May 22, 2024     Oil & Fuel Pressure transducer manifold Category: Firewall

Installed oil & fuel pressure transducer manifold on firewall with appropriate fittings and plugs installed.

  May 22, 2024     Exhaust heater muff Category: Engine

Installed exhaust heater muff on cylinder #1 exhaust pipe.

  May 20, 2024     Engine fittings, brackets & throttle linkage Category: Engine

Installed oil restrictor fitting and manifold pressure fitting on engine.
Installed manifold pressure restrictor fitting on firewall.
Installed throttle and mixture brackets (blue threadlocker used on engine case studs/nuts due to no threads showing beyond nut).
Installed throttle linkage assembly.

  May 12, 2024     Exhaust System       Category: Engine

Installed Vetterman stainless steel exhaust system. Can't wait to hear that sound!

  May 07, 2024     Battery Box Category: Firewall

Installed EarthX BB-TH thermal battery box on engine side of firewall, low on right side. Installed using #8 pan head screws on aft side of firewall, washer and nyloc nuts on engine side.

  Apr 29, 2024     Engine - Lower isolation mounts - (3.5 hours)       Category: Engine

Installed both lower engine isolation mounts. Not an easy task! Having at least three pair of hands and experienced mechanics was very helpful.
Hole alignment on both sides were at least 3/4 of a hole out.
The lower left mount was accomplished by allowing the hard rubber mount to ride outside of the engine mount/weldment cup, then finagling the bolt through the soft & hard rubber mounts into the engine case hole. A socket wrench and/or hammer was required to tap the bolt through while trying to slip the rubber mounts into place with any means possible (don't forget dish soap on the mounts). Fortunately, the threads were not damaged and a nut/washer were loose installed to pull the lower left isolation mounts into place.
The lower right side mount was considerably harder to install. A few different ideas were tried, but a strategically placed beefy broom stick provided enough leverage on the hard rubber mount to distort it into just enough alignment with the engine case hole (in the 5 o'clock position). Again, a socket wrench and hammer was used to slightly thread, then hammer tap, the bolt through with a nut/washer used to pull the lower right isolation mounts into place.

  Apr 26, 2024     Engine - Upper isolation mounts - (2 hours) Category: Engine

Installed both upper engine isolation mounts. Not as easy as I thought it would be.
First, the extremely old Harbor Freight engine shop hoist failed to lift the engine more than a few inches. Harbor Freight provided an entire new hoist (with folding/removeable legs) for only the cost of a $69.99 Repair Plan. After new engine hoist assembly, the upper right mount was the installed, and loose attached.
The upper left mount was more difficult to install, and accomplished by allowing the soft rubber mount to partially ride outside of the engine mount/weldment cup, then finagling the bolt through the the assembled mount into the engine case hole. A socket wrench and hammer was required to slightly thread, then hammer tap, the bolt through while trying to slip the rubber mounts into place with any means possible (dish soap on the mounts is a good idea). Fortunately, the threads were not damaged and the nut/washer were loose installed to pull the upper left isolation mounts into place.

  Apr 25, 2024     Engine - Unboxed       Category: Engine

Removed engine box cardboard and packing foam.

  Apr 19, 2024     Prop Governor (Hartzell)       Category: Invoices

Hartzell prop governor plus misc hardware previously deleted from firewall forward kit.

  Mar 28, 2024     Starter Solenoid Category: Firewall

Installed starter solenoid on firewall. Investigated battery location options on firewall and in forward baggage compartment.

  Mar 17, 2024     Wheel pants       Category: Landing Gear

Located, aligned and temp installed the wheel fairings with clecos only. Trimmed cutouts for approx 5/8" tire clearance all around. This process occured over several days with the help of another builder. Final installation will occur at a later date when I have fiberglass resin and plies available to reinforce the attach points per Van's recommendations.

  Dec 15, 2023     Installed wheel/axle sets       Category: Landing Gear

Greased wheel bearings with Aeroshell 22 grease. Installed wheel/axle sets with shims to reduce toe-in. Slightly modified the inbd wheel fairing attach brackets to allow easy intallation and removal of the brake calipers on both sides.

  Oct 14, 2023     Main landing gear installation Category: Landing Gear

Installed both main landing gear legs. Torqued attached bracket hardware and inboard gear leg pivot bolts.
Temp installed axles on both sides, then string measured from axle to axle per Van's drawing 45.
Discovered toe-in on both axles, and measured for shim correction per groveaircraft.com.
Left side: approx .25 degrees of toe-in
Right side: approx .33 degrees of toe-in
Ordered (2) .25 degree Grove axle shims (Grove p/n 6101-1) from Aircraft Spruce.

