EAA Builders Log Site

Project: 404BH -
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Categories

Show All Entries - (505)
Research
Workshop - (21)
Empennage - (9)
Fuselage - (159)
Firewall - (9)
Tail Feathers - (10)
Wings - (101)
Controls - (17)
Avionics - (32)
Lighting - (2)
Instrument Panel - (10)
Landing Gear - (14)
Engine - (59)
Propeller
Fuel System - (7)
Interior Finish - (26)
Paint / Decals - (26)
Inspection
Tools - (3)


Builder Name:	Greg Charest -

Project:	Companion - VIEW REPORTS
Total Hours:	2263
Total Flight Time:
Total Expense:	N/A
Start/Last Date:	Feb 09, 2020 - No Finish Date
Engine:	Lycomimg O-360
Propeller:	Catto
Panel:	Garm G3X

Friendly URL:	https://eaabuilderslog.org?s=404BH

Home or Last Project Picture

May 09, 2024 wing connections etc - (6 hours)

Category: Wings

Finalized most of the hardware and wing connections on the pilot side. I wanted some type of flow restriction in the site gauge lines to avoid having fuel released in the cabin in case of a leak or break. I was going to use a press fit rivet with a hole drilled in it but a friend suggested tapping threads in the aluminum AN fitting and drilling a hole in a hex screw. It worked beautifully.

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May 05, 2024 tail brace wires - (6 hours)

Category: Controls

Worked on getting everything level and installing the flying wires. With the wing and tail surfaces installed the tail is now to heavy to lift into a level flight position by hand so I needed to set up some jacks and make something to span the fuselage so I could jack it on the lifting handles. The bends on 1/8 4130 links that came with the kit were not even close to correct (should be 18, 29 and 59 degrees) so each one had to be adjusted and checked. In the end, the process took all day. I still need to get some additional AN4 hardware to finish.

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May 04, 2024 Rigging - (4 hours)

Category: Controls

Changed the rudder springs to a lighter set. The final springs are stainless steel, 2.75" Long, 1" OD, 0.075" wire diameter.
Rigged the ailerons using another builder's process and set the cable tension to about 28 lbs in the wings which creates about 38 lbs in the carry through cable.
Adjusted the elevator cables and added the trim tab rods. The bend in the trim tab rods needed to be moved forward a bit so I just applied a little pressure near the current bend with a tubing bender and they lined up nicely. The last step is to install the flying wires. So far everything is aligned and moves freely without significant friction.

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May 03, 2024 attach elevators, misc - (4 hours)

Category: Tail Feathers

Connected the trim cable, attached the elevators and trim tabs and attached the pitot tube. As soon as I connected the elevators I realized that the cover plate has a couple of screws that cannot be accessed because they align with the elevator rib - so a little re-work is in order to make the covers over. I think I can still use the lower half and just need to remake the uppers.

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May 02, 2024 aileron install - (3 hours)

Category: Wings

Torqued the aileron hinges to the proper point and installed and connected the ailerons. I still need to adjust the rigging etc. but they are working smoothly.

Note on the wing tips: one side fits pretty well, the other is pretty bad. At some point I will make my own to get both a better fit and a nicer finish,

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Apr 30, 2024 horizontal stabilizer - (4 hours)

Category: Tail Feathers

Started on the horizontal stabilizer. I needed to identify the correct hardware, ream out the attachment areas etc. During the process I realized that I still need to order the clevis/rod ends for the flying wires. Also the springs I have on the rudder pedals are too heavy and I need to source some that don't put so much static pressure on the cables/rudder horn.

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Apr 28, 2024 wing mounting - (6 hours)

Category: Wings

With the help of a couple of airport friends we put the wings on some stands and then bolted up the wing attach fittings and struts.

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Apr 27, 2024 paint booth removed - (6 hours)

Category: Workshop

Took the paint booth down and moved the fuselage back into the hanger in order to put the wings on.

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Apr 26, 2024 wing tips - (6 hours)

Category: Wings

Wing tip filling/sanding/painting completed. This is a significant milestone since these are the last large pieces to paint and the paint booth can be removed in order put the wings and stabilizer/elevator/rudder on the fuselage.

