Mar 17, 2024     This and that.       Category: Various

Finished installing the wooden "shims" that put the Aveo nav/strobe lights at the tight angle.

Updated the Dynon SkyView software and database.

Configuring the Garmin data link for ADSB Out has been harder.

The engine hasn't run in months, so I pulled the plugs and ran it with the starter but no compression till the oil pressure came up into the green arc. Reinstalled the plugs.

Verified the timing marks so I can shoot them with a timing light to adjust the ignition timing.

  Feb 16, 2024     Pitot Static and Mode C check       Category: Avionics

Had James from Direct Avionics come over to do my required checks to operate in the Mode C veil. There were some leaks at the Air Data Computer, which tightening the fittings cured.

Also pulled the wing tip lights to allow installation of the shims.

James let me know the Garmin ADSB Out unit will need to be programmed via a laptop and a USB connection to reflect my N-number and ownership. I have no idea whether the USB port is accessible or if I need to pull the panel apart, AGAIN.

  Feb 12, 2024     Fettling       Category: Ignition

I've been working on the SDS electronic ignition. I had to splice in some extra length to the coil trigger leads to enable me to pull the control module off the port fuselage side to adjust and program it. I marked the flywheel with some timing marks so I don't have to get so close to the prop to time it.

Also fabricated some shims for the LED strobe/nav lights so the vertical sectors are correct.

Registered the ELT.

Adjusted the Peter Anson flap stop for the right hand flap.

Secured the last few fasteners on the windscreen and puttied it up.

  Jan 19, 2024     Riding the struggle bus       Category: Various

I broke the windshield, replaced it with some detail improvements to reduce stress concentrations, and finished wiring up the SDS ignition.

  Nov 19, 2023     The last 3 weeks... Category: Various

...have involved an EPIC struggle with the panel and the fuel gauge. The newly installed brand new fuel level measuring probe leaked, quite a lot. This meant draining the fuel, pulling the probe, taking extreme measures to seal the new probe and the OLD probe I thought I had killed by mistakenly disassembling it when removing it. After taking measures to seal EVERY POSSIBLE LEAK PATH on both probes, I installed, set the Zero at the Princeton/RED electronics box, and performed the calibration procedure for the Third time at the Dynon. Two days later, the probe sense wire is still bone dry. So I've started putting the front of the airplane back together.

  Oct 29, 2023     Reassemble the panel Category: Instrument Panel

With the fuel gauge fixed, I reassembled the panel. The extension is now secure with a mix of soft aluminum rivets, easier to drill out next time, and 4-40 machine screws into the previously installed itty-bitty nut plates.

  Oct 28, 2023     Third Time's A Charm Category: Fuel System

After reviewing both the manuals for the fuel probe and for the Dynon, I have the gremlins at bay. A few points: tri gear Sonex sitting level are hard pressed to take more than about 14 gallons of fuel. To get 16 in I had to put a chick under the nose wheel. The dip tube for manually checking the fuel level didn't work very well, and is going to be replaced with a wood dowel painted flat black. The actual fuel calibration routine in the Dynon SkyView is not like the manual - you tell it how big the tank is and it will tell you the size of the Pours.. For the last Pour in the sequence you press Add, then Full.

The key was calibrating the Princeton/RED box to zero before starting in with the Dynon calibration.

  Oct 16, 2023     Replace fuel probe, etc       Category: Fuel System

Replaced the fuel probe, but it clearly needs to be recalibrated, so I drained the fuel tank.

Developed a pattern for a "bib" around the fuel filler, per Jeff Schultz, to keep fuel spills out of the cockpit.

Also worked on the timing indicator for calibrating the electronic ignition.

  Oct 01, 2023     Nut plates       Category: Instrument Panel

I wasn't happy with the accuracy I was able to achieve using these tee-ninesy 4-40 nut plates as there own drill jig, so I fabricated a drill jig using idea from Tony Bingelis, using a chunk of mild steel and a section of brass tubing located in place.

Also finished fabrication of the fuel dip stick, and pulled the malfunctioning fuel sensor probe.

  Sep 04, 2023     Windshield off, glare shield extension off       Category: Instrument Panel

With my son's help, removed the last windscreen fasteners. Later in the day, drilled the last rivets in the glare shield extension to access the back of the panel and disconnected the fuel level probe, which needs to be replaced.

Also worked on the fuel tank dip stick, clear fuel tubing with an aluminum spine. Dip, hold your thumb over the tube, pull, read the level.

  Sep 03, 2023     Ailerons connected Category: Controls

Since Lee, Bill and I already checked the rigging, they are flight ready.

Messed around securing stuff at the wing roots, wires, pitot static plumbing, etc.

  Sep 02, 2023     Pushing       Category: Various

I've resolved to remove the added glare shield extension and reattach it with nut plates so I can access the back of the panel. So I drilled as many of the rivets as I could reach, and started to remove the windscreen which is a two man job.

I also bought some hole plugs and filled some unused holes in the turtledeck.

I installed the Peter Anson flap up-stop on the right wing.

I cleaned up some more of the firewall forward wiring.

I drained the fuel tank so I can replace the fuel level probe that I ruined.

