Feb 12, 2023     Set ECO stop - (1 hour)       Category: Controls

There was one item in Section 49 (engine controls) that I had to leave undone last year because I needed an EFIS display to complete: setting the ECO stop for 98% power. When I fired up the G3X, I couldn't see where the throttle setting was displayed but Tony Kirk at Van's pointed it out. Then when I checked my ECO stop position, it only displayed 97% power. So I filed some of the back of the stop off and remounted (and repeated) until the throttle went to 98% power and locked it in place. Also checked that throttle level operates through the entire range.

I just have to install the handle, check to see if I put heat shrink at the end of the throttle cable, and reinstall the tunnel cover (can't do it yet because I haven't attached rudder cables; I should do that soon) to complete Section 49.

While searching for an errant washer, I also discovered that I didn't put a snap bushing in the bundle where it enters the air frame under the passenger area. I'll do that next.

  Jun 15, 2021     Attached throttle control cable - (2 hours)       Category: Controls

While I wait four months or more for the avionics kit, I'm tidying up a few odds and ends. I reinstalled the Adel clamps that held engine monitoring system cabling to the engne mount (which I replaced as part of a service bulletin). I attached the throttle cable after hearing from Tony Kirk at Van's that I should be able to have full travel from stop to stop (and he was right). I can't do anything more around there because I need a working EFIS (avionics kit).

Here's Tony's response:

"I think you could move the lever forward about 1/8” from where it is now, then lock it in place with the friction knob (step 4), then make the cable adjustments detailed in step 5. I think you will still have all the throttle travel necessary. The throttle arm in Figure 3 should hit the stops on the throttle body at both ends of the throttle travel. The throttle lever should not be the travel limiter. If there isn't enough movement, only then would I lengthen the slot in the throttle lever."

I dug out the overflow bottle and smothered some red RTV on the backside so it doesn't chafe with the firewall when it's installed. And drilled a 3/8" hole in the cap and added an elbow fitting.

Got the insurance quote for renewing the builder's policy. At $80,000 --> $730.

  Jun 12, 2021     Problem attaching throttle control - (.5 hour)       Category: Controls

A bit of a complication in following the step to attach the throttle cable to the throttle arm on the engine and the throttle control in the fuselage. The instructions call for you to advance the throttle lever about 3/16" from the aft cutout and then tighten and clamp it down at the engine.

My throttle lever in full aft position is still about 1/4" forward of the aft cutout. Investigation reveals the underlying lever mechanism hits the stop, which is the bulkhead. I suppose I could file that down to allow the lever to hit the aft portion of the cutout, and then set it according to the instructions, so I send support a message at Van's for their assessment.

  Mar 29, 2021     Prepped flap motor housing cover - (1 hour)       Category: Controls

Added nutplates for the cupholder and riveted the end, then primed both the cover and the cupholder, apparently the cupholder is susceptibule to UV rays. We'll see.

  Mar 28, 2021     Primed, painted throttle quadrant sides - (.3 hour)       Category: Controls

The incredibly helpful Tony Kirk of Van's support staff said the length (or lack of it) of the cable at the connection to the fuel shutoff is fine but suggested checking the nuts and lock washers at the clamping location just before the connection. He said they look loose. I doublechecked and they're quite tight.

I pulled out and deburred the two sides of the throttle quadrant and an access cover and primed them up. I didn't bother Alumiprepping and Alodining because I want the inside to be shiny to reflect light if I need to get in there sometime. I'm not doing a lot of priming on the project unless it's something critical or exposed to the elements. If a part could be replaced easily in the unlikely event that it is reduced to dust by corrosion, then it doesn't get primed unless it needs a coat of paint, which, of course, the outside of these parts does.

Meanwhile, Greg Hughes at Van's reports the shipping date for the replacement top engine mount standoff is now late April. Just as well. I'm working 10 Twins games in April and plan to drive out to Fitchburg Mass during the Twins road trip to pick up rugs and other mementos from my mother's house before it's sold.