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Apr 24, 2024 wing tips - (2 hours)

Category: Wings

I painted the wing tips with primer to be able to better see the remaining pin holes etc., and there are a lot. Jack, one of the local RC model guys suggested I use a 2 part high fill primer (Evercoat Feather Fill) so I am going to look into it. Jack is an artist with models, check out the detail in the picture of a Champ model he built!

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Apr 20, 2024 paint, misc - (8 hours)

Category: Wings

Second wing finish painted.

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Apr 16, 2024 paint, misc - (8 hours)

Category: Wings

The other wing is etched and primed. Also started work on the wing tips. Measured the required length to match the aileron end, marked the attachment holes and started filling/sanding the fiberglass.

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Apr 10, 2024 paint, misc - (6 hours)

Category: Wings

One wing finish painted.

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Apr 09, 2024 paint, misc - (8 hours)

Category: Wings

A warm sunny day for a change and it was ideal for etching and priming a wing. It would have be nice to have some help with all the scotch-brite work but everyone is at Sun and Fun!

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Apr 08, 2024 paint, misc - (4 hours)

Category: Wings

Finished a little work on the wing prior to painting: added nut plates to the rib extension for the wingtip and riveted the last aileron cove cover. Ready for etching and primer.

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Apr 06, 2024 paint booth reconfig - (4 hours)

Category: Workshop

Moved the fuselage out of the temporary paint both and into another hangar so that I can paint the wings. This required taking the front of the paint booth apart and was a good opportunity for a general cleanup

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Apr 05, 2024 paint, misc - (2 hours)

Category: Tail Feathers

Finished the access panels are started cleaning the wings.

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Apr 03, 2024 paint, misc - (6 hours)

Category: Tail Feathers

Struts top coated. Wing access panels cleaned/scuffed/etched and painted with epoxy primer.

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Mar 30, 2024 paint, misc - (6 hours)

Category: Tail Feathers

Finished the fabric painting. Cleaned, scuffed and etched the struts and painted them with primer.

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Mar 25, 2024 paint, misc - (6 hours)

Category: Tail Feathers

While waiting for paint to dry I am modifying a lifting/spreader bar set up that a friend donated. It was for a Husky and needs to be wider for a Bearhawk so I am bolting on some extensions.

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Mar 23, 2024 paint, misc - (8 hours)

Category: Tail Feathers

Still working away on painting the flaps/ailerons/tail feathers.

Some reminders for Stewarts System EkoPoly
1) You MUST reach color saturation before the top coat. I'm painting white over the gray primer and it typically needs more that 3 tack coats. Without 100% color you will see shadows of the dark primer.
2) For the first tack coat use a light cross coat method and keep the gun a little farther away than normal to avoid any striping. Tiger stripes are easy to create and hard to cover.
3) Keep enough paint in the gun. Better to lose a little at the end than to run out or get an erratic spray pattern.
4) Don't rush the tack coats. Letting them dry a little more is better than too little.
4) Make the top coat heavy enough for a good wet, glossy finish. If the top coat is a little thin it will have different textures in different areas and this will be quite noticeable. You will be tempted to repaint which will end up weighing more than putting it on a little thicker the first time.

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Mar 17, 2024 Flaps/ailerons paint - (14 hours)

Category: Wings

Flaps and ailerons painted. Elevator/rudder next. I like Stewarts System paint but getting the proper amount of paint on the top coat can be an issue. I ended up with too little on the top of the ailerons and would like to repaint them. Since they are mass balanced the weight of the paint matters. Before repainting I needed to see how they currently balance so I installed the hinges and hung one from a handy support. Based on the current balance I can add nearly 3 oz of weight and still be slightly over-balanced (which is better than under) so I can scuff the tops and re-paint them without needing to increase the balance weight.

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Mar 11, 2024 Flap fabric - (6 hours)

Category: Wings

Both flaps now primed and ready for the topcoat paint. Also spent a couple of hours cleaning/reorganizing the shop so I can swap the fuselage/wings when the wings are ready to paint.

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Mar 06, 2024 Flap fabric - (2 hours)

Category: Wings

Finished the flap fabric.

