Apr 26, 2024     Installation - (1.5 hours)       Category: Avionics

Continued installing more wire bundles to the ACM, Comm2 radio and its tuning head. Temporarily installed the SIC's panel (with the MFD) and its wire bundle.

  Apr 25, 2024     Installation - (.5 hour)       Category: Avionics

With a few minutes available I temporarily installed several connectors to the ACM and installed the connector to the EMS-220. The connectors will be readjusted to get rid of the criss crossing when the full complement are initially fitted.

  Apr 24, 2024     Installation - (4.0 hours)       Category: Avionics

Now that the diplexer is on hand and schedules are coordinated with Dean we hooked everything up and attempted to install the Avidyne IFD540. But it wouldn't seat properly. Note the gap in photo 6365. After a lot of attempts and thinking everything thru we determined that on the first attempt we didn't drill the mount holes in the appropriate location - that is, based on the original cover plate. With the new cover plate in hand we then measured a few more times before drilling the new holes - and then went for it. This time everything went well and the unit fits properly and is finally installed as in photo 6367.

  Apr 09, 2024     Installation - (1.0 hour)       Category: Avionics

With the Avidyne mount tray clecoed in place we drilled the #28 holes to secure the tray. Then we removed it and deburred the holes. Next we were ready to install the GPS, Comm, G/S and Nav cables to The back of the tray, but I was short the Nav cable. I ordered a RG400 with BNC's cable for the wing root to IFD. Amazon will have it here tomorrow.

  Apr 06, 2024     Center Panels - (1.5 hours)       Category: Avionics

Installed some of the avionic boxes into the new upper and lower center panels. The new lower center panel now has the 60A ALT CB hole drilled in place, labelled and the CB installed. The old panel didn't have this. The ELT control is awaiting battery and screws before it's installed. The upper center panel was completely redone so the the A/P and Radio are on the sides with the Avidyne B/U battery switch and the canopy eject handle now centered on the panel.

  Apr 01, 2024     Surgery - (1 hour) Category: Misc

Project temporarily on hold as I recover from cervical/spinal surgery.

  Feb 08, 2024     Parts Installation - (1.0 hour)       Category: Avionics

Took a break from taxes and installed the manifold pressure fitting in the engine and then installed and secured the hose ends.

  Feb 02, 2024     Parts Installation - (1.5 hours)       Category: Avionics

I continued the installation of zip ties to hold wires in place and I removed all the temporary ones (at least I think I got them all, there are a lot.) Also, I thought the left side was done but I found a few locations where more support was needed to safely secure everything. There is a place for adel clamps, and I guess I could have used more, but seriously the engine mount would have had dozens of those darn near impossible clamps to install and the engine mount isn't large enough to hold them all. I exaggerate, but I need to remember why I went in another direction. The right side is done - for now. There are more wires to come.

  Jan 30, 2024     Parts Installation - (4.0 hours)       Category: Avionics

I shortened cylinders 1 & 3 CHTs & EGTs wires from the EMS and then installed new barrel connectors. Again, I wrapped all the individual connections in rescue tape. All wiring attachments to the engine mount on the right side were rerouted and refastened, but rather than using adel clamps I used zip ties with multiple wraps of rescue tape on the mount to ensure NO direct contact with the zip ties on the mount. I managed to start the same procedure on the left side, but ran out of time. Also, I continued the procedure of separating the ignition wires from each other. The right side is done, but there are a couple of more on the left side that need attention. This process is ongoing as I see how the entire wiring package comes to together as the build continues.

  Jan 29, 2024     Parts Installation - (1.5 hours)       Category: Avionics

Building hint. Completely read the instructions. Turns out I planned to to do the oil pressure, fuel pressure and fuel flow at the same time since they were on the left side. Well, duh, the manifold pressure uses two of the same wires that others do, but it was on the right side and didn't get done at the same time. So I had to solder in another connector for power and use a different ground wire. No problem, but just a little more work to run the wires. Now the manifold pressure sensor wiring is complete.

  Jan 28, 2024     Parts Installation - (3.0 hours)       Category: Avionics

Research complete and the solder 'ring' is okay as is. It doesn't need to disappear. Pull tested the wires and they're secure. I finished the fuel pressure and oil pressure wiring and secured the wires. On to the fuel flow measurement wiring. I had to feed those wires thru the firewall opening - missed them on the initial feed. They were very hard to get too, but it got done. Soldered and pull tested okay. I secured all of those wires then went on to securing cylinders two and four spark plug wires on the backside of the engine. Due to the expected shaking and engine vibration, I left a little extra slack in all the electrical wiring.

  Jan 27, 2024     Parts Installation - (2.5 hours)       Category: Avionics

I completed the wiring of the EGTs and CHTs on cylinders 2 and 4. I did leave some extra slack in the harnesses so I could easily reach them and also just in case the wires should need rework in the future. The butt connectors are quite cumbersome and to protect them I opted to wrap them in rescue tape. Not pretty, but functional. I wired the oil temp sensor. Then I tried using a solder joint tube for the first time. The wires are soldered together but the solder ring isn't completely melted, I'll research that to ensure it's done correctly before I do more.

  Jan 26, 2024     Parts Installation - (1.0 hour) Category: Avionics

I did some research and found the brown EMS wires can be cut without any problems so I began the CHT and EGT wiring work on cylinders 2 and 4 with the wires being cut for a better fit. I'll still leave room for an extra 6 or so inches of slack. I'll also go back and redo the wires for cylinders 1 and 4.

  Jan 25, 2024     Parts Installation - (1.5 hours)       Category: Avionics

I completed the installation of cylinders 1 & 3 EGT & CHT probe wiring. I also decided to leave the EMS probe wires full length for now. I don't know if resistance is a factor or not because if it is, it's not a big deal as I can always cut them back later. Also, I feel I need to find some material to protect the connectors.

  Jan 24, 2024     Parts Installation - (1.0 hour)       Category: Avionics

I added a new adel clamp to cylinder 3 rocker box cover mainly to hold the CHT and EGT wires and also added the #1 plug wire thru the clamp. The wires were then thread thru zip ties that attached to the adel clamps, but not the plug wire. The right side bundle of EGT and CHT wires were zip tied to the engine mount, with plenty of slack.

