Apr 27, 2024     Easy? Then it's wrong - (1.85 hours) Category: Fuselage

I was alll too happy the prior kit owner had fabricated the floorboards. Used the lexan template I arranged yesterday; drilled the attach holes, and installed the nutclips on the frame tabs. BUT holes/floorboard does not line up. And/or they line up, but 1/2 inch length screws do not reach the nutplates. Upon review I can see the error in the currently fabricated floorboards....the dimensions have the boards sittng on the frame pipes, rather than the tabs "inside" the pipes. Will now need to rework the floorboards inherited, or completly fab a new set. Will sleep on this and make a decision next Monday.

  Apr 26, 2024     Floorboard mounting - (3.7 hours)       Category: Fuselage

The 1/4 inch thick floorboards were completed by a previous kit owner; likely not the "marine grade" plywood mentioned in the manual, as the pilot's side floorboard is warping. (Will consider a redo later). Both floorboards mount to tabs underneath; the trick is locating those tabs and the holes already drilled in place by the factory. Hobby Lobby sells plastic laminate sheets, 2' X 3' for $4.00 each. Used the existing wooden floorboards as templates, cut out a laminate "floorboard", and then put it in place instead of the wooden piece. Easy to trace tabs and holes on the laminate, which now will be the template on top of the wood to drill the mounting holes.

  Apr 22, 2024     Clecoed Covers - (5 hours)       Category: Wings

Spent way too much time trying to buff the perfect circle(s) from the inspection holes I cut out to access the auxilliary fuel tanks in each wing. And trying for perfection of flush-fit covers. Not perfect, not even Airventure show quality...but enough!

  Apr 20, 2024     Double down-down - (3.6 hours)       Category: Wings

Tool maintenance to begin the day; pneumatic squeezer was binding up in terms of gap adjustment. Took apart the yoke and power ram, cleaned and lubricated. All now ok. Then installed K1000-8 nutplates on the doublers, screwed in the covers, and used as a "pass drill template". A bit of buffng wheel trimming tomorrow and it's done

  Apr 19, 2024     Double Down - (1.9 hours) Category: Wings

Installing the nutplates for the cover plates of the new inspection holes. The sequence is important....install the nutplates for the cover first...then screw the cover to the doubler, and then when you fit the insert cover in place, you can through drill the rivet holes for the doubler to the wing skin. Result = exact positioning. If you do it reversed like the manual calls out (through drill doubler to the wing skin first, then the cover nutplates), it's a SWAG/guess to position the cover.

  Apr 18, 2024     A holy day - (5.2 hours)       Category: Wings

Back to the new hole to buff out parts of the circle which are not perfectly circular! Used a die grinder, and improved the circular cutout dramatically.

BUT of course I then realized I'd cut the hole too small. I'd inadvertently used the inside dimension of the doubler, rather than the outside diameter of the cover plate, which inserts flush with the wing skin. Groan. Moved over to the left wing, and cut in that side inspection hole correctly.

Thankfully I'd cut the Right wing hole too small; but not intuitive on how to (over) drill a larger hole without a center index (since the cutoout falls off as you complete the initial circle.) Answer? Gorilla Tape to the rescue. Took a cutout circle, aligned it carefully, and used gorilla tape to secure it in place. That stuff is awesome. Cut in half of the larger circle, moved the tape, and completed the new cut. Easy-peasy.

Then used a die grinder with a small 3M buffing wheel to better round out the hole, and fit the plates in place.

  Apr 17, 2024     Nibbling - (5.05 hours) Category: Wings

I tried using an OLFA knife tool with the hole cutting accessory to scribe-cut an inspection hole just inboard of the aux tank. No joy. So borrowed a "nibbler" cutting tool from the chapter 25 group building their Glastar in Lakeville.Cut in the new inspection hole in the Right wing. Not great (learning curve with a new tool) but reasonable circle. Dress it up with the die cutter tomorrow.

  Apr 16, 2024     Panned in St. Paul - (1.6 hours) Category: Interior Finish

Measured the lengths required for each planned antenna.
Then went back to seat pan inserts; these were previosly installed by an earlier kit owner, but need additional trimming. However, I found that the seat pans now interfere with the forward cable tunnel closeouts. Now will REALLY need to trim the pans to fit. Manana, as an afternoon meeting with the DAAC...an airport planning group which I've agreed to join.

