Apr 01, 2024     Wings fixed - (6 hours) Category: Misc

Plane with firm left roll since I started flying it. Thought I messed up attaching lift strut fairings on left side and created large “trim tab”. I cut them off and put “corrective” trim tab on right liftstrut to get more right roll. Long story short, no improvement to foll at all. I spent some time to check (confirm) the proper wing dihedral and incidence that I had originally paid extra to have factory do for me before my kit was delivered. Dihedral and wing twist was off. I recorrected to contruction manual specs. Plane flew a LOT better. Now only slight right rudder will get the ball into his cage.
I have since removed the trim tab from right lift strut and applied it with masking tape to rudder.

  Jan 30, 2024     First flights - (5.0 hours)       Category: Misc

First flight only 6 minutes airborne due to false engine over temp indications. Getting high indicated temps when I turn on landing lights, nav lights, strobe or pitot heat. Some type of electrical interference. Went up for second flight and did several touch and goes. Heavy left wing.....maybe due to solo flight with weight on left seat.

  Jan 29, 2024     Taxi tests and engine runups - (14 hours)       Category: Taxi tests

Multiple days at hangar to finalize install of floor boards, carpet, seat belts, fix coolant leak, engine run up, adjust prop pitch settings to obtain desired static rpm, brake break-in, taxi tests to learn braking with castering nose wheel is different.

  Jan 23, 2024     Plane is "blessed" - (5.0 hours)       Category: Misc

Time includes time spent on phone in last couple of weeks to complete Airworthiness application with FAA. Had to deal with Frank Sperandeo (DAR), William Champion (MIDO in San Antonio) and Geary Mockton (FSDO) in Albq. Frank said my inspection was toughest he had done.....only 6 pages of forms but took over a month to get all worked out and completed online, my phone and in person..DAR visit to "bless" the plane. DAR was not familiar with Rotax, turbo, intercooloer nor electric, constant speed prop. He twisted a few bolts, but found no significant issues.
AWC comes with operations limitations. Annotated map shows my proposed and approved plan to fly out of El Paso airport KELP. Red area is exiting immediate airport area north of heavy density housing and over the desert. The green is transition over lightly populated area to turquoise area for major test flight area.





Paperwork completed and I have my special airworthiness certificate. YEAH!!.

  Jan 11, 2024     Transition training plane and airport - (5.0 hours)       Category: Misc

Aerial photo of Reno-Stead KRTS airport AFTER plowing. Over 2 days and 4 flights at 5.5 flight hours, I did 23 landings....in a tail wheel, on packed snow, frozen and slushy ice. Never saw any dry pavement. I was able to land the plane but unable to keep plane straight after landing.....brakes and steering is WAY different. No intent to get tail wheel endorsement.

  Jan 11, 2024     Wing cuff detail from trainer plane - (1.0 hour)       Category: Misc

Photos of wing root cuffs showing fitting to wing.

  Jan 10, 2024     Other Kitfox details - (3.0 hours)       Category: Misc

Several photos of details noted on other Kitfoxes I saw in Reno

  Jan 09, 2024     Trent Palmer meeting - (1.0 hour)       Category: Misc

Earlier, had flown over Trent Palmer property. Then found out he had something to show Fred Williams and flew over to Fred's hangar after we landed morning flight.
Freedom Fox plane came too. Trent just like he appears on Youtube.

  Jan 08, 2024     Transition training - (10.0 hours) Category: Misc

Transition training with Fred Williams at Reno Stead airport outside of Reno, NV. Spent 1-6-24--1-13-24. Weather great for ski areas but terrible for flying. Able to get 5.5 hours of training. Twenty-three landings with a tail wheel on snow packed, icy and at times, slushy runways. Never saw the pavement. One day, took flight tour over Lake Tahoe, Truckee, Donner Pass, Incline Village, Carson City, multiple ski areas. Got one day skiing at Diamond Peak outside Incline Village.

  Jan 03, 2024     Move to airport - (3.0 hours)       Category: Misc

Move to airport with special trailer. Cost an arm and two legs but got to airport without any damage.

  Jan 02, 2024     Phone calls, emails, braces - (4.0 hours)       Category: Fuselage

Call to ABQ FSDO about my test flying area SE of KELP. Talked with Geary Monckton about my proposal and sent email with written plan and diagram on VFR sectional.
Folded wings and secured braces onto wings to support wings during transport. Also drove to far East side to get engraved Data plate done per Frank Sperandeo.
Sent copy of e-mail from ABQ FSDO approving my test flight area and sent photo of data plate for approval.

  Jan 01, 2024     Leaks fixed - (2 hours) Category: Engine

Not feeling well today. Didn't go out until mid afternoon. Pulled barbed brass fitting from fuel pressure transducer. Cleaned threads of fitting and used thread chaser to clean inside of transducer. Applied sealant and re-installed.
Also check and tweaked some sensor limits on GDU config to better match indications I saw yesterday on engine run. Checked coolant level and found it quite low. That would explain high CHT temps I saw yesterday.
Fired up engine again. Ran at low rpm <2200 rpm until I got to 120 degrees oil temp. NO fluid leaks, no oil blown out. Not sure why I had so much oil yesterday. What I thought was coolant, I now believe was only the gas coming from fuel transducer with air blowing across puddle of fuel and evaporating the more volatile components leaving the oily residue that I mistook for coolant. So I'm very pleased no leaks. Plane ready to travel.

