Mar 01, 2024     Rent Category: Hangar

  Feb 01, 2024     Rent Category: Hangar

  Jan 01, 2024     Rent Category: Hangar

  Dec 01, 2023     Rent Category: Hangar

  Nov 01, 2023     Rent Category: Hangar

  Oct 14, 2023     Organize & Prep - (2.3 hours) Category: Hangar

Organized additional parts on wall hangers. Prepared wings by covering individually with plastic sheet, then covering the pair with a tarp.

  Oct 07, 2023     Raw material hangers - (1.75 hours) Category: Hangar

Added some hangers to the hangar wall for storage of long pieces of aluminum construction.

  Oct 04, 2023     Hang Lights - (3.2 hours) Category: Hangar

Hung shop lights, determined details for rear wall tarp.

  Oct 01, 2023     Rent - (.1 hour) Category: Hangar

  Sep 01, 2023     Rent - (.1 hour) Category: Hangar

  Aug 20, 2023     Air Compressor - (1.3 hours) Category: Hangar

Setup air compressor hose, clean and inspect wings and cradle.

  Aug 01, 2023     Rent - (.1 hour) Category: Hangar

  Jul 01, 2023     Rent - (.1 hour) Category: Hangar

  Jun 26, 2023     Review XNB-F06 - (2.5 hours) Category: Cockpit

Review and plan glare shield installation.

  Jun 25, 2023     Move Workbench - (2.3 hours) Category: Hangar

Move workbench and other tools to new hangar. Position and organize space.

  Jun 21, 2023     Organize Space - (4.5 hours) Category: Hangar

Moved parts boxes from home to hangar. Moved tools to positions in hangar. Hung metal pieces for organization. Cleaned tool boxes.

  Jun 20, 2023     Pickup and Deliver Tools - (3.25 hours) Category: Hangar

Retrieved air compressor, grinder, sander from friend's storage unit and unloaded in new hangar.

  Jun 14, 2023     Level Flooring - (2.5 hours) Category: Hangar

Leveled area behind concrete pad, placed old partitions and covered with previously used OSB flooring.

  Jun 13, 2023     Spread rock floor - (1.1 hours) Category: Hangar

Cut open bags and spread stone.

  Jun 10, 2023     Add stone to floor - (3.5 hours) Category: Hangar

Hauled 75 bags of drainage rock for use in filling floor of hangar.

  Jun 06, 2023     Remove Impediments - (2.0 hours) Category: Hangar

Removed old aluminum framed partition panels embedded stone flooring.

  Jun 01, 2023     Monthly rent - (0.1 hour) Category: Hangar

  May 07, 2023     Evaluate and Clean New Hangar - (2.1 hours)       Category: Hangar

Caught a break at Mallory Airport and was able to move to a hangar with a concrete pad. New location dryer and more amenable to building. Started cleaning and evaluating conditions. Will likely spread three or four tons of gravel.

Looking at simple light augmentation schemes.

First quarter rent.

  May 01, 2023     Monthly rent - (0.1 hour) Category: Hangar

  Apr 01, 2023     Monthly rent - (0.1 hour) Category: Hangar

  Dec 04, 2022     Prep cradle for transport - (1.5 hours) Category: Hangar

Removed wings and set them on saw horses and covered with plastic. Examined cradle to determining if additional structure or support is necessary for transportation to new assembly building.

  Nov 23, 2022     Packing and prep for new workspace - (4.5 hours) Category: Hangar

Packed and hauled lumber, workbench and misc materials from Mallory hangar to storage space with Randy. Discussed various methods for lifting wing assemblies for storage in the assembly area.

  Oct 20, 2022     Additional work on wing cradle - (1.9 hours)       Category: Hangar

Continued work on making the wing cradle ready to stand up against weather and to provide an easier to move and secure package for the wings. Removed larger corner pads made from 1" foam and replaced by gluing 1/2" foam pads to unistrut. Ground unistrut braces to provide freedom of movement for tow hooks. Worked on rear wing spreader.

Mallory Airport (WV12) was sold at auction at noon for $560,000.
**update**
Buyer backed out. A pilot group purchased the property.

  Oct 19, 2022     Wing Cradle Inspection - (4.2 hours)       Category: Hangar

Obtained locking bolt/nut head fasteners replacing similar sized 3/8" bolts/washers/nylon nuts on wing cradle. Inspected cradle bottom, particularly welded ends.
Added tow hooks at front HF swivel wheel bolt holes. Attachment points will need grinding to radius some relief for hook to pivot.