  Jan 23, 2024     Parts Installation - (1.5 hours)       Category: Avionics

The engine sensor wires that were split into two bundles are now zipped tied, one for behind the firewall and the other forward of the firewall. The Dsub end was connected to the EMS unit and the wires threaded above all the other wires, tubing and the plethora of other important items, behind the rear instrument bulkhead. The forward wires were then jammed, I mean threaded, thru the upper firewall opening. This opening is now nearly at max capacity. I also physically installed the 12V plug in the center floorboard tab. Although the wires are connected to it, this remains to be wired to power.

  Jan 20, 2024     Parts Fabrication - (1.5 hours)       Category: Avionics

Easy day as I finished using the multimeter to verify each wire for the EMS-220's sensor harness and then separated them into firewall forward and aft bundles. A lot of wires aren't used, but I hesitate to remove them from the connector as I don't want to possibly damage an adjacent wire. I plan to make them shorter and protect the ends with a piece of heat shrink. I also need to figure out what to do with the many ground wires. The instructions aren't clear as to whether they're unused or should be grounded. Probably unused or there would be a grounding symbol on the drawing. I'll verify with Advanced Flight.

  Jan 19, 2024     Parts Installation - (3.0 hours)       Category: Avionics

This is unf'ing believable. Yes, it took three hours to finish installing one LEMO jack and one headset jack on the right side and get the floor painted - twice! It wasn't fun. Take note: The LEMO jack nut that fastens it to the floor is one of the weirdest, most user unfriendly design I've come across in quite a while. You can't just place a wrench on it. It has two small flats that are tiny and barely accessible to the average wrench. Add to that you have to shove your arm under the floor to hold the case from turning while attempting to tighten it. Good thing a friend stopped by to help. Oh yes, and the larger headset jack has a conical nylon washer with a protruding head that comes thru the floor, but it protrudes too much and the nut can't tighten down the jack before bottoming out. After sanding down the protruding head and adding two more washers on the bottom side, I finally got the jack secured. But only after screwing up my first repainting job. The second repaint was marginally acceptable, but I have had enough of this simple task. It must be me as I'm sure no one else has had this problem OR will admit to it! Anyway, the second paint job looks good from 10 feet away but will be partially hidden by the seat. All jacks are now installed and tightened.

  Jan 18, 2024     Parts Installation - (1.5 hours)       Category: Avionics

I can't believe it took me an hour and half to do this, but it did. After locating and drilling the additional 9/16" hole for the LEMO plug, I installed the pilot and copilot headset jacks - and the LEMO plug. I did screw up the paint job on the copilot side, so I'll have to fix that later. Also, a note to self; the LEMO plugs haven't been tightened yet.

  Jan 17, 2024     Research - (3.0 hours)       Category: Avionics

I decided to attempt to make sense of the EMS-220 (Engine Monitoring System) wiring. I had a couple of goals by doing this. First, since this was the only cable not labelled I wanted to be sure I had the correct wire bundle. (it is the right one.) Next, for routing purposes, I wanted to separate wires going forward thru the firewall and those that are aft of it. Then I wanted to identify each of the wires so that I could label them and get them to the right location. In doing so, I found many unidentifiable wires. Working with Advance Flight Systems, they were very patient and helpful, I was able to identify a few more. Due to time limitations, I'll have to call them back again. Also, there are many wires/pins that aren't used, so I guess I'll have to do continuity checks to see what's what.

  Jan 16, 2024     Parts Installation - (3.0 hours)       Category: Avionics

Continued installing more wire bundles. The glove box audio panel wiring bundles containing the headset "plugs" were fed thru the fuselage tunnel then over to the seat area where they'll be installed and the audio panel connector to the ACM was installed. Comm 1 and comm 2 antenna wires were marked and installed to the antennae. The comm 2 wire was installed into comm 2. In my continuing saga of misaligned boxes I adjusted the ADS-B, but it still looks off - oh well, two tries and I'm done. I discovered the transponder unit connector wouldn't quite clear the EMS unit so I had to move it up and over slightly. I should have plugged the connectors in and checked for clearances first, so lesson learned. The ground wire nut plate has been installed. I plan to run another ground from there to the battery ground, just to be safe. I started working on the sensor connector, but there's a lot to do to identify where each wire goes, A job for tomorrow.

  Jan 15, 2024     Parts Installation - (2.0 hours)       Category: Avionics

I installed oil temperature sensor, no issues here. Spent the majority of time routing and rerouting the cable bundles and temporarily installed the connectors to the ACM and other components. The reason for this is to keep the wire bundles from hanging too low, not rubbing against anything sharp, etc and to be sure the lengths are correct. So far it's fine. However, I did discover the ADS-B unit was about 3/4" of inch to high because when installed, the connector was just too close to where the canopy would close. I moved the unit down - problem solved. However, it's sitting at about .4 degrees off of vertical. It must be that the transponder is slightly off. Since it's purely aesthetic, I'll get to when I can. I know I'm being anal, but....

  Jan 14, 2024     Parts Installation - (1.0 hour)       Category: Avionics

I installed the RAMI certified GPS antenna on the top of the fuselage aft and to the right of center of the rear window. With this done all the antennae are now 'mechanically' installed on the aircraft.

  Jan 13, 2024     Parts Installation - (2.0 hours)       Category: Avionics

Today I installed the transponder antenna under the center of the fuselage and ran the RG400 cable to the transponder on the sub panel. Suggestion: It would be easier to install this antenna before the right side baggage floor is riveted in place as the antenna sits under the floor and access is tight. But not to worry, it's still doable if you already have the floor in. I began to install the RAMI GPS antenna on the top of the fuselage aft of the rear window, but I didn't have the necessary hardware to do it. I did run the RG400 antenna cable from the behind the baggage bulkhead thru the center tunnel and behind the center instrument panel. Now it's off to the aviation aisle at Lowes for the GPS installation hardware.