  Dec 31, 2023     Engine run to operating temp - (1.0 hour) Category: Engine

After condition inspection was complete and brake leak fixed, I put all back into place and cowls on and did engine start and 2000 rpm idle to get engine oil temps above 120 degrees and then ran up to about 4300 RPM. By the time I got to that point, the CHT was over 285 and flashing red so I shut down. Took off cowl and found fuel, oil and coolant leaks onto ground. Found the fuel leak in fuel pressure transducer but could not find source of oil leak nor coolant leak. I think oil may be coming from oil vent line but there sure is a lot being blown back onto fuselage, gear leg and tire. Could not find even a trace of a coolant leak. Not sure what is going on.

  Dec 31, 2023     Brake leak fixed - (1.0 hour) Category: Landing Gear

Had tiny leak in brake fitting on right brake. Had to remove, clean threads and chase threads with tap to get fitting to seat where I could re-attach brake line. By carefully removing brake line with parking brake set and controlling bleed valve, I was able to accomplish all without having to do a full brake line bleed. In process, I had to cut the safety wire and remove the brake assembly to do my repair. All went back into place and pressure test with parking brake to hold pressure showed no leaks. Brake bolts re-installed and re-safety wired. Safety wire went real quick this time....less than 5-10 minutes instead of 1/2 hour or more last time.

  Dec 31, 2023     Condition inspection - (1.5 hours) Category: Fuselage

Final assembly inspection and condition inspection completed. Found missing nut for horizontal stabilizer pivot.....oooops!

  Dec 30, 2023     Odds and ends - (3.5 hours) Category: Fuselage

Found some more loose nuts, tightened last of screws in boot cowl, attached tabs on boot cowl/windshiled for glare shield, checked rigging measurements,

  Dec 26, 2023     DAR consult - (1.0 hour) Category: Fuselage

Another hour or so with Frank Sperandeo trying to getting FAA paperwork completed correctly to his specifications. He seems much more confused than I am. Had to resend a lot of paperwork I had already sent but he wanted each document in separate e-mail.
Now that plane is "finished", I was able to send photos of three views: left side, front, right side.

  Dec 26, 2023     Final, finishing details - (4 hours)       Category: Fuselage

Checked for shorts to ground for all GNX and GDU connections and found only pin 43-47????? with slight connectivety, but more inportantly, when i only start GDU under confic settings and NOT GNX, then I get NO red "X's". I'll run with that for now.
Spent several hours using fire proof putty to help seal boot cowl to firewall. Also installed rest of my thin weather stripping used on windshield to help seal boot cowl to airframe aft of fire wall and to front windshield. Installed boot cowl and screwed in 30+ screws to secure it. Tightened up last of nuts I could find.
Red "X's" went away on GDU config screen after my re-wiring.
Sooooo, the plane is essentially FINISHED. Couple more trim items and half dozen cotter pins to install.......oh yeah, already have to do a repair and re-bleed brake lines due to leakage at couple of fittings.
But plane can fly as it is now.

  Dec 25, 2023     Condition inspection - (3 hours) Category: Fuselage

As part of initial condition inspection before airworthiness inspection next month, I started on multiple items: Vacuuming/cleaning cockpit floor, securing multiple nuts/bolts, torque witness paint as needed, lubrication of all moving parts, inspection of inside of fuselage, wings.
Also reconfirmed correct wiring connections for RS 232 between GDU-GEA 24, GNX-375-GSU 25. After panel put back, still shows error connection on GDU port 1 of RS-232. Will check for grounding short tomorrow.

  Dec 22, 2023     GAD 29 rewire - (6 hours) Category: Avionics

No answer back yet from Garmin on Config setting for ARINC RS 232 connections. I decided since I was getting similar error messages before and after redoing wiring from GNX375 to GDU 460 per page 109 of GNX 375 install to diagram on page 24-37 G3X ver AQ install manual, I decided i had a wiring error. Sure enough, I had some wires cross between GAD 29 and GNX 375.
Originally thought I would have to pull out entire instrument panel to access connectors. After removing all avionics and just a few panel support screws, I saw I could access the pins at back of GNX375 mount using jumper pins. Spent 6 hours trouble shooting, pulling pins on connector on GAD 29 and repinning to match wiring diagram located page 24-37 on G3X install manual ver AQ. During the process, i reconfirmed correct pin continuity between GDU 460 and GNX 375 were/are as shows on page 24-37 G3x install manual.
Pleased with my self, I put all back together and fired up config screen. Good new is I had another connection show up but still with couple Red X's with ARINC and RS 232 connections......very discouraging.

  Dec 21, 2023     W&B - (2.5 hours) Category: Fuselage

Couple of hours measuring arms and weight calculations. Filled standard FAA W&B sheet along with Kitfox balance sheet. Even though plane a little heavy using 2 x170# pilot/passenger, adding 23 gallons gas and 150# luggage in proper location, I'm at max gross and 1 inch forward of aft limits. I'm happy enough with load carrying capacity.

  Dec 20, 2023     Builder log updates - (5.0 hours) Category: Research

Several hours over course of several weeks to update online builder's log. I hadn't uploaded pictures since Nov 2022 and when got ready to do so several weeks back, I couldn't log entries between Sept 2022 and Aug 2023. I was clicking box top left of task lists that showed "latest dated entries" Seems it only lists backwards just a few months. I was concerned all was lost but contacted website host who told me to click on "show ALL entries" in column of tasks lists. Spent last several days uploading photos between Nov 2022 and Aug 2023. Now, I'm all caught up.

  Dec 19, 2023     tail section details - (1.5 hours) Category: Avionics

Install numerous nuts and torqued down. Finally found missing sheet metal edge roller to put slight bevel on edge of sheet metal closeouts around horizontal stab. Also put in horizontal crease on large panel to get it to fit better.