  Oct 18, 2022     Clean and Collect - (2.2 hours) Category: Hangar

Collect storage containers with interior and baffling trim pieces. Evaluate wing cradle for rust and integrity.

  Oct 15, 2022     Prepare Wings for Transport - (3.5 hours)       Category: Wings

Prepared wing pushrods and spoiler cables for transportation and storage. Plugged wing root-end entry points against intrusion from animals or insects.

  Oct 12, 2022     More platform recovery - (3.2 hours)       Category: Hangar

Break down platform. Package wings for storage and transport. Wrap plastic sheet around fuselage.

  Oct 12, 2022     Lumber recycle - (2.1 hours)       Category: Hangar

Lumber gathering for recycle, recovered 20 2x6x8s.

  Oct 11, 2022     Disassemble last of platform - (2.5 hours) Category: Hangar

Removed final three sheets of flooring, removing fasteners.

  Oct 09, 2022     Recover 2x6s - (3.2 hours)       Category: Hangar

Breakdown building platform to recover 2x6x8 material for reuse in new space.

  Oct 02, 2022     Packing up - (3.5 hours) Category: Hangar

Set wings in cradle, wrapped engine bay with film, collecting tools and material.

  Aug 27, 2022     Prep for Move - (3.0 hours) Category: Hangar

Attached elevon push rods, bottom cowling, canopy on fuselage.
Hot, humid, dust accumulation from mowing dry grass. Move will be a welcome change for working environment. Water running through hangar adds to stifling humidity.
Drop off compressor, band saw, sander at new location.

  Aug 26, 2022     Clean and Pack - (3.2 hours) Category: Hangar

Prep for move.

  Aug 11, 2022     More organization for move - (3.5 hours) Category: Hangar

More organizing, cleaning, boxing of parts and assemblies for move out of Mallory Airport.

  Aug 10, 2022     Organize and store parts - (4.5 hours) Category: Hangar

Unpack, clean, and organize parts and assemblies for storage in an out building at home.

  Aug 09, 2022     Pack and Move Parts - (3.5 hours) Category: Hangar

Collected large parts (fuselage bottom skin), windscreen, bulk aluminum sections, and plastic totes. Packed into utility trailer and transported home for storage.

  Jul 30, 2022     Clean Up, Organize, Prepare for Move - (3 hours) Category: Hangar

Collecting, cleaning in preparation to move parts, tools, and assemblies. Completed parts and raw materials will be moved to home. The fuselage and wings will be moved to a storage building for continued construction.

Mallory Airport future is uncertain due to the owners death. The space has become unpleasant to work in, humid, dust, heat, etc.

  Jun 21, 2022     Reinstall Controls - (1.4 hours)       Category: Cockpit

Reinstallation of spoiler control pulley brackets and fuel bulkhead fitting.

  May 04, 2022     Prep Cowl, wheel pants - (2.5 hours)       Category: Interior Finish

Sanded cowling and wheel pants in preparation for epoxy primer. Sprayed primer to wheel pants and cowling.

  May 02, 2022     Forward Cockpit Final Epoxy Primer - (0.8 hour) Category: Interior Finish

Sprayed forward cockpit interior with epoxy primer. Removed masking tape, reinstall throttle and mixture quadrant.

  Apr 16, 2022     Fill and Sand Wheel Pants - (1.3 hours) Category: Ext. Finish

Applied lightweight filler to seams in wheel pants. Sanded in preparation for epoxy primer.

  Apr 15, 2022     Epoxy Primer - (2.1 hours)       Category: Interior Finish

Sand and second coat of epoxy primer to forward cockpit. Sand, prep, and apply epoxy primer to lower cowling.

  Apr 13, 2022     Primer Coat to Forward Cockpit - (2.9 hours) Category: Interior Finish

Prepared forward section of fuselage by vacuum, cleaning with acetone, and taping holes and edges. Mixed a cup of epoxy primer and sprayed the forward section.

  Nov 06, 2021     Port Wing - Finishing - (1.5 hours) Category: Ext. Finish

Carve leading edge drips with new box cutter blade. Sand orange peel areas with 400, 600, & 1200 grit.