  Jan 12, 2024     Parts Installation - (4.0 hours)       Category: Avionics

I installed the Engine monitor unit and the MFD B/U battery on the shelf, but I had to move the Comm slightly forward as I found on the test fit it was needed to avoid the MFD - which actually wasn't a big deal. Then I installed the ADS-B unit on the instrument Sub Panel, but rather than nut plates I decided to use two #10 sheet metal screws due to to tight access on the backside of the Sub Panel, not a biggie since the ADS-B unit weighs only a few ounces. I can always change it if it becomes necessary. Then, moving to the rear of the aircraft, I installed the Delta Pop ADS-B antenna and attached the RG-400 cable to both the antenna and ADS-B unit. I also installed the two Delta Pop Comm antennas in the locations specified by Vans.

  Jan 11, 2024     Parts Assembly - (2.0 hours)       Category: Avionics

I decided to go to Plan B. I didn't know there was a Plan B until we inserted the glove compartment avionics assembly into the glove box and I discovered the Comm radio just didn't fit to my liking. It extended above the top edge of the glove box opening which wouldn't let me remove it. The work involved to lower it was just not worth it. I removed the assembly from the aircraft, then removed the radio and reinstalled it in place of the ADS-B box on the shelf in front of the glove box. I'll find a place for the ADS-B later. With that done, we reinstalled the assembly into the glove box and riveted it in place.

  Jan 11, 2024     Rudder and Brake Pedals - (2.5 hours)       Category: Controls

My friend Paul and I readjusted the rudder and brake pedals from the mid point to another hole more aft as the current foot to pedal distance was too long.

  Jan 10, 2024     Parts Installation - (5.0 hours)       Category: Avionics

Now that I've decided which parts will be on the shelf I finished installing the nut plates. I also final fitted the hinges and drilled the holes for forward hinge and riveted it to the sub-panel. Then I attached the shelf to the installed hinge with the hinge wire. Marked and drilled the shelf and hinge for riveting. With it now clecoed in place I swung the shelf under the instrument panel frame, drilled thru the frame and shelf and installed nut plates on the frame and inserted a couple of screws to hold the shelf up. Then I riveted the shelf to the hinge and just like that, it's done. Lastly, I drilled and then bolted the transponder holder to sub-panel and installed the transponder.

  Jan 09, 2024     Parts Fabrication - (2.0 hours)       Category: Avionics

I temporarily took the SIC panel and measured to ensure the avioncs would fit with it installed. So far so good. Then to make the avionics fit a little better I decided to move the transponder off the hinged panel and replace it with the ADS-B. Then I did a final fit of the panel, cut some more off the corner for electrical wiring access and also slightly adjusted the corner fit. I began installing a few nut plates for the avionics on the 'shelf'.

  Jan 07, 2024     Parts Fabrication - (1.0 hour)       Category: Avionics

With the comm radio now in the glovebox there are still numerous components that have to be installed. Using cardboard I mocked up a design that will use a hinged panel to fit under the SIC panel and extend back to the sub panel. Then I went to a friend's hangar and had a piece of aluminum sheared to fit. Next I will have to mount the new SIC lower panel to ensure there is adequate clearance for the avionics that will populate the shelf. I'll save that for tomorrow-maybe.

  Jan 07, 2024     Parts Assembly - (2.0 hours)       Category: Avionics

I decided to install the comm unit into the glovebox assembly after studying the available room for components. So I added 3 nut plates to the right glovebox rib and screwed the comm holding assembly in place and secured the radio.

  Jan 06, 2024     Parts Assembly - (3.0 hours)       Category: Avionics

With the glovebox ribs removed I installed a lot of nut plates on each rib to accommodate the remote audio panel rack and one of the remote backup batteries. The tight fit of the of the attach holes for the audio panel necessitated 4 nut plates, each with 2 rivet holes in a row, due to the edge distance. For the battery I included 4 extra nut plates on the right side rib just in case there was any problem with installation on the left and I had to relocate the battery. I also removed the components of the center panel so I could return it to AFS to resize the access opening for the IFD540.

  Jan 05, 2024     Research - (3.0 hours)       Category: Avionics

Another weird work day at the hangar. To say the least, trying to fit all the equipment in the area behind the instrument panel has been challenging. I installed the SIC panel to get an idea of the available space. There isn't a lot. So I decided on a drop down hinged panel below/behind the SIC panel so access would be easier in case a component had to be R&R'd. The AFS documentation has been okay, but the execution isn't easy. Pro tip: I thought installing the glove box ribs in advance would be good - wrong. To make it easy I decided to now remove them so as to install nut plates for the equipment going into the glove box area. The glued on thermal shield for the firewall was blocking access for the rib's rivets that had to be removed, but despite the great glue and stainless sheet I got it removed. On the bright side, they'll be easy to replace as will the new rivets.

  Jan 03, 2024     Parts Installation - (3.0 hours)       Category: Avionics

We worked on the installation of the center panel including installing (or trying to) the Avidyne IFD540. The tray had to go in first then the center panel and after many tries - it didn't fit. Calls to AFS resulted in taking hacksaw to the sub panel sheet metal behind the tray. Turned out to be pretty easy to do and I believe actually strengthened the sub panel, once 3/8" lip was bent to allow the tray to fit properly. Great - not so fast. Once fitted in place the nomenclature on the switch panel is not legible from the pilot's perspective without bending down to be sure you touch the correct switch - can you say vertigo? Working on that issue later. Installed the ACM with no problem, but it did take more time than I thought it would since I used nut plates rather than bolts, just in case it needs to come off at some future time.

  Jan 02, 2024     Research - (2.0 hours) Category: Avionics

Spent a couple off hours unpacking the avionics and trying to figure out what goes where and how to mount things. I guess I'll resort to reading the instructions:-)

  Jan 01, 2024     Engine Instruments - (2.0 hours)       Category: Avionics

After a VERY HAPPY START TO THE NEW YEAR! -- I moved from mechanical installations onto electrical/measurement systems. I physically installed the EGT Sensors, CHT Sensors, Oil/Fuel Pressure Sensors and the Manifold Pressure firewall fitting.

  Dec 31, 2023     Exhaust System - (2.0 hours)       Category: EXP-119

Finished installing the pilot side heat scat tube and the heat muff to heat tee scat tube. Then I installed 3 heat deflectors to protect the red cube, the throttle and mixture cables and the fuel servo. I placed RTV along the scat tubes and where they contacted other parts of the aircraft. Pretty much most of OP62 is done.

