Project: RobertFOX   -  
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Builder Name:Robert Henderson   -  
Project:   Kitfox - Series 7   -   VIEW REPORTS
Total Hours:2678
Total Flight Time:46.7
Start/Last Date:May 08, 2020 - Dec 26, 2023
Engine:EP914Ti
Propeller:Airmaster with Whirlwind blades
Panel:Garmin G3x GNX375 GMC 507 GTR 200B
 
Friendly URL: https://eaabuilderslog.org?s=RobertFOX

Home or Last Project Picture

May 17, 2024     Aircraft test flights and tweaking. - (20 hours) Category: Misc
testing
 
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 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 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.


 
Sep 16, 2023     Throttle cable - (1.5 hours)       Category: Engine
Took a while to figure out how to connect center throttle cable wire to throttle control. Going to take some getting used to strong throttle spring that keeps throttle fully open should cable nut slip. Will have to keep throttle cable locked at all times.


 
Sep 15, 2023     Panel avionics config - (2.0 hours) Category: Avionics
Able to find upload site for Garmin experimental Avionics to download current operating system for GNX375. Then played with setup for GNX375 and a little later worked some on G3X screen. Still have a lot to do
 
Sep 15, 2023     Quarter windows - (2.0 hours)       Category: Fuselage
Paper pattern then cutting of triangular windows went fairly quick but final fitting took awhile. Haven't decided yet how I'll secure them to frame.


 
Sep 15, 2023     Exhaust tail fitting - (3.5 hours)       Category: Engine
Simple job to get O2 sensor bung welded to exhaust stinger pipe. Had to find where to go first. Only 8 miles but due to construction, it took over an hour to deliver/return then go pick up finished part. Looks to be nice weld-----Westside Welding in Canutillo.


 
Sep 14, 2023     Glare shield, flaperon counter weights - (2.0 hours)       Category: Fuselage
Only a few cuts and trimming. Yeah....right... 4 hours of cutting trimming and fitting. Also spent 2 hours cleaning off the messed up paint job on flaperon counter weights using Xylene....my hands felt "wonderful" afterwards.....now ready for repainting.
Got contact to do drilling and welding for O2 sensor for exhaust from ex-patient (Rick Lomeli). Was told to try West side welding in Canutillo on Chanate Rd.


 
Sep 13, 2023     Windscreen, lower cowl fitting - (12 hours) Category: Fuselage
Several work sessions over several days fitting windshield to cockpit, Drilling and up drilling all holes for windscreen/skylight. Also drilled and fitted camlocs for lower cowl. Updrilled lower holes on front cockpit pillar for boot cowl and installed clip nuts. Riveted nuts would have been more secure but once installed, I don't intend on removing boot cowl but once a year for annual condition inspection. Did initial fitting of turtle deck by providing clearance for aft cross spar. Can't do much more until wings fitted. Still waiting for decal install. All simple jobs, but like everything else, took forever
 
Sep 09, 2023     Reading and studying for next steps - (2.5 hours) Category: Research
Spent some time writing down what needs to be done. Need to read about final windshield install details, turtle deck install, G3X config and do some YouTube searching for same.
 
Sep 09, 2023     Engine fluids - (1.0 hour) Category: Engine
Over last few days, purchased anti-freeze (Prestone long life) and 4-stroke motorcycle oil.
 
Sep 08, 2023     Panel Finalization - (9 hours)       Category: Instrument Panel
Tiring up more wires, plastic wire bundle protectors.... all just trying to keep wires from bouncing around. Recommended service .......yeah right!!. As said before I had too MUCH wire and therefore struggled to tie it all up. I checked and if (when) I have to deal with the panel, then after removing glare shield I can at least pull panel out far enough to start clipped my braided cord ties....a LOT of them. I still have access to all bus attachments....kinda...with glare shield gone but will be difficult with windshield in place. I'm hoping my wiring is good. Connectors should all be good....but did I connect the right wire into the correctg place.
I recorded the position of power wires, fuses, and grounding locations for three busses in ring note book. I still have a couple of more LED warning lights to wire in and also LED cabin lights.
Last thing is labeling all switches. I'm done for the day. I'll work on power up and configuring next week.


 
Sep 07, 2023     Tie up panel wiring - (5.0 hours)       Category: Instrument Panel
All day trying to make wiring a little neater. Also recorded power and ground connections for three Bus boxes.


 
Sep 06, 2023     Mounting instrument Panel - (3.0 hours)       Category: Instrument Panel
Finished moving all switches to final panel and shortened some leads. I was able to lay panel in pilot seat while moving switches. My plan was to be able to have instrument panel come out an lay on seat for possible future panel work. Near end of work session, I mounted the panel with most wiring in place. I was told to provide service loops.....seem to have plenty.....well.....maybe TOO much. I'll have to deal with it tomorrow.


 
Sep 05, 2023     Mounting instrument Panel - (5.5 hours)       Category: Instrument Panel
Got the other brace tube pounded, bent and fitted. Then mounted throttle sub panel. Pop-riveted the backing ring for the G3X. Started installing all switches into final pane trying to straighten wires in the process. Still wiring mess. Had to undo most of my tie wraps to loosen wires and re-position them.


 
Sep 04, 2023     Mounting instrument Panel - (6.0 hours)       Category: Instrument Panel
Mounting instrument panel. Had to shorten the mounting tabs by 1 inch for pilot grip clearance. Got bottom holes drilled and shocks mounted to be able to work on tubular top braces. Still need to mount throttle control plate.


 
Sep 03, 2023     Lift strut fairings - (2.0 hours) Category: Wings
Finished fitting lift strut fairings for both.
 
Sep 02, 2023     Lift strut fairings - (2.0 hours) Category: Wings
Worked on getting lift strut fairings cut and fitted for left lift strut.
 
Sep 02, 2023     Test grip doesn't fit either - (2.0 hours)       Category: Fuselage
As stated previously, I had an interference problem between pilot stick grip and G3X panel/knobs. I had spent couple of hours about 10 days ago researching grips and found one from Pioneer Control Grips that looked like it might work. Skylar (owner/builder/maker of grips) was kind enough to send a test grip to try out. I took apart the rest of the broken acrylic panel and shoved all the wires back, mounted panel and G3X unit. Still interference. Packed up the grip and will return next week. Sent a note Gary Phenning in Washingtion asking what grips he used and how avoided interference. About an hour or so later, the thought hit me. I went back to plane. Put my original wired grip back in then adjusted the limit screw for down elevator to prevent the stick from contacting panel. Only had to back out scew maybe 2.5 mm or so. That will change the maximum down elevator I can achieve per instructions in build manual but since I don't have a tail dragger, I don't need strong down elevator to raise the tail. Will see what Gary has to say but think I'll go with my "cheap/cheat" fix.


 
Sep 01, 2023     Lift strut fairings - (2.5 hours) Category: Fuselage
Started cutting fairings for left lift strut. I had previously fitted jury strut to mounted wing and marked spots on lift struts for jury strut bracket placement. Also recorded distance to brackets from bottom lift strut attach hole. When comparing measurements the other day between left and right lift struts, there was a significant discrepancy (about an inch) between left and right. After considerable time and even remounting lift strut onto upturned wing on saw horses, I found the issue and corrected a couple of measurements. The differences have to do with different lengths between wing jury strut tabs and the top spar pin holes on left and right side of about 1/2 inch over all and difference between spare hole and aft jury strut tab lengths between two wings about about an inch. I think all good now and jury strut brackets, worse case scenario, wont be off more than 1/2 inch inboard/outboard from "ideal".
 
Sep 01, 2023     touch up paint, door lift brackets - (2 hours) Category: Fuselage
Spent some time on odds and ends. Drilled holes for the door gas strut anchors and also brackets to mount on door frames.
 
Aug 31, 2023     Position lights installed - (2.5 hours)       Category: Lighting
Simple job but still took awhile....like everything else. Fitted mounted brackets and installed wing tips lights. Started on Landing lights but realized I needed more small #6 screws of longer length than what I had on hand. While looking for screws for landing lights, decided I needed other screw....specialty type....that I didn't want to search for at Lowe's. So pulled out Aircraft Spruce book and ordered way. Got exactly what I want with a few extra of the 3-4 different types I ordered and they are coming to my door. I would like to shop local but what specific items I need, I have to got to 3-4 different stores and kill and entire afternoon in the heat trying to find anything close to what I want. Amazon is going to put every brick and mortar out of business.
When fitting the landing lights, I thought I might need to angle one of lights down for a taxi light. I'll put in a crude angle adjustment system.


 
Aug 31, 2023     New pilot control stick - (1.5 hours) Category: Fuselage
Decided to fit my new control stick onto the mixer stub in cockpit with already drill mounting holes......holes hidden when new control stick in place. Took 1.5 hours to figure and accomplish a new through hole for new pilot stick.
 
Aug 31, 2023     Cutting exhaust tail pipe - (2.5 hours)       Category: Engine
All I had to do was a simple cut on stainless steel tail pipe. Took me over half an hour to figure how and to mark the 45 degree cut line for end of tail pipe "stinger". Then took over 1 hour of actual cutting time to cut 8.5 inches of stainless pipe that isn't even 1mm thick.
Still need to have O2 sensor bung welded on


 
Aug 30, 2023     Multiple tasks - (6 hours)       Category: Paint / Decals
Paint touch up with brush after spraying all cowls. Not the most ideal but quick. Stcouple of hours trying to verify position of clamps for jury struts. Measurements accurate. Seems the aft jury strut tab on left wing was/is one inch farther outboard than the other. Spent another hour redoing arranging the shop to stop paint booth and back to other items. Still waiting for pilot grip test handle. Moved wing back to cradle. Mounted the wing tip lights. Have to order longer screws to mount landing/taxi lights. Also order screws to hold boot cowl to firewall, boot cowl to cockpit frame and to hold/mount landing lights. Need to cock one light slightly down for landing/taxi light so needed longer screws.
Tried to drill holes for now pilot control stick to match existing. Simple job?.....not in a thousand years. Couple of extra holes and still not done. Will try again tomorrow after flying.


 
Aug 29, 2023     Prep shop for painting.and painting of cowls - (5.0 hours) Category: Paint / Decals
Spent hours cleaning and re-arranging shop for painting. Then I saw the wheel pants......they will have to wait....maybe paint them when I paint the lift struts, Jury struts and horizontal stab struts. Takes forever. I keep remembering things to do.
Watched a video on spraying Latex paint with HVLP and it suggested Floetrol to help thin the paint. I tried it and used 2/3 of max recommended mixing but paint still too thick. I had to spray from just 3-4 inches to lay down wet layer. Will have to check results tomorrow in the sun. I sure hope I don't need a second coat.

 
Aug 29, 2023     Exhaust tail fitting - (4.0 hours)       Category: Engine
Still fitting and trimming cowl and tail pipe.


 
Aug 28, 2023     Exhaust tail fitting - (3 hours) Category: Engine
Was getting cowls prepped for paint when realized I still needed to cut a hole for exhaust tail. "Shouldn't take too long".....wrong as usual. Tail piece to big and had to cut muffler side. Thirty minutes to cut through the stainless steel pipe. Mis-judged where to cut hole so exhaust hole clearance is a little lop-sided but is on bottom.
 
Aug 28, 2023     Odering decals - (2.0 hours)       Category: Paint / Decals
Spent two hours on the road over two trips to talk with Rich at e-Metro signs of El Paso about my decals for the wings. Did some test decals on my paint test fabric panels. Sticks OK but not as well as on a car but should be OK.


 
Aug 26, 2023     Sanding - (5.0 hours) Category: Paint / Decals
Last night after dinner and this morning worked on more filling and sanding and more filling on top, bottom and boot cowl. Leaving shortly on camping/hike to let last of fill cure.
Next step is painting cowl parts.
 
Aug 25, 2023     sanding and painting - (5.0 hours)       Category: Paint / Decals
Late yesterday, I had riveted avionics rack to panel and then filled the rivet heads with SuperFil. Also filled mounting holes around NACA ducts for air vents.
Today, spent most all day sanding down Superfil, re-priming sanded areas on panel, light sand on primer coat and sprayed final coat on panel and throttle control mini sub panel. Also sanded on boot cowl up to lip contacting windshield. Will sand fill edge when boot cowl comes off.


 
Aug 24, 2023     wiring parts - (1.0 hour) Category: Wiring
Ordered several items to help secure/connect soldered Dsub connectors I used for wiring from wing....special scews, nuts, etc. Also ordered a Dsub connector and backshell to use with pins for use on my new pilot stick control to patch into already patched in wiring.
 
Aug 24, 2023     Cockpit items - (8 hours)       Category: Fuselage
Was reading on Team Kit Fox about lift strut fairing install. I'm suppose to add sheet metal cuff at bottom but a lot of folks just used SuperFill and forewent the sheet metal cuff. OOOPS!! I had already done several cuts in anticipation of using sheet metal cuff.....guess I'll use the sheet metal cuff. I rough fitted leading and trailing lift strut bar fairings and carefully bent the pre-cut (and primed) sheet metal cuff. I think it will work just fine.
Trimmed sanded the repaired windshield edge and re-installed to fuselage.....fits like a glove everywhere it is supposed to. Drilled and clecoed all vertical and boot cowl attach points. I want to mount wings and see how they fit before mounting windshield on top and turtle deck edge. Also still need to fit instrument panel.
I have order a test pilot grip from Pioneer grips to see if it will work in my install. Photos/diagrams sent to me by Skylar seem to show it will fit.....it better.
Scuffed, etched and alodined the panel then used a white primer. For avionics rack, I only cleaned well with alcohol and used a white primer ("sticks to everything"). I mounted avionics rack to panel with flush pop rivets and then used Superfill on the pop rivet heads for avionics rack and glare shield riveted tabs. While I had extra mixed SuperFill, I used it on the boot cowl for holes from air vents and NACA duct defects.
Had started to cut fairings for left lift strut but the measurements are off 1 inch compared to right side. Some of marks on masking tape still on lift strut bars don't match measurements. Before cutting/fitting any more. I want to mount the wings to check/confirm jurty strut position and how first rib fits to butt ribb.
In meantime, will work on sanding.


 
Aug 23, 2023     Windscreen, lift struts, panel - (5 hours) Category: Fuselage
Ordered a bunch of tinnerman nuts and sheet metal screws to mount floor boards, console panels and glare shield. Mounted the glare shield tabs to panel. Trimmed the windshield where I add hysol to edge. I'm a little shy in areas and added more Hysol with scrap acrylic to trap proper amount of Hysol for window thickness. Pulled out lift struts and lift strut fairings and laid on table to study all. Quite a job to open the trailing edge snap channel. Worked on right lift strut and tried to determine how to work around jury strut clamps on lift strut. Decided to use measurements previously recorded on lift strut for proper position of jury strut clamps. Then decided to cut separate sections between upper and lower portion of strut split at jury strut clamp.
 
Aug 22, 2023     Panel - (2 hours)       Category: Fuselage
Spent time drill holes for instrument panel tabs used to mount glare shield. Also spent time figuring how to mount/secure to these tabs. Researched and ordered basically some Tinnerman nuts. There will not be a lot of on/off with these attachments and strength not necessary. Decided to get similar attachment for the floor boards and panels instead of just screwing into hole in thin metal.


 
Aug 22, 2023     Winshield, panel - (1 hour) Category: Fuselage
While on my walk this morning, I came to the conclusion that I could use some Hysol to bond to over-trimmed edge of windshield. I put windshield back in and secure well into place with clamps and added Hysol to the edge. Hope it works.
 
Aug 21, 2023     Windshield - (4.0 hours)       Category: Wiring
Spent about 4 hours on initial fitting of new windshield. Thought I was and "expert" now that I had already tried and screwed up one windshield. This new windshield initial fit way different than first one. I marked for initial trimming....seemed one side needed more than the other.....and was careful to initially cut shy of my mark to have a little lee-way for trimming. All looked good with first one side, then boot cowl, and finally other side seemed to be fitting great. I did a single cut on right side and multiple cuts and all the "on and off" the windshield went through. All said and done, I got it to fit, no cracks BUT lower right vertical edge that is supposed to be held my screws.....well, we'll say the screw holes are "close".....will not really. I will have three lower scew holes on right vertical "A" pillar that will on "catch" and not go through the acrylic.....trimmed off too much again. I'll make it work


 
Aug 19, 2023     More wire combing - (5 hours) Category: Wiring
Spent several more hours (3+) trying to straighten and untangle wires. With my installation, it can never be neat looking but I was able to bunch several wire groups together into a bundle held together with lacing cord. The wire bundles seem real stiff. I'm sure I'll have to retie a bunch when all moved to final instrument panel.
Spent couple of hours looking for another pilot grip with switches to install on my plane. Found a couple of promising ones.
Next is to work again on installation of windshield. I've been dreading this since replacement order for my broken one arrived the first of the year. I ordered a barrel sander for cut off air tool to trim the tricky bends on windshield on UL and UR front corners. This is where I had issues before with cracking.
 
Aug 17, 2023     Combing the wires Windshield research - (5 hours)       Category: Wiring
Finished cleaning up/Clearing out the wiring work table area. Took wings outside and washed the bottoms in prep for getting my US Navy decals and roundels. Did an hour or so research again on windshield installation. Decided to order a barrel sander for die grinding along with good supply of abrasive barrel sleeves to cut areas for front spar pass through on windshield corners. Last time I tried using only cutoff wheel and it didn't work so well and may have contributed to previous crack.
Spent couple of hours working on straightening and untangling all the wire mess. Some issues were some wire leads were way too long. I found a full bag of screw type crimp connectors and therefore, shortened several wires leads and re-did connectors to shorten wires. .


 
Aug 16, 2023     Panel prep and wiring cleanup - (7 hours)       Category: Wiring
Spent hour or so with sanding panel after adding Hysol epoxy to fill gaps between panel edge and devices. Last night did an addition of top layer of Super Fil to correct small voids. Sanded all today. Started to try in panel but had to move all wires to under boot cowl area then saw mess of wires in bottom of cockpit. Spent couple of hours tying up wires into neat bundles with lacing cord...looks pretty good. Not sure of strictly kosher not but it is done.
Next step to try in panel and figure where mounting holes do. DISASTER, Pilot control grip interferes with GDU and knobs. Panel position had NO effect in alleviating problem. Will have to get a new pilot stick......bummer.
While sorting out control stick grip, will move to windshield. Spent an hour cleaning up wiring work table to clear area for windshield work.


 
Aug 14, 2023     Cutting metal panel - (4.5 hours)       Category: Wiring
Cut the last two holes for air vents with repaired hole saw. That went quick. Then was time fitting avionics rack to panel and drilling rivet holes. Saw more issues with oversized holes. Rest of work session was masking parts to fit onto panel and applying release agent in prep for adding Hysol filler to close oversized holes. Drilled holes for mounting prop control heads. When all taped, masked and lubed, I applied the Hysol. Later same evening (about 6 hours), I removed masking tape and parts before complete, hard set of Hysol and facilitate part removal and did some initially trimming with a razor blade while Hysol still a little pliable. Checked repair with instruments/parts in place.....should come out just fine. Maybe will need a little blue SuperFill filler. Will have to check after sanding and initial gray primer.


 
Aug 13, 2023     Cutting metal panel - (4.0 hours)       Category: Wiring
Got most of holes rough cut into panel. Still lack two holes for the air vents. I had to repair hole saw and glued in the set screw holding centering drill and will wait overnight for it to set. The new saber saw worked quite well. Only issue is I should have put the kerf cut exactly on the line if not very slightly outside of line. I ended up having to do filing on inside of cuts for clearance of instruments. Overall, thought it went OK.


 
Aug 12, 2023     Final, metal panel cutting - (5.0 hours)       Category: Wiring
Spent about an hour or so transferring plans from white masonite design panel onto the my final/real panel. No real additional panel placement changes from what I ended up with on the acrylic panel. I'm sure after completed and installed, I'll see something I want to do different. If so, should be easy enough to order new blank panel and redo the whole thing.
Got most of smaller 1/2" holes drilled for switches and corner drill holes done for larger cutouts. I used circular hole cutter for one USB power and thought it a little large so went with step drill for second but both ended up same size...a couple of 1/32" oversized but external bezel will take care of that.
Was drilling the large holes for air vents with hole cutter and broke off the centering bit in just a couple of seconds. Will salvage a center drill from a duplicate hole cutter that I have....only issue is set screw holder all together is VERY tight. May need to heat it.


 
Aug 11, 2023     Panel SUCCESS - (7 hours)       Category: Wiring
The other day, my GNX375 (GPS/Xpndr) didn't power up. I was petrified that there was a problem with it. Took apart connectors and noted that cable shield wire ground screws were mounted on the two connectors in back of GNX that interfered with each other and prevented a correctly orientated attachment of connector to back plate of avionic tray. I did double check all grounds and power and reconfirmed with pin outs and wiring diagrams that I had all needed pin holes filled. Reassembled and crossed fingers when I switched on power. I had even installed the prop controls and wired it in to a 5 amp fuse (need to get confirmation on proper fuse size). All lit UP.....yeah. Next step is to see if all LRUs are talking to each other.
Did hour or so reading about next step with panel. Have to order several 8GB SD cards to update G3X with updated software before doing Config. I was able to determine that all the small boxes are talking on CANbus as all now have blinking green lights. Had to do small repair on one AP servo where female pin not totally secure. Only problem I see right now is I have an error message for GDU GPS antenna is shorted to ground. Not sure if the problem is in my connector wiring of cable or in antenna its self. In the 30 seconds before leaving for dinner, I checked continuity between center conductor and shield and found a short in the wire.....messed up connector.....which end? Cut off one end and trimmed back and found I cut correct one. I had one extra BNC connector
that I used for a replacement. SUCCESS with repaired antenna cable. No error message on Config page.


 
Aug 09, 2023     Ground and Power connections - (9.0 hours) Category: Wiring
Got ready to fire up the panel and read my G3X installation course book which suggested: First, pull all LRU fuses and check for proper grounds, then install fuse one at a time for the LRU and check for power for power pins and no power on other pins. Some of ground pins indicated with some resistance, especially RS232 TX connections. Some of pins showed low voltage on power checks...CAN bus Hi and Lo with 2-3 volts and some of RS232 with (-) volts. All went well until checking ECU unit and got bright spark when test Pin 7 on ECU male plug. Going to have to write Stolcreek about this.
I did learn more about the IBBS (internal backup battery system). IBBS PowerPass through power pins 6,7,8 needed to be disconnected. As long as bus voltage above 11.0 volts, IBBS does not supply backup power. IBBS power switch needs to be ON to supply backup power but IBBS will charge even if switch is turned off
After dinner, I went to garage and plugged in all fuses and switched on ship power. Most lit up EXCEPT for GNX375.....dead as a doornail. Will have to do some investigating. .
 
Aug 08, 2023     Last of wiring - (6 hours) Category: Wiring
Spent this morning working on last of odds and end wiring on panel/bus. Kept finding unconnected wires. I did test the heater fan connection with the dimmer/potentiometer board and it worked perfectly. I will assume that lighting for avionics and cabin LED lights will work same way. Haven't yet ordered the cabin LEDs. Think I'll wait until final panel install completed and add the wiring at that time. Also still need to wire in power for the electric controlled propeller.
Also installed the radio antenna in back of turtle deck. Now to read about powering up the temp panel and checking connections.
 
Aug 07, 2023     Avionics lighting andHeater fan wiring - (3 hours) Category: Wiring
Finished up final pin/wiring install for ELT into GDU460 connector. Cogitated for quite some time about how to wire the avionics lighting and heater fan wiring into my 4 channel dimmer circuit. I finally put the lighting power leads to the avionics into the (+) output connection on dimmer board and ran a ground wire direct to general bus ground from the dimmer board output.. For the heater fan, I plan to run (-) and (+) wires both direct to dimmer board out puts without going to general bus. I haven't acquired the white/red LED cabin lights yet but will run them strait to dim board output.
If needed, (probably should) I'll place and inline fuse holder for the heater fans, avionics lighting and LED cabin lights.
 
Aug 03, 2023     ELT install - (5.0 hours) Category: Wiring
Spent most of the time wiring in the ELT. I had forgotten that there was to be a line from GPS source to the ELT. Had to build up a connection for a shielded 3 wire cable from GDU460 to ELT and also wire in a GPS signal test wire with resistor and LED. Got all that done but don't have a location yet for "buzzer" box that goes off in cockpit it ELT is activated.
 
Aug 01, 2023     antenna cable connectors, headset jacks - (7.5 hours)       Category: Wiring
Took a LONG time to correctly install antenna cable connectors. Straight BNC center wire needed tip crimped and right angle connectors needed center wire soldered at right angle junction. Also noted that the very RG400 cable has twisted wire core instead of more common solid center on plain RG58. Soldering was easy enough. Installed finished cables....at least in the correct area. I don't have very good access to mounting the radio antenna on turtle deck and may just wait until after/during Lexan turtle deck install is complete. I can't final install GPS cables until after windshield is fully installed.
Also soldered up headset jacks. Seems I didn't order insulating washers with headset jack order....assumed the order would come with all that I needed...that's what I get for "assuming". Ordered insulating washers for jacks $17 (several extra) and couple of right angle BNC connectors for transponder antenna. Don't think I'll ever be done with ordering more "last minute" items.


 
Jul 31, 2023     Connectors, antenna cable - (5 hours) Category: Wiring
Job today to finish closing up connectors on GEA24 and GDU460 and more wire straightening and tying up. Also determined how to run the cables for two GPS, radio and transponder antennas. Decided to run GPS antenna wire directly forward and down "A" pillar posts and behind instrument panel. Radio and TXnder coax will have to run under seats and through the console tunnel. Cut the cables to length. I had screwed up and didn't order enough "cheap" RG140 cable to radio and TXnder. I had originally planned to run the GPS antenna coax aft, down and then forward under the seats but would need 15-17 feet of the $6.50/ft coax. Routing past windshield post only needed about 7-8 feet so will have a LOT of very expensive coax left over.....for transponder cable......which doesn't really need the expensive cable.....oh well....only money.
Researched that the connectors, crimpper anvils and cables were compatible. Then watched U-tube on how to install a BNC connector and promptly messed it up. Will try again tomorrow.
 
Jul 30, 2023     Pins into GEA 24 connectors - (1.5 hours) Category: Wiring
Working on placing wires into proper holes for last two connectors on the GEA 24. Had to locate wiring sheets to see what pin hole to stick the pinned wires into. Almost done.
 
Jul 29, 2023     Ammeter, dimmer - (5 hours)       Category: Wiring
Spent about an hour tying up wires to be neater, then started on install of hall effect Ammeter. Put on wire between battery contactor and battery but very tight space. Then per directions on ammeter paperwork, I moved to battery/power bus wire with more room. I had to learn more about potentiometers as I need to use one to configure G3X by tapping into connection from ammeter to GEA24 interface to put in a 2.5 volt reading to allowing zeroing of amperage. Spent couple of hours trying to figure all out. Then went back and cut all tie wraps for wire straightening I did earlier due to ammeter wire run. I opted to place the ammeter pickup in engine compartment rather than behind the firewall for easier access.


