct-2-valve/ as shown in Appendix C of installation manual https://airflowperformance.com/wp-content/uploads/2018/12/API-Installation-Service-Manual-9003.pdf. I will need to determine the best way to feed cool outside air into the filter, possibly using a cowl air scoop. https://shop.vansaircraft.com/cgi-bin/shop.cgi?ident=1615895417-102-633&browse=engines&product=cowl-airscoop

The two COM antennas and LOC/GS/VOR antenna arrived today.

Picked up two 4" 1/2X20 bolts to thread into prop flange and 3' 1/2" black iron pipe from Lowes to assist in turning over crankshaft in preparation for discharging preservation oil. Gave a bit of thought on how to best do this, reading all relevant Lycoming service docs. These recommend tiling engine to each side to aid in draining oil which can only be done while on hoist and before installation. Purchased hose to place in lower spark plug holes to aid in directing oil away from cylinders if needed. Plan to bag each cylinders head to reduce the mess. Waiting on spark plugs (Denso IKH27) to arrive.

Mar 13, 2021 Engine Prep - (4 hours)

Category: Engine

Borrowed engine hoist and with Carlos' help lifted engine off pallet onto workbench. Installed prop governor. Installed second p-mag.

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Mar 11, 2021 Installing Rear Fittings - (3 hours)

Category: Engine

Installed fitting on rear of engine as described in plans.,

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Mar 08, 2021 Panel Install continued - (6 hours)

Category: Avionics

Fabricated shelf for GDL 51R and installed unit. Mounted breaker panel after first grinding the right rear lip to provide sufficient clearance. Connected UAT coax to GTX 45 and phone line to ELT. Ran engine terminating leads through firewall pass-throughs.

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Mar 07, 2021 Panel Install continued - (6 hours)

Category: Avionics

Over the weekend, installed GTN 650xi and audio panel into center stack and connected cable plates. Connected all other cables except GDL-51R which required alternate location than planned. Fabricated shelf to support 51R on forward side of sub-panel where map box opening is. Also reinstalled all panel switches.

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Mar 05, 2021 Initial Panel Install - (6 hours)

Category: Avionics

Finished installing GTX, GEA 24, GAD 29 onto sub-panel. Disconnected wire bundle from back of panel and installed panel onto frame. Test fit GTN 650xi and audio panel. Inserted and fed wire bundles through access ports....glad I put those in!

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Mar 04, 2021 LRU Installation on Co-Pilot Side - (3 hours)

Category: Avionics

Decided to install GTX-45R on a hinge to enable servicing.

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Mar 03, 2021 Pilot side LRU install - (6 hours)

Category: Avionics

Completed installation of pilot side components.

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Mar 02, 2021 Began installing LRUs - (4 hours)

Category: Avionics

Installed GAD 27. Began building support for GTR 20 using canopy rail fixture channel.

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Mar 01, 2021 Avionics Arrives! - (2 hours)

Category: Avionics

Avionics from Stein arrived today. Unpacked and inventoried.

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Feb 27, 2021 Access Panels - (4 hours)

Category: Finish

Cut and installed Van's access panel flanges following OP-43 instructions. Did this work in Jan prior to leaving on 6 wk vacation. Just prior to leaving, used pro seal and plastic bag to make gasket following instructions. Allowed pro seal to cure while away for 6 weeks. Today, I removed the plastic, trimmed the excess pro seal, and screwed down the two access plates. Cleaned residual pro seal with acetone. Installed left step.

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Jan 15, 2021 Misc Finish Items - (8 hours)

Category: Finish

Over past few days, installed snap bushing on left side control stick wiring, tightened adel clamp securing coolant hose, Will do same on right side later. Spent better part of one day renting lift gate truck and moving engine and prop to garage. Tried epoxying nuts on back on eye ball vent, but they pulled off. Finally solved issue by installed nutplate on back of most difficult hole. Also repaired seat backs where I forgot to install bolts.

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Jan 11, 2021 Canopy Completion - (8 hours)

Category: Finish

Installed canopy seals, hinge bracket covers, canopy lock sensor, defrost fans, and canopy side pins.

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Jan 09, 2021 Rear Canopy and Seat Back Installation - (6 hours)

Category: Finish

Installed rear canopy and trimmed edge of forward canopy to fit. Installed seat backs.

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Jan 08, 2021 Wrap-Up - (6 hours)

Category: Finish

Sanded and sprayed filler/primer (Stewart) to windshield faring. Final torqued all landing gear bracket bolts. Screwed down floor access plates.

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Jan 06, 2021 Tent Removal and Garage Clean-Up - (8 hours)

Category: Workshop

Completely disassembled tent and cleaned up garage.

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Jan 05, 2021 Windshield Fariing Sanding - (6 hours) Category: Finish

Sanded faring and added additional fiberglass for low spots. Assembled seat backs.

Jan 04, 2021 Windshield Faring - Fiberglass Layup - (10 hours)

Category: Finish

Laid-out fiberglass following instructions to build windshield fairing. Allowed to cure overnight. Finish painting of seat backs.

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Jan 03, 2021 Windshield Faring - Gap Fill - (3 hours)

Category: Finish

Prepared dry micro and filled gap between canopy and top skin.

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Jan 02, 2021 Seat Backs - (8 hours)

Category: Finish

Prepped and primed all seat back components,

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Jan 01, 2021 Nose Gear - (4 hours)

Category: Finish

Completed installation of nose gear and wheel with delivery of back-ordered nose gear link assembly. Torque all nuts to specs. Sanded dry micro in areas that were filled a second time.

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Dec 31, 2020 Canopy Fairing - (2 hours)

Category: Finish

After curing overnight, sanded micro with 36 and 60 paper to smooth extension of canopy line to top skin.

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Dec 30, 2020 Canopy and Fairing - (5 hours)

Category: Finish

Installed 5 canopy clips and sanded area between elec tape with 60 grit paper. Tightened side skin fasteners. Prepared dry micro and applied to fill voids between canopy and top skin. Allowed to cure for a couple of hours then shaved down with a wood chisel.

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Dec 29, 2020 Canopy Wrap-Up - (8 hours)

Category: Finish

Inserted and clecoed the canopy in the frame and riveted the side skins and lifting tabs. Prepared aft seal and installed seal retainer. Tightened top 14 aft screws. Made and installed canopy wear indicator. Made hinge covers. Returned completed canopy to fuselage and, by removing aft engine stand and lowering tail completely, had enough ceiling clearance to just engage the canopy release pins. Closed and locked canopy.

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Dec 28, 2020 Canopy Painting cont. - (5 hours) Category: Finish

Touch-up finish painting on the canopy frame. Spend a ridiculous amount of time to remove the air vent support plates. Had to build a special tool to access the nut. Will definitely install nut plates here.

Dec 27, 2020 Canopy painting - (5 hours)

Category: Finish

Today, countersunk the canopy for dimpled side skins and screws and painted. Painted Glareshield with black SEM primer my plan being to install a liner over this area in the future. Primed canopy frame with SS smoke grey Ekoprime followed by Ekocrylic Drab Tan.

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Dec 26, 2020 Canopy Continued - (6 hours)

Category: Finish

Drilled holes #27 for canopy screws. Did this carefully to avoid any cracking. Use plexiglass bit for the lexan and normal bit for alum. Removed side skin each time to remove debris. Located and taped aft and forward faring lines. Installed five canopy clips with clecos. Filed down plastic along sides to promote a smooth transition. Marked edges of glare shield for further painting. Removed canopy and frame.