  Dec 30, 2023     Exhaust System - (2.5 hours)       Category: EXP-119

I completed the right side exhaust hangar and the secured the swivel adapter. All the exhaust pipes were torqued to 190"lbs. The passenger heat scat tube, the tube connecting the 1 and 3 heat muffs was installed, as was the inlet air scat tube. The scat tube between the two muffs has had the wire removed (per the plans) and looks kind of limp. I'll have to see how that works out.

  Dec 28, 2023     Exhaust System - (2.0 hours)       Category: EXP-119

Two hours! I can't believe it took me two hours to do what I thought was a 30 minute job. I installed a 3/4"spacer to maintain the exhaust pipe distance below the fuselage then tightened the spherical joint, spring loaded bolts, then the fun began. Getting the Adel clamp and hangar assemble installed at the right location to center the exhaust and that 3/4" distance below the fuselage. It's all my bad too because I installed that heater tee which blocked good access to the hangar assembly. I wasn't going to take that apart. After what seemed like three thousand tries with the called out hardware I decided to change the hardware out and use an AN10 bolt, make a spacer and get'er done. It worked. Right side exhaust is done.

  Dec 27, 2023     Exhaust System - (3.0 hours)       Category: EXP-119

Installed the 2nd heat muff, fabricated the right exhaust hangar and attached it to the exhaust pipe. Doesn't sound like a lot, but as typical of Van's kits that sounds easy. but isn't. But at least that part is done.

  Dec 26, 2023     Exhaust System - (3.0 hours)       Category: EXP-119

I decided to install the remaining 3 exhaust pipes. This is temporary until all the fittings and such are in place and the aft exhaust pipes are then secured. It took quite a few attempts at clamping the swivel joint spring loaded fasteners on, but I got it done. The rest of the installation went rather smoothly, but it would have helped if my fingers and arms were smaller , or I had three arms and hands ,so I could get to those bolts in the back of the engine where the pipes attach to the cylinders.

  Dec 23, 2023     Exhaust System - (1.0 hour)       Category: EXP-119

I fabricated the left hangar for the exhaust pipe and installed it, temporarily, for a fit check of sorts. The exhaust system will have to be attached in order to get a proper fit. Lesson learned (yet again), the pressed end of the hanger tubes definitely shouldn't be more than 7/16" and the corners should be chamfered in order to easily get them into the hose.

  Dec 22, 2023     Exhaust System - (1.5 hours)       Category: EXP-119

I went to work on the second set of Adel clamps for Heat Tee and decided to fabricate another aluminum tube spacer as on the first one. With that done came the compressing of the clamps and adjusting the Heat Tee for the final location fitment. This one was just as difficult as the first, no learning curve. Anyway, it's done. Second clamp and fitting of the Heat Tee is now done. I did another test fit of the hoses and they don't fit. I can readjust two the three, but I'll had to order new SCAT tubing for the final one. Lesson learned! Don't cut the SCAT tube until each one is fitted. The directions for the length of each hose aren't even close because the Heat Tee doesn't go on as depicted. Oh well. build on.

  Dec 21, 2023     Exhaust System - (2.0 hours)       Category: EXP-119

Yesterday, after closely reading OP62-20 I found that the part numbers for the heat muff end caps did not match the rev 1 drawing so I called Vans tech support to check it out. They said it was best not use the the ones I had and to use the new ones. They are sending those to me so all that work yesterday was just good practice. However, today I decided on the location for the heat Tee. It's not per the drawing but, so be it. I loosely tested the hoses and they seemed to fit, so hopefully no issues there, but getting those Adel clamps in place requires a lot of well placed safety wire and patience. One is done, one to go.

  Dec 20, 2023     Exhaust System - (2.0 hours)       Category: EXP-119

I loosely installed the #4 exhaust pipe. Take note: However, while I did expect there would be a little oil behind the temporary fitting, I did not expect the ensuing gusher after the second nut was released. I'll be better prepared for the other 3. After cleaning the mess, I proceeded to fabricate the heat muffs for the two of the other pipes. It appeared easy enough, but the clamping force required for the installation was quite high. The -43B muff was finally completed and I started the -43A but had to stop for the day. Clamp adjustment will wait until the parts are installed.

  Dec 20, 2023     Research - (3.0 hours) Category: EXP-119

Studied a gizzilion ways to align the Heating Tee as the given instructions just don't seem to work on the plane. An experienced friend recommended that it would be best to install the exhaust first then the Tee. That's now the plan.

  Dec 18, 2023     Exhaust System - (1.0 hour)       Category: EXP-119

With the engine controls complete I began work on the exhaust system. I realize this is slightly out of order, but I thought it best to get the controls in first without the exhaust pieces in the way. I'll see how this goes. I began by modifying the exhaust support tubes by rounding off the top edge, then attempting to 'squeeze" the tubes in a vise to flatten them out. My vice is a clamp on aluminum one that I have used on 2 builds, but it wouldn't make a scratch on these stainless tubes. That's good news in a strange way. A friend of mine stopped by and offered his steel vice. That worked fine. I then fabricated the scat hoses by cutting them to length and modifying the wires per the plans.

  Dec 18, 2023     Engine Controls - (1.0 hour)       Category: EXP-119

I completed the installation of the Exit Cowl cable. It was rough to get to it, but at this point, I'm just happy to have it done. The problem was getting the cable through the adel clamps -then- getting the wire into the hole of the VP-219-2 fastener. Remember for next time: It would have been better (in hindsight of course) to push the wire thru the VP fitting as the cable was also being inserted through the Adel clamps. Regardless, that now completes the engine control section. (I hope)

  Dec 17, 2023     Engine Controls - (3.5 hours)       Category: EXP-119

The throttle and mixture firewall pass thru (CT-00102) insert was drilled out slightly to accommodate the plastic wrap around the mixture control. The pass thru is in a difficult to position to reach so I decided to tape the two pieces together to hold it in place while the cover was slid into place. We then fastened the cover plate of the CT-00102 and checked that bad boy off the list. The cowl flap cable was inserted thru the two adel clamps in the cowl flap cable support assembly. We had to stop there due to my friend Dean having to leave for the day. He's been a crucial part of this build especially since my fall last year. Many thanks, again, to him. Next I tightened the controls to the control cable bracket and added the remaining zip ties. Then I made another command decision to abandon the double adel clamps to support the mixture and throttle cables. Instead I used rescue tape to protect the cables and engine mount then secured the cables using zip ties around the rescue tape. No way I could reach in there and mess with adel clamps in that particular location.