And I connected the flaps to their torque tube.

  Aug 27, 2023     "Hero" wing spar pin in Starboard side Category: Wings

I don't like threaded fasteners in these tight holes, as it can be very tough to get the alignment dead solid perfect, and if it's not, the threads can "broach" the holes oversize. The factory planes use pins. It took a few tries, but I custom fabricated pins with a long, gradual taper to help with alignment, the proper grip length, and positive locking via a clevis clip. Starboard side is in and secured.

  Aug 27, 2023     "Hero" wing spar pin in Starboard side Category: Wings

I don't like threaded fasteners in these tight holes, as it can be very tough to get the alignment dead solid perfect, and if it's not, the threads can "broach" the holes oversize. The factory planes use pins. It took a few tries, but I custom fabricated pins with a long, gradual taper to help with alignment, the proper grip length, and positive locking via a clevis clip. Starboard side is in and secured.

  Aug 19, 2023     Details       Category: Ignition

I've been struggling to replace the Alignment, heavily tapered wing pins with the "hero" pins for flight for the last few work days. I finally got the adt spar pins in.

Today I worked on finishing up the firewall penetration for the ignition and rounded off the brackets for the cowling fasteners.

  Aug 06, 2023     Weekend work       Category: Various

The heat slowed work this weekend plus I flew with an airport buddy. Pealed the last (?) Of the 20 year old protective film off the fwd side of the flaps and built a towbar from an old crutch and some scraps to make it easier to move the airplane.

  Aug 01, 2023     Cleaning up the install       Category: Ignition

Sealed the bracket to the case and safetied the bolts. Installed stand offs for the plug and sensor wires.

  Jul 30, 2023     A little progress in the last few weeks Category: Various

The fuel gauge is on the fritz. I have calls in to try and troubleshoot it.

Work on wiring up the SDS ignition proceeds slowly.

I discovered an error in the wing walk installation. Somehow, I managed to miss a rib when I riveted it up. Corrected that today. Drilling SS rivets is a PITA, and the ATS pop rivet tool makes it only slightly easier - the teeth that are supposed to hold the rivet head have a hard time getting traction on the SS dome heads.

  Jul 10, 2023     Weighed the airplane       Category: Documentation

Also found the lost gear leg fairings!

I'm a little disappointed it didn't come out lighter. No paint. Where did 60 lbs come from? I wonder if the advertised 620lbs included fiberglass tips, wheel pants, gear fairings, radios, elt, antennas, interior.

I used a floor jack to lift each wheel off the ground, then shove a scale under it. Shimmed the wheels to get it dead level.

  Jul 07, 2023     Dings, fairing strips       Category: Wings

Cleaned up the filler in the wingtip dings, pulled more rivets on the trim strips and stop drilled a few more cracks in the canopy.

  Jul 06, 2023     Wing walk, wing tips, etc       Category: Wings

Finished the wing walk, most of the right wing trim strip rivets, blew some more paint on the wheel pants, and patched some nicks in the fiberglass wing tips.

  Jul 05, 2023     Trim, wing walks       Category: Wings

The left wing root trim/wing walks is just about riveted on, the right piece is cleco'd. I primed the undersides before installing them to slow down faying surface corrosion. Lee and Bill had drilled and trimmed these pieces earlier.

In other news, I rattle canned the wheel pants and they are now Ten Footers.

And placarded the flaps.

  Jul 04, 2023     Wings on and pinned Category: Wings

After 3 days of struggle, the wings are on and pinned. But not with the "Hero" pins...in the days that follow, I'll have to replace the long taper pins we used today with the "Hero" pins from McMaster Carr that have cotters and keepers.

We had to jack the rear spar of the left wing up with a floor jack to get it lined up. The right wing was NOT budging, until I wiggled it JUST right, and it clunked into place with the sense of relief one gets from popping a zit. The wife says "popping a zit is too easy, this was more like cracking a safe." It is definitely harshing my turn on for EVER TAKING THE WINGS OFF AGAIN. So First Flight might be out of this airport.

In other news, I cut out the pattern for the gear leg fairings that seemingly got left in the rental van when we moved the airplane. And bought the wing walk non-skid and cut it out, and started a stencil for "NO STEP" for the flaps.

  Jul 02, 2023     Wings on, sort of       Category: Wings

My wife and I managed to get the left wing in, but couldn't get he right one rammed home. It was too bloody hot to continue the struggle so we quit for the day. Plus, the plug for the left wingtip light was outiside the wing, so the LEFT wing needs to be pulled and replaced again.

  Jul 01, 2023     Ignition and housekeeping       Category: Ignition

Working on the ignition wiring and moved my hangar mates car out so we can put the wings on and weigh the airplane.

  Jun 11, 2023     More ignition details, also wheel pants       Category: Ignition

I brought the wheel pants for the mains home to fill the gap between the halves. Using Smiths Fill-It epoxy wood filler, as it's both stronger and tougher than brittle Bondo. System 3 also makes a nice pre mixed filler. I wasn't in the mood to formulate my own "bog" out of microballons and fumed silica. http://www.smithandcompany.org/Fillit/ or http://www.systemthree.com/products/silvertip-quikfair-epoxy-fairing-putty
There are other ways to do this. The halves are glassed together on the inside with a single layer of glass cloth tape, leaving a gap on the outside of the gelcoated shells. I used a chain saw file to open up the gap and eliminate any possible voids. I COULD have used a very narrow strip of glass mat and polyester resin to fill the resulting gap, and that would have been stronger, but again, I pressed the Easy button and just filled it, albeit with a better grade of filler.