 
Jul 28, 2023     GEA 24 wiring - (6 hours) Category: Wiring
Spent most of the day pinning wires and connectors for the two large number connectors on GEA 24. Thought I was almost done and then recalled I need to figure out what to connect for amperage usage to/from battery. I have two hall effect sensors. Do I just use one sensor on the main battery cable or two sensors on the two alternator leads and then have to add results together in my head.
Wiring will be simpler if I just place sensor between battery contactor and battery. So will work on that tomorrow.
 
Jul 27, 2023     Hex wrenches - (1 hour) Category: Supplies
Ordered several specialty allen (hex) wrenches. I needed a long 3/32 to insert/remove avionics from panel and 5/32 wrench for my key chain for aircraft door "locks".
I've spent thousands of $ for "nickel and dime" stuff. Most of this I bought online because so difficult to find what I want/need at stores in town....even though I would really like to support local, it is so difficult to find the specialty item I need. Stores either don't carry it or "supply chain" renders it out of stock not to mention time away from project driving all over town.
 
Jul 27, 2023     More panel wiring - (6 hours)       Category: Wiring
Spent about an hour trying to determine if GNX 375 needs more wires before I attach backshells. Seems all wires accounted for. Next I spent a while trying to straighten wires into connectors for GNX 375. It was a mess to start with. Some of the single wires were really getting pulled sideways in all my wiring mess. I straightened out wires as best as I could for the GNX 375 and tied thing with lacing cord to minimize any more wire stress before connector back shells installed. Now just need to remove the GNX 375 from its rack. I got the radio and AP head removed with no problem but for some reason, I can't get allen wrench to engage with the hex screw in GNX 375.....still trying. I believe I have the correct size wrench as was same size I used to initially install it. Don't know what is causing problem
With a little more persistence, I was able to remove the GNX 375. Spent better part of 2 hours finalizing the two connectors for the GNX. Had to untangle several wires to try to make look better. Able to straighten out several cables going into connectors to minimize strain on little wires. Now connectors mounted onto brackets for radio and GNX 375.


 
Jul 26, 2023     More panel wiring - (6 hours)       Category: Wiring
First thing today was to add ground wires to couple of switches (battery and Ignition) that I had neglected to due.....came to me in middle of the night.
Also worked on wiring from radio to headset plugs....bundle of 5 shield wires. One, audio input, I will just coil up under floor boards for now. Initially, I cut headset lines to mount connections behind seats but have now gone with inset plugs near crew legs on center console. Will maintain the cable length in case I decide to still mount behind seats.
Took over an hour to tie up headset cables and feed them down through the back of the console and tie up bundle of wires going through the middle. Had to wrap some silicone tape around fuel line to prevent rubbing of wires against the fuel line while cables secured from interfering with rudder cables.
These "little" jobs just ......take....for....ever!!


 
Jul 25, 2023     GAD connectors, Zener diode RPM - (6 hours)       Category: Wiring
Finished wiring of multiple ground wires from GAD 29. Some are redundant/unnecessary but hopefully wont cause a problem. Also about to close out back shell. Only wires going to GEA 24 are 2 sets of ARINC 429 connectors to communicate with GNX 375, CANbus and multiple ground wires. Neither connector very full of wires.
Spent considerable time, 3+ hours, trying to figure out soldering to put in diodes, zener diodes per page 32-3 for RPM sensor. Did several test solderings using surplus resisters and came up with plan to solder/rig the diodes into small assembly then added to shielded wires from RPM. Got it all done and forgot to install the green shield drain with solder sleeve. Had to do open solder and cover with self sealing Silicone tape. Not pretty but very functional.


 
Jul 24, 2023     CANbus wiring - (4 hours)       Category: Wiring
Connected CAN bus to GTR200 connector. Had not connected yet on table due to mix of wires on table. Was way worse trying to connect final GDU460 to GTR200 during mock up than would have been on the table. What a mess of wires. I could really use a detangler....but, alas....will have to deal with the mass of wires.
Also did the last CAN bus wiring to connect front CAN bus wire to the one coming from the GSU 25 (ADHRS) in the tail. This was connected at the GAD 29 front right behind panel. Took awhile to remember how I was wiring the CANbus but got it done.
CANbus runs GMU 11, GSU 25, GAD 29, GMC 507, GTR200, GDU 460 and terminates at GEA 24.

BUT ALAS...... I had previously connected some wiring going to the panel and inadvertently routed them UNDER the bar supporting the instrument panel. Fortunately I did not have to pull out a bunch of pins, as I originally thought, and found I could correct problem cutting/re-splicing a single wire....BUT I had to "fix" the problem three times before I got it correctly routed.....what a mess of wires.


 
Jul 23, 2023     Co-pilot PTT, control stick wiring completed - (3.0 hours)       Category: Wiring
Finished last of pilot's control stick wiring for all the buttons. Last to do was to tie in the PTT feature for co-pilot stick with quick disconnect to allow removal of stick for passenger ease of entry.


 
Jul 19, 2023     Trim and control stick wiring - (4 hours)       Category: Wiring
Finished connecting previously installed wiring for mixing trim control from pilot stick and console trim into AP servos, GMC 507, Trim booster and trim motor.
Had to use after market Trim booster to be able to use Kitfox higher amperage trim motor with GMC507 AP and Garmin servos. Took me a long time last year to comprehend the wiring scheme but I understand it now. I used male/female connector pins covered with heat shrink tubing. Should be a secure/detachable connection much less bulky than an inline crimped connection.


 
Jul 18, 2023     Control stick wiring - (2.0 hours) Category: Wiring
Spent time re-learning buttons on my military style control stick with a bunch of buttons. I determined which of the 8 wires went to which button and now have a list to assign functions to the buttons. Found where I can IDENT the Tnx and Freq swap the radio with some unused buttons.
Now off to pick up Frank for QB meeting and tomorrow will work on trim and control stick wiring.
 
Jul 17, 2023     ECU wiring questions - (2.0 hours) Category: Research
I'm confused on the ECU wiring. I have two pages from Edge performance with conflicting info on how to wire the ECU and Alternator warning lights. Will need to get an email to Stol Creek for answers.
 
Jul 17, 2023     correcting wiring errors - (4 hours) Category: Wiring
Spent several hours trying to correct errors in wiring I did yesterday. UGH!! What was I thinking? I now have a dozen or more cut-off connectors on the floor due to my errors.
 
Jul 16, 2023     Switch wiring - (7 hours) Category: Wiring
Figured out Wig-wag feature, Nav lights, strobe wiring I had done 18+ months ago and wired in all switches for lights.
Completely wired J241 connector for GEA 24 and attached. Wires are a mess. Trying to minimize crossing of wires through middle of CANbus and connecting wires between LRU's but will be impossible. I see cutting off and redoing a lot of terminals to straighten out wiring mess after final panel install. For now, I just need to get all connected to test circuits and connections.
 
Jul 14, 2023     Odds and ends wiring - (5.0 hours) Category: Wiring
Worked on extended GMU 11 line. Worked on figuring out what I did with wing wiring and fuselage stub connections and how all fit together. Most of the markings on masking tape and on connectors faded nearly completely. Also trying to figure what wires connected the AP servos, Trim booster and how all connected together. Slowly remembering what I did a year or so ago. I seem to have lost some "Y" shape adapter wires I had made to connect stick and console trim switch connects. Will have to try to duplicate them and hopefully all the trim will work when all put together
 
Jul 13, 2023     more wiring over past week - (25 hours)       Category: Wiring
Order some more little parts, wiring, connectors, etc. Started to just order from Amazon when I found I needed something.....five separate orders in one day. I believe I'm over my period of "frozen in place" not knowing about this wiring business. Things are progress. I've anchored down the three buss blocks and have started connecting wires. CHT, EGT and associated plug completed. Trying to relearn about all wiring I did for panel avionics this past winter and all wiring I did in the tail a year or so ago. Have lost some important adapter wires I built to connect the trim booster to allow AP to trim and allow manual trim from control stick and console trim switch....oh well...probably only cost me a whole day figure out what I had done.
Able to complete wire and connector build for one of the four connectors for the GEA 24 engine analyzer box.


 
Jul 06, 2023     Thermocouples - (3 hours)       Category: Wiring
Spent hours over months on how to extend EGT thermocouple wires with proper extension. The K-type EGT probes I got came with metal plug type connectors installed that don't fit anything. Cut off the plug connectors to show that the black and white insulation had black and red (respectively) insulated wires inside. I had obtained some K-type thermocouple extension wires (colored white with blue or red/orange stripe) but didn't know which wires were (+) or (-) or which wires of extension to hook to main probe wires. Research shows that one of K-type thermo couple wires is magnetic and the other is not. Experimentation and examination shows that main K-type probe interior black wire (connects to blue stripe extension) is magnetic and (-) with the interior probe red wire connecting to red/orange stripe extension (+) is not magnetic. in a K type thermocouple, one wire is (-) magnetic (-) lead and the other (+) non-magnitic (+) lead regardless of color coding on wire. Trying to keep non standard color coded thin wire covered with non standard color coded cover maker a thicker wire connect to non-standard color wire through a polorized mechanical connector and keeping all straight was trick. The very inner wire for the thermocouple is TINY at least 26AWG if not 28AWG or smaller. Almost couldn't see the wire.


 
Jul 04, 2023     wiring progress - (20 hours)       Category: Wiring
Have been lax in log updates. Gone for nearly 5 weeks on 2 nearly transcontinental trips....train one way, pick-up truck the other way. (Toronto-Vancouver-Seattle-Poulsbo-Ft. Edward, NY.
The recorded time is over multiple 1-4 hour work sessions over 2-3 weeks
Spent a few bucks on handful of connectors, wiring, resistors, diodes and capacitors. Finally able to get alternators wired in....I think I understand what is going on. Learned about flyback diodes for the battery contactor and starter solenoids. Also placed small (tiny) capacitors across fuel pump terminals and much larger capacitors for the alternators. Wired and connected CHT, oil temp, oil pressure wiring, EGT probes are all connected and extending through the fire wall.


 
May 12, 2023     Basic wiring conundrum - (5 hours) Category: Wiring
Still trying to figure out how to wire in alternators into the system. Trying to hook up 3-4 wires into one wire with larger gauge wires, tie in two capacitors, the ECU wires and wire all into the main bus. I'll get it figured out eventually.
 
May 11, 2023     Sub panel, Capacitors - (5.0 hours)       Category: Avionics
Went from a roughly (very roughly) bent piece of 0.060 thick aluminum sheet to final sub-panel piece to hold the throttle control. Ended up much smaller than original plan as one or two of the buttons/switches was moved to the main panel. Didn't figure I would use them much. I have actually NEVER used similar switches/buttons on C-182's I fly for CAP.
Also mounted the RAM ball on mockup panel. I forgot to do it earlier. Need to get the holder and attachment arm and try it on mock panel to see if I have the ball mounted in proper position.
Started next project but leery about starting due to "fuzzy head" issue. I've had this issue off and on for several months.....long COVID....brain fog??? NOt for sure but decongestants and antihistamines seem to help but I hate having to take them every day.
I did decide to start on capacitor install (X2) for the voltage regulators. Found out that small friction quick connect tabs didn't work and would have to solder contacts. I needed two capacitors but FWF kit only had one. I bought two similar which are a little larger and slightly different from kit supplied one. I used the kit supplied one to experiment with soldering wire to terminal. Soldering worked fine for the capacitor terminals and 14 AWG wire with solder iron on 4 and larger tip.....actually too easy.


 
May 09, 2023     Mock up panel - (8.0 hours)       Category: Avionics
Scattered time over several relatively short sessions over past 2-3 weeks working on a temporary mock up acrylic panel. Using design drawn on white masonite board, I hand transferred the design then cut all the holes for everything to be mounted on the panel. After several trial fittings, I was able to get all the instruments, switches and controllers to fit and mounted all. During process, I had to get a 5/32 drill for some of drill holes. Learned a lot about how critical to measure for mounting holes as final panel will not be transparent.
I did find out problem with using a drill NOT designed to drill acrylic. I got all major holes cut with only one crack. Had to put an extra screw in panel to minimize bowing of panel due to weight and panel being very flexible. In process of trying to put in a single hole and screw, I created a major crack/break in panel, I ended up drilling another 5-6 holes to try to fix initial problem and created more cracks. Good thing this is only a temporary mock up.
Last thing I did today was print up labels for all the switches.


 
Apr 25, 2023     hole cutter text - (1.0 hour) Category: Avionics
Tested my hole cutters on piece of scrap aluminum that is 50% thicker than my panel. The cutters went through aluminum like hot knife through butter.
Heading out of town again...Cozumel for 6 days.
 
Apr 25, 2023     hole cutter trial - (3.5 hours)       Category: Research
Spent some time trying to find some hole cutters or some technique to cut proper size holes in aluminum panel. Finally came up with some cutters by Craftsman at Lowe's. Their sizes available came closest to size that I needed Bought three independent sized hole cutters in almost exact needed size.
Also spent almost 2 hours on internet trying to figure out the "three parts" from Garmin to use for the RPM pick up sensor and small resistor for oil pressure sensor wiring. Had to learn about Zenner diode and how to order a small 1/4 watt resistor. I ended up with 5 parts from GArmin. Seems I got two required resistors. two regular Diodes and one Zenner diode.


 
Apr 24, 2023     Basic power wiring - (3.0 hours) Category: Avionics
Spent several hours working on cutting and crimping wires for basic power supply between battery contactor and my proposed fuse busses and the necessary ground wiring from busses to engine ground. Still didn't get all the CORRECT wire connectors but I made do with what I have.
 
Apr 24, 2023     More videos watched - (2.0 hours) Category: Avionics
Watched multiple EAA homebuilders tips for electrical applications. The information presented actually made sense to me this time.
 
Apr 23, 2023     Finish up Avionics rack - (6 hours) Category: Avionics
I only had a couple of "little" items to finish with the avionics rack. I spent quite some time trying to open up lightening holes on side supports for the radio rack. Not saving much weight but hopefully allowing more cooling of the radio and large/heavy GPS/transponder unit. By golly, 6 hours later it WAS finished and mounted onto temp panel. Even the radios fit into the racks but the acrylic panel is not strong enough to support the avionics rack with the radios in place.
 
Apr 12, 2023     Avionics rack - (8 hours)       Category: Instrument Panel
Worked on stacking the avionic racks for Autopilot, radio, and GPS and glued them with hot glue. to hold position. Then worked on fitting side brackets to radio trays and riveting on nutplates to side brackets that hold the radio trays then ultimately riveted to back of instrument panel. I mis counted how many nutplates needed and came up short 3 or 4.
spent about $100 to get a jig saw to cut my panel. Also acquired a sheet of acrylic to draw my panel design on and do initial fit of all items.on a clear panel. This was suggested by website that would cost me hundreds and hundreds of dollars for a "professional" panel....I've spent too much already


 
Apr 11, 2023     multiple little parts to finish panel install - (12 hours) Category: Supplies
Hours spent trying to figure out what parts I still needed to get all remaining jobs done. Missing gas hinge brackets for door.(got them somewhere but ordered more), switches, wire, radio/gps cable, cable and wiring connectors, resistors, clamps, dimmers, resisters, capacitors, Thought I got it all but right after sending in order, I had to start another one.
 
Apr 07, 2023     Desing in progress - (10 hours)       Category: Instrument Panel
Multiple hours spent over several weeks with my paper cutouts for avionics tapped to panel. I have a masonite sheet I started detailed measurements for placement and cutouts. Found a website to design my panel and thought I could get a CAD-CAM file to have my panel cut....but, alas,...no. I actually got paper with drawn in switch positions and stuck all on the metal panel and tape it into place. Then put the seat, seat pads in place and sat in cockpit. I ended up moving a group of switches to a little better place.


 
Apr 03, 2023     Doors fitted - (14 hours)       Category: Fuselage
Spent several sessions working on final fitting of poly carbonate door panels to door frame. More door frame fitting, more clear panel trimming, drilling door frame and acrylic panel for mounting screws. Also mounted the hinges I had cut and fitting a couple of years ago. Found some spring pins to fit the hinges so I can pull hinge pin and doors come off. was trying to final fit the gas door struts and attachments but wings have to be on....not there yet.


 
Apr 01, 2023     Unlogged reading and research - (24 hours) Category: Research
I have been somewhat remiss in logging work hours. All kinds of squirrels (distractions) running everywhere. Trying to find wire up some of engine sensors, reading on GEA 24 wiring, long hours trying to find HI/LO for Rpm senor wire (W/Y, B/Y), ordering multiple little parts, panel design, switch design, how many switches needed, how many circuits....and on and on. Still somewhat hesitant about actually working on plane afraid I'll screw up something.
 
Mar 02, 2023     Engine compartment fixes - (4 hours) Category: Avionics
Four hours to replace some fire sleeves on oil and fuel lines. Also worked on power and grounds for both fuel pumps. Poor access for all installed items. Need to talk with whoever decided to put things where they did on the fire wall.
 
Feb 27, 2023     Panel planning - (8 hours) Category: Avionics
Eight hours (at least) has been spent over several weeks on panel layout planning. I have prints from Garmin (supposedly life size) of equipment I'm putting into panel. I just have them taped on and keep moving them around every few days. One day I need to find the online panel planner and finalize my design, then download the design and take it to someone to cut the panel.
 
Feb 22, 2023     material order for avionics Category: Avionics
Sent in a large order to Air Craft spruce....lots of odds and ends of wire, connectors, nuts, screws, clamps, aluminum, etc. Hopefully this will be able to help me finish the engine and avionics install.
 
Feb 22, 2023     more wiring/research - (10.0 hours) Category: Avionics
Hours over three days. Had to correct couple of wiring errors. Built the CAN bus for LRU's behind panel. I have the termination planned for GEA 24. Loose connection from GSU 25 hanging over the heater. Built CAN bus to connect the LRU's. Today, started plugging CAN bus pins into connectors. Got to the GNX375 and tried to locate which hole to stick the pin into......lo and behold.....NO CAN bus connection (RS 232 ARINC via GAD 29). Oh well.... I just covered up pins and labeled as "EXTRA" CAN bus node. Maybe I'll add something in future and CAN bus ready to go.
Spent some time coming up with final plan for panel lay out and determine type/number of switches needed. Also tried to read about GPS/TXpndr antennas and needed material. Would like to send in large order to Aircraft Spruce for most of final needed parts/supplies.

CAP border flight tomorrow then immediately after, trip back to mountains. Only maybe 4 weekends left in ski season.
 
Feb 16, 2023     CAN bus wiring for panel LRU's - (7 hours) Category: Avionics
I recorded 7.0 hours. Most 4.5+ was spent just re-researching/building CAN bus connection for panel LRU's. Another hour or so was trying to figure out how CAN bus connected, size of pins needed, ports to attach pins. I'm getting a little better with soldering branch connections
 
Feb 14, 2023     error correction, GEA 24 to be CAN bus term - (2.0 hours) Category: Avionics
Late start and more distractions. Had to chase down and correct some errors (inconsistencies) on wire color vs pin number designation. Fortunately unplaced pins so didn't have to remove any. Just corrected wire color/pin number on pin out sheets. I had jumpered GMC 507 to be CAN bus termination but read that one of other LRU's with terminating plug would work better so I clipped the jumper (couldn't remove tiny pins), sealed cut ends and designated GEA 24 as CAN bus termination. WIll use one of supplied plugs that provides termination and allow removal of LRU without penalty.
 
Feb 13, 2023     GNX 375 and GDU 460 config wiring - (3.0 hours) Category: Avionics
Worked on pinning the tiny wires for config modules on GDU 460 and GNX 375. Also cut wires to start process of wiring the CAN bus for the behind the panel LRU's starting at teminated end at GMC 507 and daisy chain connection to GNX, GTR, GDU, GEA24 then GAD29. Will do final CAN bus connection from GSU 28 GEA 24 at the GAD 29 when panel mostly ready to install.
Lots of squirrels (distractions) today so not much productive work today.
 
Feb 12, 2023     More on GDU 460 GNX 375 GAD 29 - (5 hours) Category: Avionics
More hours on sorting out wiring interconnections on GDU 460, GTR 200B, GAD 29, GNX 375, and GMC 507. With exception of CNA bus connection, pretty much done with wires on GMC 507, GAD 29, GDU 460, GTR 200B. Lots of wiring and much more to go yet.
 
Feb 11, 2023     Wiring GNX375, GDU460, GDU29 - (5.0 hours) Category: Avionics
Worked on six cables connecting GNX375, GDU460, GDU29. I carefully labeled new wires with LRU and pin numbers for both ends to minimize confusion on my part. It worked well....only one wrong plug in. Now I realize that I need to keep tract of wires connected on pin out sheets to be sure I don't miss supplying needed wires.
 
Feb 10, 2023     More reading on GDU 460 and GNX 375 - (4 hours) Category: Avionics
SEveral hours spent researching and understanding connections between LRU's behind panel. I pinned three wires each on P3752 and P4602 with wires from back of plane. I had them coming out of fuselage from under seat area to provide longer reach to my work table with intent of eventually feeding the connector through console tunnel..BUT a three O'clock AM realization told me that would not work once all wiring and connectors for front LRU's completed. No way all that would fit through the console tunnel.
So I then spent an hour trying multiple tools to remove the six wires. Finally able to do so with a cheap plastic pin remover.
 
Feb 06, 2023     wiring for GMC 507 AP - (4.0 hours) Category: Avionics
Some time researching, re-recording wire colors for pin outs for GTR200B, but mostly on cutting/fitting wires into the GMC 507 AP control head. A 15 pin, high density pin spacing connector. When I initially tried to crimp brass tip, it went all the way through the crimping pliers. A closer look showed that the male pins were quite tiny and I used the crimping adapter head for "tiny" pins as I had marked on it a couple of years ago when I first bought them.
Still need to connect CAN bus wires and then connect backup power directly from backup battery. Backshell still not complete either.
 
Feb 02, 2023     GTR 200B connector wiring - (7.0 hours) Category: Avionics
Spent two days working on figuring out how tray and connectors worked on radio insert tray. Determined I had to complete inserting all plugs/wires before assembling the connector in back of instrument tray. Got all wires installed with exception of Can bus wires.....a lot of wire....about 1.5 pounds of just wire. Next week, will start on 507 auto pilot head. Now...back to Ruidoso for more sled training for multiple new patrollers.
 
Jan 31, 2023     Fixed missing wires - (2.0 hours) Category: Avionics
A little closer read showed I needed some more RS-232 wires for GDU and GNX from ADHRS unit. Had to pull out the plug and add couple or more wires. Not too hard but took a while to confirm I DID need the wires and reread the diagram multiple times to confirm.
Started on wiring for GTR 200B.
 
Jan 30, 2023     More reading - (4.0 hours) Category: Research
Several hours over several days reading up on more wiring for avionics.
 
Jan 24, 2023     Connectors ADHRS, AP servo - (18 hours) Category: Avionics
Cut, stripped, crimped, wrapped, plugged, screwed wires in to back shells for both connectors on ADHRS GSU25 unit and also for roll servo. Wires for connect in panel sent forward on the floor and center console.

Also fitted Tosten pilot grip and fed wires through stick and out side of stick bottom. Had to modify the top, forward portion of stick grip with belt sander to clear panel face in full nose down position. May still have to modify tabs for panel mounting to permit full stick movement.
 
Jan 16, 2023     Actual continue with wiring project - (12 hours)       Category: Avionics
Work over several days where I'm actually working on the wiring. Pulled out wiring sheets done over year ago and re-familiarized myself with what was previously done. Wings seem complete. Worked to start with on ADHRS GSU 25. Learned wires to attached and located/labeled needed wires.
Now working on trim control, trim mixer, trim booster, pilot control handle/wiring. Ordered part to fit pilot


 
Dec 12, 2022     More reading - (30 hours) Category: Research
More and more reading. I'm kind of paralyzed thinking about the wiring. I want it done right but lack confidence in doing the work.
 
Nov 10, 2022     learning about electrical - (40 hours) Category: Research
Lots of reading in manuals for aux alternator install, EP914iS install, Rotax 912/914 install, AeroElectric connection (Bob Nuckolls) basics, AEA G3 install books from course 2 years ago
Hours for recent and for near future reading.
 
Nov 09, 2022     Various odds and ends items - (4.0 hours) Category: Supplies
Several odds and ends: nuts, bolts, screws, aluminum angle, connectors for LRU's, valves, hoses, etc.
 
Oct 29, 2022     wiring basics, wiring planning. - (6.0 hours) Category: Engine
Haven't felt very good for past week. Not much done as this "crud" has left me with fuzzy thinking for the past many days. Did a lot of studying, planning, contemplating....whatever you want to call it.....about all the wiring that needs to be done. I don't know where to start. To get my feet wet, I started on doing basic wiring of master and starter solenoid wired to battery, starter and engine ground. Got most of it done but short a couple of ring connectors for last bit of the #6gauge wires. Thinking of doing a hinged instrument panel to provide future back panel access. Not much back there to deal with in future other then replacing heater hoses and access to my fuse blocks. Looks like I need to order 2 x 12 fuse box. I count 25 circuits needing protection. I may see if I can use some inline fuses for some circuits.
I plan to mount the two fuse boxes on the back of the right side of the panel. I don't really want 25 Klxon fuses sticking out of my panel. In 25+ years of flying, I have only messed with the circuit breakers twice and once was a problem that I created with the autopilot. Then hinged panel will provide access for future wiring changes....if needed.
Slowly but surely, I'll get this done.
 
Oct 24, 2022     Windshield install practice - (1.0 hour) Category: Fuselage
Went ahead and drilled holes to mount the cracked window.....for practice. I want to be "expert" when I install new one.
I've been fighting a cold/laryngitis for over 5 days. My head still doesn't function well yet but getting better.
 
Oct 13, 2022     Windshield and camlocs - (1.0 hour)       Category: Supplies
Big order to replace windshield. I paid $250 extra to get windshield with UV protection but untinted. I didn't figure another $250 extra for "tinting" was worth the expense as not much tint in the acrylic. I believe it passes 75% of light.....I wanted it to BLOCK that much but not possible.
I ordered some extra camlocs to use on air fill doors on my wheel pants if I choose to actually use them....they are about $12.00 each for the camlocs


 
Oct 12, 2022     Windshield cracked - (2.5 hours)       Category: Fuselage
Spent several hours screwing up my windshield. I cracked the top right co-pilots corner....twice. Then trimmed too much off of the vertical post area so when windshield contacts boot cowl, there is not enough to grab when securing vertical sections to the vertical posts. Oh well......only money....a LOT!! for a new one and then have to wait for it..


 
Oct 11, 2022     Windshield study - (2.0 hours) Category: Research
Spent time looking at and studying windshield and trying to learn how it is all supposed to fit. Try fitting has whole window a little too far forward as I have almost no overhang on aft end over rear cross-through. Next work session, i'll do some preliminary trimming to see if can get to fit better.
I've read so much about care needed for this part of build. I don't want to screw up a $1000 part.
 
Oct 11, 2022     Fuel hose connections - (4.0 hours) Category: Engine
Spent work session building fuel hoses from fire wall, through fuel pump, then fuel filter, to fuel rail, from fuel rail, through FP regulator and back to firewall. Most needed the special AN 6 PTFE fittings installed. Took about an hour to re-read and figure how to do the first couple of fitting installation on the wire reinforced fuel hose. Then a re-do because I forgot to install the fire sleeve. The last couple only took about five minutes each. I came up about 3-4 inches short on the fire sleeve for the last hose. Mike at EP engines said fire sleeve optional and mostly only necessary for lines near exhaust manifold. The fire sleeve shortage I have is placed next to fire wall and FP regulator.
 
