EAA Builders Log Site

Project: SpiritOfMudsuck -
Listing for Category : Show all entries

(Please mouse-over any icon to get a description of that function).

Categories

Show All Entries - (686)
Avionics - (33)
Cockpit - (33)
Controls - (69)
Cowling - (29)
Documents - (5)
Empennage - (105)
Engine - (78)
Ext. Finish - (34)
Firewall Forward - (14)
Fuel System - (6)
Fuselage - (14)
Hangar - (106)
Interior Finish - (6)
Instrument Panel - (72)
Inspection - (2)
Landing Gear - (6)
Propeller
Radios - (8)
Research - (21)
Tools - (11)
Wings - (34)


Builder Name:	Pete Dailey -

Project:	Sonex - Xenos-B Motorglider - VIEW REPORTS
Total Hours:	1506.3
Total Flight Time:
Total Expense:	$75148.03
Start/Last Date:	Jul 01, 2016 - No Finish Date
Engine:	Aerovee 2.1 Turbo
Propeller:	Sensenich
Panel:	MGL Avionics Explorer iEFIS/ECB/RDAC

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

Home or Last Project Picture

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.

Hangar33 a

Hangar33 b

Hangar c

Hangar d

Hangar33 e

Hangar33 f

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.

Pad cradle corner bolt heads

Mounting points for hooks

Tow hook

Pad rear corner with foam

Brush and paint

Pad rear corner with foam

Rear spreader

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.

Brace @ tiedown

Tow hooks

Remove brace from outside corner

Remove brace from outside corner

Rear spreader section

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.

Held in place with film wrap

Plug pushrod and spoiler cable

Hold pushrod in place

Hold pushrod

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.

Xenos_hangar_move - 30.jpeg

Xenos_hangar_move - 40.jpeg

Oct 12, 2022 Lumber recycle - (2.1 hours)

Category: Hangar

Lumber gathering for recycle, recovered 20 2x6x8s.

Xenos_hangar_move - 45.jpeg

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.

Xenos_hangar_breakdodwn - 1.jpg

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.

Spoiler pulleys and bracket reinstall

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.

Filler

Sand

Kojo my faithful helper (RIP)

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.

Interior primer

Cowl primed

Cockpit prime

Cowl bottom

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.

Factory opening

Sanding expoxy primer

Pushrod wrapped to spar

White urethane on white primer

Orange peel areas

Gloss finish

More orange peel

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.

Port wing

Happy sander

Wet look polyurethane

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.

Ready to prep primed wing

Greg and Pete

Paint booth

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.

Fuselage botton, cleaned

Filter chunks

Fuselage bottom in primer

Aileron

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.

Second coat of primer

Fuselage panel w/self-etch

filler

Lifing self-etch primer

Lifted area

Pimpling

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.

Port side primed

Starboard side primed

Forward starboard

Forward port

Prep tape

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.

Roll out

Bare fuselage

PPE for epoxy vapor

Rolling the drips

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.

Hinge pieces as mask

Aileron channel, note epoxy marks on pin

Wing tip rib w/ 4" plastic plugs

Lightly sanding orange peel

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.

Pitot port

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.

Paint rack

Loaded paint rack

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.

Pushrod pivot

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.

Anti-critter caps

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.

Feel clico from inside spar tunnel

XNS-C06-08 in place

Spoiler pulley attach plate placement

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).

Adapter w/taper pin

Adapter w/SNB-C04-07

Tap and file to finish

Stick in place

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.

Unsupported end cleanup!

Open to 7/16"

Adapter.

Bottom of adapter

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.

Spoiler bracket patch ext

Spoiler bracket patch int

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.

File cut end

Remove knuckle with h/s blade

Apr 04, 2021 Wiring Cleanup and Prep - (2.3 hours)

Category: Avionics

Gathered and organized wiring on starboard side of the panel. Gathered bundles together to secure out of the way. Organized to determine additional actions in preparation for installation.

Stbrd side fuse blocks

FB2-1to6

FB1-1to4

Gather passenger headset bundle

FBs and Gnd block

Apr 03, 2021 Panel Wiring - (1.3 hours)

Category: Avionics

Installed eyelet ends on two short red 12ga, silicon coated wires to carry power to ECB. Will use spade connectors to connect conductors that will penetrate the firewall.
Wrapped the EFIS control wires (20 gauge, 10' long) from the iBox digital inputs (DB-25 solder tail connector) inside expandable PET split plastic wire loom braid. Took a bit of dexterity to pull back the inside edge of the braid while pushing the 10' length inside the braid with one hand. Four conductors to the HAT switch, four conductors to the individual switches, and a common conductor for the HAT and individual switches. The individual switches common will be grounded, while the HAT switches will be pulled up to 12 volts through a 4.7 M ohm resister.

Wire bundles

Bundles on starboard side

10 wires to control stick

Jan 10, 2021 Spoiler pulley bracket hole reinforcement - (1.4 hours)

Category: Controls

Cut a reinforcement to rivet on the outboard side of

Patch in place

Patch

Mis-drilled bracket

Jan 10, 2021 Dimple spoiler mounting bracket holes - (1.5 hours) Category: Controls

Used a AeroConversion dimple die set (male/female and nail) to dimple the horizontal (XNS-C06-04) and vertical (XNS-C06-08) angles. Deburred and dimpled the spar tunnel holes. Needed a second pair of hands to complete the nine horizontal holes.
Tried to fit a Stanley flexible head riveter (for pulled rivets) into the spar tunnel but it would not fit. Contacted Joe and Denise Armstrong, builders of XenosB project https://eaabuilderslog.org/?s=Parms who uploaded several additional photos to 08/16/2018 showing the XNS-C06-05 installation. Examination of the photos indicate solid rivets fastening XNS-C06 -04/-08 to the spar tunnel. Finding a second pair of hands and the right bucking bar will be challenging.

Dec 13, 2020 Spoiler control - (4 hours)

Category: Controls

Remade XNB-C06-08 angle from 0.032 inch material. Layout with spoiler pulley bracket, drilled matching holes in spar tunnel. Made XNB-C06-07. Drilled to match bracket. Fit up to spar tunnel, drilled rivet holes in spar tunnel.

Remake vertical bracket

Drill horizontal braket

Ready for dimpling

Dec 12, 2020 Remove rivets from glare-shield support - (1.5 hours) Category: Fuselage

Drilled out all but 2 rivets on the firewall that attach the glare-shield support.

Dec 12, 2020 Spoiler controls - (1.9 hours) Category: Controls

Took apart the spoiler controls to prepare for riveting. Reviewed work performed several years previously. Decided to drill out spoiler control mounting braket rivets and replace the mounting angle to provide a better fit.

Dec 12, 2020 Glare shield to firewall fitup - (3.2 hours)

Category: Cockpit

Purchased four SNB F07 09 firewall angles (2 spares). When fitting pre-drilled holes to the existing firewall holes (factory drilled as QB kit), it was found that when starting at the top half, the holes aligned well, but the lower half did not. The misalignment with the previous firewall angles demonstrated the misalignment. The angles were cut in half, which allowed the top and bottom halves of the angle rivet holes to align.

Starboard side fit

Split port and starboard angles

Port side fit, tank vent line area

Port side angle fit

Nov 15, 2020 Pin rudder and brakes - (1.1 hours) Category: Controls

Replaced several AN3, AN4 bolts on the brake linkage and rudder wire rope connection with more appropriate length bolts. Tightened castle nuts with 'hobby' size torque wrench to 5 Nm, added cotter pins. Turned spoiler port side pulley bolt nut up with cotter pin to enable easier inspection.
Removed spoiler lever and mount, removed hydraulic plumbing to valve.
Simplifying brake hydraulics by removing MATCO parking brake valve from spoiler level angle. Will look at running straight Tygon tubing to brakes.

Nov 14, 2020 Rudder and brake bolts - (0.7 hour)

Category: Cockpit

Replaced bolts on brake cylinders with appropriate sized AN-4 drilled with castle nuts.

Ready for cotter pins

Nov 14, 2020 Missing rivet - (0.1 hour)

Category: Wings

Installed a missed rivet in the aileron hinge.

Woops

Nov 14, 2020 Install wiring penetration - (1.7 hours)

Category: Firewall Forward

Installed a stainless steel firewall pass through kit (ACS Part# 09-00978). Aligned the flange in close proximity to the battery/contactor/terminal block on the port side, under the spoiler cable pulley. Used a 3/4" step bit for entry hole. Slight misalignment left a sharp lip on entry. Removed the lip with a slightly larger step bit to 'mill' the lip flush with the pass through flange and reduce the opportunity for chafing.
Per instructions, used a coating of Biotherm 100 firestop sealant on the back of the flange to ensure fire/moisture seal.

Completed FW penetration

Layout w/pass-through

Layout

Trial fit

Nov 11, 2020 Fuel tank fitup - (5.2 hours)

Category: Fuel System

Trial fit of fuel tank. Several failed attempts with the factory glare shield to firewall angle indicated the piece needed to be removed and an alternative made. Once the angle was removed the tank fit snugly between the firewall and rear glare shield stop. The vent cutout on the glare shield was cut back a bit more to eliminate the remaining interference with the vent fitting, filed and smoothed with Scotchbrite. Drilled out firewall angle rivets. Removed and primed glareshield with Optiflow epoxy primer.

GlareShield - 1.jpeg

Nov 11, 2020 Touch up primer on wings - (1.6 hours) Category: Ext. Finish

Sanded lightweight filler covering extraneous holes at the outboard end of the port aileron. Sanded edges of fiberglass wingtips. Rolled on Optiflow epoxy primer.
Cleaned the glare shield with Scotchbrite and solvent. Rolled a coat of primer on starboard side stabilizer and ruddervator.

Nov 08, 2020 Rodent cover - (0.5 hour)

Category: Wings

Constructed a metal cover to block rodents and insects from entering the interior of the wing. Cut a piece of 0.025" 6061T6, bent tabs around the edges to stiffen. Attached to wing rib with a Cleco. Bending didn't work our very well. Not an effective cover. Back to the drawing board for other solutions.

WingCover - 1.jpeg

Nov 08, 2020 Filler prior to sanding - (0.6 hour)

Category: Wings

Mixed some West System epoxy with lightweight filler and thickener. placed thickened mixture into the wingtip. I anticipate that in sanding the fiberglass to match the wing contour in this area, the fiberglass substrate may get sanded enough to cut through to the filler.

WingTip filler

WingTiip filler

WingTip_filler - 2.jpeg

Nov 08, 2020 Epoxy primer stabilators - (2.7 hours)

Category: Ext. Finish

Cleaned the stabilator top and bottom surfaces and some minimal taping. Mixed 12 oz of Eastwood Optiflow epoxy primer and applied with a wide roller. Used maybe 7 of the 12 ozs. Touched up some areas on the trailer edge of the port wing.

Stabilator_Primer

Stabilator_Primer

Stabilator_Primer

Nov 04, 2020 Wings in cradle - (0.6 hour) Category: Ext. Finish

With Brendan's help, removed the wings from hanging from the ceiling beams and placed them back on the cradle. Inspected primer from trailing edge, noting several places that will need attention. Overall, the Eastwood Optiflow epoxy primer worked well for conditions, particularly the limited clean space in the hangar and eliminated the need for erecting of a cleanroom. The simplicity of obtaining an acceptable protective finish this far into the build was a relief. Final prep for color may need some additional sanding.

Nov 01, 2020 Second coat port wing & stabilator - (2 hours)

Category: Ext. Finish

Clean and prepared the underside of the port stabilator. Mixed 12 oz of Eastwood epoxy primer and rolled the top side of the port wing. Second use of pan liner, third use of mixing cup. New foam rollers. Rolled primer on the underside of the port stabilator and the top of the port ruddervator. Used a small foam roller to prim the inside of the ruddervator and the inside of the starboard aileron.
Easy cleanup, discarded the pan liner and mixing cup. Foam rollers after they set up.
Fairly pleased with the ease of application and clean up compared with possible spray application. The objective is to establish a reliable primer surface for future color application and to combat the observed corrosion. Corrosion of the 6061 T6 seems accelerated in places that were used in early polishing trials and edges that were exposed to atmospheric moister condensation, and places touched or pushed with hands.
Color coat will probably be white, with color application using vinyl.

Stabilator_port bottom

Port ruddervator

Port wing top

Nov 01, 2020 iEFIS page collection - (0.4 hour)

Category: Avionics

Screenshots of MGL Explorer pages. Modifications from stock with several built from scratch. Screen 5 has several subpages to act as a series of checklists.

MGL Explorer page 1

MGL Explorer page 2

MGL Explorer page 3

MGL Explorer page 4

Page 5a Engine start checklist

Page 5b Taxi checklist

Page 5c Takeoff checklist

Page 5d Cruise checklist

Page 5e Landing checklist

Page 5f Shutdown checklist

Page 6 Current and video

Page 7 My six pack

Page 8 Engine performance

Oct 31, 2020 Clean, prep, prime - (2.3 hours)

Category: Ext. Finish

Cleaned port wing top side with acetone and Scotchbrite pad, wiping residue with shop towel. A second cleaning pass with Eastwood paint prep to both sides of the wing. Mixed 12 oz of Eastwood Optiflow epoxy primer & activator was just enough to roll on a second coat on the bottom and a first coat to the top of the port wing. Held the spoiler open by clamping the spoiler control wire.
Drilled out and replaced a wingtip rivet on the starboard wing top side.
Will likely remove wing tip, fill the leading interior with epoxy, and sand the leading edge to match the aluminum.

Port wing bottom

Remove/replace rivet

Port wing top

Port wing spoiler

Replaced rivet

Oct 27, 2020 Check dust cover fit - (0.2 hour)

Category: Empennage

Fit up stabilator dust and weather covers.

Starboard stabilator cover

Grommets

Port stabilator cover

Oct 18, 2020 Switch hole plugs - (0.2 hour)

Category: Instrument Panel

Installed 1/2" rubber plugs in unoccupied switch holes.

Hole covers

Oct 17, 2020 Clean, prep, prime - (3.5 hours)

Category: Ext. Finish

Disconcerting to find the spoiler was glued shut while inspecting the primed top of the port wing. Used three or four box cutter blades inserted under the lip of the spoiler to find and gently break the epoxy seal. Inserted a plastic spacer to hold the spoiler open during application of the second coat.
Scrubbed underside starboard wing surface with Scotchbrite & acetone, wiped residue with paint prep solvents. Lightly brushed the previously primed top surface of the port wing with a Scotchbrite pad.
Installed three missed rivets in the port side wing tip.
Mixed 12 oz of Optiflow epoxy primer & activator to finish the first coat on the bottom of the starboard and and apply a second coat to the top of the port wings.
Shot a yellow color coat to six inspection covers.
Trimmed foam board anti-rodent cover close to the shape to use as a template to cut an aluminum sheet. Plan is to create a more durable anti-rodent wing end cover to block any critter capable of creating a nest inside the wings.

Starboard bottom

Missed rivets

Release spoiler

Spoiler held open applying primer

Spoiler prep for second coat

Inspection covers

Ready to roll

Port bottom, second coat

Oct 12, 2020 Clean, prep, prime - (3 hours)

Category: Ext. Finish

As described previously, filled mandrel nubs from the top side of the port wing, scrubbed surface with Scotchbrite & acetone, wiped residue with paint prep solvents. Lightly brushed the previously primed surface with Scotchbrite to remove several gnats stuck to the surface.
Used 5 oz of epoxy primer left from the previous day on the outboard end of the wing. Noticeably less viscous, the primer became tacky quickly after application. So tacky that bits of the foam on the end of the roller tore and had to be picked off the surface. Mixed and applied an additional 15 oz of Optiflow primer & activator to finish the first coat on the top and apply a second coat to the bottom.

Optiflow applicator

Roll on

First coat, top side

Primed, single coat

Oct 11, 2020 Clean, prep, prime - (3.4 hours)

Category: Ext. Finish

Prepared port wing underside for application of Eastwood Optiflow epoxy primer. Initial preparation consisted of removing inspection covers, aileron pushrod fairing and pushrod. Inspected each rivet for protruding sharp nubs from the mandrel. Filed sharp ends flush. Wearing vinyl gloves, used a Scotchbrite pad occasionally wet with acetone and a clean acetylene soaked rag to scrub oxidized spots, tape adhesive, and surface oxidation. A second pass with Eastwood prep (xylene + acetone) spray and several clean shop rags to ready the area for primer. Masking tape across the reverse side of the leading edge of the wing to catch primer.
Mixed 10 oz (5+5) Eastwood Optiflow epoxy primer 1:1 with catalyst. Used half (5 oz) to coat the underside of the one wing.
The thin epoxy primer was rolled on to the vertical, leading edge up, wing. Initial rollout of the primer resulted in a lightly mottled finish, but subsequent application blends into adjoining sections. The primer seemed to adhere more readily with additional pot time. Eastwood's instructions indicate 20 minutes pot time as a maximum, but the 5 oz left in the mixing cup looked usable.
Cleanup is a simple matter of throwing out the used foam roller and tray liner.

Ready for primer

Cleaning prep

Primed, first coat

Roller coverage, first coat

Oct 10, 2020 Hang wings for priming work - (2 hours)

Category: Ext. Finish

Suspended the wings from the hangar ceiling through the main spar and hold down fitting. Began cleaning tape residue and dirt in preparation for epoxy primer.

Both wings suspended

Empty wing cradle

Starboard side wing

Port side wing

Oct 10, 2020 Wiring - (2.3 hours) Category: Firewall Forward

Continued wiring P-leads, grounds, and control for turbo cooling. Cutting wires to final length and crimping Wirefy heat-shrink connectors.

Oct 08, 2020 Panel paint - (1 hour)

Category: Instrument Panel

Taped and painted the panel matte black. Trial fit of yellow panel covers.

Pax side panel

Pilot side

Panel from bottom

Sep 26, 2020 Organize FWF wiring - (3 hours) Category: Firewall Forward

Extended two thermocouple wires to RDAC, organized wiring bundles with plastic wire ties.

Sep 19, 2020 Extend Thermocouple Wires - (2 hours)

Category: Firewall Forward

Extended EGT thermocouple wire for the #2, 3, and 4 cylinder exhaust gas temperature probes. Printed heat shrink labels and placed them before and after the splice. Used Wirefly crimp splices, testing each splice with a gentle pull on each TC wire. Applied heat to shrink the splices. separated TC from signal wires at firewall. and bound TC wires together with plastic ties.

FWFwiring - 1.jpeg

FWFwiring - 2.jpeg

FWFwiring - 3.jpeg

FWFwiring - 4.jpeg

FWFwiring - 5.jpeg

FWFwiring - 6.jpeg

Sep 19, 2020 Hangar rent Sep 2020 through Sep 2021 - (0.1 hour) Category: Hangar

Yearly rental payment.

Sep 19, 2020 Paint Instrument Panel - (0.5 hour)

Category: Cockpit

Painted two of the three instrument panel cover segments with yellow acrylic paint over the previously applied self-etching primer.

Rattlecan yellow

Instrument panels

Aug 23, 2020 Engine wiring - (2.2 hours) Category: Firewall Forward

Cleanup and secure engine wiring.

Aug 23, 2020 Pack wheel bearings with grease - (0.6 hour)

Category: Landing Gear

Used my Anson Engineering jack to lift each main wheel and packed the tapered roller bearings with general purpose wheel bearing grease.

Anson Engineering wheel jack

Aug 22, 2020 Prep Wheels - (3.5 hours)

Category: Landing Gear

Used my new Anson Engineering jack to lift TOB axles to remove wheels. Cut 3-4 threads from the wheel bolts. Ground the cut ends flat and beveled on a grinder. Polished with Scotchbrite wheel. Wire brushed corrosion from bolt heads and threads. Primed bolts with self-etching primer. Removed tubes and reinstalled with talc powder to ensure a non-binding fit. Filled inner wheel surfaces that may provide abrasion points over time. Reassembled and installed ready for greasing the bearings.

Anson Eng jack

Corrosion & long bolts

Corrosion

Trim bolt length

Cleanup complete

Trim edges

Reassembly

Aug 20, 2020 Solder pins to control stick leads - (0.8 hour)

Category: Avionics

Stripped, tinned, and trimmed stick leads to approximately 3/16 in. Clamped serial connector pins in vise and soldered leads.

Serial connector pin

CS pins

Aug 18, 2020 Checkout Tosten CS-8 Grip - (0.7 hour)

Category: Avionics

Checked switch and HAT function, created heat shrink labels for wires. Used Tosten's wiring diagram to find leads for eight switches and two common.
Debating with myself whether to use the common for ground, in which case the switch leads would need a pull-up resister to 12 volts presenting a continuous high input to the digital inputs. Then use the common to ground to change state.
Conversely if the common was at 12 volts the digital inputs would be go to a high state with a switch closure. The question to answer is what the microphone switch will require. The HAT switches could be treated differently than the other four. Will look at some bench testing.

Marked w/heat shrink

Stripped and tinned

Aug 09, 2020 Open rear spar anti-rotation pin inspection holes - (0.6 hour)

Category: Wings

The rear spar anti-rotation pin hole (still in need of reaming to final size) inspection hole were too low to put a reamer through from the rear. Using a step drill as a mill, extended the port and starboard holes upward. Used a bastard file to smooth to an ovaloid shape.

Starboard side inspection

Port side inspection

Aug 08, 2020 ELT wiring - (0.8 hour)

Category: Radios

Drilled 5/16 in holes for 1/4 in grommets to pass ELT control wiring to cockpit. Cut off RJ-11 connector on switch end to pass through grommets. Placed the ELT RJ11 connector so that it can be unclipped from the ELT when removing ELT for inspection.

RJ-11 at ELT

Flat ELT wiring to cockpit

Aug 08, 2020 XNB-C01: Mixer Details E & M - (2.8 hours)

Category: Controls

Safety wired the port rudder cable to pull it out of the way in order to put my head into the space without the wire grabbing my hair and skin.
Removed AN3 bolts from mixer/pushrod fastener stack, replaced with AN3-11A stack per plans + 1 washer. Torqued to 3N. Installed cotter pins.
Removed idler to mixer pushrod to cut the length of the sintered SYMMCO bearing at the mixer to 0.25 inches long. Installed AN4-xxA bolt-washer-bearing stack as shown in plans. Torqued to 7N and installed cotter pin.
Inspected mixer pivot bearing stack, torqued nuts and installed cotter pin.
Set the idler end bearing so that the flange contacts the idler post.

Mixer pushrod attachments

Mixer pivot - starboard

Mixer pivot - port bearing + 2 washers

Mixer pushrods

Jul 26, 2020 XNB-T03: Finish starboard ruddervator skin closure - (1.2 hours)

Category: Empennage

Used twenty-some CCP-42 rivets in closing the starboard side ruddervator, inboard rear triangular skin flap.

Starboard ruddervator close up

Jul 26, 2020 RG-58 to BNC for ELT antenna - (0.8 hour) Category: Empennage

Stripped and crimped a three-part BNC/RG-58 connector for antenna connection at ELT. Removed ELT to judge how much antenna wire to allow the ELT to be removed from its mount and feed through mixer access panel. Removed and installed with one arm through the access space. ELT mount location feels accessible for later maintenance.

Jul 26, 2020 Nutplates for starboard ruddervator pushrod fairing - (1.3 hours)

Category: Empennage

Installed six, #6 nutplates to secure the starboard side ruddervator pushrod fairing.

Nutplate locations

Fairing in place

Fairings, rear view

Jul 25, 2020 Flyboys tailwheel arm fitting - (2.5 hours)

Category: Landing Gear

Drilled a 1/4 in hole in the Flyboy's (https://www.flyboyaccessories.com/product-p/1132.htm) steel tailwheel linkage to attach a Peter Anson Engineering tailwheel steering strut (http://www.ansoneng.com/sample-page/products-summary/6-pneumatic-tailwheel-to-suit-sonex/). The hole was located 2 in (std Sonex tailwheel pivot arm) from the pivot centerline. Attached and secured the Anson fittings. Full deflection of the rudder did not result in the tailwheel and castering.
A second 1/4 in hole inboard provided just enough tailwheel deflection to unlock the tailwheel. Left turning unlocks the tailwheel more readily than a full right turn.

Anson link w/Flyboays tailwheel

Initial and second link holes

Final hole location

Final hole location

Jul 19, 2020 Tail fairing fasteners - (2.5 hours)

Category: Empennage

Installed / reinstalled #6 nutplates to secure tail fairing. Reinstalled two of the three floating nutplates on the forward end of the fairing. Placed eight along the sides. Two on the starboard side were placed a little too close to the rivet line to be able to dimple the skin. Ninety-five degree heat took the life out of finishing installation of all the nutplates. May add two additional screws on the forward end to pull up the fairing to the fuselage skin.
This piece has taken more time and effort than anticipated.

#6 screws in place

Forward end fit

Overview

Jul 19, 2020 Install rudder hinge pin - (0.5 hour)

Category: Controls

Use a length of hinge pin with the end flattened to open the holes in the hinge knuckles to more easily fit the hinge pin. The flattened pin was chucked in a hand held drill and pulled/pushed up and down through the knuckles. Filed the knuckle ends to open the clearance to better put the hinge halves together. Hinge pin is a tight fit, but coaxed the pin through the hinge.

RudderHinge_ - 1.jpeg

Jul 16, 2020 Video cabling - (0.4 hour) Category: Avionics

Installed DB-9 solder connector inside hood. Verified wiring continuity between pins and wires. Will likely terminate the video input signal to solder-tail bulkhead connectors.

Jul 12, 2020 Wiring for cameras - (0.7 hour) Category: Avionics

Began soldering shielded wires to a DB-9 connector that plugs into the MGL EFIS display.

Jul 11, 2020 Tail fairing - (1.7 hours)

Category: Fuselage

Additional rounding of the tail fairing on the edge of a table to get a better fit with the fuselage skin. Aligned three floating type nutplates to hold the fairing. The center nutplate will be removed and the through hole opened up. Located five securing holes on either side of the fairing, clecoing the fairing in place.
Marked the termination of the back of the fairing and used a hand file to remove 1/4 or so of material

Fastener locations

Middle nutplate to be reset

Fastener locations

Jul 11, 2020 Replace Rudder Hinge - (2.5 hours)

Category: Fuselage

The distinctively more robust extruded hinge on the fuselage required removal and replacement of the rolled knuckle hinge on the rudder. The rivets were first prepared for drilling the heads by using a spring-loaded center punch to drive the rivet mandrel back. Driving the mandrel exposes the rivet to effect head removal with a 1/8in drill. A first replacement hinge part was discarded after trying to align the rivet holes with the old workpiece. The drilled aluminum ruler was used on a second attempt. Several holes on the rudder skin needed to be opened to accept a rivet. The tang for securing the hinge pin with safety wire was too long, contacting a bolt head. The tang was cut back and the safety wire hole relocated. Reassembling the rudder halves is a much tighter fit. A previously used piece of rudder hinge was tapped up from the bottom. A battery powered drill will be used to pull the slightly flattened end of the hinge pin through both hinge halves to open the holes.

Mandrels driven back

Old hinge removed

Old and new

Hinge material comparison

Trial fit, contact with bolt

Trial fit

Jul 03, 2020 Plan Review - (16 hours)

Category: Research

Detailed review of plans and completed items to date. Noted discrepancies and items to purchase.
Questions:
- Drawing XNB-L03 Where is part XNB-L03-07 cable guide used?
- XNB-T09/T10 Part XNB-T10-05 rolled knuckle hinges were installed on the rudder rather than MS20001P3 extruded hinges.
- Check XNB-F03 rear spar fitting is accessible. Align holes and updrill to 5/16 for pins with wings attached.
+ Check XNB-F05 Aft tunnel web rivets
$ ABS-C01-03 pushrod fairing for enclosing rear marker light
$ Snap vents for wind screen
$ Wing tie downs
$ Pitot, Total Energy, and port plug from W&W
$ Silk thread for wire bundles
$ SNX-W18-03 cover plates for adding inspection ports

Plan System markup

Jun 27, 2020 Additional iEFIS programming - (2 hours)

Category: Instrument Panel

The active checklist idea intrigues me. Did additional work to iEFIS screen 5 (Checklists) to integrate common location of com radio and transponder controls. Exploration of substituting custom graphics for ACSIDE.mif, ACREAR.mif, ACLSYMBL.mid and ACSSYMBL.mif.
Tried customizing the look at me graphics according to MGL's instructions, but I spent too much time going nowhere. Probably should reduce the gauges on the takeoff checklist, as TO is an eyes outside portion of flight.