Some additional sanding. Cold, snowy winter. No fun for working on finish.

  Oct 17, 2021     Paint Port Wing Top - (2.5 hours) Category: Ext. Finish

Additional hand sanding with medium grit sanding block. Squared spoiler mechanism cutout with flat and bastard files. Clamped spoiler cable slightly open.
Mixed two 18oz cups of Eastwood 3:1 white urethane and medium activator. Air temperature in the mid 60s. Sprayed a wet coat with horizontal and vertical passes. Heavy coat on leading edge leading to a couple long runs.

  Oct 16, 2021     Port wing prep, top - (4.8 hours)       Category: Ext. Finish

Examined urethane finish on bottom, have some orange peal areas that needed a wetter application, but overall pleased with the results. Reconnected aileron pushrod, inspection covers, pushrod fairing. With the assistance of Greg Campbell, flipped the wing to expose the top surface. Sanded epoxy primer with 320 grit and medium grit foam sanding blocks. Extended spoiler, clamping it open. Cleaned the bare metal of the spoiler pocket with Eastwood de-greaser paint prep. Used a can of 2 part spray epoxy to prime the spoiler pocket and to trailing edge that had been sanded to bare metal.
Reattached the long aileron pushrod, covered the pushrod with 3 feet of insulating pipe foam and wrapped it to the spar with film.
Compared white urethane with white epoxy primer on the empennage, color is more of a light gray than brilliant white.

  Oct 11, 2021     Paint Port Wing Bottom - (4.5 hours)       Category: Ext. Finish

Sanded the Eastwood roll-on epoxy primer with 320 grit on cordless orbital sander. Used two batteries to complete. Removed a few roller marks without going to metal. Wiped clean, then sanded leading edge and other curved or between rivet surfaces with a medium grit 3M foam sanding block. Cleared with compressed air and wiped down with Eastwood paint prep. Taped inside aileron pushrod slot from inspection port hole, used 4in plastic map plugs to cover inspection holes, #4 machine screws in nut-plates.
The inexpensive Eastwood gun air pressure regulator would not adjust pressure at the gun. Traveled down the hill to the Sherwin-Williams store and purchased a DeVilbiss gauge/valve reducer for $50.

PPE was disposable full suit, blue latex gloves taped around wrists, face mast with fresh VOC filters (couldn't wear glasses with full-face), Mixed 20 oz Eastwood white urethane 3:1 with medium speed (70-80degF) activator. Loaded paint into 24oz DeVilbiss DeKups disposal cup. Shot patterns against masking paper to adjust gun pattern and flow. Used 1.3mm nozzle and approximately 10-20psi at the gun. Made vertical and horizontal passes, trying to maintain a wet look, but it appeared to flash a bit quicker than anticipated.

Mixed 24oz 3:1 with the slow speed (80-90degF) activator and one part reducer. The second coat lay wetter for a longer period than the first coat. No touches or contact marks (!!). Clean up for 20 minutes then pulled masking tape from the inboard rib. Cleaning the cup was as simple as throwing it away.

  Oct 04, 2021     Port wing prep - (1.2 hours)       Category: Ext. Finish

Hung a plastic sheer to reduce disturbing dust around the hangar wall. Keeping the space open to encourage air flow for reducing isocyanate exposure from urethane. Set the port wing on three saw horses with the assistance of Greg Campbell and Britt Childress.

  Oct 03, 2021     Cleanup prep for Paint - (1.8 hours) Category: Hangar

Cleanup and reorganization of hangar interior to make space for painting the wings.

  Sep 26, 2021     Prep for Primer - (2.2 hours) Category: Interior Finish

Masking with paper and tape in preparation for applying epoxy primer to forward cockpit area.

  Sep 25, 2021     Test Spray Equpment - (3.2 hours) Category: Ext. Finish

Mounted air line closer to compressor, mixed 8oz of Eastwood low VOC epoxy primer. Gun test and adjustment against a strip of masking paper held against the hangar wall. Initially, the gun spit, dripped, and produced a poor spray pattern. Removed the nozzle and cleaned it in lacquer thinner. Cleaned up the gun and tried again. Was able to obtain a good fan pattern down to 7 psi at the gun. Shot a couple sections of the empennage to good effect. Used the Devilbiss DeKups (https://www.eastwood.com/dekups-24-oz-trial-kit.html) disposable cup and lid system, saving a good bit of cleanup time and aggravation. No isocyanates in the primer, PPE use was gloves, eye protection, disposable coat and organic vapor mask.

