Project: Star   -  
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Builder Name:Phil Martineau   -  
Project:   Glastar   -   VIEW REPORTS
Total Hours:1893.85
Total Expense:$31242.81
Start/Last Date:Jun 26, 2021 - No Finish Date
Engine:Lycoming IO360
Propeller:Hartzell constant speed
Panel:Garmin
 
Friendly URL: https://eaabuilderslog.org?s=Star

Home or Last Project Picture

May 15, 2024     Blips and Zen Plates - (4.25 hours)       Category: Fuselage
Looking over the left seat pan fitment again, spotted 2 "blips"....I'd run the red pitot line over a frame tube which left it vulnerable to being compressed by the seat pan; only when working on the seat pan did this become obvious. Easy fix, unscrewed at drain junction, re-ran the tube and reconnected. Then a 2nd blip...could not initially figure out why the seatpan no longer fit flush; eventually spotted a zip tie that I'd used to secure tube-wrap was inadvertently around a control cable underneath. Removed and replaced correctly.

Then on to fabricating metal plates to allow each floorboard to be split into two to allow ease of access. The plates will basically "splice" the two segments of each floorboard. 8 holes in each (2) plates, nutplates for each of the 16 holes = another 32 holes, so total 48 holes. Then best practice of up-drilling, #40 to #30 to #19 = 144 drilling operations. Some days it all becomes enjoyable zen, even if not very earthshaking.

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May 14, 2024     Rebending fuel line - (4.3 hours)       Category: Fuselage
Finished trimming left seat pan aft edge; now aligns perfectly with the right aft edge.
Then moved on/back to the fuel line from the union-tee to the on/off valve, which interferes with the left seat pan. Removed it, did various measurements, and rebent the line. Reinstalled and wrapped.

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May 13, 2024     Feet and Butts - (3.25 hours)       Category: Fuselage
Did some final inspection of the right floorboard; the screwholes are spot on, the slow pace paid dividends.
Then moved back to the previoiusly trimmed seat pans; they now interfere with the forward tunnel closeouts. Trimmed, installed, removed, trimmed multiple times. Almost completed; still some fuel line interference/rubbing which I will solve by rebending the fuel line.

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May 11, 2024     Carpentry completed - (4.35 hours)       Category: Fuselage
Got the screwholes drilled for the left and the right floorboards. The "upside-down roofing nail technique in the foamboard template" proved to be a winner. And after locating the holes and updrilling, placing the actual floorboard back in with the roofing nails still in place confirms the screws will go in as expected. One hole in each board required a bit of ovaling, but call it complete.

Now only need to paint; prior kit owner simply varnished his try, but I plan to use an ASA 161 gray. May or may not do so now, but will decide manana.
And some builders complete the floors but then slice each board laterally with a splice underneath, to make it possible to remove the floorboards without removing the seat pans and control sticks. Another aspect to consider tomorrow.

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May 10, 2024     4th time the charm - (1.4 hours)       Category: Fuselage
Finished the cutout of the right floorboard. Can now see where the variation in various prior components has been making this step drag out.

Now back to placing the screwholes which allow the nutplates to be accessed from above. I tried this before with the Glasair method (using paint on the hole tabs underneath and ended up with paint everywhere and no conclusive placements. Then tried the classic "trial and error" (not happy with the result). Puzzling over the way to do this, and finally used sharply pointed roofing nails pointing UP through each nutplate and protruding from the tabs; then carefully lowered the foamboard template and "spiked" each hole location. Easy-peasy. Will verify the locations next time with a clear lexan plate indexed to a side tunnel panel. This makes the 4th attempt to get it right. Then transfer the hole locations from the template to the plywood and drill!

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May 09, 2024     Right Floorboard - (3.6 hours) Category: Fuselage
What more can I say...I'm continuing to redo the redo on the right floorboard. making progress, but slowly. Measure, measure, measure.
 