Checklist 5C w/com & xpndr

Jun 25, 2020 Make XNB-T01-02 fairing - (2.2 hours)

Category: Empennage

Marked the inside of a previously cut sheet of 6061-T6 with a fat felt-tipped marker. Clamped short end into a vise and used a propane torch to heat the work piece. Clamping the work piece by the short end was a mistake. As the workpiece lost temper, it wanted to fall forward which necessitated holding it in place until it cooled sufficiently to lay it on the workbench.
After the piece cooled, the wide end was marked with the dimensions from the trial work piece. Cutout marked at the wide end, and lengthwise tabs marked at approximately 5/8" wide. Setup in a HF bench brake, tabs were bent a bit more that 90 degrees. Very little spring back to the workpiece.
Formed curve in fairing by hand and by using the edge of the workbench. Tight fit at the wide end, trimming a bit on the forward edges helped.
Fairing needs some additional hand work to tighten the fit with the fuselage.

Removing temper with propane torch

Tail_fairing_fit - 12.jpeg

Fit to fuselage

Traced from plans and cut out

Marker indicator

Clamped by short end

Removing temper with propane torch

Jun 25, 2020 Aileron fairings - (2.2 hours)

Category: Wings

Ordered two ABS-C01-04 Aileron Pushrod Fairing - ABS Molded from Sonex rather than cut and shape two fairings from sheetmetal. Used a bench sander to remove/melt the ABS flashing from the fairings. Waited for the flashing to cool then broke off larger pieces. Shaped with sander, and finished with a file. Drilled five holes for nutplate locations, transferring the holes to the wing skins. Dimpled skin and installed five #6-32 nutplates on the port wing.
When attempting to reinstall the port aileron pushrod, it was found that the central nutplate contacted the pushrod, interfering with smooth operation. The central nutplate was removed. Consequently only four nutplates were used on the starboard side aileron fairing attachment.

Fit before pushrod

Port wing aileron fairing

Port wing aileron fairing

Port wing aileron fairing

Fairings sanded to shape

Nutplate locating holes, center interfered w/PR

Nutplate layout

Nutplates installed

Dimpled skin

Jun 25, 2020 Aileron Pushrod Linkage - bearings - (0.8 hour)

Category: Wings

Installed spoiler bushings XNS-W37-07 in Aurora bearings. Removed incorrect dual control pushrods. Installed XNB-W07-06 -01R/01L main push rod assemblies, torqued and checked movement. Did NOT install cotter pins.

Aileron bushings and bearings

Jun 25, 2020 XNB-T01-02 Fairing - (0.7 hour)

Category: Empennage

Cut a trial piece of sheet metal approximately 12" x 4" to use as a trial fit to determine the dimension of the fairing fit with the stabilator installation. Marked up the trial piece with a marker, clamped in a vise, and heated the work piece with a propane torch until the marks changed color to remove the temper in the 6061-T6 metal. Bent one end past 90 with a hand brake. Set the piece in place to find the bend location on opposite side.
The bend angles on the trial piece were eyeballed to the shape of the opening. The HF handbrake produced a greater radius bend than had I used the HF bench mounted brake.
Forming the sheetmetal by hand to shape was much easier than standard T6 treated.

Trial fit

Trial fit with fastener locations

Trial fit

Trial piece Clecoed

Jun 20, 2020 Tailwheel post rework - (3.8 hours)

Category: Landing Gear

On initial fitting I had drilled the taper pin hole twice. The initial hole took the taper pin off of square with the tail spring socket. Welded closed the small end of a hole through the Flyboys Sonex tailwheel. Re-drilled small end by centering a 3/8" Cobalt bit in large end clamped in a drill press vise. Used a #1 S&J taper reamer to open the hole. Boelube helps with drilling and reaming. Used reamer to take a little material from the tail spring to fit taper pin. Cleaned up surface of rust, painted with a self-etching primer and finished with rattle can red enamel.

Closed old hole

Taper pin through new hole

Taper pin square in through holes

TailWheelPost_pin - 6.jpeg

TailWheelPost_pin - 7.jpeg

TailWheelPost_pin - 8.jpeg

Jun 19, 2020 Align starboard ruddervator pushrod fairing - (0.4 hour) Category: Empennage

Filed and aligned PVC pushrod fairing on starboard side. Drilled several #40 holes in anticipation of installing #6 nutplates.

Jun 19, 2020 Port side ruddervator pushrod fairing - (2.5 hours)

Category: Empennage

Located, drilled, deburred, dimpled, and riveted six #6 nutplates for securing port side ruddervator pushrod fairing.

Nutplate arrangement

Nutplates installed

Fairing installed

Jun 14, 2020 Ruddervator pushrod fairings - (2 hours)

Category: Empennage

Worked on sanding and aligning the ABS fairings to fit the ruddervator pushrod openings. Sanded to create matching fairings. Aligned the mounting holes to create identical hole spacing. Will be using machine screws and nutplates. Adjusted trial locations to find areas conducive to installing the #6 nutplates. Too high will interfere with the upper longerons, too far forward increases installation difficulty.

Hold together for sanding.

Trial fit

Jun 13, 2020 Replace Rudder Hinge - (4.5 hours)

Category: Empennage

Aligned and drilled holes in replacement hinge. Deburred and riveted with CPP-42 rivets. Middle two rivets pressed on tail post reenforcement, distorting the lay of the hinge. Alignments with rudder looked good during trial fittings with Clecos. Bolted the tailpiece in place, torquing to 5.5 Nm using 3 Nm for the bolt/nut and 2.5 Nm to overcome the nylock friction. .After final rivet and bolting of tail post, Hinge pin wouldnt go past half way down the hinge. Used a trick introduced in Jeff Schultzs FWF seminar to open the hinge pin hole slightly. Using a piece of hinge pin, the end was flattened slightly with a hammer on a vise anvil. Ran pin through hinge to the top and chucked the pin into a drill. While turning the pin, pulled it up through the hinge, opening the holes slightly. The opened holes allowed the original hinge pin the fit through the knuckles.

New hinge in place

Hinge in place.

Hinge riveted to tail post.

Tailpost bolted in place.

Jun 12, 2020 Starboard tail tip instrument lines - (1.3 hours)

Category: Empennage

Switched 3/16" dia vinyl tubing to the correct color. Blue vinyl tubing was incorrectly installed in the Total Energy probe port. Switched it to green. Looked at methods and positions to secure the pitot and TE lines from the tail into the 3002 AL tubing lines. Will likely use an epoxied on stud to secure a pair of clamps for the vinyl tubing.
Installed a BNC fitting to the RG59 antenna wire for the ELT.

StarbTailTip - 1 (1).jpeg

StarbTailTip - 1.jpeg

StarbTailTip - 2.jpeg

StarbTailTip - 3.jpeg

Jun 09, 2020 Replace Rudder Hinge - (2.5 hours)

Category: Empennage

Sonex released a Service Bulletin for all Waiex, Waiex-B, Xenos, and Xenos-B Aircraft on 04.29.20, reference XNS-SB-003 showing cracking of the tailpost channel. Photo of issue: https://www.sonexaircraft.com/documents/plan_sheets/Tail_Post_Channel_WIX-XNS-SB-003.jpg.

Coincidentally, I found several weeks ago the rolled knuckle hinge rather than the extruded knuckle hinge had been used in this application. Removed the bottom skin around the tail wheel to better access the nuts on the back of the tailpost bolts. Removed the tailpost bolts and tailpost doubler. Removed solid rivets and hinge. Cut new MS20001P3 hinge and aligned it on tail post channel. Added this area to the preflight checklist inspection items in the POH.

Difficult to reach the nuts, will take a look at removing a little material from the tailwheel reinforcement angles to open room for my arm to fit through.

Tailpost bolt removal

Fitting new hinge

Jun 08, 2020 Sonex Corrects Aileron Pushrod Parts - (0.2 hour) Category: Research

Sonex replied to aileron pushrod dimension email by shipping aileron parts. Asked for additional spoiler bushings for the new Aurora bearings that are needed for connecting aileron linkage.
Purchased four male Aurora bearings, MM-5 5/15-24.

Jun 08, 2020 Email to Factory Requesting Aileron Pushrod - (2.5 hours)

Category: Research

Add/replace correct fasteners, washers, torque nuts to see if there is any excessive drag.

Discovered that plan sheet XNB-W07 calls out a main aileron pushrod made from SNB-C03-09 rod stock with SNB-C03-10 pushrod end fittings. The kit was not supplied with either but with a SNX-C05-05 dual stick aileron pushrod. I had purchased Aurora female rod ends and additional bushings, fitting those to the supplied dual stick aileron pushrod. The threaded end of the pushrod to the witness mark of the Aurora bearings measure 81-1/2 inches between bearing centers. The plan sheet indicates this dimension should be 89-23/32 inches.

Wrote to Sonex to clarify the 8 inch discrepancy. Sonex acknowledged the packing list error and sent the rod stock and end fittings immediately.

Wing_aileron_pushrods - 3.jpeg

Wing_aileron_pushrods - 4.jpeg

May 31, 2020 Replace Rudder Hinge - (0.7 hour) Category: Empennage

Due to not recognizing the difference in hinge types, I had inadvertently installed a piano hinge with rolled knuckles (MS20257) rather than extruded knuckles (MS20001) as called for in the plans. Drilled out the rivets on the rudder hinge and began removing the skin under the tail in order to remove the AN3 bolts holding the Y and stiffener. Will remove the stiffener to access the hinge for removal, then reinstall.

May 31, 2020 Rivet Starboard Aileron Hinge - (3.3 hours)

Category: Wings

Cut and bent a piece of angle to be used to safety wire interior aileron hinge pins. Clecod angle piece in place, ensured hinge alignment, installed 116 CPP-42 rivets, leaving off two on outboard end. May construct tab for wiring pins at outboard side.

Starboard aileron, top

Stbrd aileron, bottom

Split hinge pin

Hinge pin safety wire

May 30, 2020 Connect Aileron Pushrod Linkage - (4 hours)

Category: Wings

Worked through the 2D auxiliary details of drawing XNS-W07 to arrive at the correct part stack-up for linkage connection between aileron bellcrank and idler. A simple exploded diagram with parts orientation would have been helpful. Connected main aileron assembly. The pushrod is incorrectly identified as XNB-W07-06 in drawing but supplied part is SNX-C05-05 aileron pushrod, dual stick. Need to order 3 additional XNS-W37-07 spoiler bushings as Sonex only supplied 7 with kit.

Main pushrod

Notes

Notes

Notes

Notes

Notes

SNX aileron pushrod

May 30, 2020 Trim Bronze Linkage Bearings - (1.5 hours)

Category: Wings

Trimmed additional SYMMCO SF-610-6 bearing barrels on mini lathe. Found that a length of 0.290 inches is a good starting place for the welded aileron pushrod. Trimmed several too short. Machinists blueing doesnt stick to the Oillite bearings. Used a parting tool in the mini lathe, chucked the barrel end, supporting flange end with center. Thin bronze flash left on workpiece after parting tool breakthrough. Broke bronze with a small part of diagonal cutters. Filed flashing. Countersunk bearing ends with deburring tool.

Blueing wipes off Oillite bearing

Feeler gauge for 0.015" clearance gap

 Stack-up height

Bearings, approx 0.290" barrel length

May 29, 2020 Trim Bronze Linkage Bearing - (0.6 hour)

Category: Wings

Sprayed blueing on sleeve of SYMMCO SF-610-6 bearing barrel. Stacked bearing, welded pushrod, and SYMMCO ST-1020-2 thrust washer stacked together. Used a 0.015" feeler gauge for distance and scratched blueing with scribe. Took apart the stack, but the blueing scratched or wiped off the barrel, leaving the scratched blueing line indistinct. Chucked the bearing in a mini lathe and parted the bearing, long by a little over 1/8". Back in the lathe but wouldn't center chucked on flange end. Scored barrel and filed excess.

Trim bronze bearing

XNB-W06-detail-D

May 17, 2020 Inspection ports and port aileron linkages - (4.5 hours)

Category: Wings

Shortened the inboard hinge pin by 1/4 to 3/8 inch on starboard aileron to eliminate overlap with middle pin end.
Added 12 #6 nut-plates for inspection ports, two per port. Primed inspection port covers.
Worked on port side wing aileron to bellcrank bearing and deciphering the bellcrank to idler bearing stack drawings.

Hinge pins trimmed

Hinge pin access

Piano hinge looking outboard

May 10, 2020 Aileron Linkage - (2.8 hours)

Category: Wings

Work on connecting linkage and pushrods for starboard wing.

Stbd aileron bell crank

Stbd aileron drive

May 10, 2020 Aileron Linkage - (2.8 hours) Category: Wings

Work on connecting linkage and pushrods for starboard wing.

May 10, 2020 Update EFIS Checklists - (0.6 hour)

Category: Research

Updated checklist screens to move common functions from the paged Info modules to the Flight module.

5a Engine Start

5b Taxi

5c Takeoff

May 09, 2020 MGL iEFIS Programming - (3.5 hours)

Category: Research

Additional work on designing dynamic checklists for engine start, taxi, and takeoff. The screens are designed to display the device or measurement of the checklist item. For example, showing the primary battery voltage with a "master on" list item, oil pressure with "40 psi within 30 sec" engine start item.

5a with demo alarm

5c Takeoff

May 03, 2020 Starboard aileron hinge - (3.8 hours)

Category: Wings

Divided starboard aileron hinge, inboard half, into thirds. Removed two outboard aileron hinge knuckles 31" outboard with bare hacksaw blade. Smoothed cut knuckle edges with Scotchbrite wheel. Cut hinge sections into approximate thirds. Marked un-drilled middle section with a marker through outboard #30 holes. Drilled #40 holes over ends and thirds. Clecoed hinge section to wing, aligning hinge segments with hinge pin. Trimmed hinge pins to length, each approximately 31" long. Put a point on the free end of the pins with Scotchbrite wheel to ease hinge pin installation. Three hinge pins, two installed at 31" mark, one inserted inboard and the other outboard. Third pin installed from wingtip inboard.

Cut the long hinge pin from the original aileron hinge setup to a 36-1/2" hinge pin for use in the top wing tip attach hinge.

Replacement hinge segment

Replacement segment

Inboard hinge pins

Xenos_stbrd_aileron_hinge - 14.jpeg

Removing two hinge knuckles

Split at 31"

Replacement segment with silver Clecos

Hinge length

May 02, 2020 Finish starboard wingtip attachment - (3.8 hours)

Category: Wings

Sanded wingtip edge to alignment markings. Reattached and updrilled tip/hinge holes to #30. Disassembled and deburred hinge rivet holes. Reattached tip to wing and riveted with CCP-42 rivets.

Alignment marks

Tip sanded to alignment

Up drilling #40 to #30

Quality control inspector

Riveted stbd bottom

Riveted stbd top

Apr 29, 2020 MGL EFIS Screen Modifications - (3 hours)

Category: Instrument Panel

Added several 'dynamic' check lists by employing MGL Explorer graphics and instruments. The checklists are dynamic in that values to be referenced during execution of the checklist are displayed with some providing for changing values. For example, oil pressure is displayed next to a "check oil pressure" item.

Moving through a sequence of checklists uses a "Next" graphic screen touch button. Checklist display shows the state of electronic circuit breakers, bus voltage, oil pressure, heading, altitude, and changing radio frequency, transponder code, and barometric pressure.

Engine Start Checklist

Takeoff Checklist

Taxi Checklist

Apr 26, 2020 Starboard Wingtip Attach Hinge - (3.5 hours)

Category: Wings

With attach hinge halves connected, aligned top and bottom tip attach hinge with wingtip. Alignment placed fiberglass tight against the wing skin. The edge will be trimmed to 1/16" gap later. Marked a point mid-span on each, drilling a #40 hole through fiberglass 1/4" from the edge. Pinned with a Cleco. Clamped hinge ends to fiberglass tip. In middle of wing tip. drilled a 'starter hole' orthogonal with hinge knuckle to start the rivet fan. Marked in pencil marks 1/4" from edge to align rivet fan holes. Spaced 1" center-to-center on fan and drilled
Updrilled wing skin to #30. Deburred skin. Riveted inboard top and bottom attach hinge. Used 5 knuckle splice (36-1/2" total length) on top at aft end as done on port wingtip.
Refit tips tight against skin. Walked fan to fore and aft wingtip, drill, cleco, drill, clico.
Removed tips, marking the fiberglass at the hinge 'pockets' with blue marker. This will be the sanding line for obtaining the 1/16" gap per plan sheet SNX-W??.

Rivet fan for hole spacing

Cleco wingtip in place

Hinge mount forward

Hinge mount aft

'Walking' rivet fan

MS2001 hinge interior

MS2001 hinge exterior

Apr 25, 2020 Inspection ports and tips - (6 hours)

Category: Wings

Installed two #6 nut plates per underside inspection port (x6) to replace the Clecos that had been holding the inspection covers. Will add another 2 nut plates per port after order with AS. Countersunk nut plate mounting holes, riveted with CCP-34 pulled rivets.
Completed up-drilling, de-burring, and riveted port side wing tip attach hinge. Cut 6' hinge pin to 37".
Aligned starboard side tip over hinge, drilled initial locating holes through wingtip and hinge.

Drill nutplate mounting holes

Align nutplates

Xenos_Wings_tips - 3.jpeg

Nut plates installed

Inspection cover, need additional nut plates

Wingtip hinge attach

Apr 19, 2020 Port Wing Tip Attach - Bottom - (4.5 hours)

Category: Wings

Ordered acrobatics wing tips for initial fitting.

Mixed some lightweight Evercoat filler ($20) for holes in wing tip with extra used to fill wheel pant seam. Sanded filler and Cleco-d hinges to tip. Mounted tip to wing and up-drilled outboard side with #30 drill. Disassembled, deburred, reassembled and riveted outboard hinge using CCP-42 rivets. Repeat with inboard hinge.

Clamped and aligned top starboard wing tip attach hinge. Drilled hinge with #30 drill. Wing skin had been previously drilled and riveted for MS20257P hinge. Those rivets were drilled out and removed. Cleco-d hinge to wing skin.

Hinge pin much easier to install on extruded MS20001P hinges compared with rolled MS20257P hinges.

Lightweight filler

Port side tip bottom

Port WT bottom complete

Apr 18, 2020 Sand Port Tip Edge - (0.4 hour)

Category: Wings

Sanded fiberglass tip edge using a belt sander to remove 1/16" or so of material. Alignment line produced by tracing edge of attachment hinge. Sanded edge until just the line was visible.

Alignment line visible

Belt sander removed mtl

Apr 17, 2020 Update EFIS Screens - (1.3 hours)

Category: Instrument Panel

Updated screens, simplified by removing extraneous buttons and functions.

Having a problem programming a screen that indicates current flow through individual breakers. When the current display references circuits 1,2,3, etc, the displayed current is from the circuit one less than programmed. For example, circuit 3 supplies the communications radio. When the screen display is programmed to match the circuit, the com radio is displayed on breaker 2. When a circuit number one less is used, the com radio is correct but there is no flow indicated through circuit 0.

Com radio power

IMG_3700.jpeg

ComRDO (M1,3) as circuit 2.

No current in circuit 0

Apr 17, 2020 Drill Port Tip Attach - (0.5 hour)

Category: Wings

Completed drilling top attach hinge with rivet fan alignment and deburr of MS 20001-3 hinge.

Rivet fan alignment

Rivet fan alignment

Trim line

Apr 16, 2020 Port Side Tip Drill - (.3 hour)

Category: Wings

Continued drilling #40 tip/hinge mount holes with rivet fan.

Rivet fan alignment

Hole spacing

Apr 14, 2020 MGL ECB #5-8 Breakers - (0.5 hour) Category: Instrument Panel

Bend, soldered split ribbon cable connectors to enable ECB numbers 5 through 8. Enabled the breakers in the EFIS. Tested activation between iEFIS display and ECB LEDs.

Apr 13, 2020 Drill Tip Attach Rivet Holes - (0.5 hour) Category: Wings

Aligned rivet fan on port tip (XNS-W17-02L) with several previous alignment holes with Clecos, used fan to direct 1" rivet spacing, 1/4" in from wing tip. Wing tip was aligned closer to wing skin to allow for sanding of tip edge to produce 1/16" spacing.

Apr 12, 2020 Port Acro Cap - (4.3 hours)

Category: Wings

Identified inboard end of undersized (0.045) hinge wire on port aileron hinge. Used a drill chuck to hold hinge wire, using the drill to ease the wire in and out of the 73" aileron hinge. Marked, cut, and bent outboard end of aileron hinge wire.

Cut MS2001-3 hinge for top and bottom attachments to port side acrobatic wing tip. Cut five knuckles from the wing side and added back a six knuckle length to make the 36-1/2" length for part XNS-W21-04 upper tip attach hinge. Set outside of knuckle flush with wing skin, drilled #40 holes and Cleco'd hinge to wing on top and bottom hinges. Aligned port side acro tip to hinge, marked tip location with hinge. Marked 1/4" line from edge of tip for drill line. Clamped, Cleco'd tip to hinge, locating attachment locations along the tip.

Hinge splice to make length

Tip fit to hinge

Aileron hinge pin

Aileron pin

Top & bottom hinges

Apr 11, 2020 Splice Tee in Pitot Tubing - (0.4 hour) Category: Instrument Panel

Spliced a metal tee into the red pitot signal tubing.

Apr 11, 2020 Wing Tip, Bottom Attach - (4 hours)

Category: Wings

Cut MS20001-3 extruded piano hinge to 35-1/2" for port and starboard wing tips. Aligned knuckles flush with wing skin, clamped, drilled, cleco'd, deburred bottom port and starboard wing tip mounts.

Had previously installed MS20257P5-3 piano hinges on a utility tip. Installing the hinge pin would stick on the last 2 or three rolled knuckles. Using the MS20001-3 knuckles provides a smooth pin insertion. Extruded hinge is $35 per 3' segment.

Starboard bottom tip attach

Starboard bottom hinge

Starboard bottom hinge

Starboard top previous incorrect hinge

Port tip attach, knuckle flush

Apr 09, 2020 Install Analog ASI - (0.4 hour)

Category: Instrument Panel

Installed air speed indicator to look at how the pitot line will attached. Plan is to put a barbed tee fitting in the incoming line and supply both the iBox and the analog ASI.

ASI mounted in panel

Red is pitot

Apr 04, 2020 SP-12 GPS Checkout - (1.2 hours)

Category: Instrument Panel

Wired power for MGL SP-12 GPS. Attached antenna and powered up panel. Waited 10 minutes or so for GPS to download ephemeris. Switched between internal and CAN bus GPS successfully.

CAN bus GPS (MGL SP-12)

EFIS GPS primary source switch

Internal GPS (iBox)

Mar 29, 2020 Prep Panel Underside - (0.7 hour)

Category: Instrument Panel

Trimmed piano hinge for GPS mount.
Cut temporary panel support leg in half to split right/left sides. The supports hold the radio and GPS away from the bench top. Supports are Cleco'd to panel and sub panel.
Cut, rounded, Scotch-Brite edges of short angle riveted to a stiffening tab on the GPS mount to push com radio wiring harness away from the sharp edge of stiffening tab on mount.

Bench top support

Inst panel support

Mar 28, 2020 Radio and GPS Attachment - (2.5 hours)

Category: Instrument Panel

Located, drilled, deburred, riveted piano hinge to ends of com radio/AHRS and GPS mounting plates.

Com(L) & GPS mounts

MGL SP-12 GPS mount

Com/AHRS(not visible) & GPS between panel & sub panel

Mar 22, 2020 Attach Com Mounting Hinge - (1 hour) Category: Instrument Panel

Aligned hinge on aluminum ruler drill guide, drilled #40 holes. Up drilled, deburred, countersunk hinge and com mount. Riveted hinge to mount with 4-3 soft Al rivets.
Installed radio RS-232 cable and inspected fit. Found com bundle wires would rest heavily against the edge of the bend stiffening the SP-12 mount. Rubbing of wires in com bundle can be addressed by sticking a plastic tie anchor to the aft most bottom of the iBox and pulling the bundle rearward.

Mar 21, 2020 Rivet Piano Hinge to SP-12 Mount - (0.9 hour)

Category: Instrument Panel

Up drilled, deburred, countersunk piano hinge and mount for MGL GPS. Riveted hinge to mount. Attached to rear sub panel hinge.
Trimmed edge from panel/sub panel separator stiffening tab with large metal sheers.

Com & GPS mounts

Com fore hinge attach

GPS aft hinge attach

Mar 08, 2020 Revamp FW Wiring Runs - (2.3 hours) Category: Firewall Forward

Reworked wiring runs for ground (black), power supply (red), and instrument (blue, white) to the grounding block, terminal block, and RDAC.

Mar 08, 2020 FW to AI Fuel Connections - (0.5 hour)

Category: Fuel System

Used a 45 deg AN6 Female/Female adapter to connect bulkhead fitting to inline fuel filter to the AeroConversions AeroInjector. Stacked length of fittings pushes the AeroInjector a bit out of plumb. At least an initial assessment appears to provide an acceptable fit.

Inline fuel filter

Mar 07, 2020 Clamps for Secondary Ignition Wires - (1.5 hours) Category: Engine

Explored ways of mounting spark plug wires from port side secondary ignition to coil on firewall. Used doubled 5/8" cushion clamps to hold wired together. Mount doubled clamp set to clamp on frame member.

Mar 03, 2020 MGL GPS Mount Layout - (0.3 hour)

Category: Avionics

Layout and drill initial rivet holes for securing MGL SP-12 TABS to underside of instrument panel with piano hinges to hold the mounting plate to the underside of the instrument panel.

Overall fit of two piano hinged fixture

Forward end

Cleco'd forward end

Mar 01, 2020 Repair Canvas Tear - (0.8 hour)

Category: Hangar

When my tool is a rivet gun, every problem looks like a rivet. Repaired a tear in the canvas door with a piece of scrap aluminum and a handful of aluminum rivets. Replaced a grommet in the lower seam that supports attachment of the chain weight.

Reinforced canvas seam

Riveted seam to previous repair

Mar 01, 2020 FW Terminal Strip Mount - (1.5 hours)

Category: Firewall Forward

Aligned nutplate locations to 1/8" thick AL backing plate. Located, drilled, countersunk (with a deburring tool), and riveted nutplates with soft solid rivets. Located backing plate on FW, drilled 1/8" pilot holes, enlarged to 3/16" with step drill. Deburred back end of stainless firewall with the step drill. Mounted the terminal block with #10 screws, aligned to approximate center of through hole and tightened mounting screws to hold the backing plate. Drilled two of the four mounting plate holes for CPP-34 blind rivets. Installed with hand rivet tool.

Terminal block installed

Terminal & backing plate

FW_terminal

Cockpit view of backing plate

Feb 29, 2020 Mixture Control Arm Clamp - (0.6 hour)

Category: Engine

Changed out barrel wire clamp on the AeroInjector that was binding the pivot action on the arm. Operation works well on the simple solid wire Bowden cable. Will likely change the 5.5 foot cable with a A-790 VERNIER CONTROL with a red knob.

Mixture cable-2.jpg

Mixture cable-1.jpg

Feb 29, 2020 Backing Plate for Terminal Block - (0.6 hour) Category: Firewall Forward

Cut, filed, sanded and smoothed cuts with Scotbrite wheel for backing plate for firewall terminal block.

Feb 27, 2020 Layout for SP-12 Attachement - (1.5 hours) Category: Instrument Panel

Removed rivets from reinforcing corner. Corner will be replaced with a mounting plate for MGL SP-12 TABS GPS. GPS provides qualified signal for ADS-B. Squared mounting plate, cut to size. Marked reenforcing bend locations.

Feb 23, 2020 Mixture Control Cable - (1.5 hours)

Category: Engine

Opened FW hole to install aluminum pass-through bushing. Loose control slide with mixture control arm on AeroInjector will need upgraded to a mixture cable with a vernier.
Explored locations for firewall terminal block.

