Project: RickWeiss   -  
            Listing for Category : exp-119
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Builder Name:Rick Weiss   -  
Project:   Vans - RV-14A   -   VIEW REPORTS
Total Hours:2059
Start/Last Date:Jul 21, 2020 - No Finish Date
 
Friendly URL: https://eaabuilderslog.org?s=RickWeiss

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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 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     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.


 
Oct 03, 2023     Cowling - (2.0 hours)       Category: EXP-119
Work continues as I trimmed the lower cowling's aft and upper trim lines. I also redid the cowling #40 holes in the front that are use for alignment. It's coming along as the aft trim now has the lower cowl butted up against the forward skin and the upper trim line (not yet trimmed to fit) fits more easily under the upper cowl. Still not ready for prime time but it's getting closer. I also squared the mating surfaces of the front of the upper and lower cowls - again. Sadly, much more trimming left to do:-(


 
Oct 01, 2023     Cowling - (1.0 hour)       Category: EXP-119
I started the lower cowling installation and after quite a few measurements I decided to reduce the lower cowling upper flange to get a better fit for measurements. I managed to cut into the first piece about 3 inches and the cutter disintegrated. I'm out of cutters so I wen on to fabricating the aft vertical hinges and hinge pins and the oil door for the upper cowling. It's off to the store tomorrow for new cutters. Shattering happens and it does hit the fan.


 
Sep 28, 2023     Cowling - (2.5 hours)       Category: EXP-119
Now that the upper cowling fits nicely on the hinges it's time to take the plunge and sand it down to .050 along the firewall skins. I found that 2 hotel room keys are not only good for smoothing and spreading Superfil but are exactly .050 in thickness (see the top of the home picture). It took quite a few sanding, being careful not to take too much off and still maintain the 3/16" prop spinner clearance, but it's done and close to being symmetrical. I'm surprised it took so long but doing the fit checks each time and then sanding a little at at a time, was worth it. Now I need to read up on the Skybolt installation for the upper cowling. Also, tomorrow (I hope) it'll be time to drill out the 42 rivets holding the upper firewall hinge in place.


 
Sep 27, 2023     Cowling - (2.0 hours)       Category: EXP-119
Lots of sanding but I finally got the upper cowling to fit inside the forward skins and 3/16" from the spinner. It's an almost perfect fit and now I can draw the line on the cowl that will provide the ideal setback for the Skybolt system and paint allowance, then trim to that mark. It's not by the book, but I think it will work for my plane.


 
Sep 26, 2023     Cowling - (4.0 hours)       Category: EXP-119
Interesting day as I started the trimming process of the upper cowl. My friend Dean and I discussed some options and I decided to deviate from the plans as I'm using Skybolt fasteners instead of hinges. I am leaving the upper hinge in place to use as a resting place for the aft trim of the cowl until it has been fitted. Then I'll drill out the 42 rivets, remove the hinge and begin the replacement process with the Skybolt system. So for now I determined the center line of the aircraft and drilled and clecoed the angle to the cowl with a full size washer underneath the angle. (By the way, I chose to use the full washer because my experience has been that the engine will settle a little more than the directions suggest.) I placed 3, 3/16" bolts in between the spinner and the cowl. I'm using a MT prop so the directions aren't quite correct for me since my spinner extends aft past the bulkhead plate. I do have the luxury of having the spinner and hub assembly available without the blades. Also, the 3 blades add another 23 pounds so I have a back pack hanging from the assembly with the correct weights in it. I laid out a cut line on the forward skin and transferred that dimension to the aft portion of the cowl and did the first trim. My theory is to not be aggressive on this cut. It'll take another sanding or two to get it just right. So far so good.


 
Sep 25, 2023     Cowling - (2.5 hours)       Category: EXP-119
Continued trimming work on the upper and lower cowlings. As can be seen from the previous entry, I was disappointed in the fit of the cowlings. However, after following the directions (who needs them? - right!) I determined the upper cowl required about 3/8" trimming so I did that, pretty easy. The refitting showed another 1/16" was necessary to make it darn near perfect, so I did that (sorry, my OCD kicked in). With that done, I drilled the 2 #40 holes, separated the pieces and temporarily placed the top cowling on the plane just to enjoy the look:-). To end this work session I made the angle piece that will fit on the top of the cowl/spinner for spacing


 
Sep 23, 2023     Cowling - (3.0 hours)       Category: EXP-119
Completed fabricating the left and right cowl inlet ramps. I'm sure there will be more to do getting them to properly fit, but that's for another day (or week.) It was somewhat fun and I think they turned out good. Then it was on to more cowling work as I prepped the lower and upper cowl by sanding the inside cowl lower cowl flange flat for future nut plate installation, measured the 'step' on each side and sanded the upper flange to accommodate the lower flange. I opted to keep the upper cowl area just a little bit thicker to provide more support for the eventual screws that will go there. The upper cowl inside flanges were 'squared' off so it would fit better on the lower cowl. Finally, I placed the cowls on 2x4's on the floor and clamped them together. Quite disappointing as they didn't fit as well as I had hoped for. Obviously more trimming and sanding to do. Oh well.