  Dec 19, 2023     GDU GNX rewire - (4.0 hours) Category: Avionics

Multiple hours to change wiring from pintout diagram from GNX 375 install book to diagram on page 24-34 G3X install Ver AU. After finishing up wiring and re-installation connector, fired up config screen.....still issues with connection. Another Help request into Garmin

  Dec 17, 2023     DAR paperwork help - (2.0 hours) Category: Research

Will call it "research" to learn from DAR Frank Sperandeo how to fill out paperwork for Airworthiness inspection coming in about 4 weeks

  Dec 17, 2023     GDU GNX wiring issue - (6 hours) Category: Avionics

Over several days (now going into weeks) I've been dealing with connection problems between GDU 460 and GNX 375. I originally wired GNX 375 per GNX install instructions. G3X per page 25-27 in install manual Ver AP, AQ, AU shows different wiring config. Will no luck getting RS-232 and ARINC taling between GDU and GNX, two contacts about problem with Garmin G3xpert with modified config settings, I decided to rewire to meet the suggested wiring on G3X to GDU pin outs. Spent today trying to figure out which wires were which, which to cut and which two wires to splice to accomplish the goal.

  Dec 11, 2023     Configuration - (3.0 hours) Category: Fuselage

With corrected wiring between GTR200B and GDU460, I now have audio alerts. Also re-set some other limits for sensor read outs.
HOWEVER, I still have issues with RS-232 and ARINC connections. GDU system doesn't "see" GNX375 at all. Another query into G3xpert.

  Dec 10, 2023     Cotter pins and safetry wire - (2.5 hours) Category: Fuselage

Tried to locate all bolts/nuts needing cotter pins and safety. Need to get a slight smaller cotter pin for nuts on nose wheel. Took several tries to safety wire the three bolts on disc brakes.

  Dec 10, 2023     Rewiring of GTR200 - (3.0 hours) Category: Fuselage

eWorking on more panel config, discovered I had lost audio alerts for GDU 460. An answer from G3expert said I had mis-wired. Spent couple of hours and corrected mono audio to connect with GDU and removed Stereo outputs from GDU. That wire that originally went to GTR200B is now stubbed out and behind right panel and can be wired to 3.5mm Jack to provide hard wired external music via cable.

  Dec 05, 2023     tightening nuts and bolts - (3.0 hours) Category: Fuselage

Went through most of airframe parts installed when moved to driveway to tighten nuts bolts and replace some temporary connections with proper bolts.

  Dec 05, 2023     Install windshield and wing tips - (3.0 hours) Category: Fuselage

Spent about 3 hours screwing in about a 100 screws...about half with washers and nuts to final install both wing tips and windscreen. After all screwed in, then I found out about a cement to repair crack in top left corner.

  Dec 04, 2023     Polish windshield scratches - (6.0 hours) Category: Fuselage

Hours and Hours trying to remove some scratches on right side of windshield where I had added some Hysol to get window to fit better. During smoothing of Hysol, I created some scratches on the inside. I worked and worked. Went to store to get more grits of wet sanding paper and buffing compound. Then it dawned on me that the scratches were on the other side of the window. Once those were removed, all quite shiny. Now I won't be bugged by knowing scratches were there.

  Nov 29, 2023     RS-232, ARINC connection - (2.0 hours) Category: Avionics

Still can't get all RS-232 and ARINC connections to talk to each other. Tried some more settings per manual but don't work, Got some pictures and will send to GarminG3xpert.

  Nov 29, 2023     Fuel leaks, engine start - (8.0 hours) Category: Engine

Spent most of morning working on fuel leaks and going through comm/radio check list. For whatever reason, I've had no comm Rx since radio installed. I did determine at one time I needed to enlarge pass-through hole in AC frame to allow better BNC connection. Today, I couldn't figure out why no comm Rx when all basic tests showed wiring was correct. So decided to double check antenna cable......ya know....when the antenna cable IS connected to the antenna, you can get reception.....DUH!!!. Antenna cable laying on floor of cargo.
More torque on couple of copper crush gaskets fixed couple of leaks and then another popped out. Had to remove fitting into main fuel line for fuel pressure, dry, clean and use more thread sealer. Then the moment came......On fourth try, the engine started and ran.fine. 88 psi oil pressure.

  Nov 16, 2023     Flaperon rigging - (2.0 hours) Category: Wings

This was going to be a quick job to set flaperon movement limits on the control rod mixer. Long story short, it took two hours to set flaperons, measure angles, and finally determined that the desired flaperon angle movement needed ALL lateral control movement available. All I did was screw in limit screws to touch the control stick. and will tighten lock nut. I spent a lot of time checking angles and wondering why the flaperons drooped compared to the wing. Then I read about checking angles at different flap settings.......ooooh...seems the first measurements I took were with flaps partially deployed instead of secured. I re-did all measurements using the App on my phone and all measurements within 2.5 degrees of desired. Left and right are within 0.5 degree of each. Then left for Colorado for Thanksgiving for 10 days.

  Nov 15, 2023     Configuration - (6.0 hours) Category: Avionics

Worked most all day on configuration of panel. Tried various inputs for ARINC and RS-232. Did not that I have pinouts and wiring diagrams for two different ways of wiring between GNX375 and G3X (GDU460).. I didn't confirm for sure which way I did it but pretty sure that I used page 109 from GNX375 install manual. Found I have to spin airplane to configure/calibrate the magnetometer. Still with issues of ARINC and RX-232 connections. Not sure what I did but red "x" on GPS is gone on system page on GDU460 config page. I have all green checks with yellow "!" for magnetometer since hasn't been calibrated.