Mixture cable pass-through

Throttle and mixture pass through FW

Mixture cable-1.jpg

Feb 22, 2020 Mount for MGL SP-12 TABS GPS - (0.3 hour) Category: Instrument Panel

Sketch out location under control panel for mounting certified GPS receiver for incorporating into ADS-B transponder.

Feb 22, 2020 Mixture Control Cable - (3 hours)

Category: Engine

Removed slave throttle control.
Locate and drill firewall pass-through for mixture cable. Connected cable to AeroInjector. Securing cable in clamp binds against the control arm resulting in poor control from the simple solid cable.
Added final 12 CCP-42 rivets to glare screen attach angle.

Mixture cable path

FW penetration above throttle

Glare shield rivets

Feb 10, 2020 Begin Tank Vent Relief on Glareshield - (0.5 hour)

Category: Cockpit

83.jpeg

85.jpeg

86.jpeg

91.jpeg

Feb 10, 2020 Spoiler Pulley Mount Assembly, XNB-C06-10 - (2.3 hours) Category: Cockpit

Made pulley assembly from drawing XNB-C06-10. Substituted two 0.125" spacers made from angle for the 0.25" thick -13 spacer. Substituted AN-3a bolts for AN525 machine screws.

Feb 07, 2020 Additional Panel Designs - (0.3 hour)

Category: Instrument Panel

Designing panel configurations with all controls and switches operated with the left hand.

XenosB_rev11_2.jpg

XenosB_rev11_4.jpg

XenosB_rev11_5.jpg

XenosB_rev11_6.jpg

Feb 02, 2020 Rivet Glare-shield Mounting Angle - (0.6 hour) Category: Firewall Forward

Placed 8-10 1/8" rivets in the top and sides of the glare shield mounting angle attachment to glare shield.

Feb 02, 2020 Mount Throttle - (3.2 hours)

Category: Controls

Located and drilled holes for AN-3 bolts to mount pilot-side throttle control. Added steel washers on either side of firewall penetration. Attached main throttle cable and adjusted range of travel to ensure full open/close. Attached solid control cable to slaved passenger side throttle control. Some filing of AeroConversions throttle control to help alignment. Slaved cable seems too short, both overall and the solid steel control wire. Control wire needs 1/4" to allow the cable end to extend from both throttle control clamps.

PAX trial location

Pilot throttle mount

Xenos - 7.jpeg

Throttle bracket

Throttle control to FW

FW

FW pass-through

Feb 01, 2020 Wire for OAT and Aux Sound - (3.5 hours)

Category: Instrument Panel

Crimped Faston connectors on OAT probe, checked operation on EFIS panel. Need to add OAT display to electrical screen.
Used a temporary RS-232 D25 to test auxiliary sound output from iEFIS into com. Was unable to pickup sound until the com settings where changed to set the aux input mute level. Used the Explore sound test to check audio. Voice seems to have excessive bottom end, too much bass.

12.jpeg

Feb 01, 2020 Rewire Avionics Power, OAT - (3.5 hours)

Category: Avionics

Changed the wiring from the ECB to avionics fuse box. In the original configuration, the ECB was used to switch the power conditioner supplying power to the avionics fuses. In the most recent configuration, the ribbon cable connector for ECBs 1 through 4 were soldered to their respective grounds. Power from the conditioner was then switched to the avionics fuse box. The poor photograph and incomplete description in the MGL documents required bridging each of the ribbon connectors to determine which pins to solder together.
Attached outside air temperature sensor connections and tested in EFIS.

ECB solder bridges on ribbon cable pins

ECBs 1-4 w/solder bridge

ECB/ribbon

Rewire avionics master switch

Jan 26, 2020 Throttle Control Installation - (2.5 hours)

Category: Controls

Established length of outer sheath by stripping 3/8" of PVC sheath first to Aeroinjector, then through firewall to cockpit throttle control. Trimmed end with a hacksaw and removed 3/8" outer jacket at cockpit. Stripped an 8" section of jacket where the cable passes through a Cable Safe II for 1/4" cable holder at the firewall.

Pilot hole over battery box

Pilot hole

Mixture cable

4.jpeg

6.jpeg

Sketch throttle & mixture location on FW

Throttle_Quad_Install.pdf

Jan 26, 2020 Repair Roof Leak - (0.5 hour) Category: Hangar

Replaced metal sheet that had been picked up and displaced by the wind allowing the roof to leak.

Jan 26, 2020 Reinstall Com Radio - (0.8 hour)

Category: Instrument Panel

Reinstallation and test of MGL V16 communication radio and Razor control head after firmware update at MGL.

Electronic circuit breaker monitoring panel indicates current passing through ECB#2 not the radio breaker ECB#3. Checked programming through MGL Simulator, indicating ECB#3.

IMG_3699.jpeg

IMG_3700.jpeg

Jan 20, 2020 Prep panels for paint - (1.2 hours) Category: Instrument Panel

Removed scratches and dirt from 1/8" instrument panels with Scotchbrite, cleaned with acetone. Applied 2 coats of self-etching primer.

Jan 18, 2020 Remove Glare-shield Rivets - (0.6 hour) Category: Firewall Forward

Removed the remaining 5 rivets from the glare shield attachment angle by filing the shank flat, then used an automatic center punch to push the shank into the rivet far enough that a drill bit could take off the factory head.

Jan 12, 2020 Remove rivets from glare-shield support - (1.50 hours) Category: Firewall Forward

Drilled out all but 5 rivets on the firewall that attach the glare-shield support to firewall. Support needs to be riveted to glare-shield then glare-shield support riveted to firewall. The five rivets had their shanks even or proud of the shop head.

Dec 10, 2019 Update MGL Firmware - (0.65 hour) Category: Avionics

Updated G3 Explorer iEFIS firmware to FlightOps system G3 iEFIS 1.0.0.3. iEFIS application G3 A 1.1.0.1 (22 October 2019).

When updating the V16 VHF radio firmware using the Explorer/SD card method, the update routine in the iEFIS asked to cycle the power to the radio. Since the radio power from the ECB is switched in software from the Explorer, cycling the power while leaving the Explorer running was not possible so power was removed from the Explorer. The V16 radio & Razor head power was wired to a physical switch and the update attempted.
After the update routine called to cycle power to the radio, the Razor head indicated no Com radio available, and the Explorer update routine stopping at 1% with a no ack error. Returned the V16 and Razor to MGL for service.

Did not update iBox firmware.

Nov 30, 2019 Wiring VHF Com Radio - (2.5 hours) Category: Avionics

Opened pass-through in sub-panel support to accommodate a 3/4" dia snap bushing. Organized power and ground instrument panel wires loosely with plastic ties and anchors. Cut, marked, and crimped Faston connectors for power and ground.

Nov 17, 2019 Wire Runs - (1.5 hours) Category: Instrument Panel

Ran supply wiring for pilot and pax accessory outlets. Supply for 'cigarette lighter' 12 v power outlet.

Nov 09, 2019 Integrate MGL V16 Radio - (3 hours)

Category: Radios

Built bracket to secure AHRS and V16 radio between panel and sub panel. Used piano hinge to secure mount to subpanel. Temporary use of Clecos to secure to front panel. Secured radio with screws into nutplates on mount. Mounted AHRS above radio. Connected power and CAN bus.

Mounted under iBox

V16 on bottom

Radio wiring harness

Oct 26, 2019 Glare Shield Prep - (1.1 hours)

Category: Cockpit

To prepare the cockpit for glare shield/fuel tank, the Peter Anson (http://www.ansoneng.com/sample-page/products-summary/fresh_air_intake/) air vents were removed. One vent had broken the 3D printed mount holding the open/close nut. Removed center control stick to provide room for the fuel cell.Drilled out port side rivets on glare shield angle, as riveting the glare shield with the angle attached to the firewall doesn't permit riveting the glare shield to the angle. Will rivet angle to glare shield and then rivet the angle to the firewall.

Cockpit_vent-18.jpg

Oct 20, 2019 Mount Radio and AHRS - (1 hour)

Category: Radios

Drilled mount location for AHRS and V16 radio to auxiliary support/mount fit between panel and sub-panel. Separating ground connections to two blocks. EFIS, AHRS, and related to one ground block and radio and accessory grounds to a separate ground block.
Will run individual grounds from battery to each ground block.

V16 & AHRS

V16 and AHRS mount

Rat's nest

Oct 13, 2019 ELT mount in panel - (2 hours)

Category: Instrument Panel

Cut rectangle for mounting ELT panel. Opened area behind accessory USB ports.
Using machinist blueing was probably a mistake. Too much trouble for little benefit. Back to using blue micro Sharpies.

Xenos_EFIS_cutout - 1.jpeg

Xenos_EFIS_cutout - 5.jpeg

Xenos_EFIS_cutout - 4.jpeg

Xenos_EFIS_cutout - 3.jpeg

Xenos_EFIS_cutout - 2.jpeg

Sep 15, 2019 Final Design Choise - (.5 hour)

Category: Instrument Panel

Choose an instrument panel design from the many under consideration. Compelling features provide for left-hand control of engine switches and trim.

Panel_rev11_6.jpg

Sep 14, 2019 Final Designs - (20 hours)

Category: Instrument Panel

Design considerations converging on a single panel with an analog airspeed gauge and compass. Designs cover the period of Sept 2017 through Sept 2019.

XenosB_rev10_0.jpg

XenosB_rev10_1.jpg

XenosB_rev10_2_Full.jpg

XenosB_rev10_2a.jpg

XenosB_rev10_3.jpg

XenosB_rev11_0.jpg

XenosB_rev11_0_Full.jpg

XenosB_rev11_1.jpg

XenosB_rev11_2.jpg

XenosB_rev11_4.jpg

XenosB_rev11_5.jpg

XenosB_rev11_6.jpg

XenosB_rev6c_Full.jpg

XenosB_rev6d.jpg

XenosB_rev6e.jpg

XenosB_rev6e_Full.jpg

XenosB_rev7.jpg

XenosB_rev7a.jpg

XenosB_rev7a_Full.jpg

XenosB_rev7b.jpg

XenosB_rev7c.jpg

XenosB_rev7d.jpg

XenosB_rev8_1.jpg

XenosB_rev8_2.jpg

XenosB_rev8_3.jpg

XenosB_rev9_1.jpg

Sep 12, 2019 Update XPanel 5000 Design - (0.5 hour) Category: Instrument Panel

Latest design reflecting current metal layout. Will use several plugs to reduce the number of switch holes.
Trimming the aluminum radio mount that will bridge the bottom of the panel with the sub-panel.

Sep 07, 2019 Install Isolated Grounding Blocks - (0.8 hour) Category: Instrument Panel

Installed two 2x5 terminal strips back-to-back through the side panel. Isolated terminal strips referenced to engine ground to prevent ground loops.
Replaced strips with terminal blocks with spade connectors later in the build.

Aug 11, 2019 Building screens for MGL Explorer - (4.5 hours)

Category: Avionics

Used the MGL Simulator to start several new engine monitoring screens. Setup includes monitoring the current flow through each ECB circuit. Tests using the radio circuit was not entirely successful in displaying the current flow through the intended ECB. The circuits were programmed from 1 to 4, the indication is that the first four circuits are numbered from 0 to 3.

Std MGL, slight mod

Std MGL, slight mod

Std MGL, med mod

New, altitude focus

New, electrical focus

New, 'six pack'

New, performance

Aug 10, 2019 Top cowling alignment - (1 hour) Category: Cowling

Fit top cowling and drilled pilot holes for fasteners on the starboard side. Cleco'd in place.

Aug 04, 2019 Paint top cowling - (0.8 hour)

Category: Cowling

Cleaned the interior of the top fiberglass cowling with acetone. Used two coats of white latex paint on the inside to seal fiberglass cloth weave.

100.jpeg

97.jpeg

98.jpeg

Aug 04, 2019 Add ECB CAN bus - (1.6 hours) Category: Avionics

Built cable to add the ECB to the EFIS/iBox CAN bus. Took several tries setting the ECB DIP switches to set profile 31, permitting circuit breaker programming through the MGL EFIS. EFIS/iBox/ECB. Testing of power input from Power Conditioner appeared to blow 5 amp fuses ahead of the iBox. Tested MGL wiring harness for shorts but nothing evident. ECB
When the EFIS is powered through an ECB, switching off the EFIS then requires cycling main power to ECB to re-enable EFIS (circuit programmed to ON during power up.
The current display through the ECB circuits is done in the Simulator selecting ECB tab and providing an ECB circuit number.

Aug 03, 2019 Working with ECB - (3.6 hours) Category: Avionics

Powered EFIS and iBox through the electronic circuit breaker (ECB). Several dip-switch profiles were tried along with grounding ECB circuits 1 and 2. bridging the ribbon cable outputs did not activate the breaker(s) every time the power was cycled. Build a wiring harness with CAN bus connections and ground with a DB9 and to enable programming the ECB. Was able to program the EBC from the EFIS, setting profile 31, breaker name, trip time, trip current, and startup state.

Aug 02, 2019 Wiring for EFIS power - (0.8 hour) Category: Instrument Panel

Cut, labeled, and attached Wirefy heat shrink spade connectors. Power from ECB to power conditioner, and from power conditioner to six port fuse box. Fuse box to EFIS power. Wired ribbon cable connection switching EBC1 circuit to power conditioner. Grounding the ribbon cable energizes EBC1.
Power conditioner holds a charge after de-energizing the EFIS circuit, which prevents an instantaneous reactivation after switching ECB1.

Jul 27, 2019 Cut and Shape Cover Panels - (1.5 hours) Category: Instrument Panel

The two-piece 1/8" cover panel that fit flush was cut into three panels. Panel edges were cut and shaped to leave a 1/8" reveal around the panel perimeter. Separating the panels will allow for cleaner removal and replacement of the switches and displays.

Jul 20, 2019 Paint interior lower cowling - (1.2 hours)

Category: Cowling

Sealing the fiberglass cloth interior surface of the cowling was suggested by Bob Mika during the Sonexflight firewall forward seminar. The inside of the lower cowling was cleaned with mineral spirits to remove dirt and oil. Two coats of white latex paint were brushed on inside of cowling to seal fiberglass cloth. Required a little less that half a quart of paint.

128.jpeg

129.jpeg

Cowling-51.jpg

Jul 13, 2019 Makeup new oil lines - (3.5 hours) Category: Engine

Made new oil lines to route from engine to oil filter and oil filter to turbocharger using braded AN4 hose and Aeroquip fittings. Secured lines to engine mount tubes with cushion clamps.

Jul 13, 2019 Attach Oil pressure Gauge Tap - (0.3 hour) Category: Engine

Removed VDO oil pressure sensor and attached HF oil pressure gauge port from adapter provided with Harbor Freight gauge kit.

Jun 22, 2019 Turbo cooling plumbing - (1.5 hours) Category: Engine

Adjust turbo cooling circuit hose lengths to fit. Shortened 5/8" hose and added 18" of 1/2" to provide a smooth bend radius to radiator.
Using Oeticker clamps for more permanent connections, hose clamps for removable connections.

Jun 20, 2019 Fit cowling - (1.3 hours)

Category: Cowling

Removed fairing material from open end of cowling inlets to fit upper and lower cowling halves. Test fitting indicates an little more fiberglass needs trimmed to allow a tighter fit.

405.jpeg

406.jpeg

412.jpeg

413.jpeg

Cowling-27.jpg

555.jpeg

Jun 15, 2019 EGT sensors - (1.5 hours) Category: Engine

Drilled 3 holes in exhaust pipe 4" from manifold flange, starting with #40 pilot to 3/16" with an ending hole diameter of 13/64". Started exhaust wrap on port-side exhaust.

Jun 10, 2019 Low oil level mark - (1.5 hours) Category: Engine

Added 2 qts of 20-50 Brad Penn oil, rolled the fuselage to the runway, waited ten minutes then marked the low oil level on the dipstick with the edge of a small triangular file.
Removed flaking engine paint from the top of the block (I regret painting the magnesium block!).

Jun 10, 2019 Check Wheel Track - (0.75 hour)

Category: Landing Gear

Paul Thonnard, whom I had met at the Sonex Flight firewall-forward seminar in Lee's Crossing, MO, spent the evening in Charleston. He visited the hangar where we moved the fuselage onto the runway, and added two quarts of oil. Per the AeroVee instruction, set the dipstick low-level mark with the edge of a triangular file.

Mudsuck

Looking at wheel alignment

163.mov

164.jpeg

167.jpeg

170.jpeg

Jun 08, 2019 Additional inlet fairing - (1.2 hours) Category: Cowling

Mixed West System epoxy and white pigment to fill and reenforce cooling outlets with cloth. Tried wetting 1" wide fiberglass cloth to the inlet edges, but the cloth was too thick and wouldn't lay down.
Added 404 gap filler to thicken the mixture and used it to fill old rivet holes in cowling.
Added 407 fairing filler for additional fairing behind the cowling inlets.

Jun 08, 2019 Turbo Exhaust Flange - (1.5 hours) Category: Engine

Cut six threads from 1-1/4" turbocharger exhaust flange mounting bolts, and stud. Filed ends and polished on Scotchbrite wheel. Installed graphite gasket and checked clearance of lengthened exhast pipe. Weld extenton on tubo exhaust pipe and extension is clear of motor mount frame.

Jun 08, 2019 Secure oil lines - (1 hour) Category: Engine

Tightened oil line penetrating starboard side engine flange, secured fittings to external oil filter. Checked fitting turbocharger extended sump, however the size of the sump interfered with the wastegate actuator mounting. Reinstalled the standard oil flange fitting and gasket.

Jun 06, 2019 Cut Double D Holes - (1.8 hours) Category: Instrument Panel

Mounting a voltmeter and USB socket with 'double D' case configurations. The case width across the flats of the D is 1 inch. Used a step drill to 1". Then using the side of a flat file cut two notched flats on to fit the case width. A bastard file was used to open and elongate the holes to fit the case. Case is held in place at the flats. The flats prevent case rotation while tightening the backing nut.

Jun 02, 2019 Remove FAILED JB Weld Epoxy - (0.5 hour) Category: Cowling

The JB Weld used previously to attach fiberglass cowl inlet delaminated, separating the scoop from the cowling. Removed rivets and sanded cowling and inlet scoop surfaces to prep for West system epoxy and filler.

Jun 02, 2019 Epoxy cowl vents to cowling (again) - (0.8 hour) Category: Cowling

Mixed West System epoxy with 406 colloidal silica filler, bonding the inlet scoop to the previous cowling cut-out. Used previous rivet holes to align and secure scoop to cowling.

As mixure thickened, the Clecos were replaced and cleaned in acetone.

Jun 02, 2019 Install turbo oil gasket - (0.4 hour) Category: Engine

Installed standard turbo oil port with AN6 fitting to turbocharger body with a purchased Garrett T-25 gasket. Purchased this: https://www.ebay.com/itm/Turbo-Oil-Return-Drain-Gasket-Set-For-Garrett-T25-T28-44mm-hole-to-hole-5PACK/292347309985?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649

May 31, 2019 Fair Fiberglass Cowling Inlets - (1.5 hours) Category: Cowling

Lightly sanded fiberglass cowling. Mixed West System slow cure epoxy with plenty of 410 Microlight fairing filler to fair the area behind the cowling inlets, as suggested during the Sonexflight FWF Seminar by Jeff Shultz.
As the compound hardend, material was removed near the locations where the bottom cowl flange would fit. Testing indicates the 410 fairing filler will be easy to sand.

May 26, 2019 Drill holes For Switches - (0.8 hour) Category: Instrument Panel

Drilled #30 pilot holes through instrument panel cover (1/8") and frame (0.025"). Up-drilled frame holes to 15/32" and added #30 for locking washer pins.

May 25, 2019 Switch Layout - (0.8 hour) Category: Instrument Panel

Layout switch locations on port-side instrument panel. Layout CAN bus wiring from iBox to ECB.

May 17, 2019 EFIS wiring - (1.5 hours) Category: Avionics

Set grounding tabs in sub-panel, riveting two back-to-back. Gathered and organized power wiring to/from ECB and breaker panels.

May 13, 2019 Instrument Air Lines - (1.5 hours) Category: Instrument Panel

Located, drilled, deburred holes for grommets in the instrument subpanel. Holes to pass pitot, static, AOA, and TE lines to iBox. Set location for accessory 4-port fuse box next to 6-port on side of subpanel.

May 07, 2019 Sort & label wiring harnesses - (1.2 hours) Category: Avionics

1/2" Dymo heat-shrink label for EFIS power harness. Assemble sub-panel to front panel frame.

May 04, 2019 CHT & oil pressure wiring - (0.5 hour) Category: Engine

Add VDO oil pressure sensor wire. Drilled exit hole for snap bushing to pass CHT and oil pressure wiring.

May 04, 2019 Attach oil cooler baffling - (2.5 hours) Category: Engine

Drill, deburr, rivet oil cooler baffle to port side rear baffle. Added #6 nutplates to attach starboard side rear baffle.

Apr 21, 2019 Oil Cooler Baffling - (3.0 hours) Category: Engine

Used thin cardboard sections to layout templates for baffling around engine oil cooler. Middle section angle cuts to match top deck of engine block. Port and starboard pieces located step from VW engine deck to mounting flange step. Templates aligned together and traced on to a sheet of 0.025" 6061-T6.
Drilled relief holes for inside corner cuts. Used shears to cutout engine contour in Al sheet. Sanded and fiiled contour on bottom of baffle section across the oil cooler. Once the seal across the bottom didn't show an air gap, the starboard side was bent 90 degrees and the bottom and vertical step were filed to provide a similar light-tight seal.
Riveted a short angle to the starboard rear corner. Will set two #6 nutplates to engage the rear baffle.

Apr 21, 2019 Cutout cooling air doorway in baffle - (1.3 hours) Category: Engine

Layout for oil cooler air flow opening. Drilled corner holes and one in center for sheetmetal nibbler. Used nibble to remove the middle of the ductwork. Filed to match layout marks.

Apr 19, 2019 Punch Out for Radio Control - (1.5 hours) Category: Instrument Panel

Prepared patch of 0.025" material to cover previously punched instrument hole. Aligned 1/8" front panel and patch, drilled pilot hole. Drilled and deburred hole for 1/8" rivets for attaching patch to rear panel. Removed front panel, updrilled pilot to 5/8" with step drill. Used panel punch to put hole in front and back panels. Drilled additional rivet holes, placed to not interfere with location of switch holes. Scraped and filed hole interior on rear panel to fit radio remote.

Apr 19, 2019 System Test Failure - (1.4 hours)

Category: Avionics

Reinstalled the MGL iEFIS panel, connected LAN and power cables. The setup had been used for several hours earlier in the week to update firmware on iEFIS and iBox. A thick brown, acrid smoke came from the iBox, with the iEFIS showing sensor alarms. Shut the system down immediately, but too late to prevent damage.
On inspection, one of the large diodes on the iBox board was damaged, which in term damaged the circuit board traces and nearby IC. Although I was unclear as to what and why the failure occurred, the iBox was returned to MGL for examination. MGL was unable to repair the unit. The failure mode suggested was that the DB-9 carrying the power was improperly attached to the DB-9 CAN bus port.

MGL_iBox-1.jpg

MGL_iBox-1.png

MGL_iBox-2.jpg

MGL_iBox-2.png

iBox-1.jpg

iBox-2.jpg

Apr 16, 2019 Punch Out Hole for Airspeed Indicator - (1.8 hours) Category: Instrument Panel

Drilled pilot hole through 1/8" panel front and 0.025" rear. Up-drilled to 5/8" with step bit to locate hole cutter. Used a deburring tool to remove excess material from inside. Test fit Falcon airspeed indicator.
Hole cutter: https://www.aircraftspruce.com/catalog/inpages/ats123chole.php

Apr 14, 2019 Wiring ID and Power Conditioner Test - (1.3 hours) Category: Instrument Panel

Organize MGL EFIS/iBox/ECB wiring harnesses. Marked cable bundles with heat-shrink labels. Applied 15 to 11 volts to the power conditioner input from a variable power supply while measuring output voltage and observing iEFIS.

Apr 13, 2019 Turbo Radiator Mounting Bracket - (1.5 hours) Category: Engine

Fabricated a short mounting bracket to brace the turbocharger radiator against an engine mount tube. Incorrectly fabricated the first bracket with two nutplates. Second attempt used a single #10 nutplate for mounting to a cushion clamp, with the #8 nutplate attached to the radiator plenum securing it to the bracket.
The arrangement provides a three-point mount for the radiator.
Cut several pieces of rubber tubing to connect the pump and radiator.

Apr 13, 2019 Sort Through Avionics Wiring - (0.8 hour) Category: Instrument Panel

Upsized small stiffener bracket over side panel, drilling, deburring holes for 1/8" rivets. Removed EFIS, disassembled subpanel and riveted stiffener to rivet stiffener.
Reassembled panel, putting protective film on the MGL EFIS then covered the display with a piece of cardboard to protect from scratching. Sorted through power cable assembly and CAN bus harnesses to check fit and locate possible terminal block mounting. Printed a heat-shrink label for EFIS power wire bundle.

Apr 11, 2019 Install Trim Control - (1.1 hours)

Category: Instrument Panel

Layout and drill panel for trim control mount. Layout per location on drawing XNB-C07. Updated the working drawing in XPanel to reflect trim control mount, location of analog airspeed and communication instruments. Card compass and future variometer locations as well as switch position locations have been reorganized once again. Designed to locate switches that would be used in flight within easy reach of the pilot's left hand, while other switches mounted to the right side of EFIS. Considering punching holes now for instruments that maybe added or located on the panel in the future - card compass and variometer. Would use blanking plates to fill the holes. The thought is to powder coat the panel, with later instruments reducing the opportunity to disrupt the powder coat finish.

337.jpeg

338.jpeg

Apr 10, 2019 Install Nutplates for iEFIS Mount - (1.3 hours) Category: Instrument Panel

Marked, drilled, deburred, dimpled, riveted nutplates with solid rivets. Nutplates for mounting MGL Explorer iEFIS with #4 machine screws. Drilled the plastic MGL EFIS panel to pass machine screws.

Apr 06, 2019 Mount Power Conditioner - (1 hour) Category: Instrument Panel

Removed a nutplate that was misaligned, preventing all four mounting screws on the Power conditioner from engaging. Removed one nutplate and reinstalled a floating nutplate. Cleaned machinist bluing (won't use that again) from the panel. Sketched another layout on the panel with blue ultra-fine Sharpie.

Apr 06, 2019 Tighten/replace Hangar Door Nuts Category: Hangar

Replaced nuts on canvas hangers that had vibrated loose with fiber lock nuts.

Apr 04, 2019 Setup Panel Instrument Layout - (1.5 hours) Category: Instrument Panel

Setup instrument panel and sub-panel on workbench, Cleco'd to table top. Removed bluing from right side, reverting to blue Sharpie for layout planning. Bluing experiment left light scratches that will be removed before painting. Planning for switch locations, number, and type. Layout for Falcon airspeed and card compass gauges to the right of iEFIS. Radio control head to the left. Trial fit of Conversations trim assembly and control knob on panel.

Mar 31, 2019 Panel Layout - (1 hour) Category: Instrument Panel

Using machinist's bluing for layout was a mistake. Cleaned bluing from right side of panel and sketched instrument mounting hole location with blue Sharpie.

Mar 30, 2019 Research Dzus quarter turn fasteners for cowling - (1.0 hour) Category: Research

Research sizing, mounting, and adjusting of Dzus fittings for cowling mount. May need some specialized tools for aligning the fasteners. May use screws and nutplates due the installation simplicity.

Mar 30, 2019 Remove Center Flashing Between Cylinders - (0.8 hour) Category: Engine

As demonstrated by Bob Mica at Jeff Schultz' Firewall Forward seminar in Lee's Summit, used a 3/16" drill bit to open up the area on the AeroVee's cylinder head in the central area between cylinders. The starboard head had a small space, however the port side was completely closed off by casting flash. Drilled a series of increasingly larger holes in the area trying to overlap holes, using the side of the bit to 'mill' between holes. Used a medium thickness flat file to smooth sharp area between holes. Drill chuck marred the ends of the cooling fins adjacent to the central space.