 
Sep 22, 2023     Cowling - (3.0 hours)       Category: EXP-119
I continued attacking the upper cowling smoothing out the oil door opening, as well as cutting to both the upper and aft scribe lines. All work went fairly well and little details like getting the surfaces as flat as possible took quite a bit of time. Also, the curve coming around the front to the air inlets proved a little challenging. The instructions are correct as there will be a slight gap right in the front of both sides where cowling starts to go aft. I knew this when I started and tried to avoid it, but it's apparently a function of the geometry, so it's there, just as called out. With the remaining few minutes that I had left for today I decided to begin to trim the upper inlet ramps. I started on the left one and while I didn't finish I made some progress. I did use the bandsaw for the initial cuts so I didn't have to setup the vacuum, lighting and clamping of the part for the Dremel cutter, and then called it a day.


 
Sep 21, 2023     Cowling - (3.0 hours)       Category: EXP-119
Today's goal was to now cut and sand to the scribe lines on the lower cowl. It took a while, and with no surprises the lower cowl has almost been cut to the scribe lines. Though there's still more to do, like taking care to get each area flat and right on the scribe lines which happens later in the construction. With this done I decided to get a start on the upper cowling by cutting the oil filler door opening. I drilled holes where the opening had sharp bends then did a rough cut out. Smoothing to be done later.


 
Sep 20, 2023     Cowling - (2.0 hours)       Category: EXP-119
I removed the area forward of the 3.5" mark on the forward corners of the lower cowl. There was no need to smooth the vertical portion as it will be removed later. I still need to sand to the split of the scribed line on everything being done, that is once the cowling is clean enough to see it without magnification. Also, note to self: post better pictures of this area. With this done I cut out the nose gear area. It looked daunting but it went well. Sure did generate a ton of a dust. So, the most enjoyable(?) part? Making the cutout for the nose gear. I used a combination of nearly every sanding tool I had, including a little old fashioned sanding by hand to make the required curvature. I think it actually looks good. But I always remember the words of my 4th grade art teacher, Mr. Mustari. He said, and I quote "self appraisal stinks"! So I'll have to let fellow builders here in Spruce Creek be honest (they will) and critique the work.


 
Sep 18, 2023     Cowling - (1.5 hours)       Category: EXP-119
Began the process of trimming the air inlets and area around the spinner for both the upper and lower cowlings. I found some substantial 4x4's and heavy motor to stabilize the cowls and a vacuum to help suck the dust away. What a dirty, filthy job this is:-) I used a Dremel cutting wheel then a combination of Ryobi hand held belt sander and flat sander in addition to a sanding plate. It can be seen in the photos that there's a little more to go to split the scribed/felt tip marker lines. A little more to sand in a couple of areas, then I can move on to the upper and lower cowl scribe lines. Yep, the fun just never ends.


 
Sep 16, 2023     Cowling - (2.0 hours)       Category: EXP-119
The upper cowling scribe lines left me questioning whether or not mine were correct or perhaps some were missing. I went to friend's house and looked at his cowling and sure enough a couple of scribe lines are on his, but not mine. I went to my hangar and added these lines to my cowl. There are still one or two in question and his were no netter than mine. More research to do. I took my MT hub and spinner assembly and installed it on the aircraft, not torqued, but only snugged. You may notice some AN3 bolts between the hub and flywheel. These were temporarily used so that the final snugging of the attach bolts were done more symmetrically. I'll use the spinner assembly and a spacer for aligning the cowl pieces. I also located and marked the engine center line on the forward fuselage and secured a tape measure along the forward fuselage for future marking for the Skybolt fasteners.


 
Sep 13, 2023     E Mag - (2.0 hours)       Category: EXP-119
After examining yesterday's work I decided to redo the attachment of the spark plug wires on the top of the cylinders by adding a piece of silicone to the attachment in order to provide more clearance from the engine hardware. I installed the adel clamps for the top plugs of cylinders 1 and 2. I also used the aft adel clamps on the back of the baffles (be careful that blind cylindrical retainer nut doesn't fall out:-) NOTE: The adel clamp call outs in the plans are not correct for E-Mag wires so I decided to up the size from the DG- 4 to a DG-5 due to the larger diameter of the spark plug wires.


 
Sep 12, 2023     E Mag - (3.5 hours)       Category: EXP-119
After the research done on Sunday a lot more research time went into today's work. I also downloaded an additional E Mag document to better understand how to sort out the spark plug wiring scheme and get my head wrapped around which wires go where. After studying the installation and laying out the wires and labeling them I was ready to install the top spark plug wires. Easy task - NOT! Those little plastic wire holders that are screwed into the nut plates on the back of the rear baffles were a bear to install. NOTE: Turns out those plastic do-hickeys were sized for regular mag wires, not E mag wires. I finally had to drill them out to 5/16 to fit the wires. With that done, I became a contortionist trying to fit them in place, but after a lot of struggling, I got it done. It must be me and my fat hands. A normal person could have done it in a lot less time. Oh well, it is what it is and at least it's done!