  Nov 14, 2023     GMU 11 issue - (5.5 hours) Category: Avionics

Spent hours trying to track down issue with GMU 11 (magnetometer). Found a blown fuse for GMU 11 and replaced it.....but new one blew immediately. I traced wires and from wing wiring connector to fuse bus, Wiring seems OK. Checking from connector to wing tip, I show no continuity on either power/ground pin but do measure ship voltage across same GMU 11 connector pins 7 and 9. I'm at a loss for now.
Found the issue....but can't explain it. Issue seems to be with the power and ground pins on GMU 11. A white wire and white/blue stripe. Long story short, I found the GMU 11 white wire "becomes" the white wire with blue stripe and visa versa at wing root connector. I'm 99.9% sure I used a single, un-spliced 2 wire, shielded cable between GMU 11 and wing root connector. Down stream, I connected the shielded cable wires to simple white and black wires for power and ground respectively. The fix was to switch wires at the power bus. White wire is now connected to ground and black wire to power.
Fuses stay together and GMU 11 shows up now on CANbus. Need to spend some time to configure the GMU 11 module.

  Nov 14, 2023     More fuel leaks - (1.0 hour) Category: Engine

Re-checked and re-tightened all previous fuel connections I had been working on. Opened all valves and no leaks. Turned on fuel pumps to get 41psi pressure and had definite drips on both ends of large fuel filter even with copper crush rings.
Decided to work on electrical

  Nov 13, 2023     Fuel leaks - (5.0 hours)       Category: Engine

Multiple hours to address fuel leaks from 5 connections. Major drips/leaks on fuel return line under console, large engine fuel filter, and firewall pass-thru connection on fuel return line. I pumped out fuel from header tank and shutting all valves. I added copper gaskets to fittings on fuel filter and had to completely replace a section of hard fuel line under console. Only way to get to it easily was to remove console....a pain. Put all back together a't nd opened fuel line to fill header tank. Fuel wouldn't flow when reading 2 gallons remaining. I closed valve and added another gallon of gas and then opened tank valve which allowed header tank to fill. Unbeknownst to me, fuel was pouring out from console lines. By time I noticed, a cup or much more was on floor of cockpit.....this was WITHOUT fuel pump pressure. I shut everything down and went to my meeting.

  Nov 13, 2023     Camlock adjustment - (1.5 hours) Category: Fuselage

Spent an hour or so adjusting camlock receptacles to proper length. Also adjusted numbers on fuel level in tanks to reflect amount left in tank and not including header tank and fuel lines.

  Nov 12, 2023     Fuel level recording - (2.5 hours) Category: Fuselage

Spent couple of hours adding 2 gallons at a time to right (only) fuel tank and marking known levels with labeling tape. I ended up putting 15 gallons into 14 gallon right fuel tank. Seems I didn't account for 1 gallon or so in the header tank. I placed gallon amounts with "arrow" to level noted on site gauge at bottom of meniscus.
Will have to go back and replace numbers to account for 1 gallon in header tank.
I did quickly find reason for massive fuel leak when pumps activated. I had forgotten I had not totally tightened one fuel line connection into large fuel filter after fuel pumps. My intent was that fuel flow requirements would be met before finally tightening.
After filling right tank, I used fuel pumps to empty main tank and determined that fuel pumps put out at least 2/3 gallon per minute. I needed 9 gph and my pumps put out almost 40gph.....more than enough but needed for high pressure for fuel injection.

  Nov 12, 2023     Cowling camlocks - (2.0 hours) Category: Fuselage

Spent couple of hours working on engine cowlings to get all camlocks to work properly. I worked with 4-5 at a time to get proper depth adjusted to allow quick, quarter turn counter-clockwise to release. Then pulled the little pin on female receiver to lock position. Then worked a couple of more receptacles until all completed. Had to install and then remove top cowling each time. Seemed to take forever.

  Nov 02, 2023     Oil pressure! - (4 hours)       Category: Engine

Futzing with motor. Had sent in email to Mike at STOL creek about oil pressure. Talked with him couple of hours later and my issue with no oil pressure registering. He said he filled oil cooler before installing it and then hand filled all oil lines. I had to wait until Jeanne came home to find a turkey baster syringe to use to fill main oil lines from oil sump to oil cooler and from bottom of engine to oil sump. Took several full basters to fill oil lines. Then I hand spun prop another 20-30 times. I then hit the starter (still with plugs out) and started getting oil pressure readings almost immediately and peaked at 50+psi.
Great!!! Now I can do an engine start. (Late evening night before leaving house tomorrow at 3:00am for dive trip to Caymans). I installed plugs and decided I needed to check fuel pressure and for any fuel leaks before starting engine. I disconnected ground power unit and re-connected ships battery for start. I hit #1 fuel pump and saw 50+ psi and then switched to #2 and saw same. THEN heard something dripping. Stopped all and checked to find engine covered in gas from major fuel leak. Had to run fuel pump to see where leak was. Seemed to be coming from fuel connector going into large fuel filter after fuel pumps. Will have to deal with all when return from dive trip

  Oct 31, 2023     Research on avionics config - (1.5 hours) Category: Avionics

Still trying to figure out how to program oil pressure, ARINC and RS232 connections to GNX 375. Haven't even started on GM507 and radio yet. Still have to program TOGA button.

  Oct 31, 2023     Fuel containers, fuel and NO start - (2.0 hours) Category: Engine

Went to Autozone and found some 5 gallon containers with a bottom drain to fill fuel tanks without having to lift and tilt to pour. All new gas containers have a plastic flame prevention screen just into spout that prevents using a siphon hose or similar. Also got 5 gallons of premium with intent to start engine.
After confirming that both fuel pumps worked separately, I hand spun propeller again then rewired to ship's battery and tried starter....3 times, 300-400 rpm, for 5-7 seconds each time with no oil pressure indication. Not sure what is not going on.

  Oct 31, 2023     Fuel pump wiring confirmed - (1.0 hour) Category: Engine

Confirmed re-wiring for 2 fuel pumps is now correct with two, completely separate circuits.

