Apr 15, 2024     Completed SB-00088 - (3 hours)       Category: Service B's

I prepped up the replacement bracket, drilled out nutplates on the oil cooler, added the bracket, installed new nutplates and bolted the bracket on. Then cut the rubber grommets and put them in the outside holes, making the cut portion to the right and filling with RTV (although suspect the grommets turn when tightening), added the bushing and bolted the radiator to the new bracket on the oil cooler, bolted the top back on and reattached the hoses. All bolts and nuts torqued. To me, it seems like the oil cooler might wobble a little so we'll wait for THAT service bulletin.

  Dec 29, 2023     Completed service letter SL000068 - (2 hours)       Category: Service B's

I borrowed Vince Bastianii's rivet gun and riveted the nutplate, spacers, and bracket assembly on the outboard bracket. Tough getting in there with a bucking bar but I did so. I had previously squeezed the rivets on the inboard assembly. then I reattached the inboard assembly and riveted the top and bottom into place on both sides and reinstalled all bolts holding things to the spar; torqued.

I'm not ready, I guess to reinstalled the emp on the fuselage. Everything is dusty. I polished a couple of areas on the VS and stabilator skin that might be some corrosion but I'm not sure. Better safe than sorry.

I loosely attached the VS per instructions in section 11 of the KAI.

  Dec 28, 2023     Prepped spacers etc - (2 hours)       Category: Service B's

I primed the bare metal of the brackets then prepped each of four spacers by deburring and radiusing the forward edge. I dimpled the thing spacers and countersunk the thick ones but couldn't rivet them all in place until I can borrow a rivet gun.

  Dec 26, 2023     Started on Stabilator service letter SL0000-68 - (2 hours)       Category: Service B's

It was good to get back out to the hangar to do some work. The little camper has been given away so have more elbow room. I took the stabilator, put it on the worktable and started working on the service letter. I don't really know what the point of this is. Allegedly, it was hard to install washers when attaching the stabilator to the empennage. I don't know. I don't remember that long ago. I know there are washers super-glued to the brackets and these, I guess, are replaced by shims. Whoopdy-doo. I'm not the best driller-outer of rivets and a few have to be removed to remove the inboard brackets and nutplates. But I got most of the out without trouble and the ones that gave me troubled didn't result in buggering up the hole too badly. The next step is to prime some bare metal on the brackets where I've sanded super glue away so I've got to hit the NAPA store and see if I can find some.

  Dec 25, 2023     SL-00070 - (.1 hour) Category: Service B's

There's a service letter out to install an optional fuel tank access fitting to make it easier to check the fuel pickup strainer. I haven't done anything on the project since returning from back East because it's cold and the canopy is loosely sitting on the frame and I don't want to touch it. So I'll wait but ordered and received the installation kit.

  Jul 24, 2023     Complied with SB 00059 - (.1 hour)       Category: Service B's

I hadn't attached the old canopy latch block yet so complying with this one didn't require much. Just had to find the screws and pull out the new canopy latch block and screw it in.

  May 08, 2023     Complied with Stabilator counterweight service bulletin - (1.5 hours)       Category: Service B's

Finally gorgeous weather in Minnesota so took the e-bike over to the hangar looking for something to do. Originally I was considering putting the stabilator on for good so pulled out the service bulletin and kit which is pretty easy. Just take the weights off and throw away the hardware (I don't reuse hardware), fit the new "mass balancing straps" and then use them as the drill guide to drill 3 holes on each side. Remove, deburr, reinstall and then rivet with six Cherrymax rivets. The only question I had was Van's sends four washers where only two are indicated. Knowing how cheap Van's is, I'm not sure what that's all about.

Anyway, I didn't drill any weight out of the counterweights because that's to be done after painting. But everything else is done.

Almost warm enough to drill some rear window holes, which at the moment is holding everything up. C'mon, summer!

  Mar 08, 2023     Complied with SB-00064-RV12 - (.5 hour)       Category: Service B's

After I finished trimming the cowling around the radiator and the oil cooler, I doublechecked to be sure none of the exhaust components were interfering with the bottom cowl, then removed it and installed the "flat springs" around the slip joints on the #1 exhaust tubing. Simple

Also I have to remember the red RTV on that spring.