 
Sep 09, 2023     Research - (3.0 hours)       Category: EXP-119
Spent a lot of time trying to figure out the E Mag ignition wiring. There are no labels and the drawings weren't much help. With the engine installed I couldn't get a good picture of the back of the E Mags in order to figure out how to do this. I tried using mirrors and other tricky things with the camera, but no joy! The E Mag manual was somewhat helpful, but you have to be able to see the back of mags. SUGGESTION: Take a picture of the back of the engine before installing it and focus on the E Mags. Fortunately, after a while I found a drawing that someone on VAF had developed that I believe will solve the problem. I wish I had the builder's name handy to give him credit, if you search I'm sure it will pop up.


 
Sep 08, 2023     Cowl Baffles - (3.0 hours)       Category: EXP-119
Again, with the glue now dry on the template for the left front air filter cover baffle I began the process of bending it to fit the baffle ramp. I modified a small piece of wood to give me a shallow angle rather than the typical 90 degrees. Using the hammer turned out to be adequate and the pliability of the material allowed my fingers to help form the correct shape. Checked it using the bend radius template. Pretty darn close. Once i was done it took quite a while to get the adhesive off - good stuff for sure. After getting it cleaned up I installed it, match drilled for the nut plate, took it apart, installed the nut plate with flush rivets then reinstalled everything with the new air filter.


 
Sep 07, 2023     Cowl Baffles - (2.0 hours)       Category: EXP-119
Now that the glue has dried I started bending the CB-00034 right front ramp piece. Last night I couldn't get my head wrapped around the process to do the bending, but after getting to the hangar and placing it in the vise, it all came together. I used a digital protractor to check on my progress. (about 9-10 degrees for each bend number). Although not perfect it was a good guide as to how it was going. Once done I checked it against cowl baffle and ramp. A little tweak here and there and the fit showed to be excellent. Drilled, deburred, dimpled and riveted it in place and it was done.


 
Sep 06, 2023     Cowl Baffles - (.5 hour)       Category: EXP-119
I cut the templates for the left and right forward curved cowl pieces and glued them to the parts. It now time to let the glue dry before I bend the parts.


 
Sep 06, 2023     Snorkel Alternate Air - (.5 hour)       Category: EXP-119
The epoxy has cured and as expected, the errant hole is solidly in place. I cleaned up the surface of the alternate air inlet and it's nice and smooth although the picture makes it look awful. I went to the aviation aisle at Harbor Freight and purchased a socket set with a 7/32 socket to grab those crummy little steel locknuts. It worked, but it was still difficult to tighten, but I got 'er done. I did add two thin washers under the nut as the collar of the screw protruded a little too much for my comfort. With that done I added the washer and finger tight locknut on top of it, I screwed in the door until it had the correct 'tightness' or 'looseness' (your call). Regardless, it now operates smoothly, although it's not very pretty. Fortunately it's something that's routinely seen. Time to move on.


 
Sep 05, 2023     Snorkel Alternate Air - (1.5 hours)       Category: EXP-119
With the alternate air inlet epoxied in place, I cleaned up the holes and surrounding areas and set the rivets. I was concerned that riveting this thin piece of metal into the thin fiberglass would be a problem, but fortunately things went well -- until the last rivet. Then it went to hell. The rivet gun sort of dented the plate around the hole and the rivet was a disaster. I should be happy 4 out of 5 went well, but I'm not. Also, the hole got too enlarged to use an AD4 rivet so I thought a large flat head screw with a steel lock nut would work well, but then I thought of something going really wrong and the nut could come loose and go into the fuel injector and then the engine. Scratch that idea! Then I decided to just re-epoxy the hole and the surrounding area, fill the dented area then sand it smooth. It's now curing. Problem solved. The chances of even actuating the Alt Air are slim so I'm comfortable with this decision.


 
Sep 04, 2023     Snorkel Alternate Air - (4.0 hours)       Category: EXP-119
Today I laid out the pattern for the alternate air opening in the snorkel and drilled out the main hole then smoothed the edges after fitting the alternate air inlet. A hole saw would have made this a tad easier, but you have to have one the right size. Oh well, I then drilled the attach holes into the snorkel for the air inlet, followed by bending the the door tab to fit the closure door. With that done, I dimpled the #30 and 40 holes, riveted the nut plate in place, installed the screw, opened the #40 hole to a #19 hole and finally the 1/4" hole to 'hold' the nut plate in place. After sanding and cleaning the area, I clecoed the assembly in place on the snorkel and stuffed epoxy filler into the appropriate areas including the alignment holes in the frame. Now it's sitting around curing. NOTE to OTHERS: The drawing depicts 3 #30 holes to the right of the upper tab and two to the left. I checked around and the actual part has 3 holes to the left of the tab and two the right. With Van's being closed for Labor Day I made a command decision that the drawing is wrong and my part, like many others, is correct. I'm building on, however your mileage may vary - check it out for yourself.


 
Sep 03, 2023     Snorkel Installation - (1.5 hours)       Category: EXP-119
This morning I mixed up the flox mixture and sealed the areas around the frame and snorkel. Used Boelube to protect the clecoes from getting stuck in the frame. Now it's chill out time as it'll take all day to cure. It certainly went faster and better than expected.