Mar 30, 2019 Port rear baffle fitup - (0.8 hour) Category: Engine

Removed the port-side rear baffle. Upsized the engine vent passthrough to 1" for fitting a 5/8" ID grommet. Fit the baffle to 'tuck' the tab into the engine SuperTin as discussed during Jeff Schultz' Firewall Forward seminar in Fall 2018. The backend of the baffle now looks to seal well, and appears to minimize areas of leakage.

Mar 30, 2019 Fit Turbocharger Intake - (0.5 hour) Category: Engine

Have struggled with fitting the 2" 45 deg silicone intake tube to the turboharger for some time. The area next to the starter is a very tight fit, with the starter mount in firm contact with the intake tube. Was able to get the intake distribution assembly to fit by starting with the silicone around the distribution assembly, putting the assembly under the engine mount cross tube, then working the turbocharger end.
George suggested loosening the starter to allow it to clear enough to push the silicone into place. The port-side distribution assembly to intake pipe connecting silicone tube must be pushed out of the way to permit loosening of the starter mounting bolts.
With the starter loose, the hose clamp could also be put into place, providing a vibration wear shield for the silicone tube.

Mar 20, 2019 Nutplates for Radio Remote Mount - (2 hours) Category: Instrument Panel

Opened up instrument mounting hole for a looser fit. Used instrument drill template to layout and drill through-holes for nutplates. Drilled #40 nutplate mounting holes, deburred, and dimpled. Cut and riveted a patch to back panel to cover earlier hole.

Mar 19, 2019 Port Side Baffle 'tuck in' - (1 hour) Category: Engine

Removed port-side rear baffle and reinstalled the baffle by tucking tab into the super-tin next to cylinder fins. No additional trim to the baffle part was required. Oil line bulkhead fitting aligned with hole in baffle. Replaced side baffle on AeroVee.

Mar 10, 2019 Trim Upper Cowling - (0.8 hour) Category: Cowling

Trimmed intake lips on upper cowling with Dremel oscillating saw.

Mar 10, 2019 Locate cowling fasteners - (0.8 hour) Category: Cowling

Layout and drill fastener locations on port side top/bottom cowling.

Mar 09, 2019 Reinforce oil filter mount - (1.5 hours) Category: Engine

Cut a scape section of C-channel to stiffen oil filter and turbo cooling reservoir mounting plate. Aligned and drilled mounting holes for oil filter. Left inlet hose length and routing. Outlet hose length needs shortend.

Removed turbocharger extended sump, using original flat outlet. Replaced 45 elbow with a straight fitting. Adjusted pickup hose mounting clamps.

Jan 12, 2019 Turbocharger Mounting - (1.5 hours) Category: Engine

Working on clearing the conjested area around the turbocharger to intake manifold connection. Looking at two options;
1) Changing the cold-side port to vertical rather than 45 degrees. This option may require a 90 degree silicone adapter.
2) Cutting exhaust to move turbo mounting flange by 0.40 inches (least desirable)

Jan 05, 2019 Turbo Radiator/Plenum - (0.3 hour) Category: Engine

Secured turbocharge radiator to plenum with self-taping sheet metal screws.

Jan 04, 2019 Screen Design - (1.5 hours) Category: Avionics

MGL Avionics G3 iEFIS Explorer screen refinements. Screen 1 modified engine1 and fuel1 sections. Adds 'opposed' RPM & MAP roundels, measured and virtual fuel bars. Removed ladder bar 'noise'. Screen 5 moved look ahead airspace and added look ahead terrain. Screen 8 engine combined two bar segments for measured and virtual fuel quantities. Will adjust EGT and CHT alert and warning levels.

Dec 16, 2018 Mount/Plenum for Turbo Radiator - (3.1 hours) Category: Engine

Bent 0.025 sheet to a 1" angle, cut 2" long. Cutouts for lines, riveted to plenum. Added #8 nutplates to corners for mounts. Added metalized duct tape at corners to seal holes. Mounting plan will use short lengths of angle secured to cushion clamps on engine mount tubing. Mounting location is targeted around lower starboard section of engine mount outboard of the secondary coil position.

Dec 15, 2018 Set Cooling Lines for Turbo - (4.0 hours) Category: Engine

Found the Sonex turbo cooling parts list to be incorrect for several parts. The cooling pump in/out is closer to 5/8"; the electrical terminals to the pump are incorrect in the parts list;
Purchased one foot lengths of 5/8" and 1/2" silicone tubing for turbo cooling lines. The 5/8" fits a Prius pump inlet/outlet. Transition 5/8 to 1/2" tubing with a barbed reducer, then from to a 1/2 x 3/8' barbed reducer to 3/8" which will fit to the surge tank and radiator connections.

Dec 09, 2018 Set Nutplates on Turbo Coolant Catch Can - (0.3 hour) Category: Engine

Set a pair of 1/4" nutplates on the turbocharger cooling circuit catch tank.

Dec 09, 2018 Master Contactor/Fuse Mount - (0.8 hour) Category: Engine

Set #8 nutplates on contactor sub-assembly. Updrilled contactor sub-assembly mount for riveting to battery mounting braket. Countersunk rivet holes to maintain clearance on inside of mount for battery to set flush.

Dec 01, 2018 Waste Gate Actuator Sense Port - (1.0 hour) Category: Engine

Cleaned and opened the turbocharger waste gate sense port with a 1/8" NPT tap to extend the barbed turbo charger pressure port connection away from the crowd of clamps around the turbo inlet. Added a 1/8"NPT x 2" brass nipple and 1/8"NPT x 1/8"NPT elbow. The brass hose barb connction was then moved to the end of the elbow.

Dec 01, 2018 Turbocharger Fitup - (1.0 hour) Category: Engine

The outlet pipe of the stock exhaust from the turbocharger does not clear the engine mount structure. Sonex sent a blank (no exhaust pipe) flange in order to weld an exhaust pipe that would clear the engine mount tubing.
I found that the blank flange thickness would provide just enough spacing to enable the stock flange & pipe to clear the engine mounts.
In fitting the flange stack, one of the holes on the blank flange required drilling oversize to 3/8". Drilled with a cobalt drill bit with Boelube as a HSS bit simply overheated in the stainless.
Stacked the blank turbocharger exhaust flange and exhaust flange with pipe to turbocharger. Used 5/16" x 1.25" exhaust bolts from JEGS. Will likely replace a bolt with a stud in order to hang the stack during assembly.

Dec 01, 2018 Cleanup - (2.00 hours) Category: Hangar

Raked leaves, reorganized and cleaned hangar and equipment.

Nov 13, 2018 Research alternate turbo cooling radiator mount - (0.3 hour) Category: Engine

Looked for alternate locations for mounting the turbocharger bearing cooling radiator. The radiator is used at the end of a flight for 20 to 30 minutes. The factory recommended location on top of the engine compartment seem too prominent a location for the short period of use. An acceptible location for the plenum appears to be the lower starboard side of the motor mount. Three cushion clamps, several small fabricated struts may enable placing the radiator out of the way of other accessories.

Nov 13, 2018 Repair Door Hangars/rent - (7.50 hours) Category: Hangar

Removed bent canvas hangers, replacing with new sections and reenforcing the haner with doubled sections.
Rent+

Nov 10, 2018 SonexFlight Firewall Forward Seminar - (15 hours)

Category: Research

Attended the first 2018 SonexFlight Firewall Forward Installation Seminar in Lee's Summit, MO. Seminar topics included
• Sonex Aircraft FWF Instructions
• Electrical System Design
• Fuel System: Design for simplicity and Reliability
• Engine Cooling Theory: Keep those Heads Cool!
• Fitting the Cowling, and Modifying for Best Efficiency
• Baffling Tips for Success
• Tuning the AeroInjector
• Exhaust System Considerations
• Maintenance and Upkeep
The major goals of the seminar were designed to better understand the instructions provided by Sonex Aircraft, LLC (or lack of!); equip the attendees with techniques to plan reliable electrical and fuel systems; demonstrate proven refinements to cowling and baffles to keep engine temps under control; and to demystify tuning the AeroCarb.
Bob Minka assisted Jeff Schultz by flying his Sonex to the event and showing various construction points.
Cost of seminar was $395, with the balance of the expense capturing travel expenses.

EAA Chapter

Seminar participants

Seminar participants

Nov 03, 2018 Starboard Cylinder Heat Temp Thermocouples - (1 hour) Category: Engine

Blocked starboard intake ports to prevent chips from entering. Drilled #36 holes 9/16" deep for AeroConversion thermocouple mounting hole. Installed thermocouples with supplied self-tapping screws. Marked cylinder number and RDAC input point on thermocouple wire with printed heat shrink tubing.

Nov 03, 2018 Cooling Pump Test - (1.0 hour) Category: Engine

ested the Prius pump that will be used to circulate cooling fluid through the turbocharger after shutdown.
Used a Toyota turn signal connecter obtained here (https://www.amazon.com/Connector-2-way-Toyota-Signal-90980-11162/dp/B01E3C6YS2) to power the pump.
Initial connection to a motocycle battery that had been on a solar trickle charger found that the pump would not turn. Placing the pump in a dog's water bowl proved unsatisfactory, with a surge of water every second or so.
With a voltmeter across the battery, it was determined that a meager 11 volts was supplied to the pump. Placed a charger across the battery for an hour and a half, until an indicated 12 volts on the meter. Second wet test in a plastic container proved a good flow through the pump. Good water-tight connection at the turn signal power fitting.
As a side note, this pump - ordered as suggested from the Sonex part list, requires 5/8" diameter silicone tubing to properly fit the pump ports. The 1/2" tubing specified by Sonex will not fit the inlet ports of this pump.

Nov 03, 2018 Aft oil line clamp - (1.3 hours) Category: Engine

Made a short bracket from scrap 0.060" Al to bolt into existing engine case threaded hole to hold cushion clamp. Put a bend in the clamp to keep oil line from contacting nearby exhaust pipe.

Oct 21, 2018 Remove Turbo, Tap Exhaust Bolt Sockets - (0.5 hour) Category: Engine

Removed turbocharger to run a tap in the five 5/16" x 18 TPI holes that secure the exhaust flange. Removed oil lines, air line, flange bolts, and waste gate beacket. Removal route was down through the starboard side. A little twisting to orient for removal. Planning how to remove the coolant catch can with turbo in place. Tap bound at depth > 1/2" on most holes. Rust/scale/paint cleaned from threaded holes. Applied silver anti-sieze compound to exhaust bolts.

Oct 21, 2018 Oil return line from turbo - (1.5 hours) Category: Engine

Instaled aeroquip straight fitting on AN6 braided hose and connected to 45 degree elbow on turbocharger drain. Measured length to oil pump, cut and installed 90 degree aeroquip fitting.
Secured line to bottom of engine with cushioned clamp, and to motor mount member with double cushion clamps. Adjusted oil line between clamps to free contact with exhaust and engine mount.
Used technique demonstrated by Dick Koeler in an EAA video for holding cushion clamps together.

Oct 20, 2018 Turbo Shroud - (1 hour) Category: Engine

Rolled ACV-T05-44 turbo shield into a cylinder over the edge of a sawhorse. Bent, drilled, and riveted angle attachment to sheld. Moved mounting location 3/8" inboard due to additional turbo outlet flange thickness used to clear motor mount tubes. Updrilled mounting hole to 21/64".

Oct 20, 2018 Secure Oil Lines - (1.5 hours) Category: Engine

Used the techique demonstrated by Dick Koeler in an EAA video (https://video.eaa.org/detail/video/5033854492001/easy-adel-clamp-installation) for attaching Adele clamps.
The method was very effective, enabling easy instalation of cushioned clamps securing braided oil lines to engine mount tubes. Secured clamps with #8 x 3/4# machine screws with torque washer and fiber nut.

Oct 20, 2018 Install Port CHT thermocouples - (0.5 hour)

Category: Engine

Used an extended length #32 drill bit to drill port cylinder heads inboard of spark plugs. Attached spring-loaded drill stop to bit allowing 9/16" depth. Held vacuum near bit to capture chips. Used Sonex Aircraft supplied #6 x 1/2" self-tapping screw to secure thermocouple eyes to cylinder head.

CHT_Install.pdf

Oct 09, 2018 Mount ELT - (2 hours)

Category: Radios

Mounted ELT under the passenger shoulder harness mount.

ELT mounting bracket

Bracket installed

ELT in place

ELT

View through access port

ELT_mount - 6.jpeg

Sep 23, 2018 Plenum for Turbo Cooling Fan - (3.0 hours)

Category: Engine

Remade plenum to the dimensions of the radiator in hand rather than the Sonex plan sheet (duh). Cut a 4-1/8" diameter hole for the fan with a flycutter. Cut the standoffs from the fan enabling a 1/2" recess. Installed nutplates to attache cooling fan with #8 screws.

Turbo_Cooling_System.pdf

Sep 23, 2018 Oil Vapor Vent Line - (0.8 hour) Category: Engine

Cut and bent 5/8" AL tubing for oil vapor vent. No tubing bender large enough, used the round back of a chair as a bending aid. Not optimal but functional.

Sep 22, 2018 Install AN4 oil lines - (3 hours) Category: Engine

Installed solid aluminum AN4 oil line from engine tee fitting to bulkhead fitting secured to hole drilled through baffle and rear engine flange.
Made up braide hoses using the techniques in this video: https://youtu.be/KwmvRWuAwno
Briefly considered the "Koul Tool" suggested in the video, but at $29 ea and a set of three for $79 it seemed a ridiculous price per fitting. Helpful were the video suggestions. Used a cutoff wheel on a die grinder to make square cuts in the braided line clamped between vise jaws identical to those in the video, Clamping the braided lines and fittings during cut and assembly made those stages of the process simple. Must wear safety glasses as there is substantial debris as the braiding is cut.
A convenient small tube of assembly oil from JEGS was also very helpful. The assembly lube is a light mineral oil. The oil providing greater confidence that the braided line isn't pushed out of the socket by the tapered inlet as happened on a previously made dry AN6 fitting. Marked the hose at the socket line and checked for movement after assembly.

Aug 19, 2018 Additional Panel Design - (0.3 hour) Category: Instrument Panel

Modifying design to promote controls and switch operates with the left hand. Eliminating the map box as there is not enough room after mounting devices to the subpanel.

Aug 18, 2018 Turbo/Intake/Starter Fit-up - (3.0 hours) Category: Engine

Cut additional material from the 45 deg silicon adapter to relieve the clearance with the engine flange.The waste gate pressure port is very difficult to install and clamp due to interferance with the intake silicone adapter.
Purchased a 1/8" x 2" tipple to extend the hose barb, however the threading in the turbo did not seem to match.
Tried carving away at some of the rubber tube and using silicone grease but was still unable to get the clamp in place.
The starter motor edge also impinges on the intake manifold adapter. With the turbo loose on its mounts it is almost impossible to fit the silicone adapter in place. I'm guessing some fit problems are due to distortions in the exhaust manifold.

Aug 18, 2018 Turbo Cooling Circuit Plumbing - (1.5 hours) Category: Engine

Using a straight AN6 into an AN6 elbow didn't provide clearance with the firewall. A 45 degrees AN6 fitting was used as illustrated in the AeroVee manual. However, a 30 second operation to screw in the fitting turned into 30+ minutes as there was insufficient clearance when threading the 45 into the turbo body.
Was unable to install an AN6 45 elbow without removing material from the turbo housing. Best tool for removing the majority of material was a Vixen file to take off the edge of the edge of the housing.

Aug 18, 2018 Install oil pressure sensor - (0.8 hour) Category: Engine

Determined that the Sonex supplied 1/8" street tee would not align the flare fitting without another full turn. Afraid of cracking the engine case with the NPT thread, a close nipple and female tee were substituted which allowed the arrangement to tighten and orient fittings without fear of splitting the crankcase.

Aug 17, 2018 Tubocharger Fit - (2.5 hours) Category: Engine

Worked on fitting the turbo charger to the engine compartment. Installed turbo oil sump with high temperature silicon sealant as a gasket material. Allowed silicon to set before attaching long sump. Clearance issues with the waste gate actuator bracket required several attempts at removing and smoothing the bracket angle on a grinder.

Aug 17, 2018 Manifold Alignment - (0.5 hour) Category: Engine

Checking final fitup of intake manifold indicates the 45 degree silicone elbow needs additional trimming to remove contact between the intake collector and the engine acessory plate.

Aug 17, 2018 Install bulkhead to engine case - (0.5 hour)

Category: Engine

Step drilled engine baffle to case mount through #6 baffle mounting hole. Then step drilled 1/4", 3/8, 7/16" and 19/64". Deburred engine case flange and rear cooling baffle plate.

574.jpeg

Engine_oil_lines-6.jpg

Aug 17, 2018 Begin Tank Vent Relief on Glareshield - (0.5 hour) Category: Cockpit

Opened hole to 1", filed and deburred relief notch for fuel tank vent in glareshield.

Aug 12, 2018 Spark plug passthrough - (0.5 hour) Category: Engine

Drilled and filed hole for spark plug wire and jacket to pass through a rubber grommet on the starboard side cooling baffle at the corner.

Aug 04, 2018 Cooling Baffle - (3.0 hours)

Category: Engine

Add #6 nutplates and rivets to secure starboard and front baffle segments.

599.jpeg

Jul 29, 2018 XNB-D04: Rudder Cable Fairings - (1.3 hours) Category: Fuselage

Trimmed flashing from cable fairings on disk and belt sanders. Sanded aft end of cable fairing to match angle, leaving the rear open. Aprehensive about drilling through the bottom longeron for fairing mount attachment.

Jul 29, 2018 XNB-D04: Place Pushrod Fairings - (0.3 hour) Category: Fuselage

Purchased fairings from Sonex as they were not included in the kit purchase. Remove flashing from ABS ruddervator pushrod fairings. Aligned cable and push rod fairings, set in place with painter's tape.

Jul 29, 2018 XNS-P10: Engine Baffle - (1 hour) Category: Firewall Forward

Riveted and installed nutplates on port baffle pieced to set rear, side, and fore sections.

Jul 28, 2018 XNB-C05: Fit Ruddervator Pushrod Fairing - (1.5 hours) Category: Fuselage

Sanded port and starboard ruddervator pushrod fairings. Drilled 1-1/4" hole with a step drill rather than remove the aft end by sanding. Maintain the integrity of the four corners. May remove it later.

Jul 28, 2018 Secure Port Side Baffle - (1.5 hours)

Category: Engine

Drilled and riveted angle to port side baffle. Installed nutplates for two # 6 screws on fore and aft ends.

672.jpeg

Jul 18, 2018 XNB-P14: Prepare Battery Box for Installation - (2.5 hours) Category: Firewall Forward

Cut two 0.080" x 1" x 6" backing plates, laying out three 1/4" mounting holes with nutplates to spread the weight of the battery across the two plates to the firewall. Drilled six matching through holes in the firewall, a bit oversize to allow space for bolt alignment. Holes in the SST firewall were most easily drilled with a step drill. Step drill was also used on the cockpit side to deburr the holes. Test fit mounting plates to firewall to mark and drill locating holes for a pair of flush pulled rivets in each backing plate to secure the backing plate to the firewall. Firewall rivet holes drilled and dimpled. Backing plates riveted to firewall. Test fit battery box. AN4-5A bolts a little longer than required.

Jul 18, 2018 XNB-P14: Install Battery Box - (1.0 hour) Category: Firewall Forward

Purchased a stamped aluminum battery box for an 680 batter. Prepared 1/8" aluminum plates as backing plates, using 3, 1/4" bolts on either side of box to secure it and the battery to the firewall. Firewall rivet holes drilled, deburred, and dimpled for flush rivets. Countersunk and drilled in backing plates for mounting battery box to firewall. Backing plates riveted to firewall. Test fit battery box. AN4-5A bolts are a little longer than required.

Jul 16, 2018 Drainage - (1 hour) Category: Hangar

Dig and install slotted plastic drainage pipe.

Jul 15, 2018 Baffle Support - (1.5 hours) Category: Engine

Installed baffle support to port side of engine from piece of aluminum angle. Angle bolts to engine head and riveted to baffle.

Jul 15, 2018 Additional Work Light Category: Hangar

Added LED work light to rear of hanger over drill press, sander, band saw, grinder.

Jul 09, 2018 Repair Wheelbarrow - (2 hours) Category: Tools

Wheelbarrow required for digging drainage for hangar. Replaced wheelbarrow handle by welding washer on tub bottom, drilling holes in handle for fasteners.

Jul 07, 2018 Pilot Side Seat Pan Nutplates, XNB-F08 - (4.5 hours) Category: Cockpit

Install nutplates for fastening the pilot side seat pan. Seat pan removable to allow installation of remote radios and transponder.

Jul 04, 2018 XNB-T03: Finish Starboard Stabilator Riveting - (3.0 hours) Category: Empennage

Completed the top skin surface of the starboard stabilator.
Completed 95% of lower skin.
Drilled holes for tip nutplates. Countersunk solid rivets for nutplate mount.

Jul 01, 2018 XNB-T02: Set Stabilator Travel - (0.8 hour) Category: Empennage

Used the shoulder harness to hold the stick full rear. Spec asks for 11 degrees of deflection at full up.
Adjusted mixer ends to leave a little over half the threads showing. Adjusted pushrod length at the stabilator to provide at least 11 degrees travel up.

Jul 01, 2018 XNB-T03: Rivet Starboard Stabilator Skin - (2.3 hours) Category: Empennage

Riveting top side of stabilator, many CCP-42 rivets breaking proud of the head.

Jun 30, 2018 XNB-T02: Starboard Stabilator Category: Empennage

Install ruddervator hinge on starboard side stabilator. Initial hinge rivet holes were drilled centering the holes on the hinge rather than locating on center of knuckle as in plans. Second hinge set made from two shorter pieces and aligned correctly.
Stabilator tip cutout at 7/8" about 1/8" too much. Notched leading edge for instrument air port clearance.
Connected ruddervator pushrod with mixer.

Jun 20, 2018 Spar Tunnel, Seat Attachment - (2.5 hours) Category: Cockpit

Alternating pattern of rivets and #8 screw along width of spar tunnel. Rivets secure tunnel edge while the tapped holes provide for removable seat pans. Plan to locate remote radios and transponder under seats.
May need nutplates installed along seat rear at 1" angle and fiber nuts inside spar tunnel in the front.

Jun 20, 2018 Seat back Install - (1.5 hours) Category: Cockpit

Used nibbling tool to rough in cutouts for control cables and wiring. Drilled and riveted top seat back hinge. Set bottom hinge rivet holes and Cleco'd in place. Could have used another 1/8" down from top.

Jun 16, 2018 Determine Seat Pan Attachment - (1.5 hours) Category: Cockpit

Determined that the seat removal can be accomplished by using #8 screws with a tapped hole on the spar tunnel and rear spar angles. Nutplates will be used for seat support.
Using CCC-44 flush rivets in a 2-1-2 alternating pattern, with two rivets, a screw for securing the forward seat pan, and two flush rivets.
The rear seat pan will us all #8 tapped holes to secure the seat.

Jun 10, 2018 Cut Seat Pan - (2 hours) Category: Cockpit

Cut seat pan into port and starboard sections. Trim port side to fit opening. Plan for three removable seat sections, port and starboard to conseal radios and transponder.
A center section will need to be made to replace the cutout.

Jun 10, 2018 Mark Dip Stick - (0.5 hour)

Category: Engine

Paul Thonnard, whom I had met at the Sonex Flight firewall-forward seminar in Lee's Crossing, MO, spent the evening in Charleston. Paul visited the hangar and we moved the fuselage onto the relatively level runway, and added two quarts of oil. Per the AeroVee instruction, set the dipstick low-level mark with the edge of a triangular file.
Paul worked on removing flaking ceramic engine paint from the AeroVee's magnesium block.

Paul T

Level runway

Jun 08, 2018 Fit Fuse Panel - (2.5 hours) Category: Instrument Panel

Fit support panel that will hold fuse blocks between instrument panel and sub-panel. Fuse panel will screw into or connect with piano hinge to glare shield. A piece of angle riveted to the instrument panel will support the port side of the sub-panel.

Jun 03, 2018 XNB-T04: Install Tip XNB-T04-04 - (1.3 hours) Category: Empennage

Layout and drilled trailing nutplates with a diagonal orientation. May need to remove and reinforce one or both due to outside rivet proximity to edge.
Layout and drill rivet holes for stabilator tip XNB-T04-04. Cleco'd tip to fiberglass initially in two places on top. Moved tip trailing edge to minimize gap at trailing edge, then updrilled adjacent hole to secure alignment.

Jun 03, 2018 XNB-T04: Align and Rivet Tip - (0.5 hour) Category: Empennage

Deburr and rivet with CPP-42. One rivet created a small crack in the fiberglass.

Jun 03, 2018 Sub-panel Support - (1 hour) Category: Instrument Panel

Cut out 8 x 8.5" panel, bending 1/2" tabs on the 8" dimension to be used as a support between the instrument panel and sub panel. Will also provide real estate for mounting of fuse blocks. Needed additional trimming around panel angle bracket mounts to clear nut-plates.

Jun 02, 2018 XNB-T03: Port Stabilator Tip Alignment - (1.3 hours) Category: Empennage

Taped a length of aluminum angle to the leading edge of the stabilator to help align the leading edge and stabilator tip seam. Filed a cutout in the stabilator leading edge to clear the instrument air pickup port.
The cutout for the ruddervator was a little too wide due to neglecting to ensure the instrument air port was clear of the tip.

Jun 02, 2018 XNB-T03: Port Stabilator Nutplates - (2.0 hours) Category: Empennage

Upsized alignment holes in stabilator, dimpled #30 holes with 5/16' dimple die. Mounted 8 of 10 nutplates to the fiberglass tip with recessed solid rivets. The last 2 nutplates didn't allow for the mounting ear on nutplate enough room to mount parallel to edge. Plans indicate diagonal rivet mounting.

Jun 01, 2018 XNB-T04: Port Side Ruddervator Cutout - (2.5 hours) Category: Empennage

Cut fiberglass stabilator tip cutout with a wood blade on a battery powered oscillating saw. Started cutout with a 3/4" relief, with room for sanding to 7/8" relief.

May 28, 2018 Cooling Baffle Fitup - (3.5 hours)

Category: Engine

Align cooling baffle parts, file and trim pieces to fit. Left corner required a good bit of trimming around exhaust.

872.jpeg

873.jpeg

May 13, 2018 Initial Fence Baffle System Installation - (4.5 hours)

Category: Engine

Installation and fit-up of the AeroVee cooling baffle system, began with rear left and right fence progressing around right side. Opening for oil return pass through needs increased opening to not interfere with fence positioning. Will need some sort of grommet to seal tubing to fence.
Research revealed that the lower sheet metal supplied by Sonex is not required for a top mounted cooler.

858.jpeg

869.jpeg

870.jpeg

873.jpeg

May 13, 2018 Cut Replacement Left side - (0.4 hour) Category: Instrument Panel

Cut and filed replacement left side 0.080" material. Replacement part is to drop the airspeed hole by 1/4" and eliminate the hole drilled for mounting at that location.

May 12, 2018 Secondary Ignition Trigger Orientation - (1 hour)

Category: Engine

AeroVee pg35. When swinging the propeller by hand, it was found that the flywheel trigger contacted the starter housing's unmachined face which was incorrectly fit up with the solenoid outboard due to the stator plate incorrectly clocked to one position CCW. The stator plate interference with the starter solenoid was the cause of the incorrectly installed starter.
The starter was unbolted from the frame and the starter face with a machined clearance was on the outboard side. This led to discovery of the incorrectly clocked stator plate.
The stator plate was unbolted and clocked to the correct position.
The ACV-Z01-12 screws were left loose waiting for Loctite 242.
Starter awaiting reinstallation.

Ignition_trigger-1.jpg

Ignition_trigger-2.jpg

May 12, 2018 Install Seat Belt and Inertial Real - (3.5 hours) Category: Cockpit

Attached Corbeu inertial reels ( pilot red, passenger yellow) using bushing and AN5 bolts. Inboard seatbelt attachment needs to be threaded through seatpan and then bolted. Appears to not be possible to maintain seatbelt access with riveted seat pan.
Testing operation indicates additional knowledge for adjusting Corbeau inertial reals.

May 08, 2018 Sub-panel Braces - (0.5 hour) Category: Instrument Panel

Cut two braces for spacing the sub-panel and panel bottoms from scrap ribs. Trimmed material from ends to leave 5" in center for spacing. Can attach ends to bottom of panel and sub-panel with screws or rivets. Will use angles and uncut U sections rather than trimmed ribs.