Registered the ELT with noaa.gov. Received the aircraft registration from the FAA, now officially N404BH.

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Mar 05, 2024 Flap fabric - (2 hours)

Category: Wings

Got a couple more hours in to work on the tapes.

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Mar 04, 2024 Flap fabric - (3 hours)

Category: Wings

Finished rib stitching on the flap. Move the fuselage to give me a little more room to paint the tail feathers.

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Mar 03, 2024 Misc finish work - (6 hours)

Category: Fuselage

Painting the Bearhawk logo didn't turn out very well. I was not surprised as Stewart's paint relies completely on a mechanical bond and it wasn't really possible to adequately sand the base paint inside the small and somewhat delicate letters on the stencil. It looked fine but clearly was not well bonded to the paint below and would have started flaking off pretty quickly. Plan B was to use vinyl so I made up a version using a small vinyl cutter and it worked perfectly. Obviously plan B should have been plan A!

Poking around on the net while trying to decide on how to make some headset hangars and I found Axia Alloys. They make a variety of items designed for roll cages. Not only do they have headset hangers but also some sun visors that are a perfect fit in a Bearhawk. Not inexpensive but still 1/2 the price of a comparable Rosen Visors product.

Also worked more on the flap. Fabric is now up to the rib stitching stage.

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Feb 28, 2024 paint, misc - (4 hours)

Category: Engine

Painted the logo on the cowl. Also, when I was doing the fabric work, I left one flap undone. I'm finally getting around to completing it. Got the basic fabric on today. Still some work in the hinge coves, rib stitching, tapes and final shrinking to go.

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Feb 25, 2024 paint, misc - (2 hours)

Category: Engine

Prep for painting the Bearhawk logo on the cowl.

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Feb 24, 2024 Propeller and misc - (6 hours)

Category: Engine

Replaced the cracked acrylic window, installed the trim pieces for the rear windows, installed the prop and tightened and safety wired the alternator.

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Feb 23, 2024 windows - (2 hours)

Category: Fuselage

Installed the poly-carbonate windows in the baggage area. Installed the acrylic window in the pilot side frame but when I took the plastic off the co-pilot piece there was a significant crack so I'll have to cut out another one.

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Feb 22, 2024 interior re-install - (3 hours)

Category: Fuselage

Put the interior back in, including the painted trim and re-done carbon fiber sill covers, for what could possibly be the final time.

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Feb 19, 2024 paint, misc - (3 hours)

Category: Fuselage

Painted some trim pieces black.

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Feb 18, 2024 Sill protectors - rework - (3 hours)

Category: Fuselage

The first set was acceptable, but could have been better, so I laid up another pair today. I also added some sheet metal screws and finish washers to hold the carpet in place.

Update: new pieces look good, just need a surface coat of epoxy.

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Feb 16, 2024 Misc finish work - (4 hours)

Category: Fuselage

Finished the lifting rings. Connected the static ports. Safety wired the plugs on the GSU25 (important as the plugs are inverted and will fall out if the hand screws back out). Cut out the silicone rubber for the shock strut seals and will add the strut holes when I am ready to install them. Finally I installed the canvas cover in the baggage are to see how it looks.

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Feb 15, 2024 Misc finish work - (3 hours)

Category: Fuselage

Spent some time trimming/fitting things so that the doors work smoothly. Installed the OAT sensor. Finish riveting the data plate on.

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Feb 14, 2024 paint, misc - (5 hours)

Category: Fuselage

I finished the fuselage paint work except for an access panel and the strut boot covers on the belly. I needed a little extra trimming on the windshield fairing and window trim to get the door hinges to fit. The data plate needed to go on the fabric since I didn't create a fixed mounting point for it. I made a backing plate and used Stewart's glue to attach it on the inside of the fuselage. I will rivet the data plate to the backing plate. I also added a stainless steel strap that goes around (but does not touch) a fuselage tube. This should survive a crash/fire scenario.

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Feb 12, 2024 Painting - (2 hours)

Category: Fuselage

I had to fix an sag in the paint and since the area is small it is easiest just to repaint it. I also have some small issues with paint leaks under the fine line tape that I need to touch up. Once I do that, the fuselage paint will be complete.