Oct 09, 2022     oil hose connections - (5 hours)       Category: Engine
A long time to fit just three hoses and six fittings. I had to change out three barb connectors on oil coolers and oil tank to allow oil hose connections, Then cut hoses to length and figure final route position and cover with fire sleeve. I had to reposition return line for turbo 4 times to get it right. Also had to remove, reinstall, remove, reinstall several fittings and intercooler to allow access for hose installation and tightening of screw clamp on hose end. I perish the thought of having to remove these items in the future (5 year hose replacement required for Rotax). VERY secure fittings of oil lines. When comes time to replace, I'll need a very sharp knife to split the ends.


 
Oct 07, 2022     Odds and ends - (8.0 hours) Category: Engine
Fitted heater hoses to heater core. Tightened screws on heater core ECU. Sanded front cowl. Fitted oil door. Rivet bottom hinge to oil door and drilled out oil door holes on top cowl. Drilled holes to mount CamLocks on oil door. Added vacuum hose on engine....still need to order barbed "T" fitting for MP line. Marked and made three straps (until I got it right) to mount/secure the large fuel filter just in front of the battery. Used Adel clamps to secure the aluminum strip and will use some dense rubber material to cushion fuel filter when secured with SS screw bands onto the metal strap. Cleaned up some and put away all tools in prep for install fitting of windshield.
 
Oct 05, 2022     Cowling and Electrical tray - (6.0 hours) Category: Engine
Worked today on getting electrical trays in place using the sticky tape and some half round pipe hangers to secure the tray. I had gone to Lowe's aircraft supply to get needed nuts/screws, etc. I plan to wire the majority of the boxes on a bench so decided to just put screws into empty holes so I won't misplace them. Now, electrical tray ready to install all boxes....shouldn't take more than hour or so install.....yeah....right!. Took me 4+ hours yesterday to drill a couple of dozen holes.
Sanded a little more on cowls, reinstalled and added more Superfill. Also working on process to replace cowl tab I had to cut off to get upper and lower cowls even close to fitting. I'm trying to fit a small metal tab to the two cowl halves using Hysol to get better fit for bonding and riveting to allow proper function
Opened and checked the EGT probes and found they fit nicely into EGT bungs. Only going to put in one for each side for now. I guess I really need to order a couple of more. Can do it now or wire into EIS with plans to add other EGT probes at later date. The probes are pricey.....$150+
Also determined location for the manifold pressure and fuel pressure sensor. They need to be in area less than 240 degrees. So mounted them on firewall with sensor on cabin side and fitting on engine side. Should work real nice. I've learned how to drill stainless steel and only took about 30 minutes to up-drill two holes near top of firewall (only area accessible to my drill). Measurements off and one interferes with tubing structure. I believe a nut can be installed to make it fit better.
 
Oct 04, 2022     Cowling and Electrical tray - (6.0 hours) Category: Engine
Sanded the Superfill on front of cowling. Still need another fill layer but need to remove engine cowling and boot cowl for several items. Decided that electrical tray final fit and position determination would be easier with boot cowl off. Spent most of the day doing final positioning of the electrical tray components and marked on the tray, mounting holes marked, spiked and drilled for 30+ mounting holes. Several trial fittings to be sure drilling in correct place....of course not all drilled correctly....measured 3-4 times and still messed up a couple of holed. Applied protected strip of HBS tape to secure electrical trays and decided to use some 1/2 inch "U" shaped support brackets to be sure tray will not come loose in future. Had to go to Lowe's aviation department for some short mounting screws and nuts. I actually found the needed screws.....supply issues seem to be easing.
 
Oct 03, 2022     Cowling and Electrical tray - (4 hours)       Category: Engine
Worked on mounting cowling and adding Superfill to uneven areas where upper and lower cowling meet. When partially set, i trimmed some excess with a hunting knife and added more as needed for fill. Spent time working out where items were to go on the electrical tray behind instrument panel. I pretty close to my final plan.


 
Oct 02, 2022     Oil door on upper cowl - (5.0 hours)       Category: Fuselage
Spent most of the day trimming, fitting and sanding oil door to fit into indent. Cut out opening into upper cowl and then trimmed and smoothed edges. More time to trim for hinge to fit. Trimmed hing and drilled holes in cowl and door to fit hinge. Had to do a little body fill to get door to fit better. Day or so later, drilled and fitted Camloc receptacles


 
Sep 28, 2022     hoses and instrument tray oranization - (2.0 hours) Category: Engine
Worked on putting in oil hoses. Took couple of tries to get correct length for left side oil hose from engine to oil tank. Forgot I needed to order some different oil cooler fittings to allow better fit/path for the oil hoses from oil tank to oil cooler and from oil cooler to oil pump. I mocked up fit to determine I needed a 45 degree and 90 degree oil cooler fitting. Trying to run hoses to avoid exhaust pipes and turbo as much as possible yet keep them clear of bottom cowling and radiator intact duct. Decided taking oil line to lateral side of turbo intercooler is best route for oil cooler hose and also the oil line from turbo direct to oil tank.
Also worked some more on figuring position of boxes on instrument shelf. Was told I could place ECU with connector to side but NOT up. Think I'm getting close to final configuration.
 
Sep 27, 2022     Engine sensors - (6.0 hours) Category: Research
Did a little final fitting of CamLocks on upper cowl. Drew circle on front cowl to trim back of spinner backing. Most of the time was talking with Mike Busenitz of Stolreek about sensor and wires on engine. Then spent time trying to find compatible sensors for the engine. Did research on internet and TeamKitfox suggested to check G3x install manual. Found what sensors and models Garmin has used in past. Most of the CHT, MP, and Fuel pressure sensors I had already in "cart" for AC Spruce order. Then spent time trying to figure out where to put the large fuel filter after the electric fuel pump and how to run fuel lines and what fittings I needed. Another hour or so, I finally pulled the plug and ordered some AN6-PTFE fittings for fuel line and the sensors and smaller parts like windshield gaskets and anti skid paper for rudder pedals. Now back to CAP stuff...of course.
 
Sep 26, 2022     Engine e-mail to Stolcreek - (7.0 hours) Category: Research
Spent all day composing e-mail to STolcreek asking about various items on my engine. Also did lot of reading on G3X install to try to understand about sensor and sensor leads.
Also got permission to return some unused kit items: i.e. dual pin door latch and choke cables for carbs.
Filled out paperwork for AC registration and asked Kitfox for correct Bill-of-sale with correct airframe serial number.
Packed and shipped parts back to Kitfox and got Notary sig on AC registration.
 
Sep 25, 2022     Coolant lines, parts, CAmLock install - (4.00 hours)       Category: Engine
Still working around engine. Had to re-do coolant lines AGAIN. I forgot about fitting with coolant temp sensor for ECU. Needed some more screw clamps.
Spent hour or so trying to figure out how to run fuel lines and what additional fittings I need. Thought some more on boxes behind panel location.
Went to Lowes for screw clamps and came back with other fittings for wiring through fire-wall, brackets to hold vertical ECU. Also got new yard thermometer. The other one was over thirty years old.
Spent couple of hours trying to figure out camlocks function and how to install. Then go to rolling. Easy....when you know how. Battery ran out mid job.


 
Sep 23, 2022     Hoses---re-do, thinking and CAMLOC install - (6.0 hours)       Category: Engine
Over last couple of days, I've had to re-do the coolant hoses over two times. I keep finding interferences and have to move hoses....which end up too short or too long. Then I remember a section with coolant temperature sensor and had to splice that in....had to cut four different lengths of hoses to get it fit properly.
Then looked at Camlocks.....then the placement for fuel lines and fittings supplied by Edge Performance. Spent at least 2 hours over couple of days trying to figure out where my assortment of supplied fuel fittings would work the best and what fittings I might need. I think I have it figured out. Spent an hour or so trying to figure out the "unclaimed" wires from the engine. Decided to re-read the install instructions for any clues and got one more wire matched up to connection. I'm confused about the Edge Performance intake vacuum manifold and what ports are to be used and what to cap off. Instuctions are somewhat contradictory in that reading one way, only one other line connected to manifold (then why the manifold) then I read it again and three lines are connected. This is on my list to call and ask about with Edge Performance. Still one wire I can't account for. The wiring diagram in instructions doesn't make my setup......many questions.
Other Item I stewed on a long time was the Camlock install. I spent long time trying to figure them out and remember reading somewhere about how to adjust the grip length. I couldn't find any instructions and ACSpruce is confusing as ever with multiple "wrtten" options but few pictures pertaining to my specific install. I read and re-read Camlock install----a whole paragraph.....must be at least 5-7 lines. After some experimentation, I determined that the studs WILL fit through initial suggested hole size (upsized one size to get stud prongs through preliminary holes)...I just have to hold stud collar and depress screw head and insert end with dogs at an angle into female recepticle then turn stud clockwise to tighten whol assembly to substrate. Spent 1.5+ hours trying to figure this out, 15-20 minutes trying one install....saw/understood my issue then did preliminary install of 10+ Camloc bases in about 15 minutes which are now ready for rivet hole drilling. Should not take long tomorrow to finish install.


 
Sep 22, 2022     Radiator hoses - (1.5 hours) Category: Engine
Got all radiator and coolant hoses cut and connected. Water pump outlet was a little tricky as very little room between outlet and engine mount. Hoses installed and clamps placed.
 
Sep 21, 2022     Sanding lower cowl - (2.5 hours) Category: Engine
Sanded blue Superfill on inside of NACA ducts for radiator and intake manifold air intakes. Not a perfect NACA duct but I believe shaped and sanded well enough for my application.
 
Sep 20, 2022     Odds and ends - (4.0 hours) Category: Engine
Just couple of hours each day doing odds and ends. Added some thicker washers under castle nuts on engine mounts to better line up cotter pin holes in more ideal location. Simple job but took most of an hour. Also tightened some nuts on micro slipper plate for electric prop control. Then moved a clamp holding fuel line in the area.and dropped the bolt. Took over an hour to find the bolt in the engine. Then took delivery of some aircraft supplies. Put the thick, extra washers I got for the prop bolt in the bag of 30-40 more washers....same size...that I already had in small parts buckets.....who knew.....wont run out of these size washers, thick or thin version. Got a quick drain oil valve and promptly lost the copper sealing washer. Spent better part of an hour trying to find that or order replacement. Finally found copper washer....was prepping with thread seal and lost washer again, this time only 4-5 minutes.
Was going to send back some extra plane parts I don't plan to use to KitFox and use credit to order some angled oil cooler flanges. Found out that the throttle control I ordered from Spruce won't fit my application because it has a solid, inner push control. I needed one with inner cable. Determined that the dual throttle control for 914 I already had would work perfect for my application...I just need to cut off one of the cables. Still need to see about returning dual pin door latch....too complicated to install for little benefit for me. John McBean said really only needed for air loads encountered with aerobatics. Also, special door handle I plan to install that props door open for ventilation wont fit on dual pin. I process of playing with throttle control, I lost retention nut that attaches throttle control cable to throttle valve. Spent almost hour looking for it and then found replacement in Spruce catalog. Was coiling some extra wire I was trying to label on the engine and found where I had carefully set the missing nut. All told, I spent almost two hours looking for small dropped items.
Tried on and fitted coolant hose on left side engine. Then tried the right side. Left side fit with a little trimming. Right side....couldn't get hose onto hose bib.
Last item I did was apply Superfil blue to the recently bonded air scoops on bottom cowl. Tried to smooth well and have enough to sand to shape
 
Sep 18, 2022     Winshield and glare shield install - (4.0 hours) Category: Research
Several hours spent on researching TeamKitFox about installing windshield and glare shield. Picked up a couple of pointers but most problems seemed to be with breakage on older posts. Other issue with how much overhang of plexiglass over butt rib onto/over #1 rib. Also looked at ways to seal windshield to boot cowl.
I still don't don't know how to do word search on Team Kit Fox as most of my searchs on "windshield" never mentioned windshield at all in listed posts.
 
Sep 17, 2022     Propeller comparison - (1.0 hour)       Category: Propeller
Photo of comparison of one blade of my prop setup with blades on CAP C-182


 
Sep 16, 2022     Engine study - (2.0 hours)       Category: Engine
Trying to determine where all wires go and how oil and water lines will attach to engine. Found where a majority of engine wires go but still have two I have no idea about what they are or where they go. Also determined I had to rotated engine's water pump outlet elbow 180 degrees to point in direction water line will eventually go. Next, I need to work on attaching hoses and then determine how to run my extra wires for engine electrical and sensor wires.


 
Sep 15, 2022     parts and supplies - (1.0 hour) Category: Engine
Had to order more Superfil for future body work on cowl and lift struts. Also ordered some external wire mesh for shielding the secondary alternator wiring, quick drain oil valve for oil tank. Seems most people completely remove oil tank to clean it but with quick drain, I wont' have to deal with 2-3 quarts of oil still in tank. Re-ordered correct washers for waste gate bolts and got some extra locking washers for prop bolts. The special washers negate need for safety wiring prop bolts but can only be reused once. Got extra in case I need to remove said prop.....now just need to find a place to store them and then remember the special safe place where I store them
Removed clecos from the cowl gluing and all clecos came out and still functioned....the lubing helped immensely
 
Sep 15, 2022     Cowl fitting - (6.0 hours)       Category: Engine
Spent all day refining temp fit of cowl with radiator air scoop. Got real good at taking cowl on and off....now I can do it in just a few seconds. It dawned on me that every time I did a trial fit holding air scoop with tape, all would be in slightly different position and I would NEVER be finished, soooooo I got air scoop close and started drilling holes in flange and used clecos to hold securely in place and THEN completed my fitting. Could have save and hour or so if I had done this earlier. Tried all in and found had to move air scoop about 3/16-1/4 to prevent air scoop from rubbing on radiator. Drilled a few more holes. Marked lines on cowl to determine cut-out for radiator scoop and felt as long as I was at it to determine air scoop for the turbo air induction intake position. Turbo on back right side of engine about mid- length down cowl. The NACA air scoop (preformed as was the radiator air scoop) wouldn't sit very flat in a strictly horizontal position so I canted the entrance up a few degrees. I could have spent some amount of time modifying the flange to fit but decided the few degree slant won't matter that much-----after all i'm NOT building the Space Shuttle. Got all parts position marked, cleco holes drilled, intake openings cut for both and somewhat smoothed edges, roughed up the flanges, fabricated a doubler for straight opening for radiator air scoop, mixed up Hysol and glued in all parts using well lubricated cleco tips to hold position and pressure.


 
Sep 13, 2022     Install radiator/oil cooler/air scoop - (7 hours)       Category: Engine
Spent all day trying to fit scoop to radiator group. Still more cowl on and off. Finally decided that I needed to have oil cooler permanently mounted to radiator and the group mounted in final position onto engine mount, THEN due final trial fitting of air scoop and then determine where to mount the air scoop. Spent couple of hours mounting the oil cooler onto the radiator, The brackets were made early with pop-rivet holes drilled but had to determine where oil cooler mounted in relation to radiator. Temp masking tape holding oil cooler was torn off before I determined position on radiator.....so had to re-establish position with more trial fittings. Then had to re-bend brackets slightly to get proper fit, bolted brackets to mounting holes, drill holes into radiator and pop-riveted brackets
to radiator. Last I did today was mount radiator group into final position (but not final nuts) and re-installed cowl with air scoop.......then saw I still have trimming to do on air scoop to fit around just installed oil cooler mounting brackets.........


 
Sep 13, 2022     Radiator mounting straps - (6.0 hours) Category: Engine
Incredible amount of time spent making two (only 2) straps to hang radiator from engine mount. Trying to get holes drilled in straps, straps twisted 45 degrees, mounting traps on radiator and mounting all to air frame. Trying to figure out where radiator is to fit on cowl and therefore how fits within engine compartment. Hot glued radiator to lower cowl with 3/16" as directed under "middle" of radiator. Marked straps for top holes. Spent hour or so drilling hole and trimming excess material around screw hole. Then mounted radiator, installed cowl again and discovered interference with turbo intake manifold along with radiator impinging on floor of cowl....supposed to be 3/16" clearance. Seems my 3/16 shim under "center" of radiator should have been on edges of radiator to take in account of curvature in bottom of cowl. Sooooo.....had to re-drill top strap holes and file/cut off almost 1/4" of SS strap. Easier said than done, Another hour or so drilling, trimming, fitting strap and had to trim more due to weld on the mounting tab.....that meant more filling, fitting, etc. Finally got
 
Sep 12, 2022     Radiator air scoop fitting - (8 hours)       Category: Engine
Temp mounted oil cooler to radiator with masking tape to determine how air scoop would fit around radiators. Determined interference with scoop and radiator, turbo air intake, muffler, exhaust, etc. Had to cut out corner of scoop to permit fitting around turbo air intake. Cowl on, fit air duct, mark to trim, remove cowl, trim scoop, reinstall cowl, then repeat two, three, 7, 9, 12, 15 times. I lost count. Cowl went on and off more to fit the air scoop than fitting cowl to start with. Was using oscillating multi tool to cut/trim scoop outside on back patio, VERY strong wind overnight and causes multi tool to fall on blade. Had to journey to Harbor freight to get new blade and better cobalt drill bit to upsize drill holes in SS straps.


 
Sep 10, 2022     Time for logging on this site - (3.0 hours) Category: Research
Couple of weeks behind in logging what I have done and 2.5 months behind in loading pictures to match my logs. Will try to stay more current in future.
 
Sep 10, 2022     Engine cowl - (10 hours)       Category: Engine
Three work sessions and over ten hours to fit the cowl. Key is to fit the very front of upper and lower cowl together, then mount and center around the prop flange and spinner backing plate. Secure with tape, be sure everything is kind of even all around, mark and trim cowl fit to joggle on boot cowl, Drill and cleco top and bottom cowl to boot cowl, trim and fit the top cowl side panel to lower cowl horizontal joggle. Drill and cleco side panels. Simple....all I had to do was trial fit, remove, trim, trial fit, remove, trim.....again...and again....and again....and so on......until it all fit. Removed and replaced couple of dozen times. Lots of dust.


 
Sep 06, 2022     Figuring out prop installation - (4.0 hours)       Category: Propeller
Spent several hours trying to figure out how prop installs. Some Rotax flange prop bolt flanges need to be installed but checked with Airmaster about how deep they were supposed to seat. Determined I have to install prop bolts and flange inserts at same time or after install of prop flange inserts alone, I would be unable to insert bolts due to length and interference of gear box output. Installed the 2 inch prop extension, spinner back plate to be able to fit the cowl.
Red arrow on prop extension photo shows the prop flange lug. When properly and completely installed, the wide flange to the left will be flush to back of prop flange. However, the prop bolts must be inserted along with the "LOOSE" prop flange lugs as I believe once the lugs are completely seated, I will NOT be able to insert the long prop bolts due to the extension of the gear box output housing. Not a problem, but the fit is very precise and even with trial fitting of the spinner back plate to fit the cowlings, the lugs had to be tapped out to remove the temp bolts I have been using. Final install of prop lugs will require hard set Loctite glue which will make removal a little tricky.


 
Sep 04, 2022     Learning about prop - (6.0 hours) Category: Propeller
Spent most of the day going through boxes and reading two manuals concerning prop usage and installation. Took awhile to understand how all went together. I'm excited. Not much work done but learning about prop.
 
Sep 01, 2022     Propeller ARRIVED!! - (6.0 hours)       Category: Propeller
Working on odds and ends before leaving for Ruidoso ski area when DHL showed up with my prop. Popped open boxes to confirm no damage. All looks good.


 
Aug 31, 2022     Various task - (5.0 hours)       Category: Engine
Scattering of little tasks. Worked more on trying to drill SS oil cooler brackets, Angled bracket for back spar carry through, position of ECU Autronic unit. Padding for tail through ceiling, trimming and painting of angled back spar carry-through bracket to be bonded. Cleaned work area and put away lots of tools.


 
Aug 31, 2022     Time for logging on this site - (2.0 hours) Category: Research
Spent an hour or so down-loading photos, labeling and describing event logs
 
Aug 30, 2022     PROP SHIPPING - (0.5 hour) Category: Propeller
Got email from Debra at Kitfox that my Airmaster prop is shipping and due within one week. Only few days short of one year between order and delivery of prop.
 
Aug 30, 2022     Oil cooler mounting - (8.0 hours)       Category: Engine
A LOT of time spent on making 4 brackets to mount oil cooler to front of radiator. Took most of an hour to find the SS metal strips in the garage....couldn't find in the garage because they were up on Scott's bed. Hacksaw worked better than air driven cut-off tool to cut the strips. Measured 3-4 times cut parts and still screwed up as two parts with one length and two parts with longer length....but initially cut four all same length. Cut lengths, smoothed edges and spent hours trying to get the bends correct and figuring out how to bend the metal strips using just what I had. A five to ten minutes with metal brake table but a hammer, wood block, "C" clamps, metal bucking bar and work bench took several hours. Over two hour refining bends to get all four brackets to fit on radiator and oil cooler mounting holes. Speaking of holes, I only got 6 mounting holes drilled before bits too dull to cut SS metal anymore. Had to order several drills from Spruce. Twelve pop-rivet holes to drill plus 20-30 holes to drill in firewall for cowl mounting.


 
Aug 28, 2022     Engine mounted - (1.5 hours)       Category: Engine
Patrick came over and with some effort, we were able to get nuts onto all four engine bolts though bottom two are two short to install cotter pins. Order placed with Aircraft Spruce for bolts, washers, nuts, fuel shutoff valves for wing tank lines, throttle cable.


 
Aug 25, 2022     Motor Installation onto airframe - (1.5 hours)       Category: Engine
Initially thought that the Hoyer lift from Jeanne's mom wouldn't lift high enough but able to shorten lift straps with some carabiners. Had about 2-3 inches lift height extra. I pre-positioned the engine bolts on engine mount and held them with masking tape. I was able to get all four bolts through mounting holes on engine mounting frame and one top nut secured. I struggled to get second top nut onto threads. Measurements indicated that bottom bolts will be too short. In process, I dropped two nuts and washers into engine "spaghetti" and could not see nor retrieve them. In frustration, I removed engine completely to retrieve the missing nut and washers and place engine back onto its shipping platform before then immediately leaving for Ski Patrol training in Ruidoso. I didn't trust leaving engine hanging on hydraulic lift all weekend.


 
Aug 17, 2022     Hard fuel lines - (5 hours)       Category: Fuselage
One of the things I had been dreading and concerned about was the hard fuel lines from firewall to header tank. I keep putting off and finding other things that "prevented" me from working on it. FINALLY, I decided to work on just one short pipe connection which led to another and another. Got the hard lines put in the cockpit running under console, under knees of co-pilot and down right side cockpit nearly on the floor. Only couple of screw ups.


 
Aug 15, 2022     Learning about my engine - (8.0 hours)       Category: Research
I spent hours reading about engine, install instructions for Rotax 912iS, 914, EP914STi, Kitfox instructions, I have to take bits and pieces from each to get install done. Also learning what all components mounted onto engine do or function.


 
Aug 12, 2022     Nose gear install - (2.0 hours)       Category: Landing Gear
Nose gear installed.


 
Aug 12, 2022     Moved engine inside       Category: Engine
After 10 months sitting in box out on the drive, I used Billie Jean's Hoyer lift to move engine inside.


 
Aug 10, 2022     Nose gear strut plug - (2.0 hours) Category: Landing Gear
Spent about an hour making plug for nose gear strut to seal inside against moisture long term. Easy enough but thought that as long as I was going to mix some Hysol, I would final bond butt rib closeouts. Spent about an hour fiddling with the closeouts to get them to fit better and then figure how/what I needed to do to get intimate contact on upper door frame. I realized that some of door hinge mounting will go through the multiple angle bend of the closeout panel that mounts at the top of the door frame. I had to be sure that area fit very well. Of course, Hysol all over my hands and a dozen paper towels to clean the mess. Maybe, this is the last Hysol I have to mix.....not holding my breath
 
Aug 10, 2022     Up sizing holes - (3.0 hours)       Category: Firewall
Spent an hour or so trying to find a couple of bolts for the engine mount. Then worked on up-drilling all the holes for mounting various parts.


 
Aug 09, 2022     Drilling and screw purchase - (5.0 hours)       Category: Firewall
Finally decided to go with the mock-up placement I had been working on. Worst case scenario.....i have to drill more, different holes in the future. I used a center punch to make a distinct dimple in SS metal then went with 1/8" drill for pilot hole. Then sized needed screws/bolts for all parts to be put on firewall and decided to go local and try to find what I needed in stainless steel. It took about an hour to find all I needed at Lowes 4-5 prepackaged #8, #10, 1/4" then several individual parts in the 5/16" size. Didn't think I got that much but total came to $30.


 
Aug 08, 2022     Firewall research - (2.0 hours) Category: Research
Still trying to visualize how to put all together. Got some hints from builder on EAA builders website. Not much help found on Team Kitfox. I kind of see about mounting stuff on firewall. Still working with mock-up placement on the floor.
 
Aug 03, 2022     Firewall research - (9.0 hours) Category: Research
Have spent many hours over several days trying to figure out what and where holes are needed in the firewall. The SS firewall material is very hard to drill when mounted on airframe. With firewall on floor with wood block backup, holes are easily drilled. I came up with idea to lay firewall on the floor and use masking tape to attach components to the firewall to see how will fit and work with each other. I have read Kitfox engine install for 914, Edge performance install for EFI on Rotax and Rotax manual for 912iS and 914...all trying to learn all parts that need to connect and what needs to be mounted on firewall...somewhere.
 
Aug 03, 2022     Firewall mounting - (10 hours)       Category: Research
Research on firewall. Trying to figure out all holes needed to drill. Very difficult to drill SS firewall material when on airframe. Much easier when laying on floor with wood block backing for drilling. Spending time to get my head wrapped around engine install and all the items to be mounted on or through the firewall. I even laid out the firewall on floor and used masking tape to hold items in position to see how all fit together. Last thing was to install all fuel fittings to see how fittings meshed with engine mount framework. Once I'm happy, I'll start marking and drilling holes.


 
Jul 21, 2022     Brake lines bleeding - (2.0 hours)       Category: Landing Gear
Now brake lines fitted and nuts tightened, time to add hydraulic fluid and bleed the brake lines. I've never done this before so will be a totally new experience. Going online for some hints. Firewall not yet installed so had to rig up a temp hydraulic fluid reservoir until final install of firewall and mounting of "real' fluid reservoir.


 
Jul 21, 2022     computer research time - (2.0 hours) Category: Research
Computer research on nose gear and how to bleed aircraft brakes.
 
Jul 21, 2022     Nose gear trial fit and plan for final install - (2.0 hours) Category: Landing Gear
Spent an hour or so trying to do a trial fit of nose gear to fuselage, Had to re-ream pivot blocks and fuselage holes to get ideal hole match to allow bolts to pass through without binding. Came up with a game plan to do final nose gear install: Trial install nose gear without firewall in place using temp bolts so all very visible, then one by one replace temp bolts with final bolts, torque nuts as needed all time with nose gear strut supported. Then final install firewall and engine mount then attach nose gear piston.
 