  Dec 16, 2023     Engine Controls - (4.0 hours)       Category: EXP-119

I thought this morning's tasks would only take an hour or two at most. Surprise, actually it's not a surprise, I should have known better. I made more progress toward completing the throttle and mixture controls with only the firewall pass-through to go and a pair of Adel clamps to install after the pass-through is completed. I also completed the prop control installation and the alternate air cable. The only remarkable issue was the installation of the dual Adel clamps for the cable. It was really tough to get them aligned and tightened. Another command decision. I changed the length of the screw to 1" instead of a 1/2" making it easier to get those darn clamps to close enough to get the nut installed.

  Dec 15, 2023     Engine Controls - (3.0 hours)       Category: EXP-119

The left cabin heat control was installed in the cockpit as were the throttle, mixture, alt air and exit air controls. The throttle and mixture control controls were adjusted/rigged for the proper throw between idle cutoff and full rich and idle and full throttle. Still, some finish work remains for throttle and mixture. The alt air cable needs to be fit, cut and installed as does the exit air.

  Dec 14, 2023     Engine Controls - (2.0 hours)       Category: EXP-119

Today I pulled the Alt Air Control cable out the required 6" and yes, the ball bearing fell out as predicted. I measured and cut the cable the required length then spent about 10 minutes reinstalling it. Done - not as bad as I thought it would be. Moving on to the right side cabin heat control, my buddy Dean squeezed himself inside the floor area and we got the cable secured and fastened in. Finding the right tools to make this job easy was half the battle. Also, replacing the metal lock nut with a fiber locknut was necessary due to the accessibility of getting your body in a position to apply torque. Another command decision made. If it it's that hot in the cockpit that a metal locknut is necessary - well, I'm landing ASAP and getting out of there.

  Dec 13, 2023     Engine Controls - (1.0 hour)       Category: EXP-119

Cut the left and right heat control cables to their 36" length. Called Van's regarding the Alt Air cable. The tag states to not pull the cable out beyond 3 3/8" or the ball bearing will fall out, yet the OP62 instructions states to pull the cable out 6" before making the 19" cut. Van's tech support told me to pull it out the 6" and don't lose the ball bearing. I'll try doing it tomorrow.

  Dec 11, 2023     Engine Controls - (1.5 hours)       Category: EXP-119

Today I laid out the controls for the engine; throttle, prop, mixture, cowl exit door, and alternate air then took off all the hardware, seals, etc, in preparation for installation. The cabin heat controls are unwrapped and will be marked for cutting soon. Interesting dilemma: the CT A-700 control (cowl air door) has a label stating not to extend the pull of the cable beyond 3-3/8" or ball bearings will fall out rendering the cable useless. However, OP62-26 step 2 states to cut the cable and also states to pull the knob out 6" for the cut. I'm confused, so a call to tech support may be in order. I also installed the F-14107-1 plate (engine controls) in place on the instrument panel. I then loosely installed the prop control cable in place.

  Dec 10, 2023     Engine Controls - (1.5 hours) Category: Research

I spent a little time gathering parts and studying the best way to install the engine controls and exhaust pieces. Looks like controls go in before exhaust pieces because of easier access. A little out of sequence, but so be it.

  Dec 09, 2023     Parts Assembly - (1.0 hour)       Category: EXP-119

I bought the Blue RTV and secured the P-Mag blast tubes and also provided a 'bumper' for the vertical hinge pin.

The workday was cut short because today is our annual Spruce Creek Christmas Toy Parade. The weather was perfect with a few clouds, light winds and a temperature of 80. The event started with a fly-by formation of Van's and other experimental aircraft, warbirds (T-34 fighters) and even a resident owned P-51, 38 aircraft in all. Then there was the parade of residents who decorated their antique cars, tractors, a kids train and golf carts. There were also dance groups, a drill team (battery operated drills of course) and much more that paraded down Taxiway Cessna which was lined lined with a thousand or two of friends from the community. I've included a very small sample of pictures of the nearly two hour annual event. Note Captain Paul's (DAL/NWA 747 Captain-retired) and the fabulous 747 float that he built. It's a real 747 traveling engine cowl complete with smoke, fire, music, bubbles, an original spiral staircase from a 747, first class seats and a host other goodies for kids and adults. Today was truly a magical day. ENJOY!

  Dec 08, 2023     Parts Assembly - (.5 hour)       Category: EXP-119

After sending hours cleaning up and putting away tools and parts from the cowl build, I installed the P-Mag cooling air blast tubes. Not a big deal but needed to be done. I still have to get some RTV to complete this task.

  Dec 07, 2023     Cowling - (3.0 hours)       Category: EXP-119

Sing-along: And now the end is near (-- or is it? Anyway,) I did it my way. Lower cowl: My maze of tape showing the outlines of the areas for epoxying of the pieces of heat insulation used for the bottom cowling. These individual pieces were necessary, IMHO, to minimize the wrinkles and the epoxy primer is to keep the ends of the heat shield down. Upper cowl: To seal the filler I also decided to epoxy the complete area around the ramps. A little blue pigment made the mess look a little better despite that it will not normally be seen. Now to let it dry and clean up the work area. Still remaining (at a future date that's TBD) - epoxy resin around the aft edges of the upper cowl to get a better fit.

  Dec 06, 2023     Cowling - (2.0 hours)       Category: EXP-119

Sanded the cowl ramps smooth then used a Bondo type filler to fill in a few low spots and smooth the edges. I countersunk the cowling oil door hinge holes and riveted the hinges to the cowling and the door. Placed the pin through the hinge, installed the oil door Skybolt fasteners, which needed a little adjustment and will probably need a little more later on after everything is painted. I kept the spring out for now.