  Oct 30, 2023     Oil pressure? - (3.0 hours) Category: Engine

I thought I read somewhere to put in oil and hand spin engine 40-70 times until oil pressure registers. Oil has been in oil sump for weeks. I initially tried turning engine without prop using starter (Per STOL Creek mike) but I didn't get any indication that I had oil in engine oil lines. After prop installed couple weeks ago, I tried hand spinning 70+ times. Initially kind of stiff but then loosened a lot but still no oil in oil return line. I spun it some more....still no oil in lines. Today, spent couple of hours removing oil cooler and found it about 1/2 full of oil....so..some oil is getting through but still no indication of oil in oil return line where it connects to top of external oil sump. I disconnected the oil return line at top and dropped to level of bottom of engine and OIL RAN OUT. At least there is oil in bottom of engine.

  Oct 30, 2023     Brackets throttle, fuel lines - (4.0 hours)       Category: Fuselage

Several hours to figure out some kind of brace/support for my throttle. After throttle install, it was VERY wiggly when used. I figured out using a couple of cable clamps on the throttle shaft and bracket above it for fuse busses. Clamps connected with tube with smashed ends similar to what I used to brace top of instrument panel. It is 98+% better. Still slight movement but very tolerable and MUCH more secure than previous.
Also used cable clamps to secure fuel lines coming from fuel tanks and secured just below the fuel shut-off valves I installed.
Both jobs took a lot of thought on my part before several tries to check if proper application before final tightening.

  Oct 29, 2023     Avionics config and "stewing" - (8.0 hours) Category: Fuselage

Several hours stewing and researching over what to do about: 1) leaking at brake shoe line fittings 2) floppy throttle 3) How to program GDU, GNX, Radio 4) Whiskey compass need (or not) 5) Trim position indication 6) proper voltage showing up (main and IBBS) 7) low IBBS volt indication 8) Ipad holder interference 9) Discrete button pushes for AP disconnect, radio switching, IDENT,
Also spent hour or so trying to fit strakes between aft, inboard wing and turtle deck.

  Oct 28, 2023     Turtle deck, fuel lines, Wind shield, wing wiring labels - (8.0 hours)       Category: Fuselage

More time on turtle deck smoothing more trimmed edges, redoing some Camlock studs, Pulled pins on camlock receptacles to lock adjustment. Checked trim position sensor actuating tab on horizontal stab and seems to be WNL.
Trimmed more on windshield/front spare junction for more clearance. Sanded and smooth the trimmed areas on windshield.
Fuel and fuel vent lines/hoses installed to header tank.
Put some printed labels on plus connectors coming from the wings before the marker writing totally fades away.
Magnetometer not online...red "X", checked the plug, checked CANbus wiring pulses running up and down, checked voltage and showed almost 12 volts so I guess I killed the magnetometer on one of its drops....i'll have to order another one.
More research into configuration for GNX 375 and GDU 460.

  Oct 27, 2023     Flaperon interference, Turtle deck camlock studs, Cracked windshield - (7.0 hours)       Category: Fuselage

Couple of hours spent filing down flaperon control arm where it interfered with fuselage cross member below the pilot seat. Check to be sure no longer any interference and painted exposed areas with touchup paing
Spent an hour or so working to get Camlock studs just right on Turtle deck. One stud in center at back took well over an hour as I had drilled it off center and stud wouldn't engage properly. I used a file to enlarge hole to be able to line up properly but then stud keeper wouldn't hold it in position. I filled hole with some Hysol and hopefully will work.
Hours filing on push tube for flaperon control that had interference with one of bottom fuselage beams. I though better to remove material only from push rod and not structural fuselage member. Used touch up paint to cover exposed metal.
Started to install more fuel lines. In process, saw where front spar inboard on port wing was rubbing on windshield cutout. I worked on sanding but then saw a CRACK at the corner running about two inches. I did a stop drill hole and used air grinder to really remove interference.
Guess crack occurred when I pulled the aft pin on wing to lube it and wing swung forward, I remember hearing a crack but thought it metal to metal.
Oh well, it cracks more, I'll just have to replace it. I'm getting good at doing that

  Oct 26, 2023     Turtle deck Camlocks - (2.0 hours)       Category: Fuselage

Who would have thought it would take 2 hours to drill 7 holes and trial fit 7 camlock studs?

  Oct 25, 2023     Flaperon push rod rigging, Fuel line - (4.0 hours)       Category: Wings

Several hours to adjust push rods and hold control stick in proper position to determine rod ends adjustment length.. Had to mount some flaperon jigs with 4 foot sticks out front using a 2 13/16 wood block as brace to hold flaperons in a neutral postion while contol stick in neutral position and then adjust/install push rods.
Able to get fuel lines fitted to wing tanks in tricky access area. I had soaked the fuel lines in lawn mower gas for several days as result of a hint to help install tight fitting fuel lines. Use a little LPS 1 lubricant also and hosed slide right on. I did have to rout out a wing rib on right fuel tank to allow access to place and tighten hose clamp and also to provide access (with more routing) to remove/replace brass fuel tank fitting if needed in future.
Had to get some smaller 5/16 hose clamps as I guess I used all my allotment in the engine install

  Oct 25, 2023     Transport braces - (5.0 hours) Category: Wings

Multiple hours to get the transport braces adjusted to fit, holes enlarged, through holes drilled, appropriate nuts, bolts, washers collected and installed on transport braces....all this to be used for possibly only one trip to the airport.