May 08, 2018 Countersink and Airspeed Cutout - (3 hours) Category: Instrument Panel

Drilled oversize mounting holes and countersunk 0.080" panel for bugle head mounting screws. Layout of airspeed indicator. Thought the airspeed housing would clear mounting nut-plate but too close by 1/8". Had to remove nut-plate. Used 3-1/8" flanging tool to cut mounting hole for instrument. Face of airspeed indicator was very tight against 0.080" panel, required filing with half-round to provide clearance. Squared case of AI with bottom of panel and drilled instrument mounting holes.

May 07, 2018 Panel Attachment - (3.5 hours) Category: Instrument Panel

Layout and drilled locating holes through 0.032" and 0.080" panel sections to locate nut-plates. Cleco'd panel sections, then updrilled screw holes to 3/16". Located nut-plates on 0.032" panel, Countersunk nut-plate mounting holes with C-frame, deburred and used solid rivets to mount nut-plates.

Apr 29, 2018 Cut Port side Panel - (0.5 hour) Category: Instrument Panel

Cutout the shorter left side of instrument panel from 0.080" 6061-T6. Shaped the panel close to marked tracing line with sander.

Apr 29, 2018 Set Drain Line - (.8 hour) Category: Hangar

Dug a shallow trench for placement of flexible plastic drain. Set drain pipe. Anchored ends with dirt, middle with steel walkway.

Apr 28, 2018 Installation of Starboard Fresh Air Vent - (1 hour) Category: Cockpit

Starboard side took a lot less time than port. Used the HB air nibbler to carve much closer to the outline, much less work with a file.
The vents will need to be removed before installing the glare screen.

Apr 28, 2018 Layout and Install Subpanel Nutplates - (2 hours) Category: Instrument Panel

Layout sub-panel for mounting of MGL iBox, ECB, and Powerwerks. Layout, drilled, deburred, dimpled, mount angle for nut-plates for sub-panel mounting to glare shield.

Apr 28, 2018 Placed drainage pipe - (.8 hour) Category: Hangar

Dug a shallow drainage ditch to place plastic drain pipe.

Apr 27, 2018 Cockpit Vent - (0.6 hour) Category: Cockpit

Located the port-side Peter Anson Engineering cockpit fresh air vent to clear the spoiler control handle. Made a template by laminating Peter's dimensional drawing to a piece of foam board and cutting out the NACA outline.
Best location follows the advise on the Sonex builders board recommending as 'high and far forward as possible'.
Anson Engineering vents: http://www.ansoneng.com/sample-page/products-summary/fresh_air_intake/

Apr 27, 2018 Install Port side Fresh Air Vent - (3 hours)

Category: Cockpit

Drilled initial forward mounting hole from inside the cockpit. Clamped template to hole, using template to drill remaining #40 holes.
Up-drilled to 1/8", deburred, used simple dimple tool to dimple skin.
Drilled #40 holes at inside corner locations. Drilled large hole in center trying several air tools to cut away material. Nibbler provided te best results.
File work, sanding and Scotch-brite finished NACA cutout.

Cockpit_vent-1.jpg

Cockpit_vent_layout.jpg

Apr 21, 2018 Oil Return Line - (1 hour)

Category: Engine

Cut and installed oil AN6 flared aluminum return line.

Engine_oil_lines-1.jpg

Engine_oil_lines-2.jpg

Apr 21, 2018 Locate Hydraulic Parking Brake Valve - (0.8 hour) Category: Cockpit

Looked for possible MATCO hydraulic parking brake (AS p/n 06-17200) , best candidate looks to replace the factory location for the master cylinder.
Bolt length is close to rubbing against fuselage skin
MATCO valve: http://www.aircraftspruce.com/catalog/lgpages/matcoPBVALVE.php?clickkey=7491.

Apr 18, 2018 Clear Drainage Category: Hangar

Removed pea gravel from drainage pipe in the front of the hangar, Replaced gravel with large river rock. Heavy rain later in the day didn't have any runoff into and through the hangar.

Apr 15, 2018 Rivet Starboard Y and Stabilator - (0.8 hour) Category: Empennage

Riveted Y fitting to starboard side stabilator. Used mirror to verify rivet placement through inboard rib.

Apr 15, 2018 Close Port Stabilator Skin - (2.5 hours) Category: Empennage

Riveted port side stabilator skin, hinge, triangular insert. Triangular skin required material to be removed from the inboard side. Excess material prrevented ability to line up holes on trailing edge.
Installed ruddervator and set 15 degrees at mid ruddervator.

Apr 15, 2018 Sand Cowling Vent Shape - (0.3 hour) Category: Cowling

Removed and cleaned Clecos from cowling vent scoops. Sanded edges to remove high spots and to provide a smooth transition.

Apr 14, 2018 Rivet Port Y to Stabilator - (1.3 hours)

Category: Empennage

Used 1/8" drill to clean paint from rivet holes. Used CPP-44 for outboard (single Y) and CP-48 for inboard (double Y) rivets. None broke proud of head, though many needed two strokes to pull completely.
Was unable to properly locate bottom in board rib rivet. Will need to drill hole though Y to rib tab and rivet.

Xenos_Emp_Y - 1.jpeg

Xenos_Emp_Y - 2.jpeg

Xenos_Emp_Y - 3.jpeg

Xenos_Emp_Y - 4.jpeg

Xenos_Emp_Y - 5.jpeg

Xenos_Emp_Y - 6.jpeg

Apr 14, 2018 XNB-T01: Install Port Ruddervator - (1.3 hours) Category: Empennage

Ran length of 16 gauge through vinyl 'conduit' to stabilator tip for video camera. Riveted bottom skin trailing edge to triangular insert.
Cleco'd ruddervator hinge to stabilator. Attached stabilator. Installed bushing to adapt AN3 bolt in port pushrod

Apr 14, 2018 Attach Cowling Vents (1st time) - (1 hour) Category: Cowling

Smoothed and finished vent cutouts. Moved the attachment points 1/8" forward, redrilled for Cleco attachment.
Used JB Weld epoxy on scuffed fiberglass vent to attach to interior of cowling. Clamped in place with Clecos. Cleaned excess epoxy with acetone.

Apr 14, 2018 Connect Port Ruddervator Pushrod - (0.6 hour) Category: Controls

Pressed bushing into rod end. Fit pushrod to mixer and stabilator. Undable to set control deflections due to digital protractor needing battery. Verified control movement. Could use some metal removal from bottom of fuselage passthrough.

Apr 08, 2018 Sand and Attach Vent Scoop - (0.5 hour)

Category: Cowling

Sanded starboard cutout straight and smooth with oscillating tool.
Fit side vent scoops to cowling with 1/8" holes and Clecos.

1043.jpeg

Apr 08, 2018 Fit port side scoops - (0.5 hour)

Category: Cowling

Sanded port side cutout and fit scoop to hole.

1037.jpeg

1038.jpeg

1039.jpeg

1040.jpeg

Apr 08, 2018 Change Vent Location Cutout, XNB-P13 - (0.6 hour)

Category: Cowling

Had a difficult time understanding where the reference datum was located until noticing a half cutout for cowling intake in an alternate view on plan sheet XNB-P13, detail P. Determined the drawing reference line uses the top of the vent to the bottom of the cowling lip distance to be 6-1/2". Rear edge of vent located 2" from the cowling/fuselage seam.
Drilled an 1-1/4" hole for the foreward top vent and 1/8" for all others. Used an oscillating tool with wood saw to cut fiberglass.

1062.jpeg

1067.jpeg

Apr 08, 2018 Installed trim actuator, XNB-C07 - (1.7 hours) Category: Controls

Apr 08, 2018 Check Quick-release pins, XNB-C07 - (0.3 hour) Category: Controls

Checked button head clearace with control movements.

Apr 07, 2018 Initial Vent Layout, XNB-13 - (0.1 hour) Category: Cowling

Initial layout of cowling vent centered in lower cowling. Doesn't quite look to be in the correct location. Need additional research to determine correct position.

Apr 07, 2018 Prep for Cowling Vent Opening - (0.8 hour) Category: Cowling

Trimed template to fit cowling vent opening. Aligned opposite vent on outside of cowling, 6-1/2" from bottom of fuselage to FG vent bottom and 2" from cowling seam to FG vent edge. Fit template into vent. Removed FG vent and traced template onto cowling.

Apr 07, 2018 Cut Quick-release button head, XNB-C01 - (0.4 hour) Category: Controls

The initial head diameter was not trimmed enough on the lathe, resulting in interferance with the control to idler pushrod in some orientations. Reduced the diameter of the quick release pin heads to just over the plan's dimension of 0.53".

Apr 06, 2018 Cowlng Vent Layout - (1 hour)

Category: Cowling

Copied and scaled up vent detail P in drawing XNB-P11. Mounted the paper copy to a foam board for a cutout template. Clamped a straight end parallel to the fuselage as a guide.It was difficult to location the break in the cowling in drawing XNB-P11.
When set against fiberglass vent, bottom angle didn't fit correctly. Trimmed foam board template to better match fiberglass vent opening.

Cowling_vent-3.jpg

Cowling_vent-4.jpg

Cowling_vent-5.jpg

Apr 06, 2018 Horizontal Trim 'Down' Spring Installation - (0.6 hour) Category: Controls

Located and drilled hole for down spring. Attached spring and spring clip. Adjusted spring location to be snug in down control stick position.

Apr 06, 2018 Aileron Quick Release Pins, XNB-C01 detail N - (1.5 hours) Category: Controls

Turned bottom of pin body to fit the pocket in SNB-04-08 control horn. The added 1/8" allows ball to extend through the horn and lock.
Turned the button head, but not enough to completely clear contact with SNB-C03-04 stick to idler pushrod.

Mar 30, 2018 Replace Canvas Door Bolts - (0.5 hour) Category: Hangar

High winds vibrated loose several nuts holding the canvas door to the door hanger. Found bolts on ground, reinstalled with fiber lock nuts.

Mar 25, 2018 Bottom Cowling Attach Hinge Rework, XNB-P13 - (1.5 hours) Category: Cowling

Rework of prior cowling hinge placement.
Fit and marked hinge half on cowl side with cowling anchored to prop hub fixture. Marked approximately 1/8" from center of hinge knuckle and 1/8" closer to knuckle edge. Drilled with #40, Cleco'd and removed cowling assembly for updrilling with #40, deburred. Used alternating soft solid rivets for 1/2 the hinge holes and pulled CPP-44 rivets for the other half of the hinge attchement holes.
Cowling fit is much improved over previous effort.

Mar 25, 2018 Pilot Seat Belt, XNB-F04 - (1.4 hours) Category: Cockpit

Updrilled shoulder harness attach point to 7/16" to fit inertial reel.
Drilled 7/16" hole in seat support to fit 5/16" reamer for opening seat belt attach points.
Ordered 7/16" OD x 5/16" ID stock to make bushings for seat belt holes.

Mar 18, 2018 Removed bottom hinge - (2.5 hours) Category: Cowling

Drilled out rivets to remove lower hinge, cowling side. Due to not securing the lower cowl to the prop hub fixture while laying out the hinge, the lower cowl was shifted 1/8 to 1/4" binding the hinge and moving the prop hub center.
Drilling out rivets in fiberglass can be difficult, with heat building quickly from the drill, loosening the rivet fit and spinning the head. Used a Dremel cutoff wheel to cut the backs of the rivets. Held the rivets with pliers while drilling out the heads. Several ways to remove rivets.

Mar 18, 2018 Turbocharger Mount - (1.3 hours)

Category: Engine

Filed and smoothed turbocharger flange support bracket edges with Scotchbrite wheel. Turbo flange hole was undersized, opened to 3/8" with drill. Secured waste gate actuator to bracket. Loosely bolted waste gate actuator mount, support bracket to exhaust flange using supplied intake gasket.
Am unable to fit the lower exhaust pipe, as there is no clearance between its path and the engine mount struts.

1158.jpeg

1163.jpeg

1167.jpeg

1169.jpeg

1206.jpeg

Turbo-1.jpg

Turbo-2.jpg

Mar 16, 2018 Repair Torn Grommets - (1 hour)

Category: Hangar

The lower two canvas door grommets on northern end tore through. Used two pieces of angle flashing, bent in half, drilling #40 holes for two rows of rivets. Held the flashing on the edge of the canvas while drilling #30 holes through canvas. Deburred front and back, cleco'd together and riveted with 1/8" Harbor Freight rivets.

Drilled 1/8" locating hole for lag screws, updrilled with step drill.

402.jpeg

403.jpeg

404.jpeg

Mar 04, 2018 Bottom Attachment Hinge II - (2.5 hours) Category: Cowling

Aligned and drilled foreward hinge half for rivets. Riveted hinge. When installing cowling, aligned and installed left and right vertical hinge pins then the bottomm Alignment very tight along the length. Fit resulted in a 1/8" movement at prop hub.
Will remove one side of the bottom hinge rivets, re-align and rivet with cowl held by hub alignment block.

Mar 04, 2018 Drill & Tap Oil Return - (0.6 hour)

Category: Engine

Drilled a series of increasing holes to 7/16" dia for 1/4" NPT tap into the magnesium engine block. Stuffed a rag in the filler port and held a vacuum nozzle on bit/tap to prevent chips from falling into engine. Hole located 1-1/2" below fill fitting. Tap was very easy, used a 1/2" socket to drive the end of the tap. Attached NPT to AN-6 flare, 90 degree elbow.

1150.jpeg

1151.jpeg

1152.jpeg

1153.jpeg

1154.jpeg

1155.jpeg

Engine_oil_lines-1.jpg

Mar 04, 2018 Check Upper Turbo Exhaust - (0.5 hour)

Category: Engine

Checking the alignment of the upper turbocharger exhaust revealed a problem in clearing the engine mount structure. With the exhaust manifold in place, fit the turbocharger with inlet gasket, flange brace, and waste gate actuator. Then fit upper exhaust without graphite gasket.
Hung a plumb bob to check inboard wall clearance. Found a half pipe diameter interference with the engine mount. Sent finding to the factory to determine disposition.
Also appears that the lower spring attachment hoops are located where the springs would contact the framing.

1159.jpeg

1161.jpeg

Turbo_exhaust-2.jpg

Mar 03, 2018 Bottom Attachment Hinge - (2.3 hours)

Category: Cowling

Light trimming of gear leg openinig to remove interference for level bottom edge. Pilot drill #40 on hinge halves. Mark 3/16" from firewall bottom edge. Removed bottom rivet from vertical stiffener to clear interference with hinge. Drilled (#40) and Cleco'd firewall side hinge. Updrilled (#30) and deburred hinge and interior firewall burrs. Rivet (CPP-42) hinge to firewall.

1131.jpeg

Cowling-19.jpg

Cowling-21.jpg

Mar 03, 2018 Mount Exhaust Manifold - (2.5 hours) Category: Engine

Mounting exhaust manifold to Aerovee with exhaust flange gaskets. Drilled flange keyholes to round the straight section of 'keyhole' to provide thread clearance for square bolt alignment.
Much pulling and pushing of exhaust tubes to align and install bolts. Technique for final flange (#1 cylinder in this case) was to pull flange into position with opposite flange bolt in place. Pull the exhaust pipe while tightening opposite flange bolt. Last flange bolt could then be aligned and tightened.
Flange bolt bottomed before bolt head engaged flange facing on cylinder #1. Used washer for thread take up. May try running a tap into the hole.

Feb 25, 2018 Cowling Installation, XNB-P12 - (4.3 hours) Category: Cowling

Continued trimming fiberglass cowling to accomodate landing gear. With a new bottom cowl, it may have created a closer fit had the initial holes been drilled an inich or so inboard,
Riveted port and starboard vertical hinges. Fiberglass trimmed around air inlet, Mismatch of 3/8" on cowl front.

Feb 24, 2018 Trim Cowling - (1.3 hours)

Category: Cowling

Fit alignment spacer to prop hub. Initial trim using 1-1/4" dia holes within a diameter of the aft edge for landing gear clearance were not large or deep enough to accomodate engine mount. A 2" hole partially overlapping the first holes was a deep enough cut to accommodate landing gear legs, but required additional trim to the inboard side with an angle grinder with a flap disc.

1200.jpeg

Cowling-10.jpg

Feb 24, 2018 Trim and Trial fit of Top Cowling, XNB-P11 - (0.5 hour) Category: Cowling

With bottom cowling held by hinge attach points, rough trim of top cowling. Set top cowling in place to determine additional trimming to get a close fit between halves.

Feb 24, 2018 Cleco Hinges to Cowling - (1.8 hours)

Category: Cowling

Used drilled aluminum ruler to drill #40 holes in hinge. Aligned with firewall hinge with forward end of cowling pined to the prop space with partial depth drywall scews. Easy to chip clearcoat with too much pressure from drywall screws. Marked inside of cowling at hinge rivet locations. Drilled and Cleco'd vertical hinges to cowling. Trimmed air and prop openings in top and bottom cowling pieces. Fit to firewall hinge.

Cowling-13.jpg

Feb 24, 2018 Divert Rain Water from Interior - (0.8 hour) Category: Hangar

Spent some time diverting water flow through the hangar to an outside wall.

Feb 23, 2018 Alignment, XNB-P11 - (3 hours)

Category: Cowling

Fit MDF alignment spacer to prop hub. Cut and trimmed cowling face to accommodate prop hub. Measured 1-1/2" clearance needed around gear legs.

1204.jpeg

1205.jpeg

1214.jpeg

1216.jpeg

Feb 11, 2018 Test Fit Cowling Intake & Exhaust, XNB-P10 - (0.8 hour)

Category: Cowling

Test fit lower cowling in preparation for marking and trim for landing gear legs. Fit turbocharger waste gate actuator bracket, intake manifold, Aeroinjector, and turbo exhaust manifold. All parts are loosely assembled without gaskets.

1202.jpeg

1203.jpeg

Feb 03, 2018 Engine Mounting, XNB-P10 - (2.2 hours) Category: Engine

Used 1/4" reamer to clear mounting bolt holes. Placed rear engine mount rubbers. Up drilled the Aerovee lifting hole in magnesium web in case to accommodate swivel shackle pin. Secured HF 500# rated chain hoist to ceiling beam. Lifted engine and maneuvered fuselage closer to engine. Engine pitches forward when hoisted from the single point, used roller stand to help square the Aerovee mounts. Sprayed door and lock lubricant (wet/dry TFE lube) on rubber mounts to help move them into position when securing with AN4-35 bolts.
Bolt threads bottomed when tightening nut, will replace with AN4-34.

Jan 20, 2018 Drill Landing Gear Legs at Axle, XNB-L01 - (1 hour) Category: Cockpit

Setup landing gear legs on drill press with leveling stand supporting the far end. Near end clamped in vise. Using drill marks set with axles assemblies on air-frame, drilled half way through diameter with a 1/8" HSS-Co bit. Took time to not heat the drill bit, using Boelube wax as a cutting oil. Turned leg to mark on reverse side to complete through hole. Both leg holes broke through from reverse hole near the center, resulting in centered 1/8" pilot hole through gear legs.

Jan 12, 2018 Accumulated Design Time - (12 hours) Category: Instrument Panel

Accumulated 12 hours design time does not accurately reflect design and modifications. Using XPanel 5000 for general layout and Front Panel Designer for specific, to scale panel. Intention is to use Front Panel Express to cut panel in 2.5 mm thick material. Will cutout sections of 0.035" Sonex-supplied panel and add nut-plates to attach 0.09" front Panel Express panel.

Dec 29, 2017 Make Trim Spring Holder, XNB-C07 - (0.9 hour) Category: Controls

Dec 28, 2017 Fuel Tank Pressure Test - (0.5 hour)

Category: Fuel System

Used the technique described in the Sonex Oops Fitting installation guide.

FuelTankPressureTest_1 - 11.jpeg

FuelTankPressureTest_1 - 2.jpeg

Transfer pump pressurizes tank

FuelTankPressureTest_1 - 6.jpeg

Glove attached with silicone tape

Oops_Fittings.pdf

Dec 17, 2017 Enlarge rudder cable pass-through - (1.3 hours) Category: Fuselage

Opened the holes in the rudder cable pass-through immediately behind the mixer assembly to alleviate cable chafing. Chafing occurred at extreme fore and aft control movements. Opened holes from 3/4 to 7/8".

Dec 17, 2017 XNB-F21: Inspection Cover Nutplates - (2.0 hours) Category: Fuselage

Dimpled fuselage members and installed recessed nut-plates for mixer inspection cover. Installed nut-plates with solid rivets and a squeezer.

Dec 16, 2017 Up-drill Windscreen Skirt, XNB-D01 - (2 hours) Category: Cockpit

Up-drilled windscreen skirt with #30 bit. Broke a bit point in fuselage. Removed several nearby rivets to provide assess to the bit tip. Backed broken tip out with needle nose after removing skirt.
Placed windscreen to observe fit with pre-drilled holes in skirt.

Dec 16, 2017 Test Fit Instrument Panel - (0.6 hour) Category: Instrument Panel

Fit glare shield, cleco'd sub panel. Fit instrument panel to glare shield with a couple screws. Preparing to bend sub panel mount angle to curved section.

Dec 10, 2017 Test Fit Windshield - (2.5 hours) Category: Cockpit

Drilled and cleco'd skirt to fuselage.

Dec 09, 2017 Fit Canopy Skirt, XNB-D01 - (2.5 hours) Category: Cockpit

Marked the firewall contact points with blue marker to ensure visibility though the skirt holes. Fit canopy skirt to fuselage, aligning front cutout and rear to longeron. Matched drilled forward-most 3/8" bolt holes and cleco'd.
Measured 5/8" firewall overhang from plans and carried the dimension around the forward edge of the windshield skirt. Drilled with #40 through SST firewall and cleco'd.

Dec 06, 2017 Drill sub-panel Attach Angle - (0.5 hour) Category: Instrument Panel

Layout and drilling of flat section of attach angle with #40 holes. Will install in aircraft to identify the correct side geometry for the bend between left and right longerons.

Dec 03, 2017 Additional Rudder Pedal Adjustment Sizing - (0.3 hour) Category: Controls

Trimed an additional 1.25 inches from the pedal adjuster.

Dec 03, 2017 Sub-panel Angle Bracket - (0.5 hour) Category: Instrument Panel

Cut 1" angle to size, removed 1/2" from edge, and drilled pilot holes for securing sub-panel with rivets. Test fit using (bending?) pliers to form radius.

Dec 01, 2017 Trim Rudder Pedal Adjuster - (2.0 hours) Category: Controls

Shortened the port side cable adjuster length by 1/2" to pull rudder away from spoiler pulleys. Fit and tested. The port toe brake contacts spoiler pulley attachment. Will need to trim an additional inch or so to bring the pedal and brake travel away from the spoiler pulley assembly.

Dec 01, 2017 Nutplates, Secure Instrument Panel - (1.5 hours) Category: Cockpit

Used solid rivets to attach instrument panel to attach angle at rivets that were loosened during dimpling. Removed several pulled rivets that had become loose, using a small pliers to hold the back end during drilling. Used squeezer to set recessed rivets for countersunk nut plates.
Attached instrument panel to glareshield with #10 countersunk screws.

Nov 29, 2017 Install Nutplates on Instrument Panel - (2.5 hours) Category: Cockpit

Drilled glarescreen holes to 3/16" and dimpled for funnel head screws. Drilled, deburred holes for riveting nutplates to glarescreen attach angle. Riveted several recessed nutplates in place. Found that solid rivets were more reliable in securing nutplates, as sever pulled rivets loosened and had to be removed.

Nov 24, 2017 Paint and Hang Sign - (3.5 hours)

Category: Hangar

Finished painting letters on sign. Mudsuck refers to the name of the stream at the bottom of the hill at WV12. With Perrin and Jeff Robinson, Chase and Tom Gorman, and Brendan Dailey hung the 4'x16' sign on the front of the hangar.

Afterwards we had a bonfire with two bushels of oysters to roast!

Another pan of oysters

Roasting oysters

1518.jpeg

1527.jpeg

1535.jpeg

Hangar panorama

1734.jpeg

Nov 23, 2017 Rivet and Space Sub-panel - (1.5 hours) Category: Instrument Panel

Deburred attachment angle edges to the sub-panel. Drilled, deburred, and riveted attachment angle to sub-panel. Cut hole for mapbox with air nibbler.

Cut test 'rib' from a piece of U-section to set a 9" spacing between panel and sub-panel.

Nov 22, 2017 Layout Hangar Sign - (2 hours) Category: Hangar

Initial layout and painting of lettering on hangar entry sign. Projected "Mudsuck Aircraft Mfg & Slvg" from laptop. Traced outline of lettering with pencil. Began painting of lettering using leftover Kills primer.

Nov 19, 2017 Instrument Sub-panel - (3.5 hours) Category: Instrument Panel

Cut sub-panel face from a sheet of 0.028" sheet by tracing the panel outline. Cut a length of angle to 44" which spans the interior of the glare shield. Trimmed the left and right ends of the sub-panel approximately 1 inch shorter than the panel. Cut one side of the angle to 1/2 in with bandsaw. Used crimping pliers to create radius to match glare shield.

Bent the bottom 'tray' of the sub panel to the same dimensions as the main panel, with tray toward fuel tank. Considering cutting a window in the sub-panel in order to view the fuel tank - particularly with a cameras.

Nov 18, 2017 Kitbashing Van's Mapbox - (1 hour) Category: Instrument Panel

Reminiscent of kit-bashing plastic airplane models, the Van's mapbox kit cut back 1 inch and assembled with solid rivets. Placed fuel tank in position with glare shield and control panel Cleco'd together. Begin planning of sub-panel as a mirror of the control panel. Sub panel to act as attachment for iBox, ECB, 4 port USB power, Once cut and fit to the space, a cutout for the mapbox and supporting angles will secure the passenger side of the panel assembly.

Nov 17, 2017 Bend Mapbox Tabs - (1.5 hours) Category: Instrument Panel

Used a HF sheet metal brake to start a new bend in flattened and shortened Van's mapbox. Brake couldn't bend a 90, but provided a crease sufficient to permit hand bending. Assembled and drilled holds for rivets.

Nov 15, 2017 Modify Mapbox - (1.5 hours) Category: Instrument Panel

With the iEFIS and ECB providing a clean panel, a mapbox in front of the passenger would provide storage for the POI, registration, and paper map. The kit is slightly too long for the area between the fuel cell and panel. Cut an inch from the closed end of a Van's prepunched mapbox kit to allow room for the fuel tank. Cut opening in the kit's included sheet act to as a reinforcement frame for the panel opening.
Van's Mapbox Kit: http://vansaircraft.com/cgi-bin/store.cgi?ident=1510800304-192-393&browse=airframe&product=mbox

Nov 13, 2017 Fit Starboard Seat Throttle Through ABS Trim Cover - (1.2 hours) Category: Controls

Fit an AeroConversions throttle lever inside the right side ( SNB-XXXX ) panel.

Nov 12, 2017 Fit interior ABS panels - (0.8 hour) Category: Cockpit

Removal of flashing and fit up on right side ABS parts.

Nov 12, 2017 Wiring to Tail - (1.3 hours) Category: Instrument Panel

Open holes with step bit and fit plastic snap bushings for wiring. Ran 25' of 20 gauge 4 conductor twisted pair from passenger cockpit to starboard stabilator.

Nov 11, 2017 XNB-G05: Determine Convergence For Toe-in - (2.5 hours)

Category: Research

Determined convergence point in front of aircraft for a toe-in angle of 0.7 degrees. With a 68" wheelbase gives a centerline to inside axle dimension of 34". Tan 0.7 = 34/X, X = 2,783 inches or 232 feet. The prelim calculation indicates that the slight toe in will need additional work to arrange in a 40 foot hangar.
Worked up complimentary methods to set the wheel alignment with axles other than Sonex.

toe-in.jpg

Oct 22, 2017 XNB-F29: Rivet Rudder Stops - (0.8 hour) Category: Fuselage

Countersink and flush riveted rudder stop plates to tail-cone.

Oct 22, 2017 Connect Instrument Air Tubing to Ports - (.3 hour) Category: Avionics

Connected pitot and total energy ports to aluminum air tubing lines. Inspected rear tail-cone section for installation of static port(s) on port and starboard fuselage skins.

