Mar 26, 2024     Section 41 - Wing Attachment 14 - (5.2 hours)       Category: Sec 41 Win A

Today I installed JD Air fuel tank vents, fabricated the aluminum tubes, and AN connections for the fuel tank vents. I closed the wing and verified that ELT was getting GPS information.
I also spent a little time showing the project to a friend. He helped me remove the canopy to make a small adjustment on the forward edge of the canopy that was catching on the forward top skin.

https://youtu.be/SgvV-M2-Hqo

  Mar 24, 2024     Section 41 - Wing Attachment 13 - (0.8 hour)       Category: Sec 41 Win A

I decided to redo the hardware to support the fuel filters. I cut 2 pieces of hexagonal aluminum pushrods and reshaped the cushion clamps to comply with a better fit according to the position of the fuel filter. It seats nice now with no tension on the filter.

https://youtu.be/LiZyo1mgIIQ

  Mar 21, 2024     Section 41 - Wing Attachment 12 - (2.5 hours)       Category: Sec 41 Win A

Today I am installing the wing root fuel filter system from Aircraft Specialty. The kit is not a total drop-in solution. for the fuel filter, the provided screws will not sit high enough to allow the cushion clamp to clamp the filter and I don't like the idea of dropping plain washers on top of a dimpled skin.

Having said that, my approach was to fabricate a "dimple washer" using a thick piece of aluminum. I countersank this piece and rested it on top of the dimple to protect the dimpled skin from the movement of the screw/washer combination.

The screw for the filter clamp had to be twice as long, which required the fabrication of a piece of aluminum stand.

The right-wing screw was stripped and I will have to replace it. Overall it seems like a good setup. I final torqued all connections and sealed the NPT threads with Loctite liquid sealant. I will have to remove these connections when I install the final wing bolts though. But I wanted to get this installed so I can test run the engine and make fuel tank leak tests.

https://youtu.be/LjB1iWIHZqo

  Mar 20, 2024     Section 41 - Wing Attachment 11 - (1.8 hours)       Category: Sec 41 Win A

During the process of rigging the ailerons, it is necessary to fix the control stick in a "full neutral position". The Elevators should be leveled with the control stick at 4 degrees aft and 90 degrees sideways.

After fixing the controls I adjusted the aileron pushrods to result in 1/16 inch up aileron when compared to wing tip trailing edge. It required 1 turn of the left bearing rod end and a half turn on the right. This all has to be done with the trims in the center position and for that, I connected to the VPX unit to find the aileron trim servo center.

Next was the flap adjustment. According to the plans, the flaps must be at 7 degrees lower than the flight deck side rail/wall. Using the digital level, I was able to get 7.1 degrees on the left side but barely 7.5 on the right side. There is no way the flap will go higher than that. I think this is acceptable but I am also thinking if that might induce roll. Probably it will. But won't be noticeable. A little trim adjustment will probably take care of it and I won't even remember this 0.5-degree difference.

I set up the flap positions in the VPX, and everything is looking good. The next step will be the fuel line connections at the wing root. Also, during the process of setting up the trim sensor travel, I found out that the elevator servo position was not working. I will have to troubleshoot that connection. Probably a bad connection again.

https://youtu.be/71f5EPPVbjE

  Mar 19, 2024     Section 41 - Wing Attachment 10 - (3 hours)       Category: Sec 41 Win A

I started the day checking if my oil cooler was within the list of affected units from a service bulletin SB-00080 REV 2, issued by Vans and the oil cooler manufacturer. My unit is not affected.

After complying with the service bulletin I started to work on anchoring points for the wing wire harnesses. I used number 14 and 11 cushion clamps and anchored all wires and pneumatic lines. It is now a very neat and stable connection and I think I won't have more bad connection issues. As I was in it, I noticed that the fuel sensor wire was way too close to the spar webs and I decided to add some edge protection for the wire, just in case.

Next on the agenda was gluing the wing spacers on top of the wing spars, followed by installing the aileron control pushrods. This process starts by fixing the elevator in the neutral position and then installing the rods in place. Next, I will adjust the length of the pushrods based on the trailing edge position of the aileron, in comparison to the wing tip trailing edge. It has to be 1/16 higher the the wing tip trailing edge.

To close the day, Garmin called and informed the replacement servos were on their way.

https://youtu.be/wSl4DiBWM08

  Mar 16, 2024     Section 41 - Wing Attachment 9 - (4.5 hours)       Category: Sec 41 Win A

I was finally able to troubleshoot my CAN-Bus connector. It turned up that the issue was the MOLEX connection at the wing root. These connectors are not the best type and I am sure I will end up swapping all of them in the future as they fail... But I am happy everything is working now as it is supposed to. I still need to check how things are working with the GPS reception and need to configure the landing height system too.