Sunday I made it out to the hangar in the late afternoon and finished the last plug wire, installed the manifold pressure port, and started work on installing the firewall pass- thrus.

I had also ordered a hall effect sensor with a longer "pigtail" from Ross at Simple Digital Systems/Racetech and cut it down to fit my installation per the previous version. The longer pigtail will enable me to mount the control box closer to the pilot. Ross is great, and gives excellent service.

  Jun 05, 2023     Ignition wires       Category: Ignition

Making up the ignition wires was surprisingly hard. Working the boots was the tough part. Stripping the wires way back to get the boots on by grabbing the white insulation layer and pulling the well lubricated wire through worked. I rode the Struggle Bus and got 3 of them done. Also dry fit the sensor bracket to the final configuration, setting the clearance of the sensor to the magnets.

  Jun 03, 2023     Still Igniting       Category: Ignition

Mounted coil pack, started to rough in the electrical, drilled the intake manifold for the manifold pressure tap, tightened up the fittings on the oil pressure sensor, pulled the switch that grounded the old magnetron ignition to re-purpose it for the coil pack ignition.

  May 29, 2023     Still with the ignition       Category: Ignition

At home, glued the trigger and synch magnets into the shaft collar. Fabricated firewall pass through grommets (per Tony Bingelis) for the manifold pressure sense hose and the new electrical connections between the coil pack and the controller.

The "orbit" of the "flying magnets" was too close to the surface of the prop hub, so I clearanced the sensor mount so that it would clear.

I emailed Ross Farnam of SDS bout how to tap into the intake manifold to sense manifold pressure. On a built, installed, tightly cowled engine, it's HARD. See the sketch. Ross says the tap should be on the plenum before the runners split, else you get a sine wave(s) from the intake pulse of each cylinder. We'll see if that's possible, the join is buried pretty deep. I might be able to drill with a right angle drill, but can I get the riv-nut tool in there? ID of the MAP sensor hose is about .1".

  May 28, 2023     More ignition progress       Category: Ignition

My skinny, limber nephew helped me deburr the interior side of the firewall and rivet in the nut plates to mount the coil pack. We also snaked the bottom magnetron out of the accessory case. It MIGHT be possible to change the lower magnetron with the engine mounted but I don't see how.

Once I got home, I put the pattern I'd developed on the shaft collar and drilled it for the magnets.

  May 28, 2023     Ignition bracket is mostly done       Category: Ignition

Draft Two. Did some fab at home during the week. Rock solid. Need to drill for the Hall Effect sensors.

  May 21, 2023     Ignition bracket       Category: Engine

More fettling in the ignition. First Draft was ALMOST good enough. Learned there is a minimum flange depth of about 1/2 inch for the press brake. Decided the AeroVee distributor block off plate could go.

  May 20, 2023     Cleanup, starting ignition bracket fab       Category: Various

Lots of parts and materials arrived this week. Plugged some holes in the panel. Figured out the fastener for the threaded hole by the prop bearing I'll use to secure the lower end of the ignition bracket. Did a test bend with my new press brake, after dulling the sharp edge of the punch, put a little radius on it. Chewed the flat blank out of 14 gauge Stainless, overkill, but it needs to be stiff.

  May 13, 2023     Engine run, starting on brackets for Ignition       Category: Engine

Ran engine to set idle, 1000 RPM. Pulled mixture to shut down, and adjusted the idle stop on the carb itself.
The shaft collar I ordered from McMaster Carr fits on the prop hub. I started on a pasteboard pattern for the bracket needed to hold the Hall Effect sensors. Ordered some 14 gauge Stainless Steel to fabricate it.
The aluminum spacers I bought to mount the coil pack are too long, new ones on order.

  May 08, 2023     More trials       Category: Engine

Fuel gauge is DEFINITELY not working, which is a drag, since accessing the box means pulling the windscreen and the glare shield again.

Templated the Subaru coil pack and drilled pilot holes to mount to the firewall.

Ran some more, first start up engine quit after a few seconds. Long story short the 20 year old Curtis valve on the gascolater was leaking so badly it was starving the engine of fuel. Replaced temporarily with a pipe plug and carried on.

EGT 1 and 4 are inoperative. Ran down to about 900 RPM, but idle is rather rough. Ran it up above the 2000 RPM of yesterday after leaning the needle some more, but it feels scary to run any faster with the cowling open.

Took the hood off and removed the top magnetron. Bottom magnetron looks hard to remove, intake manifold in the way. Tightened some fittings weeping a little oil.

Labeled valve covers, and numbered the cylinders in a more visible manner.