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Feb 11, 2024 paint, misc - (6 hours)

Category: Fuselage

A lot of prep and masking to paint some stripes etc. Since the paint requires some wait time between coats, I made another set of lifting rings from 1/8 304 stainless. When the paint is finished I can measure and add the second hole.

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Feb 09, 2024 skylights/interior panels - (6 hours)

Category: Fuselage

Put the seat belts back in with the proper hardware. Mounted the panels that cover the wing root. Installed the skylights with screws and washers that have rubber seals to prevent leaks. The polycarbonate has oversized holes like the windshield to allow for expansion. Some of the screws will be used to attach the wing fairings so I left them all loose.

Also started the FAA registration paperwork and located a DAR that will do the inspection.

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Feb 08, 2024 lifting eyes - (3 hours)

Category: Interior Finish

Installed the seat belts and made a pair of lifting eyes to attach at the main spar fitting. The stainless steel I had on hand was 3/16 x1 which is overkill but these will work (at the cost of a couple of ounces in weight). I'll make another set using 1/8" plate at a later time.

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Feb 07, 2024 windshield - (6 hours)

Category: Interior Finish

Added an Adel clamp to keep primer line higher up under the panel to keep it away from the pilot getting in. I also connected the AOA indicator. I installed the windshield using some 1/16 thick felt from LP Plastics between the fairing and the acrylic. I held the felt back 3/16" or so from the edge of the fairing so that later I can use some 3M caulk material as a seal. Since the side attachment screws go through the windshield, the holes are drilled oversize to 1/4" for #8 screws. I put some silicone hose around the screw to allow for expansion and keep the screw centered in the hole.

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Feb 04, 2024 carpets and a cable rub vlock - (4 hours)

Category: Interior Finish

The right side rudder cable comes quite close to the seat belt attachment bolt (the pilot side clearance is fine) so I attached a rub block to hold the cable down 1/4" or so and prevent any interference with the seat belt fitting. I installed the carpet and did some final trimming. I also added some teflon anti-chafe tape to the bottom of the windshield to keep it from squeaking and maybe help it move a little. The general idea is to let the windshield float a bit to reduce the chance of it cracking. The holes for the side attachment points are oversized and I will put some plastic tubing around the screws to avoid metal to acrylic contact and allow for expansion/contraction.

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Feb 02, 2024 interior re-install - (2 hours)

Category: Interior Finish

Reinstalled the floor and interior panels after connecting antenna cables and checking bolts, cotter pins etcc.

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Jan 31, 2024 Misc finish work - (6 hours)

Category: Fuselage

Made some templates to use for making shock strut boots, added some nut plates for the boot flange pieces, reassembled the lower sheet metal pieces and put some spiral anti-chafe protection on the brake lines where they exit the fuselage.

Started on figuring out how to seal the windshield fairing. The black fabric in the picture is some thin wool felt I am going to use behind the fairing.

Update: after talking with my IA friend, I am going to use a combination of pressure sensitive adhesive felt from LP Aero Plastics and 3M strip caulk.

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Jan 28, 2024 shock strut boots - (6 hours)

Category: Fuselage

I made up the cover plates that hold the gear leg boots before I had fabric on the fuselage and they were not quite right so I made a new set. It took a couple of tries to get it right. I also had to resolve another sheet metal/fabric issue at an overlap joint on the lower part of the fuselage. The nut plates I used to connect the two aluminum pieces created some interference with the belly fabric. I needed a couple of holes in the fabric for clearance so I reinforced it with an aluminum backer glued to the fabric on the inside.

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Jan 26, 2024 punch list - (2 hours) Category: Engine

Finished up the firewall forward punch list.

Jan 21, 2024 insspection plate , engine details - (4 hours)

Category: Fuselage

Finished the fuselage belly inspection plate attachment. I found some some small, reasonably priced clip nuts and used them instead of tinnermans. In my experience, pk screws tend to fall out when installed inverted and I think these will be better. I also finished the engine punch list from the review.