  Sep 05, 2021     Prep Spray Equipment - (3.1 hours) Category: Ext. Finish

Prepared air compressor with an additional tee and 1/4 turn stop valve, attached desiccant line, cleaned new gun with lacquer thinner, added and adjusted regulator at the gun. Had some difficulty initially with the inexpensive regulator continuously venting.
Sand primer on glare shield and seat back.
Relocated 50 foot air hose/reel.
Gun and epoxy primer expense included in this entry.

  Sep 05, 2021     Yearly Hangar Rental - (0.1 hour) Category: Hangar

Sep 2021 to Sep 2022

  Aug 21, 2021     Replace rivet under spoiler pulley - (0.3 hour) Category: Fuselage

Aligned spoiler pulley bracket with support angles and replaced the middle rivet in the floor that had been removed some time ago.

  Aug 21, 2021     Prep for primer - (1.1 hours) Category: Cockpit

Removed rudder pedals, throttle/mixture controls, through lines and fittings for brakes, spoiler pulleys and brackets. Vacuumed and wiped down forward cockpit with acetone.

  Aug 21, 2021     Starboard Aileron - (0.6 hour) Category: Ext. Finish

Sanded epoxy primer to remove orange peel with foam sanding block. Installed aileron on wing, had to spray on and wipe off WD40 on center pin to get the pin to full insertion..

  Aug 08, 2021     Hang & Cover - (0.5 hour) Category: Ext. Finish

Inspected epoxy coating on starboard side tail. Inspected and cleaned up primed fuselage floor. Stored floor on back hangar wall.

  Aug 07, 2021     Prime Small Parts - (1.4 hours) Category: Ext. Finish

Sanded reverse side of fuselage bottom skin to remove excess Optiflow primer resulting from rolling the opposite side. Cleaned the sheet with with acetone, wiped with tack cloth and sprayed with Eastwood canned two part epoxy primer wearing respirator. Same to starboard ruddervator hinge joint and windscreen strap.
To date, the epoxy primer appears more permanent with better adhesive character than automotive rattle-can self-etching primer.

  Jul 31, 2021     Finish Spoiler Controls Mount - (0.5 hour) Category: Cockpit

Finished back-riveting the vertical attach bracket to the spar tunnel with my nephew Chase. The bottom rivet was difficult to set squarely due to interference with the rivet gun.

  Jul 31, 2021     More sanding fairing filler - (1.5 hours) Category: Ext. Finish

Sand in prep for epoxy, concentrating on the fuselage/empennage section, aileron.

  Jul 31, 2021     Last of the Optiflow Primer - (1 hour)       Category: Ext. Finish

Filtered, mixed, and applied the last of the Eastwood epoxy primer to the starboard side fuselage, the faired areas at the fuselage/empennage junction, rear fuselage underside, starboard side cockpit, and bottom of starboard aileron.
Primer and activator seem to have held up through winter temperature cycling. Time will tell.

  Jul 18, 2021     Reorganize Storage - (0.8 hour) Category: Hangar

Pulled up older, thick plastic from the rear of the hangar and disposed of in trash. Gathered plastic that had covered the fuselage and replaced it with a fresh piece of medium weight plastic.
Moved tools to open some space. Cleared/cleaned off wooded shelving and stored construction materials.
Moved the propeller to the rear wall.

  Jul 18, 2021     Fill and sand - (1.7 hours) Category: Ext. Finish

Added lightweight filler to underside of ruddervator/fuselage joint.
Sanded previous epoxy primer on fuselage. Removed a few slumps, runs, and dust bits.

  Jun 21, 2021     Sand Fuselage - (2.9 hours)       Category: Ext. Finish

Knocked down slight 'pimpling', orange peel, and roller marks from epoxy primer with 240/320 grit by hand. Applied scratch filler. Wiped down dust.
Found that the fuselage bottom panel, previously sprayed with self-etching rattle can primer several year ago, had areas that lifted from temperature cycling and incomplete bonding. Sanded and wiped down bottom fuselage panel with acetone.

  Jun 21, 2021     Hangar Cleanup - (1.1 hours) Category: Hangar

Replaced the plastic sheeting used to cover the aircraft and tools.

