Mar 22, 2024     Been on the road       Category: Misc.

Been on the road since Feb. Stopped by to see these folks, but sadly, it was the weekend.... Oh, well. Hopefully I'm back into the shop next Tuesday 26th. We will see.....

  Aug 13, 2023     Van's Laser Drill Parts Update       Category: Misc.

Whew! I have lucked out on the LCP anomaly. My empennage kit was packed for shipping 9-2020, so well before this issue arose. Only 2X tail-feather items I need to replace are the 2 flap spars that countersunk wonky and were re-ordered. They had a build date of X-2022, thus affected. I had them ready to install and a close look with a 12X eye loupe shows small craters on the dimple (although no dimples have cracked). The wing kit, that came in March 2023 is a different story. Various items on the Van's RV-10 Wing Kit List are applicable. Tried some Section 5 techniques to affected Flap Ribs, but still look like heck. The holes are not circular and are barely below the maximum diameter after working the defects out. Sample dimpling did not crack the rib dimple hole but there is lots of slop in the hole when a sample -3 rivet is installed.

  Aug 13, 2023     Van's Laser Drill Parts Update Category: Misc.

Whew! I have lucked out on the LCP anomaly. My empennage kit was packed for shipping 9-2020, so well before this issue arose. Only 2X tail-feather items I need to replace are the 2 flap spars that countersunk wonky and were re-ordered. They had a build date of X-2022, thus affected. I had them ready to install and a close look with a 12X eye loupe shows small craters on the dimple (although no dimples have cracked). The wing kit, that came in March 2023 is a different story. Various items on the Van's RV-10 Wing Kit List are applicable. Tried some Section 5 techniques to affected Flap Ribs, but still look like heck. The holes are not circular and are barely below the maximum diameter after working the defects out. Sample dimpling did not crack the rib dimple hole but there is lots of slop in the hole when a sample -3 rivet is installed.

  Jul 24, 2023     Oshkosh 2023       Category: Misc.

Took some time for a week in Wisconsin and 4-days at Oshkosh. Got dang hot Thursday! Stayed at a house about 5-mins from the venue. Had Warbird parking passes courtesy Paul Stojkov, my co-captain. Did the usual, plus the Van's "laser drilled parts" forum. See next post on parts from my new Wing Kit that are affected.

  Jul 17, 2023     Duramax LBZ all back together       Category: Misc.

OK. Finally had the time to finish the LBZ head/engine rebuild. New heads/valves and gaskets, ARP studs, Turbo rebuilt with new 11-blade compressor wheel, new turbo intercooler and intake pipes, new exhaust manifolds with less restriction, new up-pipes, new down-pipe without the restriction, fuel lift-pump with pressure gauge, post CP3 high pressure fuel gauge, new fuel lines, fuel manifolds, injector pipes and 8 new Bosch OEM fuel injectors. Lots of power, cooler EGT's, too much Boost! (29"+)

  Apr 05, 2023     Still rebuilding LBZ       Category: Misc.

OK. Turbocharger overhauled, new billeted compressor wheel. Have the new heads installed, the valve-lash adjusted, valve covers back on and the new injectors and glow plugs with a new high-pressure fuel rail assembly installed. Y-Bridge intake (red) was also installed, but had to replace OEM nuts with SS allen hex head screws and grind down the head of the aft passenger side screw to clear the compressor housing. I'm on the road flying now but back end of week (15-APR)

  Mar 12, 2023     Putting Engine back together       Category: Misc.

Ok. Still no work on the RV-10. Finally all new engine parts in, rebuilt turbocharger and now putting engine back together. I have to fly this week so will not be back into shop until the end of March. Thank goodness for pictures of teardown. Just hope I don't have a bag of important looking stuff left over....

  Feb 11, 2023     Taking a break for a diesel engine rebuild       Category: Misc.

Had to take valuable time away from RV-10 project to replace my 2006 Duramax LBZ Head gaskets before summer RV season. Failed head gasket (#7 cylinder) verified, thus a complete teardown of the upper end of diesel engine. 240,000 hard miles and 5800 hrs on her poor back. Road hard trailering the new Mothership 2.0, but she was never put up wet. New heads and gaskets, 8-new fuel injectors, new turbo compressor wheel (11-blade), new turbo bearings, new up pipes and removal of some tubing no longer desired. Hope to be back on RV-10 within a week or so. Ok, now it looks like March now.

  Jul 03, 2022     In Europe for a little longer... Category: Misc.

Folks. I'm still traveling in Europe for my clients. Will be back in the shop late July, early August.

  Jul 30, 2021     Back from OSH Category: Misc.

OK. Officially off work for the next 6 months! First project is to finalize the paint booth design. But first a run to Washington State to pick up the 5th Wheel "Mothership II"

  Feb 27, 2021     Conversion Coating - (3 hours) Category: Misc.

Darkroom trays used for conversion coating of VS and Rudder components, will make trough for long spar items. New SW Primer came today need to design and build paint booth and prime, then start assembling. Only have another week home though....

  Feb 12, 2021     Conversion Coating - Alodine 1200S - (8.0 hours)       Category: Misc.

Designed long tanks for spar conversion coating. Using darkroom trays for smaller items. Being VERY careful using this material. Thick rubber gloves, 3M purple respirator, eye protection. No splashing, drips allowed on floor/counters. Mixed 5 gallon batch at 85F, temps drops quickly in trays, will design tray heater from heating pad and beer fridge thermo control. Used acetone to remove marks/glue etc from sample parts. Washed in Dawn dish detergent. Rinsed. DEOX B is phosphoric acid etcher, 3-min, as I used a 1:3 ratio then water rinsed. Kept in rinse water until ready to drop into Alodine tray. First sample item was waaaay too converted after 3 minutes. Finally found 1+30 optimum even with tray cooling down. Will added other samples pictures later (on road trip)

  Feb 09, 2021     Alodine Work Area - (5 hours) Category: Misc.

Designed tables and racks for alodine conversion coating.

  Oct 17, 2020     Inventory - (4 hours)       Category: Misc.

Inventory and organizational placement of parts on shelves. Was only missing 1 piece of AN hardware, was given even some extra hardware. The shipping and wrapping of the materials in the crate from Vans was exceptional! FedEx ground delivered kit, my Wife took bucket off the Kubota and replaced it with fork lift to remove crate and place in shop - She's a keeper!