Mar 15, 2024     Cabin Top       Category: Fuselage

Dug out cabin top and marked the 2 x 7 holes on mid cabin decks.
Cut off the rear excess joggle width with a dremel wheel and a pen grinder.
Mounted the cabin top on the fork lift.
Started running the scribe lines with a marker.
Finished scribe lines, trimmed side windows and front window.
Trimmed rear bottom including rear side of door frame.
Built aluminum frame that resembles the fuselage door cutout to make it easier to sand the canopy to size.
Trimmed the bottom rear edge to 0.75 in and used Dremel to make joggle square.
Fabricated sandwiched aluminum stack with 1/8 wide slot.
Final fitting of the cabin top. After minor sanding corrections, the cabin top fit well.
Trimmed around the door entrance to about 1/8 thickness.
Trimmed intersection with front panel cover.
Marked rear interference with bulkhead.
Sanded rear edge and right bottom corners for final fit.
Filed and sanded rear joggle step.
Assembled everything for cabin top match drilling.

  Mar 02, 2024     ELT       Category: Avionics

Tested ELT antenna when it has proper ground plane.
Mounted ELT on carrier bracket, so ELT is parallel to the door bottom sill.

  Mar 02, 2024     Servo Swap       Category: Avionics

Received new servos from Garmin and exchanged the previous yaw and pitch ones.

  Feb 26, 2024     Flap Controls       Category: Fuselage

Started match drilling the torque tubes for the flap controls.
Finished match drilling, manufactured the bearings.
Made the spacers but they need to be thinner than spec-ed.
Enlarged the holes in the side and rib skins.
Test-mounted the flap motor and torque tube.
Printed all pipes from the inside.
Adjusted the spacer's thickness to fit the motor.
Final-mounted the flap controls.
Did math for POS12 position sensor, attach point need to be 10.44 mm over tube surface to have the sensor run from 5% to 95%.
Tried 10.4 mm but setting the optimal rotation wasn't easy. One of the two ends often showed the maximal resistance, so risk of mechanically running the POS-12 towards its end stop. Drilled a new hole, about 9.5 mm above the tube and resistance was repeatedly running between 160 Ohms on one end and 4.3 kOhm on the other (mechanical min is 6 Ohms, mechanical max is 4600 Ohms).
Changed the hinge bolt from 4 mm threaded to 4 mm non-threaded.

  Jan 26, 2024     Control System       Category: Fuselage

Cut the center elevator pushrod out of 1.5" to length (previously painted on the outside since I had extra paint).
Printed hole pattern, taped it on and drilled #40 pilot holes.
Match drilled holes into the rod ends.
Cut the front elevator pushrod out of 1 1/8" to length.
Printed hole pattern, taped it on and drilled #40 pilot holes.
Match drilled holes into the rod ends.
Fabricated shim for elevator idler arm, drilled one hole and match drilled 2 more from idler arm into the shim.
Primed all parts. Pushrods primed inside using a sliding plug and an inch high of primer.
Drilled safety wire holes and riveted the rod ends to the rods.
Assembled rod end bearings and established correct hole to hole length (threads calculated to be 0.39 into the rod ends).
Added safety wire loop for one of the rod ends.
Assembled F-1090 push rod.
Assembled 2 x F-1064 push rods
Assembled F-1065 push rod.
Riveted elevator idler arm.
Removed battery mount / bellcrank in tailcone. Threaded in both elevator push-rods.
Boltet rear push-rod to bellcrank.
Removed Garmin servos to execute recall.
Bolted battery mount / bellcrank back in.
Mounted idler.
Connected rods to idler.
Drilled control stick / holder.
Mounted control column.
Fitted bearing into control stick base.
Fitted control stick bases into control column. Added grease to outer surface of brass bushing.
Primed aileron pushrods.
Mounted control sticks and adjusted connecting rod to achieve parallel orientation (needed some 5 turns shortening).
Test mounted control sticks.
Reinstalled horizontal stabilizer and elevators.
Shortened the control stick and manufactured a 3D printed inset that corrects the Tosten grip angle. Checked for panel interference.
Ordered manufacturing of the adapters.
Tapped the set screw hole and mounted the grips with the adapters.
Mounted the control sticks and removed interference with powered file.
Added aileron push-rods.
Added rubber boots over aileron push-rods.

  Jan 20, 2024     Fuel Lines       Category: Fuselage

Installed fittings.
Installed under-seat fuel inflow fuel lines.
Reinstalled fuel pump shelf and fuel pump.
Reinstalled fuel valve.
Installed fuel hose between valve and pump.
Installed fuel hose between pump and firewall.
Installed fuel hoses between valve and tunnel rib fittings.
Installed fitting for return line in firewall.
Installed return line from valve to firewall. Fabricated standoff holders for Adel clamps that hold the return line.
Added grommets and installed the under seat return fuel lines.
Mounted the four F-1084B Sytems Bracket Clips.
Fabricated standoffs for brake fluid reservoir and re-mounted the reservoir.

  Jan 04, 2024     Brake Lines       Category: Fuselage

Reamed main gear weldments to 7/16 for 45 degree fittings. Painted reamed hole with rust protection paint using a nylon cord with stripe of paint.
Enlarged center holes in tunnel ribs for fuel lines and installed brake fittings in the aft holes.
Put 2 ID 0.375 (3/8), OD .469 (15/32) grommets each on under-seat brake lines.
Enlarged the F-1084 rear holes to 15/32 for brake line grommets.
Drilled holes into the side panels for the fuel return lines.
Fluted and match-drilled the F-1099G wing root fairing supports.
Trimmed the washer part of the TCW bushing to go above the fairing supports.
Alodined the side skin that will be under the fittings and the fairing supports.
Fabricated standoffs for brake fluid reservoir and re-mounted the reservoir.

  Dec 26, 2023     Side Covers       Category: Fuselage

Added 4 nutplates to F-1034C-R.
Mounted the rear seat side panels on both sides.

  Dec 25, 2023     Rear Seat Floors       Category: Fuselage

Match drilled the right rear seat floor and riveted it down.
Same for left floor.

  Dec 10, 2023     Baggage Door       Category: Fuselage

Split the hinge pin to make the baggage door removable.
Riveted the door hinge to the hinge frame and the hinge frame into the fuselage.
Added safety wire to the hinge pins.
Match drilled and riveted F-1081, the left baggage cover.