  May 06, 2023     Another engine run Category: Engine

Mixed results. Just a very slight drip from one valve cover. Magnetron ignition is DEAD, in spite of ANOTHER new magnetron. It's coming off, to be replaced by a Simple Digital Systems CIP. I have the Subaru coil pack in hand already, and I have ideas about mounting the "flying magnet" for timing pick off. I had this possibility in the back of my mind since I bought this project, I decided to give the stock AeroVee system one more try before adding weight and electrical load to the airplane. No Joy....

In other news, installed a ground power plug so I can connect a charger (solar or otherwise) to the airplane with the cowling on.

Ran engine for about .2 tach hours. CHTs all stayed within range. Oil pressure good. Oil temperature pretty slow to rise. #1 and #4 EGTs seem to be dead. And I need to double check if the fuel gauge is actually working.

I had tweaked the mixture about 1/4 turn Lean since last week, but it still takes almost full pull on the mixture to kill the engine. I want it to kill at about 1/2 pull. Tweaking the needle is somewhat of a PITA - the stainless set screw that locks the needle carrier can go walk about in the carb body, and it's only mildly magnetic so it's a bee-yatch to fish it out. I'll put some grease on the allen key before I tweak it again, but it clearly can go leaner.

  Apr 30, 2023     Engine Start       Category: Engine

Started the engine and ran it up to 2000 RPM, tied to the HHR, with the cooling hood in place. Ran good, clearly a little rich. But the valve covers leaked a lot, in spite of silicone gaskets from AirCooled.Net. Pulled the covers off, started over with new cork gaskets, hylomar, and heavy grease. This weekend will tell if I fixed this problem or not.

  Apr 24, 2023     More engine start preps       Category: Various

Built wheel chocks, added an extension to the oil breather, pulled the plane out and secured it, ran the starter till it showed about 35 lbs oil pressure.

Flecks in oil drained earlier turned out to be Lubriplate assembly lube from about 20 years ago.

  Apr 22, 2023     Preparing for engine start       Category: Various

Changed the oil, replaced the battery which I'd flattened by leaving the Master on, tailored the cooling hood to fit.

  Apr 16, 2023     Back on       Category: Windscreen

Museum wax was the magic for getting this done. I glued the washer to the nylok then used the sticky wax to grab the back of the lexan.

  Apr 11, 2023     Glare Shield secured       Category: Glare Shield

The plans call for stainless rivets. Previous builders used threaded fasteners to the Longerons. And several on/off cycles meant some of the firewall holes were wallowed out, so I used a mix of stainless machine screws with medium loctite, and 5/32 "oops" pulled rivets. Not pretty, but it's airworthy and done.

  Apr 09, 2023     More progress       Category: Various

Brakes still clear of air, so removed the temporary reservoir. Reconnected fuel lines.figured out a minor Dynon glitch. Put the glare shield back on, but haven't riveted it in.

  Apr 08, 2023     Brakes finally bled?       Category: Various

Reverse bled from the bottom up, using a syringe and a temporary reservoir.

  Mar 25, 2023     Brakes, heat shielding       Category: Various

Another frustrating session trying to bleed the brakes. I have concluded the pressure bleeder I borrowed introduces air bubbles into the line, so I'm going to try a different setup tomorrow.

I wanted to have some success so I used the last of my small roll of header wrap to insulate one cylinder exhaust, and I fabricated a heat shield for the Starboard side slip joint which is close to the fuel line inlet to the carb.

  Mar 19, 2023     Brakes, carb and controls       Category: Various

Finished the revisions to the braking system by mounting the new master cylinder, plumbing the lines, and the parking brake valve, bleeding. I like the new setup and it's much more maintenance friendly than the toe brakes.

Also changed the carb needle to a 2.5 and the air filter to a K&N at Jeff Schultz's suggestion, and reconnected the mixture and throttle controls, and cleaned up some cable routings ahead of the firewall. I love stainless steel ty wraps! Oh, and wired the carb to the intake manifold in case the rubber boot fails. Somehow the kill switch wire from the lower mag got disconnected and it was a Bee-yatch getting it back on.

  Feb 11, 2023     New Brake Master Cylinder Category: Controls

After receiving the needed angle from Sonex, I fabricated the mounting brackets in my home shop and took them to the hangar to start the install. I needed to drill out 4 existing rivets on the Port lower Longeron, and 2 were easy, the other two took a 40 minute ride on the Struggle Bus. And I had to modify the brackets to clear the dust boot on the master. The dimensions on the drawings for the holes in the brackets that the AN5 bolts pass through are wrong, as are the holes that attach the outboard bracket to the Longeron.

  Feb 05, 2023     Rocker Shaft Upgrade       Category: Engine

I bit the bullet and replaced the stock VW rocker shafts with CB Performance bolt together shafts. It took some fiddling with the spacers to get the proper clearances.

  Jan 16, 2023     Labeling, cleanup, skins       Category: Avionics

Replaced temporary labels on blue tape with proper Klein wire labels.
Vacuumed up swarf from fuselage nooks and crannies.
With fear and trembling, tested SANDING the residue of the 20 year old protective film from the flaps and ailerons. Started with 320 - yes, it leaves swirls, but it cuts the crud, and leaves a nice matte finish, that 600 grit further refines. I'm going to use this on the TOP of the control surfaces before First Flight.