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Dec 24, 2020 Canopy Drilling - (5 hours)

Category: Finish

Took my time to find the best canopy fit before drilling screw holes. Removed side skin to clean after drilling each hole. Will need to do some filing along the aft edge later. The forward fit seems acceptable; it mostly lays down flush with slight pressure.

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Dec 23, 2020 Canopy Installation - (2 hours)

Category: Finish

Reinstalled canopy release mechanism and inserted canopy into hinges. Removed a small amount of the top skin edge to relieve binding. Canopy fits well.

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Dec 22, 2020 Forward Top Skin - (5 hours)

Category: Finish

Completed cutting in access panels in forward top skin and riveting/prosealing to forward top substructure. The access panels made it much easier to complete the riveting.

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Dec 22, 2020 Canopy and Access Panels - (5 hours)

Category: Finish

Completed riveting of canopy frame and test fitting on fuselage. Received access plate kit to complete top skin attachment.

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Dec 20, 2020 Canopy - (6 hours)

Category: Finish

Completed assembly and riveting of forward canopy frame.

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Dec 18, 2020 Engine Mount - (3 hours)

Category: Finish

Installed engine mount. Also started to install nose gear but discovered a back-ordered has not yet been shipped. Completed running brake line to main gear. Laid-out avionics using Stein templates and confirmed.

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Dec 17, 2020 Main Gear Install - (15 hours)

Category: Finish

Completed installation of main gear and wheels, a very challenging step! Primed and installed the left-side upper gear brace. Repeated attempts failed to fit the leg into the lower gear brace due to very close tolerances. Was finally successful by filing the leg mating area and polishing on the demurring wheel. Cut, primed and installed the upper attach angle. Bolts were difficult to insert and even more difficult to thread with nut due to close quarters and took no small effort. Will final torque with ordered torque wrench adapters arrive. Had similar problems on right side and more challenging hole alignment issues.

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Dec 14, 2020 Main Landing Gear - (3 hours)

Category: Finish

Raised fuselage to prepare for installation of landing gear.

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Dec 13, 2020 Various Interior Finish - (5 hours)

Category: Finish

Over the past few days, re-installed interior components removed for painting. This included canopy release mechanism and canopy latch.

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Dec 09, 2020 Interior Painting - (6 hours)

Category: Finish

Completed finish painting of cabin interior and all access panels using Stewart Systems 'Drab Tan' EkoCrylic over 'Smoke Gray' primer.

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Dec 07, 2020 Baggage Floor - (4 hours)

Category: Fuselage

Completed installation and riveting of the baggage floor.

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Dec 05, 2020 Insulation - (4 hours)

Category: Finish

Completed installing SoundEx insulation on baggage floor. Also ran 1/2" flexible conduit for later routing of ground wires from wing instruments. Secured coolant hoses and installed grommet edge trimming.

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Dec 04, 2020 Air Conditioning - (2 hours)

Category: Air Cond

Ran #8 coolant hose and secured with Edel clamp.

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Dec 04, 2020 Insulation - (6 hours)

Category: Fuselage

Started laying down SoundEx insulation on belly under baggage area.

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Dec 03, 2020 38.4 Rear Canopy - (6 hours) Category: Finish

Completed installation of rear canopy after removing the sheared tap, 38-02,03. Started assembly of forward canopy frame after priming.

Dec 01, 2020 38.3 Canopy Rail Assemblies - (6 hours)

Category: Finish

Fabricated the left and right canopy rail assemblies, 38-11,12 and the canopy handles on 38-13. Prepped but did not rivet the forward canopy frame assembly, 38-06 to 10.

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Nov 30, 2020 38.2 Canopy Latch - (8 hours)

Category: Finish

Completed 38-04 to 38-06, installing canopy latch mechanism. Started on the main canopy framing.

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Nov 29, 2020 38.1 Rear Canopy - (3 hours)

Category: Finish

Completed 38-01 to 38-03, Step 3. Sheared 6-32 tap while working on Step 4. Ordered a #3 Watson tap extractor and halted further work to avoid damage, hopefully that works.

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Nov 27, 2020 Remote Avionics Layout - (2 hours)

Category: Avionics

Layed-out remote avionics based on email from Josh Swensen at Stein.

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Nov 26, 2020 Fuselage Priming - (2 hours)

Category: Fuselage

Sanded and did a final priming on the fuselage interior.

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Nov 25, 2020 JDAir Canopy Latch - (3 hours)

Category: Fuselage

Installed canopy latch from JDAir using updated installation instructions from Darwin. Installation was straightforward and it looks great.

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Nov 21, 2020 A/C install - (4 hours)

Category: Air Cond

Ran coolant hoses through new pass-through holes in main spar.

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Nov 20, 2020 Common harness - (3 hours)

Category: Avionics

Installed left-side common harness. Ordered additional snap bushing from Stein.

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Nov 19, 2020 Common Harness - (4 hours) Category: Avionics

Installed right common harness and tidied up wiring in aft fuselage

Nov 18, 2020 37.3 Roll Over Structure - (2 hours)

Category: Fuselage

Completed riveting roll over structure to fuselage. Received pitch servo from Stein and installed.

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Nov 16, 2020 37.2 Roll Over Structure - (10 hours)

Category: Fuselage

Completed assembly of roll over structure over period of several days.

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Nov 13, 2020 37.1 Roll Over Structure - (3 hours) Category: Fuselage

Prepared and primed roll over structure. Fabricate pitch servo control rod.

Nov 12, 2020 Fuselage vents - (6 hours)

Category: Fuselage

Fabricated and primed vents. Primed and installed canopy release mechanism. Top coated bottom of forward top skin with Stewart Systems Drab Tan to assess color.

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Nov 11, 2020 35.3 Upper FWD Fuselage - (6 hours) Category: Fuselage

Installed forward top skin doublers (35-17), cowl attach hinges (35-18), and riveted and installed forward top skin up to riveting (35-19).

Nov 10, 2020 36.4 Fuselage - (3 hours) Category: Fuselage

Installed aft elevator push rod but need to bring horizontal stab back to complete attachment. Returned to 35-11 to complete canopy deck installation.

Nov 09, 2020 36.3 Fuselage - (8 hours)

Category: Fuselage

Productive day. Primed aft baggage area that was part of aft fuselage. Used new DeVilbis Dekups system, worked great. Completed 36-06 to 36-14. Assembled elevator bellcrank, installed elevator pushrod, control sticks, control stick pushrod.

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Nov 07, 2020 36.2 Elevator Pushrods - (4 hours)

Category: Fuselage

Completed installing rod end fittings and adjusting to required length (36-03,04). Installed CS-00001 and bolted to control arm, torqued, and sealed. Prepared parts for priming bell crank and servo support (36-05,06). Confirmed use of Classic Aero floor carpeting/foam for hiding refrigerant lines. Cleaned and taped baggage area in preparation for priming areas of aft fuselage not yet primed.

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Oct 29, 2020 35.2 Upper Forward Fuselage - (8 hours)

Category: Fuselage

Prepped and primed additional parts. Completed 35.02 through 35.07.

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Oct 27, 2020 35.1. Upper Fwd Fuselage - (4 hours)

Category: Fuselage

Prepped and primed parts.

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Oct 25, 2020 33.4 Rudder, Brakes, and Panels - (18 hours)

Category: Fuselage

This entry summarizes work completed during week of 10/18 to 10/25/20.
- Installed rudder pedals and brake lines. Expanded existing holes in main spar and ribs for routing brake lines.
- Prepped and primed baggage floor and side panel sections. Will not rivet to baggage ribs at this time pending coolant hose routing.
- Prepped and primed flap support bracket and related parts.
- Connected rudder cables to rudder pedals and installed guides and clamps.
- Prepared, primed and installed flap control rod.