Oct 21, 2017 Close Box - (1.0 hour) Category: Fuselage

Updrilled, deburred and riveted the bottom sheet of bulkhead box.
In hind sight, riveting this piece so early in the process was a mistake, and should have been left for later.

Oct 21, 2017 Install Instrument Air Tubing - (1.3 hours) Category: Avionics

Tubing runs for pitot, total energy, and static lines from probes in stabilators to instruments. Straightened three 10 foot lengths of 3/16" OD aluminum tubing from coil by using the method in this YouTube video. Put tubes inside a length of PVC conduit to prevent bending while feeding tubing through grommets in bulkhead web. Forward through holes in bulkhead web drilled with closer spacing than plans to accommodate prep and riveting of box.
YouTube video: https://www.youtube.com/watch?v=E-wbErheI14

Oct 20, 2017 Panel Layout Modifications - (1.5 hours) Category: Instrument Panel

Additional design modifications in XPanel 5000 and front panel face cutouts and possible ignition panel on 3 mm red anodized aluminum in Front Panel Designer. Moving elements around to provide better left hand panel, switch, and knob access to the iEFIS and ignition.

Oct 15, 2017 Fit Tailcone Fasteners - (0.5 hour) Category: Empennage

Fit washers and nuts to tailcone fasteners. AN3xx-5 is correct size, -6 need two washers.

Oct 15, 2017 Rudder Pedal Springs - (1.3 hours) Category: Controls

Sized and fit springs to fit space for pedals. Right spring to plan dimensions, left modified with a longer, lower straight wire to not interfere (as much) with the left side fuselage spoiler pulley assembly.

Oct 15, 2017 Install Mixer Drive, XNB-C02 Category: Controls

Fit mixer drive with #1 taper pin; reamed mixer drive rudder cable attachement holes to 3/16", installed bronze bushings and cable ends.

Oct 13, 2017 Prep Rudder Drive - (0.3 hour) Category: Controls

Removed powder coat from mixer pivot shaft by heating with propane torch and wire brushing residue.

Oct 09, 2017 Panel layout modifications - (1.2 hours) Category: Instrument Panel

More work with XPanel 5000 and Front Panel Designer to design layout. The time recorded is very low compared with the actual time spent on non-construction tasks.

Oct 08, 2017 Explore various ELT locations - (1.5 hours)

Category: Radios

Explored, discussed, and tested several ELT mounting locations in the mixer assembly area with reach of the mixer access cover. Considerations pointed out in the ELT manual included forward orientation and not more than 10 degrees from horizontal.
Plan drawings indicate that longeron and shoulder harness attachment web provide excellent orientation. Discussed several opportunities to add flanged material and mount ELT with George Jones, however adding two pieces of scrap to match longeron thickness would provide a flat mounting position under the shoulder strap web.

ELT model

Fit check

Mount location

ELT in place

Placement

Oct 08, 2017 Torque Forward Stabilator Spar Splice Plate - (0.5 hour) Category: Empennage

Torqued splice plate bolts to fuselage bulkhead.

Oct 08, 2017 Instrument Sub Panel Layouts - (2.5 hours) Category: Instrument Panel

Sketched several control panels - iEFIS, Instrument, ignition switch - using Front Panel Designer for possible production by Front Panel Express.
* Front Panel Designer: http://www.frontpanelexpress.com/download/front-panel-designer
* Front Panel Express: http://www.frontpanelexpress.com/

Oct 07, 2017 Align and Bolt Stabilator Forward Spar to Fuselage - (3.0 hours) Category: Empennage

File port stabilator skin to minimize center gap (0.015") between stabilator forward spars. Aligned XNS-T02-02 Forward splice plate with forward spars. Drilled initial alignment with #40, updrilled to under 3/16 then reamed to 3/16". Drilled lower bulkhead/skin rivet to relieve shop head interference with bolt head.
Removed and deburred stabilator forward spar, including using a chip chaser between spar plates.
Installed bolts with washers and nuts, but did not torque to 5.5 nm - will get helper to assist.

Oct 01, 2017 XNB-T02: Prep Stabilator Attachement - (3.5 hours) Category: Empennage

Pilot drilled starboard side stabilator forward splice plate XNS-T02-02. Pilot drilled all exept outside lower hole which was unreachable with drill.
Updrilled top left hole to 3/8" and inserted bolt.
Filed left side skin which appears to prevent full centering.

Oct 01, 2017 XNB-F21: Complete Tailcone box - (0.8 hour) Category: Empennage

Riveted remaining tailwheel vertical angles. Replaced three rivets on the port side that didn't hold the angle tight to the skin.
Aligned and drilled spacer. Up-drilled tail cone skin and longerons.

Sep 30, 2017 XNB-T02: Fit stabilators to bulkhead - (3.0 hours) Category: Empennage

Drill rivets on old rear spar cap, replace cap drilling new holes for rivets. Dimpled spar and ribs where necessary, aligned and riveted replacement rear spar cap in place.
Drilled for skins and Cleco'd. Fit stabilator to tail and drilled Y-fitting holes. Disassembled and deburred.
Riveted recessed leading edge skin to forward spar cap.

Sep 30, 2017 XNB-T02: Fit stabilators to bulkhead - (1.5 hours) Category: Empennage

Aligned right side stabilator to bulkhead after determining the bolt head from the forward spar root rib attachment was preventing 1/8" of the spar attachment from centering. Used a 1/2" sanding drum to remove material from bulkhead/skin allowing full movement of the spar attachment fitting.

Sep 27, 2017 XNB-T05: Cut and shape replacement stabilator rear spar - (0.5 hour) Category: Empennage

Located and drilled hole with step drill to 1" diameter. Sawed two segments tangent with hole. Filed and deburred edges.

Sep 25, 2017 Clean and Prime Mixer Drive - (1.3 hours) Category: Controls

File and sand mixer pivot and drive from welding internal reenforcement sleeve. Drilled and reamed #1 taper, fit taper pin.

Sep 24, 2017 XNB-T02: Test Fit Stabilators - (1.3 hours) Category: Empennage

Test fit stabilators to tail cone box. Will remake right side stabilator aft spar as it was damaged by rivet gun when attempting to use an oversized rivet on outer rib.

Test fit left ruddervator to stabilator.

Sep 24, 2017 XNB-F21: Inspect Forward Tailwheel Mount - (0.3 hour) Category: Empennage

Inspecting the forward tailwheel mount and verticals determined that spacer XNB-F22-16 was neglected.

Sep 24, 2017 Bolt Engine Mount to Firewall, XNB-P10 - (1.5 hours) Category: Engine

Determined the correct bolt size for the top engine mounts to be AN5-27A and AN5-33A for the lower. Fourth hole needed slight alignment drilling to fit bolt.

Sep 23, 2017 Mounting tabs for BNC panel mount in stabilator - (0.8 hour) Category: Radios

Cut several 1-1/2" angles from 0.032" angle stock to rivet on stabilator rib. Angle stock to mount a BNC panel fitting.

Sep 23, 2017 NB-T02: Port Stabilator Installation - (0.4 hour) Category: Empennage

Installed port stabilator with Clecos. Installed length of LMR-400 inside stabilator for future antenna mount in stabilator tip.

Sep 23, 2017 XNB-F21: Forward Tailwheel Attach/Verticals - (1 hour) Category: Empennage

Fit forward vertical angles to forward tailwheel attach angle. Removed and re-riveted right side angle to allow it to lay flatter against the skin. Additional rivet place on right side.
If remaking this assembly, I would have drilled the bolt holes in the tailwheel mount and matched the forward attach angle rather than drilling the holes in the attach angle first.

Sep 23, 2017 XNB-F23: Bolt Y Fitting and Tailwheel Mount - (1.5 hours) Category: Empennage

Bolted Y fitting, tail post assembly, and tailwheel mount using AN3 bolts with AN365 nuts with washers sized per drawing. Torqued nuts to 5.5 Nm.

Sep 23, 2017 XNB-F23: Bolt Y Fitting and Tailwheel Mount - (1.5 hours) Category: Empennage

Bolted Y fitting, tail post assembly, and tailwheel mount using AN3 bolts with AN365 nuts with washers sized per drawing. Torqued nuts to 5.5 Nm.

Sep 23, 2017 Reverse Pulleys, XNB-F26 - (0.8 hour) Category: Controls

Removed rivets on pulley brakets assemblies XNB-F29-02, removed from forward end of bulkhead and reassembled on aft end of bulkhead.

Sep 22, 2017 Antenna Cable through Stabilator - (0.5 hour)

Category: Radios

Placed a length of LMR-400 antenna cable inside the stabilator structure to prep for possible antenna placement inside fiberglass stabilator tip.

Instrument air, conduit, antenna

Stabilator closeout

RG400, vinyl conduit, instrument air

Sep 22, 2017 Repair Mixer Drive - (1.3 hours) Category: Controls

Previously, multiple hole locations were drilled in the mixer pivot shaft XNS-C02-05 ($84.75) due to fitting the XNS-C02-06 drive fitting ($63.25) upside down. Turned thick 1/2" x 12" shim stock from AS to fit inside the pivot shaft with approx 1/4" on each end. Plan is to weld ends and tack through previous holes to secure support to shaft, then drill new hole for #1 taper pin.

Sep 17, 2017 XNB-F21: Tailwheel Mount & Vertical Angles - (1.2 hours) Category: Empennage

Fit and drill rivet holes for left and right vertical angles mounting to tail wheel mount attach angle. Fit to tail-cone, drilled and deburred holes in vertical angles. Fit and drilled 3/16" dia tailwheel mount to angle holes. Riveted vertical angles to tail wheel mount attach angle.

Primed and painted tailwheel mount.

Sep 17, 2017 Rudder springs - (0.5 hour) Category: Controls

Shaped spring to plan dimensions. Fit to right side pedal. Could be a slight bit tighter. Left side may fit over spoiler pulley mount with a longer straight section.

Sep 17, 2017 Idler to Mixer Pushrod, XNB-C01 - (1 hour) Category: Controls

Installed #2 taper pin in control stick fitting. Drilled location for idler to mixer pushrod. Drilled 7/16" dia for bearing. Full forward stick throw bottoms on tunnel rivets rather than mixer stop.

Sep 16, 2017 XNB-T04: Prep Starboard Stabilator Skin For Riveting - (3.5 hours) Category: Empennage

Dimpled leading spar with super-simple dimple ground on edge to fit sections where 'hockey sticks' are riveted to forward spar. Used squeezer to dimple outboard sections. Dimpled outboard rib at tip.

Cleaned skin interior with acetone. Primed interior surface with Duco Self-etching primer. Assembled with Clecos.

Sep 15, 2017 Dimple Forward Spar Skin - (0.8 hour) Category: Empennage

Dimpled skin holes for flush rivets in forward spar.

Sep 14, 2017 Updrill and Deburr Right Stabilator - (1.5 hours) Category: Empennage

Complete up-drilling and deburring of skin and substructure.

Sep 11, 2017 Fit and Drill Right Stabilator Skin - (1.0 hour) Category: Empennage

Sep 10, 2017 Fit Rudder Springs - (1 hour) Category: Controls

Sep 10, 2017 Front Wall Sign/rent - (1.5 hours)

Category: Hangar

Glued 4 pieces of 4'x4' composite bead board with 6" x 12" 1/2" MDF mending blocks glued each half. Trimmed target pattern with razor knife. Painted bullseye to left end. Rolled remaining 1/2 gal gry floor paint over 4'x12' right section. Ripped 2" backing boards, glued and screwed boards behind the 16' top and bottom sections. Cut 2-1/2" strips glued between edge and mending plates.
Rent+

1894.jpeg

1895.jpeg

1896.jpeg

Sep 09, 2017 XNB-T04: Align and Drill Skin & Substructure - (1.0 hour) Category: Empennage

Drilled a representative sample of #40 holes across the underside forward spar, the triangular inboard patch, and several #30 holes in the underside trailing edge for temporary rivets.

De-riveted the #? rib to bend and move slightly for better alignment and filed the forward tab edge for better clearance with the forward spar. A slight bend in the forward tab centered the forward rib edge.

Flipped and removed top trailing temporary rivets. Cleco'd bottom trailing edge. Compressed and aligned top substructure.

More 'cautious' align/drill/examine then previous stabilator using 2x4 and webbing to compress. This method provides a greater opportunity to slightly adjust the subframe.

Outboard rib has a bit of cant to pull into vertical.

Sep 09, 2017 Pulley Cable through Seatback - (0.5 hour) Category: Cockpit

Examined interference point between cable and seatback. It would be desirable to maintain the seatback cutout resting on the lower longeron, possibly by drilling a semi-circular hole on the outboard side of the seatback to permit the cable to run without interference.

Sep 08, 2017 Updrill/Deburr Stbd Stabilator Skin - (1.5 hours) Category: Empennage

Up-drilled #40 to #30 except the forward spar which were drilled to 1/8" in anticipation of hole expansion from dimpling.

Sep 07, 2017 Align Stabilator Skin - (3.0 hours) Category: Empennage

Aligned stabilator skin on sub-structure. began with bottom outboard corner with edge of skin extending 3/4" from outside of outboard rib. Opened the instrument probe mount hole in leading edge and drilled the forward spar to outboard rib rivets to allow better rib placement.

Aligned top in aft outboard corner and drilled several rivet holes on top trailing edge. Installed temporary rivets in top aft edge to maintain alignment when inverted on workbench.

Sep 04, 2017 Deburr Y Fitting - (0.3 hour) Category: Empennage

Deburr mating section of Y fittings.

Aug 31, 2017 XNB-T04: Fit Right Stabilator Skin - (1.3 hours) Category: Empennage

Drilled 1/2" hole in skin for instrument probe. Marked outboard skin edge at 3/4" using the mark to trial fit skin to outside edge of substructure.

Aug 30, 2017 Deburr Y Fitting/Stabilator - (1.0 hour) Category: Empennage

Deburr holes on Y fitting and stabilator substructure.

Aug 29, 2017 Up-drill Y fitting attachement - (0.8 hour) Category: Empennage

Up-drill rivet attachment from Y fitting to stabilators.

Aug 27, 2017 XNB-F: Mount Y Fitting and Stabilators to Workbench - (1.0 hour) Category: Empennage

Secured Y fitting to workbench. Drilled several #30 holed through Y fitting and stabilator aft spar for Cleco's to attach right stabilator sub structure.

Aug 26, 2017 XNB-T05: Complete Right Stabilator Substructure - (3.8 hours) Category: Empennage

Make ribs XNB-T06-16,-17,-18. Rivet ribs to stabilator substructure.

Aug 20, 2017 Install Time-Serts, Starboard Side - (2 hours)

Category: Engine

'Loosely' reinstalled left head (no torque), removed right. Drilled spark plug holes and installed Time-Serts. Filed threads where thinned aluminum exposed sharp edges to combustion chamber.

Time-Sert_filing-1.jpg

Time-Sert_filing-2.jpg

Time-Sert_filing-3.jpg

Aug 19, 2017 Spoiler Pulley Gusset - (3.0 hours) Category: Controls

Drilled rivets and removed factory installed gusset plate - see previous posting showing non-conformance with drawing. Preped (file/Scotch-brite/drill holes, deburr) replacement gusset plate XNS-F17-04. Rivet to stiffeners. Set single cable from inboard side of handle (clear interaction with longeron) through to gusset pulley.

Aug 19, 2017 Install Port Head Time-Sert - (1.5 hours)

Category: Engine

After reading Mike Smith's post on Sonex Builder's Net (http://sonexbuilders.net/viewtopic.php?f=7&t=3850&p=29348&hilit=time+serts#p29348) and recalling my own life experiences with aluminum thread galling on motorcycles, I concluded that adding Time-Sert thread inserts to the AeroVee would be inexpensive and prudent. Removed right side head, cut and installed Time-Sert 42123 M12 X 1.25 X 15.0 SP TIME-SERT (WASHER SEAT) from Thread Kits Company (https://www.threadkits.com/catalogsearch/result/?q=42123&cat=) using a liberal amount of WD-40 to lubricate and flush cuttings.
Thanks to Mike Smith (mike.smith208@comcast.net) for the loan of his installation tool!

Time-Sert cutting

Time-Sert installation

Time-Sert hole prep

1917.jpeg

1921.jpeg

Aug 13, 2017 Control Stick Taper Pin - (1.5 hours) Category: Controls

Used #1 reamer to cut tapered hole for #2-12 taper pin fitting single control stick tube SNB-C04-03 to control stick fitting SNB-C04-07. The #1 taper is just able to cut enough taper for the #2 pin. Used Boelube solid as a cutting lubricant.

Drilled the aft end of the control stick fitting for push-to-talk wiring. Cut fore and aft slots in stick to match hole in fitting.

Aug 08, 2017 XNB-T05: Prep Stabilator Ribs - (1.5 hours) Category: Empennage

Drilled and trimmed ribs for right stabilator.

Aug 05, 2017 Spoiler Drive Firewall Pulley Mount, XNB-C06 - (2.5 hours) Category: Controls

Cut XNB-C06-18 attach tube, drilled firewall mounting holes for pulley axle and attach tube rivets. Mount attache tube to firewall. Aligned and riveted attach plate to attach tube and firewall stiffener. Assembled pulley assembly with spoiler control cable. Slight friction between pulley and cable guide. Light sanding of pulley edges.

Aug 05, 2017 Spoiler Drive Fuselage Pulley Mount, XNB-C06 - (1.8 hours)

Category: Controls

Up-drill, deburr, rivet spoiler pulley mounted on fuselage/firewall. Location appears to conflict with rudder return spring installation.

1944.jpeg

1968.jpeg

1969.jpeg

Aug 05, 2017 Spoiler Drive Firewall Pulley Mount, XNB-C06 - (2.5 hours) Category: Controls

Aug 04, 2017 XNB-T06: Remake Stabilator Ribs - (0.2 hour) Category: Empennage

Cut ribs #3, 4, 5, and root to length.

Aug 02, 2017 XNB-T05: Right Stabilator - (1.2 hours) Category: Empennage

Right stabilator structure; rivet forward spar.

Jul 30, 2017 Fit Fuselage Spoiler Pulley Mount - (2.5 hours) Category: Controls

Locate and drill attachment holes in fuselage and firewall for spoiler pulley mount.

Jul 29, 2017 Spoiler Handle Pivot Bushing, XNB-L03 - (0.8 hour) Category: Controls

File and sand XNB-L03-06 spoiler handle pivot bushing to allow friction fit with nylon washer. Plans call for "snug but free" fit. Has plenty of free, still requires additional sanding with medium emery cloth to achieve snug.

Examination of riveting XNB-L03-05 / -16 clip to spar tunnel looks to be a complicated interaction with several elements between the clip and tunnel.

Will look at fastening the aft end of the handle mount angle with a square tube to fuselage skin instead of the -16 clip.

Jul 29, 2017 Attach Rudder Controls - (4.1 hours) Category: Controls

Trim rudder cable adjustment plates to length per plan method. Drilled adjustment plates, temporary fit to rudder pedals. Trimed approximately an inch of poly tube sheath on pedal to mixer cables to prevent riding through bulkhead pulleys.

Jul 25, 2017 Spoiler Cable Adjustment - (1.2 hours) Category: Controls

Cut, shaped, drilled spoiler cable connection plates.

Jul 22, 2017 Control Stick Horn Assembly Spacer - (0.3 hour) Category: Controls

Cut and trued Al tube for XNB-C0310 spacer.

Jul 22, 2017 Control Pulley Bracket Installation - (6.0 hours) Category: Controls

Layout, drill, rivet rudder control cable pullies.

Jul 16, 2017 Pulley Brackets, XNB-C02 - (0.6 hour) Category: Controls

Locate, drill, updrill upper port side rudder pulley bracket.

Check alignment and location of spoiler pulley bracket at spar tunnel.

Jul 15, 2017 XNB-F22-05R/L: Remake Vertical Angles - (1.2 hours) Category: Empennage

Remade left and right vertical angles. First set didn't align to the tailwheel mount attach angle well.

Jul 08, 2017 Spoiler Pulley Makeup - (3.5 hours) Category: Controls

Bend and assembled spoiler pulley mounts.

Jul 05, 2017 Control Fixtures, XNB-C06 - (6.0 hours) Category: Controls

Spoiler handle mount fixture.

Jun 27, 2017 XNB-F25: Inspection Cover Installation - (1.5 hours) Category: Empennage

Experimented with countersunk fasteners and nut plates rather than sheetmetal screws. Dimpling cover for bugle head screw creates undesirable distortions.
Will likely replace cover and use std #8 pan head screws.

Jun 27, 2017 Drainage Ditch - (0.8 hour) Category: Hangar

Started digging drainage ditch for plastic drain pipe. Broke the makeshift wheelbarrow handle.

Jun 24, 2017 XNB-F23: Rudder Installation - (2.5 hours) Category: Empennage

Rivet together rudder hinge, channel, and fuselage. Connect rudder control cables to mixer. Add right side pulleys. Mark pulley location in cockpit.

Jun 17, 2017 Fit Tail Cone Parts - (3.0 hours) Category: Empennage

Drawing XNB-F21.

Jun 14, 2017 XNB-T05: Stabilator Structure Prep - (0.8 hour) Category: Empennage

File, sand, and Scotchbrite right stabilator spar cap edges to remove marks from laser cutting.

Jun 13, 2017 XNB-T05: Up-drill Right Stabilator Substructure - (1.7 hours) Category: Empennage

Up-drilled and deburred right stabilator substructure.

Jun 08, 2017 XNB-T04: Pilot Drill Stabilator Sub Structure - (0.8 hour) Category: Empennage

Tip rib location, drill pilot holes, evaluate ribs.

Jun 06, 2017 Rough Cut Control Parts, XNB-C06 - (2.7 hours) Category: Controls

Identify and cut to rough dimensions parts XNB-C06-07 -08 ... etc

Jun 03, 2017 XNB-F22: Tail Vertical Angles - (1 hour) Category: Empennage

Layout, cut left and right XNB-F22-05 L/R vertical angles from SNX-Z03-04 channel stock.

Jun 02, 2017 XNB-T06: Stabilator Spar - (1.5 hours) Category: Empennage

Layout and cut right stabilator spars.

Jun 02, 2017 Illuminated Exit Sign - (0.3 hour) Category: Hangar

Installed illuminated exit sign above door.

May 31, 2017 Trial Fit Y-Stack - (0.3 hour) Category: Empennage

Trial fit of Y-stack. Tailwheel mount a bit tight.

May 30, 2017 Up-drill Y Fittings - (4.0 hours) Category: Empennage

From aligned Y fittings, upper & lower attach tabs, tailwheel attachment, all but two #40 holes were drilled and reamed to 3/8". The fit of remade upper tab was unsatisfactory. Remade upper tab XNB-F23-02 and bent to 94 degrees.
Will fit XNB-F23-02 to the #40 holes in the tail cone, then mark and drill to 3/8" on the Y fitting/channel stack.
Lower attach tab hole a bit too close to the angle web. Filed a washer edge to permit flat fit of bolt head.

May 29, 2017 Rear Rudder Cables - (2.0 hours) Category: Controls

Removed bottom aft fuselage skin by drilling out rivets and removing 4 - AN3 mushroom head bolts. Two bolts were stuck and required drilling out the head to gain accsess to the skin. Bolt stubs still stuck in fuselage.

Trial fit of mixer-to-rudder cables.

May 28, 2017 Trial Fit and Mark of Y stack - (2.5 hours) Category: Empennage

Drawing XNB-F23: Alignment and trial fit of Y, channel, and tailwheel mount components for drilling upper and lower mount tabs.

May 27, 2017 Fuel Tank outlet, level, and vent fittings installation - (1.8 hours)

Category: Fuel System

Installed tank fittings using the wire and washer method described in the plans.

FuelTankFittings - 10.jpeg

FuelTankFittings - 11.jpeg

FuelTankFittings - 12.jpeg

FuelTankFittings - 15.jpeg

FuelTankFittings - 16.jpeg

FuelTankFittings - 17.jpeg

FuelTankFittings - 18.jpeg

FuelTankFittings - 19.jpeg

FuelTankFittings - 20.jpeg

Outlet and sensor fittings

Tools

Locate vent fitting hole

FuelTankFittings - 8.jpeg

Snaking wire from outlet

May 27, 2017 Rudder Controls - (6.0 hours) Category: Controls

Removed sheetmetal from bottom of fuselage by unbolting and drilling rivets. Had to drill the centers of two button head screws to enable removing the head allowing the sheetmetal to be removed.

May 26, 2017 Control System Parts - (2 hours) Category: Controls

Made spoiler pulley restraint parts.

May 21, 2017 XNB-G01: Fuel Tank Fit to Frame - (2 hours) Category: Fuel System

Drilled rivets on glare shield firewall angle. Removing firewall angle provides room for tank to move forward in front of stop.
It is my current understanding that the supplied firewall angle was installed to simply hold the glareshield curve during shipping. Will be replaced with the supplied firewall angle SNB-F07-09.
After contacting the factory for a replacement angle, I was told that the supplied angle was an easier installation than the one called out in the plans. Several years later, I understand that Sonex was correct in providing the mount.
Located and drilled for rear tank strap. AN3-20A bolt in drawing is too long. Several years later I regret trying to mount the fuel tank so early in the build without more complete understanding of the kit construction steps.

May 21, 2017 Mixer Mount - (1.1 hours) Category: Controls

Mounted mixer assembly to fuselage. Plans indicate the mounting nut face outboard, which would place the nut and cotter pin in a difficult to inspect location. Installed mounting fasteners in a reverse orientation to better allow inspection of the retaining nut and cotter pin.

May 21, 2017 Mark Fairlead Blocks for Installation - (0.4 hour) Category: Controls

Aligned fairlead blocks for mounting in fuselage. Cleco'd in place with #40 pilot holes. Drilled through holes on drill press followed by 1/4" step drill 1/2" deep.

May 21, 2017 Drill Fairlead Blocks - (0.5 hour) Category: Controls

Drilled faillead hole into phenolic blocks cut and supplied by Interstate Plastics. Used a 3/8" pilot followed by a 3/4" step drill through both sides.

Plans incorrectly indicate the insert is 3/4" in length. The AS part is 1" long.

Snap ring pliers work well for easy assembly of nylon lead guides.

May 20, 2017 Winshield Bow Rivets - (1.5 hours) Category: Cockpit

Cut MS20426AD6-14 rivets by 1/8" to make MS20426AD6-12. Initial riveting with C-frame riveter put marks on Windshield bow as keeping the bow square to the frame was difficult. Final technique was to set initial rivet with two hits using the C-frame, followed by 'squeezing' with 12 ton bottle jack press.

May 19, 2017 Ream Control Stick Taper - (0.5 hour) Category: Controls

Drilled and reamed #1 B&S taper on aileron pivot tube.

May 19, 2017 Drill Mixer Output Arm - (0.8 hour) Category: Controls

Mixer output arm and mixer pivot pilot drilled for #1 taper pin.

May 18, 2017 Pickup Mixer Assembly - (0.3 hour) Category: Controls

Pickup mixer assebly parts at hangar for assembly in home shop.

May 17, 2017 More XPanel Designs - (20 hours)

Category: Instrument Panel

Developed a Sonex B-model panel template from a drawing supplied by Sonex Aircraft. Designs exploring two displays.

XenosB_rev4b.jpg

XenosB_rev4c.jpg

XenosB_rev4d.jpg

XenosB_rev4e.jpg

XenosB_rev4f.jpg

Xenos_B_rev5.jpg

Xenos_B_rev5B.jpg

Xenos_B_rev5E.jpg

Xenos_B_rev5d.jpg

Xenos_B_rev5f.jpg

Xenos_B_rev5g.jpg

Xenos_B_rev5i.jpg

Xenos_B_rev5k.jpg

Xenos_B_rev5k_Eng_Full.jpg

Xenos_B_rev5k_Full.jpg

Xenos_rev4a.jpg

May 14, 2017 Seat Back Top Hinge, XNB-F08 - (1.5 hours) Category: Cockpit

Cut, drilled, deburred, riveted top piano hinge. Rivets used where soft, solid Al AN rivets installed with squeezer. Alerted Sonex to the error in drawing XNB-F-08 seat back assembly. Bottom hinge should be XNB-F-08-05 hinge 1 and not -06 hinge 2.