May 08, 2024     Tiny but sweet learning.... - (0.05 hour) Category: Fuselage
I've used a tape measure my entire life. Always noted the tab/hook at the end was not fixed in one place, it moves back and forth.
Finally had the "aha" that this was done on purpose. Why? Nobody could give me a good answer until today.
It move "out" when you want to measure away from the back side of the board. But when you want to measure from the "inside" of the board (think of a drawer's inside dimension), you should move it "in".
Why? The end of the tape tab has a thickness that will give you erroneous measurement unless you push or pull the tab accordingly.
Hey I don't claim to be curing cancer or performing brain surgery...in my (woodworking) defense, I'm an old sparkie.
 
May 08, 2024     Penance and Lessons - (2.2 hours) Category: Fuselage
Only place I've found the 5-ply plywood in the cities is Rockler. (Not marine grade, but not just 2 or 3 ply either). Of course after driving yesterday half an hour to the south store, didn't buy any since they wouldn't rip it for me. Then another hour back to the north store, discovered someone had just come in and cleaned them out of the material. So then back in the car, and another half hour drive to their west store (we'd called ahead)and got the last 2 pieces (30" X 30") Must be a 1/4 inch plywood festival in town. Like I said...penance.

But then today I miscut the piece for the right side. Back in the car again, 20 miles south, and procured the piece.
Penance. (?)

Today in the hangar was more productive. Got the right template fitting, and made the initial sizing cuts to the plywood.

Lessons learned; don't hurry, don't work tired, don't keep working when you haven't eaten lunch, don't assume since your metal working skills are greatly improved that the same is true for your wood working skills (they aren't), really learn the other tools, and so on.
Paul Poberezny called it....educational. Roger that.
 
May 07, 2024     Pride goeth before the fall... - (3 hours) Category: Fuselage
Finished a new template for the Right floorboard. On a roll! Was then too casual/in a hurry to finish...and cut the plywood short. :( Now a $25 piece of scrap/sawdust.

This is where it would be easy to say good enough/not structural. But can't tolerate such a visible rookie mistake and will do over. Manana.
 
May 06, 2024     Left floorboard template and plywood done - (2.05 hours) Category: Fuselage
Got the template (1/4 inch foamboard) in place. Then cut the 5-ply wood to shape per the template. 3 minutes of sanding,and kerplop...the floorboard dropped in place. Small victories keep you going.
 
May 04, 2024     Procurement - (2 hours) Category: Fuselage
One of the benefits for the old TWTT program in Arlington was their procurement function. You assumed all the parts were there, and "built on" everyday. But building a kit at the local airport means you do all your own purchasing/supply chain work. Needed "marine-grade 1/4 inch plywood" for the new floorboards. Easy one, right? Nope....just no local sources, be they one of the big boxes, or a marine supply house. Found one source in Boston who had a product from Europe, but the freight charge was prohiibitive. Finally chose a 5-ply available at Rockler; not the special glues, but I don't plan to leave these out in the rain. Procured the plywood, cut the outlines, and spenty more time on the template. (Time claimed does not include "sourcing" time.)
 
May 03, 2024     New left floorboard template - (4 hours)       Category: Fuselage
Cut a totally new template for the left floorboard out of 1/4 inch foamboard, wish I'd tossed the inherited and warped ones right from the start. Also wrapped the diagonal in 3/8th inch clear plastic tube which levels the space with the welded tabs. Straightforward although still had a few slips...the photos show the blue tape putting back in some of the slips. Will now use this template to cut the plywood.

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May 02, 2024     Floorboards Category: Fuselage
Stiiiilllll working on the left floorboard. Tip from another builder to split a clear plastic hose to wrap the diagonal cage tube to equalize the level with the tabs. Tried working with the original clear lexan template I started with, but too brittle to be of much use....also too "floppy". Getting close, but have also decided to split each floorboard laterally to allow ease in future removals. Will also need to test whether the base of the control stick will interfere with the floorboard.