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Oct 17, 2020 33.3. Rudder Pedal Assembly - (3 hours)

Category: Fuselage

Complete riveting of brake pads and attached to rudder pedals. Installed Beringer cylinders. Plan to replace the stock pads with custom product which will move hydraulic lines behind rudder pedal.

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Oct 15, 2020 Design Approval - (2 hours)

Category: Instrument Panel

Completed design scope with Nick over several weeks and made final decision on color scheme today.

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Oct 15, 2020 30.4. Aft Fuse Attachment - (2 hours) Category: Fuselage

Complete other half of bottom skin riveting with Carlos' help

Oct 15, 2020 33.1 Rudder Pedals - (2 hours)

Category: Fuselage

Prepped rudder pedals for riveting.

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Oct 14, 2020 33.2 Brake System - (4 hours) Category: Fuselage

Initial assembly of Beringer brake cylinders and routing of lines. Drilled pass through holes through floor ribs.

Oct 13, 2020 31.2. Fuel System - (4 hours) Category: Fuselage

Completed installing fuel lines from Aircraft Specialties and securing to floor ribs using supplied clips. Completed all steps.

Oct 12, 2020 30.3. Aft Fuse Attachment - (2 hours) Category: Fuselage

Completed about half of the bottom skin rivets (30-08) with Cate's help

Oct 11, 2020 30.2 Aft Fuse Attachment - (8 hours)

Category: Fuselage

Completed pages 30-04 to 30-07. Installed primed aft baggage bulkhead and riveted to upper fuselage.

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Oct 09, 2020 30.1 Aft Fuselage Attachment - (8 hours)

Category: Fuselage

Attached and clecoed aft fuse to main fuse and mounted for and aft on engine stands. Time includes transporting wings to hanger and returning aft fuse.

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Oct 07, 2020 31.1 Fuel System - (3 hours) Category: Fuselage

Completed initial fit of Aircraft Specialties sourced pre-fabricated fuel lines and wing-mounted fuel filters. Installation was a snap.

Oct 06, 2020 29.6 FWD Mid Fuse...Continued - (8 hours)

Category: Fuselage

Prepared and installed root fairings (29-17,18) and seat back brace (29-19).

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Oct 04, 2020 29.5 FWD Mid Fuse Continued - (15 hours)

Category: Fuselage

This entry describes work over period of several weeks. Completed 29-14 through 29-16 including fully riveting side skins and structural members.

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Sep 25, 2020 29.4. FWD Mid Fuse Side Structure - (12 hours) Category: Firewall Forward

Completed side skin preparation and longeron countersinking (29-09). Prepped and primed internal skin structural members (29-10, -11). Discovered missing part F-01422 from kit and ordered from Vans. Riveted aft side skin members and section plate/drag fitting to side skin (29-12) while skin clecoed to fwd section which worked well (29-13). All work completed over two weeks.

Sep 25, 2020 Finish Kit Delivery - (1 hour) Category: Finish

Finish kit arrived today and placed in hanger.

Sep 17, 2020 29.3 FWD Mid Fuse - (10 hours)

Category: Fuselage

Completed riveting of bottom skin (29-04) and fabrication of longerons (29-06, 07). Prepared shims and hinges and fitted to firewall (29-07,08)

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Sep 12, 2020 29.2 FWD Mid Fuse - (4 hours)

Category: Fuselage

Completed pgs. 29-05. Fabricated and installed control column without need for extra shims. Used safety wire to line-up the washers.

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Sep 11, 2020 29.1 FWD Mid Fuse - (6 hours)

Category: Fuselage

Completed pgs. 29-02 to -04, but not completing riveting yet. Primed lower drag fitting and gear brace black.

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Sep 08, 2020 28.3 FWD Fuse Completion - (14 hours)

Category: Fuselage

Back at it after a 3 wk Western hiatus to escape the heat and humidity of the NC summer. Completed pgs. 28-07 through -10 over three days which includes fabrication and priming of the vents and initial installation of the Forward Center Section Bulkhead. Made a mistake installing the right cable bracket since it's not mirror image of the left, but easily fixed it.

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Aug 16, 2020 28.2 Firewall Assembly to Bottom Skin Assembly - (4 hours)

Category: Fuselage

Completed pgs. 28-05,-06.

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Aug 14, 2020 28.1 Forward Bottom Skins and Muffler Shroud - (8 hours)

Category: Fuselage

Completed pgs. 28-02,-03, -04.

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Aug 12, 2020 27.3. Tunnel Installation and Final Assembly - (8 hours)

Category: Fuselage

Completed pgs. 27-06,-07

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Aug 11, 2020 27.2 Firewall Assembly - (6 hours)

Category: Fuselage

Completed pgs. 27-04,-05

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Aug 09, 2020 27.1 Firewall Angles - (4 hours)

Category: Fuselage

Prepped and primed parts for firewall angles on pg. 27-02,-03.

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Aug 08, 2020 Section 26 Completion - (4 hours)

Category: Fuselage

Completed all steps on pg.26-21,-22. Got some help from Cate with riveting.

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Aug 07, 2020 Step Attach Assembly - (6 hours)

Category: Fuselage

Completed all steps on pg. 26-15,-16,-17,-18,-19-20

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Aug 05, 2020 Bulkhead to Skin Assembly - (12 hours)

Category: Fuselage

Completed all steps on 26-12,-13,-14.

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Aug 02, 2020 Rivet Doublers and Stiffeners to Bottom Skin - (4 hours)

Category: Fuselage

Completed all steps on pg. 26-11

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Jul 25, 2020 Baggage Ribs, Bottom Skin Prep - (15 hours)

Category: Fuselage

Completed all steps on pg. 26-08,-09,-10. Primed all rbis using SEM self-etching primer and bottom skin using Steward Systems product and procedures.

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Jul 19, 2020 Bulkhead Assembly - (10 hours)

Category: Fuselage

Completed fluting to shape outboard rib flanges and primed. Completed all steps up through 26-07.

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Jul 12, 2020 Mid-Fuse Lower Structure - (4 hours)

Category: Fuselage

Prepped and primed seat ribs (26-03).

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Jul 11, 2020 Baggage Ribs - (4 hours) Category: Fuselage

Prepped and primed baggage ribs (26-02)

Jul 11, 2020 Paint Tent - (6 hours)

Category: Painting

Erected paint tent inside garage shop from car shelter.

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Jul 01, 2020 Forward Mid Fuse Bulkheads - (15 hours)

Category: Fuselage

Completed fabrication of mid fuselage bulkheads, Section 25, Fabricated bearing bracket assembly (25-03). Had to enlarge the countersink on the shop head side to make room for the long 3-7 rivets called out in the plans. Ground down shop head to flush and repainted.

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Jun 25, 2020 Brakes, Wheels, and Fuel Lines - (1 hour) Category: Wings

Ordered complete Beringer wheel and brake system from Aircraft Specialties. Also ordered custom fuel lines with duel wing-root filter.

Jun 25, 2020 Right Wing Finish - (6 hours)

Category: Wings

Completed installation of wing tip nav light and lens. Installed wing tip rib in wing tip. Right wing is now done!!

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Jun 23, 2020 Right Wing Finish - (8 hours) Category: Wings

Installed trim servo to pushrod springs and attached cover plate. Fabricated and installed other two wing access plates. Installed landing light and wiring. Cut and completed initial installation of wing tip.