 
Sep 02, 2023     Snorkel Installation - (3.0 hours)       Category: EXP-119
The snorkel installation is well underway. It's been fitted with very little, if any preload. The fuel control end has had the slots cut and the drain hole drilled. The attachment to the air filter frame has been completed with the drilling of the 8 alignment holes. (These get filled with epoxy later.) With the alignment holes drilled I marked the the top of the snorkel for trimming and trimmed away. It looks like it'll be a good fit. The surfaces of the frame and snorkel are roughed up and clean, waiting for the epoxy work to begin. I wish I was building a metal airplane.


 
Sep 01, 2023     Snorkel Installation - (1.0 hour)       Category: EXP-119
Following the instructions to remove the air filter frame turned out to be a little challenging after stripping a screw due to the prop governor being in the way. Once out though, everything went smoothly with the snorkel needing minimal trimming for the proper fit. That's as far as I got. Next on tap is cutting the slots trimming the top of the snorkel, etc.


 
Aug 31, 2023     Cowl Baffle Tension Rods - (3.0 hours)       Category: EXP-119
Yep, 3 more frustrating hours of installing those &*#$ tension rods nuts. It looks so simple. Anyway, they're installed and secure. I did find a very, very small socket wrench that worked. Along with my friend Ron's helping hand, we got'er done - finally! I'm sure it was just me and others may not have this problem - at least I hope not. The pictures below show the underside of the installed tension rods.


 
Aug 30, 2023     Cowl Baffle Tension Rods - (3.5 hours)       Category: EXP-119
Fabricated the 4 baffle tension rods for the lower part of the baffles. Cutting the 6-32 threads into the stainless rods took more time and effort than I originally thought. I had to use plenty of oil to cut the threads and I found once a thread was started (which was somewhat difficult) cutting the next 1/2 inch of threads was easier. The rods were cut spot on and precisely bent per the plans and then the plastic was cut to fit. Those -3 size locking nuts and washers are tough to hang on too (they're so damn small) and unfortunately, the rods are a pretty tight fit so they kept popping off. In retrospect, I should have cut them slightly longer - HINT! I found it best to attach the hardware on on one end, slide the rod thru the hole in the baffle, then slide on the plastic tube and then 'try' to attach the washer and nut on the other end. I just couldn't do it today as I ran out of patience and time, so I'll try again tomorrow. I may have to purchase a teeny tiny socket set to fasten them. My current wrenches aren't up (or is it down) to the job and frankly neither am! If I only still had little kids around the house.


 
Aug 29, 2023     Cowl Baffles - (2.0 hours)       Category: EXP-119
This morning I installed the left and right forward baffles and ensured all fasteners were secure. Pretty straight forward process, but the CB8-31 'nut' on the right was difficult to install due to the slanted baffle preventing a good head on wrenching opportunity and a small clearance preventing a ratchet wrench on the bolt. Other than a superb, but tight fit, the baffles are now in place. After Hurricane Idalia passes us tomorrow, I'll get out to the hangar and press on.


 
Aug 28, 2023     Cowl Baffles - (4.0 hours)       Category: EXP-119
The left and right forward cowl baffles are now 'complete' and ready for installation once the RTV has dried. Actually, there is more work to do on them, but the basic construction is done - for the time being,


 
Aug 28, 2023     Engine Oil Dipstick Tube - (.5 hour)       Category: EXP-119
Finally got my fat fingers into the right place and the safety wiring of the tube is complete. Not especially pretty, but it's done.


 
Aug 27, 2023     Engine Oil Dipstick Tube - (1.0 hour)       Category: EXP-119
After much consternation, cussing and a series of calls to Lycoming tech support the replacement tube from Lycoming arrived and was finally successfully inserted into the engine. Safety wiring it in place remains and will be done soon. Many hours have been spent trying to resolve this issue and thanks go to the techs at Lycoming for their help. If they could have only had the right fitment from the beginning there would have been less anguish. Oh well, it's done.


 
Aug 27, 2023     Cowl Baffles - (3.0 hours)       Category: EXP-119
Started work on the forward left baffle. The fiberglass air filter frame was trimmed along the, barely visible, scribe lines. Using the band saw and Dremel cutter the part was perfectly trimmed. The nut plates were attached and the rest of the baffle parts were clecoed then riveted in place. Final trimming of the fiberglass frame was accomplished so the CB-001 baffle could be riveted in place. Rather uneventful, but rewarding morning.


 
Aug 26, 2023     Cowl Baffles - (2.5 hours)       Category: EXP-119
This morning I decided to remove 2 small screws in the aft corners of the engine. These seemed to interfere with the installation of the adel clamps. I taped the bottom of the engine where it appears the CB8-31 cylinders were supposed to be installed. I believe they were already installed and the tape kept them in place during the installation. Both sides were completed and everything fit fine. I could not find these screws or fittings on any of the documentation, but hey, it worked. I moved the CB-0004 bracket to the left side of the engine (as I did on the aft bracket). I cut the called out tube about 7/8" long and installed it with the AN4-16A bolt and other hardware. It was a real bear getting everything in place with my fat hands, but it I got it done. So the left and right aft cowling pieces are completely installed - less of course the final RTVing. Check it off! I also began the deburring of nearly all the remaining baffle pieces.