  Apr 15, 2024     Study Hall - (1 hour) Category: Avionics

Spent most of the day at the hangar reviewing/researching/planning the antennas. (I'd agreed with Aerotronics to wait until the panel was in and the antennas known to decide on coax cable lenghts and routing.) Need antennas for Com #1, Com #2, GTX375 waas, G3X gps, Xm, transponder, etc.

  Apr 13, 2024     Not much - (1.1 hours) Category: Avionics

REviewing cable runs and antennas, Rerouted/reconnected the ELT remote audio warning at the panel.
Researching fuel senders.

  Apr 11, 2024     Owatanah - (1.35 hours) Category: Avionics

Took the morning off...joined with Jerry S and rode along to Owatanah to visit Dennis V's hangar, where his Sportsman was opened up as he finished his annual condition inspection. Man is his work impressive....not just following the manual like I do/did, but also lots of creative "experiemental" touches. And what is it about pilots and sportscars lurking in their hangars. And starting yet another project (starduster biplane in his case). Fun morning with EAA chapter 25 members.

Got back into my own hangar in time to install the other aux tank fuel level sender. Still unsure and thinking about what to do with the main tanks' fuel level senders. Currently have a square hole (flange) and round senders (flange), and round to square adaptors that have a center hole too small to fit the other two Stewart Warner senders I have. Rubrick's cube.

  Apr 10, 2024     Aux Tank Senders. Attenhut! - (2.7 hours)       Category: Avionics

Did a "incoming QC" inspection on the 4 fuel quantity level senders; all four are old style Stewart Warner 385 AB models made in 2018 and 2021. Metered each sender, and confirmed the range is from 31 ohms to 247 ohms. And did the service bulletin on these senders to insure the bend in the arm and the gap with the internal plastic body is sufficient. Then installed one in the left aux tank before running out of time. Will get to right tank tomorrow, with an open question still about using an adaptor for the two main tanks. Originally the Glastar had a mechanical gauge readout only in the wing root.

  Apr 09, 2024     Tubing research and completion - (3.55 hours)       Category: Avionics

While I basically completed the pitot/static lines last time, there was a nagging question as to whether my inherited lines were "Nylo-Seal" or "Nyla-Flow". The difference is in the connections, the Nylo connection is complete as-is, while the Nyla connection requires an insert. Spent time reviewing (ACS has detail pages), the Glastar manual, the parts I had already put in place, and the parts still in my inventory. Concluded I had Nyla and used the inserts before a final trim and tighten.

Next puzzle is the fuel quantity sender for the main fuel tank. Glasair in their wisdom did a running change from a circular flange to a (TWTT driven) square flange, which my existing senders do not fit. I purchased adapters from an owners site member 2 years ago...just can't recall the detail. The puzzle continues. Manana.

  Apr 04, 2024     G5 and GSU 25 Connection - (1.85 hours)       Category: Fuel System

Received a "care package" from Aerotronics with the pitot/static fittings/plumbing ready to go. Aerotronics is my all time favorite vendor....smart, responsive, always exceeding my expectations. Really! Got the G5 and the GSU 25 connected along with the rest of the plumbing. Now just have to run the pitot from the wing, and the static line to a tee from both static ports. Making progress/

  Apr 04, 2024     Fuel Quantity Senders' QC - (2 hours) Category: Fuel System

Each of the 4 tanks have a Stewart Warner 385 AB-P quantity sender. While these can be changed out if defective, I've done it once before on a different plane,and it is a real PITA. So scrutinized each of the 4 senders as I took them out of their packing. One does have a gouge on the float, but as best I can determine, it is not compromising the float's buoyancy. Then discovered no matter how long I searched that I'm out of NAS603-8P screws which mount the sender to the tank. Ordered from ACS and will arrive next week.

  Apr 01, 2024     Yoga and bulkhead A rivets - (1.25 hours)       Category: Avionics

Took sime time off to enjoy my RV12iS, she's been neglected this winter. Updated all the SD cards, a time consuming exercise in patience. That's her tail lurking in the background.