Jun 20, 2020 Right Wing Close Out - (6 hours) Category: Wings

Completed riveting of bottom skins to spars and ribs. Reinstalled flap.

Jun 18, 2020 Fuselage Crate Delivery - (2 hours)

Category: Fuselage

Fuselage crate arrived with external damage but no apparent internal damage. Completed inventory and contacted Van's regarding missing parts.

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Jun 02, 2020 Right Wing Close-Up - (2 hours)

Category: Wings

Tidied-up wiring, confirmed all nuts/bolts torqued to spec, in preparation for installing bottom wing skin.

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May 31, 2020 Right Flap - (20 hours)

Category: Wings

Assembled right wing flap over about a week. TE came out looking great.

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May 26, 2020 Roll Trim Servo - (6 hours)

Category: Avionics

Assembled roll trim servo and temporarily installed on access panel.

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May 25, 2020 Right Fuel Tank - (7 hours)

Category: Wings

Cleaned and leak-tested tank, no leaks observed. Installed fuel tank onto main spar and completed assembly of aileron torque tube.

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May 24, 2020 Roll Servo Installation - (4 hours)

Category: Avionics

Installed Garmin GMA-28 roll servo obtained from SteinAir and Van's install kit. Fabricated push-rod by tapping ends for 1/4" bearings. Installed stop bracket over servo mount bracket as approved by Garmin G3X install instructions using the four screws supplied and was satisfied the stop cage was securely attached. Checked travel and for interference. Found that I had to move the bearing attach point to the far end of the cam rather than closer hole to prevent interference between the bearing attach screw and stop bracket attach screws. Confirmed upward aileron deflection limited by mechanical stop at inboard hinge and downward deflection limited by servo stop bracket. Enlarged molex support hole slightly to clear molex plug.

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May 22, 2020 Right Fuel Tank - (6 hours) Category: Wings

Installed nut plates on tank attach zees and clecoed to tank baffle with pro seal. Completed riveting of fuel tank. Applied additional pro seal to all potential leak points.

May 20, 2020 Right Fuel Tank - (4 hours)

Category: Wings

Returned to complete installation of inboard rib and baffle with pro seal. Covered every rivet shop head inside tank with pro seal. Installed inboard rib, attached and torqued vent tube to bulkhead union, and installed tank baffle with pro-seal and 100% clecos. Finally, installed fuel sender with pro seal.

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May 19, 2020 Right Aileron Actuation - (8 hours) Category: Wings

Fabricated aileron torque tube and push rod assemblies and connected to bell crank. Mounted Garmin servo and support bracket. Van's sent wrong bearings in servo mount kit so couldn't make servo pushrod. Ordered replacements. Fabricated aileron torque tube assembly and temporarily mounted to pushrod.

May 15, 2020 Right Aileron - (1 hour)

Category: Wings

Riveted trailing edge. Aileron came out very straight and tight.

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May 14, 2020 Right Aileron - (4 hours)

Category: Wings

Completed assembly and riveting of right aileron. Installed countersunk trailing edge with double sided 3M tape and left overnight with weights.

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May 13, 2020 Right Aileron - (4 hours)

Category: Wings

Prepared skin stiffeners and riveted to dimpled skins. Assembled aileron and match drilled common holes.

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May 11, 2020 Panel Order - (1 hour) Category: Instrument Panel

Spoke with Stein and put panel order in queue. Stein estimated 8-10 mo!, so panel may be last thing to go in.

May 11, 2020 Right Aileron - (6 hours)

Category: Wings

Prepared leading edge from spar forward.

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May 09, 2020 Right Wing, System Wiring - (4 hours) Category: Wings

Installed wing conduit and ran lighting harness. Installed servo harness in lower rib web openings. Ran short of bushing and ordered more from Vans. Ordered Garmin roll servo from SteinAir and servo install kit from Van's since it seems better to install before closing up bottom skin.

May 08, 2020 Right Fuel Tank - (4 hours) Category: Wings

Bent fuel sender wire and temporarily installed in fuel tank. Adjusted wire bend to meet travel and clearance specifications. Ordered more nut plates for tank-Zs.

May 07, 2020 Right Fuel Tank - (4 hours) Category: Wings

Completed riveting ribs with pro seal-dipped rivets.

May 06, 2020 Right Fuel Tank - (4 hours) Category: Wings

Riveted stiffeners to skin using pro seal-dipped rivets.

May 05, 2020 Right Fuel Tank - (4 hours)

Category: Wings

Dimpled skin and clecoed ribs and stiffeners with 220 g of freshly prepared pro seal. This went much smoother than for left tank. Made sure to add plenty of excess pro seal below tank attach bracket where I previous had leak on left tank.

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May 04, 2020 Right Fuel Tank - (8 hours) Category: Wings

Prepared ribs, stiffeners, tank attach bracket, and all other parts and clecoed to skin. Preparation include match drilling, deburring, dimpling, edge filing and deburring, rounding the forward flange of the ribs, sanding the flange contact area to improve sealant contact, and finally cleaning with acetone.

Apr 30, 2020 Finish Kit Order - (1 hour) Category: Firewall Forward

Ordered finish kit minus wheels and brakes to get in before NC state tax will be collected. Delivery is 14 weeks, so expect in August.

Apr 30, 2020 Leading Edge - Right Wing - (4 hours)

Category: Wings

Completed riveting ribs and stiffener to skins. Started trimming and installing landing light lens.

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Apr 29, 2020 Leading Edgeing Edge - Right Wing - (6 hours)

Category: Wings

Riveted skin to ribs and stiffener. Trimmed lens plastic.

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Apr 27, 2020 Leading Edge - Right Wing - (6 hours) Category: Wings

Prepped leading edge ribs and primed. Prepared stiffeners and dimpled skins.

Apr 24, 2020 Right Wing, Upper Skin Completion - (4 hours)

Category: Wings

Completed riveting upper skin to ribs and spars, including outboard aileron hinge

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Apr 21, 2020 Outboard Skin, Right Wing - (4 hours)

Category: Wings

Dimpled and began riveting outboard top skin to ribs and spars.

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Apr 20, 2020 Inboard Top Skin, Right Wing - (6 hours)

Category: Wings

Countersunk and match drilled wing walk doublers. Dimpled and riveted inboard top skin to ribs and spars.

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Apr 18, 2020 Right Wing, Rear Spar Assembly - (6 hours)

Category: Wings

Completed assembling rear spar including doublers and flap/aileron hinges and mounted to ribs.

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Apr 17, 2020 14.2 Right Wing Ribs - (6 hours)

Category: Wings

Completed priming and riveting of wing ribs to main spar. Started rear spar prep, match drilled doublers and building modified outboard aileron hinge.

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Apr 15, 2020 14.1 Right Wing - Rib Prep - (7 hours)

Category: Wings

Prepared ribs. Filed and deburred all edges and lightening holes, dimpled flanges, fluted as needed, assembled flap brackets and torque tube. Drilled holes for snap bushing and wing conduit for running system wiring. Mounted on main spar and match drilled bolt holes in forward flanges.

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Apr 14, 2020 13.1. Right Wing - Main Spar Prep - (6 hours)

Category: Wings

Cut and match drilled short and long j-channels. Countersunk and riveted fuel tank and access panel nut plates to main spar. Countersunk all rib attach holes. Primed spar flanges.

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Apr 13, 2020 Wing Tip Lens - (4 hours)

Category: Wings

Trimmed and installed wing tip lens. Left wing is now fully complete!! It took 3 mo and 250 hrs!

