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

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

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

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

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

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

  May 09, 2021     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.

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

Additional coat of yellow enamel to the spoiler pulley bracket.

  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.

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

Cut a reinforcement to rivet on the outboard side of

  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.

  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.

  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.

  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.

  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.

  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.

  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.

  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     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     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     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.

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

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

Trimed an additional 1.25 inches from the pedal adjuster.

  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.

  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.

  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.

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

  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 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 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.

  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.

  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 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 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

  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 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     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 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 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 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     Control Cable Adjusters - (0.8 hour) Category: Controls

Made control cable adjusters from 0.190 Al stock.

  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 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     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.

  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.

  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 07, 2017     Drill & Fit Pulley Mounts - (4.0 hours) Category: Controls

Make spoiler handle mount.

  Aug 08, 2016     Controls and Gear Kit - (1 hour) Category: Controls

Initial purchase of controls and Gear Kit.