  Jun 18, 2021     Prep and Prime Fuselage - (2.1 hours)       Category: Ext. Finish

Wiped down bare surfaces with acetone and Scotchbright. Sanded prior application to knock down orange peel and 'pimpling' areas with 320/400 grit on 5" cordless orbital sander. Wiped down with tack cloth. Taped holes to reduce flow through.
Wore organic solvent filter. Stirred and strained 6 oz Eastwood OptiFlow epoxy base, added 6 oz catalyst. Twelve oz was just sufficient quantity to apply to entire fuselage, the leading edge and control surfaces of the tail. Started interior priming at high wear (hand and finger prints) surfaces at cockpit bulkhead.

  Jun 18, 2021     Drill Subpanel for RCA Jack Inputs - (0.7 hour) Category: Avionics

Layout and drill for RCA male jacks. Stepped up in drill size to get the correct diameter for the insulating plastic washers. Step drill didn't have the correct diameter; the process was to drill, deburr, check fit, step up another size, repeat until a snug fit with the insulating ring on the plastic washer.

  Jun 13, 2021     Drill Video Subpanel for Power Jacks - (0.4 hour) Category: Avionics

Layout and drill the power connectors for the video sub-sub (sub� panel.

  Jun 13, 2021     Roll Primer on Fuselage - (1.0 hour)       Category: Ext. Finish

Prepared rear fuselage by wiping surface dirt and grease with acetone, knocked down a couple proud rivet shanks. Made up 12 oz. of Optiflow epoxy primer rolling it on to the rear fuselage, recently sanded starboard ruddervator, and seat back. Wore filter mask in heat - better than breathing the ever-present catalyzed fumes.

  Jun 12, 2021     Sand Wing Tip and Ruddervator - (0.9 hour) Category: Ext. Finish

Sanded epoxy primer, removed runs, on starboard wing tip and ruddervator with 5" cordless sander using 400 & 600 grit (depending on the depth of orange peel).

  Jun 05, 2021     Prep and Prime Control Surfaces - (2.7 hours)       Category: Ext. Finish

Prepared port side aileron and elevon surfaces by sanding orange peal and small bubbles with 320/600 grit on cordless 5" sander. Orange peal and small bubbles were a result of a long (>24 hr) pot life using Eastwood Optiflo roll-on epoxy.
Used extra pieces of hinge to mask control surface hinges from excess epoxy from hinge pin. Used two cans of Eastwood two part epoxy (https://www.eastwood.com/ew-2k-aerosol-epoxy-primer-gray.html) on hinges and channels to coat places that aren't conducive to a thick coating with roll-on primer to bind hinge and pins. Spray epoxy set rather quickly. The the masking hinge pieces were removed and hinge pins cleaned of epoxy residue with acetone.

  May 31, 2021     Sanded filler on wheel pants - (0.9 hour) Category: Ext. Finish

Sanded filler that filled and evened the mating of fiberglass Sonex wheel pants.

  May 28, 2021     Sanding fairing filler - (3.2 hours)       Category: Ext. Finish

Sanded filler around pitot and TE ports, ruddervators.

  May 21, 2021     Refuse disposal - (4.5 hours) Category: Hangar

Burned dried vegetable waist from cleanup, vines, logs. cardboard and plywood scrap. Removed sections of mine belt defining a tie-down area.

  May 21, 2021     Fairing Empennage - (1.3 hours) Category: Ext. Finish

Sanded filler around fuselage to ruddervator intersections and around pitot and TE probe sockets.

  May 16, 2021     Paint rack - (0.6 hour)       Category: Ext. Finish

Finished assembling the Eastwood paint rack and mounted several pieces for coating with Eastwood canned two-part spray epoxy.

  May 16, 2021     Main aileron pushrod storage - (2.3 hours)       Category: Wings

While removing the main aileron pushrods (XNB-W07-08) to better enable storage by covering the lightening holes with 3 and 4" plastic mailing tube caps, found the port wing rod end bearing bolt was an AN3A-12 rather than a drilled AN3-12. It took a surprising amount of time to gently remove the incorrect bolt without putting undue force on the idler. Resorted to using a spring-loaded center punch to encourage the bolt to back out of the assembly by repeatedly punching the bolt center. Replaced the bolt with AN3, torqued the nut to 3.5 N, and installed a cotter pin to both port and starboard idlers, leaving the main pushrod rod ends in place on both wings.