  Jan 15, 2023     Rigged "pigtail" for future aux fuel       Category: Fuel System

Plumbed up a fuel inlet per Jeff Schultz's schema. http://www.sonex604.com/aux_fuel.html

Also finished removing the toe brakes, and cleaned up the wet, cold shop.

  Jan 08, 2023     Nose wheel pant, more baffling refinement, removing the toe brakes       Category: Landing Gear

I never liked the look of the nose wheel pant, so I removed it. I don't see an easy way to modify it to suit me, so Someday I'll fabricate one out of sheet aluminum. Removal involved jacking up the front of the airplane and pulling the nose wheel strut.

I spied a leak in the baffling so I installed another little sheet stock patch.

Then I wrapped the other exhaust pipe with header wrap, secured with stainless steel ty-raps.

Then I started pulling off the toe brakes. Found some odd details. Parts are on order to replace them with a single master.

  Jan 08, 2023     Brakes, Canopy hold open       Category: Controls

After picking up the pressure bleeder from Lee @ KCCR, I surveyed the brake situation and decided even if I bleed the existing toe brakes, they will NEVER be easy to service, so I ordered a new dual master cylinder and associated handle and mounting bracket from Sonex. Then turned my attention to installing the Sea Dog hatch spring as a canopy hold open. I wish the spring was a little longer, but it works really well, and does not distort the canopy when closed the way the gas strut did.

  Jan 02, 2023     More work on mixture and throttle relocation       Category: Controls

Cut bracket down some more and riveted it to bottom of panel, re-routed cables. Discovered bubbles in brake lines. Revised engine baffles.

  Jan 01, 2023     More work on engine controls Category: Controls

Got the tank loose and finished pulling back the controls. Painted bracket, and started to install, but realized it interfered with full stick movement. Cut it down and repainted it.

  Dec 20, 2022     Auditing carb, relocating controls       Category: Fuel System

Pulling the throttle and mixture controls to move them from the center to the left hand fuselage side. Access to everything is extraordinarily difficult. Checked the free motion of the throttle slide while I'm at it. I'll have to pull the tank to re-route the cables, so I drained it.

  Dec 19, 2022     Fuel flow test       Category: Fuel System

Used a farm jack to put the nose up as high as possible, over 20 gph achieved for an engine that burns 6 gph at full throttle.

  Dec 02, 2022     Like peeing on the fence post....       Category: Paint / Decals

Added MY tail number, data plate and other placards. No leaks in the fuel system.

  Nov 29, 2022     Calibrate fuel sensor       Category: Fuel System

With the help of my lovely wife, we calibrated at the Dynon the capacitive fuel probe. The tank WILL NOT accept the advertised 16.5 gallons as a tri-gear with the upper Longeron level, about 14.5 was all you could get in before it dribbles out the filler neck. We propped up the nose wheel and got 16 in it, we could have likely got a little more but as a practical matter I think "full" is 14.5 gallons.

  Nov 22, 2022     Finish new latch       Category: Canopy

Took off the gas strut and suddenly the canopy fits! The strut seems to tweak the frame slightly. Finished installing the new latch, recharged the battery (left Master on) and peeled off the "DB" suffix on the tail number as the reservation has expired and someone else has snagged it.

  Nov 06, 2022     Fitting Peter Anson latch       Category: Canopy

Worked on fitting the Australian made canopy latch, and decided I could not live with the mis-match between the fuselage and the canopy. The canopy/frame is slightly too wide. Fix pends.

  Nov 05, 2022     Registration received       Category: Documentation

Someone snatched the tail number Lee T had reserved that combined Eaa chapter 393 and the original builder, Don Baldwin, so I used my initials and the chapter number. Having this makes it feel real.

  Oct 14, 2022     Fuel cap, tank, door       Category: Fuel System

The over center lever fuel cap would not fit under the fuel door, so I built a hot knife to shave down the neck of the tank without putting any debris in the tank. Also filed down the handle a bit.

  Sep 05, 2022     Baffling lily gilding       Category: Engine

Plugging every hole. ALL the air that comes in the nostrils WILL flow THROUGH the heads, and NOWHERE else!

  Sep 03, 2022     Mailed in the registration application Category: Documentation

FAA's backup is pretty fierce (5 months?) and the plane needs to be registered before certification.

  Aug 31, 2022     Vent, fuel door       Category: Fuel System

Put the Port cowl on, bent the Peter Anson vent assembly to fit, and cut the fuel door to suit.

  Aug 31, 2022     More with the baffles       Category: Engine

I liked the Starboard side so much I did the Port side too. And refined the Stbd inlet.

  Aug 30, 2022     Baffling       Category: Engine

After buttoning up the stbd intake, I realized I'd forgotten the "Cool Tin" which clips under the barrels before the pushrod tubes and the heads gi on. Rather than dismantle that side of the engine, I elected to fabricate and install some Remaster style head and cylinder shrouds. Once I installed them, I finished reinstalling the exhaust and the Stbd side baffles.