  Dec 05, 2023     Cowling - (2.5 hours)       Category: EXP-119

Sanded the first coat of Super-Fill to the upper cowl ramps, then added the second Super-Fill coat to the the upper cowl ramp areas. I filled the extra drilled holes in oil door and countersunk the holes in the oil door.

  Dec 04, 2023     Cowling - (2.5 hours)       Category: EXP-119

I removed the top cowl from the aircraft to begin the ramp and oil filler door work. The oil door fasteners have been received and temporarily installed and the unused hinge holes in the door are taped off for filling later on. The clecoes were removed from the ramps and the required areas were roughed up to accept the super-fill. Due to the thickness of the filler that's needed I've decided to do this in two applications. The first application has been applied and somewhat smoothed and in the next day or so I'll finish applying the filler and begin sanding it smooth.

  Nov 27, 2023     Cowling - (3.0 hours)       Category: EXP-119

With the oil filler door install on hold awaiting the door fasteners I switched gears to getting the left and right inlet ramps bonded in place. Both sides were fit to the inlets and side walls, outlined for resin application, the #40 attach holes were drilled and the edges to be bonded were sanded. I mixed the resin and flox, spread it around and attached the ramps to the cowl with clecos. With all that done I installed the cowls onto the aircraft so the parts could dry in place.

  Nov 23, 2023     Cowling - (1.0 hour)       Category: EXP-119

I took a little break this Thanksgiving morning and laid out the hole patterns for the hidden hinge oil fill door and drilled the holes to #30 for extra support. The provided oil door hole pattern doesn't fit the aftermarket hinge (which is spring loaded open) so I laid out the new pattern and will fill the old holes later.

  Nov 20, 2023     Cowling - (2.0 hours)       Category: EXP-119

Lower cowl: 100% of the thermal barrier is now in place, the appropriate holes have been drilled thru the thermal material and the trimming is complete. Looks just like the instruction sheet. A few more odds and ends to do then the lower cowl can be set aside for now.

  Nov 19, 2023     Cowling - (1.0 hour)       Category: EXP-119

Added more thermal protection to the lower cowling. Maybe 50% done with the thermal barrier material at this point.

  Nov 18, 2023     Cowling - (2.0 hours)       Category: EXP-119

I sanded the lower cowl's Superfilled areas to 220 grit just to get rid of the excess material. The finish work will be done in the future. Using blue tape, I outlined the cowl heat resistant material placement and applied the first piece. I thought I was going to do the whole bottom at once, hah! The jokes on me. That material is tough to work with on curved surfaces. I got about 20% done and sort of smoothed out. It wasn't as easy as I thought it would be and it'll take more time too. Should have known better:-)

  Nov 16, 2023     Cowling - (1.0 hour)       Category: EXP-119

Using a small batch of Superfill, I filled the countersunk rivet holes in the lower cowl and smoothed out the floxed holes in the upper cowl. Now I'll give it a day or so to dry before sanding smooth. I also repackaged the prop hub for some additional storage time.

  Nov 15, 2023     Cowling - (1.0 hour)       Category: EXP-119

Most, but not all, of the cowling work (for now) was accomplished. Both upper and lower pieces were removed and finally, the MT Prop hub assembly used for fitting the cowling was removed. It'll be permanently reinstalled later on, but this time with the prop. A little bit of Superfill will be applied to the flox'ed areas and alignment holes in the next day or so.

  Nov 13, 2023     Cowling - (3.0 hours)       Category: EXP-119

Today, there is light at the end of the cowling tunnel. The top cowling was installed and all the Skybolt fasteners now securely fit. The fix I put in place yesterday cured and is holding solid. Just minor finish work is needed and this disaster will be in the history books. I proceeded to install the two nut plates on either side of the cowling nose. The fit is fine, however, it should be noted I decided to install a stiffener on the right side due to the fiberglass layup on that side being too thin (IMHO) to support the nut plates. I then deburred, dimpled the X-over cowl close close-out plate, then riveted 7 of the 8 nut plates to it. I was shorted one, so I'll have to order it.

  Nov 12, 2023     Cowling - (2.5 hours)       Category: EXP-119

Yesterday's .5 hours of work is included in today's writeup. I epoxied a strip of fiberglass to the backside of the upper cowling Skybolt holes to support an epoxy/flox mixture. The holes were offset too much; ranging from about 1/8" to 1/4" and slightly oversized, causing the retainers to not be properly aligned. (All my fault for trying to get the gaps to perfection.) Today we drilled the remaining holes on the bottom of the lower cowl and fastened the retainers and nut plates to the appropriate flanges. With the lower cowl secured in place I installed the upper cowl and placed an epoxy/flox mixture into the holes to "shrink" the holes, as mentioned above, into the right position and right size. Time to let the flox set before I right size the holes.

  Nov 10, 2023     Cowling - (2.0 hours)       Category: EXP-119

Midcourse correction on the the lower Skybolt fasteners. Seems the inboard flanges hang over the exhaust mold curve just a little too much. Moving them more outboard defeats the purpose so I decided to use the existing nut plate feature for the inboards. The outboard flanges are riveted in place and the holes for the inboard and outboard attachments are now drilled into the cowling. My friend Dean gets most of the credit for realigning my thinking.

  Nov 08, 2023     Cowling - (3.0 hours)       Category: EXP-119

Work continued on the cowling, by removing the upper and lower cowlings. Decided to make a new hinge pin for the port side due to an extremely tight and somewhat bent fit. Polished and removed both and lubed them up. Better fit now. Began fabricating the lower Skybolt fittings. The left side is ready for countersinking and the right side is now ready for drilling. I also made an adapter plate for the right side of the lower nose cowl to accept the future nut plates. Seems I removed too much fiberglass during the trimming process.

  Nov 06, 2023     Cowling - (4.0 hours)       Category: EXP-119

Ugh. Work continues on the upper cowling. All the fasteners to the lower cowl are complete, however the ones on the top, which air now oversized fit about 3 or 4 and the others are now too large. Minor repair work coming up. The holes for the cowl screws are now both #40 with the left side needing a slight adjustment because the lower tab was too short. Not a big deal, but more work.