Plan: purchase new 5-ply plywood tomorrow, create new 1/4 inch foam template, and use a piece of clear glass to place the side holes one-by-one at a time. Enough time has been spent on the warped boards.
 
May 01, 2024     Floorboards Forever - (4.5 hours) Category: Fuselage
Yet again working on the left floorboard. Seemingly infinite amount of measuring. Getting closer but no joy.
Rereading the assembly manual, I realize by context that the boards have to sit on top of the cage pipes, and not just the tabs as I previously concluded in error. In fact, the manual notes the accompanying drawinge overemphasizes the fitment detail. And the diagonal frame pipe under the floorboards is NOT level to the side pipes/tabs. But now clear what needs to be done. The existing inherited boards are indeed warped, too wide (for the space with the closeouts in place first), and were not cut long enough to give a good closeout under/aft of the rudder pedals.
 
Apr 30, 2024     Floorboards continue still - (3.9 hours) Category: Fuselage
Got the right floorboard trimmed, in place, holes drilled, and actually screwed down. Not pretty. Will redo this one regardless. Also, the 3/8th length screws just do not have the reach..used 5/8th lengths. Then returned to trying to make the warped Left side floorboard work. Patience grasshopper.

I continue to try and get both left and right floorboards in place, even though quite chewed up with attempts to get the holes to line up...I will redo both, but want to have a good "template" when I do so.
 
Apr 29, 2024     Floorboards Continue - (5 hours) Category: Fuselage
Started working again on the left floorboard. Lots of measuring. Then right floorboard again. Just not able to get them to fit in place and locate the holes in the underlying tabs. Frustrating. Also did a fair amount of (on-line) searching for local source of "marine-grade plywood". The existing floorboards I inherited are warped (commecial 3-ply wood). ALSO I realize that the existing floorboards were done before I did the forward cable closeouts = narrower width to work with between the closeout edge and the fuselage wall across.. No joy.
 
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.

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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!

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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

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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.

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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.

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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.

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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/

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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.

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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.

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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.

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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.

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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.

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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.

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Mar 11, 2024     Completed battery shelf - (2.3 hours)       Category: Avionics
The additional layers of resin and glass tape are completely cured. Redrilled the shelf flanges (this for a Glastar not a Sportsman), and drilled/clecoed into the fuselage laminates. Used blind rivets -42's. Now to just crimp on the aft battery cable rings.

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Mar 07, 2024     Battery shelf laminates - (3.05 hours)       Category: Avionics
Marked the position of the battery shelf 3 inches aft of bulkhead A. The shelf is really from a Sportsman vintage, and is a bit wider than it needs to be for my Glastar. (Making the shelf top absolutely level gets it closer to the cables to the tail than I'd like). Chose to leave a bit of a slope to the shelf top in an abundance of caution relative to the controls. Roughed up the fuselage floor with 80 grit, then vacuumed, then acetone. Mixed up a batch of resin (200 g and 2.2 grams of mekp) and laminated one layer of DBM for the upper flange, and two layers for the lower flange (looking to get the shelf top closer to level).

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Mar 05, 2024     ELT Completion - (2.85 hours)       Category: Avionics
The DBM lamination cured overnight and allowed me to position the shelf level and drill for the blind rivets. Completed the riveting....inadvertently bent the forward elt strap, but easily straightened. Also made a rookie mistake...didn't pull the blue tape I'd used for postion accuracy while the lamination was still wet. I now have some blue tape scraps forever. Didn't I already say my goal is completion and safety, not perfection?

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Mar 04, 2024     Aft of Bulkhead A - (4.25 hours)       Category: Avionics
Aft of bulkhead A lives the battery and the elt. Cut out some DBM cloth and laminated it to the fuselage where the ELT shelf/tray rivets will penetrate. Then drilled the battery tray to the battery shelf, mounting them together with AN3 bolts and nuts. Still not clear whether I'll need to penetrate the fuselage all the way to the external skin for the battery set up; smalll, but quite heavy. The old Glastar manual process is to laminate layers of resin and DBM cloth, but I have the newer Sportsman style shelf and tray. Mana'na.