  Oct 24, 2023     folding wings, flaperons - (4.0 hours) Category: Wings

Patrick came by and spent couple of hours working on installing the flaperons and trimming side hole in turtle deck to fit. Then worked on folding the wings process.
After Patrick left, found I had locked the upper turtle deck onto fuselage and had to use cutoff tool to trim enough to allow the upper turtle deck to pivot aft and upward. Now have a wide slot....oh well.

  Oct 23, 2023     Turtle deck screw up and fix - (2.0 hours)       Category: Fuselage

On turtle deck, I did not cut side at correct angle. Had a narrow slit through flaperon control arm hole but after flperons installed and confirmed that hole cut-out on turtle deck side cleared control arm, I found I could NOT remove the whole turtle deck assembly. Therefore; I had to proceed with cutoff tool to remove 1/2" arc below the hole (as I should have marked and cut along to begin with) to allow deck removal. Oh well....one step forward and two steps back.

  Oct 23, 2023     Flaperon rigging - (5.0 hours) Category: Wings

Five hours on flaperon rigging and STILL not done. After several issues with trying to hold stick in neutral position with Gorilla tape while doing initial adjustments for flaperon rigging, I finally gave up when heat caused gorilla tape to let go. After several issues trying to install the flaperon actuators rods, I discovered there is a right and a left. Of course I had them bassacward.....one seemed too long and the other seemed too short. Thought my other actuators were misaligned. Just now switch tubes....getting hot and I'm dehydrated....again.
Before stopping this job, I removed main flaperon push rod running under my seat due to significant rubbing on floor stringer. Have to file off the powder coat and a little metal to get adequate clearance.

  Oct 22, 2023     Finding parts for flaperon - (2.0 hours) Category: Wings

Couple of hours looking for parts to rig the flaperons. Needed to find instructions, nuts, bolts, washers, rod ends, flaperon wood jigs, 2 13/16" block, spirit level, strapping tape....all to rig the flaperons

  Oct 22, 2023     weighing the plane - (1.5 hours) Category: W&B

Had borrowed some car scales with ramps from EAA 555 up in Las Cruces that all are using to weigh planes. Easy enough! Hardest was figuring out where/how to use the scales. We ended up using 3 layers of 2x4" wood cut-offs to block up nose until bottom fuselage frame was level. We rolled the main gear onto scales then lifted nose, placed blocks then scale under nose wheel with plane level front/back and side to side. Unit said 921# total, 246# on nose, and 338# for each main gear wheel. Seems kind of heavy for the model. Extra paint layers, extras on plane, extra radios, autopilot servos, zillion miles of wiring, etc. Too busy and didn't get photos of the process.

  Oct 22, 2023     Flaperon install - (1.5 hours)       Category: Wings

Patrick came over to give me a hand installing flaperons, Got them installed and bolts/washers/nuts inserted and tightened. I'm short about 6 of proper size/type of bolts and have used temp substitutes...two outer brackes left flaperon and innermost bracket of right flaperon. Proper diameter, just not same length/shape as all others. Also got nuts installed on elevator hinge bolts.
Too busy working and didn't get any photos of install

  Oct 20, 2023     Flaperons counter weight install - (4 hours)       Category: Wings

All I had to do was glue/rivet four counter weights to flaperons, Holes were all ready drilled. Why did it take so long?

  Oct 19, 2023     G3X programming - (2.0 hours) Category: Fuselage

Finished going through configuration screen of G3x. Have to get the magnatometer online to finish do this and also connect up the flaperons to see which way the roll servo needs to move for right and left roll.
Need to still figure out how to put trim position onto G3X. I'm sure one of the discrete coding interfaces. Still need to do the GNX375. I still get error message for transponder function.

  Oct 19, 2023     Turtle deck hinge cutting - (5 hours)       Category: Fuselage

Several hours to cut turtle deck hinge, sand edges, fit hinge, try temp fitted turtle deck hinge onto plane, remove, drill small bolt holes, mess up back drilling aluminum angle stiffener, fix my mess up, install turtle deck, check flaperon temp brackets with broom handle, trim opening in turtle deck side for broom handle, install turtle deck in prep to mount flaperons.

  Oct 18, 2023     Turtle deck hinge cutting - (4.0 hours)       Category: Fuselage

I had obtained some extra flaperon mounting brackets and installed them temporarily to guide broom handle to turtle deck side and marked spot for flaperon torsion spar to penetrate.

  Oct 18, 2023     Parts for plane - (1.5 hours) Category: Fuselage

Had to find some 10/32 screws to secure upper and lower cowls inlet ducts right behind propeller. Also got a sun shade to protect the greenhouse glass window and roof from sun.

  Oct 18, 2023     G3X configuration - (3.5 hours) Category: Instrument Panel

Worked on configuration of G3X. There are 30+ tabs to select and configure. Some are easy and straight forward. Many are not and I don't completely understand the choices I have in drop down menus.

  Oct 17, 2023     Jury struts - (1.5 hours)       Category: Wings

Got jury struts mounted. Lower left front bracket off center about 1/2....shouldn't be a problem

  Oct 16, 2023     Door brackets - (2.0 hours)       Category: Fuselage

Spent most of the day recovering from rollout yesterday. Did work on installing both door frame brackets to hold gas piston.supports. Also cleaned garage. Garage looks weird empty.

  Oct 15, 2023     ROLL OUT DEBUT - (10 hours)       Category: Wings

Had 10-15 friends, CAP members and neighbors over to help move plane out and attach wings, doors, rudder, elevator and horizontal stabilizer. At least got screws put in. Still need to confirm nuts and proper washer placement is done. Some of tail surfaces don't seem to be moving as far as they should....will have to check, confirm and/or fix/adjust.
Completely assembled plane looks good in the sunlight.