 
Aug 25, 2023     Cowl Baffles - (4.0 hours)       Category: EXP-119
Deburred the forward and aft cowl attach parts (CB-0004 and CB-0016). Did the RTV application per the drawing to the left and right rear baffles and let it set up. Now learning the hard way - if you're doing this use caution, unless I read the drawings incorrectly (I can do this) the aft bracket is depicted going on the left side of the engine - WRONG! It attaches to the right side, else it won't fit properly when the left and right rear baffles are attached. Be careful out there. Please note: I included pictures that show the brackets attached on the left side (incorrectly), but I also included the pictures showing the correct installation. I attached the left cowl baffle side first, with little problem - so far. Then I attached the right side. However, I know the instructions say 'to make it easier remove the cylinder 3 oil line', but I chose not to. Turns out I guessed right (finally). With a little encouragement, everything fell into place. The aft screws to the center bracket were a little tough to align, but it did get done. The screws over cylinders 3 and 4 went in easy and the single screw just below the engine mount on the right went in okay. However there are two screws, one on each side in the lower engine area, that protrude out and prevent the CB8-31 part from being installed. I called it a day after that so I could do some research in that area. A little more to go and the aft portion should be complete, less RTV'ing - I hope!


 
Aug 24, 2023     Cowl Baffles - (3.0 hours)       Category: EXP-119
Began the right aft baffle construction. A little more complicated than the left one. The excess material was removed and the main part deburred. All the parts needing dimples were dimpled either via the dimpler or machine dimpled. The CB-00010 was prepped and painted because it got 'scratched' up in order to machine dimple. The 'bridge' pieces were assembled and riveted to form an assembly and then the assembly was riveted to the main structure. Parts needing painting because they weren't alclad were prepped and painted with high temp black paint then assembled. The baffle for cylinder 3 was riveted in place. Right rear baffle nearly complete.


 
Aug 22, 2023     Cowl Baffles - (1.5 hours)       Category: EXP-119
Despite the difficulty of having to use the rivet gun, parts of my body, and the vise to hold things steady, I managed to get the riveting done without too many dings and no DNA marks on the aluminum. The cowl baffle over cylinder 4 was also attached to the rear baffle. Left rear nearly complete.


 
Aug 21, 2023     Cowl Baffles - (1.0 hour)       Category: EXP-119
Began fabrication of the left rear cowl baffles. I discovered that the CB-00023 baffle was one of the laser cut pieces. It had no blue film to peel off and terrible holes, somewhat jagged holes with turn marks. In order to keep doing work and since this was a low stress area, less the possible vibration issues, I decided to up size drill the holes to 1/8 inch and use AD4 rivets. There were no edge distance issues so it seems like this will work. I also took quite a few thousands off the edges during deburring. Again, no issues with that. I completed about the half the work on the left rear and wasn't happy about my crummy riveting on these flimsy parts, but I'll get over it - maybe!


 
Aug 19, 2023     Baffles - (2.5 hours)       Category: EXP-119
Began building the baffle system. The baffles on the outside of the cylinders were completed (not yet installed and the work on the left rear baffle began. The CB-00023 baffle was laser cut (2022) and appears to have the damages one would expect. However, I'll give it a good look and since it's not in a high stress area, I may upsize drill the holes and use larger rivets as well as trim an extra few .001 around the edges and see if I can bypass the work hardened areas. I fall else fails I'll call Van's and get a new part - if available. I don't think this is a critical area but.....


 
Aug 18, 2023     Oil Filler Tube Problem - (3.0 hours)       Category: EXP-119
The saga continues as to why the oil filler tube will not thread into the engine. This is now the second one that won't fit as Lycoming replaced the first one earlier this week. (Many folks have tried to install both tubes (unsuccessfully) which thankfully means it's not me.) The remaining options, in talking with Lycoming tech support, are 1, they have a bad batch of filler tubes (my hope is this is correct) or 2, they incorrectly sized the fitting in the engine in which case the engine will be have to be returned to Lycoming for correction. This would be torture to have to remove, uninstall everything, repackage it for shipping AND then have them repair the engine, send it back and reinstall it. Essentially starting the engine installation all over.


 
Aug 18, 2023     Parts Assembly - (.5 hour)       Category: EXP-119
Installed the oil hoses on the oil cooler AN fittings and secured them with tie wraps per the plans and one additional one on the VA-190 hose.


 
Aug 16, 2023     Parts Assembly - (4.0 hours)       Category: EXP-119
I completed the oil cooler tray by countersinking the #40 holes and riveting the nut plates and supports to the frame. The firewall protection I installed earlier proved to be a little too thick to let the assembly align properly so I had to cut off a piece of it to allow the tray assembly to fit properly. Once that was done it all came together. I ran a bead of RTV on the cooler inlet assembly and let it dry a little while. I placed the oil cooler on the tray then the assembly on top of that. Bolted it together, then RTV'd the slight openings in each corner. Now the system can sit and cure before attaching the inlet and outlet hoses.