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Jan 16, 2024 FF review - (2 hours)

Category: Engine

Asked a local IA to review my firewall forward installation and received a number of good corrections/recommendations. Also finished a bit of painting on the cowl.

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Jan 14, 2024 Cowl painting, door assembly - (6 hours)

Category: Paint / Decals

Painted the gray portions of the lower upper and lower cowl. Installed the windows in the doors, used some velcro to attached the interior door
covering, put the doors, boot cowl and the aluminum piece that is over the gear leg on the fuselage.

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Jan 12, 2024 paint, misc - (6 hours)

Category: Paint / Decals

More painting. I've been doing it slowly which has pros and cons. On the plus side I am finally getting to the point where I can get a nice finish with Stewart's paint. The wet coat has to be just right on the first pass.

I didn't think far enough ahead to add tabs or another mounting surface for the data plate so it will have to go on the fabric. I made a small backing plate and will add a strap that encircles, but doesn't contact, a fuselage tube. Worst case, in a fire, the data plate will still be attached to the fuselage frame.

Finished installing the pilot side rear access plate.

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Jan 05, 2024 prep work - (3 hours)

Category: Paint / Decals

Light sanding. taping, masking etc for fuselage pieces.

The monadnock nuts I have are a bit too long for the aluminum frame the screw into. Looking for shorter ones I found that they are $5 each at ACS! Back to tinnermans.

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Jan 04, 2024 inspection/access plates - (2 hours)

Category: Fuselage

Installed 3 of 5 inspection/access covers using tinnemans and pk screws. I have one access plate on the aft belly and I will use manadnock nuts for that one as I find sheet metal screws tend to fall out over time if they are installed upside down. The covers still need to be painted.

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Jan 01, 2024 Fueselage stripes - (4 hours)

Category: Paint / Decals

Re-work. Despite being pretty careful with the layout, the two sides of the airplane ended up quite different at the doors. We found one error but not enough to explain all the differences. Decided to just start again, carefully level the plane, reestablish a level line with the laser level and do it again.

1/1- 1/2

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Dec 31, 2023 Fueselage stripes - (4 hours)

Category: Paint / Decals

Laid out the fuselage design with some fine line tapes. Having zero experience with this I started with a level line from the split at the node bowl to the back and worked from there. Looks like it should work out ok. Changed to a vinyl type decal for the experimental placard. This one has tight kerning between the letters and fits nicely aft of the fuel gauge.

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Dec 30, 2023 paint layout - (6 hours)

Category: Paint / Decals

After painting the top section of the cowl and the top of the nose bowl, I installed them in order to layout the stripes on the side of the fuselage. During the process, I realized that it is really hard to access two of the nuts that hold the bracket air filter frame on the air box. OK, change it to use nut plates. Unfortunately, for some reason the gasket had bonded to the front of the air box so strongly that it couldn't be removed without tearing it up. What should have been a 10 minute job took a couple of hours! Nevertheless, next time it really will be 10 minutes.

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Dec 27, 2023 Painting - (2 hours)

Category: Paint / Decals

The windshield fairing needed a little more fitting so I did that and primed it along with the spinner.

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Dec 26, 2023 panel deck - (4 hours)

Category: Paint / Decals

Made a few adjustments in the front most floor panel to allow routing coax cables on each side. Installed the AOA display. Re-installed the boot cowl. The recommended amount of flattener I used in the black paint resulted in something closer to satin. Good enough and not worth the time to repaint it but if you are using Stewarts paint and really want flat you might want to try some tests before the final coat. It looks like I would have needed 50% more flattener than was suggested.

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Dec 24, 2023 Paint behind windshield - (4 hours)

Category: Paint / Decals

Painted the area under the windshield flat black to reduce reflections. It is made up from 4 different sections, three of which needed to be masked off. Used the windshield fairing trim as a guide for the paint line tapes. The wet paint was still fairly glossy, we will see how it looks when it is dry.

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Dec 22, 2023 side panels - (6 hours)

Category: Interior Finish

Fit the kydex plastic side panels and attached them with some aluminum clips I had previously made. I needed to install the floor panels to fit everything. I also temporarily hung one window and installed a door to check all the clearances.