  Aug 28, 2022     Details       Category: Cowl

Installed a Tinnerman to secure the lips of the cowl outlet flaps together, and added retaining washers to the Cam-Locks

  Aug 28, 2022     Finished remote fuel shutoff       Category: Fuel System

Completed the "rod" (actually some channel stock I had on hand) and the bracket to remotely actuate the fuel tank outlet valve.

  Aug 21, 2022     Installed fuel tank vent       Category: Fuel System

I ordered one of Peter Anson's fuel tank vents, complete with check valve to keep fuel in the tank in an overturn. Pete Fernel had an external vent on his airplane and it's a handy attitude reference. Pin the vent on the horizon and you are approximately level. Beautiful part. I have his canopy latch and flap up-stop as well, yet to be installed.

  Aug 21, 2022     Finished tie down       Category: Wings

Installed tie down in the right wing

  Aug 10, 2022     New magnetron is in       Category: Engine

Changing the top magnetron on an assembled engine is bloody hard. It takes a long hemostat or nut starter and patience. Put your shim against the flywheel magnet before you drop the magnetron in. The magnetron has slotted holes for the attach screws, but mine were bottoming out with the shim in place.

Also changed the wire canopy limiter to Paracord to back up the gas strut. The wire had no give and it had the wrong swage fittings. Still working on the remote fuel shutoff. Finished one tie down fitting, but could not find the other eye bolt, ordered some more. Sealed a gap between the canopy and the turtle deck

  Jul 24, 2022     Mod for top vent       Category: Firewall

I've decided to go with the top exit for the fuel tank vent, which requires a bite out of the firewall flange.

  Jul 18, 2022     Planning the last mile       Category: Documentation

I've managed a lot of projects over my work career, and one of the things you ALWAYS want is an Integrated Master Schedule. There are several tools for doing this, GANNT Charts, CPM, PERT, etc, but I hadn't used ANY of them, until now. Using Google Calendar, I brainstormed all the tasks I could think of needed to get me in the air, broke some of them down into sub-tasks, and started putting them on the calendar. The good news is that even with my limited time available to work on the project, I can get it done this calendar year.

  Jul 18, 2022     Cockpit Work Platform       Category: Fuselage

The temporary seat I made is good, but I needed something WITHOUT the back so I can crawl under the panel to work on the fuel system. This is the result, it has legs underneath it so it sits close to level and bears on the SEAT cross-member, NOT on the relatively flimsy rear spar carry through. I can stick my legs down the tailcone and get well under the panel. I wish I was younger sometimes.

  Jul 18, 2022     Stop drilling the cracks in the canopy.       Category: Canopy

As previously described, pulling STAINLESS rivets on the Port and Starboard canopy sides in tight holes cracked the canopy all along both sides. I modified a 3/32 or so drill bit per Bingelis "The Sportplane Builder" to a needle like point, and flattened the cutting edges so it scraps rather than carves. I drilled MOST of the cracks, just beyond the tip of the visible crack, IF they had run up far enough to be visible above the aluminum trim. Next I'll fill the holes with clear silicone caulk.

  Jul 10, 2022     Do it like the plans       Category: Fuel System

The plans show an aluminum fuel line running through the firewall via a grommet. My airplane has a bulkhead fitting on the firewall. It adds weigh, expense, two points for leakage, and forces you into fabricating a short line with complex geometry you have to tighten up in two places. It took me ALL DAY to make this line, and to install it I have to crawl under the panel. Which I can only barely do with the seat out and my legs down the tail cone and a temporary plywood platform spanning the spar carry throughs.

  Jul 05, 2022     Breather mods for a cleaner belly       Category: Engine

Various external devices have been fabricated and sold to keep the breather mung off the belly of VW powered airplanes. SONEX sells one.

My VW Engine Sensei (R.S. Hoover, "Veeduber") taught me to keep all that crap inside the engine. The cam gear sprays a lot of droplets toward the breather. The stock VW has a little louvered plate that fits between the top of the case and the generator/alternator tower to knock that down, and the surface area of the tower itself cools down the vapors so it condenses, and by the time it exits the engine, it's relatively clean, just exhaust gases, water, etc.

None of this happens with the stock Aerovee breather.

Veeduber would stuff as much stainless steel scrubbing pad, trussed up with safety wire, as would fit in the void at the top of the case, below the block off plate. Due to the rubber novelty, sourced from a late 1960's Camaro, used to connect the AeroVee plate to the breather tube, the stock baffle won't fit. So I fabricated one. It acts as an inertial separator, by changing the flow direction, any droplets that get past the pot scrubber (think stainless steel breathable foam) fall out of "solution" when they can't make the corners to get past the baffle. My rubber novelty is ozone checked, and it took some digging to find a replacement (Dorman 47052, available everywhere).

  Jul 04, 2022     Temporary Seat       Category: Fuselage

The Sonex seat is very light, very clever, and very much a PITA to install and remove. I need the wings on and off and on this airplane before it flies, so I have no desire to put the seat in at this time, but it's also a PITA to try and work in the cockpit without one. This temporary version is 1/2" ply bottom and 1/4" back, with a Hardware Store piano hinge at the junction. The foam "tractor seat" makes it bearable to sit on.

  Jul 04, 2022     Mods to make it easier to get wings on and off       Category: Wings

I had a chance earlier this year to examine and fly a built airplane with some neat mods, some of which I'm adopting.