 
Aug 15, 2023     Parts Assembly - (3.0 hours)       Category: EXP-119
I attached the oil pressure hose at both ends and also ran the hose thru the adel clamp shared with the + battery terminal. Attached the oil supply and return hoses on the engine side. The left and right oil cooler seals were adhered to the cooler with clear silicone adhesive. The curvature of seal (due to packaging) made it difficult to keep them straight so I wrapped them to the cooler in blue tape. Ugly, but it seems to have worked. I'll know tomorrow:-) I sealed the eight corners of the cooler inlet assembly with Blue, Hi-Temp RTV. (The adhesive and RTV need 24 hours to fully cure.) Meanwhile I deburred and primed/painted the F-01405 support.


 
Aug 14, 2023     Parts Fabrication - (1.5 hours)       Category: EXP-119
The duct flange was primed/painted to match the rest of the assembly and the oil cooler had the inlet and outlet elbow fittings attached at the precise angles called out on P. 49-07. Helpful hint: Be sure to check the P. 49-01 drawing to make sure the fittings match the drawing. IMHO the P.49-07 drawing isn't that clear. Out of an abundance of caution I didn't tighten the fittings as much as I thought they should be as they were getting much too tight. Now I think they're a little too loose, but we'll see when there's fluid going through the system.


 
Aug 13, 2023     Parts Assembly - (1.0 hour)       Category: EXP-119
Fabricated the cooler inlet assembly by riveting the duct flange to the oil cooler inlet assembly. I'll paint the duct as assembled, mainly because I missed the call out, duh, no big deal. The corners have been taped off for the application of RTV. The photos show the painted tubes and support flanges as well as the duct assembly.


 
Aug 12, 2023     Parts Fabrication - (2.0 hours)       Category: EXP-119
Completed the installation of the power cable for the alternator. Started on the oil system: The 4 oil spacer tubes were cut, deburred and prepped for painting as were the oil cooler tray supports. All the parts were pirimed/painted. Van's excellent parts service sent the missing sniffle valve exit tube so now it was cut and installed.


 
Aug 11, 2023     Parts Assembly - (2.0 hours)       Category: EXP-119
Attached the alternator to the engine, but that's it. Complete installation will have to wait until the flywheel is attached. I also ran the power cable from the alternator to the interior of the cockpit. While it appears easy, it isn't. Those adel clamps are tough to work with with, especially in hard to reach places. Putting two together is not fun, but it is doable.


 
Aug 10, 2023     Parts Assembly - (2.0 hours)       Category: EXP-119
Time to install the fuel servo. I opened the box and hit the jackpot. It was chock full of parts; - nuts, bolts, washers, electrical connectors, gaskets and a lot more, and oh yes, the servo. It's a good looking piece of hardware. However, there were no installation instructions, parts lists, etc. I did go online and found a lot of good info about the servo, but nothing really specific to the RV-14. Time to resort to the database in my head. I did get it installed using one gasket, 4 steel lock nuts and 4 washers. That's it. I taped up the inlet for the time being to keep out the dust and dirt until the snorkel is installed. I then installed a wire, per the plans from the start solenoid to the starter. The ring terminal on the starter side didn't fit so I enlarged the hole just slightly and that seem to work. I may revisit that later and install a larger ring terminal. Finally, I secured the wire to the start cable and engine mount. One last note to share. For the fourth or fifth time I took a crack at installing the oil/dip stick tube. No joy. Called Lycoming support - excellent service. They said others have had this problem so they will replace it under warranty. Seems the plastic threads don't always fit right.


 
Aug 09, 2023     Parts Assembly - (3.0 hours)       Category: EXP-119
Completed the installation of the starter cable by attaching supporting adel clamps to the engine mount and then attaching the aft end of the cable to the start solenoid. I also secured the fuel transducer inlet line to the engine mount. I then attached the fuel inlet line from the firewall to the fuel pump. I learned of another good hint to pass along although I may be the last builder to know this. Rather then use safe wire to close the adel clamps for installation as called out in the plans, my friend John C. came by and suggested using small zip ties. Brilliant. Now I've stopped leaving my DNA on the plane, just saying!


 
Aug 08, 2023     Parts Assembly - (4.0 hours)       Category: EXP-119
I fabricated the sniffle valve tube and the short rubber attach elbow to the valve and installed it on the engine. Attached the starter end of the start cable to the starter then installed the adel clamp on the crankcase to support the cable (that was a real bear to install). Began the installation of the oil breather line by attaching the elbow to the engine outlet then installing the breather tube to the other end. The two adel clamps were also installed. Hint: Install the adel clamps on the firewall, then slide the tube thru them, then install the elbow on the engine. I found this much easier to do, your results may vary. The remainder of the installation, the rubber tube that goes over the exhaust, will have to wait until I get to the exhaust KAI.


 
Aug 07, 2023     Parts Assembly - (3.0 hours)       Category: EXP-119
I installed the sniffle valve (the center fitting on the bottom of the sump comes out with a 3/16 hex wrench - see the picture) and began the installation the oil breather tube. Fabricating the angle and installing the clamps were easy. A real simple installation one would think, BUT the location of the 'down tube' behind the engine makes it 'nearly' impossible to install the adel clamps unless you have three hands:-) It might be better to loosely install the tube before mounting the engine. Just a thought. The upper clamp is now installed (using two hands, cuss words + patience.) Actually it wasn't that bad. The lower clamp is bit more challenging and I'll do it another time.