Then gritted my teeth to redo a bad job of riveting one of the BH A nutplates. A simple process to drill out and re-rivet...BUT could not be in a more awkward location. I'm sure there must be a yoga pose name for what I contorted to get at it. Just inside the baggage door hole, up high on the right side of the bulkhead. Got it done, a bit ugly, but strong and algined. whew.

  Mar 29, 2024     You don't know what you don't know. And a bit of rework - (4.05 hours) Category: Avionics

Working to plumb the static and pitot tube system. Made a decision to run the pitot tube down the lift strut. Wired the pitot heater element which runs via the cannon connector (ground is at the rib inboard of the pitot mast.). Didn't realize that there were NO nylo seal parts on hand required to do the final connections to the Garmin GSU25 and ALSO the Garmin G5 (logical...it includes an air-data computer...just wasn't thinking about it before now). AND I will not do an AOA with my Glastar...did so with my Sportsman....but I've discovered the (unused) AOA must still be plumbed into the static source....more fittings I didn't know about. Placed an order with Aerotronics....might be (?) a bit higher price than A.C.S., but dependable to not miss any items. Hopefully to arrive early next week.

When I installed the MAP sensor inside the cabin, I used the larger adel clamps I had in my inventory. Having received a reorder, I redid the double adel clamps; got smart and simply safety wired the one, allowing the new one to more easily install. Still awkward, but no real problem.

  Mar 28, 2024     Plumber on duty - (2.1 hours)       Category: Avionics

Completed the plumbing for the pitot tube connections in the wing. Ran (red) 1/4 inch tubing from the wing, through a lift strut, and measured from bottom of strut into fuselage next to the main gear leg to the drain in the belly. Can now cut the tubing to length as required to have lengths for inside-the-fuselage connection to the Garmin. Also realized no need for another/separate connector for the pitot heat; can simply butt splice it in since I've already got it pathed through the wing cannon connector.

  Mar 27, 2024     Pitot - NO! - (1 hour) Category: Avionics

Owners' site posted for sale a heated pitot tube; my current one has a slight ding in the nose, mostly a cosmetic issue. So I purchased and when it arrived it looked in great shape. However prior to final installation, I went to record its serial number...no joy, it had been scratched out. Nope, not going to put that kind of a part on my build. Seller was quite responsive, didn't realize it (inherited it in a box of parts), and is refunding my money. Will use my original. Recording an hour, but much longer in terms of study, investigation, initial fitting to the mast, etc before I realized the situation.

  Mar 26, 2024     Ditto Yesterday - (2.6 hours) Category: Avionics

Skimmed/re-read the Glastar assembly manuals I and II looking for the wing wiring connections for transfer pump and pitot heat. Did find them, and used butt connectors per the manual to tie in the left and right transfer pumps. Now concerned over the fuel capacity sender connections for the outboard aux tanks......there is NO inspection hole in the wing for the section with access to the aux tank. And you can't hook up the electrical to it until after it's installed. But you can't install the aux tank until completing top wings riveted on. And then no access. Catch 22.

  Mar 25, 2024     Wiring Miscellaneous - (1.5 hours) Category: Avionics

Didn't really want to work at the hangar today, but set modest goals for the day and went anyway. A secret of "homebuilder success" in my opinion.
First reviewed in detail the TWTT "Step 5300 Wiring", and picked up a half a dozen to-do's for my open list. Then moved on to crimping ring terminals on the outboard fuel quantity wires, which will get connected when the top skins are done and the fuel tanks are reinstalled. Still puzzling over the routing the fuselage to wing wires, and nearing a must-decide point as I finish the clean up on the miscellaneous wiring.

  Mar 23, 2024     Completed Magenetometer Install - (4.05 hours) Category: Avionics

Worked on right wing inspection plate "C". Removed one of the four previously installed nutplates to accomodate the need to position the magnetometer to a cardinal direction. Chose east...so drilled out the nutplate already in that position which interferes mechanically. Significant amount of time measuring and positioning the device, and got it drilled and installed. Garmin spec calls for it to be within .5 degrees (that's 1/2 a degree) so it matters. Then basically repaired the plate itself for mounting a 4th screw in a different clock position. So magnetometer is now aligned at 3:00 and the plate screws are at 12, 3:20, 6, and 9.