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Apr 12, 2020 Wing Close Out Tip - (4 hours)

Category: Wings

Completed wing tip installation.

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Apr 11, 2020 Wing Tip - (4 hours) Category: Wings

Finished trimming wing tip and installed position light. Temporarily mounted to wing outboard and sinched with strap. Match drilled and began installing nut plates.

Apr 10, 2020 Left Wing Closeout - (6 hours)

Category: Wings

Finally completed all bottom skin riveting. Trimmed wing tip to fit and temporarily fastened with tape.

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Apr 08, 2020 Left Wing Closeout - (6 hours) Category: Wings

Completed most of riveting of outboard skin. Very challenging to reach all rivets.

Apr 06, 2020 Left Wing Closeout - (4 hours) Category: Wings

Riveted inboard skin to j-stiffener with some difficulty.

Apr 05, 2020 Fuel Tank - (2 hours) Category: Wings

Inserted and torqued bolts holding fuel tank to main spar. Inserted #6 screws to secure fuel tank. Lengthened stall warning lead and connected to indicator.

Apr 04, 2020 Leading Edge - (2 hours) Category: Wings

Riveted upper side of leading edge to main spar with Cate's help. Leak tested fuel tank using balloon method and it held pressure for several hours confirming the repair was successful. Clecoed the fuel tank to the main spar.

Apr 03, 2020 LL Lens - (4 hours) Category: Wings

Fabricated landing light lens and installed in leading edge. Riveted bottom side of leading edge.

Mar 31, 2020 Wing Wiring, Tank Leak Test - (5 hours) Category: Wings

Rerouted conduit through new holes in ribs and re-installed harness wiring. Removed pitot/AoA support bracket previously installed, deciding it was not necessary and would complicate any future maintenance. Re-routed AoA and pitot tubing to bulkhead fittings to simplify run and remove any kinks or tension. Twisted pair of black/red wiring for pitot heat and threaded through conduit. Riveted leading edge section to main spar. Pressure test of fuel tank failed due to significant leakage where the tank attach bracket mates with the rib and skin, an area I could not reach easily with sealant. I cleaned the outer seam and applied fresh pro-seal from the outside. I used the shopvac held at the fuel filler to carefully apply vacuum to the tank in an effort to suck some of the sealant into the gap. I expect this should seal the leak.

Mar 30, 2020 Panel Design - (2 hours)

Category: Instrument Panel

Spoke with Stein to revise panel layout. Will delete emergency canopy release and place it behind panel for maintenance use. This allows G5 and autopilot to be shifted up.

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Mar 27, 2020 18.11 Left Fuel Tank - (6 hours)

Category: Wings

Sealed and clecoed baffle and z-brackets to ribs and skin. Installed fuel sender and float per directions.

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Mar 25, 2020 18.9 Left Fuel Tank - (4 hours)

Category: Wings

Wet riveted end rib, Bent and tested fuel sender.

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Mar 24, 2020 18.9 Left Fuel Tank - (6 hours)

Category: Wings

Riveted j-stiffener and clecoed attach bracket sub-assembly to skin with pro-seal. Installed fuel tank vent line. Build cradle for wings and relocated.

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Mar 23, 2020 18.8 Left Fuel Tank - (4 hours) Category: Wings

Completed wet riveting of second side of fuel tank and sealing shop heads on all rib rivets.

Mar 23, 2020 18.7 Left Fuel Tank - (4 hours) Category: Wings

Riveted one side of rib to skin attachments.

Mar 20, 2020 18.6 Left Fuel Tank - (4 hours)

Category: Wings

Pro-sealed and clecoed ribs.

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Mar 19, 2020 18.5 Left Fuel Tank - (4 hours) Category: Wings

Riveted skin stiffeners.

Mar 18, 2020 18.4 Left Fuel Tank - (4 hours)

Category: Wings

Finished dimpling skin. CS fuel flange and installed along with stiffeners to skin using pro-seal with 100% clecos.

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Mar 17, 2020 18.3 Left Fuel Tank - (8 hours) Category: Wings

Cut and prepared tank attach zees. Match drilled and dimpled j-stiffener. Dimpled skin stiffeners. Machine countersunk skin at baffle attachment. Started dimpling skin.

Mar 16, 2020 18.2 Left Fuel Tank - (5 hours) Category: Wings

Wet riveted flanges and anti-rotation plate....very messy operation. Deburred and dimpled all ribs. Cut skin stiffeners.

Mar 15, 2020 18.1 Left Fuel Tank - (3 hours) Category: Wings

Prepared ribs for assembly. Installed fuel flanges and anti-rotation plate with pro seal with 100% clecos and allowed to cure overnight.

Mar 15, 2020 23.3 Aileron Actuation - (3 hours) Category: Wings

Completed installation of aileron torque tube and pushrods. Cannot complete until fabrication of fuel tank.

Mar 14, 2020 23.2 Aileron Actuation - (4 hours)

Category: Wings

Fabricated aileron to bell crank push tube and torque tube. Temporarily installed aileron torque tube and modified pitot/AoA tubing route to clear.

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Mar 13, 2020 23.1 Aileron Actuation - (7 hours)

Category: Wings

Completed TE riveting and mounted aileron to wing. Fabricated torque tube and aileron push rods.

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Mar 06, 2020 Fuselage - Placed Order - (1 hour) Category: Wings

Placed order for fuselage. Expect delivery end-May

Mar 02, 2020 22.3 Left Aileron - (8 hours)

Category: Wings

Continued assembly up to riveting bottom skin and TE. Back-riveted skin stiffeners on 2'X4' steel plate, worked well. Went slow and double-checked often...many opportunities to make a mistake!

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Feb 29, 2020 22.2 Left Aileron - (2 hours) Category: Wings

Completed drilling and mounting counterbalance.

Feb 28, 2020 22.1 Left Aileron - (2 hours) Category: Wings

Started assembly of left aileron.

Feb 27, 2020 21.5 Left Flap - (4 hours)

Category: Wings

Back-riveted trailing edge on a 2'X4' steel plate...came out very well. Completed final riveting of bottom skin and mounted to wing.

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Feb 26, 2020 21.4 Left Flap - (3 hours)

Category: Wings

Riveted bottom and top skin to leading edge and spar. Riveted top skin to ribs. Glued trailing edge with 3M tape and secured overnight with clecos and weights.

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Feb 24, 2020 21.3 Left Flap - (8 hours)

Category: Wings

Continued to work on left flap. Very tedious, lots of match drilling, countersinking, jig fabrication, priming, and fabrication of sub-assemblies.

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Feb 22, 2020 21.2 Flap - (6 hours)

Category: Wings

Finished prepping ribs, trailing edge, and clecoed entire assembly.

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Feb 21, 2020 21.1 Flaps - (2 hours) Category: Wings

Began prepping parts to assemble flaps

Feb 21, 2020 Left Wing Landing and Nav Lights - (4 hours)

Category: Lighting

Build and black-primed anding lens bracket and wired to mount on outboard end of left wing. Wired nav lights.

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Feb 20, 2020 20.1 Bottom Wing Skins - (7 hours)

Category: Wings

Prepared and primed aileron gap fairings and riveted to rear spar and top skin. Prepared and clecoed ADAHRS mount. Dimpled bottom skins.

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Feb 19, 2020 19.4 Wing System Routing - (6 hours)

Category: Wings

Decided to modify pitot/AoA routing by removing the service loop and installing a mounting bracket for the unions. Was concerned for moisture getting trapped in the service loop. Also plan to install bulkhead fittings on the wing root for connecting pitot/AoA.

