Mar 03, 2024     38-10 Rudder and Brake system step 2-8 - (2 hours)       Category: Controls

I had to reroute the cables as they had contact where they cross.
I installed the F-1014 rudder cable links after priming and painting RAL 7016.

  Feb 26, 2024     38-10 Rudder and Brake system step 2-8 - (3 hours)       Category: Controls

Drilled the F-1048G, matchdrilled all the parts. Installed on the tunnel panel to match drill the lower hole. The right F-1084G looks fine. Unfortunately on the F-1084G left side the lower hole is not centered as the Cable guide slipped slightly. Not sure if i need to replace.
Installed the hardware to check movement. Need to prime the F-10104 Rudder Cable Links.

  Feb 25, 2024     38-8 Rudder Pedals and brake system step 1-5 - (2 hours)       Category: Controls

Installed the plastic snap bushing. Installed the two clamps at the F-1011 Bulkhead. Installed the two plastic sleeves in the Tailbone side skin ovals. Torqued the Bolt for both clamps.
Routed the two cables towards the cockpit. Installed the two clamps in the tunnel to hold the last sleeve in the pilot-copilot sides of the tunnel

  Feb 25, 2024     38-10 Step 1 - (1 hour) Category: Controls

drilled the F-10104 Rudder cable links per measure for the most forward pedal position. One cable link has an enlarged hole. Part already ordered

  Feb 12, 2024     39-5 Control System Step 3-4 - (3 hours)       Category: Controls

Lucio installed the F-1089 Elevator Pushrod and F-1090 elevator pushrod assembly. Attached the pushrods with hardware indicated. Only change is that i used self locking castellated nuts with cotter pin.

  Feb 12, 2024     39-4 Control System Step 1 - (1 hour)       Category: Controls

Preparation of safety wiring for F-1089 forward. Not clear why this is necessary. Checked again position, length and correct positioning of the different bearings.

  Mar 01, 2022     40-3 Flap System step 1 - (1 hour)       Category: Controls

Redone the drilling on a new W-1013B flap horn and into the Flap torque tube double checking the use of the bell crank jig and the correct clamping to the table.
the result is definitely better than the first one.
Final drilled #12 and 1/4 as indicated.

  Feb 28, 2022     40-5 Flap System step 1-4 - (3 hours)       Category: Controls

Installation of the Flap torque tube, bellcrank and flap horn assembly. All the nylon bushing were very tight so i decided to adjust them a bit. For some reasons mounting the hardware has been a bit complicated and i needed to slightly enlarge few holes, however i don't believe this is a major issue.After tightening the nuts the assembly doesn't have any loose part.
I also checked the full retracted and full extended position with the flap motor in place and the two horns are aligned and no difference is visible (this was my concern as the use of the bellcrank jig in the first attempt was not perfect).

  Feb 24, 2022     40-6 Flap System step 1-4 - (4 hours)       Category: Controls

Made the spacers out of the aluminum tubing. Some adjustment required and more adjustment required when mounting the flap motor.
Drilled with some difficulty the 1/16 hole in the flap motor rod. The indication not to move the jam nut and the rod creates a bit of a pain when drilling the hole. Result acceptable.
Preinstallation of the flap motor was easy, some additional trimming of the bellcrank bushing was required.
I also installed the flap positioning sensor and i tested the basic functionalities with the switch following the instructions. It seems that the extension need to be managed by the pilot as the sensor doesn't position automatically the flap in the next position. Retracting works step by step.
Pictures indicate the full retracted and full extended position with blue and red dots on the side skins. Measurement indicated that there is a minimal difference between left and right.

  Sep 07, 2021     39-9 Control System: PRELIMINARY INSTALLATION - (5 hours)       Category: Controls

Installed hardware and all the parts according to the different instructions in section 39 in order to check for movement and potential interference with other systems / structure. I also verified alignment of the two controls stick using a small rig to check sticks are parallel.
result seems to be ok. Pending verification with Lucio and final installation (after final installation of fuel tubing and brake tubing.

  May 27, 2021     39-8 Control System step 1 - (3 hours) Category: Controls

Pretty long work to adapt bushing (reaming) and the WD-1011 Left and Right in order to comply with the indications (Pivot tube of the WD-1011 has to be 1/32-1/16" SHORTER than the control stick base bushing.