One of the hardest parts of getting the wings on and off is hooking up the flaps. The dropped fasteners I fished out of the leading edges of the wings once they were off attest to that. John Monnet used pins and clips on the prototypes, see the videos, for both the front and rear spars and the flaps, and I'm doing the same. The built airplane I looked out had the two front lightening holes joined into one, to make access from the fuselage into the wing much easier, and I've done the same. There is ANOTHER rib VERY close outboard of the root rib, and I flanged the openings I enlarged to keep the local stiffness needed to maintain the airfoil shape and the structural stiffness in this area for flight loads.

  Jul 04, 2022     Stress cracks       Category: Canopy

It's been over a year since the canopy was finished - it was glued on the frame with Sikaflex, per many RV builders. But the lower trim pieces on either side of the canopy at the upper longerons were riveted on, with STAINLESS rivets, and they have stress cracked pretty badly. I'm not sure whether to leave them, in hopes they've relieved themselves, or stop drill every single one of them. ALUMINUM rivets should have been used in my view, as they take far less force to "pop", preferably in oversize holes. This would lead to less compressive stress, and allow the acrylic to move a little. Threaded fasteners, LOOSELY torqued, with nylocks, would have been another good choice. Keep Loctite away from acrylic, it will craze and crack it.

  Jul 04, 2022     From finger strainer to firewall       Category: Fuel System

Several hands have worked on the fuel system, and it no longer made sense to me. The plans have the line (aluminum tubing with flare fittings) running straight forward, along the airplane's centerline, to a grommet in the firewall. MANY people consider the grommet to be cheesy, and use a bulkhead fitting, but this forces the line slightly off centerline, and creates a possible interference with the rudder pedals.

On THIS airplane, the original builder turned the line 90 degrees with an elbow, and modified the original handle for some form of remote actuation, now lost, when EAA 393 completely re-did the panel. The handle was replaced (see previous log entries), but it was still tough to reach to actuate - not what you want in an emergency. Also, the new handle did not fit the valve properly, and was only held on the stem with a few threads of a shear nut.

I didn't like any of it. So I took it all out, and now have to re-fabricate the line in the image of the plans, and rig a remote actuator, using the various examples on Sonex Builders.

The pictures show the fuel valve and handle as I found them, the handle side view after modification, the valve full open (note the little aluminum shim super glued in place to take up some slop between the handle and the stem), and the valve full open.

  Jul 04, 2022     Top of the engine       Category: Engine

I don't like the AeroVee valve covers. They don't actually cool as well as the thin steel stock covers, and they leak. BUT the stock units won't clear the valve train with the Elephant Foot adjusters, and the high lift cam in the Aerovee. I don't necessarily recommend anyone do as I have done, but I:
1) ground down the rocker arms to get more clearance for adjustment and articulation - those Elephant Foot adjusters are TALL between the rocker and the valve stem. This step in NOT necessary with the "Courier" or "Captive Ball" adjusters currently provided with the AeroVee kits.
2) cut down the adjusters till the slot in the end just about disappeared, cut a new slot, and dressed the ends.
3) Pounded precision dents in the tin valve covers to clear the tips of the adjusters.
4) Cleaned up the chipped paint, painted them inside and out with rattle can black, and baked the dried parts in my toaster oven for an hour at 200 deg F. Convection.
5) Bought the best silicone valve cover gaskets I could find. Buttoned it all back together.

Notice my rocker arms use the "clips and wavy washers". Current AeroVee kits use "bolt together" rocker arm shafts. For the moderate lift and low RPM of our engines, I think this is fine, but there is no question the "bolt together" rocker arms are more secure. Everything is assembled with Red Line Synthetic Assembly Lube, which the GearHeads at my local NAPA swear by. I found caked up Lubriplate in several places in this engine, which was first assembled over 20 years ago.

The rocker arms and adjusters on this engine are from CB Performance, and use 3/8" x 24 tpi threads, which is NOT the same as stock, and is no longer the aftermarket standard. They were used on AeroVees up until 2006. I'm trying to track down some replacement adjusters, SCAT seems to still make that size. If I can't find any, I'll have to replace the rocker arms as well as the adjusters.

  Jul 04, 2022     Cleared some interferences       Category: Controls

I discovered some interferences between the controls and other structure. The first problem was between the aileron stops on the control sticks (this will ONLY ever be an issue on DUAL controls and TRI-GEAR) and the attach bolts for the tri-gear mains. At extreme forward elevator and extreme aileron, they interfered. I shortened BOTH the aileron stops (not enough to diminish their function in any way) AND the second bolt end DOWN from the top of the spar to eliminate it.

The second problem was that pushrod for the aileron servo for the autopilot was chafing on the elevator pushrod, again, at the extreme (full back elevator) of the range. I put a very slight bow in the aileron servo pushrod to fix this one.

  Jul 03, 2022     Push rod tubes       Category: Engine

Pushrod tubes - the tubes on the engine as I received it had a thick coat of silver paint, and were dented. These are new, and have a THIN coat of BLACK paint, for better heat transfer. Rattle can enamel, baked when dry in my thrift store toaster oven, 200 deg F convection for an hour. Almost as hard as powder coat.