 
Aug 05, 2023     Parts Assembly - (2.5 hours)       Category: EXP-119
Fuel flow transducer location decided: Those rubber clamps didn't seem like a good method for installing the red cube. Since I had to remove the intake manifold and pipes and reinstall them (twice) because the first time, upon reflection and inspection the o-rings just didn't look good. I decided I had to remove the red cube to free up the intake pipes. Then it was a no brainer to make a new bracket and use the two holes in the crankcase as the attachment. In either case I was concerned about heat affecting the instrument, so I took some heat shield material and completely covered the aft side of the bracket. In the next few days I'll add a hose clamp to secure the fuel hose to the engine mount. If in the future I find that this method didn't work, the next option is to put the red cube on the engine mount and order new hoses to complete the installation.


 
Aug 02, 2023     Parts Assembly - (2.0 hours)       Category: EXP-119
Back from a great time at Oshkosh. For those using the EXP version of the 390, I've learned some interesting information. As I mentioned before, I was installing the control bracket for the fuel injector and while I was torquing the right rear intake manifold bolt it sheared with the end of the bolt stuck in the engine block. I did have many restless nights, but after doing a lot of research and buying some good EZ outs, today we removed the intake manifold and pipes, filed the stuck portion of the bolt flat, center punched it, drilled it and hammered in the EZ out. One twist of the EZ out and the remnants of the bolt was easily removed by hand. I purchased new gaskets, o-rings, etc and reassembled the parts. Not happy with the left side pipe to manifold o ring seals, I'm going to redo it. I also decide to remove the fuel flow transducer to another, yet to be determined location. I'm just not happy with the way the plans call for it to be installed. More to follow another time. So, while at Oshkosh I learned that mine wasn't the only bolt that had sheared. Coincidence, I don't know, but just be cautious when installing those bolts. Lycoming Tech Support was very helpful while I 'suffered' thru this problem.


 
Jul 20, 2023     Parts Installation - (3.0 hours)       Category: EXP-119
The installation of the fuel flow sensor was interesting. The sensor, now with the in/out fuel lines installed, was attached to the mounting plate and the fuel pump outlet line was installed finger tight. With the sensor now sitting on the adel clamps it was quite the struggle to get the final bolt installed, but with my friend Dean's help and safety wire and adel clamp pliers and some cursing, we managed to get the nut started and then tightened up both sides. If you're reading this and haven't yet done this, relax and take your time doing it - with a friend. If you've done this. Congrats.

Next was the WD-10 plate installation, one of the easier things to do, except one of the bolts sheared. I had no idea I was that strong. The call is into Lycoming for the procedure to remove the remnants of the bolt. 2.5 hours on hold and I gave up and asked for a return call. Oh well, s**t happens.


 
Jul 19, 2023     Parts Installation - (2.0 hours) Category: EXP-119
Finished removing the desiccant from the engine and started on the installation of the fuel flow sensor.
 
Jul 18, 2023     Installation - (3.0 hours) Category: EXP-119
SImple - picking more desiccant crap out from between the cylinder fins. No pictures needed.
 
Jul 16, 2023     Installation - (6.0 hours)       Category: EXP-119
I waited to provide this commentary. The engine box was opened this past week and during the reveal, when the top cover came off the box, I discovered that 2 of the desiccant packs were ripped and that crap was everywhere on the engine. The box was in great shape so this must have happened by the clumsy packers at Lycoming. Today, Ron and I continued to clean up the mess. Vacuum and pressure were only minimally useful as this stuff was lodged in-between the cylinder fins. I cant believe the incompetence for a multi-thousand dollar piece of equipment!!!! Yes, I'm PO'd. The picture of this stuff on the floor only shows about a third of what we got out of the engine, but doesn't due justice to show what happened.


 
Jul 15, 2023     Parts Assembly - (1.0 hour)       Category: EXP-119
I drilled, countersunk, cut and deburred the fuel flow mounting plate and located the numerous parts it's going to take to make that installation.


 
Jul 14, 2023     Installation - (3.0 hours)       Category: EXP-119
It seemed so simple but it took 3 freaking hours and a lot of help to add the 2 washers and reinstall the engine, but it's done. I don't know why 3 hours, it didn't seem like it, but that's the way it was. So if you're doing this install, watch for those 2 lower washers that go against the engine and remember to put them in. By the way, the torque on those bolt/nuts is high. I went to a little over 40 ft-lbs which places it in the mid-range. IMHO, perfect!


 
Jul 13, 2023     Installation - (2.5 hours)       Category: EXP-119
After a lot of adjusting and tweaking we got the four engine mounts on. However, the lower two mounts will have to be slightly redone to install a washer I told myself not to forget - duh! I still think it looks great. Still remaining - torquing of the -7 hardware after the reinstall.