  May 15, 2021     Lightening Hole Plugs - (0.2 hour)       Category: Interior Finish

After watching the local A&P removal a birds nest from inside the wing of a C172 during an annual inspection, a plane that had not been flown for three years, steps where taken to discourage birds or vermin from residing inside the Xenos wings. Purchased several 3 and 4" mailing tube plugs and test fit into the lightening holes in the inboard and outboard fore and aft wing ribs. Caps have a slight taper and ribbing that locks nicely into the holes. Will purchase additional and trying trimming a couple to clear aileron pushrods and spoiler control wires.

  May 15, 2021     XNS-C06-08 Spoiler Pulley Mount Angle - (2.8 hours)       Category: Controls

Riveted the XNS-C06-08 spoiler pulley mount angle to the spare tunnel with solid rivets. Two person job, one person locating and bucking the rivets from inside the spar tunnel while the other riveted from the cockpit side. Used AN4-5 rivets. Three were not acceptable and were removed and redone.
Slow and deliberate effort.
Setup and started XNS-C06-04 attach plate but decided to finish another day.

  May 14, 2021     Control stick adapter machining - (3.5 hours)       Category: Controls

Milled a relief slot for the Tosen control stick wire bundle exit. Started with a 1/4" slot, but trial fit of wiring bundle was too difficult so a 3/8" slot was milled. Drilled #21 holes to be tapped for #10-32 screw to hold the control stick in the adapter. Chamfered the edges of the slot to break the sharp edges. Fit the adapter 1/8" from the bottom of SNB-C04-07 control stick fitting to allow for misalignment. Marked previously drilled taper pin locations. On mill, drilled adapter through the diameter with a 1/4" hole (small end of #2 taper pin). Inserted adapter in control stick fitting and used a #1 S&J taper reamer to cut adapter. The #1 taper requires using the far heal of the reamer to cut enough taper for a #2 pin. The taper in the adapter provided a good taper pin fit at the stick adapter. Finished the adapter by using a rat tail file to put a slot in the control stick adapter to remove any sharp edge in contact with the control stick wire bundle.
Tapped 2 - #10-32 threads in the upper part of the stick adapter in the recessed steel control stick frame(needs photo).

  May 13, 2021     Control stick adapter machining - (0.1 hour) Category: Controls

Fit the adapter to SNB-C04-07 control stick fitting to determine length of wire relief slot to cut in adapter.

  May 09, 2021     Solder ELT DIN connector - (0.4 hour) Category: Radios

Soldered shielded wires to the ELT DIN connector. Red stripe to power, blue stripe to ground, white to RS-232 input. Separate short length to RS-232 output. The output is used to check for NMEA flow on input. Needs an LED w/current limiting resistor for test.

  May 09, 2021     Machine control stick adapter - (2.2 hours)       Category: Controls

Cut a 1" diameter solid aluminum rod to adapt eight-button Tosten control stick to XenosB. https://www.steinair.com/product/tosten-cs-8-aircraft-stick-grip/
Cut the 1" x 12" solid rod to five inch length with an powered hacksaw. The one inch diameter was too large to pass through the three jaw mini-lathe chuck leaving several cutting operations unsupported. Don't like the lack of support, but... Trimmed solid rod to length with a couple parting tool cuts, cleaned ends and cut a small hole for tail-stock support. Drilled a 7/16" hole through the piece. Opened the bottom end of the adapter to enable a bolt to pass through along with with the ten conductor wire bundle.
Will need to drill and tap adapter for set screws to lock in control stick as well as drill and ream the bottom for connection to the control stick angle.
HAT switches will be wired as pull-up inputs to control the iEFIS screens, the other four buttons will ground the inputs for microphone and other, to be determined, inputs.

  May 02, 2021     Sanding fairing filler - (0.7 hour) Category: Ext. Finish

Sanded lightweight polyester filler at pitot and TE probe sockets, stabilator to fuselage areas, and wheel pants.

  May 01, 2021     Switch wiring - (1.2 hours) Category: Instrument Panel

Labeled and prepared a 10' length of two conductor shielded 20 ga with spade connectors for primary ignition grounds. Labeled and prepared a 10' length of shielded three conductor 16 ga for ELT power and GPS input. Added a short length of unshielded 16 ga for testing NMEA stream at ELT.