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Feb 18, 2020 19.3 Wing System Routing - (4 hours)

Category: Wings

Planned power wiring to pitot. Ran wiring plan by Chris at SteinAir. Ordered parts from SteinAir. Will run black and red 14AWG twisted pair from pitot, through the conduit, terminating the red power lead to pin #4 in C400P and coiling enough black wire to ground to the fuselage, avoiding interference that might occur by grounding to the wing. Completed bottom skin modification for accepting pitot mast.

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Feb 17, 2020 19.2 Wing System Routing - (6 hours)

Category: Wings

Fit pitot/AOA and routed tubing. Routed wing tip lighting harness through conduit and ADAHRS harness through rib snap rings.

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Feb 16, 2020 19.1 Wing System Routing - (2 hours)

Category: Wings

Prepared Gretz pitot mounting plate and fit to bottom wing in bay adjacent to access opening.

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Feb 15, 2020 17.5 Outboard Leading Edge - (4 hours)

Category: Wings

Forward-riveted assembly and clecoed to main spar clamped across the narrow side of my workbench with a little help from my wife.

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Feb 14, 2020 17.4 Outboard Leading Edge - (8 hours)

Category: Wings

Identified too-heavy primer application as cause of blistering. Apparently, in a heavy initial application of a fast-drying primer like SEM, the outer surface dries first sealing the wet primer adjacent to the part, causing the trapped solvent to lift the primer off the surface. Re-priming using 2-3 light coats resulted in far better adhesion and no blistering. Completed the stall warning subassembly and fit. Re-installed all ribs and began riveting to skins.

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Feb 13, 2020 17.3 Outboard Leading Edge - (5 hours) Category: Wings

Match-drilled J-stiffener and prepared nutplate parts. Dimpled skins.

Feb 12, 2020 17.2L Outboard Leading Edge - (4 hours)

Category: Wings

Finished preparing all ribs. Had serious issue with primer pealing that I now suspect is bad primer and not surface prep procedure. Each piece was sanded with Scotchbrite pad and cleaned thoroughly with SEMSolve until no residue remained. The primer came from a new case of SEM self-etching primer I purchased on Amazon.

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Feb 10, 2020 17.1L Outboard Leading Edge - (4 hours)

Category: Wings

Moved the main left wing assembly off my workbench to make room building the outboard leading edge. Fabricated the LE supports from the template drawn on the shipping crate lid at Vans per instructions. Initially fit and numbered all ribs. Ribs flanges are square and required little to no fluting, owing to the process Vans is now using to make the ribs ( these arrive without vinyl and have machining marks and scratches). Starting with the outboard rib, nearest the landing light, I filed, deburred, and polished the edges, inserted into the skin resting in the cradle, fully clecoed and match drilled the #40 flange holes to skin. I then removed the rib, deburred the holes, dimpled the flanged, applied a single coat of primer, and then reinstalled with alternating clecos.

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Feb 09, 2020 Engine Delivery Update Category: Engine

Got an update from Vans that my approximate ship date for the IO390 is 9/22/20....so most likely I will see the engine in Oct. That's 9 months away!

Feb 09, 2020 16L. Top Wing Skins - (20 hours)

Category: Wings

This was a challenging section to complete, mainly due to the size and weight of this wing section and large number and location of rivets. My effort to use a 2'X4' 1/4" cold-rolled steel plate for back-riveting was only partially successful since the rib rivet stems were hard to reach with an extended back-riveting attachment and completely unacceptable for the wing-walk sections. Here, the expanded rivets tended to catch the wing walk doublers and stand proud above the top skin when fully riveting. Many rivets had to be removed. In the end, I normally bucked or squeezed all the rivets I could reach and back riveted those I could not, mainly those forward toward the main spar. Overall, the results are acceptable, with tight skins and only a few dings that will either be covered with wing walk fabric or painted so they won't be noticeable. Finally, I glued Van's conduit to the edge of the lighting hole of each rib with pro seal and secured with cable ties.

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Feb 02, 2020 15.2 Rear Spar - (8 hours) Category: Wings

Completed assembly and riveting of doublers and rear spar to wing ribs. Primed all doublers and spot primed areas that were deburred. Riveted inboard aileron bracket following Fig 14 of SB 16-03-28.

Jan 31, 2020 15.1 Rear Spar - (8 hours)

Category: Wings

Fabricated and primed the replacement inboard aileron bracket assemble per SB 16-03-28, which took a little extra time to understand. Fabricated and primed the outboard aileron bracket. Match drilled rear spar doublers and clecoed all parts to wing ribs.

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Jan 30, 2020 14.3 Wing Rig Installation - (8 hours)

Category: Wings

Match drilled bolt holes. Enlarged system holes and installed snap bushings in all wing ribs. Drilled #30 hole in each rib for supporting wing conduit. Spot primed each rib. Installed bolts as per drawing, torqued to 25 in-lb, and applied torque seal on each nut. Riveted each wing rib to main spar. Installed Van's wing conduit through second forward lightening hole.

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Jan 28, 2020 14.2 Wing Ribs, continued - (6 hours)

Category: Wings

Bouncing around the instructions a bit, riveted both flap hinge assemblies and torque tube support bracket to corresponding wing rib webs. Filed and deburred all wing ribs, including lightening holes, and dimpled lower rib flanges. Cleaned each rib with acetone. Checked that each rib web was perpendicular to flanges and only needed to flute the upper flange of the far inboard rib.

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Jan 27, 2020 14.1 Wing Ribs - (6 hours)

Category: Wings

Temporarily installed ribs and removed and stored bolts. Assembled and temporarily installed torque tube support and flap hinge assemblies.

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Jan 26, 2020 13.3 Main Spar Wrap-Up - (3 hours)

Category: Wings

Primed flanges, installed snap bushings, nutplates, and aileron bellcrank bracket.

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Jan 18, 2020 13.2 Nutplate Installation - (8 hours)

Category: Wings

Hours and hours of nut plate riveting and countersinking.

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Jan 15, 2020 13.1 J-Channels - (4 hours)

Category: Wings

Prepared upper and lower wing box j-channels. Lots of match drilling and clecoing. Deburred all holes in j-channels and set-aside for later.

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Jan 14, 2020 Delivery and Inventory - (6 hours)

Category: Wings

Received delivery of wing kit. Crates were damaged but to internal damage. Discovered Van's sent wrong wing tip LEDs, otherwise inventory was accurate.

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Dec 18, 2019 Empennage Fairings - (10 hours)

Category: Empennage

Completed and installed horizontal and vertical tip fairings. Disassembled empennage from aft fuselage and transported to my hanger for storage.

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Dec 03, 2019 Aft Fuselage: Fairings - (6.0 hours)

Category: Empennage

Completed rudder top fairing and elevator end fairings.

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Dec 02, 2019 Aft Fuselage: Fairings - (2.0 hours)

Category: Empennage

Completed tail light installation to rudder fairing. The Molex connection drawing that came with the kit has a mistake. The leads from the light need to have male ends since the wiring cable came with female end pre-installed.

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Dec 01, 2019 Aft Fuselage: Fairings - (6.0 hours)

Category: Empennage

Completed trim TE riveting and reinstalled. Confirmed rudder/trim tab spacing. Left rudder and v. stab in position on fuselage to install rudder fairing. Fairly tedious work to trim and sand fairing to fit to lower rudder assembly, match drill, dimple, countersink, and rivet nut plates.