Jul 20, 2022     Nose gear - (6 hours)       Category: Landing Gear
Several shorter sessions over couple days working on Nose Gear. Trying to fit bearings into 5 bushings. Had to remove powder coat. Went to Lowe's and got what paint remover they had (environmentally friendly, even). Painted it on and let it set for 30, 60, 120 minutes......did nothing. Got some of my PolyBrush reducer, soaked a paper towel with reducer, put wet/damp towel into bushing and sealed with masking tape. Waited over night for test bushing and just 30-40 minutes for the others. With a little scraping, all coating came out.
Press fit bearings, my ass... Can press a size 6 bearing into a size 5 hole no matter how hard you push.....been there and done that!! So I locked the bearings into a vise and did the "shoe-shine" trick with 1 inch wide belt sanding strips. On average, took about 40 minutes per bearing to get to fit. Glued them in per manual.
Also assembled rubber donuts for nose gear piston and test fit. Test fitted nose gear pivot blocks to fuselage, test fitted nose wheel yoke to nose gear strut.
Test mounted nose gear assembly to fuselage and came up with plan on how to perm mount gear and get 4 bolts into fuselage and be able to see and access mounting holes before firewall installed.


 
Jul 19, 2022     Brake lines - (2.0 hours) Category: Landing Gear
After fabric covering of console and re-installation of same, I re-connected brake lines onto parking brake and to fittings on landing gear. Then tightened all the nuts.
 
Jul 18, 2022     Console, side panels fabric cover - (3 hours)       Category: Landing Gear
Trimmed and glued fabric to console and console side panels. I had been quite nervous about doing this and had put off the task for several months. Went pretty easy. Spray glue I used is very tenacious and have to be VERY careful as NOT able to reposition fabric once the glue surfaces touch. Correct initial alignment during glue is a must.


 
Jul 17, 2022     Various task - (5 hours)       Category: Fuselage
Worked on several little items that need to be done before many projects come to completion. Worked on engine mount, firewall, side panels for console, bought paint stripper, assembled battery box, bent mounting band for antifreeze overflow bottle, sanded nose gear piston to allow friction washers to slide, filed nose gear piston bearing to fit into top nylon piston washer, removed powder coat on upper end of nose gear piston to allow fit into nose gear bearing. Using MEK overnight to help remove powder coat from bearing fitting bushing on nose gear and engine mount. Will still need to file down bearings to get them to fit. Removed console to bond fabric covering before final install. Need to do that before I pressurize the brake lines and start installing hard brake lines.


 
Jul 15, 2022     Engine mount - (2 hours)       Category: Firewall
Worked today to drill out powder coat from of engine mount bushings then thread chase the screw holes on bottom engine mount and the two ends of nose gear piston. Tried to install engine mount onto firewall....didn't fit. Took off firewall and tried fitting engine mount by itself. Bottom three bushings aligned near perfect but the top two needed to be pulled a little. Bolt would NOT go through top bushings and fuselage. Mounted 3 good bolts and tried reaming again. Still problem with getting bolt through when I determined that store bought, temporary bolt was bent. I can get one of top two bolts in at a time but not both. Had to walk away from project for awhile.


 
Jul 14, 2022     Up drilling holes firewall - (2.0 hours)       Category: Fuselage
Up drilled all holes on bottom of firewall rudder assembly nut access with tapered stepped hole drill. Holes ended up close enough to see the nuts but if have to be removed, the holes will need to be enlarged. Had to pull the firewall off because of difficulty drilling the SS.


 
Jul 13, 2022     Battery Box - (2.0 hours)       Category: Fuselage
Worked on figuring out battery box assembly, drilled some holes and treated the aluminum for painting. Got some temp bolts for mounting engine mount to firewall and another can of paint for the battery box.


 
Jul 13, 2022     Firewall - (2.5 hours)       Category: Fuselage
Spent time on various, scattered projects jumping job to job. Most work time spent on figuring holes to be made into firewall. 1-2 hours to figure out where the holes go then about 30 minutes drilling pilot holes. Holes for fuel lines, holes for battery box, holes on bottom to access rudder pedal assembly mounting nuts.


 
Jul 03, 2022     Brake lines and firewall - (6.0 hours)       Category: Fuselage
Worked on running brake lines from parking brake to calipers. Heat formed brake lines as needed to lay flat under seat and also to fit from gear leg to top of brake caliper and allow caliper to be removed easily without disconnecting brake lines. Also redo a couple of lines under rudder pedals and removed all the zip ties I put in. Zip ties created too much stress on the fittings causing passive fittings for several lines to fail. I did use ample vinyl tubing to protect the brake lines from the very limited potential chaffing.
After replacing a couple of brake lines.....I think I'm happy now with all brake lines....I torqued the compression nuts for the 8 fittings under rudder pedals then replaced the firewall. I had the cabin heater coolant connectors and firewall corners held on with clecos. I replaced with pop rivets and sealed with red RTV silicone.


 
Jul 02, 2022     Brake lines - (6 hours)       Category: Fuselage
Another "simple" job that took forever. I had done some preliminary fitting of brake lines but wasn't sure how the slack would work with firewall in place.
I re-installed the rudder and connected to rudder pedals and got a more accurate vision of needed slack for brake lines. To minimize tube length and avoid tight bends with the stiff tubing, I used a hint from TeamKitFox per John McBean to put a wire into brake lines then heat carefully to bend to desired shape and remove wire when cool. Wire in tube prevents kinking when heated/bent. I was able to run much shorter tubing and minimize chafing with custom fitted bends on tubing.
Tried mounting brake fluid reservoir but predrilled holes don't match so will have to enlarge holes. I want to charge the brake lines and test them before perm attaching firewall and engine mount. I also want to get all holes drilled into firewall before it is mounted so will need a lot of research for engine install to determine what I need next.
During a break, I went to TeamKitfox again to see how folks ran brake lines under the seat and found good photo of how lines are best connected on master cylinders. Soooo.....I went back into garage and completely re-routed everything I had already done...2-3 times previously...and now for fourth time, I'm much happier with the layout with all lines running along the bottom. I have pictures of "before" and "after" re-routing lines. I believe it was worth the effort, much less strain on some of the connections. I just did a loose fit of tubes into their fittings and worked rudder pedals at extreme limits of movement and now none of the lines pop out of their loose fittings....a sign that nothing is tugging. I found some clear, vinyl tube just big enough for brake lines to fit inside for use as chaffing protectors against some of "pokey" things at base of rudder pedals.


 
Jul 01, 2022     Firewall and boot cowl - (6.0 hours)       Category: Fuselage
Worked on initial fitting of boot cowl onto firewall. Also re-mount rudder and re-attached rudder cables to better visualize slack needed for brake lines and clearances with firewall attached. Got the firewall mounted the other day and rough trim on boot cowl (almost too much trimmed off). Also pre-drilled holes in forward door frame for the mounting of boot cowl. Today, i tweaked the bends on the firewall to better match to shape of booth cowl, secured the rough trimmed boot cowl, clipped to fuselage, took my measurements, then back drilled door frame holes into booth cowl. I removed boot cowl and did final trim. Then pulled the firewall and started drilling for through-fittings for cabin heater and for riveting the triangle piece for foot well on firewall.


 
Jun 30, 2022     Boot cowl - (4.0 hours)       Category: Fuselage
Worked today and some yesterday to build a simple "hole finder". Simple concept but took almost 2 hours to make the first one....only to be too short. Second one (longer) still took more than an hour (screw up or two along the way). Spent an hour reaming holes for the firewall. Today, worked on drilling holes in door frame to mount the booth cowl. Next step is to mount the boot cowl and adjust firewall flanges to boot cowl.


 
Jun 29, 2022     Odds and ends - (5.0 hours)       Category: Fuselage
Found couple of more unpainted parts for cabin heater that I had to paint. Worked on getting brackets drilled for nut plates and holes drilled for mounting brackets. Eight pop rivets to mount bracket and I screwed up one of those. Then needed 4 pop rivets for the nutplates and screwed up 3 of the four. Got them fixed with a hammer and small anvil to smash the pop rivets. Then reamed the five engine mount holes in fuselage to be able to temp mount the firewall to be able to mount/fit the boot cowl
Everything is taking 3-4 x amount of time that it should. Frustrating


 
Jun 29, 2022     AC spruce order - (1.0 hour) Category: Supplies
Order placed for some small pull rivets to use in-lieu of pounded rivets for future installs. I bought an air hammer but can't seem to get it to work right. Also ordered a flare tool to form fuel lines under pilot seat and up to fuel valve then firewall.
Also bought couple more cans of paint.
 
Jun 28, 2022     Boot cowl and FWF install research - (3.0 hours) Category: Research
Spent time online with TeamKitfox and build manual to learn about boot cowl install and start of FWF install. I need to get my head wrapped around future steps to digest and completely understand what I an suppose to do.
 
Jun 28, 2022     heater - (3.0 hours)       Category: Fuselage
Pulled out the box with supplies to install the heater. I'm trial fitting several parts in preparation for fitting firewall and boot cowl. I'm missing two long bolts for assembly. The package only had protective sleeves and no bolts. I'm sure I checked off inventory but was only checking off inventory control numbers on bag and not looking and description of what was to be in the bag. I need 2 x 10-32 x 4 inch bolts...none to be found in town....ACSpruce help needed.
Found parts, cut and drilled as needed and then primed/painted with rattle cans.....except for two made mounting brackets I forgot about.


 
Jun 27, 2022     SS door channel install - (2.5 hours)       Category: Fuselage
Here was another simple job to install SS door channel to protect wear to fabric on bottom and lower back door frames for getting in and out of AC. Only had to fit 4 pieces. SS is VERY tough to cut even with 8,000 rpm air driven cut off wheel. All pieces fit quite well and holding nicely with just friction fit.


 
Jun 26, 2022     Rudder tail light wiring - (2.5 hours)       Category: Tail Feathers
What a simple job to do. Thirty minutes to put the rudder back on.....trying to line up three sets of bearings/bushings. Then 30 minutes trying to figure out what to do and how to do it. I attached the tail light to it's housing. Fed the wire without its connector through the rudder. Find access hole for wiring I cut into back of vertical stabilizer. Find the wire and plug for tail light in fuselage. Find my notes from months ago about which colored wires go with which colored wires via the connector. . Then carefully laid out my plan which necessitated soldering wires together to connect wires to the connector plug. Put some shrink wrap onto the wires before soldering. Once the soldering was done,...i realized I had very carefully and purposefully SCREWED up. I was trying to stagger the four connections so I wouldn't have a large blob of connections to fit through my tail access slot....two connections at one length and the other two at different length.....but, I put only a single piece of shrink tubing to cover two solder connections......That's not going to work. So a trip to Home Depot to get some electrical tape and then insulated joints with double wrap of electrical tape and shrink tubing to hold all in place.


 
Jun 25, 2022     Fuel tank R&R and paint - (1.0 hour)       Category: Fuselage
Removed and re-installed the header tank to paint the tank. Done amidst other tasks. Not sure tank needed painting but easy to remove and do it now.


 
Jun 25, 2022     Several little projects - (5.8 hours)       Category: Fuselage
Figured out parking brake and temp installed. Installed most of brake fittings using Permatex thread sealant. Worked on cutting brake lines and figuring out how much line I needed to have enough for full pedal travel, tested heat bending Nylaflo tubing for 90 degree bend to fit through fabric to gear leg fitting, Also placed doillies for brake line penetration for conventional and tri-gear brake line fittings. Mounted rudder to allow fitting of rudder cables. Threaded rudder cables through fabric penetration port a bottom of tail. Installed the connector plates with the metal eye, fed the cable around the eye and pulled enough on the cables to remove all slack. Crimped on the swedge to hold the "eye" and used cold chisel to remove excess wire rope rudder cable.


 
Jun 24, 2022     brake lines - (3.0 hours)       Category: Research
Spent several hours reading about brake line install. Picked up several pointers.


 
Jun 23, 2022     Tail inspection plate install - (5.0 hours)       Category: Tail Feathers
"Simple" job took almost 5 hours to fit the inspection plates on/around the horizontal stabilizer. I had to make another cut on the panel I had completed. Directions were confusing as they offered three distinct ways to cut and fit around the elevator pivot. I had made the panel with the plan for the lease amount of cuts. Had to fit and remove 4-5 times on each side to locate mounting holes. Tried to be careful but messed up position on back-drilling upper horizontal row of holes....got them too low and didn't realize until all holes cut....oh well... screws and nutplates will still work....just not as secure as desired. Drilled all holes and place the Tinnerman nutplates. Panels removed and stored until absolute final assembly. Same with the inspection panels.
Everything cleaned up and put away in prep for next set of tasks.


 
Jun 22, 2022     Rudder and horzontal stab mounted - (1.0 hour)       Category: Tail Feathers
Mounted the horizontal stabilizer in preparation for fitting tail inspection panels. Had to briefly hang the painted rudder to see how it looked.


 
Jun 20, 2022     Wheel pants - (6.0 hours)       Category: Landing Gear
Started trimming and fitting of wheel pants. First thing I had to do was put the fuselage rottisere frame back on to lift weight off the wheels. Had to remove the wheel for part of the fitting. Over trimmed the wheel opening on the bottom for the right pant. I guess, obviously, that I don't know how this wheel pant is supposed to fit onto the gear as after carefully cutting out inside of both wheel pants exactly to the template supplied that was suppose to allow pant to fit over the gear and brake caliper.....yeah....right. Hours of trimming later, got both to fit, with screw holes drilled out (well oversized to get 4 screws to fit) and last step to bond the aluminum spacer on outboard axle bonded to the inside of wheel pant. At this point I realized that I had mounted wheel pants to parallel the inside vertical edge of the gear strut instead of being vertical to the ground.....so pants are set at an inboard angle as plane sets on ground. Oh well. We'll do test flights with and without wheel pants and see how much of effect they have. If significant and I choose to keep them on most of the time, then I'll consider "straightening" them and putting on little doors to access air valve. As of now, wheel pants have to come off to service the tire....a real pain.


 
Jun 18, 2022     Axle and wheel fitting - (1.5 hours)       Category: Landing Gear
Axle mounted along with torque plate and wheel plant mounting plate.


 
Jun 17, 2022     Fitting Grove gear and clamps - (3.0 hours)       Category: Landing Gear
Spent couple of hours fitting Grove gear to fuselage. Fuselage worked well turned on its side. Gear was able to be propped up next to fuselage on its side and all fit perfect where it was supposed to go. Such a tight fit for the four clamps to hold gear required removal of of paint on gear and clamp surfaces. Then all fit perfect.


 
Jun 15, 2022     Clean up - (3 hours) Category: Workshop
To reclaim the garage, I spent couple of hours or cleaning up all painting equipment and re-claiming garage from tarps, trash dirt, tape, hoses, paint cans, solvent, paint rags, etc.
 
Jun 14, 2022     Rudder painting - (4.0 hours)       Category: Tail Feathers
Painting of Rudder. Taped to paint bar and stripes on Rudder similar to tail painting of pre-WW II trainer aircraft. The dark blue shade for the vertical dark stripe is as depicted. The red paint from SW was supposed to be "stop light red" but originally came out salmon shade. I went back (this paint was used on SKi Patrol sign back in 2020) to have more tint to make it "red". I don't know how many dollops of tint were added until the paint looked "red". Came out looking great.


 
Jun 13, 2022     Taping for rudder - (3.0 hours) Category: Tail Feathers
Drew on rudder to get 13 stripes (Red/white) each side. This to honor pre-WWII paint schemes for training planes. Have one side taped and 2 coats of red applied.
 
Jun 11, 2022     AC tire change video - (.7 hour) Category: Research
Online research about mounting tire and tube on AC wheels. I had general idea but watched video anyway to confirm procedures. Spent longer learning how to do the tire mounting and locating the parts in the garage than to actually do the tires.
 
Jun 11, 2022     mounting of tires and tubes on wheels - (2.0 hours) Category: Landing Gear
Decided to mount tires. Only issue, was took a couple of days to find tires and wheels in the garage. Hadn't put my hands on them in over 2 years. I went online to find YouTube video on changing AC tire. Once I got the hang of it, didn't take long to mount the wheels.....a WHOLE lot easier than a motorcycle and and even easier than doing a bicycle tire.


 
Jun 10, 2022     Paintlng Fuselage - (8 hours)       Category: Fuselage
Several hours over 3 painting sessions to, so far, cover about 1/2 of fuselage with 2 coats of Bahama Blue paint (SW Emerald Urethane enamel) sprays very nicely. Very good coverage. In process, primed and painted the quarter window trim with rattle can enamel, self etching primer and white, satin enamel for white base.


 
Jun 08, 2022     Order for GNX 375 and antenna - (1.0 hour) Category: Avionics
Have been waiting 8 months for back-ordered GNX 375 GPS/transponder and associated antenna. Finally got note from SteinAir that part was ready to ship. I sent check and had them delay shipment because we were suppose to be gone to Cuba for Scuba diving. Jeanne turned up quite sick day before trip with symptoms possibly of COVID> We canceled trip. GOOD THING....Jeanne tested positive the day we were to leave and I showed up positive 3 days later on June 13.
 
Jun 07, 2022     Painting tail system - (12 hours)       Category: Tail Feathers
Multiple sessions to finish 2nd spray coat of Poly brush, then 2 coats of white base coat (SW Emerald white Satin) followed by 2 coats of yellow. Very disappointed in performance of the yellow paint (SW Resilience). Did the wings several months ago and still slightly tacky. After 3-4 days, newly painted parts are still tacky


 
May 30, 2022     Poly brush spray coats - (6 hours)       Category: Fuselage
Couple of work sessions to move items around in preparation for spray last couple of Poly Brush spray coats. Also fitted trim slat to aft opening of cargo bay. Secured with Hysol, trim filled with micro-fill to smooth margins. Then covered with fabric.
To date, have done first spray coat of poly-brush over about 1/2 of unpainted structures.


 
May 26, 2022     Clean up and painting small parts - (12 hours)       Category: Fuselage
Couple of work sessions comprising clean up from months of fabric covering. Cleaning and epoxy priming using Stuart Systems 2 part Epoxy. Used double amount of the expensive paint that I needed....threw away $25+ of paint not needed/used during 4 hour pot life. Paint went on smooth. Then following day, painted the parts with either white, rattle can enamel or the SW Bahama blue paint for parts to be used on fuselage. Multiple inspection covers remain white until I pull out the yellow paint.
Bought some additional tarps to cover parts in garage until their turn to be painted.


 
May 25, 2022     Prep for small parts alodine Tx - (4 hours)       Category: Fuselage
Multiple small parts rounded up to paint: Door hinge, Instrument panel tabs, inspection plates, aluminum angles, grove landing gear, gear mounting blocks, tail inspection plates.


 
Apr 24, 2022     Leading and trailing edge finishing tapes - (6 hours)       Category: Tail Feathers
All I was going to do was smooth the leading and trailing edge finishing tapes I placed yesterday....2 hours tops....yeah..right!!. Six hours later, I have smoothed all tapes on both pieces of horizontal tale. Then did last coat of Poly Brush over the finishing tapes. Took SIX hours. Still have to do some minor (I hope) smoothing after last application of Poly Brush to tapes
Only one more short strip of finishing tape to apply over a bonded metal angle over aft turtle deck area. I still have to paint the metal angle and turn fuselage at least 1/4 turn to install.
But 99.9% of fabric has been bonded and installed!! Yeah!!! Now all I have to do is spray 2 coats each of poly brush, white primer and color coats over all of fuselage, rudder, vertical and horizon stabilizer and elevator.


 
Apr 23, 2022     Finishing tapes - (3.0 hours)       Category: Tail Feathers
Trying to figure out how to apply bias cut finish tapes.....not as easy as it looks. Had 6 corners to do on horizontal stab and elevatgor. Applied first tape and secured about 2 inches using Poly brush. Allowed to dry for about an hour and then tried stretching and securing tape around my first corner. Came out terrible and I ripped off what I did. Tried again 6 more times. I took 5 corners to figure out how to do it correctly. I decided to use 4" bias cut to cover the entire width as I didn't have enough regular cut 4" tape to cover all leading and trailing edges. I finally determined to secure unstretched to straight portions within 1 rib of corner, then pulled tape around corner and secured tape just past corner. Had to hold tape in place while Poly brushed dried but then able to lay tape flatter and with less folds, bubbles and creases in straight sections when done in a separate Poly Brush application. I had to pull tension on tape with one hand while other fingers to smooth tape into applied Poly Brush and using brush to smooth tape into pink stuff. I tried butting two pieces of the Bias cut tape on straight end (to salvage short section of tape) but that didn't work well. The bias cut tape is very easy to distort when manipulating it.
For 5 of the corners and even some of the straight sections


 
Apr 21, 2022     Filing parts - (4.0 hours)       Category: Fuselage
I went through my box of uninstalled parts and pulled out remainder of metal pieces. Spent a couple of hours and filed smooth sharp edges in prep for primer coat of paint. A couple of days later, I cleaned/etched metal and treated with alodine chemical in preparation for 2 part epoxy primer. Some of these will need to be cut and shaped before use.


 
Apr 18, 2022     finish tapes - (5 hours)       Category: Tail Feathers
Spent about 5.0 hours applying chord wise finish tapes on horizontal stab and elevator. Have some 4" bias tape on order but not yet arrived so can't finish leading or trailing edge tapes yet.


 
Apr 17, 2022     Covering horizontal stabilizer and elevator - (18 hours)       Category: Tail Feathers
Lost count on hours to cover horizontal stabilizer and elevator......18 hours and still counting. Didn't get many pictures of horizontal stab covering but got several pictures of same process on elevator. Just....takes.....forever. Ironically, only spent about 30 minutes total actually gluing on fabric but several hours needed to prep metal skeleton, rough cut fabric to shape, partially bond fabric to the large, straight spar, fine time fabric edges, heat form around tubing, then after gluing, heat smoothing to remove wrinkles, stretch tighten fabric, apply poly brush, mark lines for finishing tapes.
I midst of this, I covered two 16 x 24" wooden picture frames. Thought I could did them quickly.......if 8 hours is quick.
Pictures represent about 5-6 work sessions over week and a half. (one week in Breckenridge for Powderfall for ski patrol)


 
Apr 15, 2022     Supplies - (2.0 hours) Category: Tail Feathers
Broke down and ordered some VERY expensive 4" bias cut tape to cover corners of Horizontal stabilizer and elevator.
Also bought some more picture frames to cover with poly fiber process and paint to use as test pieces in sun for long term outside to see how my paint system holds up. 87KF will always be hangared so will use test panels to see how system ages with full sun. Had some other panels but wind blew away one of them....of course the most important one.
 
Apr 04, 2022     Auxiliary 15 amp alternator - (5.0 hours)       Category: Engine
Secured a 15 amp auxiliary alternator from Edge performance....actually from another customer who decided to go with larger engine 915iS after custom building a 914. I had found a 30 amp from Rotec but mounted on engine with pulley and belt drive but seemed to mount in same location as electrical pickups for electric propeller. Mike Buscenitz noticed it for sale on Kitfox forum and told me about it. Also acted as broker to purchase the alternator.


 
Mar 31, 2022     Rudder covering - (10 hours)       Category: Tail Feathers
Three x 3-4 hour work sessions to cover the rudder. Used one piece joined on trailing edge. Only single layer of fabric on leading edge of rudder fiberglass former so laid up some 4",3" and 2" finishing tapes where potential for rudder to rub aft vertical stabilizer. I'm too cheap to buy a $60 roll of 4" bias cut finishing tape to go around the curves on the rudder, elevator and horiz stab. Tried to heat form regular 3" tape around bend on top of rudder. Gave up. Cut section off and placed a 3" regular tape and cut several darts both sides and heat smashed. Edge of finishing tape is NOT smooth around the finish line BUT fabric is NOT coming off. Plane will still fly well.


 
Mar 27, 2022     Finished finishing tapes - (6.0 hours)       Category: Fuselage
Spent about 1.5 hours marking placement for the finishing tapes. Then following day, spent 5 hours applying finishing tapes....went faster than I thought it would. Will allow drying overnight and then iron all tapes.


 
Mar 25, 2022     Fuselage covered - (3 hours)       Category: Fuselage
Finished all covering of fuselage on all sides and tapes done on top and both sides leaving bottom covered but no finishing tapes...yet. All seams were ironed and second coat of Poly Brush applied to all tapes. Only bottom still needs finishing tapes. Fuselage was turned from upright to one side. Jeanne is gimp due to her two broken legs so I attempted to turn fuselage onto its tail. Didn't quite make it before tail slipped off of the stool I had the tail resting on for last several months. Jeanne heard commotion of fuselage hitting floor and came running. She steadied the tail as I tipped fuselage the last 90 degrees up onto tip of tail.


 
Mar 25, 2022     Razorback curve tape - (3.0 hours)       Category: Fuselage
Decided to work just a small segment of finishing taping in the curve of the razorback on top of fuselage. I had a hell of a time trying to bond and smooth the top fabric in the curve area. I thought that just working with a few inches of the tape right in the curve would make the process easier.....not so. I carefully bonded just the edges of the finishing tape one side at a time and leaving middle 3/4 uncovered with Poly Brush. My thought was I could heat shrink fairly quickly and end up with smooth tape that I would bond to lower layer with wet coat of Poly Brush. I still ended up with a mess!! Spent over an hour serially bonding the small fabric piece then spent well over an hour smoothing the 10" piece of finishing tape. Just like the fabric below, I only got smoothed out about 95%.....not perfect..but functional.


 
Mar 20, 2022     Fuselage finish taping - (14 hours)       Category: Fuselage
Multiple hours over several sessions prepping bonded fabric for finish taping. Several hours bonding fabric, then ironing all seams. I rotated the fuselage using the legs bolted to firewall area of frame.


 
Mar 17, 2022     Poly brush- brush coat - (7.0 hours)       Category: Fuselage
Multiple hours spent drawing pencil lines around areas where finishing tapes are to be embedded. Thought pencil would mark easier on bare fabric. Only took little over an hour to apply brush coat of Poly-brush.


 
Mar 15, 2022     Fabric application - (12 hours)       Category: Fuselage
Several sessions to trim, attach, heat shrink fabric to fuselage and vertical stabilizer. Couple of times with large amount of bunched up fabric after bonding all edges. Left front side near bottom was one such area....able to iron out most all except for some tiny creases that should hide under finishing tapes. The worst was on curve of razor back just in front of vertical stabilizer. Can see from picture the disaster. I knew it would never work but continued to work on ironing. I was able to remove about 95% of wrinkles in the area but not able to get ideal shrinkage/tightness I would like.....but....was it worth ripping off and redoing 5-6 hours of work? Is it perfect?...NO Will I see the error?.....yes. Will other people see the error?......maybe. Will it fly OK?.....YES, definitely


 
Mar 08, 2022     Drilling holes antenna and turtle deck - (1.5 hours) Category: Fuselage
Drilled holes for turtle deck mounted comm antenna....a degree or two off of exact midline....but not going to correct it. Read about needing to mount turtle deck plate on after end of baggage opening. Acquired some 8-32 machine screws, washers and nylock nuts. Started to drill holes to begin mounting Cam-locks to hold turtle deck window.
 
Mar 08, 2022     More parts/supplies - (3.0 hours) Category: Supplies
Various parts/supplies. 2X4x8 for frame turning repair. Screws for comm antenna, upgraded fuel tank drains (with nipple to attach fuel drain hose). Picked up an air hammer to drive multiple solid rivets. Had to order a flush rivet set tip for air hammer.
 