May 13, 2017 Tail Post Test Fitting - (1.5 hours) Category: Empennage

Drawing XNB-F23. Test fit tail post channel and Y support. Very tight between channel and Y stack. No room to Cleco the tail post channel for the purpose of aligning all Y sections, channel, and tailwheel mount. Will use -03 forward Y fitting for bolt hole alignment. Test fit port side stabilator briefly to check fit.

May 13, 2017 Rudder Pedal Fit - (1.5 hours) Category: Controls

Used a propane torch to remove the powder coating from the bearing ends of the rudder pedals. Fit the Delrin bearing blocks to the fuselage and align drilled the mounting holes. Weld-end of pedals tight against the bearing block.
Chamfer bearing blocks at ends A and C to relieve pressure points, rease bearing ends, paint pedal ends with rattle can black

May 13, 2017 Seal Roof - (1.5 hours) Category: Hangar

Spread fiber-ed sealant on roof concentrating on ventilation fan area leak.

May 12, 2017 Mixer Pivot Bearing Prep - (0.5 hour) Category: Controls

Removed powder coat from shaft of XNB-C02-05 using the propane torch method as demonstrated by John Monnett in this EAA video. Assembled to mixer frame.
Video: http://bcove.me/tmde51re

May 10, 2017 Remake Tail Tab Mounts - (2.3 hours) Category: Empennage

Drawing XNB-F23. Remade XNB-F23-02 -05 -07. Prior effort left dimensions too short by approximately 1/8".

May 10, 2017 Control Cable Adjusters - (0.8 hour) Category: Controls

Made control cable adjusters from 0.190 Al stock.

May 08, 2017 Remake Upper and Lower Mounting Tabs - (0.8 hour) Category: Empennage

Drawing XNB-F23. Began cutout for F23-07 tail wheel mounting tab and -2, -.
Found the Y mounting tabs too short by 1/4 - 3/8" across the wide part of the tab. Began new 2" angle cutouts.
Using scrapped channel and clamps as a band saw fence helps maintain consistent cuts.

May 07, 2017 Second Rudder Block - (1 hour) Category: Controls

Cut the 1" hole with a Forstner bit which left a rough finish requiring sanding and Scotchbrite to remove 'fuzzy' finish. Sanding left a less desirable finish than the paddle bit.

Broke the sharp edges with a deburring tool and file. Fine emery cloth on second block. Restored the black finish somewhat with the motorcycle detailing spray (name?). Left a black dull finish which appeared more aesthetically pleasing that the grey from sanding. Done again, the paddle bit pushes the chips leaving a nicer cut than the Forstner bit.

May 07, 2017 Pulley Bracket Assembly - (6 hours) Category: Controls

Identified and assembled several pulley brackets, pressed Xenos pulley inserts into pulleys, identified missing fasteners.

May 06, 2017 XNB-B01: Fuel Tank - (1.5 hours) Category: Fuel System

Test fit fuel tank with glare shield. Having a difficult time getting tank to seat in the last 1/2 - 3/4 inch. Tried removing the flashing with a belt sander to provide additional room, but was unable to fit the tank.
Finally determined that I was using the fuel tank instructions for the legacy model, causing a misunderstanding that the factory supplied the incorrect firewall/glare-shield angle. As now understood, the tank is to be lifted into position and the retaining straps secure the tank to the longerons.

May 06, 2017 Test Fit Y to Fuselage - (1.5 hours) Category: Empennage

Drawing XNB-F23. Drilled out remaining 'red' rivets in tail cone to open area for installation. Test fit Cleco'd Y mount to tail cone. Remove a rivet to enable fitting top attach angle in tail cone.

May 05, 2017 Finish First Rudder Pedal Block, XNB-C02 - (2.5 hours) Category: Controls

When attempting to finish the second block, found that the paddle bit shaft had bent enough to wobble when starting to drill. Purchased a Forstner bit at HD to see if it will finish the 1" hole.

May 04, 2017 Fitting Tailpost - (2.0 hours) Category: Empennage

Drawing XNB-F23. More tail post fitting to Y. Align to Y doubler, drill, deburr.

May 04, 2017 Layout, Cut Rudder Blocks - (0.8 hour) Category: Controls

Layout and drill Delrin blocks for rudder pedal support. Used smaller HS drill bits (#40 then 3/16") on drill press to align mounting bolts. Bearing hole drilled by clamping both blocks bolted together and opened holes with 3/8" HS twist bit, then HF step bit to 1" from both sides. Finished first block with 1" paddle bit. When attempting to finish the second block, found that the paddle bit shaft had bent enough to wobble when starting, slightly damaging face of block. Purchased a Forstner bit at HD to see if it will finish the 1" hole.

May 03, 2017 Fit Y Attachment - (2.5 hours) Category: Empennage

Drawing XNB-F23. Fit upper and lower attachment (-02, -05) to Y.

May 03, 2017 Fuel Tank Stop - (1 hour) Category: Cockpit

Drilled and dimpled holes in glare shield for fuel tank stop. Found that in my haste to rivet the stop angle, the angle was incorrectly facing aft. Drilled and removed rivets, faced the stop angle correctly and riveted.

Apr 30, 2017 Y Tail Mounting Tabs - (2 hours) Category: Empennage

Drawing XNB-F23. Layout and cut XNB-F23-02 and -05 top and bottom mounting tabs on bandsaw. Step drill for 7/8" hole, bandsaw to open space for tailwheel mount.

Apr 30, 2017 Spoiler Handle - (0.8 hour) Category: Controls

Bend, drill, deburr/finish spoiler handle. Considering laminating a wood grip to the handle to provide a larger, warmer feel.

Apr 28, 2017 Hardware Spreadsheet - (6 hours) Category: Research

Brief Description: Hardware Spreadsheet
Developed a Google Worksheet for Xenos-B hardware. Sheets updated as missed hardware is found,
Started the pricing based on Wick's website, but ultimately found Aircraft Spruce's site easier to find and order from. Used Interstate Plastics cut-to-order for Delrin(Acetal) rudder pivot blocks and Phenolic fairlead holder blocks. Aircraft Spruce did not show a 3/4" long, 1/4" dia fairlead as called for in the plans, so a 1" x 1/4" diameter was substituted. Looks like the plan sheet is in error. Needed to reorder thicker Phenolic blocks for the fairleads in the tail.

Ultimately, the parts worksheet reflected the errors in bolt lengths from the plans. Sent a note to Sonex detailing plan errors, but never saw that the errors where addressed in plan updates.

Apr 23, 2017 Skin Left Stabilator - (11.3 hours) Category: Empennage

Drawing XNB-T03. Fit skin to structure. Deburr, used self-etching primer on skin interior. Dimpled leading edge rivets for CCC-42. Prepared hinge for ruddervator. Test fit ruddervator to stabilator. Test fit Y structural part to aft stabilator structure. Rivets a half diameter too close to Y in first half dozen inboard bottom trailing edge rivets.

Apr 22, 2017 Rudder Layout & Drill - (4.5 hours) Category: Empennage

Drawing XNB-T09. Rudder layout, drill, up drill, deburr, rivet.

Apr 22, 2017 Prep Stabilator Skin - (3.5 hours) Category: Empennage

Drawing XNB-T02. Prepared skin and structure for riveting. Cleco'd top and bottom sides. Up drilled top. Key factor in alignment was to correctly locate top outboard rear corner. Then worked top bottom edge. Hole for probe had to be expanded outboard slightly to allow for slight structure movement.

Used a ratchet strap and a 2x4 across the underside leading edge to bring skin to alignment on bottom aft edge.Alignment to aft channel edge and 3/4" outboard skin to outboard rib.

Apr 21, 2017 Rudder Cut and Prep - (3.5 hours) Category: Empennage

Drawing XNB-T09/10. Cutout rudder skin. As delivered, top and bottom were rough. Once trued to within 1/16", the forward height was 1/8" less than plans 12".
Trimmed ABS/fiber tip cap with bandsaw. Trim rudder drive plate cutout. Layout rivet locations on rudder skin.

Apr 20, 2017 Rivet Port Stabilator Structure - (3.5 hours) Category: Empennage

Drawing XNB-T03. Layout, drill, dimple (aft inboard under Y-plate), true, rivet, and install instrument piping and conduit on port side stabillator.

Apr 19, 2017 Prep Left Stabilator Structure - (3.8 hours) Category: Empennage

Drawing XNB-T06. Prepare forward spar and channel for riveting. Deburr, sand, smooth spar edges to remove laser cut marks and surface oxydation. Medium and fine emery and Scotch-brite. Marked outside of spar channel with rivet sizes. Rivet forward and aft spar caps to channel, with Cleco's in rib tab holes from inside to prevent riveting.

Apr 18, 2017 Chemical Weeding - (1 hour) Category: Hangar

Chemical spray application of Eraser to suppress weeds around hangar and runway.

Apr 17, 2017 Fit Left Stabilator Structure - (3.5 hours)

Category: Empennage

Drawing XNB-T06: Fit, drill, deburr, Cleco left stabilator structure. Need to remake root ribs in 0.032" channel. Had used 0.025" channel.

Ruddervator

Tab connection

Structure

Ruddervator structure

3/8" air drill TOO HEAVY!

Holes for pitot, lights, antenna

Orthogonal alignment

Xenos_empennage_B - 46.jpeg

Apr 17, 2017 Locate Airspeed Mounting Holes - (1 hour) Category: Instrument Panel

Set FAP instrument drill jig square to panel and drilled airspeed mounting holes. Inserted instrument mounting nuts for #4-40 screws and test fit to front panel. Front panel holes drilled to 1/8". Additional work removing excess material from inside mounting hole.
FAP Drill jig: https://www.aircraftspruce.com/catalog/topages/instrumentmounting.php
Instrument mounting nuts: https://www.aircraftspruce.com/catalog/hapages/instmountnuts.php?clickkey=4875692

Apr 16, 2017 Ground Instruction on Xenos - (1.5 hours)

Category: Research

Met Martin Walker at his base located in the Warrenton Airpark. Received an introduction to the Xenos, preflight, startup, and taxi to get the feel of the Xenos tailwheel's turning radius.

Martin's Xenost

Ground handling

Martin and I

Apr 14, 2017 Stabilator Forward Spar Cap Bending - (1.5 hours)

Category: Empennage

Drawing XNB-T06. Used 20 ton HF press, 1" bolt, and wood blocks to bend stabilator Forward Spar Caps. Target angle is 14.3 degrees.

10 ton press over V-block

Bending radius w/1" dia bolt

Bending ruddervator

Apr 14, 2017 Layout Stabilator Structure - (5.0 hours) Category: Empennage

Drawing XNB-T05. Cut spars and layout ribs for what I thought was the right, but is now the left stabilator structure. Seem to occasionally visualize the incorrect view of parts from the drawing, particularly where the drawing view is not described (as in right underside). Align the tip end, squaring with the aft spar and measuring the length at forward spar intersection. Bent the right side forward spar cap, shown in next entry.

Apr 14, 2017 Layout Stabilator Structure - (5.0 hours) Category: Empennage

Apr 13, 2017 Rivet Ruddervators - (3.5 hours) Category: Empennage

Drawing XNB-T06: Completed drilling and deburring of left ruddervator. Aligned and riveted ribs, skin, and hinges. Inadvertently riveted left side hinge with end flush with outboard edge. Drilled out rivets and moved hinge to align inboard edge. The consistent one inch spacing due to the drilled aluminum ruler (see previous link) helped enormously in dealing with the error.

Apr 12, 2017 Ruddervators, drill & rivet - (2.3 hours) Category: Empennage

Drawings XNB-T06 -07 -08: Bent right ruddervator drive plate. Riveted drive plate to rib. Riveted right ruddervator.
Set and drilled 'used' hinge to left ruddervator. Updrilled and cleco'd left ruddervator.

Apr 12, 2017 Drill and Deburr Y Plates - (2.3 hours) Category: Empennage

Drawing XNB-F23. Opened and deburred 88 holes with #40 drill. Consumed 4 drill bits in the process. Combination of 1/4" Mac drill and drill press. Starter hole with air drill, then followed up drilling the stack with a drill press. Broke 2 bits in three plate stack.

Apr 06, 2017 Material for Avionics Tray - (0.7 hour) Category: Avionics

Drilled out discarded left ruddervator (scarred interior skin) to recover ribs and skin. Material will be cut and formed to make an avionics frame to hold EFIS screen, iBox, and electronic breakers.

Apr 05, 2017 XNB-T07 Ruddervators - (1.3 hours) Category: Empennage

Drill left side drive rib, rivet left side drive plate to root rib. Debur and reassemble right side. Wrong left side ribs (-04 not -03).

Apr 02, 2017 Close Inspection & Prep - (1.0 hour) Category: Fuselage

Located and drilled out the 'red' rivets on bottom panel to remove panels set in place from the factory quick build.

Apr 02, 2017 Port Ruddervator Fab, XNS-T07 - (4.0 hours) Category: Empennage

Markout, cut, deburred fit drive plate to left ruddervator.

Apr 02, 2017 Brush Cutting - (4.5 hours) Category: Hangar

Cut brush from the north rear of hanger, loose stack of previously cut trees. Cleared vines from rear wall. Cut most of the way through a large limb on the large oak in rear. Roughly girdled a black walnut. Will need to rope and direct the fall of this tree so as not to damage the neighboring hanger. Cut additional shrubs in the slip. Moved excess loose plastic drainage pipe from draining area. Burned the cardboard box and paper packing from the QB parts.

Apr 01, 2017 Review Plan Set - (2 hours) Category: Research

Plan set arrived. Spend several hours in study of layout. Began highlighting items to be sourced and purchased.

Apr 01, 2017 Starboard Ruddervator - (2.5 hours) Category: Empennage

Drawing XNS-T07. Mark, cut, fit, drill, deburr right ruddervator.
Used Dremel rotary saw for diagonal skin cut and pocket. Abrasive 'metal' blade created a fair bit of heat. Cut had significant dross on edges. Tool was very controllable and enabled close cuts resulting in reduced filing effort.

Mar 25, 2017 EAA Sheetmetal Class - (12 hours)

Category: Research

Attended EAA's Sport Air sheetmetal workshop in Batavia, OH (Clermont County Airport). Instructor was Bob Koehler. Worthwhile introduction to forming, layout, riveting sheet metal. Sporty's hosted a lunch on Saturday for the class.

Classroom in EAA meeting space

Bob Koehler, instructor

Sporty's Pilot Shop on site

Mar 18, 2017 Updrill Ruddervator for Drive Plate, XNS-T04 - (1.3 hours) Category: Empennage

Updrilled rivet holes to #30 in starboard ruddervator. Drilled out port ruddervator drive plate rivets and recovered riveted drive plate.

Mar 18, 2017 Drill Ruddervator Drive Plates - (1.3 hours) Category: Empennage

Drill and debur port and starboard ruddervator drive plate and root rib.

Mar 18, 2017 Drill Ruddervator Drive Plates - (1.3 hours)

Category: Empennage

Drill and debur port and starboard ruddervator drive plate and root rib.

Xenos_empennage_B - 22.jpeg

Xenos_empennage_B - 3.jpeg

Xenos_empennage_B - 4.jpeg

Mar 15, 2017 Door Maintenance - (1 hour) Category: Hangar

High winds loosened several chain attachments and canvas hanging bolts. Replaced with nylok nuts.
Pickup parts for aileron construction at home.

Mar 10, 2017 Add Snap Bushings to Bulkhead Passthrough - (0.5 hour) Category: Controls

Drilled bulkhead passthrough to 1-1/8" an installed nylon snap bushing to prevent cable chaffing on smaller passthrough hole at extreme control throws.

Mar 08, 2017 Bend Stabilator Tabs - (0.5 hour) Category: Empennage

Put bends on mounting tabs using a floor-mounted metal brake at Mallory. The floor brake gives better initial bend than hand brake which tends to round the tab behind the bend.

Mar 08, 2017 Complete Workbench #2 - (1 hour) Category: Tools

Complete, level, and secure workbench at hangar. Install additional LED shop light.

Mar 07, 2017 Mark Stabilator Ribs for Bending - (0.3 hour)

Category: Empennage

From plan sheet XNS-T03, marked fore and aft ribs for bending on brake.

Xenos_empennage_B - 14.jpeg

Xenos_empennage_B - 15.jpeg

Mar 07, 2017 Drill & Fit Pulley Mounts - (4.0 hours) Category: Controls

Make spoiler handle mount.

Mar 05, 2017 Deburr & Prep Fore Channel - (1.5 hours) Category: Empennage

After a 6 month wait for 0.032" channel parts from Sonex (two months after Quick Build delivery) prepared long edges of tail stabilator rib mounts. Remove dross and deburred edges on Scotch-Brite wheel.

Mar 01, 2017 ST-1 Probe Mounts, XNS-T03 - (4 hours)

Category: Empennage

Constructed and mounted ST-1 probe mounts for pitot and total energy probes.
- Layout and bend aluminum mounts.
- Probe diameter 1/2 inch
- 1/2 inch wide rivet tabs
- 1 inch probe mount
- Test fit mount.
Prep rib tip and probe mount with medium sandpaper for epoxy to 'bite'. Mould aluminized epoxy into ribbons, embed probe mounts. Compressed mounting bracket to extrude epoxy. Cleanup and rivet mount to rib.

Xenos_probeMnt - 2.jpeg

Probes attached to rib

Probe mount w/epoxy

Feb 27, 2017 Assemble/plan map box - (1 hour) Category: Instrument Panel

Received a Van's mapbox kit. Cleco'd and sketched cutout on instrument panel. It will fit in the passenger space. However, it is 1/2" too long and would likely contact the fuel tank. Looks to be possible to cut several inches from the front on the box and bend new mounting flanges.

A sectional is 10.5" long, so cutting the map box down to 11" and bending new flanges for the panel connection should work.

Feb 26, 2017 Stabilator Ribs, XNS-T06,-03 - (4.5 hours)

Category: Empennage

Additional rib work to locate and drill access through ribs for probe (5/16" hole/AN931-3-5, 3/16" ID), conduit (5/16" vinyl tubing 9/16"/AN931-5 for lighting/video), and antenna cable (RG-58).
Tried using small flute bit on router table to cut the rib edges. Found that the 4041-T6 aluminum stuck and clogged the router bit.

Ribs

Router table with 1/8" birch guide

Router table

Feb 26, 2017 Stabilator Ribs, XNS-T06,-03 - (4.5 hours) Category: Instrument Panel

Additional rib work
Locate and drill
Probe, 5/16" hole/AN931-3-5, 3/16" ID
Conduit (5/16" vinyl tubing) 9/16"/AN931-5-9, hole for lighting/video
Antenna cable, RG-58 holes.

Feb 26, 2017 Stabilator Rib Tabs - (1 hour) Category: Instrument Panel

Mark and cut the rib tabs from drawing XNS-T06, preparing for probe and conduit holes.

Feb 25, 2017 Study Tail Kit Plans, Stabilator - (1 hour) Category: Empennage

Tail Plans Arrived. Studied the materials and tools required for tail assembly.
From drawing XNS-T03 Stabilator Assbly, parts to fabricate a clamp to secure pitot and TE probe.
To purchase:
For attachment of fiberglass stabilator tip MS24694-SS Machine Screw, qty 10 left, 10 right
MS21047 Anchor Nut, qty 10 left, 10 right
SSC-34 Flush Blind Rivet, qty 20 left, 20 right
Need a countersink.
Grommet AN931-3-5, qty 21 right only for aluminum instrument tubing lines for Total Energy, pitot, and static pressure sense probes. Check requirement for a single like this ILEC mount: https://www.cumulus-soaring.com/ilec.htmf. Found this Article on Total Energy Compensation in practice: https://www.cumulus-soaring.com/ilec/TotalEnergyCompensationInPractice-Brozel.pdf.

Feb 25, 2017 Door Repair, APRS - (2 hours)

Category: Hangar

Riveted aluminum panel section through canvas into aluminum frame to repair the tear. Added reinforcement to a closure grommet that had pulled through.
Setup Kenwood D-700 on APRS with call sign WV12, in anticipation of establishing a weather station to broadcast winds at mid-field.

1682 - Copy.jpeg

1683 - Copy.jpeg

Feb 20, 2017 Door Repair - (3 hours) Category: Hangar

Layout of an aluminum frame from scrap to back a piece of reflective aluminum sign scrap. Cleco'd the assembly onto the canvas hangar door.

Feb 18, 2017 Aileron hinge, polish wing experiment - (2.5 hours) Category: Wings

Received MS20257P3 piano hinges from Aircraft Spruce. I'm afraid that AS's S&H charges will be costly over the life of the project, particularly without a complete drawing set to determine how excessive the Xenos-A hardware kit from Wicks (http://www.sonexaircraft.com/eshop/cart.php?target=product&product_id=17544&category_id=442%22) for the B-model Quick Build kit.
Cut hinge to length (46-1/2"). Setup clamps on drill press to space #40 holes 1/4" from edge of leaf. Drilled 47 holes centering hole on hinge knuckle.
Deburred holes.
Spend an hour and a half polishing a section of the wing.

Feb 11, 2017 Variometer Research - (2.5 hours)

Category: Research

Looking at variometers and probes; configuration for mounting in stabilators. Choices are
Single probes for Total Energy, Pitot, and Static Port, All-in-one probe as shown in the factory drawings.
Vendors are Cumulus Soaring, Inc. and Wing and Wheels.
Variometers
LX EOS Speed-to-fly Variometer with GPS flight recorder, navigation, Thermal Assistant, and FLARM display for $1,295.
VariometerILEC SC-7 Variometer with Audio and Averager, $795
Probe mountST-1 8mm mount for Total Energy Probe, $30.

Wings and Wheels suggested that the triple probe has three o-rings that would be more problematic that using single probes. Looking at other TE options, like the MGL Avionics G3 series that can use TE inputs.

Single vario probe socket

Feb 11, 2017 Sliding Hangar Door Category: Hangar

Took down temporary side boards and replaced them with 2 x 12 lumber on existing strap hinges. Secured top 14 ga angle pieces as canvas carriers. Secured canvas and bottom chain to side boards. Twisted the north side #2 hanger after removing the roller supporting the #1 hanger. Added 12 ga angle support from side board to canvas hanger to bear the weight.
Learned that the damage on the south corner was due to a C170 on first landing after purchase. One of the main gear brakes locked and the tailwheel swivel stuck. Aircraft wing struck the hangar post bending the metal skin. Will add a red bullseye target to the corner to ward off similar incidents (aim here!).

Feb 10, 2017 Antenna Research - (1 hour) Category: Research

2-10-2017
VHF Communication and Navigation Antenna - Perpendicular Connector, $149.
transponderL2 Transponder Antenna. $99

A bit early to select antenna, but good to have ideas to consider.

Feb 09, 2017 Part Construction from XNS-T08 - (1.0 hour) Category: Empennage

Shape clips with file. Smooth edges on Scotchbrite wheel. Mark bend locations on forward spar caps, AKA 'hockey sticks'.

Feb 08, 2017 Stabilator Parts Construction, XNS-T08 - (1.5 hours)

Category: Empennage

Part -08R & -08L rough cut.

Xenos_empennage_B - 2.jpeg

Feb 05, 2017 Dwg XNS-T06: Stabilator Parts Planning - (2.0 hours) Category: Research

Stabilator Construction Planning, Ribs
XNS-T06 Stabilator Substructure Details
-08 Root Rib Clip, from 1/8"x2"x2" angle
--09R, -09L R&L hand clips, from 1/8"x2"x2" angle
-12 Rib #2, from SNX-Z02-Z04 channel stock. Finished length=19-7/8" + 31/64" + 1/2" + trim allowance = 21" + 1" allowance = 22"
-13 Rib #3, from SNX-Z02-Z04 channel stock. Finished length=17-27/32" + 31/64" + 1/2" + trim allowance = 19" + 1" allowance = 20"
-14 Rib #4, from SNX-Z02-Z04 channel stock. Finished length=16" + 31/64" + 1/2" + trim allowance = 17" + 1" allowance = 18"
-15 Rib #5, from SNX-Z02-Z04 channel stock. Finished length=14-3/32" + 31/64" + 1/2" + trim allowance = 15-1/4" + 1" allowance = 16-1/4"
-16 Rib #6, from SNX-Z02-Z04 channel stock. Finished length=12-1/16" + 31/64" + 1/2" + trim allowance = 13-1/4" + 1" allowance = 14-1/4"
Stabilator channel required for a single set of ribs is 90.5".

Spar channel material SNX-Z03-02 absent from shipped kit parts!

Feb 04, 2017 Polish Test - (.3 hour) Category: Research

Fifteen minutes of working Nushine IIF on the fuselage skin. Should have reviewed Kerry Fores EAA video (http://www.eaavideo.org/video.aspx?v=25190150001%20target=) on the use of Nuvite polishing. Obtained proper twisted wool bonnets.

Feb 01, 2017 Construct EAA Std Workbench - (4 hours) Category: Tools

Assembly of two workbenches from EAA Chapter 1000 Standardized Work Table (attribution in Google document). Modifications from standard table substitutes MDF for plywood. MDF is very easy to cut, there is no splinter hazard that requires the addition of trim for protection. Filled screw holes and paint work surface.
Reference my google doc https://docs.google.com/document/d/1UCXtlvPDARMduPalVMtjP0iy_UHZRKj_c71DIGuTr78/edit?usp=sharing

Jan 31, 2017 MGL iEFIS Programming Documents - (2 hours)

Category: Documents

Collect iEFIS documents from MGL Avionics web site.

Autopilot.pdf

capstan servo install.pdf

iEFIS Autopilot.pdf

iEFIS alteration guide.pdf

iEFIS relocatable modules.pdf

Jan 31, 2017 MGL iEFIS Explorer Docs

Category: Documents

MGL ECB.pdf

iBOX V1 installation manual.pdf

iEFIS installation manual.pdf

iEFIS user manual.pdf

Jan 31, 2017 AeroVee 2.1 Turbo

Category: Documents

AeroVee_2point1_Turbo_Manual.pdf

Jan 29, 2017 Study Tail Kit Plans, Stabilator - (1.0 hour) Category: Research

Tail Plans Arrive. XNS-T03 Stabilator Assembly, fabricate clamp to fit pitot and TE probe.
Parts to purchase for attachment of fiberglass stabilator tip MS24694-SS Machine Screw, qty 10 left, 10 right
MS21047 Anchor Nut, qty 10 left, 10 right
SSC-34 Flush Blind Rivet, qty 20 left, 20 right
Need a countersink tool.
Grommet AN931-3-5, qty 21 right only
The three lines are for Total Energy triple sense probes lines (https://www.cumulus-soaring.com/esa.htm#Triple_Probes) as used on the factory aircraft. Check requirement for a single like this ILEC mount
Article on Total Energy Compensation in practice, https://www.cumulus-soaring.com/ilec/TotalEnergyCompensationInPractice-Brozel.pdf

Jan 28, 2017 Roof Maintenance - (1.5 hours) Category: Hangar

Added fasteners to secure metal roof panels against wind.

Jan 22, 2017 Drainage and Weatherization - (7 hours) Category: Hangar

Dug drainage ditch at the hangar entrance, north side. Installed permeable fabric in ditch. Installed perforated flexible pipe in ditch. Covered pipe with pea gravel from hangar floor. Covered gravel with walkway grate, ballasted with additional gravel on front north hangar entrance.
Cut T1-11 panels to 4' x 42" for hangar entrance above door. Hung one panel. Welded/screwed panel pieces on south wall to cover crash damaged area cuts.

Jan 21, 2017 Detailed Inventory - (7.3 hours) Category: Inspection

Reconciled received items with packing list provided with XenosB kit. Marked storage areas and containers, i.e., W1, W2, ... sections on west wall. B1, B2, B3,... boxes 1, 2, 3. Noted storage locations on packing list.
Found two items missing, a brake fitting and fuel fitting.

Jan 19, 2017 Unpack and Cursory Inventory - (2.5 hours)

Category: Inspection

Unpack and inventory parts. Repackage parts in marked bins. Recorded bin locations on packing list.