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Nov 30, 2019 Aft Fuselage: Trim Tab and Rudder Attachment - (6.0 hours)

Category: Empennage

Returned to trim tab assembly. Used RTV to glue foam ribs and set aside with weights overnight. Removed v. stab and final drilled two 1/4" h. stab attachment holes. Reattached v. stab and installed rudder assembly. This took some time to get the three eyebolts aligned. Did not final torque any bolts at this time since it will all need to come apart again later.

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Nov 28, 2019 Aft Fuselage: Control Horn Drilling - (3 hours)

Category: Empennage

Confirmed right and left elevator travel and gaps. Left and right full up deflection measured 31deg and left and right full down deflection 29 deg. Elevator gap is 0.15 in (left) and 0.11 in (right). Measured torque tube to aft spar gap 9/64" greater than min required. Drilled hole through horns for attachment to clevis joint. Needed to turn down e-drill bushing to fit and pre-drilled #30 on drill press. Drilled hole in horns for later attachment of control rod.

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Nov 27, 2019 Aft Fuselage: Install H. Stab and V. Stab - (3 hours)

Category: Empennage

Bolted H. stab to fuse and match drilled aft spar for attachment bolts. Threaded eye bolts on elevators and temporarily mounted to h. stab.

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Nov 26, 2019 Aft Fuselage: Top Skin Riveting - (4 hours)

Category: Empennage

Riveted top skin using gun and bucking bar fore and aft as far as my arms would allow. Then turned fuse upside down and back-riveted the remainder. Worked pretty well.

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Nov 19, 2019 Aft Fuselage: Left Side Skin and Top Skin Attachment

Category: Empennage

Installed clear tubing at intersection of j-stiffener and bulkheads to prevent wire chafing, not called out in plans. Secure tubing with RTV filet. Dimpled and riveted left side skin to aft fuselage. Applied 3M double-stick tape and clecoed top skin to side skins.

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Nov 18, 2019 Aft Fuselage: Right Side Skin Attachment - (8.0 hours) Category: Empennage

Finished riveting aft deck. Installed and match-drilled vert. stabilizer (10-28). Dimpled and riveted top skin (10-29). Dimpled and riveted right side skin to aft fuselage (10-30,31).

Nov 17, 2019 Aft Fuselage: Rudder Cable, Static, UAT and ELT, Phone, and Aft Deck - (8.0 hours)

Category: Empennage

Completed control and electrical installation including rudder cable (10-21), static lines (10-22), UAT antenna (10-23), ELT antenna (10-24), phone cable (10-26) and secured aft harness (10-25). Completed most of the steps on 10-27 to install aft deck.

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Nov 16, 2019 Aft Fuselage: Skin Riveting, Nutplates, Bushings - (5 hours)

Category: Empennage

Completed side skin riveting (10-19) and installed nutplates (10-20) and snap bushings.

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Nov 15, 2019 Aft Fuselage: Rivet Side Skins - (10 hours) Category: Empennage

Long day riveting side skins, completing page 10-19, except for rivets securing side skins to bottom skins.

Nov 14, 2019 Aft Fuselage: Dimpling and Clecoing Side Skins - (8.0 hours)

Category: Empennage

Completed page 10-14, dimpling side skins, stiffeners, and longerons, feeding control wiring, and clecoing to bulkheads. Cut and finished aft bottom skin (10-15, 16), riveted to aft bulkhead, and installed under and riveted to aft skin (10-17).

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Nov 13, 2019 Aft Fuselage: Fuselage Assembly - (6.0 hours)

Category: Empennage

Started page 10-14.

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Nov 12, 2019 Aft Fuselage: Battery Angle, Bellcrank, and Bottom Skin Assembly - (6.0 hours)

Category: Empennage

Completed pages 10-12 and 13. Placing bottom skin upside down on saw horses worked well for riveting. Has to use a slightly longer rivet (3-4 instead of 3-3.5) for the Stiffener Clip and Rudder Cable bracket.

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Dec 31, 1969 30.1. Aft Fuse Attachment Category: Fuselage

Clecoed aft fuse to main fuse and mounted on engine stands.

Nov 11, 2019 Aft Fuselage: Bulkheads and Battery Angle - (5 hours)

Category: Empennage

Completed bulkheads and battery angle, pages 10-09 and 10-10.

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Nov 10, 2019 Aft Fuselage: Bulkheads - (5 hours)

Category: Empennage

Completed 10-05,07,08,09. Note that #30 holes just left and right of the tie down bracket should not be dimpled. Primed non-alclad parts and attachment bulkheads.

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Nov 08, 2019 Lycoming Engine School: Day 5 - (6.0 hours) Category: Engine

Class review of fuel injection, magnetos, etc. Completed magneto timing in shop.

Nov 08, 2019 Lycoming Engine School: Day 5 - (6.0 hours)

Category: Engine

Class review of fuel injection, magnetos, etc. Completed magneto timing in shop.

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Nov 07, 2019 Engine: Lycoming School Day 4 - (7 hours)

Category: Engine

Reviewed in class engine maintenance and troubleshooting topics. Reinstalled cylinders and valve train in lab.

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Nov 06, 2019 Engine: Lycoming School Day 3 - (7 hours) Category: Engine

Tour of Lycoming factory

Nov 05, 2019 Engine: Lycoming School Day 2 - (7 hours)

Category: Engine

Reviewed crankshaft and camshaft design and servicing. Reinstalled both and reassembled case.

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Nov 04, 2019 Engine: Lycoming School Day 1 - (7 hours)

Category: Engine

Day 1. Reviewed Lycoming service documentation sources, definitions, and history. Worked in group to fully disassemble O360 engine. Class held at Pennsylvania College of Technology, Montoursville, PA

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Nov 02, 2019 Aft Fuselage: Part Separation and Preparation - (6.5 hours)

Category: Empennage

Separated and deburred parts (10-02,03). Prepared horiz stab attachment bars and fabricated attachment bar and rudders stops (10-04). Primed parts per instructions.

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Nov 01, 2019 Elevator: LE Rolling and Close-Out - (6.0 hours)

Category: Empennage

Completed left and right elevator LE rolling, TE riveting, and final close-out riveting. Waiting on more tank sealant to complete trim tab.

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Oct 31, 2019 Elevator: Pitch Trim Servo - (2.0 hours)

Category: Empennage

Completed pitch trim servo assembly and molex connector (09-24, 25).

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Oct 30, 2019 Elevator: Hinge Pin - (2.0 hours)

Category: Empennage

Prepared bent hinge pin and secured to rear spar with spare piece of hinge (pg. 09-24).

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Oct 29, 2019 Left Elevator: Final Assembly - (5 hours)

Category: Empennage

Completed left elevator front spar insertion and riveting (09-20,21,22). Glued TE ribs to both elevators using tank sealant and set aside with weights.

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Oct 28, 2019 Left Elevator: Assembly - (9 hours)

Category: Empennage

Assembled left elevator. Prepped interior surface for TE rib installation (09-15), assembled front and rear spars (09-16,17), counterbalance skins and elev horns. Riveted rib and spar to skins (09-18,19). Used special bucking bar to rivet rear spar to skin (09-20).

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Oct 27, 2019 Trim Tab: Initial Assembly - (2.0 hours)

Category: Empennage

Started assembly of trim tab completing 09-13 and starting 09-14

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Oct 26, 2019 Left Elevator: Initial Trim Tab Assembly - (2.0 hours)

Category: Empennage

Trimmed TE to fit. Countersunk TE and trim tab spar (09-13). Picture shows set-ups used for countersinking.