Mar 08, 2022     Reading and YouTube - (3.0 hours) Category: Research
Spent 3.0 hours scattered over couple days to read ahead in KitFox assembly manual and figuring out what to do next and how to go about doing it.
 
Mar 07, 2022     Fabric and static port - (6 hours)       Category: Fuselage
Finished ironing out wrinkles on right side. Went quicker since I didn't have so many wrinkles. Went to turn fuselage to up right position and one of the legs on the firewall wooden turning frame split vertically. Had to stop all and figure out repair. Able to replace split board fairly easily....purchase took longer than repair.
Also worked on parts to make the static port. Cut round disc from aluminum stock, filed and back drilled holes. Then cleaned and alodined all aluminum parts. I boogered up the process of installing round plate on static port and had to do a new one. First one took me well over an hour and then another hour to figure out assembly. The re-do only took about 30 mintues total and about 5 minutes to install. Glued assembly to fabric after using Poly Brush on small area. Then after dinner, applied a doily on inside and will place another outside when all other finishing tapes applied.


 
Mar 01, 2022     Covering right side - (5.5 hours)       Category: Fuselage
Did much better getting fabric laid out on right side of fuselage and edges cemented down with only very minimal bunching. Only slight amount of ironing needed to correct wrinkles on this application. Got fabric cut, laid out, edges cemented, then overlap cemented, wrinkles ironed out. Tomorrow will work on heat shrinking and making static port attachment.


 
Feb 28, 2022     Covering left side - (8 hours)       Category: Fuselage
Two work sessions split by probably last trip for decent skiing at Ski Apache. Covered left side. I messed up getting initial fabric sealed down around door frame and ended with LOTS of wrinkles on left side bottom aft of lift strut attachment. LOTS of 250 degree iron pressure (per Poly Fiber manual) eliminated 98+% of wrinkles. Final heat stretching smoothed everything out. Only wrinkle defects remaining hopefully will be covered by finishing tapes.


 
Feb 22, 2022     Covering bottom of fuselage - (12 hours)       Category: Fuselage
Twelve hours over several days.
Last bit of sanding fill, cleaning before covering. Set up tables. Re-read Poly Fiber manual for covering. Arranged chemicals, Bought more 1" brushes (need more). Only have 1/2 of one can of Poly Tak...will need another can. Spent 30 minutes trying to arrange fabric on bottom then marked for rough trimming. Started by tacking down front portion under rudder pedals and then tried to evenly stretch and tack down fabric around edges. Then went back and trimmed to have about 1.25 inch fabric passed tacked area to wrap around tube. Then spent about 2 hours ironing to 250, removed all wrinkles, then 340 shrink. Came out fairly decent.


 
Feb 16, 2022     Pre cover for fuselage phots - (1.0 hour)       Category: Fuselage
Multiple photos of fuselage (upside down) prior to covering showing wiring and routing of wires. Then fabric roughly cut out and clipped to fuselage just before trip to Copperstate Fly-in in Buckeye, AZ to west of Phoenix for 4 day trip.


 
Feb 15, 2022     Fuel pump/ Alternator questions Category: Research
Talk with Michael Busenitz at Stolcreek.

Fuel pumps CAN be mounted forward of fuselage. If near exhaust, may need metal deflector.

Electric Fuel pumps will pull 5-6 amps consistently as they are primary.....no mechanical fuel pump on engine. Recommend alternate between fuel pumps during usage to balance wear. Run only one at a time.

Look at EFI install download for info on engine install. Lot of photos on later pages

BNC 425 alternator driven off of vacuum pump pad will NOT fit as accessory pad on rotax on back of gear box at top.....no room between mount and intake manifold. Look for belt driven alternator from Rotax.
 
Feb 10, 2022     Engine install research - (6 hours)       Category: Research
I'm stuck again. Trying to figure out what all I still need to install before covering fuselage. I know I still have fuel lines to install but will do that after I cover and turn fuselage back upright. I saw that fuel pumps need to be installed. Trying to figure out what and where they go. I looked in my engine crate and found a large, dual fuel pump assembly but no instructions with my engine about how to install all the parts. Looking at Kitfox engine install and Rotax install instructions for 914 and 915iS. Kitfox said fuel pumps behind or under seat pan and on fire wall with special container. Rotax says 914 pumps NOT on fire wall. No room under seat pan for my pumps. Could mount behind seat but would require 10+ feet of additional fuel line under seat pan.....fuel tank to shut off valve, shutoff back to fuel pumps, fuel pumps back past shutoff to firewall. Would be nice if could mount on firewall and protect pumps somehow.
I have a call into Stolcreek and Mike Busenitz about this and other items.


 
Feb 09, 2022     Fuel header tank install - (2 hours)       Category: Fuselage
Installed fuel fittings into fuel header tank. Had to pull out tap set to enlarge threads into header tank to allow at least 3 turns of fitting engaged with fitting bung.
Then installed header tank on fuselage.


 
Feb 07, 2022     Trim control boxes and GSU 25 installed - (6.0 hours)       Category: Wiring
Spent couple of sessions fitting a piece of aluminum plate (0.035) to area behind pilot seat to accommodate the TCW booster box, the GSU 25 and the Ray Allen trim controller. Previously had temporarily connected all and trim worked great.


 
Feb 07, 2022     Fuselage wiring - (20 hours)       Category: Wiring
Over last couple of weeks, have spent 20+ hours over multiple sessions on wiring in fuselage. Had held wiring in place with masking tape. Have now removed all masking tape and tied shielded wire directly to fuselage tubes with lacing cord. Down port side, got some split plastic conduit 3/8 and 3/4 diameter to protect unshielded, single conductor wire from trim motor and other wiring to pitch servo and thence to area of aileron control behind pilot seat area.
I started to continue with wiring of connectors at GSU 25 and GSA 28 but decided I needed to wait until panel avionics establish to wire in correct length of wiring. All existing wire rolled, bundled and tied to structure in preparation of starting fuselage covering.


 
Jan 26, 2022     trim controller Ray Allen - (8.0 hours)       Category: Avionics
Found out I need another trim controller to tie in my Tosten grip with trim. Already had to get a box (TCW booster to get to work) to make Tosten grip work. Now I have to have a box for the box so that the box works that is run by the box (Ray Allen controller, TCW servo booster, GSA 28, GMC 507...respectively)
Also order some small screws and washers to ground shield wire to connector cases (not supplied in expensive connector kit). Several hours spent researching the TCW booster, Ray Allen controller, reviewed CAN bus wiring protocols.
Some days later after receiving all supplies, spent 4-5 hours temp wiring the trim control circuit together and adding power. Got the circuit to work just fine....only after I spent hour or so chasing a non-existant problem due to my hooking up battery backwards to circuit and creating hot, smokey wires. No problem with my wiring....just hooking up battery wrong.


 
Jan 25, 2022     Wing and fuselage wiring - (18 hours)       Category: Wiring
Bought some more wire and connectors. Several sessions of about 4-5 hours working on wiring. Finished all wing connectors and most of fuselage harness to connect to wing connectors. Turned out NO problem with wiring on GMU 11. Called Garmin and they said "don't check circuits for continuity if connected to LRU or can damage" So....I guess I need to trust my connections. I have been double/triple checking connector construction along with crimp and solder wire connections to be sure I can't pull them apart. Process slow but I have a lot of wire hanging about. Still need to figure out connection of two trim controllers into AP. I
I did purchase the TCW safety controller along with their back-up battery setup. Got some more wire and Sub DB9 connectors also.....almost 1 AMU (aircraft monetary unit = $1K)


 
Jan 13, 2022     wiring and connectors - (8 hours)       Category: Wiring
Finally trying to get rolling again on construction. Have been stuck for several weeks not knowing how to wire in AP with needed power boost to run Kitfox trim motor. Ordered more solder sleeves, pins, connectors and wire from Aircraft spruce.
Found out today that some cheap DB9 connectors required soldering. Watched video on how to do it and not too bad. Built 4-5 connectors for wing side of wing disconnects. Still need to do fuselage side of connectors. Seems I have some electrical conductivity issue with GMU 11 wiring. Will have to work on it next week after trip to Ski Apache for Young Adult Patroler training.


 
Jan 12, 2022     GSA 28 wiring search - (15 hours) Category: Research
After many hours of research over days and weeks and reading and final contact with Kitfox, determined I needed the TCW booster pack to get the GSA 28 AP to work. Trim motor needs over 5 amps and GSA 28 can only handle up to 1 amp. Never could get a straight answer from Garmin if GAD 27 would work instead.....so another AFU (aviation financial unit) needed to solve problem. Will try to hawk GAD 27 on RV user group. They can use its capabilities more than Kitfox.
 
Jan 03, 2022     Reading on AP servo connections - (8 hours) Category: Research
Still trying to figure out wiring for AP servos and incorporation of GAD 27 into the mix. Email into Brandon at KF. Then need to call Garmin for confirmation
 
Dec 29, 2021     Wiring research - (8 hours) Category: Research
Still trying to get my head wrapped around all wiring especially GSA 28 servos and use of GAD 27 (electric controller). I spent $600 for GAD 27 but not sure I really need it. Still trying to figure out wiring for AP servos. If GAD 27 is used, then much more wiring involved.
 
Dec 28, 2021     Multiple - (14 hours)       Category: Wiring
Three-four sessions over as many days doing odds and ends. Eight+ hours spent on research for wiring. Still trying to get my head wrapped around all of coming wiring. Micro fill on wing tip defects and sanding of same X 3 times. Ran wiring down both wings for wing tip lights. Researched wiring diagrams of wing tips. Trimmed space on wing tips and rudder post to allow passing of plastic connector for quick disconnect. Attached 4 conductor connector onto landing and nav lights. Then soldered opposite connectors on wing tip wiring. Now have quick disconnect plugs for wing tips ready to install after painting.
Still trying to get my head wrapped around wiring.
Trying to find crimping pliers for molex open barrel tips to use for extra plastic connectors included with wing tip lights. Kitfox sent better, water tight connectors for use in wing tips. Extra molex type connectors were included in Aeroleds boxes. I plan to use them for wing quick disconnects. Couldn't find Molex crimpers in town so ordered some online.
Had planned to cement trim fabric on console. Unable to find recommended fabric adhesive locally....ordered online.


 
Dec 23, 2021     Txponder antenna holes - (2.0 hours)       Category: Fuselage
Measure twice (no three times) but still drilled too big of a hole in fuselage bottom mounting plate for transponder antenna. Drilled second, correct size hole and patched first one with Hysol and sanded smooth.


 
Dec 22, 2021     More parts/supplies - (2 hours) Category: Wiring
Ordered comm antenna, multiple solder sleeves, pins, control stick grips with push buttons, special door handles from Aircraft Spruce, Tosten grips, Bowen Aero. I'm going to be nickel and dimed to death.
 
Dec 10, 2021     Wing tip fill - (4.0 hours)       Category: Wings
When fitting wing tips, was left with 1/8-1/16" gap between fiberglass and wing rib. Mounted the wing tip and filled with Hysol on top and bottom. Also worked to use blue Super-fil for remaining defects in fiberglass wing tip.


 
Dec 09, 2021     Wing holders - (8.0 hours)       Category: Wings
Built a wing holder to provide more compact storage for wings and allow easy access to wing ends for wiring. Used some plans I found on internet and repurposed one set of wing rotisserie stands for the wing holder. Still had to buy more 2x4's and one 4x4. Cut needed gussets from scrap chip board from other projects. Sacrifice a small dolly to take the wheels off to put on wing holder.....much cheaper than buying wheels separate. Only one little minor screw up but only resulted in structure 3 inches shorter than planned....no issue.


 
Dec 07, 2021     ELT install - (3.0 hours)       Category: Avionics
Ordered ARTEX ELT and install kit. Install was easy with no fuselage cover. Would have been very tricky to wait. Only took about an hour or so to install bracket and antenna. Spent more time trying to figure out what to order and how to install than actual installation......although only the main body is installed. I still have to wire it to panel switch and GPS.


 
Dec 01, 2021     Avioinics, misc order - (2.0 hours) Category: Avionics
Ordered radio, LRU boxes for engine monitor, connect GPS, connectors, mounting hardware for back ordered GTX 375, ELT, antenna.....everything needed for panel and completion except for mentioned GTX 375 with expected June 2022 delivery. I was able to find mounting kit for GTX 375 at Stein and also ordered GPS same place. Should be able to have (theoretically) everything ready to just drop in GPS to holder.
 
Nov 12, 2021     AP servo for roll installed - (1.0 hour) Category: Fuselage
Use Rust-o-leum self etching primer and Semi-gloss enamel spray (rattle cans) to paint the aluminum bracket to mount the AP servo. Finally placed required rivets after painting and then bolted on the servo. Re-installed roll servo and did preliminary adjustment for AP servo arm limiter. Seems the 2" actuator arm is too short. Need to order the 3" arm to accommodate the required movement of control stick and flaperons.
 
 
Nov 11, 2021     Fuselage turner contraption installed - (1.0 hour)       Category: Fuselage
Installed fuselage frame turning contraption to firewall. Then next day, turned fuselage upside down. Cross bars (side to side) need to be longer to prevent boot ribs from contacting ground when turned.


 
Nov 09, 2021     Trim off interference for elevator push rods - (3.0 hours) Category: Fuselage
When adjusting the rod lengths per instruction manual, I determined there was an interference between the front elevator control rod and bracket for center seat belt attachment. Significant filing need on both pieces. Got tired and quit today with about 90% of adjustment filing completed.
 
Nov 08, 2021     Adjust push rod length - (3.0 hours)       Category: Fuselage
Spent several hours just adjusting push rod length to obtain proper control stick, rod, elevator and aileron control placement/position with horizontal stabilizer and elevator mounted. I had already spent time reinstalling the trim actuator and re-confirming actuator extension limit and horizontal stab position to proper starting position. I then determined that thin tab bonded to posterior horizontal stabilizer designed to press on trim position sensor was inhibited from moving freely when horizontal stab was placed in full nose down trim. I determined about 4 mm of material on central square tube used to support bearing for horizontal stab needed to be relieved. After control rod adjustment done and tail surfaces removed, I quickly trimmed off small portion of square tube coming from fuselage frame.


 
Nov 06, 2021     ELT order - (1.5 hours) Category: Avionics
Spent an hour or so researching for ELT for plane. ACK E-04 ELT 406/121.5 with antenna. Placed order with Aircraft Spruce and Specialty.
 
Nov 05, 2021     Trim motor painting and refitting - (3.0 hours)       Category: Fuselage
Trim motor extension rod had rusted from high humidity this summer. I had removed the trim motor with intentions of paining the bare steel extension rod....that was several months ago. Painted the bare metal with self etching primer and white satin finish enamel. Then reinstalled the motor and checked adjustments done almost a year ago. Found that tab on horizon stab that actuated trim indicator rheostat was hanging up on horizontal stab extension. I need to trim several mm's.


 
Nov 03, 2021     Workshop re-do - (3.0 hours) Category: Workshop
Spent several hours cleaning up from painting, sweeping floor, moving wings to side, moving fuselage stage center.
 
Nov 02, 2021     Flaperon hinges install - (7.0 hours)       Category: Wings
Two work sessions over last two days to install flaperon hinges. I'm very disappointed with paint. It is still tacky after 2-3 days…particularly the flaperons. Paint slow to cure and flaperon picked up some wood splinters from long boards I had them on after painting to move them around. Many nicks in yellow paint with slightest insult. Tried on countrrweights and marked location. Tapped edges and tried different solvents to remove yellow paint to epoxy primer to prep for eventual bonding of weights. Didn't have to look far. Alcohol removed paint quickly.
When using hydraulic rivet gum, some of oil (brake fluid) leaked out. I wiped it off but residual weakened paint.
After attaching wing hinge brackets with flaperons, I placed them on hooks at ceiling. If paint doesn't set hard, will consider removing paint on flaperons and leave in epoxy primer.


 
Oct 31, 2021     Finished painting wings - (5.5 hours)       Category: Wings
Time today for setup, mixing paint and spraying bottom of left wing. Yesterday had noted slight-moderate orange peel on first of what I painted.. toward end of session, my arm was tired and I kind of hurried the spry passes. Lo and behold, I ended with better, smoother finish…..putting on too much paint. Today, passes were quicker and farther away by 2+ inches giving wider spray fan and less passes as a result. Bottom of wing only took 30 minutes as opposed to upper taking 90 min…..a LOT of paint on wing. First passs didn't seem to cover well but by time I started x-coat, paint had flowed and very little additional color saturation with second. Now that over half of painting done, I've figured out how to spray the paint. I calculated about 14-16 pounds of paint per wing.
Spent almost 2 hours cleaning and reconfiguring to work on fuselage but decided to finish install flaperon brackets on left wing before I store the flapper and put away the left wing.


 
Oct 30, 2021     Painting - (17 hours) Category: Wings
Bought more paint…..2 gallons of white (Emerald Urethane satin) and one more yellow. Took more than anticipated for base white and color. Determined today (after painting top and bottom one wing) that I'm applying too thick/heavy.
17.0 over three past days for setup, prep, light sanding of overspray, spraying, and cleanup. Arms and back are tired.
 
Oct 25, 2021     Final color - (8.5 hours)       Category: Wings
Spent all day applying final yellow color on left wing. Paint went on a little "rough" so I slowed spray passes to see if would flow out....it didn't.....just used a LOT of paint. Found out I could spray faster (use less paint) and still get the needed coverage. Thought I could paint all wing and tail surfaces with just one gallon. Nope!! Will need two gallons and then will only have a little left over. I had spent almost 3.5 hours straight painting and was 1/2 panel of being "done" for the day....when I remembered: the flaperons and hinges.....rats! I still had paint in gun and a little more in mixing bucket. I put a wet towel on the spray gun tip and rounded up the parts to paint. Took 1.5+ hours to retrieve flaperons from ceiling and locate the flaperon hinges. Then got some soapy water and 3M scotch bite pad to clean dust and overspray off of flaperons and break epoxy glaze. Spray top side of flaperons, waited 2 hours dry time, flipped and painted the other side.
Color paint is Sherwin WIlliams Resilience exterior acrylic latex with satin finish cut with -20 degree washer fluid with about 3.75:1 paint/washer fluid. Paint color is Cheerful SW 6903 yellow. Paint went on a little rough but leveled to some degree. Finish is nice satin with very slight orange peel which does an excellent job hiding a LOT of surface defects that would be blatantly obvious with gloss finish. Color wont cover dark areas well. I'm extremely happy I did a white undercoat base.


 
Oct 24, 2021     Finding paint and reflective lights - (2.0 hours)       Category: Wings
Spent the day recuperating from painting last several days. Arms weak and legs ore very sore from crouching as I sprayed vertical wing....maybe a little to do with a high speed hike I took the other day and then fell...backwards just short of turn around....banged head when rock step went out from underneath me.
Went to Sherwin-Williams to see about getting some paint. Couldn't get my Emerald urethane enamel in white, but able to get it in my close to "Bahama Blue" and also my "cheerful Yellow" in Relience acrylic latex but no white Emerald urethane----Covid 19 BS.
Also stopped by Harbor freight and got some shop lights to help with spray painting by reflected light. Will try it out tomorrow.


 
Oct 23, 2021     Painting wing - (14 hours)       Category: Wings
Well,,,painting didn't go quite as planned. Many hours spent over several days to start painting process. Had tested some paint I had in garage on test panels then tried spraying same paints on test panels. Determined that SW Emerald water borne Urethane enamel (single component paint....not catalyzed) I used on Ski Patrol sign sprayed very nicely. Some other paint, SW Weatherbeater, I got at Lowes didn't spray worth shit. I spent couple hours on YouTube trying to determine problem and got few pointers that made SW Emerald spray even better. Went to SW paint store to buy my paint for white base and for color......not that simple. COVID has messed up supply chain. No SW Emerald available. Also can't tint that paint to desired Yellow and blue anyway. Have to use a different paint, Resilience, for the color. None of that available either. Have to start with pre-colored yellow and blue base paint and tint to desired color. Before committing to buying $100's of paint, I bought quart of yellow tinted satin color to see how would spray. Sprays OK, but not as nice as the Urethane; however, it does level nicely and quite a nice finish. Thinned the paint with -20degree windshield washer fluid per Weinerdogaero.com about painting with Latex. Thinned it more than I was trying for but sprayed and covered nicely. I sprayed top and bottom with immediate cross coats (N/S and E/W) for thicker paint film. The white covered the pink Poly-Brush very nicely with only one spray coat. After one day drying, I sprayed another cross coat layer for total of 4 passes of paint on top for better UV protection. Only couple of small runs. Paint has a lot of titanium dioxide which is supposedly good UV absorber. I used this to avoid all sanding required for PolySpray silver but still spent hour or so sanding off small imperfections and drip runs on first paint try.


 
Oct 19, 2021     Sprayed Poly Brush - (5 hours) Category: Wings
Two sessions to clean up, prep and prepare garage for spraying the Poly brush. Mixed up reduced PolyBrush (determined that previous wing was NOT sprayed with reduced Poly Brush (Seems when I measured the reducer to add to can of reduced Poly brush, I poured the measured amount of reducer back into dispensing container of reducer. That would explain the pink colored reducer coming out of the reducer can I had been using) and sprayed 2 coats on top and bottom of wing and also on two test panels. Only one small run fixed with clean brush and reducer.
 
Oct 18, 2021     Engine arrived - (1.0 hour)       Category: Engine
My Edge Performance EP914Ti, turbo and fuel injection arrived today. It's shipping crate will have to live in the driveway until I'm ready to hang the engine.


 
Oct 18, 2021     Horizontal finish tapes - (12 hours)       Category: Wings
Multiple sessions to apply longitudinal finish tapes on leading, trailing edges and top of rear spar. Also many hours of ironing to remove high spots and rough areas. Did manage to glue bottom 2" final horizontal tape 1" too forward. Didn't notice until I applied the final leading edge 4" tape on top of 2" tape when I noticed the problem. I didn't have enough tape on bottom leading edge to cover aft portion of front spar to have 1/2-1" extension past possible wear on fabric. I just added another 2" tape just aft of bottom aft edge of the 4" horizontal tape. Added extra coat of Poly=Brush over the junction of the 4" and 2" tape. Then when ironing smooth, I tried to fill joint between the two tapes. Came out OK, the extra tape should not lift even though it's leading edge is technically in the wind stream. Junction between the two tapes is now pretty smooth.


 
Oct 14, 2021     Smoothing some finishing tapes - (3.0 hours) Category: Wings
Spent 3.0 hours smooth areas prior to applying longitudinal finishing tapes. Also pre-coated same areas with Poly-Brush
 
Oct 13, 2021     Finish tapes Right wing - (6.0 hours)       Category: Wings
Got most of the finish tapes applied today along with dealing with last minute tax issues for Tax extension filing deadline on Oct 15. Will finish tapes in next day or so.


 
Oct 12, 2021     Poly brush tapes - (6.0 hours) Category: Wings
Hours spent applying Poly Brush to reinforcing tapes, then layer Poly Brush prior to applying finish tapes, had to cut some more doilies, applied all the doilies to right wing, second coat to doilies, drawing lines for finish tapes, mixing more 3-1 reduced Poly brush, dealing with CPA over extended tax filing deadline (last minute items to be answered NOW)
 
Oct 11, 2021     Rib lacing finish and Poly brush - (5.5 hours) Category: Wings
Finished up the rib lacing. Cleaned wax off of lacing with alcohol. Determined I was short a couple of doilies. Pulled out stretching frame and stapled some more light weight Poly Fiber on frame and shrunk to 250 degrees. Then cut out 6 round, 3 rectangular and 6 smaller round doilies. Two coats of Poly brush applied to re-enforcing tapes and laces. Then applied poly brush coat to rest of my test fabric panels. I want to have some panels to test spray painting.
 
Oct 10, 2021     Rib lacing - (8.0 hours)       Category: Wings
Finished applying re-enforcing tapes on rib caps. Spent hour or so marking and drawing lines for finishing tapes. Also marked chalk lines for position of lacing holes. Then about 45 minutes reviewing modified, hidden seine knots on EAA.org homebuilders hints. Next was tying lacing knots. Got about 2/3 of lacing done today. May go hiking tomorrow morning (haven't been in several weeks)


 
Oct 09, 2021     Rib lacing - (3.0 hours)       Category: Wings
Spent several hours chalk striping the wings top and bottom in prep for rib lacing. Used strip of fabric I had marked out on first wing to mark rib lacing points on second wing. Measured and cut all the re-enforcing tapes for the lacing and applied about half of tapes. Need to relearn how to lace.


 
Oct 08, 2021     Wing tip metal brackets - (8.0 hours)       Category: Wings
Had applied the single brush coat of Poly Brush last night and worked today on correcting defects: drips, brush hairs, oogats, etc. Also turned and smoothed excess fabric at leading and trailing edges on inboard and outboard ribs. Then melted fabric out of wing tip mounting holes on rib #10. Mounted the metal strips, fitted wingtips, marked wing tip mounting holes, drilled holes through wing tip and mounting bracket, drilled holes for nut plates, counter sunk holes, hammered in the solid rivets, remounted the metal brackets, redrilled and counter sunk holes on outboard rib, tried on the wing tip, detached all and bonded metal mounting strips to last rib with Hysol and flush rivets.


 
Oct 07, 2021     GDU 460 arrived - (0.3 hour) Category: Avionics
Surprise, surprise, surprise (as Gomer Pyle would say). GDU 460 arrived two months before earliest expected arrival. More incentive to finish fuselage and cover/paint fuselage to start on wiring.
 
Oct 07, 2021     Poly Brush first coat - (4.0 hours)       Category: Wings
Clean up and prep of fabric for Poly brush. Applied Poly brush and came up with plan for next day to try to catch up with planned work for the month of October.


 
Oct 07, 2021     Anti Chafe tape - (2 hours)       Category: Wings
Couple of hours getting set up and changing around the workshop. Moved left wing to edge of garage and pulled out the other wing skeleton. Decided while research paint to finish covering the other wing and get it painted while I still have swamp cooler running for next 3-4 weeks. Applied the anti chafe tape to several pokey area on right wing that I found on Left wing.


 
Oct 07, 2021     Test painting - (6.0 hours)       Category: Research
Did more research on painting with Latex (actually 100% acrylic). Had some white primer paint, some white paint from doing First Aid sign at ski area and some paint I plan to use for final color. My plan is to cover pink Poly Brush with white paint and then go to color. Took my test fabric covering frame and covered with couple layers of Poly Brush then applied the primer, urethane/acrylic, and Weather beater brand of paint. After two days, able to scrape off Primer but NOT the other two paints. Even did similar test on the four coats of very shiny Poly Brush to see how bonded. After two days, unable to remove ANY paint at all from the fabric test frame nor from the small patches on the plane.


 
Oct 07, 2021     Ironing and smoothing - (8 hours) Category: Wings
Spent couple of work sessions working to clean up excess Poly Brush and resealing tape edges and any other rough areas in prep for painting white primer paint.
 