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Dec 19, 2023 avionics checks - (4 hours)

Category: Avionics

Getting ready close things up so I went through the avionics wiring behind the panel to check, safety wire, etc. everything. Also added the panel label overlay for the primary switches. After powering things up one more time I can put the boot cowl and wind shield on more or less permanently.

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Dec 17, 2023 wind shield/fairing - (8 hours)

Category: Interior Finish

Installed 2 color engraved placards for flap setting, baggage weight limit and map/cabin light switches. Finished up the fiberglass wind shield fairing and added nut plates to attach it. Made up some small angle brackets to hold the windshield in place on the inside.

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Dec 11, 2023 Panel labels - (4 hours)

Category: Interior Finish

I used rub-on lettering for panel labels but I can already see that even with a clear coat over them, they are not going to be very durable. Plan B is some sort of overlay so I've been working on creating engraved overlays using a small hobby grade CNC router. These machines are inexpensive but lack both rigidity and accuracy - still, with some care, they work pretty well. The picture shows one done in 2 layer plastic and another in 2024 aluminum.

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Dec 11, 2023 wind shield/fairing - (8 hours)

Category: Fuselage

Created the windshield fairing with 8 layers of fiberglass. After some rough trimming, it looks pretty good. It still needs some filling/sanding etc.

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Dec 05, 2023 wind shield/fairing - (4 hours)

Category: Fuselage

Taped up everything in preparation for laying up the fiberglass.

Also added some aluminum clips to attach the kydex interior pieces.

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Dec 03, 2023 wind shield/fairing - (4 hours)

Category: Fuselage

Re-installed the wind shield in order to lay up the fiberglass fairing. Should have done this before painting the boot cowl pieces but it's not a big issue. I located and drilled the holes in the aluminum trim pieces and temporarily screwed things together for the fairing layup.

Also added a 90 degree tube adapter on the cabin heat box so that the continuous hot air flow is directed toward the cowl outlet and away from some wiring and fuel lines.

Made an overlay for the air cooler control to add labels etc. I am experimenting with a hobby grade CNC machine and this is the first effort at engraving. 2 layer plastic to start, aluminum later. There is a mountain of stuff to learn regarding CNC machining but engraving is pretty easy and the result is excellent.

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Nov 25, 2023 Map updates and GDL-50 check - (3 hours)

Category: Avionics

Configured and checked the RS232 connection to the GDL-50 and updated the map databases since I had a free update. Also finished adding nut plates to the other wing for the wing tip attachment.

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Nov 23, 2023 GDL-50 - (4 hours)

Category: Avionics

Built the wiring harness to connect the GDL-50 to the MFD and finished the installation. There needs to be enough of a service loop in each connector to allow the display to be easily removed from the panel. The ADSB unit will get GPS data via the RS232 connection from the MFD so I don't need a separate GPS antenna for it.

I also replaced the battery in the IBBS. I got the backup battery for free the lithium cells were a few years old. Since replacing them in the future will require working under the panel, I decided to do it now when the boot cowl is off.

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Nov 21, 2023 GDL-50 - (1 hour)

Category: Avionics

Mounted the GDL-50 remote ADSB receiver.

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Nov 21, 2023 Fuel/oil connections - (1 hour)

Category: Engine

Torqued the remaining fuel and oil line connections

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Nov 19, 2023 Aluminum pieces - (6 hours)

Category: Paint / Decals

Top coat applied to all of the misc pieces except for some cover plates etc. The shop is usually around 65, this time I increased the temp to >70 and the Stewart's paint seemed to go on a bit easier.

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Nov 17, 2023 Doors/windows - (6 hours)

Category: Paint / Decals

Primer on the doors and window frames. This is my first time using Stewart's epoxy primer and it is pretty easy to apply. Not critical with respect to viscosity and goes on well.

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Nov 13, 2023 more parts primed - (4 hours)

Category: Paint / Decals

Primed some more pieces. I decided to add an ADSB-in receiver which requires an additional antenna. Since I don't want the transponder and ADSB antennas too close to each other, I had to move the existing transponder antenna location. The small panels that bridge the tunnel to boot cowl on each side are a reasonable spot.