  May 01, 2022     Heads       Category: Engine

Got a new head from Sonex, and got the OLD head, that I accidentally punched a hole in the exhaust port of when cleaning up the abundant casting flash, back from a professional welder, so an interesting comparison of the Circa 2001 CB Performance based heads to the 2020 Empi based heads. The Empi (current) heads are on the bottom of picture from the intake ports, and the top of the picture from the chambers, and have much less casting flash, and a higher surface finish. They are the nicest aftermarket VW heads I've ever seen.

  May 01, 2022     Belly Skin is on Category: Fuselage

Finished riveting up the belly skin last month. Spent the day today updating the plans, with the revisions from circa 2001 until now.

  Mar 20, 2022     Still on the belly skin       Category: Fuselage

Riveted most of the belly after about 2 hours of struggle getting the machine screws in the tail where the cross tie joins the lower longerons. The picture shows the ONLY access. The screwdriver is at the head of the screw.

  Mar 06, 2022     Aft fuselage belly skin Category: Fuselage

I started about 2 weeks ago fitting the aft fuselage belly skin, after finishing the repairs to the dent in the turtledeck. The pre-drilled skin did not match up 100% with the structure, and I needed some hardware. Today i used some long bar clamps to tweak the fuselage a little bit to get the pilot holes for the machine screws at the forward end line up, and drilled and reamed them to the finished size, and installed the fasteners. I fabricated the needed spacers for that end, and drilled them to suit, and riveted them in place. It was getting cold and I was tired, so I quit before finishing, and there are still some pesky fit up issues.

  Jan 23, 2022     Pulling dents       Category: Fuselage

The turtledeck got a little banged up in moving the airplane, as the clamp we improvised to keep the rolling door up was not 100% effective. This afternoon I worked on the skin. As you can see, I drilled the rivets that join the port and starboard skins, and tie them into the C-channel that forms the "spine". Since the Bottom Aft fuselage skin in not on yet, I can (barely) access the underside to "sister" the buckled "spine" - today was about persuading the skin back into alignment using a "Pops-A-Dent" glue pulling tool. It's taking some careful hammer and dolly work as well as this tool, but I'm getting there, without having to re-skin the aft fuselage or fabricate a complex insert. The hot melt glued "dolly" literally pops off the panel when you screw the center knob to the limit.

ALSO installed another inspection port cover plate.

  Jan 22, 2022     Shadow Board and Plans stand       Category: Workshop

A place to lay out the plans and hang tools, plus it protects my hangar mate's car.

  Jan 22, 2022     Insulating the exhaust       Category: Engine

I'm generally not a fan of header wrap. Corrosion Under Insulation is a Thing. But the exhaust runs SO close the fuel line on this installation, it seemed prudent, along with fire sleeving the fuel lines as seen in another entry.

  Jan 22, 2022     More recent completions - Fire Sleeve       Category: Fuel System

Fire sleeved all the fuel lines from the firewall forward.

  Jan 07, 2022     Work Continues       Category: Cowl

Ryan Young here, the new owner of this project. I've moved it to San Rafael airport, CA35, established my "shop" in half of a leaky Port A Port, and I'm pecking away at the details, mostly firewall forward, sealing up the baffling, improving air flow through the heads, working on the battery box, and putting the lips on the cowl outlets to create a low pressure zone to suck hot air out even in a climb, fabricating inspection port covers, and HOURS of knocking off the 20+ year old protective coating off the flaps and ailerons, not pictured.

  Aug 21, 2021     Moving Day - (12 hours)       Category: Project Sale

I am pleased to report that the EAA Chapter 393 Don Baldwin Sonex project has been purchased by fellow chapter member Ryan Young. Today the wings were removed and the project was loaded into a Uhaul truck and moved to its new home.

  Aug 14, 2021     fabricate Tools To Drive Out Wing Temporary Retaining Pins - (3 hours)       Category: Tools

Lee Teicheira secured bolts and fabricated tools to drive out pins temporarily retaining wings to fuselage.

  Jul 31, 2021     Continue Assembling Hardware For New Owner To Be Able To Finish Assembling Aircraft - (8 hours)       Category: Workshop

Lee Teicheira and Bill Lawrence continued referencing the plans to determine additional hardware needed to complete the project build, assembling the necessary pieces, bagging and labeling such and sorting the bags for rapid transfer to the new project owner. In addition, we sorted and organized some additional hardware for the shop.

  Jul 28, 2021     Continue Assembling Hardware For New Owner To Be Able To Finish Assembling Aircraft - (3.8 hours)       Category: Workshop

Lee Teicheira and Bill Lawrence continued checking the plans for hardware requirements necessary for new owner to finish assembling the aircraft, collecting and labeling that hardware that is in inventory and gathering together for new owner.

  Jul 27, 2021     Begin Gathering Materials To Go With The Project When It Is Sold - (4 hours)       Category: Workshop

Lee Teicheira and Bill Lawrence began gathering materials and pieces that have not yet been installed on the aircraft due to awaiting transfer to new location by new owner and inspection for airworthiness certification.