Oct 04, 2021     Covering right wing - (12 hours) Category: Wings
Several work sessions to glue on top and bottom fabric. Then hours and hours of ironing to take out wrinkles. I did a much better job of covering the first time. Maybe beginners work. Sure made a mess of the second wing. Ended up with HUGE wrinkles on leading edge bottom.....but.....with all the ironing at different temps, time and pressure removed 95% of wrinkles I created. Still several inches of creased, almost flat fabric in several places but I hope that finishing tapes will hide the worst of the errors.
 
Oct 03, 2021     Wiring and GMU 11 connector - (6.0 hours)       Category: Wings
Spent multiple hours placing wiring in right wing for magnetometer, GMU 11, and fabricating connector. I installed GMU 11 onto its bracket shelf before covering and then decided would be whole lot easier to fabricate connector and plug it in before covering. Spent several hours researching and reading about wiring in- and out-puts for the GMU 11 and e=mailed former avionics instructor about what was needed. Determined only two shielded cables with four internal wires needed. Re-read about CAN-BUS and termination. Installed CAN-bus terminated onto GMU 11 and then placed and secured the connector I fabricated. Going to use standard shielded 22 ga, two wire for CAN Bus. Re-learned about crimping pins, pin-out charts and fabricated connector before installing . Over 5 hours to accomplish a 5-10 job. Soldered pig tail from shield to connector case ground.


 
Sep 27, 2021     Patrol refresher and bad back Category: Wings
Ski Patrol refresher and tweaked back kept me out of garage for almost one week.
 
Sep 21, 2021     Spraying Poly brush - (6.0 hours)       Category: Wings
Two days to spray four coats of poly Brush. After finishing, got to reading directions closer and determined that depending on how you interpreted the instructions, either 4 coats of sprayed Poly brush needed or just 2 coats. I contacted Poly Fiber and found out needed......just two coats. $90 of extra poly brush sprayed on Left wing.


 
Sep 20, 2021     Latex painting research - (2.0 hours) Category: Research
Research again about using acrylic latex enamel to cover plane.
 
Sep 20, 2021     prep and Poly Brush spraying - (6 hours) Category: Fuselage
Spent couple of hours doing final prep and getting all set up for spraying Poly Brush. Used Poly Brush reducer to remove some of thick Poly Brush and drips.
I agonized doing the spraying but actually went quite well....no visible runs or drips. Did medium coat and heavier coat today and repeating same tomorrow.
Only took about 15-20 minutes to actually spray wing. Used about 2 qts of reduced for each coat of spray for total of about a gallon.
 
Sep 18, 2021     Taping and ironing - (10 hours)       Category: Fuselage
Spent about 10 hours over several work sessions to work on place width wise finish tapes on leading, trailing edge and top of spar tapes. Also covered top of wingtip rivets. Then hours smoothing tape edges, lumps and bumps


 
Sep 14, 2021     Door hinges - (6.0 hours)       Category: Fuselage
Went over to former patient's house, Niel Gunn, and had him cut the supplied hing material into pieces per the plan then spent hours and hours hand filing to smooth. Got basic holes cut. Was going to mount door hinges and clear door skin but I want to add some "door channel" aluminum to door threshold to prevent wear on fabric covered edge. Not sure if that added thickness will affect the door frame fit I have now or not. Regardless how I go about it, I still have to remove and then re-install temp fit door frame (which I was trying to avoid). So door frames will come off and stored until after fuselage covered.


 
Sep 13, 2021     Nutplates - (5.0 hours)       Category: Wings
Took awhile to learn to do these and come up with a system. Only up-drilled two holes wrong....(wasn't supposed to up-drill holes for poprivets to wing). Checked to be sure that wing tips would fit after enlarging holes then Hysol bonded the metal strips and pop rivetted strips to rib #10. Added filler to wing tip with unused Hysol.


 
Sep 12, 2021     Ironing finish tapes - (4.0 hours) Category: Wings
Spent several hours ironing and flattening bumps, wrinkles and raised edges. Will still have to do this with the false rib tapes and leading/trailing edges but got wide tapes ironed.
 
Sep 11, 2021     Wing tip fitting - (2.0 hours)       Category: Wings
Had to stop my finish tape attachment process to get the wing tip fitted. Poked holes through fabric at sites of previously drill mounting holes for metal strip to be used to mount wing tips. Then used my new soldering iron to melt/burn holes to uncover counter sunk holes.....ruining solder tip in process....another tip now on order so will have one for melting fabric and one for electrical soldering.
Next step is to learn to rivet nutplates


 
Sep 10, 2021     Ironing finish tapes - (4.5 hours) Category: Wings
Spent many hours ironing down finish tapes that have been applied. Still waiting on order for 1" finish tapes for false ribs. Had done the spanwise finish tape for spar on top of wing. Was going to place the one for tail when thought about how I was going to find holes for mounting metal strips for wing tip mounting. Read the instructions (what a novelty!!)....suppose rivet on wing tip mounting plates BEFORE finish tapes on #10 rib. Oh well, just one more layer of tape. NOT a safety of flight issue....just cosmetic. After riveting metal strips, will put another finish tape to cover over rivet heads.
 
Sep 08, 2021     Finish tapes - (12 hours)       Category: Wings
About 12 hours of work over three work sessions to draw lines on wing to position finish tapes and doilies. Then applied coat of 3:1 Poly Brush, let dry, apply doilies and finish tapes. Had to order some 1" finish tape.....didn't want to cut 150+ feet of 2" with pinking shears.


 
Sep 03, 2021     Firewall forward kit - (3.0 hours)       Category: Firewall
Finally received firewall forward for Rotax 914 (actually ordering EP915Ti....fuel injected, turbo charged stock Rotax from Edge Performance). Box filled entire pallet. Only one exhaust part missing. Got 5 pieces of fiberglass for cowling...top, bottom, boot cowl, NACA duct. Spent some time unpacking and able to store all items at home. Scott's room is full of airplane parts. Did inventory, cut up and disposed of lots of cardboard and lots and lots of brown paper "stuffing"
Had ordered this kit back in January 2021 when if found on YouTube VLOG that there was a substantial back log. Also backlog on GArmin G3x and Airmaster prop.....both not due to ship until Jan 2022


 
Sep 03, 2021     Doillies - (4.0 hours)       Category: Wings
Went to Lowes to get some 2 x 2 wood to make stretching frame for light weight fabric to make doilies. Had ordered 2 yds of light weight fabric assuming 72" wide. ended up on 70" wide and not wide enough to fit on frame. I messed up trying to make a 3' x 3' frame..... ended up 37.5" x 37.5" but fabric only 35" x 36 " and could not get 2 full square yards to shrink on the oversized frame. Long story short, had to put more 2 x 2 on inside of frame to make is smaller....worked.....but quite heavy for its function.
Stapled fabric to frame and shrunk at 250degrees. Used paint can, piece of cut off PVC and desert dish to draw three different sized doilies. Took and hour or so to cut out all patches.


 
Sep 02, 2021     Wing covering and lacing - (15 hours) Category: Wings
15 hours over 3 sessions for Poly Brush, re-enforcing strips, lacing, more poly brush. After spending several hours Spent about 3-4 hours trying to see how to rib lacing and tie knots on practice boards. Knots tolerable but not very tight. Didn't take as long as I thought to do lacing. Initially, took about 5 minutes per knot but later got it down to about 2.5 minutes. Would have been a lot quicker with curved tip. That order arrived late today with only 5 lacing knots left. Those five went VERY quick with curved tip.
Took hour or so to apply re-enforcing strips on capstrips. Then about 4-5 hours for lacing. 1.5 hours spent on priming re-enforcing strips with 4+ coats of poly brush to fill the weave.
 
Sep 01, 2021     Prop order - (2.0 hours) Category: Propeller
Found out there is a 5 month lead time for prop. Placed order with Kitfox. Expected delivery in Jan 2022
 
Aug 29, 2021     Fabric and needle lacing order - (1.5 hours) Category: Wings
Got all prepped to start rib lacing and found Kitfox had sent only a straight needle. It works but necessitates multiple needle passes top to bottom to advance running Seine knot to next hole. I decided to bend the tip.....not a good idea....hardened steel.....tip broke off. I quickly ordered curved tip needle and half moon needle for lacing just top capstrip and some lightweight fabric for doillies as suggested by Poly Fiber.
In meantime, I wanted to start lacing so took some small stones and formed a new tip.
 
Aug 28, 2021     Heat shrinking and iron calibration - (6 hours) Category: Wings
Spent long time heat shrinking fabric. My infrared thermometers don't read accurately when pointed directly at bottom. I get better reading when teflon paper placed on iron and thermometer pressed directly onto teflon that is directly on iron. It seemed my expensive digital iron wasn't functioning properly. I ordered some Silicone heat shrink paste and bought couple of cheap clothing irons at second hand store. Place candy thermometer I got with Kitfox builders kit into silicone paste wrapped in teflon paper on top of stack of towels. Candy thermometer proved to be worthless. Best temp results came when silicone heated and infra-red reading taken off of silicone immediately after iron removed. None of my irons heat over 325..... I guess to keep people from scorching their clothes. I did shrink top and bottom to about 325 degrees.
 
Aug 27, 2021     Covering initiated - (12 hours)       Category: Wings
Before trip to Washington for TJ's retirement bash, Got everything prepped and ready to cover left wing. After return from trip, over two work periods, was able to bond both top and bottom fabric to left wing. Have to work really fast with Poly-Tak and use heavy application to be able to "bed" the fabric into cement. Don't have the 5-10 minutes as described....more like 20-30 seconds. Learned NOT to be neat when gluing fabric, Just get it aligned and glue quick. Several creases and wrinkles in the bonded areas but I learned with proper heat and adequate time for heat application, ALL creases and wrinkles were eliminated on the bonded areas. Tomorrow I start heat shrinking top and bottom fabric.


 
Aug 27, 2021     Fire wall foreward kit order - (1.5 hours) Category: Firewall
Got notice and billing for firewall forward. Crate shipped two days ago. Supposed to arrive Sept 1.
 
Aug 06, 2021     Order for Garmin G3X GDU 460 - (2.0 hours) Category: Avionics
Found out at Garmin lecture at Oshkosh that major backlog for G3X panel due to world wide chip shortage because of COVID mess. Same for a lot of cars/trucks in US......no chips...no drive/fly. Put in order and now estimate delivery in Jan 2022.
 
Aug 06, 2021     Painting aluminum pieces - (3 hours)       Category: Wings
After prepping aluminum pieces, used some of remaining Steward System, water borne paint to epoxy paint prime for several aluminum pieces yet to install. Used foam brush to apply, Not best finish but a little sanding and topcoat of final color with correct issue.
Getting ready to head to SEattle for 2 weeks, (TJ retirement ceremony). Before leaving, got everything ready to start covering. Unrolled fabric and cut section to start covering on bottom left wing.
Got a picture of draped fabric and sample of painted pieces on wing.


 
Aug 06, 2021     Poly Tak and aluminum panel prep - (4.0 hours) Category: Wings
Picked up $33 of Acetone, Lacquer thinner for Poly brush and painting clean up. Put one coat of Poly Tak on all rib caps per KitFox instruction manual...only took about 30 miniutes. I'm short on time due to upcoming trip to Seattle in 4 days and 3 days flying CAP before leaving. Spent about 3 hrs and Pulled out several aluminum panel pieces, filed/smoothed edges, etched, Alodine Tx in preparation for epoxy primer....sometime down the road.
 
Aug 05, 2021     Set up work shop and Poly brush primer - (4.0 hours) Category: Wings
Spent hour or so re-arrangement position of wings and fuselage to work primarily on one wing. Mixed some reducer/poly brush to place two coats of cut polybrush to fuel tank and leading edge per Poly Fiber instructions.
 
Aug 04, 2021     Practice wing covering process - (4.5 hours) Category: Wings
Practiced covering backside of previous practice panels and tried another technique. Laid down glue, let dry, applied fabric, applied glue/MEK cut mix to soak through and reactive glue to stick to fabric. I couldn't get to work well. Tried very heavy/wet application on 4-6 inches and placed fabric into glue, applied another 4-6 inches with pulling off previous stuck fabric, then used brush to tap all wet fabric back down. Quick glue dry even with 60+% humidity.
 
Jul 26, 2021     Oshkosk - (96 hours) Category: Research
3 days at Oshkosk looking at finished Kitfoxs and attending forums on Garmin install. Good trip, Camped out. Rained on two of three nights. Gear inside tent stayed dry. Walking around in 85+ temps and 85% humidity got me soaking wet.
 
Jul 22, 2021     Fitting left door bubble - (3.0 hours) Category: Fuselage
Fitted left bubble door to frame and drilled 3 holes to center again after fabric covering. Won't finish sanding/smoothing edges until final fit after fabric installed and door channel fitted.
 
Jul 21, 2021     Bubble door panel fitted right side - (4.0 hours)       Category: Wings
Trimmed and fitted right door panel. Went better than I thought. Had watched FarmFox build by Harlan for his door fitting. Panel with Barely clearance from door frames but will be better after block sanding/smooth the edges. Still need to fabric cover door sill before final fitting of door panel/frame.


 
Jul 20, 2021     9 pin D sub connectors - (1.5 hours) Category: Lighting
Ordered some 9 pin D Sub connectors for wing wiring disconnects and wing tip disconnects. Didn't realize until I received them that were only plug bodies M/F but no back plate. I'll have to get those later
 
Jul 20, 2021     Wing tips light fitting holes - (2.0 hours)       Category: Wings
Pulled out wing tips, nav and landing lights. Read up on wiring and how to mount lights. Drilled holes and cut slots for Nav lights and landing lights. Found out I still have a little bit of fill work needed on wing tips. Need to order some #6 nut plates to use for mounting lights into wings. Holes all drilled for nav light mounting bracket. Slot drilled for landing light in wing tip leading edge recess. Holes drilled to mount. Clear lexan cover fitted for joggle in leading wing tip edge...ready for screw mounting.


 
Jul 18, 2021     Panel mock up - (4.0 hours)       Category: Avionics
Several hours over several sessions trying to find out about how to print lift size photos of future avionics. Printed photos and fitted them to panel. I'm sure several switches are missing...I just don't know what.


 
Jul 18, 2021     Door frame fitting - (3.0 hours)       Category: Fuselage
Fitted both door frames by slightly bending to get best fit. Drilled holes in frame for securing bubble door panels. Secured frames into door with hot glue and wood wedges.


 
Jul 18, 2021     Covering, wiring, avionics research, paint - (5.0 hours) Category: Research
Spent several hours doing various research about wiring, covering, paint, avionics. My mind running all directions trying to learn all. Need to get proper wire secured into wings before covering. Trying to figure what to order for avionics, wiring for CAN bus.
 
Jul 13, 2021     Practice wing covering process - (3.0 hours)       Category: Wings
Worked on 2 painting canvas frames I got at Hobby Lobby. I stripped the canvas and epoxy varnished the frames to tolerate the Poly Tac. Measured and cut spare fabric (obtained last year from EAA covering process class in Las Vegas). Use Poly Tac to glue fabric. Used the small iron with Kitfox basic tool kit but won't hold temp well and heat shoe with various temperatures around the heating area. I paid some bucks for a digital iron (believe got it from Kitfox). It worked VERY well and more consistent temp. Results pretty good considering very sharp corners on picture frame and work to heat contour and cement into a contoured side. Not bad for first try. Need to remember to coat fabric and surface to have enough cement to wet through the fabric


 
Jul 13, 2021     More supplies - (3.0 hours) Category: Supplies
Spent time today to order some Red and black 20 ga single conductor, unshielded wire and some black 12 ga wire to properly wire the pitot tube. Got some clear shrink tubing to secure wire labels. Played about hour yesterday (or day before) with label machine to see what font and how to make labels. I had seen something about "special" can bus wire needed. Saw some 4 conductor, shield wire for $5.00 plus per foot. Did more reading and found that the 22 ga. mil-spec two conductor wire I have is acceptable per Garmin install.
Figured I need a bunch more poly brush, some access rings and access covers, along with drain grommets. Poly brush is $90+ per gallon and reducer is $60+ per gallon.....I needed 7 gallons....lot of money for cover that I though I had already paid for with "cover kit" Seems cover kit is only minimal to get started to cover maybe one wing. Inventory shows enough fabric but not enough chemicals.
 
Jul 11, 2021     wiring tools - (2.0 hours) Category: Tools
Ordered crimping tool that does insolated connectors and coax cable connections with removable anvils. Read and watched how crimpers worked. Also getting soldering iron, and pin extractors.
 
Jul 11, 2021     Figuring out next steps - (9 hours) Category: Research
Spent 9 hours over couple days trying to get my head wrapped around next steps. Wings ready to cover and tail feathers almost ready (need to smooth and/or varnish rib edges on tail feathers). Before finishing covering wings, need to run some wiring. I need to figure out to run/secure wiring. Need to create plugs at rib #10 to accommodate removable wing tips. Still need to figure out how to run wiring done rear spar. Also need to run wire and pitot tubes left wing and wiring for magnetometer in right wing.
 
Jul 08, 2021     Deglossing wing varnish - (3.0 hours) Category: Wings
Spent several hours de-glossing all areas to be coated with Poly-Tack to glue on fabric. Instructions don't call for it but I do recall fabric covering class mentioned to use Scotch brite to buff bonding areas.
 
Jul 01, 2021     Wiring - (2.0 hours) Category: Supplies
600 feet of wire (1.50+ per foot). Chalk line, Hour or so spent figuring out type, gauge and amount of wire needed. Ordered only a guesstimate amount of wire.
 
Jun 30, 2021     Varnish on end caps - (1.0 hour) Category: Tail Feathers
Final varnish coats (three coats) on all end caps.
 
Jun 30, 2021     Touch up prep for covering - (7.0 hours) Category: Wings
Multiple work sessions to accomplish. Did final fill and sanding on wings and empenage. Then did two coats Poly varnish on areas sanded to wood during faring of all ribs, tank, etc. Then used some of Stewart system water based epoxy to paint bare trailing edges along rib #1-#3 and touch up exposed aluminum here and there. Forgot to paint the fuselage formers....again.
 
Jun 24, 2021     Fuel tank false ribs - (6.00 hours)       Category: Wings
Several work sessions to trim/fit/bond fuel tank false ribs on left wing. Used belt sand resting upside down on work bench to gross trim extra false ribs to fit on bottom of fuel tank. After bonding, used 24" level to check and trim contour of false ribs to match contour of Ribs #1 and #3. Also finish bonding Rib #2 to bottom using shims to match bottom contour of Ribs #1 and #3.


 
Jun 20, 2021     Magnetometer mount - (5.0 hours)       Category: Wings
Came up with idea for mounting magnetometer in right wing similar to Pitot mount in left wing. Cut a couple of wood blanks and sent them to TJ to cut a rabbet to help sit on bottom rib cap, small wing spar, and false rib. Cost $22 for postage to and from TJ. Good fit. Mounted near end of false rib to make for easier access through future access panel in fabric


 
Jun 13, 2021     Flaperon hinges remounted - (4.0 hours)       Category: Wings
Had realized I had mis-measured location of flaperon hinge brackets by more then 1/2" on right wing. Re-mounted and re-drilled ribs for hinge brackets. Then filled in incorrect holes with Hysol


 
Jun 12, 2021     Repair, Magnetometer and Pitot mounts - (5 hours)       Category: Wings
Spent hour or so figuring out how/where to mount the magnetometer in the right wing. Has to be 36" from heavy steel or power consumption. Able to locate spot about 34 1/2" from from spar strut bracket and lights in wing tip.
Also found good spot for Pitot mount on fuselage side of rib #5. In plans, calls for pitot mount farther towards wing tip by rib #7. Reading builder logs shows people bump pitot a lot in this area. Rib #5 position put pitot above lift strut and below wing in protected area.
I plan to mount magnetometer similar to the mount for the pitot with 1/4" plywood bonded between main rib and next outer false rib. Have sent two wood blanks to TJ to have him cut some rabbets along one side to help mount wood square to main rib. Cost $22 to mail and return postage for $3 of wood.....well... beats trying to do the impossible myself.....and save a lot of time.
Also worked hour or so figuring repair of broken upper false ribs on outer right wing. Repaired with a bonded scab "splint"
Cleaned, acid etched and alodined the added trailing edge behind both fuel tanks. Then bonded in the aluminum stiffening tubes into trailing edge.


 
Jun 12, 2021     Flaperon mounting Left wing - (4.0 hours)       Category: Wings
Mounted the hinges for left flapern. Looking at instructions, I realized I had mounted the right wing flaperon INCORRECTLY by measuring 1/8" on wing flaperon bracket in wrong area.
Left flaperon mounted with #1 and #9 rib brackets only off 1/16".....tolerate with "slop" in flaperon hinge bushings.


 
Jun 11, 2021     Research and reading - (4.0 hours) Category: Wings
Couple of weeks ago, bought a 1/4" plywood board for shelving for magnetometer.
Not much work done recently due to kids and families came to town for a week for Billie Jean's memorial. Great family reunion in Ruidoso.
Spent most of today trying to figure out mounting of pitot tube and magnetometer. Came up with a plan for both. Have sent two blanks of wood to TJ to have him cut a rabbet in both to help fit to wing full rib and false rib and allow room for magnetometer mounting. Position is almost 36" (desired distance) from steel spar stiffeners and wing strobe lights per Garmin install instructions
 
Jun 04, 2021     Filling and sanding - (6.0 hours) Category: Wings
Multiple hours over several sessions using Superfill to fair fuel tank to front spar and adjacent ribs. Also filled on front and back ends of multiple ribs. Also attached Rib #2 and trailing edge from Rib #1 to Rib #3. Lots of sanding and filling. While doing so, also took opportunity to fill around metal trim around doors and triangle window.
 
Jun 01, 2021     Engine order - (4.0 hours) Category: Engine
Several hours spent over several months on engine decision. Decided on Edge Performance engine EP914Ti....basically a Rotax 912 on which Edge Performance adds their own EFI and turbo for same price at Rotax 914 and also a few pounds lighter.....3-4 month lead time.
 
May 25, 2021     Fuel tank install - (2.0 hours)       Category: Wings
Installed fuel tank in left wing with adhesive. Had spent several hours before trip to Colo for Jason's memorial getting tank fitted and spars painted. Today, also took wheel pants out of shipping box, stored them in empty shelf in garage and disposed of large box. Kids coming from Billie Jean memorial and need to make room for Scott.


 
May 18, 2021     Flaperon alodine and paint - (8.0 hours)       Category: Wings
8 hours spent over couple days to hang drapes to prevent overspray onto items in storage shelves in garage, Cleaned and alodined flaperons, spray painted the spars, flaperons and flaperon hinge wing brackets Had also fitted right flaperon to right wing and drill holes for flaperon brackets.


 
May 18, 2021     Flaperons - (12 hours)       Category: Wings
12 hours over several days. Final fitting, filling and sanding of flaperon end caps, inboard end cap with fitting of #1 rib hinge for flaperons. Also worked with jigs to adjust "clocking" of flaperon angle actuator


 
May 07, 2021     Flaperon...right - (3.0 hours)       Category: Wings
Worked on right flaperon. Install trailing edge rivets, drilled drain holes, fitted inboard end cap, fitted and bonded outboard end cap (preformed plastic). Drilled mounting holes for inboard end cap. Had to re-bond flaperon skins to internal foam rib on inboard side. Not sure if necessary as end cap only couple inches away.


 
May 07, 2021     Snading and filling - (1.5 hours)       Category: Wings
More sanding and filling on right wing tank fairing to rib and spar.
Also worked on sand and fill right end cap tip


 
May 06, 2021     Reading - (2.5 hours) Category: Research
Couple of hours for Team Kitfox research
 
May 06, 2021     Flaperon mounting jib - (7.0 hours)       Category: Wings
Had to get two pieces of 1.5 x .75 x 4-6 feet sticks to make the jig to hold flaperons to properly clock time the actuating arms for roll. I screwed up the first set of jigs, then got better doing second set. A lot of time spent for jigs to be used for just 5-10 minutes to properly set the control arm for L and R flaperons.


 
May 06, 2021     Super fill contouring - (2.0 hours)       Category: Wings
Super Fill to contour fuel tank to ribs and spar.


 
May 05, 2021     Flaperon counter weights - (1.5 hours)       Category: Wings
drilled holes for flaperon counter weights 1.5


 
Apr 27, 2021     Fuel tank false ribs - (4.0 hours)       Category: Wings
Several work sessions over three days. Trying to get ready and pack for Cozumel dive trip. Bonded false ribs to bottom of fuel tank. Used Hysol with coating of SuperFil to fair tanks to front spar and #1 rib. Will need to sand and re-fill. Also place wood braces between tank and #1 rib to prevent rib distortion when fabric shrunk.


 
Apr 24, 2021     Fuel tank false ribs - (5.0 hours) Category: Wings
Spent hour or more trying to figure out how to fit false ribs to bottom of fuel tank. Spare false ribs came with the kit....quite warped. So I had bonded a 1/8" stiffener to each rib to straighten it. Now I had to shorten height of each rib substantially to fit on tank bottom and blend into airfoil contour. I thought initially that the stiffener would be a problem but actually helped the fitting process. Instead of shim under ribs, I ground and fitted the ribs to fit flush with tank bottom.
I don't have picture yet, but yesterday, I did fit Rib #2 and cut/fitted the metal trailing edge. All are now ready to bond to tank.
 
Apr 24, 2021     Fitting fuel tank - (11 hours)       Category: Fuel System
Spent hours and hours fitting tank to rib #1. Fitted brass nipples to tank but elbow into finger screen fitting didn't seat far enough to allow clearance with bottom cap strip of Rib #1. In my Team Kit Fox research, found out that strongly suggested that finger screen be removed on annual condition inspection. Position of fitting on tank would mean cutting a slit/slot in bottom of fabric or installing inspection plate in the area to allow removal. Position of tank and fitting precluded removal unless most of bottom of Rib #1 removed. I tapped fuel tank to seat finger screen deeper and obtained additional parts to use two pieces for the ell fitting to allow easier removal. In photos, original suggested/supplied parts are resting on fuel tank and final parts are install. Other photo shows bottom of installed fuel tank showing valve clearance to cap strip and easier removal of parts....hopefully.


 
Apr 24, 2021     Tools and supplies - (2.5 hours) Category: Supplies
Different fittings for fuel tank finger screen, 1/4 x 4 inch ratchet wrench (old one didn't work well), two step drills for round holes, 4 foot level for #2 rib and false ribs, 2x2 piece of wood for flaperon jig, belts for belt sander.
 
Apr 21, 2021     Avionics-System LRU kit - (1.5 hours) Category: Avionics
Ordered System LRU kit with GSU 25C, GMU 11, GTP 59 and configuration module from Kitfox.
 
Apr 21, 2021     Epoxy primer - (3.0 hours)       Category: Wings
Epoxy primer applied by brush to all metal parts on wing. Used some Stewart System 2 part epoxy primer I got some months ago. Says can be applied by brush with "good" results but I found it didn't apply very smoothly. Expensive paint so will use in "hidden" area.


 
Apr 15, 2021     Super fill contouring - (2.0 hours)       Category: Wings
Used cutout leading edge contour template to get proper airfoil contour to leading edge. Had to sand some high portions on top, front edge of rib caps near the front spar. Used Super Fill to slightly over fill needed contour. Then sanded back. Sand paper kept gumming up and Super Fill didn't seem to be completely hard. I read directions again. Suppose to mix 2:1.....I had mixed at 1:1. Not perfect, but it will work....material will eventually set.