  Nov 05, 2023     Cowling - (4.0 hours)       Category: EXP-119

Today I marked the location of the upper cowling fasteners that I want to shift to make a better fit. I then gorilla taped the upper cowling into a better position and then drilled out all of the remaining upper and lower cowling Skybolt fastener holes (except the bottom ones that I'll get to later). Once done with the drilling I removed the upper cowling (yet again) and riveted the retainers to the flanges, except the ones in the corners which I need to revert to movable ones to allow for inaccuracies in measurements.

  Nov 04, 2023     Cowling - (1.0 hour)       Category: EXP-119

Removed the cleoces and unlatched the top cowl. Removed the magnets and inserts that were match drilled yesterday and installed some of them on the remaining udrilled flanges. Then I drilled the #30 holes and then removed the upper cowl again and removed the inserts. The fit of the upper cowl is not to my liking so I'm going to give some thought on the best way to tweak it.

  Nov 03, 2023     Cowling - (3.0 hours)       Category: EXP-119

I Installed the temporary Skybolt quarter turn fasteners on the upper cowling. HINTS: I ran into a slow down as the cowling gets very thick from the middle to one end which made the installation very difficult. Each hole had to be ground down in the thick areas to allow the temporary O ring to be installed. This O ring keeps the fastener body installed until the permanent metal ring is put in place after painting. I managed to get some of the magnetically centered holes drilled and clecoed. I didn't have all the magnets I needed so I did what I could and the others will have to come later. Also, the engine is so close to the flanges in some areas, those holes will have to be enlarged with a small sanding disc and not the step drill. By the way, the color coded tape is to keep me from putting a drill thru a valve cover or cowl baffle. To make life easier, I also marked where I didn't have any centering magnets.

  Nov 02, 2023     Cowling - (4.0 hours)       Category: EXP-119

Left side upper and lower cowl flanges were drilled, deburred, countersunk and riveted. This side came out much better than the right side. Practice, practice practice. I installed the centering receptacles and magnets on the majority of the flanges in preparation for finding the centers and clecoing the cowl to the flanges.

  Nov 01, 2023     Cowling - (2.0 hours)       Category: EXP-119

The remaining right side flange is now riveted to the fuselage skin. The left side cowl flanges have been fitted and trimmed and are ready for drilling.

  Oct 31, 2023     Cowling - (2.0 hours)       Category: EXP-119

The right side cowl flanges have been deburred and riveted. One last flange on the right side upper cowl remains to be riveted.

  Oct 30, 2023     Cowling - (2.0 hours)       Category: EXP-119

The right side lower cowl flanges have now been drilled using the holes previously drilled. I added one hole/countersunk at each end and the alignment is much better. At least I think so. Oh yes, to be sure all is okay I had my assistant, Penny, do a quick cat scan. She meowed that all is well so I can move on to deburring and riveting.

  Oct 28, 2023     Cowling - (4.0 hours) Category: EXP-119

After pondering the right side cowling flange spacing I had a semi sleepless night because I thought it would be okay to not have a fastener in the corner. The motor mount was in the way of perfect spacing as were the hinge pins. I was wrong. The engineer side of my brain said do it over and do it right and forgo the exact symmetry. So I removed all the right side flanges and redid the spacing so the corner had a fastener. So while the vertical portion of the cowling is not spaced, is very acceptable, misses the motor mount and allows for installation and removal of the side hinge pins. The horizontal row is spaced at about 3.50. I will use new flanges and drill through the existing holes on the right side of the cowl. The problem (in my head) solved. The left side hasn't been done yet, so it's just a remarking exercise.

  Oct 27, 2023     Cowling - (3.0 hours)       Category: EXP-119

I riveted each flange to the lower cowling (on the right side).

  Oct 26, 2023     Cowlng - (3.0 hours) Category: EXP-119

I drilled each hole to attach the Skybolt flanges. I then removed the flanges and countersunk each hole.

  Oct 24, 2023     Cowling - (4.0 hours)       Category: EXP-119

After laying out the hole pattern I attached each flange with cleco clamps to get a good look at the layout.

  Oct 23, 2023     Cowling - (3.0 hours)       Category: EXP-119

Now that the lower cowling is in place I began the layout of the flanges that will attach the upper cowling to the lower. The layout included identifying where each flange needed to be trimmed to acquire the correct distance between the fasteners, developing the rivet pattern for attaching the flanges to the lower cowling and identifying the need for longer rivets were the flanges overlap. Not a big deal but necessary to do this correctly.

  Oct 22, 2023     Cowling - (1.5 hours)       Category: EXP-119

A little more trimming between the cowling halves to get the exact "credit card" thickness the painter would like - almost there. I also started the flange preparation by laying out the attach line, countersinking each hole for riveting on the lock devices and determining that a 3.1" separation for each Skybolt fastener may work. The final separation distance of the flanges will be determined after the upper cowling's lower flange distance is finalized.

  Oct 21, 2023     Cowling - (3.0 hours)       Category: EXP-119

Again progress is being made. The hinges were deburred, the holes in the fiberglass were countersunk and the hinges riveted to the cowing. The lower cowling was installed on the plane. There are two minor trouble spots needing attention: 1: the hinge pins are difficult to install and remove. I think a little polishing may allow for a better fit as well as some lubrication. 2: Of course the usual trimming continues. The fit between the upper and lower cowling pieces is excellent, but a slight paint gap is necessary. HINT: Trying to get the correct gap I'm still using a 'hotel room key card' thickness (.025") between them is a challenge. I found that taking a piece of 100 grit sandpiper and placing it on the card and going back and forth in between the cowlings halves works pretty good. A couple of minutes of doing that, then removing the sandpaper, then sliding the room key back and forth to check for the gap is a good way to get it correct. Your results may vary. Still some tweaking to do there. Of a lesser concern there is a slight excessive gap of about .050 on the right side upper cowling to forward skin. Some filler may have to be used to close that gap OR perhaps after final installation of the top cowl, that gap may sufficiently close. Either way, not a big deal.

  Oct 20, 2023     Cowling - (4.0 hours)       Category: EXP-119

Progress! The lower cowl was slightly trimmed and the aft vertical hinges were connected to the airframe hinges and drilled. They are now awaiting countersinking and riveting. The upper cowl Skybolts are now installed.