Channel stock

Part bins

Fiberglass parts

Fiberglass & ABS items

Marking & labeling

Jan 17, 2017 Receive Wing Quick Build - (2 hours)

Category: Wings

Rented 26 foot U-Haul and met Partain's over the road driver Michael and his dog Bear. Transferred QB fuselage, wings and boxes in a large isolated parking lot 1/2 mile off the Interstate. Took two trips to transfer the QB kit to Hangar 40 at WV12.

wing-port.jpg

wing_stbrd.jpg

Jan 17, 2017 Receive Quick Build - (9.5 hours)

Category: Fuselage

fuselage_in_trailer.jpg

Xenos-B QB after Sonex Delivery.jpg

Jan 17, 2017 Unload & Transfer QB Kit Parts - (9.5 hours)

Category: Documents

Fuselage @ hangar

Loading Wings In UHaul

Randy Installing Tie-down in UHaul

Fuselage in Partain trailer

wing-port.jpg

wing_stbrd.jpg

Jan 16, 2017 Prep for Quik-Build Kit - (6.5 hours) Category: Tools

Jan 15, 2017 Cradle Assembly, Test, and Cleanup - (6 hours)

Category: Tools

Cradle assembly, test with 2" x 12" x 12' lumber, and work area cleanup.

WingCradle-2.jpg

WingCradle-test.jpg

Jan 14, 2017 Redesign and Assemble Cradle - (8 hours)

Category: Tools

Design change in supporting lower cradle. Purchased strips of carpet to support wing leading edge. Assembled strut segments.

WingCradle-1.jpg

Jan 12, 2017 Cradle Base Assembly - (5 hours) Category: Tools

Assembled base components, including wheels and castors with 1/2" bolts and brackets. Initial design with bolted split wheel struts couldn't hold my body weight without folding. Redesign with cut and welded single 36" 12 gauge wheel struts. Lower slots on the 12 gauge axle supports were cut and ground to fit 5/8" bolts for fixed axles. Axles MIG welded to SSt.

Jan 10, 2017 Cut Cradle Superstrut Sections - (1.5 hours) Category: Tools

Cut and finished most of the Superstrut (Lowe's trade name) sectons. Bolted spreader to upright (18" 12 ga to 12" 14 ga) sections with 1/2" 4 bolt 90s.
Superstrut Cut List:
2 - 10' 12 gauge
2 - 36" 14 gauge TBD
4 - 18" 12 gauge
8 - 12" 14 gauge

Jan 08, 2017 Wing Cradle Assembly - (4 hours) Category: Tools

Very cold temperatures remain with the propane tank vapor pressure insufficient to maintain space heater. Cut and fitting of several pieces of Unistrut together.
Created list of additional fasteners as design evolves.

Jan 07, 2017 Wing Cradle Frame Design - (4 hours)

Category: Tools

Sketched out an idea for a metal wing cradle based loosely on an EAA wooden cradle design. Gathered supplies, cut and trial fit of Superstrut sections for a wing cradle. Design objective is to hold 2 - 24 (20' wing + 4' spar) foot wings with pneumatic wheels. Straight axle rear with castering front wheels for mobility.
Will require welding 4 tee sections to secure spreader pieces.
Very cold work environment, 10deg F in hangar. Propane tank was so cold that the propane wouldn't vaporize and light off.

6how to make a wing stand1.jpg

Jan 02, 2017 Hang Shop Lights - (4 hours) Category: Hangar

After breaking an 8' fluorescent overhead bulb, the resulting disastrous and incomplete cleanup initiated a reevaluation on the use of glass in the work area. A broken bulb over the aircraft would be impossible to completely remove the debris.
Purchased eight, 46 inch LED work area lights, along with a battery backup EXIT sign (mostly for fun).

Jan 02, 2017 Install Shop Lights - (4 hours) Category: Hangar

After breaking an 8' fluorescent overhead bulb, the resulting disastrous and incomplete cleanup initiated a reevaluation on the use of glass in the work area. A broken bulb over the aircraft would be impossible to completely remove the debris, so the lighting was switched to LED shop lights. Purchased eight, 46 inch LED work area lights, along with a battery backup EXIT sign.

Jan 01, 2017 Wire Outlets, Hang Lights - (6 hours)

Category: Hangar

Run wiring and install outlets. Hang LED shop lights. Collected excess gravel in hangar and spread across walkway to side door
.

2489.jpeg

2490.jpeg

2503.jpeg

Dec 31, 2016 Power Conduit - (6 hours) Category: Hangar

Welded additional conduit supports, ran PVC conduit and pulled 120 vac wiring across hangar. Purchase LED shop lights, paint.

Dec 25, 2016 Platform, Electrical, Cleanup - (3.5 hours) Category: Hangar

Fastened OSB sub-flooring to platform joists. Welded additional Unistrut sections to hangar frame for conduit support.Cleanup sawdust and work platform area.

Dec 23, 2016 Canvas Door Hangers Category: Hangar

Storm winds vibrated nuts loose from canvas-bottom chain and top hangers. Placed 2x6 on existing hinges and lag screwed the canvas grommets to 2x6, securing soft hangar door side openings.

Continued work on preparing construction platform by placing and leveling decking blocks.

Dec 18, 2016 Screen Programming - (7 hours) Category: Avionics

Study of MGL iEFIS G3 Explorer Simulator and screen alteration guides. Built a standard six pack arrangement using PhotoShop to create instrument backgrounds from photos. Six pack layout was designed to minimize the crowded stock screens. Engine screen designed to compliment a two screen panel. Rejected second screen for lack of panel real estate].
With addition of MGL electronic circuit breaker (ECB), a screen for push buttons and specific current flows will compliment the six pack and engine. Working on an uncluttered navigation screen, but it will be difficult to beat Foreflight on a mini iPad. Current panel layout 5B has a center console to mimic a Diamond HT36 center consol. Pilot uses left hand stick, right hand power during powered operation and right hand stick left hand spoiler for glider operation.

Dec 17, 2016 Factory Quick Build

Category: Wings

Xenos-B_010217-03-20_1.jpg

Xenos-B_010217-06-20_1.jpg

Xenos-B_010217-08-20_1.jpg

Xenos-B_010217-13-20_1.jpg

Xenos-B_010217-18-20_2.jpg

Dec 17, 2016 Work Platform Extension, Outlet Wiring - (7.5 hours) Category: Hangar

Purchased and transported additional 2x6x8 and sub-flooring for 8' x 16' work platform extension. Began welding unistrut to hangar support members for the support PVC conduit wire runs across the hangar width.
Wind damage bending the canvas door supports prompted the examination of more permanent and secure folding door design.

Dec 12, 2016 Wing cradle idea - (.5 hour) Category: Tools

Put two 90 degree bends in full 90" piece of 2" exhaust tubing to be used as support for a wing cradle assembly. This idea for a wing cradle didn't go much farther than purchasing 2" exhaust tubing. Also found removing the aluminized coating is a PITA in preparation for welding.

Dec 11, 2016 Customize Screen Design - (5 hours) Category: Avionics

Worked through two "Six Pack" flight screen variations for programming practice.

The six-pack screen design is intended to be a simple, clean flight instrument layout. Prepping instrument photos in Photoshop for use as background images.
I didn't care for the standard six-pack screen that comes as part of the MGL default as it gives up its screen real estate to fit a moving map display. I find the default layout performs both flight and navigation poorly, hence the custom design.
The first design attempt did not use constructions rectangles from the Drawing Primitive. Sizing and layout suffered to a point. However with the addition of 200 x 200 pixel backgrounds, the background size drives the layout. Second design effort boxed each instrument into a square, with smaller MAP and RPM in gauges in the box intersections. That really doesn't work out. Maybe a second Explorer screen is in order to support the primary. Each CHT and EGT sensor can be represented as squares that change color depending on caution or warning settings, which might be and idea for an unobtrusive addition.

Dec 11, 2016 Prep for Work Platform Expansion - (2.5 hours) Category: Hangar

Level deck blocks for 2" x 6" x 8' framing to add an additional 8x16 section to existing work platform.

Dec 10, 2016 Door Lockset & Brush Control - (3 hours) Category: Hangar

Set the side door lockset strike plate. Brush cutting and cleanup. Cut final piece of brush obscuring view down runway 33 from hanger.

Dec 07, 2016 iEFIS mockup - thermocouples - (1 hour) Category: Avionics

Connect thermocouples to RDAC. Fuel capacity, RPM range setup. Tested ILS approach to KCRW 05. Began to design a "glider" screen.

Dec 06, 2016 iEFIS Mockup Mount - (4 hours) Category: Avionics

Paint and mount MGL Explorer screen, iBox, RDAC, SP-6, and SP-7, GPS antenna to frame. Wired CAN bus and thermocouple inputs (T/C).
Power supply is 110VAC to adjustable 12 VDC ( nominal 13.6v ).
Nota bene: T/C red is negative. Carry/spacing bar on top, magnetic 'tape' for GPS attachment. Took it 'flying' around the block in the seat of my car.

Dec 05, 2016 Load iEFIS with Terrain Data - (3 hours) Category: Avionics

Download navidata, high resolution terrain, and map data for MGL iEFIS Explorer.

Dec 05, 2016 Avionics Mockup - (2 hours) Category: Avionics

Cut and fit aluminum scrap for iEFIS mount. Cutout for MGL iEFIS Explorer. Added mounts for iBox & RDAC.

Dec 04, 2016 Install Entry Door - (3 hours)

Category: Hangar

Plumb and secure 32" metal side entry door.

2451.jpeg

Entry door.jpg

Exit_door.jpg

Nov 30, 2016 Setup EFIS SD Card - (4 hours) Category: Avionics

Setup of MGL iEFIS Explorer, G3 B.
Downloaded and read the MGL iEFIS User's Guide.
1. Installation of the latest firmware.
2. Download GPX file of US and Canada from www.navaid.com
3. Add to database.
4. Download Digital Obstical File (DOF) from FAA. (https://www.faa.gov/air_traffic/flight_info/aeronav/digital_products/dailydof/)
5. Download Airspace Vector Files. (http://www.stratomaster.com/Data/North%20America%20Airspace.exe)
6. Download female voice file from MGL.
7. Download several VFR sectional files from the FAA. (https://www.faa.gov/air_traffic/flight_info/aeronav/digital_products/vfr/)
8. Run MGL Central version 1.9 to import and compact into a database file.
9. Transfer to micro SD card
10. Load firmware, Navaid, Waypoint, DOF, terraindatabase to iEFIS Explorer.
Installation to database consisting of Navaids, Waypoints,

Nov 27, 2016 Entry Door Framing - (3.5 hours)

Category: Hangar

Selected area on hangar skin that had been damaged resulting from aircraft previously departing runway 15, hitting the side of the hangar, coming to rest inverted onto the hillside at the rear of the hangar. Used plasma cutter to remove steel brace and hangar skin for 32" x 80" pre-hung door frame. Leveled and screwed framing to steel hangar skin.
Patched damaged section with scavenged steel piece.

2505.jpeg

2512.jpeg

2514.jpeg

Nov 25, 2016 Soft Door Hanger - (8 hours)

Category: Hangar

Five foot hanger/roller assembly too long, grommets too wide at 18". Revised the cotton duck door hanger/roller, using 5 - 4 foot lengths of 1-1/2" 14 gauge slotted angle (Lowes 69815 ). 2" strap hinges welded to angle pieces.[Hinges were later found to promote twisting of the supports and were cut away from the hangers]. Roller hanger 1/2" threaded rods bolted to center of 4' angle canvas hanger span. Used a gallon of Latex roof seal and plastic mesh for a double layered seal around roof vent. Wired 240 AC outlet to panel board.

2518.jpeg

2522.jpeg

2523.jpeg

2525.jpeg

2528.jpeg

Nov 24, 2016 Side Door Prep Category: Hangar

Gathered material and built a 2x6 framing for a 32" metal entry door. Fit frame against hangar metal skin.

Nov 20, 2016 Self-launch endorsment - (3 hours)

Category: Research

Dual instruction in DIMO HK 36 TTC motorglider to obtain self-launch endorsement. Some thermal hunting, three emergency return to landing 270s from 300 feet.

Self-launch endorsment

Nov 20, 2016 Experiential Flight in a Sonex - (1.4 hours)

Category: Research

Examined and flew in George's Sonex N607LT in KPAN Payson, AZ. An hour flight with 0.6 as PIC.

N607LT

N607LT

Cabin Heat

Vans Wheel Pants

Cabin heat control

Nov 16, 2016 Quick Build Progress

Category: Wings

Photos from Sonex showing quick build progress.

QBwings - 1.jpeg

QBwings - 2.jpeg

QBwings - 3.jpeg

QBwings - 4.jpeg

Nov 11, 2016 Hang Right Side Door - (6 hours)

Category: Hangar

Hung right side canvas door.

2515.jpeg

2517.jpeg

2518.jpeg

2519.jpeg

Nov 08, 2016 Canvas Door Holder/slide - (3 hours) Category: Hangar

Welded hinges to 16 gauge slotted angle sections.

Nov 06, 2016 Right-side Hangar Door - (6 hours) Category: Hangar

Worked on the right side door track. Drilled and tapped two additional 1/2" holes for National Hardware 293BC 1/2X6 Bolt Hook, Zinc (Tractor Supply). Each hook supports a Galvanized Box Rail Splice Bracket which holds (National Mfg. Plain Box Rail 450 lb. Capacity w/24" OC Brackets - 10' Galvanized N105-213) rail, with 1/2 in. Zinc-Plated Offset Flexible Box Rail Hanger Kit.

Brush cleanup and burning party.

Oct 23, 2016 Wiring & Curtain Door Planning - (11 hours) Category: Hangar

Completed wiring for two 8 foot fluorescent fixtures. Found after installation that one was for T12 slimline rather than the desired T12 HO. Exchanged the slimline for high output. [Removed florescent lights after accidentally breaking one while moving something on the platform.]
Installed left side roller track and poly tarp. Needs a stiffener/support or hinged top. Twenty foot tow chain for weight and to secure the
Ordered heavy (12oz) cotton duck tarp for each side from tractor supply. Plan will be to use the cotton duck for exterior and a poly tarp for the inner member in a 'shower curtain' configuration.

Oct 22, 2016 Push-rod Assembly - (1 hour)

Category: Engine

Measured and cut push-rods to length. Measured length using the push-rod tool - cut at bottom of socket hex.

Pushrod debur.jpg

Pushrod length-2.jpg

Pushrod length.jpg

Oct 22, 2016 Interior Conduit Installation - (8 hours) Category: Hangar

Installation of conduit for hangar interior lights. Drilled and tapped pipe for additional roller track hangers. Hangers are 1/2" gate hinges, roller track hangers drilled to 1/2" and secured with 1/2" tubing clamps.

Oct 15, 2016 Assembly - (8 hours) Category: Engine

My time-lapse assembly videos:
1. https://www.youtube.com/watch?v=faYICUGHNoo
2. https://www.youtube.com/watch?v=BQNv6iA_N6A

Oct 14, 2016 Determine Cylider Head Volume - (2.5 hours)

Category: Engine

Determined cylinder head volume using a sheet of Plexiglas with a hole and a syringe.
Cylinder 1:
Cylinder 2:
Cylinder 3:
Cylinder 4:

Volume measurement

Oct 13, 2016 Trim cylinder head studs - (2 hours)

Category: Engine

AeroVee 2.1 Turbo page 23. 9:00 - 10:53 pm Installed starboard head to check stud dimensions. Removed 0.275" (7mm) from each stud.

2554.jpeg

Stud_file.jpg

Oct 13, 2016 Evaluate & Dress Heads - (2.5 hours)

Category: Engine

Received head assemblies from AeroConversions. Evaluated the clean up work to the castings. Cut, filed, and smoothed cooling fins around dual plug cuts. Fit-up of heads to cylinders indicates the studs will be much longer than necessary.
Measured stud length to leave 2-3 threads. Removed 0.275 in (7.0mm) from each cylinder stud. Procedure to cut studs to have 2-3 threads showing is to chuck stud into padded vise, measure with micrometer, cut, chuck into lathe, dress end with file, Applied Curil K2 to case end and snug into case saver. Pushed #4 cylinder bottom case saver into case, pulled it back and snugged into case.

Sharp edges from machining

Smoothing stud end

Stud end

Intake matchup

Sharp edges on fins

Intake matchup

Oct 09, 2016 Prep For Hagar Door Rollers - (7 hours)

Category: Hangar

Planning to use rollers running in track to support cotton duck doors. Removed the balance of metal from front of hangar doorway. Evaluated AEP's work to meter stack.Cut more limbs from trees on the north rear of hangar.
Anna finished painting the picnic table.
While drilling and tapping entry pipe for roller track, felt slight electrical shock from stray electrical current. Called AEP to report leaking current, measuring 80+ volts between the hangar pipe framework and the dirt. Ground cable in box felt hot to the touch.

2540.jpeg

Sep 29, 2016 Prep for AEP Power Connect - (3.5 hours) Category: Hangar

Met AEP's engineer to discuss connection plan. Easy install for AEP. Need flood plane permit number. Called county planning, they are sending flood plane permit to AEP. Called AEP's planner/scheduler Drema and left word that the county planning department was sending the permit number.

Spent several hours constructing and hanging unistrut for lighting and outlets
. Half and hour trying to set flashing around the turbine vent. Need additions flashing and sealing for the vent area.

Sep 26, 2016 Setup Compression Ratio - (4.5 hours)

Category: Engine

5:45 am weighted piston + rings + wrist pin:
Cyl #1 518.0 gr; Cyl#2 517.6 gr; Cyl#3 518.8 gr; Cyl#4 518.8 gr
Deck height on all cylinders +/- 0.001" of 0.0. No additional shims. Assembled a shim pack for 7.0 : 1 compression ratio. Page 22 indicates a shim stack of 0.17. With shims from kit plus additional 0.01" shim stack is 2 x 0.06 + 0.04 + 0.01. Will re-evaluate after measurement of combustion chamber volume and re-calculate compression ratio.

2594.jpeg

2600.jpeg

2601.jpeg

2636.jpeg

Sep 26, 2016 Electrical Inspection Fixes - (10 hours) Category: Hangar

Added #6 wire to run (ground from meter to service); changed conduit entry to meter stack.

Sep 25, 2016 Assembly, Torque Gland Nut - (11.5 hours)

Category: Engine

Assembly of external engine components, manual pages 29-35 and 40-42 while waiting on back-ordered head assemblies to ship.
To torque the gland nut, used the body weight torque technique. The method is modified from Wilson "How to rebuild your Volkswagen Air-Cooled Engine". Rather than pushing down on the 'cheater bar', the AeorVee was bolted to a wood frame with two anti-torque plates holding the motor in place.

A 1/2" breaker bar with a cheater made from a motorcycle fork tube was used as the lever. Desired torque in the neighborhood of 300 ft-lbs (315 ft-lbs, Wilson, pg126); 315/200 = 1.575 * 12 = 18.9 = 19 inch lever arm marked on fork tube. Alignment mark on breaker/fork. Used a seated pull-up to use my body weight to supply the correct amount of force. Discernible movement of the gland nut, movement between marks on nut and flywheel.

2616.jpeg

2617.jpeg

2625.jpeg

2626.jpeg

Case_assembley.jpg

GlandNut_torqueMark.jpg

OilSump_torque.jpg

Sep 24, 2016 Case Prep & Assembly - (12 hours)

Category: Engine

Finished case prep by grinding/sanding/Scotchbrite outside of engine case. Wash with mineral spirits followed by a wash with soap & water. Checks for loose casting flashing. Taped and painted cylinders and engine crankcase with ceramic engine paint. Prepare crankcase for assembly, mount port side case to engine stand. Assemble bottom end. Used Curil K2 rather than the recommended Permatex Aviation sealant for case haves, obtained good sealant squeeze-out around case perimeter.

CamshaftTimingMark.jpg

Sep 23, 2016 Crankshaft & Connecting Rod Assembly - (3 hours)

Category: Engine

Crank placed in freezer for 24 hours prior to assembly.Timing gear and prop hub heat soaked in oven at 500degF for two hours to get a blue color on the cam timing gear. Main bearing #1 oil supply hole enlarged to 1/8" with the outboard end chamfered slightly. Assembled with JEG's assembly lube, part number: 555-28000. Engine assembly stand slide bolt was loose resulting in crank falling onto my foot/toes after assembly. (ouch!).

Used Plastigauge green to check main bearing bores. Clearances OK. Cleaned bores, connecting rod layout per photo. Connecting rods caps with hex nuts and ACV-P06-33 part number, but no 'star' head. Used red Loctite and 'clean' torque progression per step 5 to 8/15/24/30 ft-lbs.

Crank & prop hub

Connecting rod

AeroVee_conrods.jpg

ConRod_torque.jpg

2667.jpeg

Sep 23, 2016 Case prep - (6 hours)

Category: Engine

Grind, sand, Scotchbrite polish external crankcase casting irregularities. Washed case in mineral sprites. Rinse with soap and water. Taped and painted case with black ceramic heat paint. [Later regret for painting the case, as the paint readily flaked off.]

2672.jpeg

2677.jpeg

2682.jpeg

Sep 22, 2016 Cam and Crank Assembly - (1.5 hours)

Category: Engine

Polish stamped number with emery cloth while turning camshaft in lathe. Assembled bearing, cam drive gear with wavy washers and prop hub per AeroVee 2.1 turbo instructions on page 10. Needed 425 degF in oven to get the camshaft drive gear to turn blue.

2666.jpeg

2667.jpeg

Sep 21, 2016 Electrical Inspection Misc - (1.5 hours) Category: Hangar

Left re-inspection fee in box for inspector.

Sep 20, 2016 Pickup AeroVee Kit - (1 hour)

Category: Engine

Pickup AeroVee at XPO Logistics. Pallet fit in the back of 2003 Toyota Rav4 with the rear seats removed.

2683.jpeg

AeroVee_pickup.jpg

AeroVee_sn.jpg

Sep 16, 2016 Electrical Inspection - (8 hours) Category: Hangar

Added #4 Al ground to make 4-4-4-4 run from meter to service panel. Added 2" PVC conduit to 1-1/2 knockout in meter stack. Installed 120VAC 20 amp outlet below service panel for testing. Added bonding block on board with bare #4 Cu to ground rod at stack.

Sep 13, 2016 Grounding, Place Outlet - (3 hours) Category: Hangar

Used Bosch hammer-drill to set ground rods. Set single outlet for circuit test after inspection and AEP power hookup.

Sep 10, 2016 Pull Service Wires in Conduit - (7 hours)

Category: Hangar

Some water leakage from roof after heavy storm. Placed additional fasteners in metal roofing.
Pulled 110 feet of 4-4-4-(removed #6 ground) aluminum wire from service box to meter stack. Set two grounding rods.[This was later found to be not to code. Grounding happens at meter end, not surface end.]
Assembled used picnic table from the West Side Wonder Wall.

2692.jpeg

2693.jpeg

2694.jpeg

Aug 25, 2016 Underlayment and Metal Sheeting - (8 hours)

Category: Hangar

Progress on rehabbing the metal roof. Mike Mallory told me the hanger had been built around 1998.
Monday 3.5 hrs, Tuesday 2 hrs, Wednesday 2 hrs (left phone in tool belt), Thursday 3.5 hrs. M + T pleasant temp and slight breeze. W + Th very humid & hot.

2708.jpeg

Aug 21, 2016 Rehabilitate Roofing - (7.5 hours)

Category: Hangar

Installed drip edge on NNE end to provide straight edge for underlayment. Installed turbo roof vent. Placed 2 rolls of 15# felt underlayment. Reinstalled several full-length runs of previously used economy corrugated metal roofing. Butyl caulk placed across the bottom edge of each course of corrugated roofing.
Light morning rain. Humid.

2713.jpeg

2714.jpeg

2715.jpeg

Aug 20, 2016 Strip Metal Sheeting From Roof - (12 hours)

Category: Hangar

Stripped the majority of metal roofing, stacked for later re-installation. Replaced several rotted sheathing sections.Trimmed NNE edge of wooden roof line with circular saw in preparation for drip edge. Cut hole for roof vent.

Heavy, rain shower in early afternoon. Rain shower overnight.

2719.jpeg

2721.jpeg

2723.jpeg

2724.jpeg

2725.jpeg

Aug 16, 2016 N-number Reservation - (0.1 hour)

Category: Documents

FAA N-number reservation confirmation for N25XB.

FAA Registry - Aircraft - N-Number Inquiry.pdf

Aug 14, 2016 Electrical Power Conduit - (9 hours)

Category: Hangar

Installed conduit, conduit supports, and clamps with twelve feet left to connect to main.

Rain shower mid-afternoon, leaks predominate at metal section joins. Soaked work platform flooring.

2693.jpeg

2699.jpeg

2705.jpeg

Aug 13, 2016 Electrical Power Installation - (12 hours)

Category: Hangar

Installed 100 amp breaker panel. Started 2" conduit run to meter approximately 150' away.

2698.jpeg

2703.jpeg

Aug 13, 2016 Build work platform - (16 hours)

Category: Hangar

Collect material from Home Depot.
Built 8' x 16' platform from decking blocks, 2x6x8 lumber, and 4x8 OSB sheets, metal angles and hangers.

2735.jpeg

2738.jpeg

Aug 12, 2016 Initial Panel Layouts - (14 hours)

Category: Instrument Panel

Installed xPanel (https://www.xpanelsoftware.com/) software to develop ideas on some panel designs. Used the original Sonex panel template supplied by XPanel.

InstrumentPanelrev1.jpg

InstrumentPanelrev3.jpg

InstrumentPanelrev3c.jpg

InstrumentPanelrev3e.jpg

Aug 10, 2016 Required tools, lubricants, thread lockers for engine - (12 hours)

Category: Research

Waiting for heads to ship, painted turbo, fit turbo with oil drain. Drain flange has bolt holes that are too small for the specified fasteners. Setup intake manifold, found a straight coupling and 45 degree silicone pieces missing from shipment. Two extra silicone adapters in kit. Sonex sent missing parts and arrival within the week. Started to setup air filter to carburetor, purchased 10-32 tap for AeroInjector intake bell.

Research and purchase required tools and shop supplies. Engine stand, thread lockers, oil cooler lines an fittings purchased from Jeg's.
Ordered recommended book on Volkswagen engines "How to Rebuild Your Volkswagen air-Cooled Engine (All models, 1961 and up)" from Amazon.
In reading other builder's log entries, found it not uncommon to have leaks of stock pushrod tubes. Researched alternate push rod tube arrangements with German-mad CSP (http://www.csp-shop.com/technik/pdf/deeng/26686.pdf) highly rated but expensive at $270 USD.
Purchased red anodized 2-piece with internal O-ring seal and external springs ($90). Also ordered woven red heat shielding for spark plug covering.

2613.jpeg

Aug 08, 2016 Full Kit Discount - (.2 hour) Category: Research

Full kit purchase discount. Subtract $2,900 from total (EAA log will not accept negative numbers).

Aug 08, 2016 Initial Purchase - (0.5 hour) Category: Landing Gear

Initial purchase of AeroBrakes and 6 inch tailwheel.

Aug 08, 2016 Initial Purchase Category: Cowling

Initial purchase of cowling.

Aug 08, 2016 Controls and Gear Kit - (1 hour) Category: Controls

Initial purchase of controls and Gear Kit.

Aug 08, 2016 Initial Purchase - (1 hour) Category: Wings

Initial purchase of AeroVee standard gear mount.

Aug 08, 2016 Initial Purchase - (1 hour) Category: Wings

Initial purchase of Wing kit plus Quick Build service.

Aug 08, 2016 Tail Kit Purchase - (1 hour) Category: Empennage

Initial purchase of Xenos tail kit.

Aug 08, 2016 Initial Purchase - (2 hours) Category: Fuselage

Fuselage kit plus Quick Build service.

Aug 02, 2016 Clean hanger space - (14 hours)

Category: Hangar

Cleared debris, sprayed vegetation with ERASER. Hauled a trailer full of refuse to the Charleston Landfill.

Roof assessment with UV N343DR photos.

2742.jpeg

2773.jpeg

2774.jpeg

Jul 31, 2016 Evaluation & Cleanup/rent - (6 hours)

Category: Hangar

Evaluation of hanger space. Measure openings, Begin cleanup.
Rent+

2744.jpeg

2745.jpeg

2749.jpeg

2768.jpeg