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.

  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 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 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     Nose Wheel Fairing - (10 hours)       Category: Finish

Completed nose wheel fairing over a period of several days.

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

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

  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.

  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.

  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.

  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.

  Oct 11, 2021     Wheel Fairings - (4 hours)       Category: Finish

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

  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 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.

  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.

  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.

  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.

  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.

  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.

  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 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.

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

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

  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.

  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.

  Jan 11, 2021     Canopy Completion - (8 hours)       Category: Finish

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

  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.

  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.

  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.

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

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

  Jan 02, 2021     Seat Backs - (8 hours)       Category: Finish

Prepped and primed all seat back components,

  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.

  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.

  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.

  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.

  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.

  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.

  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.

  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.

  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.

  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.

  Dec 20, 2020     Canopy - (6 hours)       Category: Finish

Completed assembly and riveting of forward canopy frame.

  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.

  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.

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

Raised fuselage to prepare for installation of landing gear.

  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.

  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.

  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.

  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.

  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.

  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.

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

Finish kit arrived today and placed in hanger.