  Apr 21, 2021     Wire cleanup, RS232 connector - (0.5 hour) Category: Instrument Panel

Reorganize wiring to free RS232 connector to serial inputs. Will be opening the connector to solder a data out wire from a serial port to supply the ELT with a GPS NEMA position stream. The MGLiBox GPS NEMA baud rate is 4800 while the ELT standard rate is 9600 baud. Looking for a jumper to use in the ELT to change the baud rate to match the iBox.

  Apr 20, 2021     Spoiler pulley bracket paint - (0.2 hour) Category: Controls

Additional coat of yellow enamel to the spoiler pulley bracket.

  Apr 20, 2021     Wiring List - (3.3 hours) Category: Instrument Panel

Working through the instrument panel wiring to do list 1) Power from ECB4 to SPST LSw3 for ignition coil power 2) Power from ECB7 to SPST RSw4 for transponder and SP-12 GPS power. 3) Power from ECB6 to LSw1 for starter solenoid power 4) Added 12 gauge wire to sub-panel inboard ground terminal, wire run to ground point on firewall.
Continued cleanup and bundling of wiring behind the panel.
Found that Aircraft Spruce has an LED light that will fit a switch mounting hole, 12VDC input, internal current limiting resistor, with a couple of screw terminals (https://www.aircraftspruce.com/catalog/elpages/indicatorlamps13-15811-5.php). Mounted a red to indicate (Part# 13-15812) of power to the turbocharger bearing cooling system. The system gets power from an always active firewall fusebox. The circuit has a manual and automatic mode, with the auto mode switched by a 250degF thermal switch in the coolant line. The light serves as a warning that the cooling circuit is powered after shutdown.

  Apr 19, 2021     Prep for additional undercoating - (3.1 hours) Category: Ext. Finish

Removed hinge pins, unbolted pushrods and control cable from rudder and removed both ruddervators. Starboard side ruddervator pin was particularly difficult to remove due to excessive length. Long end of pin had been bent to prevent the pin from backing out.
Removed tail tips, applied masking tap to control over spray. Applied lightweight filler to fair between fuselage and root of tail planes. Added filler to wheel pants and tail tips where needed to fill voids or mold marks. Sanded undercoat to removed bumps that developed from rolling on day-old epoxy. Eastwood epoxy undercoat is very difficult to remove from fittings and areas that were inadvertently marked by the roller during application.
Cleaned and taped areas to be coated with spray epoxy around control surface hinges.

  Apr 18, 2021     Panel wire review - (0.5 hour) Category: Avionics

Identified the OAT probe connections and verified probe operation. Moved and gathered several unused parts of wiring harness into a bundle and secured them with plastic ties to the top of the iBox.

  Apr 17, 2021     Spoiler pulley bracket patch and paint - (0.7 hour)       Category: Controls

Rivet patch w/ solid 4-5 soft rivets. File/sand edge to match. Paint with yellow.

  Apr 11, 2021     Complete Rework of Port Aileron Hinge - (1.2 hours) Category: Wings

Several inches of excess length on the inboard hinge pin permitted enough length to flattened the end somewhat with a hammer on a anvil. Repeated hammering on the end widened the pin end enough to be very snug in the hinge knuckles. Chucked the opposite end of the pin in a battery powered hand drill and used the flattened end as a reamer to open the clearance of the hinge knuckles slightly (tip learned at Jeff Shultz firewall forward seminar).
Same treatment to the outboard hinge knuckles. Cut and bent the inboard hinge pin. Pin fit for inboard and outboard hinge pins can be inserted freely, but remain snug.
Sanded areas of primer to smooth pebbly surface. Added lightweight filler to close several holes in aileron skin.

  Apr 10, 2021     Panel changes and documentation - (1.5 hours) Category: Avionics

Moved the master switch to the right side. Documented fuse blocks, fuse number in block and the assigned circuit. Tested radio Tx wiring to control stick switch. Recorded assignments to Google worksheet.

  Apr 06, 2021     Rework Port Aileron Hinge - (1.5 hours)       Category: Wings

Removed the single 72" 0.045" length of piano wire hinge and replaced it with three standard length hinge pins as configured previously on the starboard aileron. Cut 2" of hinge knuckles (4) with a hacksaw blade as the insertion point for the two inboard hinge pins. Trimmed the outboard and middle hinge pins to the same length.