 
Apr 13, 2021     Counter sink rib #10 - (1.5 hours)       Category: Wings
Used my fancy counter sink assembly to counter sink rivet holes in rib #10 for future installation of metal backing strips for wing tips


 
Apr 13, 2021     Side stringer fitting - (2.0 hours)       Category: Fuselage
Fitted right and left side stringers and drilled holes for pop rivets


 
Apr 10, 2021     Leading edge fitting - (2.0 hours)       Category: Wings
Fitting and bonding of leading edge extrusion


 
Apr 09, 2021     Butt rib and closeout - (7.0 hours)       Category: Fuselage
Spent most of the day working on the right butt rib and butt rib closeouts for L and R. Yesterday I messed up mounting the butt rib, as I finished back drilling the butt rib through the butt rib brackets, I noted that when temp mounting the butt rib to #1 rib that things shifted (dropped) and the rib cap on butt rib was almost 3 mm lower on aft end than it should have been. Only thing to do was pull everything apart and start over for the third (maybe fourth) time. Of course that meant more holes in butt rib that are very close together after adjustment. I'll just fill the holes with epoxy when pop-rivets placed......than all should be good.
I just did all the same on the left side just 2.5 months ago.....a lot of water under the bridge and I had already forgotten how I did things before.
Fitted the butt rib closeouts and cut slots for the butt rib mounting tabs that come off of top of door frame.
No photos.....yet


 
Apr 08, 2021     Butt rib install - (4.0 hours)       Category: Wings
Spent quite some time today to do process to install butt rib. Had to drill new jig to be able to drill holes in small, tubular butt rib brackets. Got all butt rib brackets trimmed, drilled and installed with clecos when I realized that the temp mounting of butt rib was incorrect, 3.5 mm too low for matching with #1 rib. Determined that only choice was to remount butt rib and redrill cleco holes. Spent 1.5 hours redoing what already was done.

When drilling the holes in small diameter tube of butt rib brackets, had to drill a new jig because alignment hole was over drilled. Couldn't remember what drill I used in Jan 25 to do previous jig. Finally determined that 1/2 spade wood bit was what was needed. Got #30 holes drilled into block fairly true and holes into tube done quickly.


 
Apr 02, 2021     Jury strut, #1 rib fitting - (5.0 hours)       Category: Wings
Patrick came over again to help mount right wing. Had to file fuselage tubes on forward and aft mounting points but got file done and allowed pins to drop with minimal internal hole reaming. Forgot to trim and mount #1 rib before mounting wing. Went ahead and fitted jury strut, bonded jury strut brackets and figured location of jury strut clamps. Removed jury strut. Jeanne and I very easily removed the wing onto sawhorses. Trimmed, fitted and bonded #1 rib. Then very easily replaced wing. Had left the lift strut in exact position when wing fitted so made removing and reinstalling wing a cinch.
These tasks were done over a couple of days.


 
Apr 01, 2021     Fuselage cockpit area - (6.0 hours)       Category: Fuselage
Finally started on some projects on the plane. Had seen about interference of seat buckles anchors and header tank on co-pilot side. Spent hour or so sorting out the issue. No picture taken but did bend out the seat belt attach bracket on both lateral sides. Able to see how header tank would mount and seat belt buckle would play together. Adjusted so all would play nicely. Back drilled head tank tabs so tank ready to mount. Still need to place hose fittings and adapt fuel sump drain tubing.....have to find the parts first.
Fitted and set the nut plates to secure the seat pan. Nut plates with pop -rivets went fairly quickly and smoothly after I figured out how it was suppose to work and how to drill for the rivets.
Also bonding side door and window frames/sills for the right side. Left side metal is already fitted from some time ago


 
Apr 01, 2021     Reading - (3.0 hours) Category: Research
Spent about 3+ hours over couple of days to figure out what to do next. Looked up Rivet nuts, Nut plates, Nutserts, teamkitfox.
Trying to figure out about future installation of either nut plates, or rivet nuts or something else.
Dedcided to go with instruction manual for time being and consider rivet-nuts down the road. Rivet-nuts need a special tool and adapters for each size of machine screw used.....cheap tool is over $80.
 
Mar 31, 2021     Rotisserie - (10 hours)       Category: Supplies
Worked 10 hours over two days. I couldn't drill a straight hole with hole cutter. Hole cutter larger than 1 7/8 OD pipe. Tried doing end supports without 3rd led (propping leg) for storage purposes but very unstable so added 3rd support leg and attached with bolts so can remove support leg and store more easily. If you look very close, you can see I used popcicle sticks to jamb into gap between hole in 2x4 and pipe to be able to cinch down on bolt in T-nut to tighten and prevent rotation of "spit". Work's OK but not the best. Only needed for one job.


 
Mar 29, 2021     Supplies for Rotisserie - (2.0 hours)       Category: Supplies
Supplies for rotisserie. Had seen similar at Gary Phennings start of build in Leavenworth, WA. One sheet plywood (maybe 3/8 chip board), 4 2x4x8, multiple bolts, nuts, screws, glue, T-nuts. hole cutters.


 
Mar 23, 2021     Various tools and supplies - (2.0 hours)       Category: Tools
Ordered small bucking bar, countersink cage, counter sinks, grease and lubricant, wire stripper, wire crimpers for connectors,


 
Feb 25, 2021     Multiple small tasks - (6 hours)       Category: Wings
Multiple tasks over several work periods. Alodine treated flaperon brackets, door frame moldings, wingtip attachment metal strip, trailing edge stiffeners, console trim panels.
Drilled, fitted and installed flaperon brackets for both wings. Fitted and bonded trailing edge stiffeners. Fitted wing tips both sides along with metal attachment strips.
Decided not to slosh anti-corrosion treatment inside of spars on right wing due to debonding of six ribs on left wing. In future, will use Corrosion-X or similar to treat inside


 
Feb 20, 2021     Various wing projects - (8.0 hours)       Category: Wings
Eight hours over several work periods.
Wing tip fitting of trailing edge to match wing trailing edge. Had to split tail of fiberglass wing tip to fit. Filled with Hysol and will need more SuperFil later.
Also fitted leading edge. Used masking tape to hold edge in position. Supposed to trim leading edge to fit around front spar lift strut bracket. I trimmed WAY TOO much and had to patch over-trim. Used balsa wood and hysol for bulk fill then day or so later with some SuperFil. Trimmed and sanded to contour. Went pretty quick, only took about 40 minutes over couple of days.


 
Feb 20, 2021     Sand blaster and parts - (2.0 hours)       Category: Wings
Various items, tape, hobby sticks for mixing, cups, countersink cutters with cages, lubricants, air gun for sand blaster.
Was on internet and saw how to make crude sand blaster for steel parts before painting
Generic plastic bottle with hole drilled through neck to tightly fit the metal air gun nose. A notch is cut into tube for sand pick up when activated. Look at tip of my finger. Tube hole inserted into bottle, bottle filled with sand, sand siphoned out when air activated.


 
Feb 18, 2021     Flaperon hinge brackets - (4.0 hours)       Category: Wings
Worked on trimming smoothing and fitting flaperon brackets. Pre-drilled one side fitted and clamp matching bracket pair, drilled, cleco, deburred, bonded and riveted bracket onto ribs #1,3,5,7,9.


 
Feb 11, 2021     Alodine treatment - (6.0 hours) Category: Wings
No photos but did Alodine treatment of aluminum spars/braces on left wing. Used material called Bonderite. After pre-cleaning with a metal prep material called Bonderite C-IC alumiprep and rinsing on exterior and interior slosh. Internal sloshing was a mess as solution leaked out of all the pop-rivets on the wing. Spent about an hour on previous day filling all rivet holes with Super Fill. Filling holes would have worked great had I filled ALL the holes....missed a group of rivets. Next day, set up wing on saw horses, plugged spars with foam ball covered in plastic wrap, poured in solution into spars, removed one saw horse and pivoted wing up and down. Used alumi-prep and Bonderite Alodine to treat inside and outside. Left surface with slight brown/gold appearance....not as much as I expected. Hope will provide the needed protection. I decided against painting inside and outside of spars as the Alodine treatment is supposed to be sufficient enough for protection unless plane operates on floats or in water.....which is wont be.
 
Feb 09, 2021     Fitting of wing tips - (4.0 hours)       Category: Wings
Jumped between working on fuel tanks and fiberglass wing tip fitting. First had to fit metal strips to cap strips on #10 rib. Drilled and clecoed strip. Had to remove about 1/2" of front spar to be even with outside edge of #10 rib cap to allow proper fitting of wing tip. Trimmed top of wing tip, fitted marked and trimmed lower portion of wing tip. Both top and bottom cuts right on "scribe" line faintly visible in gelcoat. Very little fitting needed after cutting carefully.
Had to spit the trailing edge of wingtip to fit around metal strips and then patched tip with Hysol. Will work on filling, finishing and sanding on wing tips and then wait on final holes and nutplate mounting until after fabric covering.


 
Feb 08, 2021     No work, no time - (0.1 hour) Category: Wings
Very little work recently due to flying with CAP and working at ski area. Got to fly to Ozona last week to deliver "gray ghost" back to Georgetown squadron. We had had the plane since late November for Falcon Virgo and then spent over 30 days in maintenance for 100 hr.
Then spent several days/flights learning new-to-us plane, C-182RG, with Shane. Finally got checked out yesterday so no legal to fly the retractable gear plane.
 
Feb 05, 2021     Fuel tank work - (4.0 hours)       Category: Fuel System
Trial fitted brass fittings into tank. Only the small 1/8" NPT fittings actually engage the pre-tapped holes in the fuel tank more than 1/2 to 3/4 turn with most of pipe threads still showing. I had a 1/8" NPT tap and with very little effort was able to chase/cut threading a little deeper. Got the 1/8" fittings to seat over half of thread length. Couldn't get the 3/8", 1/4" fitting to screw in at all. I ordered some 3/8", 1/4" NPT pipe taps off internet
While waiting for the taps, I started by taping the holes in fuel tank with masking tape, poured in two cups of acetone and started sloshing the tank. Pressure built up quickly due to the volatile acetone and loosened the tape seals.....acetone everywhere. Decided to follow other instructions which said to use NPT pipe plugs to seal holes. I found a local plumbing store that carried the plugs but of course they had every size except what I was looking for. I ordered a set off the internet for 1/3 of price for special order from Lowe's or Home Depot. Amazon lost that package and had to re-order.
When both orders came (taps and plugs), I set to work. I spent almost an hour with short 5" spanner trying to work the 3/8" tap into the hole. I tightened, loosened, tightened, loosened trying to cut threading deeper. VERY slow going. Sent text question to KitFox AC asking if permissible to cut deeper threads on Saturday morning. Didn't get answer until late Monday morning. In meantime, I had pulled out a 12" spanner and really leaned into torquing the wrench/tap to cut the threads. Took almost 40 minutes putting more and more pressure into torque before i could finally seat the fuel outlet/strainer more than 4 threads. Second tank went quicker because I had learned I wasn't going to crack/split fiberglass in the area. Only cut threads maybe two full turns on tap which got very warm due to energy to cut the fiberglass resin. Then got call from Brandon at Kitfox who said OK to cut deeper but not too deep as when sealer placed, would act as lubricant and fittings would seat deeper.
I placed the plugs with teflon tape to seal and repeated the acetone/gas rinse on the right tank. All went fine. Then moved to left tank.....oh, noooo!!!!.....fuel lead in corners where "lid" and "tub" portion of tank meet. Took pictures and sent to Kitfox. Brandon called hour or so later and said would have to send new tank as leak was not repairable. Special fiberglass resin is necessary to avoid degradation by fuel.


 
Feb 05, 2021     Butt rib work - (4.0 hours)       Category: Wings
Fitting of butt rib close out sheet metal that fits above door and below butt rib. Also found some balsa wood sheet to close up front and back holes in butt rib just leaving the center hole open to view fuel level. Also painted the butt rib.


 
Feb 04, 2021     Supplies - (2.5 hours) Category: Tools
Various parts/supplies obtained for build: two boxes cheap paint brushes, masking tape, 1/4" and 3/8" NPT taps for fuel tank, NPT pipe plugs for fuel tank cleaning/sloshing of Acetone. Balsa wood to close out holes on butt rib.
 
Feb 01, 2021     Supplies - (1.5 hours) Category: Tools
Ordered parking brake kit, epoxy primer paint, more epoxy varnish.
 
Jan 25, 2021     Root and Butt ribs - (5.0 hours)       Category: Wings
Yesterday, had Patrick Mulvey stop by and with his and Jeanne's help, got the wing mounted on fuselage. Only had to do some minor filing on hole of front spar reinforcing brackets to be able to drop the bolt....probably 0.1-0.2 mm had to be remove on one side of hole. Then fitted the jury strut, marked position of jury strut brackets on spars, drilled holes, bonded and riveted the brackets, fitted the jury strut clamps, record the distance to jury strut clamps. Bonded in the root rib to wing. Today, after slow start at 3:00pm, I fitted the butt rib, butt rib brackets. Did drill holes for butt rib brackets in wrong place for three of four brackets, so had to had another hole. Extra hole on top of bracket and once completed, no one can see it unless they use a mirror. No structural/functional issues with extra hole.
I don't have a drill press. Had to come up with idea on how to drill hole into a round tube. Came up with idea of small block of wood with 1/2 inch hole drilled to tightly fit bracket and guide hole drilled through the top of the wood block. Put the wood block with the bracket into the vise and drilled #30 hole with no prom. Since soft wood, guide hole only good for 3-4 holes. When right side done 2.5 months later, had to drill a new block.


 
Jan 23, 2021     Autopilot servos - (3.5 hours)       Category: Fuselage
Tried in mounting brackets for auto pilot servos. Mounted and installed pitch servo and adjusted mechanical limit frame to allow full movement of pitch push rod.
Secured servo mounting bracket to frameowork with 5 small screw clamps. One clamp was enough to firmly secure bracket so 5 is overkill. Roll servo mounts to aluminum bracket which needs to be riveted to plate on airframe. Worked to get roll AP servo all set up ready for final mounting after installation of mounting bracket. Have to treat and prime the aluminum bracket before installation.
Each servo and installation hardware weigh just short of 2 pounds. With wiring, total weight will be about 5 pounds.


 
Jan 23, 2021     Tail access covers - (2.0 hours)       Category: Fuselage
Initial fitting of tail access covers. Instructions are not clear and somewhat contradictory. Not totally clear exactly where/how to cut and rivet after portion. Trying to figure out how many cuts needed in covers to allow easy application and removal. Only did cuts I am sure about and riveted support patches....exactly the same on both panels.....oops...should have been mirror images. Drilled out most of wrong rivets. Left one to hold patch in place so not lost. Have to re-order the small aluminum rivets to do a repair....3 minute job. Will do final fitting after horizontal stabilizer back on plane for final assembly.


 
Jan 22, 2021     Research and reading - (3.0 hours) Category: Research
Research and reading to understand upcoming build projects.
 
Jan 22, 2021     Builder log entries - (8.0 hours) Category: Research
Multiple hours over last several months doing updates to builders log.
 
Jan 22, 2021     Supplies Category: Wings
Bought another gallon of denatured Alcohol and some small foam balls to use to plug ends of spars to allow internal cleaning and painting.
 
Jan 22, 2021     Fitting of console side panels - (2.5 hours)       Category: Fuselage
Trimming and fitting of side panels. Adjusted the panels for bottom edge to fit between wood flooring and fuselage mounting tabs.


 
Jan 21, 2021     Pitot fitting - (1.5 hours)       Category: Fuselage
Fitted Garmin pitot into pitot extension. Fitted extension through wood fitting. Found where on wing for Pitot fitting to go and removed neighboring Hysol to allow good fit in proper position.


 
Jan 21, 2021     Trying in seat pads and interior trim - (1.5 hours)       Category: Fuselage
Spent some time after initial fitting of console side panels placing carpet, side panels and seat cushions to try them out. Found that seat cushion too thick and puts my head near aft carry through spar. Will need a thinner cushion.


 
Jan 19, 2021     Brake master cylinders - (1.5 hours)       Category: Fuselage
Simple enough install of brake master cylinders on all rudder pedals.


 
Jan 18, 2021     End caps - (5.0 hours)       Category: Tail Feathers
Worked on end caps over several work sessions to fit the balsa wood blocks with 5 minute epoxy, then gross filling with Hysol, rough shaping, then re-filling with Super-Fil and more shaping. Also filled divots between ribs and frames and smoothed said items. Horizontal and vertical stabilizer are near ready for cover. Rudder, HS and elevator removed and stored. (Then decided to fit the tail access covers....should have left the horizontal stab on plane to determine positioning of tail covers.


 
Jan 10, 2021     Tail end cap fillers - (6.0 hours)       Category: Tail Feathers
This work done over couple of days and work sessions. Glued on pieces of Balsa wood couple of months ago. Filled gaps with Hysol. Used pocket knife to trimmed excess wood. When cured, used belt sander to rough finish end caps on horizontal stab, elevator and ....oops....forgot to do the rudder. Filled with blue colored Super-Fil and sanded again. Then went over all surfaces and joints between wood ribs and frame and used Super-fil to smooth transition.


 
Jan 07, 2021     MIsc small jobs - (3.0 hours)       Category: Fuselage
Door latch block, re-drilled Jury-lift strut brackets, drew cut lines for door hinges,


 
Jan 05, 2021     Door frame trim - (3.0 hours) Category: Fuselage
Finishing trim fitting on right side and started fitting on left side. Did some cleaning, organizing to get restarted on build after 2 months off for Thanksgiving visit, Falcon Virgo with scanner/observer training beforehand to have enough crew and Wreaths across America.
 
Jan 04, 2021     Trim position indicator - (3.0 hours)       Category: Tail Feathers
Installed a trim position indicator for horizontal stabilizer. Had to mount small switch to mounted lug and used existing hole. Then had to glue on a metal tab about size of large popcicle stick to aft horizontal stab at pivot point that pushes trim position indicator button as stabilizer is raised/lowered


 
Dec 31, 2020     Horizontal stab trim sensor - (1.5 hours) Category: Controls
Installed trim sensor in horizontal stabilizer. Simple enough. Spent more time studying than installing.
 
Dec 31, 2020     Inventory on new order - (2.0 hours) Category: Controls
Inventory on list of additional parts. Garmin AP controllers for pitch and roll plus installation kit and connectors Garmin pitot, Turtle deck hinge. Trailing edge stiffeners, Trim position sensor.
 
Dec 30, 2020     Engine research for Edge Perormance models. - (3.0 hours) Category: Research
Trying to decide what engine to install. I heard about Edge Performance engines from Norway base on Rotax cores. 20 extra horsepower using big bore cylinders, Turbo charged with fuel injection setup for much less than Rotax. 50 psi boost gives 150hp.
 
Nov 18, 2020     parts order - (1.5 hours)       Category: Research
ordered parts:


 
Nov 18, 2020     Horizontal stab and elevator limited adjustment - (2.0 hours)       Category: Tail Feathers
30 minute job that I crammed into 2.5 hours. Kept screwing up. Clamp on elevator to hold level while elevator push rods adjusted to length per specificaitons. Then used phone again to measure elevator Up and Down limits using ladder for prop. Horizontal stab set to 1 5/16 inch, then stick held at 80 degrees to flat floor. Elevator control rods loosened and rod ends adjusted to length as documented...39 degrees up and 20 degrees down. Used an app on my phone for an electronic level and a ladder to support the elevator at desired location while limit adjustment made and jam nuts tightened.


 
Nov 16, 2020     Balsa wood for tail tips - (1.5 hours)       Category: Tail Feathers
$6 for block of balsa wood that was cut down with jig saw and impromptu table saw with vise gripped, upside down jigsaw. Was suggested by several builders that balsa wood was better than the very friable foam. Cut rough fill pieces for all 6 tail surfaces and used masking tape to hold into position.


 
Nov 16, 2020     rudder stop repair - (3.0 hours)       Category: Tail Feathers
Had filed the fixed rudder stop too much and had 30 degrees deflection instead of desired 25 degree. Fabricated some steel strap blanks to fit on/over the fixed rudder stop on vertical stabilizer. Used phone app to measure rudder deflection and placed the steel blanks in appropriate place and used super glue to secure in place. Rudder removed and single 1/8" hole drilled. Rudder replaced and confirmed proper placement for new, fabricated rudder stop blanks. More super glue to secure. Both holes drilled and then updrilled to 3/16". Order some AN bolts for the 4 drilled holes. Plan is to bond (Hysol) and bolt the addition/repair.


 
Nov 13, 2020     Problem here - (2.0 hours)       Category: Tail Feathers
Got the trim motor connected then I connected the elevator rods. Now control stick will move the elevator. Rudder cables not yet connected to rudder so I went to tail and moved surfaces by hand. Seems to be a problem....see photo....can you see the problem. I had very carefully filed and filed on rudder stop "Y" at bottom of vertical stabilizer on tail aspect to get a 30 degree side to side rudder limit. Photo shows a problem. I went to instruction manual. OOOPS!!!! Was only supposed to be 25 degrees. Don't know how I missed that one. Would have saved me a couple of hours of filing to stop at 25 degrees. Took awhile to figure out a "fix" but came to me fairly quickly. Got the parts today: a 3/4" wide steel strap and some metal cutting jigsaw blades (maybe I could just use my hacksaw)


 
Nov 09, 2020     trim motor - (6.0 hours)       Category: Fuselage
Simple job. Only four bolts and multiple washers. Well......wasn't that simple. Took awhile to get my head wrapped around the mounting and ALL the washers. Had to clean, sand and paint some scissors hing parts. Some tabs had some holes (that I missed early on) that needed reaming to bolt size....easy enough.....had I reamed them BEFORE bonding in horizontal stab ribs. Now limited (actually, NO access). Two special trips to Lowe's (first drill wouldn't cut), second drill wouldn't reach one hole. After 2-3 hours, I resorted to Amazon order to get a 12" drill to drill ONE hole. My left fore finger points to offending hole.
Got the trim motor installed. Very tricky trying to get bolt, holes, and washers all lined up at same time. Pulled out a battery charger and got the trim motor to run up and down......YEAH!!


 
Nov 09, 2020     mounting horizontal stab and elevator - (2.0 hours)       Category: Tail Feathers
Mounted the horizontal stabilizer and elevator. Simple but took about 2.0 hours to coax all the bolts (even temp bolts) to mount the two parts. This was after storing last wing on ceiling and moving fuselage around. As parts are added, fuselage getting heavier.


 
Nov 09, 2020     Rudder pedal assembly install - (2.5 hours)       Category: Fuselage
Rudder pedal assembly has been finished for several weeks. Decided to install the assembly because it already "fit" and would only take 10-15 minutes to install and check off......NOT!!!. One of the brackets, master brake cylinder bracket, had too much lateral pressure when all nuts for assembly snugged up. Lateral pressure torqued the rudder pedal assembly to point that NONE of the rudder pedals, left nor right, would move hardly at all. Had to remove most of nuts to loosen bolts and remove the brake cylinder bracket in middle of assembly on each side and file to fit, file to fit, file to fit, file to fit.........2.0 hours later, they fit and bolts just dropped into holes. Rudder pedal assembly installed. Fifteen minute job only took 2.5 hours.


 
Nov 08, 2020     Rudder cable - (10 hours)       Category: Fuselage
About 10 hours of work over couple of days. Rudder cable runs through several fittings welded to frame. Nylon tubing inserted into the fittings to re-direct cable path under seats and luggage back to tail. Tubing was shipped all coiled up and even cutting into small pieces left all pieces with curves that didn't fit into fittings. I used a hair dryer to warm the tubing and then pressured tubes to become more straight. Finished bonding false ribs onto last wing and used left over epoxy to bond in the tubing to fittings.
Next was to cut the wire rope (cable) into four pieces, manufacture terminating eyes that attach to adjustable rudder levers, then route cables through guide fittings to the tail. It was pretty but manual said could use a cold chisel and couple of hammer whacks to cut the cable. I had a piece of RR rail in side yard that Scott brought home many years ago that I occasionally use as an anvil. First practice cable cut worked perfect, but each additional "real" cut was worse and worse. Finally looked at the tip of the cold chisel and realized that the temper on the RR rail was much higher than for cold chisel. I was trying to "cut" the cable with a cold chisel with flat tip. Got out my hand file and re-sharpened the cold chisel and found a large rock to use as cutting anvil. Worked pretty well.


 
Nov 04, 2020     Finished rudder tried on - (.7 hour) Category: Tail Feathers
Stripped off all of masking tape used to hold rudder fairing in place and installed on vertical stabilizer. Now seems to be plenty of room for fabric on front of rudder and back of vertical stabilizer.
 
Nov 03, 2020     Rudder pedal assembly install - (3.5 hours)       Category: Fuselage
Now that I have the console finished, I looked to complete the cockpit area completion of install. I didn't know if I would need to remove things or not so I have used temp nuts or not torqued down real ones as yet. I started with the rudder pedals which I thought would take 5-10 minutes to install and torque nuts. It did only take few minutes but then pedals wouldn't move well. I determined a master brake cylinder bracket was the issue and had to loosen assembly to remove the small brackets and file to fit and file and fit and file and fit and file and fit....you get the idea. By golly, 3 hours later, they did fit and rudder pedals work great.


 
Nov 02, 2020     False ribs-not on fuel tank - (2.0 hours)       Category: Wings
After installation of lift brackets on spars, needed to install 3 false ribs on top and two false ribs on bottom of wing. I had varnished all wood parts as soon as I opened kit to prevent warping. Looking back, I remember the false ribs as being distorted somewhat when I first got them and kept them clipped to table for some time. They became reasonably straight and after varnishing, I threw them into a box on top shelf assuming they were protected. When I retrieved them, (15-16), all but 4-5 were noticeable warped. I found some 1/4" square poplar/pine pieces and epoxied them with multiple clamps. Came out fairly straight.


 
Nov 02, 2020     Console riveting of flaps, rudder adjustment - (2.0 hours)       Category: Fuselage
Finally took delivery of a 100 degree counter sink drill.....very hard to find. Did the counter sink on top of console and riveted into place. Thought I had lost two screws and corresponding spacers for the brackets. Very carefully cut down an aluminum spacer I found at Lowe's and got it perfect. When assembly parts for try-in, all of a sudden I had extra parts. Thought I needed 8 screws and spacers but only needed 6.


 
Oct 30, 2020     Speedster tail cuffs - (11.0 hours)       Category: Tail Feathers
Acquired multiple wood parts for rib stiffeners, tail tips, sanding blocks and sand paper, thin metal wire and cold chisel for rudder cable cutting and whipping cut wire rope ends.
Sharp increase in COVID cases in EP area caused city to close non-essential businesses today for two weeks. Glad I went parts shopping yesterday. I have enough material/parts to keep me busy for week or so.
Instructions said "trim to fit and bond into place". Two items, 11.0 hours over three work sessions and counting. Trimming and fitting of speedster vertical stabilizer trailing cuff and rudder leading edge cuff has been very tedious. Parts on, off, trim wood ribs then repeat....again and again and again....couple of dozen times. Cutting the fiber glass parts was tricky using a bulky multi-purpose oscillating tool using a blade similar to one used to cut off an arm cast. Cutting worked OK but hard to cut a very accurate line, but the fiber glass trimmed easily using my metal files.