The servos were not the culprit but they are indeed affected by the service bulletin and I asked Garmin to send the new ones. So I will be swapping those shortly.

Moving on with the wing attachment, the next step is to install and drill the aluminum skin fairings into the wing root. I finished that in this step of the build and will be moving on to the aileron and flap connections in the next work session.

https://youtu.be/9rewWCHnADs

  Mar 14, 2024     Section 41 - Wing Attachment 8 - (3.3 hours)       Category: Sec 41 Win A

Another 3 hours of troubleshooting. I have an issue with the CAN bus. But now, I also found out that there is a service bulletin for all my GSA28 servos and I will have to have them replaced.... so painful this troubleshooting process. I will have to disconnect everything and go again wire by wire, pin by pin.

https://youtu.be/Yy1pg7zvR4g

  Mar 13, 2024     Section 41 - Wing Attachment 7 - (2.7 hours)       Category: Sec 41 Win A

I continued with the wing attachment and the job done today was to fix the flap dent and then test and connect all wirings. Initially, I tried to bend back the edge of the leading edge skin but it cracked. A small crack countering the last inboard rivet. To avoid crack traveling I drilled a stop/relief hole with the small drill bit I had and demurred the edge of the skin.

After fixing the flap, I started with the wiring and connections. Initially, everything worked fine but when turning on the avionics I realized there were many red crosses which I assumed could be due to wrong wiring.

After some troubleshooting, I found out that everything worked after removing the termination of the roll servo CAN BUS connection. (which shouldn't because CAN BUS network shows 120ohms)

I called SteinAir and discussed this with their engineer we think the CAN BUS communication issue could have been caused by a mismatch on SW releases (because the roll servo was never connected to receive updates).

In the next work session, I will re-terminate the CAN BUS network and redo SW updates.

All other systems are working great. magnetometer, pitot heat, OAT probe, trim servo, landing lights, store, and nav lights! Super happy there were no smoking-like wiring issues!

https://youtu.be/AMKbunsZVoY

  Mar 09, 2024     Section 41 - Wing Attachment 6 - WITH HELPER - (1.7 hours)       Category: Sec 41 Win A

In this work session, Fabia and I installed the wings using temporary bolts. The job is not difficult. It requires a bit of planning though. We installed the first wing with the flap installed and in the retracted position, and, because of that, we caused a small dent on the leading edge aluminum skin. On the left skin, we used our lessons learned, and everything went smoothly. I wish this could be the final installation. It doesn't seem trivial to de-install everything at a later step... But it will be worth it. I will be able to set up and configure many things on avionics and test tanks for leaks for a while.

https://youtu.be/8g1IEOgeOcw

  Mar 04, 2024     Section 41 - Wing Attachment 5 - (1.7 hours)       Category: Sec 41 Win A

Today I am preparing the scene for the wing attachment. I tried fitting the final bolts in the wing spars and they are going in relatively easily but I know things are going to get tougher when we have multiple bolts in place plus the main spar. It will be very tight. I have spare main bolts and discarding them wouldn't;t be an issue. But, the likelihood of me not getting the approval to make the first flight out of FXE is high. So I will not risk going through the hassle of removing these final close tolerance bolts. I will go with hardware store bolts, grade 8 good quality but a little more room to wiggle.

I bought these non-AN bolts and LPS2 spray to make sure I have I had plenty of lubrication throughout the process and until the final bolt installation.

At the hangar, I created a rolling stand for the wings to help position them easily and a 3x4 supporting structure with benches to hold the wing tip. The drift pins are fabricated out of standard 3/8, 6 in-long bolts, and I have everything ready to go now. My dearest offered to help me this coming weekend. Looking forward to it.

https://youtu.be/sx8ZQ78jbt8

  Jan 16, 2024     Section 41 - Wing Attachment 3 - (1.8 hours)       Category: Sec 41 Win A

With the primer dry, I finished working on the metal parts for the wing attachment and finished assembling the pushrods for the aileron and flaps.

https://youtu.be/9HatObdydGM

  Jan 15, 2024     Section 41 - Wing Attachment 2 - (2.6 hours)       Category: Sec 41 Win A

Continued working on the wing attachment parts. Final drilled, deburred, washed and primed parts

50ml of primer used.

https://youtu.be/jQOPLahj9m8

  Jan 11, 2024     Section 41 - Wing Attachment 1 - (1.8 hours)       Category: Sec 41 Win A

While I wait for the engine to arrive, I decide I will work on small tasks that are still possible to get done. I am starting the year with the wing attachment skins and push rods.

https://youtu.be/Pf684cdg_hA