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Mar 02, 2024     Another short day... - (1.45 hours) Category: Avionics
Made a lunch, and promptly forgot it at home = short day.
Completed mounting the ELT tray to the shelf, used AACQ blind rivets per Glasair. (The AACQ's are a flush blind rivet, not to be confused with an AAPQ blind rivet). Next step, next day into the hangar, will be to mix a batch of resin, laminate DBM cloth to the fuselage belly, and hopefully do this for the battery shelf at the same time as well. Looking forward to getting the battery installed and power to the panel!
 
Mar 01, 2024     ELT - (2.15 hours)       Category: Avionics
Short day, as felt crappy. Worked on the shelf for the ELT (aft of BH A).....mainly because the shelf for the Main Battery is on another shelf right across from the elt....and I want to finish up the wiring/install the battery AND power to the system. Nothing special, just typical sheet metal work.

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Feb 29, 2024     Got some traction today - (6.35 hours)       Category: Engine
Productive day. Again organized the wires and tubes firewall forward. Then wired the Emag control connectors and got them installed without too much drama. It was helpful to lace the wiring to the connectors, and my sewing skills are improving. Moved on to some rework of the wiring in the wings; drilled out several support tabs on each wing, which I'd previously riveted in to handle the conduits I ran. After pulling out that conduit (!), no need for the metal tabs, but wanted to have some (nylon) tabs in place for the new wiring. Re-riveted them in place. Worked on various alternatives to route the fuselage wiring into the wings; no conclusion yet but likely via the struts.

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Feb 28, 2024     Chubby Checker...Not! - (2 hours) Category: Engine
Started to connect the control wiring for the Emags, only to discover I'd inadvertently TWISTED one wire coming out of the right firewall passthrough. around an engine mounting frame pipe. While not a safety issue, I just could not "do" the TWIST permanently. Thankfully the wrapped wire went to the oil temp probe at the base of the spin on oil filter, and by taking the probe out I was able to untangle the TWIST. Then the gyrations to get the probe safety wire back in place, made a bit more awkward since all the other wires, MAP tubing, spark plug wires, and so on, were in place. Gritted my teeth and got it down. NO Chubby Checker am I.
 
Feb 27, 2024     MAP clamps at the Emags - (6 hours) Category: Engine
Plumbed in the manifold pressure line forward of the firewall to a T feeding the map nipple on both mag sides. Inserted in the line a pressure damper. This was the easy part; getting a mini-clamp around the silicon hose at each of the Emags was challenging. Finally learned the best (only?) way was to take the silicon hose and preload the clamp flush with the end of the hose. Then slide the hose over the emag nipple as well as the clamp, and simply tighten the clamp further. VERY difficult to get at the sides of the Emags boxed in by spark plug wires, etc.

Then moved on to wiring the mag control plugs; will complete this stage tomorrow.
 
Feb 26, 2024     Grounding away.... - (5.05 hours)       Category: Wings
Grinding away; returning to wing work (wiring) for the moment. The manual calls for fabricating ground straps for the auxiliary fuel tanks fuel level senders, and did so. It's been so long since I did wing laydown work I had to dig out the old manual pages and review. Sure enough, time to dance the 2-step....discovered I'd put the main tanks' vent lines into the wrong boss....used the fuel return line boss instead of the tank vent boss. Easy to swap around the fittings, as only Continental engines use the fuel return boss, and I'll simply be plugging it further along.

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Feb 24, 2024     MAP thru firewall but also to Emags - (2.75 hours)       Category: Firewall
Working on old to-do list; researched the latest on fuel vent lines at the wingtips. Will order the check valve recomended by owners'site. ( CK250-H-B ) and come back to this one. Then removed the bulkhead fitting for the MAP into the cabin and replaced it with a T-version (AN804-3D) to create a port for the map to also go to the Emags FWF.