 
Oct 28, 2020     Checking other build videos. Reading manual - (3.0 hours) Category: Research
Spent several hours looking at other KitFox build videos. Also spent some time reading construction manual for next steps.
During this time, I finally destroyed my broken laptop computer (frozen hinge with crack screen bezel), new computer wouldn't start, decided to replace weak battery on my iPhone.
My older laptop developed a "frozen" hinge. First noticed when I tried to close computer and heard a "crack". Hinge would move and screen bezel cam apart on left side exposing multiple wires and connections.....but,,,it still worked. Got a new laptop (HP Envy) and really a lot nicer than old one. I kept the old one while I used used to using the new one. Was going to keep old, broken one in garage near workbench for convenience. I moved the rudder, which moved the build manual, which fell off the work bench, which hit the power cord, which pulled the computer to the floor, which caused the screen to completely break off of the keyboard. But then my replacement battery arrived for my i-phone. Using i-Pad and new computer to watch videos on battery replacement technique. I had problems with new computer getting to sign-on screen. I would start computer, keyboard didn't work and computer would shut down. No problem still had my i-pad. The 3-5 minute job touted on You-tube to replace battery was total BS. I spent a good 45 minutes reviewing 4 different instructional videos and watched each a couple of times......none totally agreed with the others....several significant differences in technique. I used a combination of steps but it still took almost 20 minutes to get phone split open. After opening phone three times (short some tools and problems getting battery out) I make a final try....I get the battery out and upon trying to finish and close phone, I see ANOTHER torn cable......phone has been killed. I race down to Verizon to get another phone before store closed for two weeks. New computer fixed same day......there is a key on keyboard that locks the keyboard......who knew?!?!
Things did get better over next day or so.
 
Oct 25, 2020     Slider blocks - (3.5 hours)       Category: Tail Feathers
$30.00 for various small parts, replace broken drill, wood stiffener strips for warped false ribs, epoxy for strips. off-set drill attachment.
Spent couple of days with belt sander reduce size of polyethylene block to use as slider blocks on front edge of horizontal stabilizer. The trim for this plane is similar to J-3 cub and Mooneys as trim is a Jack-screw that moves the entire horizontal stabilizer instead of small trim tap. The sliders allow the front end of the horizontal stab to move up and down along metal guide bar with the electric trim motor with minimal wear/friction.
I neglected to get pictures of original block (one large piece) and the fitting process. Trying to get the holes drilled correctly with the correct amount of sliding block sticking out and no gaps with about 1.5 hour ordeal. Finally had to get a new drill (broke the only one of correct size) and also an off-set drill attachment. Only took about 5 minutes to actually install the parts that took almost 3.5 hours to trim and fit.


 
Oct 22, 2020     stabilizer slider bars - (3.5 hours) Category: Tail Feathers
Worked on the plastic sliding bars for front of horizontal stabilizer. Simple....only had to drill 4 holes....not that simple.....couldn't match drill previously drilled holes as vertical stabilizer ribs in the way. Marked and free hand drilled holes.....didn't work well. Tried again....got closer----on one side at least. Did the other side....screwed it up and tried again...got one hole drilled and then broke drill.
Went to store to get universal joint angle drill, replace broken drill, 1/4" square poplar sticks to straighten soon to be glued false ribs on wing and got some more epoxy glue for rib straighteners....37.00
New parts allowed me to match drill last plastic slider hole in about 5 minutes.....should have had the new parts sooner.
 
Oct 22, 2020     Strut tryon and spar reinforcement fittings - (8.0 hours)       Category: Wings
Not much work in last 1.5 weeks as kids in town. They did help with getting wing down and supporting while I tried on left wing strut. I had paid for pre-rigging of wing and bolts into wing/fuselage lugs and strut fittings fit perfect. Will assume right wing is ok also. Took many hours to trim, fit, drill, debur, clean and bond the reinforcement fittings for both wings. My pneumatic rivet puller quit after only a couple of pulls. Rest of the 56 rivets had to be hand pulled.
Had to move ceiling hooks to store wings as Rib #1 would not allow both wings to be hung on ceiling with rib #1 attached (won't be done for awhile). Scott helped to move wings several times.
Got one rib #1 trimmed and fitted over the reinforcement plates.


 
Oct 10, 2020     Ribs for Vertical stabilizer and rudder - (9.0 hours)       Category: Tail Feathers
Picked up a multi purpose oscillating tool, cutter blade for plastic/fiberglass and counter sink drills.

Over last several days, have been working on final fitting of ribs for vertical stabilizer. Had previously finished cutting and drilling mounting holes for tail access panel mounting strips. Prep took much longer than expected. Two batches of 1.0 oz total mix of HYsol used to bond ribs for rudder and vertical stabilizer. I did a separate mix for each. Then needed 0.8 oz total mix Hysol to bond forward tail bulkhead along with gluing/riveting metal mounting strips to multiple ribs in vert. stab. Hysol is a real mess. Fortunately most of the ugly mess will be under the painted fabric.


 
Oct 02, 2020     Rudder pedals assembly, pulleys, LIft strut brackets - (12 hours)       Category: Fuselage
$105 for odds and ends. Hydraulic pop rivet puller. Paint cup, paint strainer, counter sink drill, IR laser thermometer (finally back in stock after COVID run).
ABout 12 hours over several days finishing Rudder assembly install. Alodine, Stewart system EcoPOxy primer on console, rudder and flap adjust ratchet brackets, hold down brackets for rudder assembly. EcoPoxy went on very blotchy with foam brush. Did top coat with Rustoleum white enamel which made it look better. Placed rudder pedal assembly and drilled holes. Then back drilled through floor board. Temp mounted assembly and placed screws to verify fit and function. Removed and stored parts under final assembly.
Rudder cable pulleys under back of front seat installed. Vertical stabilizer forward wood bulkhead fitted and metal angles for access panel fitted but not yet drilled.
I had neglected to varnish the tail bulkhead earlier so now done along with small stringers used to stiffen ribs. Now all wood varnished and ready to glue and bond to vertical stab and rudder.
While waiting for varnish to cure, I pulled down a wing and fitted lift strut brackets. Had to drill a LOT of holes but with new, sharp drill, drilling went quickly. Have to pull SS pop rivets, 160 plus. My hand were tired after pulling 9 rivets on the rudder tubes so got a hydraulic rivet puller. Harbor freight had one for about $45. Brought it home and attempted to activate it. Had to put in some hydraulic fluid. Didn't know I needed it. Had some old brake fluid so used that. I mis-understood directions about where and how much fluid to put in. I thought it needed about 6-8 oz. only needed about an oz. the other 5-7 oz of fluid ended up all over the floor. Brake fluid attacked the garage floor paint. Wing strut brackets for left wing are ready to install.


 
Sep 24, 2020     Rudder and Flap adjustment bracket - (10 hours)       Category: Fuselage
Long layoff from construction due to work on instrument rating. Failed first check ride and barely passed second try. Did better on flight on my own couple of days later.

Spent about 10 hours over 3-4 partial days of work to adapt adjustment brackets for rudder length and flap setting. Also treated pre-fabricated aluminum parts for rudder pedal assembly and flap/rudder adjustment with cleaner and alodine solution. Have fitted parts and dis-assembled to allow painting with Stewarts system of 2 part, water base epoxy primer.

IR thermometer finally back in stock after COVID-19 caused a run on thermometers. Acquired IR thermometer to calibrate iron for fabric heat shrinking while in stock for now.


 
Aug 16, 2020     Impass - (10 hours) Category: Research
I've been kind of stuck about getting anything done. Very apprehensive about next few steps and they seem to be critical and I have no clue and minimal confidence. I'll push through eventually
 
Jul 28, 2020     Rudder pedal assembly - (6.0 hours)       Category: Fuselage
Bought some "C" clamps for portable vise and other uses. Also got 7/16 clevis pin and wood dowel to try to use to wet sand brake pivot tubes. Glued some used 400 grit paper glued to 7/16 wood dowel. Worked well to smooth inside of brake tube pivots after spending almost 2.5 hours filing the inside with a rat tail file to reduce enough for the rubber/plastic tubes that will be pivot and bearing for brake pedals.
Drilled and pop-riveted the outside pedals onto torque tube. Before pop-rivet, I used white grease to well lube all bearings for concentric rudder tubes and for brake pivots. Then placed blue masking tape to keep from losing plastic bearings until unit is installed.
Worked about 6 hours over two days to finish basic rudder torque tube assemly


 
Jul 24, 2020     Rudder pedals - (12 hours)       Category: Fuselage
Hours listed for this period were done over several days/sessions.
Picked up a right angle drill as I could not find a suitable Dremel tool. It worked quite well. Spent MANY hours sanding off powder coat off of metal tube exterior and interior, sanding down outside plastic bearing. Not much visible progress but a LOT of work to get concentric rudder tubes and bearings to operate smoothly. Other builders post said this is critical to get right for rudders to function properly down the road.
Someone suggested a brake cylinder reamer to remove powder coat inside tubes, but didn't work well. The right angle drill worked better than the old Dremel tool I got from Bill LIvely. Used coarse arbor bands on mandrel to clean inside of tubes. Used sand paper strips for belt sander by hand to reduce diameter of outside bearings and paint removal from tube exteriors starting with very coarse grit. Use of gloves allowed more pressure to be placed on sanding strips without hurting hands and prevent overheating of bearing. Got all parts to move smoothly working over several days.
Spent about $45.00 for right angle drill from harbor freight and some 1.0" wide sanding belts in coarse and medium grits to remove powder coat.

Not much progress as I have been focusing most on flight training for my instrument rating. Also Jeanne recently with hand surgery for ruptured tendon and not able to cook. So not only learning to fly on instruments but also learning to cook again. Once Jeanne is healed and I've done my instrument check ride, then can work full time on plane.

Recently watched EAA webinar on painting plane with house latex paint. As crazy as it sounds, think I'll do it. No fumes, no spraying, no paint booth, $2-3000 cheaper than "official" paint for plane.


 
Jul 12, 2020     Vertical stabilizer ribs - (2.5 hours)       Category: Tail Feathers
Bought some aviation shears at Lowe's....splurged and spent a little extra to get USA shears as have a lot of sheet aluminum to trim

Over two sessions, fitted ribs to vertical stabilizer. Then cut and fitted metal mounting strip to largest rib for vert stab inspection panel. Had read about problems drilling rib after install so fitting and drilled strip before installation.


 
Jul 08, 2020     Horiz and vert stab and rudder - (3.0 hours) Category: Tail Feathers
Worked on getting horizontal tail fitted and check nuts locked down on rod ends for horizontal stab supports. Fitted vertical stabilizer ribs. Fitted rod ends and adjusted pivots for proper hanging of rudder.
 
Jul 07, 2020     fitting horizontal stab - (2.5 hours) Category: Tail Feathers
Spent some time rounding up parts and fitting the horizontal stabilizer. Temp placed horizon stabs but did due accurate measurements to level tail and locked down check nuts on rod ends for stabilizer. Also labeled each strut so can be quickly re-installed on final assembly.
 
Jul 07, 2020     Floor boards - (1.5 hours) Category: Fuselage
Spent some time final fitting floor boards and back drilling holes. Also varnished (poly-urethane) what I had to grind to fit.
 
Jul 05, 2020     Rudder pedals - (2.0 hours) Category: Fuselage
Revarnished some of vertical stab ribs that didn't look well covered/protected. Will recoat again tomorrow. Primed and painted the safety straps for rudder cable pulleys....not sure why other than protect metal....possible that the strap material is stainless steel and painting not needed. Four little pieces of metal strap to fit onto the rudder cable pulleys. Took 1.5+ hours to fabricate the first part to a successful fitting....only took 10 minutes to fabricate last of the four parts.
Have all the parts out for the rudder pedal assembly with instructions laid out. Trying to get my head wrapped around how all this fits together. Seems to be a LOT of powder coat to clean off and pieces to fit.
 
Jul 04, 2020     started on rudder pedals - (4.0 hours) Category: Fuselage
Worked two sessions about 4.0 on rudder pedals. Finished rudder cable safety strap for adjustable rudder pedals. First strap took be about 1.5 hours to figure out how and what to bend strap over. Pounded strap flat to start over 2-3 times. Last of four straps took 10 minutes TOTAL. Started by rounding up all parts and pieces.
 
Jul 04, 2020     Install ribs to horizontal - (8.00 hours)       Category: Tail Feathers
Spent couple days working on fitting and gluing ribs to horizontal stab and elevator. Finished ribs and hung for storage. Haven't done end caps yet. Probably will do horizontal end caps along with vertical stab and rudder.


 
Jul 04, 2020     Bearing fitting for elevator - (6.0 hours)       Category: Tail Feathers
Spent hours trying to figure out how to do get bearings and bushing to fit into elevator hinge. Fitting was about 0.3mm difference....not very much but enough not to fit at all. Finally figured how to lock bronze bearing onto a bolt with couple of nuts and chuck into drill. Then used file and Boley gauge to reduce to desired diameter. Steel bushings done same way.


 
Jun 22, 2020     Varnish for wood parts - (15.0 hours)       Category: Fuselage
Got about $10 worth of pain brushes. Spent 3 days and 15.0 hours mixing and applying two coats of varnish to all wood parts: flooring, wing ribs, tail feather ribs. Finished late this afternoon.
For past couple of weeks, Have been going to Donna Anna county airport for IFR training on Redbird Sim with Shane Lipson as instructor.....I'm struggling


 
Jun 16, 2020     control column and mixers - (15 hours)       Category: Fuselage
Spent several sessions working on fitting and installation of control column and mixers for ailerons and flaps. Total of at least 15 hours over 3-4 days Control column was pain to get controls loose and smooth but not too loose. Installed and removed several times to get reaming and trimming of plastic bearing with metal bearings on right side of control column to work smoothly. Installed bearings for aileron/flaps mixer but neglected to install the pivot bolt during bearing gluing. Had to ream out the glued bearings to get the mixer to pivot freely.
Just as I finished installation, I had a COVID-19 CAP flight to San Angelo (in bed by 0200) then Bob and Arlee Emmott stopped by for 3 days to visit.....good time.


 
Jun 12, 2020     control column and mixers - (15 hours)       Category: Fuselage
Spent almost 1.5 hours drilling two holes for pop river in elevator limit block. Ready to mount to fuselage.
Also received seat cushions and trim fabric. Received two part epoxy, and several other items for treating and protecting multiple aluminum parts with cleaner, alodine and epoxy.
One box from aircraft spruce had been cut open and contents inspect but I guess the thief didn't want paint.
We're gone for weekend when packages arrived


 
Jun 04, 2020     Control tube and others - (9.0 hours) Category: Fuselage
Worked on control tube more. Tired of waiting for epoxy painted and sprayed 4-5 parts with rattle can self etching primer and riveted elevator stop bracket. For that part, had to use some well lubricated ����clamps to press in steel tubes into aluminum block. I calculated couple of hundred pounds of force using the screw clamp to seat the pins, suppose to drill through aluminum and steel tube and place pop rivet but drill wouldn't penetrate steel and slipped off. I don't thing the steel pin is going to come out. Had to relieve several bushing to accept the bronze bearing and flue them in. Then had to relieve inside of bearings to allow bolt and thin steel sleeve to pass through. Several small parts ready for final install on control tube. Nylon type bearing, lamp, anchor trimmed to fit and close to fitting control tube onto fuselage frame.
Started to fit some bearing into bosses 9n fuselage then left town to Ruidoso for several days. I believe paint mask came in along with epoxy paint. Now hope to spray and wipe varnish on a
L wood parts before assembly.
 
Jun 02, 2020     Assembly and prep - (1.5 hours) Category: Fuselage
Picked up some files....round and half round for trimming. Used one of new files as soon as got home. Able to put all parts together for control yoke first part assembly. File allowed right control arm connector to "twist" into place. Bearings glued and bolts, washers and nuts loosely into place. Also round up parts bags for next several pages.
WAiting for epoxy primer and paint respirator to varnish all wood parts and prime aluminum parts for next many steps.
 
Jun 02, 2020     shopping - (1.0 hour) Category: Preliminary
trying to find files and future tools for future jobs....right angle drill suggested for rudder rib install. Also spent some time getting parts to repair Jeanne's garage door that is falling apart......not installed properly 26 years ago so door breaking. Spent 1.5 hours patching/re-enforcing top of garage door where lifting mechanism attaches. Also shortened/tightened the chair so not hanging down so much. Reprogrammed the keypad door opener.
 
Jun 01, 2020     More reaming - (10.0 hours) Category: Fuselage
More and more and more reaming for controls. Trying to get control links to fit. Ground the shit out of right control boss to make from for control link. Took an hour or so but finally got it early the next day. Tried glue in washers on control arm to simplify the fitting of rod end. Reglued 3-4 times. finally got all put together. Parts picture today and finished product in tomorrow's post.
 
May 31, 2020     Reading/finding parts - (1.5 hours) Category: Preliminary
Trying to decide what to start on next. Waiting for Epoxy primer and paint respirator so can varnish all wood parts and start on treating/painting aluminum parts.
Spent time reading steps for controls and rounding up parts.....time killer tying to find parts.....I've misplaced some bearings for the control lever. Will look through all boxes again tomorrow.
Last couple days, havn't felt super spiffy. Did a tough hike yesterday that kind of kicked my ass....MU-2 canyon. Very sore and achy.
 
May 31, 2020     YouTube reseach - (1.0 hour) Category: Research
Watched several videos Kilo7fox, Project Kitfox for a couple of sites, for several building hints and see what I'm faced with.
 
May 31, 2020     more sanding - (1.5 hours) Category: Tail Feathers
Found I hadn't done anything about the ribs in rudder and elevator. Got them done while doing more YouTube research
 
May 31, 2020     More reaming - (1.5 hours) Category: Fuselage
More reaming of horizontal stab. Used some 3in1 oil.....worked much quicker and smoother.
 
May 30, 2020     More reaming - (1.5 hours) Category: Tail Feathers
Reamed three more bushings. A little bit of oil on reamer helps a lot.
 
May 30, 2020     Sanding wing ribs - (1.9 hours)       Category: Wings
Sanding wing ribs. Thought all done with sanding and found horizontal stabilizer and elevator ribs......more sanding.


 
May 29, 2020     Shopping - (1.5 hours) Category: Tools
Acquired more moving dollies, spring clips and ordered couple of more foldable sawhorses
 
May 29, 2020     Reaming - (2.0 hours)       Category: Tail Feathers
Watched a YouTube video on modifying reamer to fin to socket and use socket wrench. Now about 15 minutes reaming per large bushing


 
May 29, 2020     Floor - (3.5 hours)       Category: Fuselage
Trimmed, fitted and sanded flooring for front. Haven't yet drilled holes. Also did bus de for baggage area which seems to be some kind of fiberglass covered chipboard. Only going to varnish edges of chipboard as no one will see it


 
May 28, 2020     online supply order - (4.0 hours) Category: Research
Spent several hours looking into Polyfiber, Amazon and Aircraft Spruce looking for need items.....paint, chemical paint respirator, aluminum treatment (Alodine), paper cups, squeeze bags, spatula. Very difficult to find a respirator in stock and then have one delivered sooner than 6 weeks wait on deliver. Should have most of what I need in next week or so. This COVID-19 has created some real issues for me.....no respirator, no alcohol for cleaning, delayed shipments
Next, need to fit floor boards and cargo floor in preparation for varnish. Will start on control build but need aluminum treatment and epoxy primer for pre-made aluminum parts before I go too much further.
 
May 28, 2020     Sanding ribs - (5.0 hours)       Category: Tail Feathers
Gave up on the reaming for now but found a hint on You Tube on modify reamer to fit into universal socket attachment and use drill or socket wrench for reaming leverage. will have to try it. All wood parts need to be epoxy varnish coated so before gets humid, I started sanding rough areas in preparation for varnishing all wood parts. Not hard but took time to sand 40+ rib pieces....some for rudder, vertical stab and wing.


 
May 26, 2020     STARTED build. Reaming - (6.0 hours)       Category: Tail Feathers
Finally started on actually build/assembly. First item was to ream some bushings on the elevator. Took awhile to figure out how to work the reamers. Spent an hour or so trying to get reamers to work. Some of fittings too close to larger framework to use any kind of "T" handle. Had to use Vise-Grips to turn the reamer. Very slow going. I had purchased a "T" handle at Northern tools but found it will only work for the smallest of all needed reamers. I had a kit/box of die cutters and reamers I've had for 30 years or more. Only able to use the "T" handle from the kit. KitFox reamers are round and "T" handle wouldn't hold. Had to use moto-tool to grind some flat spots on shank and then "T" handle worked like a champ.
Finished reaming on elevator and hung it on wall above work bench. While had the reamer, worked on same size hole reaming in couple dozen spots on fuselage. Then started to tackle the horizontal stabilizer. Have 7 largish bushing to ream that are hinge points very close to frame. Have to use vise-grips. After 45 minutes, I managed to get about 40% through only one bushing. My hand/arm is very tired. Hung up the stab along with the elevator. Will have to work on something else while my arm recovers.


 
May 25, 2020     Reading instruction, Instrument course - (8.0 hours) Category: Preliminary
Eight hours listed is over several days. Spent the time reading through most all of assembly instructions trying to get my head wrapped around all that needs to be done. During build, will try to recall what needs to be done before what. Also to try to anticipate needed items. Right now, need to get epoxy primer, alodine treatment,
Haven't done much on the assembly reading or work on plane as I try tried to finish up my John & Martha King instrument ground course. Spent several days working through 968 review questions and 3 sample FAA exams. Scheduled to take FAA written ground exam on May 27.
 
May 14, 2020     Reading instruction, shopping for supplies - (4.5 hours) Category: Preliminary
More reading of construction instructions, Had to get a haircut (first in almost 4 months due to COVID-19). Picked up a handle for reamers. Still trying to figure out where to start. Right now, looking at doing finishing work for wood ribs, metal parts, wood flooring, primer painting, Will finish going through instructions and make decisions. Still need to spend time on instrument course.

 
May 13, 2020     Flaperons stored, parts organization, aluminum paint - (9.0 hours)       Category: Preliminary
I was able mount hooks on garage ceiling to store flaperons up on ceiling joist of garage. Couple of large boxes went upstairs in house to one of kid's room. Picked up an exposed floor bin storage unit at Harbor freight for all the parts, Went together fairly quickly. Will try to organized parts by type of part (i.e., bolts, screws, washers, pop rivets, etc.). Hopefully will decrease search time for parts. Also getting ready to actually start on horizontal stabilizer and elevator rib installation followed by flight controls. Need some premade aluminum parts painted. VERY difficult trying to find Alodine treatment solution but did find that Rust-oleum self etching primer will work on aluminum so will use that.
Still need to go through entire manual and determine build process. Did find check list to be done before covering which will help me determine what parts go in now "for good" that done have to be installed and removed for painting.


 
May 12, 2020     Reading instruction, shopping for supplies - (9.0 hours) Category: Preliminary
Starting reading instructions, making list for additional needed items, located some of parts needed for horizontal stab and elevator. Then when shopping for some needed supplies....more hooks to hang flaperons on ceiling, some various size clamps, 3M abrasive pads, loctite glue, denatured alcohol for precleaning parts.
 
May 11, 2020     Inventory more preliminary - (5.5 hours) Category: Preliminary
Finished inventory check. Only two items missing from many 100's of parts. Also returned two hooks didn't use for hanging wings.
 
May 10, 2020     Inventory and storage - (7.5 hours)       Category: Preliminary
Started today doing more inventory. Got couple more boxes checked in then stopped for brunch. Distracted by needing something from old tool chest and pulled a drawer off runners. Had to fix drawer. Had planned to replace the tool chest because all drawers didn't work well...had to use two hands to pull evenly and runners very stiff. Well, after I repaired drawer and lubricated it, the drawer worked quite well. So, it took 1.5 hours, but I rehabbed all drawers with some grease and all work nice enough now not to have to spend $550+ to replace it.
I remeasured garage, wings and available space on garage ceiling and determined room enough for them. I had some hooks but not big enough. Internet search found some at Lowe's and indicated row and bin section. My friend, Patrick came by to look at kit and spent couple of hours helping me measure, drill and hang both wings up and out of the way.


 
May 09, 2020     Inventory check - (6.0 hours)       Category: Workshop
Inventory check. Checked three boxes....two took about 3 minutes. Third one took about 6 hours...tedious. Finally figured out that most of inventory list were grouped by small packing boxes. Inventory list of parts still scatted through the information book and took awhile to find correct list to go with parts box.


 
May 08, 2020     Kit delivery - (5.0 hours)       Category: Preliminary
Kit delivered today. Unpacked boxes from boxes. I don't seem to have enough room to hold all items and still have room to work. Some may have to go into storage at the airport


 
Mar 09, 2020     EAA Electrical workshop - (15 hours) Category: Research
EAA electrical wiring workshop for basics in wiring for Aircraft panels. Did projects for antenna cable lead, various type of pressed on connectors, Wired up a basic intercom wiring harness....tested and it worked. Also did a soldering project to created minature electrical panel with basic lighting circruit along with light circuiet with a dimmer.
Course was in Fremont CA just east of San Jose in San Francisco area.

 
Feb 10, 2020     Copper STate flyin in Buckey AZ just west of Phoenix - (10 hours) Category: Research
Did a forum course for metal riviting and second course on basic fiber glassing. Also wandered exhibits learning about different systems and parts for possible inclusion into panel. Able to see fancy "Butterfly" Kitfox recently finished from Phoenix area. Talked with Debra and Richard McBean of Kitfox and found they may have turn key panel system by late May 2020.
 
Jan 13, 2020     Eaa workshop on Fabric covering - (16.0 hours) Category: Research
EAA Fabric covering workshop. Workshop in Las Vegas to learn Poly Fiber covering processing using Poly fiber chemicals. Poly-tac, poly brush, medium weight fabric cemented, overlapped, seams covered all using poly brush all used to cover a wing (actually DC-3 aileron). Team of 8 people got the wing covered and rib stitching started all first day. Fabric shrunk, demo on heat shrinking fabric on curved surfaces. Rib stitches comleted and fabric over stitches. DEmo on repair for tear in fabric.
Good course. Process with many steps but none are difficult if steps follower properly
 
Jan 08, 2020     Kitfox Test flight and factory visit - (6 hours) Category: Research
Demo flight in Kitfox.in Caldwell, ID Got to do hands-on flying for about 0.5 hrs. Talk with instructor for couple of hours on Kitfox handling and suggested engine combos.
Also took brief tour of factory.
Next day went skiing at Bogus Mountain, ID
 
Jan 07, 2020     Research on kit and possible avionics - (10 hours) Category: Research
Reading multiple articles over last several months researching Kitfox options and reading about various avionics to possibly included into kit. I have listed 10 hours but actually much more than that over last several months.
I place initial $5000 deposit back in May 2019 with estimated kit delivery date of May 2020. Just my luck that plane I have planned to build for over 25 years would become so popular in last 12-18 months. Delivery time used to be only 3-4 months. Got a call from Kitfox that production was being increased and to expect delivery in April.
I journey this coming weekend to spend two days learning fabric covering in Las Vegas EAA sponsored course. Then on to Boise area to visit Kitfox factory and determine options I want on my kit. Also plan for demo ride at Kitfox flying school just down road from factory. Updates after/during the trip
 


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