  Mar 23, 2021     Routing throttle and fuel shutoff cables - (2 hours)       Category: Controls

If you follow the Van's instructions in order, you'd probably have the tailcone assembly mated by the time you reach this step, which is why it's a good idea to listen to the people who say wait until the last possible time to do that. I can't imagine stringing and connecting the fuel shutoff cutoff cable if you had to crawl back through the baggage area or if you had to work through inspection panels. And there's still some avionics wiring that has to get strung back there.

But that got done, although the amount of extra cable I have after the connection at the shutoff is made appears to be less than what the plans show so I want to ask Van's about that.

I also threaded the throttle cable to connect it to the standoff on the engine. I routed it as best I could. I still really would like that service bulletin replacement for the top engine mount standoff so I can clamp everything down.

No word from Van's yet on the status of that. Greg Hughes says he'll check in the morning although she did say "there are a lot of orders" which makes me think it'll be awhile yet.

  Mar 21, 2021     Throttle system work - (2 hours)       Category: Controls

Over several days prepped up the tunnel covers (prime and paint) then installed the bracket, riveting it to the front and back after rigging up the spring slide on the bracket. Installed. Threaded the throttle cable through the firewall (after installing the grommet) but had to stop because the nuts are metric and I didn't have metric wrenches at the hangar.

  Mar 05, 2021     Started on throttle control brackets - (1 hour)       Category: Controls

While we wait for Van's to supply the parts necessary for the two service bulletins, I started on the engine controls section of the instructions. Deburred the large piece and then added nutplates along the side and countersunk for eventual nutplates on the forward -- or perhaps aft, I don't know -- end. I have to hunt around for the throttle spring and bracket next.

  Nov 15, 2019     Final holes drilled in flaperon - (1.4 hours)       Category: Controls

John Wanamaker came over on Wednesday and helped me take the wings off (took about 3 minutes). I removed the flaperon control horns and then drilled the bottom-side holes (2x) on each, then drilled them out to a #12.

I'll put them back on but then there I am: stck agan. The instructions say run wires from the avionics kit before putting the tail on.

I gotta order that engine.

  Nov 10, 2019     Time to remove wings - (1 hour)       Category: Controls

Having just put the wings on last week, I find it is now time to take them off. Apparently, the wings only went on to attach the flaperon control arm so that they could be drilled to the control tubes. So removing everything now.

  Nov 09, 2019     Drilled flaperon controls - (2 hours)       Category: Controls

I bought a couple of 1/16" drill bits to use as a spacer for the little tabs on the flaperons and then fit the tubes onto the doohickeys. I cut some .090 (I think) scrap for spacers under the tubes where they join the control from the rods in the center, clamped them together, and checked to be sure the arms were exactly parallel.

And they were -- that never happens to me -- each bolt center was 2 20/32s from the bottom bracket, indicating they were parallel.

Then I drilled four top holes -- two on each -- out to #30 and clecoed.

In the next session, I'll remove all of them and final drill them.

  Oct 20, 2019     Prepped flaperon brackets - (1 hour) Category: Controls

I've been cleaning the hangar out so not a lot of work, but prepped up the powder-coated flaperon brackets, adding the two plastic pieces in the slot where the inboard flaperon "stub" goes. You have to keep a 1/4" gap but the problem here is the rivets that are installed after the pieces are epoxied into place, cam protrude slightly. So I filed a few down. I was able to get a 1/4" piece of aluminum into the slot, but not without great difficulty. So I may need to adjust that at some point.

The next step is fitting the wings, but I need to get the camper put where it belongs for the winter (it needs cleaning first), and then find a helper.

We're all headaing east to Oralie's memorial service later this week.

  Oct 18, 2019     Attached flaperons to wings - (2 hours) Category: Controls

The camper is out for its final rental of the season, so I've been trying to clean the hangar out and get rid of stuff and make room for it and -- hopefully -- still have enough room left to attach the wings to the RV-12 and, eventually, add the tail section. We'll see.

I've gone back to the "airframe assembly" chapter and you have to add the flaperons to the wings first, then tape them in place to keep them from flapping-- get it? -- around when moving the wings.

Heather and Ben visited the hangar and I put them to work holding the flaperons in place and inserting bolts. Each of us took a hinge point and it went pretty well.

Once the camper is back and positioned for winter, I'll try to get a hand attaching the wings.