  Oct 07, 2023     Main landing gear attach brackets and wear plates Category: Landing Gear

Installed main landing gear wear plates & attach brackets.Torqued the wear plate attach hardware on both sides.

  Sep 26, 2023     Bolt head retainers for outboard landing gear attach       Category: Landing Gear

Installed bolt head retainers to the (4) outboard landing gear attach bolts using JB Weld. These bolts will be installed in the opposite direction from the engineering drawing to facilitate single person torquing from outside the aircraft. Note: installing the bolts from the top down requires removal & replacement of two AN509-8R bolts & nuts each side for bolt head & retainer clearance. Bolt head retainers were sourced from Eversen Performance Products, Mil-Spec Hardware @ $6.50 each (1/2" (.500") Bolt Keeper size).

  Sep 09, 2023     Engine Mount Installation Category: Fuselage

After several days and many hours analyzing the task, the engine mount was installed to the firewall. Not an easy task due to post-welding cool down distortion in the engine mount weldment. The weldment hole pattern of full size 3/8" holes did not match the firewall hole pattern of 3/16" undersized holes. The firewall hole pattern matched engineering within 1/16", but the weldment diagonal measurements were 3/16" less than engineering (calculated). The left & right top-to-bottom hole measurements were 5/16" & 1/4" less than engineering (calculated). There was no "best fit" scenario where the weldment full size holes would fully consume all undersized holes in the firewall. Some amount of pre-load would be required to install the weldment without a "snowman" hole condition in 2 of the 4 holes.

With moderate use of two ratcheting bar clamp/spreaders (Harbor Freight or similar), I was able to temporarily bench expand the weldment enough to bring the full size hole pattern into dimensional alignment with the firewall hole pattern. Knowing this, I decided to drill the firewall holes to full size using a deep cutting step-drill to get as far as possible, then finished with a 3/8" twist drill. It took a bit of wrangling/expanding to align and insert the last 3/8" bolt into the engine mount, but once started, a socket wrench was used to "thread" the bolt approximately half way into the smooth bore of the weldment mounting hole, followed by tapping the rest of the way through using a hammer. With all bolts, washers & castle nuts installed, the mount easily pulled up flush to the firewall.

  Aug 12, 2023     Moved to airport       Category: Workshop

Moved project to airport where final assembly and first flight will take place. A friend with a flatbed rollback tow truck made moving the large parts pretty easy in two loads. Fuselage, engine & workbench in load one. Wings, box containing already trimmed canopy (future workbench/junk collector), and horizontal stabilizer in the second load. All control surfaces, a collection cowlings & fairings, and miscellaneous small parts were previously moved to the airport in June with the help of another friend via pickup truck.

  Jul 26, 2023     Wing skin, lower, left, outboard       Category: Wings

Riveted left wing outboard bottom skin with aid of Joe Andre.

  Jul 22, 2023     Wing skin, lower, right, outboard       Category: Wings

Riveted right wing outboard bottom skin with aid of Joe Andre. Mostly done per Van's instructions, working inboard to outboard, but only riveting approximately 1/3 down (aft to fwd) to allow the skin to be pulled up (fwd to aft) until the rear spar rivets out to mid-wing can be completed. At mid-wing, with all inbd rivets installed, all clecos must be removed so the skin can be pulled back (outbd to inbd) to allow easy access to shoot the mid/outboard wing rib bays for all rivets using large lightening holes in ribs as necessary. Installed (1) MK-319-BS rivet in skin location c/t one flange of the reinforcement bracket installed per SB 16-03-28 at inbd aileron hinge due to no access for bucking bar (the end of the reinforcement bracket had to be round filed to allow full insertion of MK-319-BS rivet prior to pulling). The other flange of the reinforcement bracket has just enough clearance for bucking the AN426AD3-3.5 rivet using a tungsten bar.

  Jul 19, 2023     Wing skin, lower, right, inboard Category: Wings

Riveted right wing inboard bottom skin with aid of Joe Andre.

  Jul 12, 2023     Wing skin, lower, left, inboard Category: Wings

Riveted left wing inboard bottom skin with aid of Pier, then Joe Andre on the rivet gun. All riveting accomplished in wing cradle with wing oriented aft/up, fwd/down. See subsequent photos for red towel covered bench used to gain access to aft spar rivets. Lying on my back, the bench allowed comfortable access to buck the rear spar rivets using my beloved tungsten bucking bar. Strategically placed clecos aid location and steadying the bucking bar inside the wing relative to the rivets in work, especially when riveting the fwd/aft rivet rows, but inbd/outbd as well. The approximate 0.2" cleco tip inside the wing provides an anchor point for one end of the bucking bar, while finger tips control and apply back pressure over the rivet in work.