  Oct 14, 2023     Prep for roll out - (5.0 hours) Category: Wings

Plane to be rolled out of garage tomorrow. Today is prep for the event tomorrow. Can't believe it took over 5 hours to find all fasteners for parts I want help with to install. Also cleaned up garage and moved items to clear path to get plane outside.

  Oct 12, 2023     Ground power, lower cowl mod - (3 hours)       Category: Fuselage

I had an extremely difficult time yesterday getting lower cowl installed.....propeller is in the way. Today took a closer look and found I needed to enlarge the cowl cutout for nose gear. Still tight fit but got in back on in about 3-5 minutes instead of 40 minutes yesterday. Nose gear strut paint is still going to be majorly scared in future installing and removing lower cowl. Still have to pry it past back of prop spinner and even scrape blades a little.
Got a ground power supply to run avionics and not kill battery again. Power supply seems to be automatic with no controls other than power switch but it didn't come with any connecting cables. I made up a set with spare parts.

  Oct 11, 2023     Odds and ends - (8.0 hours)       Category: Fuselage

Cleaned up garage, applied anti seize to EGT probes and tightened into exhaust. Installed site tubes for fuel tank level along with split plates to hold fuel level placard. Assembled fuel shut off valves for each tank, cut and installed short section of fuel line between wing and probable area of fuel valve installation. Applied Velcro sticky tape to foot wells for cockpit trim. Cleaned barbs on fuel header tank

  Oct 10, 2023     Camlocks, fuel caps, fuel placards, site tubes - (7.0 hours)       Category: Fuselage

Camlock studs installed top cowl, top four camlocks on turtle deck. oil door installed, fuel caps painted, high temp RTV applied to wiring hole/access through firewall. Got some clips nuts install on forward fuselage just aft of firewall for anchoring boot cowl. Camlocks and looking for parts took ALL day. Didn't get as much done today as desired.

  Oct 09, 2023     More "stuff" for the plane - (3.0 hours) Category: Supplies

Multiple items for the plane: folded wing transport brackets, Kitfox decals, wheel cocks, DC ground power supply, DPDT replacement switch for fuel pumps. Appointment with flight instructor in Dennison, TX, to get required 10hrs of dual training in Kitfox model....@$350.00 per hour....OUCH!!....but necessary for safe, enjoyable flying.

  Oct 09, 2023     Odds and ends - (4 hours)       Category: Fuselage

Cleaned up last of paint job. Put windshield back on. Fitted turtle deck. Drilled foreward 4 holes (in front of hinge locatiofor camlock studs in Turtle deck. Will mount turtle deck with the four camlocks to facilitate marking flaperon access hole and hinge cut when wings mounted.
Checked installed red/white LED lights in the dark. Look quite nice.

  Oct 09, 2023     Throttle cable - (1.5 hours)       Category: Engine

Worked with curved tube (sent from Stol Creek) to install on bracket above the throttle to guide the throttle cable. After much adjustment and fiddling, I think I got it. I secured screw holding cable in throttle valve and nuts holding curved guide tube with blue Lock Tite to prevent loosening. The curved tube added enough friction that I can put a partial "brake" on throttle and it will hold position.

  Oct 08, 2023     Service loop and labeled bus covers - (4.0 hours)       Category: Wiring

Removed windshield again to provide access to panel better. I realized I tied up wires too tight and unable to remove G3X screen easily. Spent time cutting and retying to get G3X to be removed easily enough to disconnect connectors in back. Also took the time to trim the plastic covers for the fuse bus boxes to fit around my mess of wires. Then labeled the covers. During this time, I realized I had wired fuel pumps wrong. I had both pumps through same fuse so if one pump shorted out, it would "kill" function of other one also. Determined I need to order a double pole and double throw switch. I went ahead and added another fuse and wire to connect to new switch and relabeled existing wires to ID fuel pump #1 and #2.

  Oct 08, 2023     Paint touch up - (2.0 hours) Category: Wings

Spent couple of hours cleaning up from painting. Missed couple areas on my paint job yesterday and had to fix the mess the drop cloth made on fairings. Used a paint brush and some left over paint. Should be fine.

  Oct 07, 2023     Painting lift struts - (6 hours)       Category: Wings

Four and half hours to get garage setup for painting lift struts, jury struts and repaint top cowl. Then about 2 hours for paint mixing, spraying, flipping parts, cleanup. Came out pretty good and didn't make much mess. BUUTTT, seems while my back was turned, a flap of drop cloth blew over onto bottom portion of both lift strut cuffs. I'll fix it tomorrow

  Oct 06, 2023     Sanding fill on wing strut fairings - (4.0 hours) Category: Wings

Sanding on Super fill patch, repair and fill. Took much longer (as usual) than expected

  Oct 05, 2023     LED cabin lights - (2.0 hours) Category: Fuselage

Seemed to take forever to stick on LED lights. I kept dropping the spooled LED light string and had to keep winding it back up.

  Oct 05, 2023     Strut fairing body fill - (4.5 hours)       Category: Wings

Superfill used to fill in voids, close fairing cuff and patch sectioned fairing behind jury strut brackets

  Oct 04, 2023     Blades installed - (4.0 hours)       Category: Propeller

Installed all blades and spinner per instructions in Airmaster manual

  Oct 03, 2023     Pitot tube attachment - (2.0 hours)       Category: Propeller

Came up with idea to connect similar sized pitot tubing from metal to polypropelene

  Oct 03, 2023     Required FAA lables for EXPerimental - (1.5 hours)       Category: Fuselage

Application of required warning labels for Experimental category.