 
Jul 12, 2023     Unpacking & Parts Assembly - (8.0 hours)       Category: EXP-119
Uncrated the engine this morning and lifted it out of the box and its foam and plastic packing mess. Sawed the box into smaller, yet still large pieces for the trash pickup. That urethane foam is awful. Ended up using saws and pryers. Then I moved the engine, via the hoist to the workbench and placed it gently on the top piece of foam but kept the hoist attached - just in case. Then, per the plans, I installed all the fittings on page 43-06. That was fairly straight forward but I'm still searching for the brass insert for the fuel vent line. The prop governor went on with no problem and I had painted the bracket pieces and riveted them together earlier. All parts are properly clocked and taped off for the time being. I tried to install the dipstick assembly but could get the threads started so I gave up on that for now. Of course everything that looks like it should take 15 minutes took about 45. Access and removing the plugs took more time only because I spent a lot of time looking for the right tools. But, now it's ready to be hung on the mount and darn if it doesn't look nice.


 
Jul 07, 2023     Shop Preparation - (3.0 hours) Category: EXP-119
Completely cleaned, reconfigured the work area and began gathering parts for the pre-installation portion of the engine work, which I hope to begin in the next day or so.
 
Feb 19, 2023     Firewall Mods - (.5 hour)       Category: EXP-119
Removed the LP-4 rivets and installed the heat cover with new rivets LP4-4's and sealed the install with RTV.


 
Feb 18, 2023     Cowl Flap Fabrication - (2.5 hours)       Category: EXP-119
Call me crazy but I deviated from the plans, just a little. I wanted to get the cowl flap assembly installed so that it wouldn't get damaged just laying around. I didn't like the round head screws called out in the plans so I decided to countersink the holes and use flathead #8 stainless steel screws. I tested the countersinking on a scrap piece of aluminum and found that it would work if I was really careful and countersunk just short of perfectly flush. That would be acceptable to me. So I did that and it worked fine. One can barely tell that the screws are slightly proud - please don't tell anyone:-) With the tunnel screwed in place I rotated the fuselage upright and now work can continue on canopy frame.


 
Feb 10, 2023     Cowl Flap Fabrication - (1.0 hour)       Category: EXP-119
Match drilled the 4 #19 holes in the cross piece of the tunnel opening. Then I drilled and countersunk the holes for the nut plates for each hole. Here's another helpful hint: the two outboard nut plates will nearly butt up against the tunnel, therefore you have to either trim the nut plate or install them on a slight angle. Either way seems fine. I trimmed the nut plates.


 
Feb 08, 2023     Cowl Flap Fabrication - (1.0 hour)       Category: EXP-119
Completed fabricating the cowl exit door assembly by applying the UHMW tape and trimming it per the drawing. The next step was to bolt the exit door to the closeout assembly. Fortunately, I had a special tool that held the washers while inserting them into tight places which made the job easy. Once the bolts were inserted they were tested to ensure they would turn and they did, after little encouragement, like reaming the hole:-) I tested the opening and closing and there was a little binding which was resolved by filing the forward edges of both parts.


 
Feb 07, 2023     Cowl Flap Fabrication - (1.0 hour)       Category: EXP-119
Completed back riveting the exit door assembly. Fastened the cable support assembly to the closeout assembly, installed the assembly to the tunnel and then marked and drilled the rivet attach points for the cable bracket to the stainless tunnel, then deburred the holes and removed the assembly from the aircraft.


 
Feb 06, 2023     Cowl Flap Fabrication - (2.0 hours)       Category: EXP-119
Temporarily installed the closeout assembly, match drilled the #19 holes to the fuselage's F-1413 brace, removed the assembly and deburred the holes. Assembled the parts that are mounted to the closeout assembly and back riveted them in place. The F-1490-E was squeeze riveted to the side pieces.


 
Feb 05, 2023     Cowl Flap Fabrication - (1.0 hour)       Category: EXP-119
I riveted the tunnel exit door to the exit door doubler the riveted cable door brackets to that assembly. Then installed the hardware per the plans. So here are a couple of tips for what should be an easy task. First, check that large bushing will fit into both holes, a little reaming of the holes seemed to help. Also, think about this; if you rivet the brackets to the assembly first like I did, the two AN470AD3-3 rivets will be difficult to set since a squeezer won't fit in (I prefer squeezing these small rivets). A long offset rivet set will be necessary to use with a pneumatic gun and bucking bar. If you squeeze the small rivets first then hopefully the 6 rivets will be lined up for installation. (The fit is excellent so this is likely, but check first.) In retrospect, it wasn't that difficult, but I felt I made it more complicated than it had to be.


 
Feb 04, 2023     Cowl Flap Fabrication - (1.0 hour)       Category: EXP-119
All the cowl flap parts were scuffed with scotch bright, cleaned and painted silver. The paint used was a rattle can of high temperature resistant Krylon. I used silver rather than black, or other colors, so possible oil streaks would be easier to detect.


 
Feb 03, 2023     Cowl Flap Fabrication - (1.0 hour)       Category: EXP-119
Countersunk all the #40 holes on the bottom of the closeout cover and the cable bracket.


 
Feb 02, 2023     Cowl Flap Fabrication - (2.0 hours)       Category: EXP-119
The EXP-119 cowl flap parts were deburred, the exit door doubler's 37 machine countersinks were made and the closeout assembly's 6 #40 holes were matched drilled.


 


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