  Jul 05, 2023     Lower wing skin access panel cutouts Category: Wings

Installed nutplates c/t all lower skin access panel cutouts.

  Jul 03, 2023     Roll Servo Installation       Category: Wings

Completed roll servo installation with safety wire, installed zip-tie base mounts, and secured the wire harness connection.

  Jun 26, 2023     Roll Servo Installation Category: Wings

Installed roll servo in right wing. Replaced (1) AN3-6A with AN3-7A c/t the upper/right aileron bracket/servo bracket stack-up. Inserted servo wire harness in nylon braided sleeve and routed to servo through corrugated wire conduit from wing root.

  Jun 24, 2023     Replaced nutplate c/t left aileron bellcrank bracket Category: Wings

Removed & reinstalled left wing tie-down bracket from the main spar for replacement of the lower/inboard nutplate c/t aileron bellcrank bracket. Torqued the AN365-1032 nuts/bolts to 37 in-lb (23+14 friction), AN3-6A bolts c/t nutplates to 42 in-lb (28+14 friction) and AN365-428 nut to 65 in-lb (50+15 friction)

  Jun 23, 2023     Safeair1 Pitot/AOA Probe Category: Wings

Installed Pitot/AOA nylon tubing through the left wing to the probe location using spiral wrap wiring conduit for anti-chafe protection under aileron bellcrank and in rib bay c/t probe. Trimmed aluminum tube to appropriate length and installed AN-816 flared tube fittings for connection to nylon tubing. Drilled probe attach holes to the stand-off base.

  Apr 04, 2023     SV-BAT-320 Backup Battery Test       Category: Avionics

Performed Dynon SV-BAT-320 Backup Battery Test - TEST RESULT: PASS, BATT LIFE > 45 MIN
Approximately 12 hours were required for initial battery charge prior to test, then approximately 6 hours to re-charge after test.
Power supply used to power the Dynon EFIS & battery charging was Pyramid PS9KX / 13.8V / 5A constant
During charge cycle, power supply voltage initially dropped to 9.6V followed by continuous auto-resetting until a steady state "charge" was achieved.

  Aug 11, 2022     Pitch Servo wiring - (4 hours) Category: Avionics

Trimmed Pitch Servo wire harness to length and installed Dsub for connection to 5-port network hub located on upper forward baggage bulkhead behind SV-HDX1100 PFD. The servo wire harness was previously laid in place through conduit from the pitch servo actuator to under-seat location. Installed expanded braided sleeve (PET) over the loose gangle of 7-wires to facilitate wire run from under-seat location to the network hub. PWR, GND, and CWS disconnect wires will remain separate for connection to same wires from Roll Servo wire harness and later connection to PWR, GND, and control stick CWS switch.

  Aug 10, 2022     Avionics Wiring - (8 hours)       Category: Avionics

Fabricated wire harness between Dynon SV-COM-425, SV-COM-PANEL, and SV-INTERCOM-2S. Added ground wire terminations to the Intercom-2S end of the shielded wires from headphone and microphone jacks using solder sleeves. PTT wire connection at Intercom-2S end will be made at a later date.

  Apr 25, 2022     Firewall Forward Kit       Category: Invoices

Less MT Prop Governor. The 2nd invoice includes back-ordered items.

  Dec 06, 2021     Hand Hold - Right Side - (2 hours)       Category: Fuselage

Drilled and temporary installed after-market hand hold to right side of windscreen support.

  Dec 05, 2021     Hand Hold - Left Side - (2 hours) Category: Fuselage

Drilled and temporary installed after-market hand hold to left side of windscreen support.

  Dec 04, 2021     Hand Hold - Layout - (1 hour) Category: Fuselage

Experimented with various locations for two after-market hand holds to be installed on wind screen support.

  Sep 10, 2021     Canopy Skirt Category: Fuselage

Trimmed canopy skirts to near-net for fit check.

  Dec 12, 2020     Van's Service Bulletin SB-00031: QB Fuselage Firewall Fasteners - (.1 hour) Category: Bulletins

SB-00031: In compliance. The Quick Build fuselage firewall fasteners are correct, no rework required.