  Oct 19, 2023     Cowling - (4.0 hours)       Category: EXP-119

Slowly, and I mean slowly, work continues on the cowling. That being said, today was a good one for progress. The upper cowling had two Skybolt fasteners installed to sort of secure the cowling in place while the lower cowling was trimmed even more to now fit flush with the forward skins. The big trim was the upper/lower mating surface. The lower cowling was trimmed to be flush with the upper cowling and soon it will be trimmed to have an acceptable gap for painting.

  Oct 18, 2023     Cowling - (4.0 hours)       Category: EXP-119

Over the past few days I've been slowly working on the lower cowling, trimming (sometimes as little as a 1/64" at a time), sanding, over and over and over again. At this point I now have an excellent fit between the front and back of the upper and lower cowlings although the lower cowl still needs to have the aft end trimmed to allow for the paint, about .025 inches. Once that's done the lower cowling (fore to aft) will need to be sanded to match the upper cowling for the Skybolt fasteners. Also, the aft hinges, lower Skybolts, the oil door as well as the 4 plate nuts on the nose pieces still remain. However. there is light at the end of the tunnel and it's not an oncoming speeding train.

  Oct 11, 2023     Cowling - (2.0 hours)       Category: EXP-119

Completed the drilling and clecoing for the inserts on the Skybolt flanges. I tried to align the lower cowling to the upper but without too much success. It appears I'll have to trim the upper edge of the lower cowl so that it's about a 1/4" from the "likely" true edge line since it appears the current flange distance is too great to get a reasonable fit and for scribing the top and aft edge lines for the "near" final trimming. Hopefully not a big deal.

  Oct 10, 2023     Cowling - (2.0 hours)       Category: EXP-119

I decided to drive to Skybolt in Leesburg (3hour round trip and worth it - what an awesome facility) and picked up some additional inserts and magnets. I had found that using a light under each one didn't work because the gelcoat was too opaque. So, after taping the inserts, with magnets installed, to each of the flanges, I then placed the cowling on the plane, aligned it and secured it in place with Gorilla tape. Good stuff. I took another magnet and placed it near the where I thought the insert would be. Those magnets are STRONG and found the lower magnet like a bat out of hell. The idea was to mark a few dots around the magnet, find the center and drill a #30 hole and cleco the cowling to the insert. But rather than estimate the center of the insert I took a template and drew a good circle by connecting the dots. I tested this location once or twice and each time the magnet returned to the same spot. Then I took the square template, centered it and marked a square around the circle. Then connecting the corners I drew a line from opposite corners and the intersection was the center where I drilled and added a cleco. Worked each time and then I moved on to the next flange. I ran out of time, so I'll continue this tomorrow.

  Oct 09, 2023     Inventory - (1.0 hour)       Category: Avionics

I completed the inventory, to the extent possible. since I didn't want to tear into the many piece parts in the boxes. I'm confident it's all there and if there's something missing I know that AFS will make good on it. There are two pictures below. One, is the 70 pound box everything came in and the other a peek at the SIC panel with the AFS-6600, G5 and a few other items.

  Oct 09, 2023     Cowling - (1.0 hour)       Category: EXP-119

Off to a great start then bam! I found I didn't receive the magnetic inserts to align the cowling and with the gel coat it's difficult to see light shining thru the small hole in the insert. I called them so tomorrow I'll drive over and get the correct ones. Skybolt was great so it's no big deal. While trying to get the perfect fit I found it necessary to slightly bend the flanges downward to get a good fit, so at least something was accomplished.

  Oct 08, 2023     Cowling - (3.0 hours)       Category: EXP-119

The upper Skybolt flanges are now riveted to the forward skin, less the lower one on each side. All went well, but the left side spacer came loose and I used RTV to seal it in place and prevent the cockpit from possible water intrusion. Fortunately the right side sealant was fine.

  Oct 07, 2023     Cowling - (3.0 hours)       Category: EXP-119

The left side Skybolt flanges are now drilled and clecoed to the fuselage. (Measure 10 times, drill once.) Additional measurements show the nominal distance between the flange holes is about 3.5", optimum for the RV-14 and just where I wanted it to be. The lower flange on both sides are not going to be drilled until the lower cowling is fit. Both left and right lower flanges are within .15" of each other. in terms of location on the side skin. They will be marked and removed so they can be installed later next week. Next on the agenda is to rivet the flanges in place and drill the upper cowl for the fasteners.

  Oct 06, 2023     Cowling - (3.0 hours)       Category: EXP-119

Today was right side flange installation day. The flanges have been countersunk so it was time to lay them out on the top skin and properly space them to allow for the lower flange to be adjusted so as to be in line with lower cowl Skybolts . The spacing proved to be just slightly less (about 3.3") than the suggested maximum of 3.5 inches. All the flanges were also spaced 1/4" forward of the forward edge of the skin. The flanges were clecoed as I drilled thru them and the scrap metal vacuumed to avoid contaminating the engine any more than necessary. The lowest flange (blue taped) is undrilled and trimmed to avoid the vertical hinge. Now to do the left side before aligning the lower cowl. I did notice that the lower cowl vertical hinge pin may have a problem being inserted behind the lower flange, but I'll have to wait and see how things work out. There are options - I hope. Riveting will come later.

  Oct 05, 2023     Cowling - (3.5 hours)       Category: EXP-119

Long ago I decided that my upper cowling will have Skybolt Fasteners, like my RV-7A. They are simply the best!!! Also, I will have the top and bottom edges of the lower cowl also use the Skybolts, but not the aft surface. I drilled out the top hinges while clecoing the spacers to the skin. That was easy. The aft portion of the lower cowl will retain the hinge. Great decision; however upon closer inspection the lower aft hinge extends way past the split line so I had to remove many of the lower hinge rivets so the top 4 inches or so could be cutoff. Not easy, but I got it done by grabbing the top of the hinge with a needle nose, pulling it out away from the fuselage, then grabbing it with a vise grip plier while snipping it off with a metal snipper. That being done I ground the top surface flat as best as I could, sanded it smooth then reclecoed the hinge. I then cleaned up the metal shavings (which were everywhere, despite yards of tape to catch the debris) to get it ready to install the Skybolt flanges.