  Oct 02, 2023     Lift strut fairings - (5.0 hours)       Category: Wings

Clean up of excess Hysol on jury strut brackets. More got underneath bracket than I realized. I left some gaps on the fairings around the jury strut brackets not wanting to try to fit tight fairings over the brackets. I cut the fairings to leave a gap around brackets. After bonding has set, I bonded some wood stick supports across the fairing gap and plan to fit some pieces of trimmed fairing to fill the gaps.
Next, fitted bottom fairing cuffs and riveted back ends.

  Sep 26, 2023     Lift strut fairings - (5 hours)       Category: Wings

Final trimming and fitting of lift strut fairings. Then spot bonded fairings to lift struts....about 1.5 inch long "glob" every 6-8 inches.

  Sep 25, 2023     Propeller hub install - (6.0 hours)       Category: Propeller

Worked on learning how to install Airmaster propeller. Spent couple of hours reading then worked on bolting on propeller hub. Supposed to lube propeller blade bearings but could figure out how to expose the bearings. My propeller blade model is different than one covered in basic instructions. Sent note at end of the day to Airmaster in NZ.

  Sep 24, 2023     Quarter window riveted - (3 hours)       Category: Fuselage

Got quarter windows riveted on. Used some leftover windshield sealant tape to seal the triangle windows. Hope it works.

  Sep 24, 2023     Wing tips and pitot - (2.0 hours)       Category: Wings

Installed wing tips with only 1/4 of required screws in case I have to remove for electrical inspection. Installed pitot mounting post. Glossy black paint job on mounting post seems invisible within the "M" letter outline.

  Sep 24, 2023     Windshield, LED - (2.0 hours) Category: Fuselage

Finished drilling and sanding holes for wing spar pins. LED strip lighting worked with dimmer. Checked it at night and don't need foot well lighting for either red or white. Door frame white lighting sufficient for cockpit and LED's wrapped around baggage area brace seems for baggage area.

  Sep 23, 2023     LED lights, seat pan, seat belts - (9.0 hours)       Category: Fuselage

Hours and hours trying to figure out what to do with red and whilte LED strips....how to mount them, how to wire them.....do I cut them or just wrap them up.
One of the LED sets came with a power supply and dimmer switch with small plugs which plugged into the LED strips quite easily. I sacrificed the wiring for power supply and dimmer to obtain the quick connect plugs. Have wired the strips to allow using the plugs and short power/ground leads to my dimmer box. Right now, I'm thinking of lining all top of doors and back into luggage area with white strips starting in foot wells. .The red lights will light aft door frames and across turtle deck angle. I was going to put the reds into foot well also but seems the red strip is considerably shorter than white.
Cut slots into seat pan for seat belts with holes and location done per instructions. Almost couldn't insert bolt/nut for outboard co-pilot seat. Header tank in the way.

  Sep 22, 2023     Windshield, pitot mount, stinger exhaust, LED's - (8.0 hours)       Category: Fuselage

Stripped yellow paint from Pitot post and painted gloss black, Worked long time on enlarging holes in windshield for spar bolts with a hand file and sanding drums when I read about using step drill to do holes. Oh well, live and learn...only added a couple of hours to shaping the holes.both
Tried in LED strips behind and above pilot. May be enough LED to line turtle deck angle, top of both doors and down front side of door frame by instrument panel.
Installed exhaust stinger and O2 sensor into bung on exhaust both with anti-seize compound. Connected multiple serial port wires into ECU and just coiled up all wiring in area of ECU......small audio type plug into ECU, with 15 pin serial port connector and serial port to USB adapter for computer use.
Painted both strakes yellow. Wing cuff already painted blue (?). Interesting contrast. Can always repaint.

  Sep 21, 2023     Paint touch up. Wind screen weather stipping - (6.5 hours)       Category: Wings

Took a long time but did yellow touch up painting on wings and tail surfaces. Had to remove tape on elevator hinges to paint them and areas mostly hidden in fuselage just to make them look better. Touched up multiple nicks and "tears" in yellow paint,
Then placed weather stripping for windshield. Man...is that stuff sticky....and foam tears very easily. No repositioning when adhesive touches anything.

  Sep 20, 2023     black paint, power supply, LED lights - (1.5 hours) Category: Supplies

Had decals applied yesterday and one area of black decal covers over pitot tower hole. No problem, will remove yellow paint I just put on and spray black gloss to try to match decal. Ordered ground power supply with enough power to run avionics without killing batteries. Also put order for LED lights.

  Sep 20, 2023     Decals, landing lights - (7.5 hours)       Category: Wings

Got Richard (Rich) Nacim from E-metro signs to make and install all my graphic decals, roundels, N-number, U.S.ARMY logos. Also worked on installing landing lights and clear covers. Left landing light is canted down about 10 degrees hopefully to work as a taxi light. I put in an extra nut to prop the lens down slightly.

  Sep 19, 2023     Triangle window, wings - (5.0 hours) Category: Fuselage

Got some info on how to deal with throttle cable. Have a part coming. Drilled rivet holes for triangle windows. Re-configed shop to hold wings for decal installation. Started on fitting landing lights and covers to wing tips.

  Sep 17, 2023     Painting, screws, wiring - (4.0 hours)       Category: Fuselage

Wired in LED warning lights for main battery, Alt 1 and Alt 2. Painted 2nd coat of yellow on flaperon counterweights. Prepped and cleaned up garage and paint gun. Up-drilled holes between camlocks for boot cowl retention and installed tinnerman nuts.

  Sep 16, 2023     Touch up paint tail and counterweights - (2.5 hours)       Category: Fuselage

Fifteen minutes of touch up yellow paint on tail (due to blue over-spray last year) and repainting flaperon counter weights. Counter weights will need another coat or two but I think the tail will be OK with just one coat to hide the subtle blue over-spray. As usual, not much tme spent on painting but well over 2 hours for prep and cleanup. Still have to re-paint top cowl and lift struts.