  Dec 11, 2020     Dynon SV-Network cable rework Category: Avionics

Reworked (2) Dynon 36" network cables into (4) 18" network cables.

  Dec 10, 2020     AP servo motor wiring Category: Avionics

Installed D-Sub pins and connectors on both AP servo motors.

  Oct 25, 2020     Van's Service Letter SL-00014: Tailcone Stiffeners Category: Bulletins

SL-00014: In Compliance. Installation of (2) F-00773A stiffeners to the interior surface of tailcone skin under horizontal stabilizer is complete.

  Aug 21, 2020     ADSB-In antenna Category: Avionics

Installed ADSB-In antenna (1090 MHz) aft of pitch bellcrank using DAP 230 sealant, star lock washers and fiber locknut. Installed resistence = 0.3 ohm.
According to Dynon SkyView System Installation Guide, "Because the SV-ADSB-470/472 is receive-only, and the transponder frequency is “close” in frequency, any antenna suitable for use with a 1090 MHz transponder will work with the SV-ADSB-470/472".

  May 27, 2020     Van's Service Bulletin SB-00006: Kavlico Pressure Sensors Category: Bulletins

SB-00006: In Compliance. Received (2) updated Kavlico Pressure Sensors P/N 103757-000 Oil/Fuel/Coolant/Fluid Pressure Sender - Kavlico v2, 1/8-27 NPT, 150 PSI from Dynon. Dynon exchanged my uninstalled legacy sensors (P/N 101693-000 and 101716-000) purchased in 2019 for the updated v2 model. Cost = old return/exchange value plus new cost difference, tax and shipping.

  May 22, 2019     Finish Kit       Category: Invoices

Van's finish kit less spinner; add lightweight tail wheel.

  May 22, 2019     Purchased fuel pump & filter Category: Fuel System

Van's ES-AIRFLOW PUMP-1 (fuel injection) and ES-AIRFLOW FILTER

  May 20, 2019     Avionics Purchased from Stein Air Category: Avionics

Dynon Avionics, Vertical Power VP-X Sport, Wiring Kit, switches, dimmer, Etc.

  Jun 05, 2018     Van's Service Bulletin SB-14-01-31: H-Stab spar doublers Category: Bulletins

SB-14-01-31: In Compliance. Installation of doubler plates c/t H-stab front spar is complete.

  May 17, 2018     Purchased Throttle Quadrants Category: Controls

Van's CT 82F Deluxe 2 Lever Quadrant (front seat), CT 81R (rear seat), and clevis assembly. Includes shipping & tax.

  Jan 22, 2018     Van's Service Bulletin SB-16-03-28: Inbd aileron hinge bracket - (2 hours) Category: Bulletins

SB-16-03-28: In Compliance. Installation of doubler brackets c/t both inboard aileron hinge brackets is complete. Work was accomplished during initial installation of the aileron hinge brackets, no tear down required.

  Jan 21, 2018     Van's Service Bulletin SB-16-12-16: Center section bolts - (2 hours) Category: Bulletins

SB-16-12-16: In Compliance. Installed and torqued (12) center section AN4-11A bolts, washers, and nuts to 60 in-lbs. These are the bolts that were not installed during "Quick Build" in Philippines. All bolts were intentionally installed with nut on forward side of the Fwd 3/4 bar & bulkhead, the upper row of (6) bolts would only install that way apparently due to slight hole misalignment between spar and web (factory mis-alignment).

  Dec 04, 2017     Quick Build Fuselage Pick-up       Category: Fuselage

Drove to Van's and picked up Quick Build Fuselage in 26' U-Haul truck.
Includes: manual aileron trim, in-flight adjustable rudder pedals, rear seat rudder pedals and upgraded fuel valve (Andair FS 20X7T).
Note: manual aileron trim scrapped and subsequently replaced with electric aileron trim.

  Jun 25, 2012     Wing Kit Delivered Category: Wings

Began inventory of wing kit contents.

  Oct 08, 2011     Rear Spar Assy - (4 hours) Category: Empennage

Rear Spar Assy, final drilled HS-603PP & HS-609PP, HS-412PP & HS-413PP to #30

  Sep 08, 2011     Began construction of Horizontal Stabilizer Category: Empennage

Finally started construction, 5 months after empennage kit purchase. (work and travel commitments)
Radiused both HS-609PP horizontal spar reinforcements.

  Apr 08, 2011     Purchased Empennage Kit Category: Empennage

Drove to Van's, took factory demonstration flight and purchased the Empennage kit w/electric elevator trim.