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Oct 25, 2019 Left Elevator: Disassembly, Deburring, Dimpling - (8.5 hours)

Category: Empennage

Started left elevator and trim tab beginning with disassembly, deburring, and dimpling, skins and ribs and countersinking and dimpling spars (09-09, 10, 11). Fabricated pushrod and trim tab horns (09-12). Started assembly of trim tab

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Oct 24, 2019 Right Elevator: Front Spar Riveting and Close-Out - (6.0 hours)

Category: Empennage

Riveted right front spar to ribs and completed inboard and outboard close-out (Page 09-20,21,22). Taped and clecoed TE to bottom skin (09-23). Ordered tank sealant from Van's for TE rib installation.

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Oct 23, 2019 Right Elevator: Initial Assembly - (6.0 hours) Category: Empennage

Completed initial riveting of right elevator up to insertion of front spar using special bucking bar for riveting skins to rear spar (pages, 09-17,18,19).

Oct 22, 2019 Right Elevator: Disassembly, Deburring, and Dimpling - (6.0 hours) Category: Empennage

Decided to complete right elevator first. Disassembled, deburred, dimpled, and countersunk parts as outlined on page 09-09,10, and 11. Scuffed skins for TE rib installation (09-15) and riveted front spar assembly as described on page 09-16

Oct 21, 2019 Elevators: Match Drilling and Initial Assembly - (2.0 hours)

Category: Empennage

Clecoed and match drilled horns and close-out tabs. Completed initial assembly of right and left elevators, except for trim tab (09-08,09).

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Oct 18, 2019 Elevator: Initial Clecoing and Match Drilling - (6.0 hours) Category: Empennage

Initial assembly of elevators and trim tab hinges to permit trimming and match drilling.

Oct 17, 2019 Kit Order - (10 hours) Category: Wings

Ordered wings kit from Vans. Expected crate date is 12/30/19.

Oct 17, 2019 Elevator: Parts Preparation - (4 hours) Category: Empennage

Prepared TE ribs, bent close-out tabs, trimmed right rear spar, and drilled and clecoed front spar to skins (09-03,04, and 05).

Oct 16, 2019 Elevator: Rib and Shear Clip Preparation - (2.5 hours)

Category: Empennage

Completed separating rib and shear clips (09-02).

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Oct 15, 2019 Horiz Stab: Transport Cradle and Storage - (2.0 hours)

Category: Empennage

Built transport cradle and placed in temporary storage. Horizontal stabilizer shown next to vertical stabilizer in picture.

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Oct 14, 2019 Horiz Stab: Rear Spar Insertion and Final Riveting - (10 hours)

Category: Empennage

Completed all steps on 08-12 including insertion of rear spar and skin riveting.

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Oct 13, 2019 Horiz Stab: Cleco and Rivet Skins - (2.0 hours)

Category: Empennage

Started clecoing and riveting. Completed page 08-11

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Oct 11, 2019 Horz Stab: Dimpling and Countersinking - (6.0 hours)

Category: Empennage

Completed page 08-08 through 08-10 (2hr). Lots of dimpling and machine countersinking!

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Oct 10, 2019 Horiz Stab: Cradle Fabrication and Initial Assembly - (6.5 hours)

Category: Empennage

Completed page 08-05, 08-06, 08-07, and 08-09

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Oct 09, 2019 Horiz Stab: Front and Rear Spar Assembly - (4.5 hours)

Category: Empennage

Assembled and installed flange bearing to rear spar. Trimmed and deburred spar caps and stringers. Prepared front spar for riveting, lots of match drilling, deburring, machine countersinking. 3 hrs

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Oct 08, 2019 Horiz Stab: Match Drill/Debur Rear Spar and Doubler - (4.5 hours) Category: Empennage

Completed page 08-02, match drilling and deburring rear spar and doubler. Riveted hinge brackets.

Oct 05, 2019 Rudder: TE Riveting and LE Rolling - (6.0 hours)

Category: Empennage

Finished rudder, riveting TE, rolling LE and riveting. Carlos helped with rolling LE. Rudder secured to vertical stabilizer and mounted on wooden support.

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Oct 04, 2019 Rudder: Riveting Skins - (4.0 hours) Category: Empennage

Fnished riveting except for TE and LE.

Oct 03, 2019 Rudder: Glue and Cleco TE - (10 hours)

Category: Empennage

Back to working on rudder after waiting for 3M double-stick tape to arrive. Glued and clecoed TE to left skin overnight.

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Sep 29, 2019 Rudder: TE Countersinking - (2.0 hours)

Category: Empennage

Set up jig and countersinking trailing edge. Clecoed TE between skins to check fit and alignment.

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Sep 28, 2019 Rudder: Install Skin Stiffiners - (8.0 hours)

Category: Empennage

Match drilled, deburred, dimpled, and riveted skin stiffeners of the rudder. Very tedious and easy to make mistake, so went slowly (pages 07-06,07,08). Ordered 3M adhesive for mounting trailing edge and can't proceed until it arrives next week.

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Sep 27, 2019 Rudder: TE Prep and Initial Assembly - (3 hours)

Category: Empennage

Prepared trailing edge and clecoed and final sizing entire piece (pages 07-06,07). ATS tools arrived.

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Sep 26, 2019 Rudder: Cleco, Match Drill, and Riveting Skeleton - (5 hours) Category: Empennage

Clecoing, final sizing, and riveting skeleton (pages 07-03, 04, 05)

Sep 25, 2019 Rudder: Assembling Parts - (3 hours) Category: Empennage

Located and prepared parts for assembly (pages 07-01,02). Installed new metal-cutting bandsaw blade.

Sep 24, 2019 Vert Stab: Finish Riveting - (6.0 hours)

Category: Empennage

Complete riveting vert. stabilizer to finish Section 6. Carlos helped with bucking the front spar and middle rib.

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Sep 23, 2019 Vert Stab: Dimpling and Countersinking - (6.0 hours)

Category: Empennage

Dimpled and countersunk all parts. Carlos dropped by with countersink kit. Clecoed and riveted spar and ribs and clecoed to skin. Clecoed and riveted rear spar assembly.

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Sep 21, 2019 Vert Stab: Initial Assembly and Match Drill - (4.0 hours)

Category: Empennage

Completed cleco, final and match drilled all rib, spar, and skin holes

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Sep 20, 2019 Vert Stab: Forward Spar - (2.0 hours)

Category: Empennage

Completed forward spar mod. Dimpled using DRDT2 and riveted with p-squeezer. Ordered soft metal cutting blade for bandsaw since unit came with wood blade. Ordered remaining tools from ATS.

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Sep 16, 2019 Empennage: Inventory - (6.0 hours)

Category: Empennage

The empennage kit arrived on 08/30/19, but only now had time to open and inventory. Took 17 days from order to delivery from Oregon, not bad considering the expected impact of AirVentures19 orders. Everything is very nicely packed.

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Aug 29, 2019 Workshop: Island Bench

Category: Workshop

Fabricated top for island bench and set DRDT-2 on end. Installed bench sander, deburring wheel, and drill press on new bench against wall. Installed metal shelving to store inventoried parts and large wooden shelf from crate lid for larger parts.

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Aug 28, 2019 Workshop: Band Saw

Category: Workshop

The JET band saw ordered from HD arrived. It's stand mounted and seems best to locate it next to large bench.

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Aug 28, 2019 Workshop

Category: Workshop

Built workshop in garage. Total time was considerable, but did not include in build time.

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