  May 20, 2021     39-5 Control System Step 1-2 - (2 hours) Category: Controls

Fabricated the two F-1064 Pushrod Assemblies using the hex tubing provided. Primed in and out. Fabricated the F-1065 Aileron Pushrod Assembly. Primed in and out. Assembled on all pushrods the necessary ball bearing M-3414M (6 pieces in total) and the necessary jam nuts (AN316-4). Stored away for later installation

  May 13, 2021     39-4 Control System Step 2-5 - (5 hours) Category: Controls

Fabricated the F-1090 Elevator Pushrod (MID) cutting the aluminum tube to size and match drilling the ends with the template provided.
Primed internally and externally. Installed the VA-101 threaded ends and final riveting with pull rivets. Installed rod ends but i DIDNT put the safety wire.
Stored away for final installation.

  Mar 26, 2021     39-7 Control System Step 1-3 - (6 hours)       Category: Controls

Spent more time setting up the rigs and the way of drilling than drilling the different parts. Due to a misalignment i had to replace one of the control sticks.
Matchdrilling done and final drilling completed.
Preliminary installation looks ok

  Feb 15, 2021     39-6 Control System Step 1-2 - (1.5 hours)       Category: Controls

Fabricate the spaces F-1063C and drilled hole 1/8".
Preassembled the Elevator Idler arm with the spacer and the VA-146 Flange Bearing. Matchdrilled and final drilled with #30 for -4 rivets.
Primed the different parts and final riveting with AN470AD4-6 rivets.

  Feb 14, 2021     39-3 Control System Step 1-5 - (5 hours) Category: Controls

Fabricated the F-1089 Elevator Push Rod assembly cutting to size the aluminum tube and match drilled for pop rivets using the paper templates (attention to the scaling when copying ....).
As per instruction i used the primer internally and let it dry for a couple of days.
Installed the VA-111 threaded rod ends and riveted using pop rivets.
Installed the rod bearings with jam nut and stored away waiting for preliminary assembly

  Feb 13, 2021     40-4 Flap System step 1-4 - (8 hours) Category: Controls

Preassembled the Flap Horn to the Flap torque tube-. Match drilled 4th e flap horn #30 and then final drilled #12- Primed inside all the parts. Done for left and right flaps.
Trimmed the four F-1030 bushing according to the indication. Due to some imprecisions i decided to reorder and to redo all the bushing. Result is now acceptable,
I tried a preliminary test installation and it is very hard to position the bushing correctly....a bit of soft hammering has been necessary.

  Feb 05, 2021     40-2 3 Flap Systems step 1-6 and 1-4 - (14 hours)       Category: Controls

Alignement of flap torque tube and flap crank. Clecoed using predrilled and matchdrilled 1/8. Bolted the flap crank to the torque tube and matchdrilled other holes installing second set of hardware.
Matchdrilled using the Jig. Everything went fine on one side, unfortunately second side something went wrong with the alignment. After consultation with VANS they reccommended to wait until final rigging as the problem may be resolve with the adjustments. In any case i ordered another torque tube and another flap crank
All the tubes have been primed internally.
Same process on both sides.

  Feb 02, 2021     38-5 Step 1-3 Rudder Pedals and Brake System - (1.5 hours)       Category: Controls

Match drilled the F-6115 Rudder Pedal bearing block to the F-1039 using #12 drill. Preliminary installation looks ok

  Feb 02, 2021     38-4 Step 1-6 Rudder Pedals and Brake System - (4 hours)       Category: Controls

Prepared the F-6115 Rudder Pedal bearing block. Modified the F-1039 Bearing Block Mounting plate.Final drilled Bearing Block Mount Plate.
Preliminary mounted the bearing pro on both longerons. Preliminary installation of both rudder pedal assemblies.
First fitting is with original white rods, then i decided to paint them black. I also decided to install the parking brake assembly.

  Jan 31, 2021     38-3 Step 1-5 Rudder Pedals and Brake System - (4 hours)       Category: Controls

Final Drilled for #12 hole. Installed the washer and nuts according to indication. Installed cotter pins. First installation didn't pass Lucio's Check. Redone according to indication bending the cotter pins along the bolt axis and cutting to measure to avoid entanglement.