  Mar 22, 2024     ELT Finish up and Magnetometer Start Up - (3.95 hours)       Category: Avionics

Got the 90 degree RGB connector via Amazon and was able to easily for once finish up the install connections.
Moved on to the magnetometer installation. Easy but a bit tricky in terms of fitting it on a wing inspection plate and various interference points. Spent a lot of time measuring multiple times. Did have to drill out/remove one of the nut plates to get a cardinal alignment on right wing plate C.

  Mar 21, 2024     OAT & Magnetometer - (2 hours) Category: Avionics

I've got a choice on routing the wire bundles to the wings; via the hinge pin or via the lift strut.
While prepping the install of these 2 items, I spent time noodling which might work out better. Still undecided. Can also do part one way, and part the other.

Did drill inspection panel "Right D" to 5/16th for the OAT probe, installed it, and then removed/put in the wiring box for later.

  Mar 20, 2024     Outer wing wiring retention tabs - (3.3 hours) Category: Avionics

Originally I'd put conduit in each wing for the wiring. When the actual wire bundles came from Aerotronics, I reallzed I didn't need those conduits. But after pulling the conduits out, that meant going back to retention tabs where the wires crossed the various ribs. Finished up the tabs today with the outer wing sections on both sides. Very trying in working inside the leading edges forward of the forward beam, but got it done.

  Mar 19, 2024     Wingtip cable retention tabs - (1.55 hours) Category: Avionics

Every now and then, a stubborn/anal retentive streak overcomes. Today I spent almost two hours (not in the total claimed) trying to sort out/solve old (2008 and 2011) Glasair manual typos/mistakes on the tabs in the wings used to retain cables. Finally verified which p/n's were in error after reviewing multiple TWTT books, old picking lists, bom's, and best of all physical identification of installed parts.

Then drilled out the outer wing retention tabs installed in error, and redrilled for riveting the correct parts in the correct locations. Of course my air hose won't reach the left wing tip; will buy an extension tomorrow to complete the work.

  Mar 18, 2024     ELT unit installed - (2.45 hours) Category: Avionics

Installed the ELT antenna and the unit itself on previously installed shelf. The distance from the antenna to the side fuselage is limiting, but it fit in. But then the location of the antenna is inline with the coax connector on the unit. Again, very, very tight fit to get the antenna coax on without hitting the antenna base. Next time (?) I would place and install the unit BEFORE locating and drilling the antenna hole in the shelf. Although if you can't be good, be lucky.

  Mar 15, 2024     Battery Cables' Completion - (4 hours)       Category: Avionics

Finished fabrication of the aftmost end of the battery cables....nothing special about stripping, threading a nipple, shrink tube, and using a hydraulic crimper for the number 2 awg. Connected the ground, but not the positive; in fact, taped over the battery positive...want to be sure of "loose wires ?" before I put power to the system. Then went through the TWTT step 5300 (fuselage wiring) again, page by page to be certain, and discovered a tiny note about connecting an elt ground wire directly to the battery across from it. Otherwise ok. Spent a modest amount of time inspecting the wiring in each wing's tips.

There's nothing complex about these simple steps, other than the physical gyrations required while working behind the bulkhead when hunched over standing outside through the small baggage door. Glad to complete this step, although I'll still need to eventually crawl in there to secure the cables aft to/from the tail.

  Mar 14, 2024     Panel Population - (3.05 hours)       Category: Avionics

Much time searching for parts "put in a secure place" months ago Finally found the end-plugs for the Can bus that terminate the autopilot cables when the GSA-28's are not installed, and put them in place. (will be powering up the system before I get to installing the auto-pilot). Then re-populated the panel with LRU's I'd removed for safety. Will get the other end of the Can bus secured tomorrow by installing and connecting the magnetometer.

  Mar 12, 2024     Battery in place - (1.4 hours)       Category: Avionics

Placed the battery on the shelf under the tray. Awkward to get the bolts/nuts started, but persevered. Short day due to family commitments, and will fab the rest of the power cables tomorrow. Also gives a bit of time to consider what must be connected or protected in the wiring before putting power to the system.