  Feb 07, 2023     SB fix kits arrive - (.1 hour) Category: Service B's

The fix kits for stabilator mass, hinge spacer, exhaust flat spring, and canopy latch arrived. None of these should be very difficult as final installation hasn't occurred on any of them.

  Dec 12, 2022     Completed SB-00058 - (2 hours)       Category: Service B's

Everything went great in complying with the service bulletin to replace the HIC module because of reports of low fuel pressure, probably because of loose contacts in the Molex connector on the old HIC. I opened up the connector and cut the wires, checking the wire number for confirmation. I made up new labels because Stein's labels aren't covered with heat shrink and some are smudged so I wanted something permanent that also indicated what pin each wire goes into on the new connector. Then I inserted them where they go after stripping off 1/4" of wire on the 14 gauge wire. I like these connectors much better.

I did a continuity test to be sure each wire was properly connected by checking the X3 connector on the fuse and also ground points for both the airframe and "Lane A".

Then I reinstalled the ECU which is moved slightly. Thus the newly drilled holes via the TOOL-00114k. Everything looks great and now I should be able to continue with installation of the passenger side G3X.

  Dec 11, 2022     Started on SB-00058 - (1 hour)       Category: Service B's

I removed the old HIC module after moving the ECU out of the way yesterday. Then I clecoed and screwed in pace TOOL-00114, which is, basically, a drill guide. That done, removed the guide, then filed the holes a little bit to get the new HIC module -- now known as AV-600009 -- to fit in the slots. I have not yet screwed it into place.

The next step will be to disconnect the old wires from the old Molex connector and insert them into the new connector. I think that maybe gets done before I screw it in place but I didn't have heat on in the hangar today because that kerosene I'm using is really dirty and I didn't feel like breathing fumes today. And it needs to be comfortable to do some wiring work in confined spaces. Maybe tomorrow.

  Nov 13, 2022     Preparing to undo stuff for a service bulletin - (.1 hour)       Category: Service B's

I took another look at Van's Service Bulletin 00058 and realized I misread the affected models of the need to replace an HIC module that regulates power to the fuel pumps. Or I forgot what year it is. One of those. It affects avionics kits shipped before August 2022. For some reason I was thinking 2021 and mine was shipped to SteinAir in November 2021. So I've ordered SB-00058 fix kit which will run another $97 or so. Since I'll have to remove the ECU and those big cables, I'm not going to worry about those two grommets since moving the ECU will pull those grommets out for good. I'll just replace them later and do the prosealing all over again.

  Jul 15, 2022     Reinstalled fuel boost pumps (and more)       Category: Service B's

While we were on vacation, Lockwood Aviation completed the replacement of the electrical pumps per the Service Bulletin and sent it back so I reinstalled it today. I notice I had neglected the two screws in the baggage floor-to-bulkhead when I'd first installed it and so I installed those for a total of 6x.

I then confirmed that the pitch and roll servo connector labels were switched and changed the labels.

I connected the DSUB connectors for the stick grip on each side, riveted in the standoffs in the ribs on each side and connected the stick grip local ground wires to the ribs on each side.

I intended to install the headset jacks but I found that the step isolator and isolator washers for all four were missing so Nick at SteinAir is going to drop a couple of sets in the mail.

Slow going.

  Jun 22, 2022     Began routing wires aft - (1 hour)       Category: Service B's

Spent some time examining the various drawings showing routing of the wires and when they made sense, I started routing things but I had to quit because I was bleeding too much from all the scrapes from reaching into lightening holes etc.

I also sent the entire boost pump unit to Lockwood Aviation for replacement of the fuel pumps per the service bulletin from ROTAX.

  May 05, 2022     Completed SB-53 - (1.5 hours)       Category: Service B's

Primed and then installed all the clips on three forward bulkheads. Two on 1208 and 1209 bulkheads and one on the forward portion of 1210. Will make this area and a point of inspection at the time of annual condition inspections.