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Nov 12, 2023 Aluminum pieces - (6 hours)

Category: Paint / Decals

Cleaned, roughed up with scotch brite and acid etched some aluminum fuselage pieces. Painted them with Stewart's epoxy primer. Still have to do the doors and window frames.

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Nov 10, 2023 Wing light disconnects, courtesy/map lights, wing tip nut plates - (6 hours)

Category: Lighting

Finished wiring the wing tip light disconnect deutsch plugs, tested the courtesy and map lights and added nut plates on every 4th rivet on the outboard end of the one wing to use to attach the wingtip.

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Nov 09, 2023 Misc wiring and firewall forward checks - (4 hours)

Category: Avionics

Updated the G3X displays to the firmware version 9.31. Also did a rough configuration of the EIS settings. Spent some time cleaning up and securing wiring and continued checking/tightening hardware in the engine bay. Added the wing/fuselage disconnect for the MU11. Still need to do them for the wingtip lights.

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Nov 01, 2023 Avionic testing - (8 hours)

Category: Avionics

Checked power and ground circuit/pins for all the avionics boxes. This will let me power everything up without worrying about letting the smoke out ;-)

11/4 update: after a couple if hours of fiddling, everything but the transponder and magnetometer (not yet connected) is communicating. The transponder issue is probably a wiring error as it uses an RS232 connection through the GSU25.

11/5 update: added the magnetometer. Still stuck on the transponder issue but I may have found the problem - it looks like I have to use TX/RX 3 on the ADAHRS instead of 1. TX/RX3 is on the other connector so switching the serial connection might be the answer.

11/6 update: switching to TX/RX 3 on the other connector fixed it. With everything working, the boot cowl can go back on so I can install the windshield and make the fiberglass fairing strip..

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Oct 29, 2023 Wiring cleanup - (6 hours)

Category: Avionics

Added the last connectors for the engine monitoring system. Started electrical testing.

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Oct 28, 2023 wiring cleanup - (6 hours)

Category: Avionics

Cleaned up and laced most of the avionic, sensor and engine wiring. Everything is labeled and fairly well laid out. Like always, the next time will be better now that I have some experience! Just a couple more connectors on the EIS and then I can ring out and power check all everything.

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Oct 22, 2023 Doors, windows - (8 hours)

Category: Fuselage

Built a wing rotisserie from some Harbor Freight engine stands. Also fit the doors, added trim pieces and the stainless steel striker plate for the door latch pin.

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Oct 22, 2023 Doors - (8 hours) Category: Fuselage

Fitted the doors and attached a trim piece and a stainless steel striker plate so that the latch pin doesn't damage the fabric. Spent most of the time refitting some Harbor Freight stands to make a wing rotisserie for painting.

Oct 15, 2023 Doors

Category: Fuselage

Riveted the door skins to the frames including the hinge and small 'mouse' door for wing strut clearance. Spent a few additional hours modifying some HF engine stands to use for a wing rotisserie.

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Oct 14, 2023 Painting - (4 hours) Category: Engine

Put a light coat of epoxy primer on the insides of the boot cowl and cowl.

Oct 08, 2023 Engine electrical - (6 hours)

Category: Engine

Finishing up the firewall forward work - wired the regulator, routed and attached misc engine wiring. Added a small fan to the panel top section that will help a bit to cool the avionics and defrost the windscreen a bit. Finished up attaching the exhaust.

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Oct 07, 2023 Breather tube - (6 hours)

Category: Engine

I spent an embarrassingly long time trying to get a satisfactory breather tube setup. Unfortunately the fitting on the engine points directly at an engine mount tube. A 45 degree fitting would have solved the alignment problem but there was no way to thread it on without removing the engine from the mount (not 100% sure that that would be enough either). So the breather tube had to go under or over the engine mount tube. Tried bending the 3/4 aluminum tubing in multiple ways but the bends need to be too close together and too precise for the tooling I have. The final solution was to use some expensive lined (oil resistant) silicone tube to go under the mount tube and a simpler piece of aluminum for the rest.

Also added the last set of nut plates to the lower firewall flange to attach the cowl and replaced the alternator belt with a 7460 which is a bit smaller and leaves more adjustment for the future.