  May 04, 2022     Started on SB-53 - (3 hours)       Category: Service B's

Took the tailcone off and made the plawood inserts for support. But what a pain in the neck drilling out the rivets were. I've got a couple of elongated holes. I don't know how people with the tailcone attached are doing this. Took the clips, which will be inserted at each bulkhead, home for alodining and priming.

  Mar 10, 2022     Getting ready to start on SB-00053 - (.1 hour)       Category: Service B's

Van's has issued SB-00053 because of some cracking in the bottom skin at the intersection with bulkheads in the tailcone. Fortunately, I haven't permanently installed the tailcone so I should be able to remove it and get back in there manageably once the water from the spring melt leaves the hangar. STILL waiting for the avionics kit to arrive and it looks like I will reach the one-year mark on the wait soon.

  May 20, 2021     Complied with SB-00013 - (4 hours)       Category: Service B's

The other day I started on assembling the replacement parts for the muffler exhaust stacks. Cylinder #2 is easy enough but the redesign creates 3 pieces that make up stack #1 and the instructions with the original service bulletin no longer apply. Plans Chapter 48 was rewritten this month and leaves a little to be desired.

They have you torque down the exhaust nuts -- I had to order a metric crowsfoot kit -- after installing the top piece on cylinder #1 and tightening only until you see the first thread. But when you go back to install the lower two parts, you can't really get it all to fit unless you take off the top piece and even then, it's really tight. You put the nuts back on but they don't want you to torque them until the radiator goes on. But I had to tighten them enough to pull the piece into the cylinder slip joint. I sent pictures off to Van's support for their review. I don't care for the new system.

I reinstalled the springs and put a line of RTV on the front and back of each spring and in the clip to keep it from rotating and wearing.

Then I put the EGT probes in. There is very little slack in #1 and the instructions say to loosen and turn the bracket at the top to provide more slack, but turning it makes the probe interfere with other components, which the instructions specifically say don't allow to happen. I got the other three cylinders with enough slack, I think, but it was difficult.

I torqued down the probes on #2, #3, and #4 to 19 foot pounds -- 18 with the crowsfoot but I waited on #1 until I get the "all clear" from Van's on the installation.

I fit the bottom cowl to be sure the exhaust pipe fits through the hole and it's perfect!

  May 15, 2021     Complied with SB-00023 - (2 hours)       Category: Service B's

Finally got the backordered part for complying with last November's service bulletin warning of cracks in the engine mount standoff. Since I'm building as an LSA, I had no choice but to make the change. These design changes are really adding some money to the project.

Nothing too special. Remove bolts, remove old WD-1221, add new one, return bolts. Torqued to about 175 inch pounds.

The new exhaust tubes (to comply with yet another service bulletin) also arrived so my six month building suspension is over.

  Nov 01, 2020     Fully finished SD-00001 - (.2 hour)       Category: Service B's

Cut off the old connector on the wiring that comes down the tail cone. For some reason they used two white wires for power wires so I did a continuity check and identified one wire, and took a magic marker to it. This will be the gray/black wire and installed it in pin 5. Also marked it at the foreward location.

  Oct 27, 2020     Mostly finished SD-00001 - (1.5 hours)       Category: Service B's

I tested the range of travel with the motor and everything is fine. Then mounted the motor unit to the servo tray, ran the wires through the snap bushing, attached female DSub pins and stuck them in the connector. I screwed up a couple of pins but I had about 50 left over from the RV-7A project years ago, so no problem.

I reattached all of the components to the servo assembly and called it a day.

The only thing I still need to do is cut off the old connector on the wire at the rear fuselage and add new DSUB pins and connector

  Oct 26, 2020     Began SD-00001 fix - (1.5 hours)       Category: Service B's

SD-00001 requires replacement of the Rob Allen servo that powered the trim with a new motor. That's another $200 fix for parts that haven't even flown yet.

I disassembled the existing control arm and motor, made up a new servo tray, and attached a bushing and clevis which is finger tightened to 15 degrees and then, with a drop or two of Threadlocker, final tightened to 0 degrees (perpendicular to the tray.