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Oct 01, 2023 Engine and cowling - (6 hours)

Category: Engine

Filled a few more imperfections on the nose bowl and checked the landing light fit. Finished wiring and attaching the CHT and EGT sensors on the co-pilot side. Decided on the final routing for carb and cabin heat scat tunes and cut and attached them. Replaced a couple of rocker oil return tubes that needed to be modified after the baffling was installed. Worked a little more on engine wiring (added a couple of in-line fuses for the shunt that measure alternator charge.

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Sep 30, 2023 nose bowl finishing - (5 hours)

Category: Engine

More sanding and filling of the nose bowl to get ready for paint. Added the rest of the nut plates and primed it in order to see any last spots that need work.

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Sep 23, 2023 Firewall forward/nose bowl - (8 hours)

Category: Engine

Put filler on the nose bowl - more sanding needed. Wired the CHT, EGT and other sensors (still need to wire ALT Current . Removed prop to install alternator belt, clock ring gear and torque starter and alternator bolts. The Gates 7465 belt recommended from the B&C site will work but the tension adjustment will be near the end of it's travel and if/when the belt stretches I may not have much to work with. Gates has many different versions of this v-belt so I am going to try a 7460 which is a bit shorter.

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Sep 21, 2023 Engine and cowling - (4 hours)

Category: Engine

Replaced some temporary nuts with metal lock nuts, spent some time trying different routing for scat tube, safety wired the oil filler tube (I used a o-ring for the gasket but have 2 other types to try if it leaks) and worked a little more on the taxi light mount.

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Sep 19, 2023 Exhaust - (2 hours)

Category: Engine

Reinstalled the muffler portion of the exhaust system. Put a layer of fiberglass on the lower cowl for the light mount.

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Sep 17, 2023 Baffling completed - (8 hours)

Category: Engine

Riveted and finally finished the baffle seals. Installed the ignition harness (New Horizons, Maggie Systems). Started on modifications to the lower nose bowl for the landing light.

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Sep 14, 2023 Misc, plumbing, baffle seals fitting, taxi light - (4 hours)

Category: Engine

Added some fire sleeve around the oil pressure sensor line that I had neglected to add when I installed the line. Trimmed some baffle seal in a few spots, decided on a location and mounting approach for the Baja Pro 2 taxi/landing light.

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Sep 10, 2023 cowl etc - (3 hours)

Category: Engine

Riveted the top cowl and doors together. First fitting on the baffles. Will need some trimming and adjustment but are close.

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Sep 09, 2023 cowl etc - (8 hours)

Category: Engine

Added nut plates to the nose bowl top section and side rails, finished dimpling the top cowl center section, tightened and marked all the AN lines for the brakes and the fuel system below the floor, finished drilling/clecoing the baffle seals. Drilled a hole in the tunnel for for the gascolator fuel drain.

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Sep 04, 2023 Baffle seals - (2 hours)

Category: Engine

All of the seals are temporarily attached. Now I can check the cowl fit and then attached them permanently.

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Sep 03, 2023 Baffle seals - (6 hours)

Category: Engine

Spent a couple of hours cleaning the shop and then started the baffle seals. Paper patterns completed, rear portion fitted.

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Sep 02, 2023 cowl etc - (3 hours)

Category: Engine

Put the cowl back on and trimmed and sanded portions of the nose bowl to make sure that there was no rubbing or binding on the ring gear, flywheel etc.

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Sep 01, 2023 cowl etc - (4 hours)

Category: Engine

Finished the lower cowl and added the nut plates to the lower nose bowl section. Also install the stainless steel roll at the bottom of the firewall that may help with smoother airflow out of the engine bay.

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Aug 26, 2023 cowl etc - (11 hours)

Category: Engine

Riveted the airbox cover/scoop together. Used pan head screws/nut plates with nylon washers to hold on the front piece since it will be removed fairly frequently to change the air filter and these should avoid some paint chipping etc.

Update 8/27 - another 5 hours of cleaning up the pieces, de-burring, dimpling, adding nut plates and riveting. One more session to go to attach the air box cover.

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