Just to be sure no Threadlocker dripped down into the motor and shaft, I stood the unit on its Clevis overnight until cured.

  Feb 06, 2020     SB 19--08-26 Replaced nose gear - (1.3 hours)       Category: Service B's

Van's issued a Service Bulletin a week or so ago because a flight school in Florida found a crack in the nose gear last year, so it redesigned the gear to strengthen it. Mine arrived today ($390), and I took the old gear off and bolted the new gear on, then reattached the wheel assembly.

I'll have to take the tire off at some point when it's more comfortable to work in the hangar because I have to set the breakout force for the assembly, then drill a hole for a cotter pin.

  Feb 01, 2020     Reinstalled flaperon controls - (2 hours)       Category: Service B's

I haven't done any work on the plane all winter because I really need an engine to continue. But I had drilled the flaperon control arms so decided to reinstall them. Problem. I had mislabeled the inboard parts and caught my mistake and installed them correctly. But was the outer arm marked "R", for example, also mislabeled? I gambled that they were, although I did check to see that each is compatible with the other. We'll see when the wings go back on.

Van's issue a service bulletin to replace the nose gear. So I've ordered that at $325. Swell. With the tax return, I may have enough -- mostly -- for an engine.

  Oct 07, 2019     Stabilator service bulletin - (1 hour)       Category: Service B's

I reattached the cable attach brackets, torqued the bolts (25 inch pounds) and then riveted the attached doublers to the spar assembly.

The rest of the service bulletin describes remounting the stabilator to the tailcone assembly and I'll do that later.

  Oct 06, 2019     Stabilator service bulletin - riveted gussets - (1.5 hours)       Category: Service B's

I reattached the cable attach brackets, torqued the bolts (25 inch pounds) and then riveted the attached doublers to the spar assembly.

The rest of the service bulletin describes remounting the stabilator to the tailcone assembly and I'll do that later.

  Oct 04, 2019     Stabilator service bulletin - (2 hours)       Category: Service B's

Created new hinge brackets. I used some acetone to take the old 416L washers off the old brackets (since I don't have any more) and superglued them to the new ones. No heavy lifting here. Just following the instructions.

Separately, I clecoed, then drilled four gussets to the spar and ribs. It's quite a beefed up area now.

  Oct 01, 2019     Started on service bulletin - (2 hours)       Category: Service B's

I've been unable to focus on the project in recent weeks because I don't know what to do next. I don't have the money for an engine, and apparently it's too soon to start on the canopy. Eric at Van's says the rear window should be in place soon, which means it's time to start assembling the airframe.

That's a little odd because I've heard I shouldn't start adding the tail stuff until the fuel system is in place, including the fuel pump, ELT etc, which sit on the back of the baggage bulkhead and are easy to reach only with the tail section off.

But I'll start assembling what I can, which means it's time to get to the long-postponed stabilator spar service bulletin to strengthen the area around the hinge brackets.

So I removed the existing brackets, as directed, and matched drilled a doubler underneath each, then removed the gizmos with the stops (they're to be thrown away) and removed three pop rivets on each forward side of an internal rib. I prepped the doublers. They are to be match drilled into the forward spar (man, there's a lot of new holes going into the spar!).

  Oct 01, 2019     Service Bulletin 18-02-02 - (2 hours)       Category: Service B's

I've been unable to focus on the project in recent weeks because I don't know what to do next. I don't have the money for an engine, and apparently it's too soon to start on the canopy. Eric at Van's says the rear window should be in place soon, which means it's time to start assembling the airframe.

That's a little odd because I've heard I shouldn't start adding the tail stuff until the fuel system is in place, including the fuel pump, ELT etc, which sit on the back of the baggage bulkhead and are easy to reach only with the tail section off.

But I'll start assembling what I can, which means it's time to get to the long-postponed stabilator spar service bulletin to strengthen the area around the hinge brackets.

So I removed the existing brackets, as directed, and matched drilled a doubler underneath each, then removed the gizmos with the stops (they're to be thrown away) and removed three pop rivets on each forward side of an internal rib. I prepped the doublers. They are to be match drilled into the forward spar (man, there's a lot of new holes going into the spar!).