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Feb 22, 2024     Sloppy but Solid - (3.2 hours)       Category: Interior Finish
Unscrewed the aft cable cover....pita as the screws are low on the side and the curvature of the fuselage bottom makes it difficult to use a screw driver. One of my favorite tools is a small ratchet from Klein Bike Tools with interchangeable bits which works ok. Held my breathe and thankfully the re-resin of the one tab that had broken off was very strong...sloppy (needed to be more like chunky than creamy Pnut Butter consistency to avoid running) but will work fine. Particularly since it's under the aft cable tunnel cover. Safe and Strong is way more important than fragile and pretty.

Did a resort of the "to do's and redo's"...then started finishing up skipped steps. RTV'd the wing wiriring from the cannon plug mid-wing.

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Feb 21, 2024     Sewing - (3.9 hours)       Category: Interior Finish
Finally back to the aft cable covers' laminated tabs, where I'd inadvertently put the nutplates on one (left) side on outboard rather than inboard. While drilling out the 16 rivets, one of the tabs broke loose. So after finishing all the drilling and nutplate re-riveting, decided to route the cables aft to bulkhead A before re-laminating the one loose tab.

Jerry S brought one one of the Glasair gurus Dennis V visiting my hangar last week; he convinced me to use waxed cord to "sew" the cable routing rather than zip ties. Gave it a try, and learned another new skill. Grade was a "C" at best, but as this section will be hidden soon, a good place to try it out.

Mixed up a batch of resin, cabosil (to mayonaisse thickness) and then plus Q-cell to more of a peanut butter thickness. Wax release around the loose tab, and buttered both sides and screwed the cover in place. Will take a look tomorrow at the new bonding.

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Feb 20, 2024     Success - (4.05 hours)       Category: Interior Finish
Final trim for overhead console frame, and then paid attention to the "rotational position" of each standard jack. Managed to clear the width and the pipe as well.

Then moved on to reinstalling the nutplates for the aft cable covers. Due to narrowing of aft fuselage, not possible to get at the AN470 rivets with the squeezer tools. Finally realized I could use AN 1097 rivets (aka "woops" rivets) OR since not structural, use blind rivets..easy peasey.

I'm convinced the reason there is an experience qualifier to get an A&P is NOT that you know what is correct....rather you've had to work your way out of your mis-step or flat out mistakes.

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Feb 19, 2024     Compactor - (3 hours)       Category: Interior Finish
Trimmed (twice up and down) the overhead console frame to max the opening. Then drilled the new (replacement) metal insert plate for the overhead console, and assembled the six audio jacks. This is a very tight fit due to the central cage pipe that runs forward/aft. I now have clearance from the central pipe, but unfortunately the lateral dimension width fights the insert (wiring side) from going into the console. Ran out of time (family commitment) but will resume tomorrow.

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Feb 18, 2024     Misc - (2.5 hours) Category: Interior Finish
Drilled out the last (#8) nutplate installed on the aft cable cover brackets in error.
Then moved on to drilling the new metal insert for the overhead console...spent a crazy amount of time looking for the small air hose that connects to my drill. Found it hiding with the cables inside the plane. :( Then did the insert measuring and prep work, and called it an early day. No sense working on the plane when I'm still irritated/angry at not being able to find the hose.)
 
Feb 16, 2024     Top to Bottom - (1.95 hours)       Category: Interior Finish
Overhead console now in place (top)....will insert metal insert with audio jacks tomorrow. Moved on to correcting a mistake from last September; one row (left side) of laminated brackets for the aft cable covers (fuselage bottom) ended up with the nutplates outboard instead of inboard. So drilling out the nutplate rivets to reinstall on the inboard side of the brackets.

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Feb 14, 2024     OH Console redux - (3.05 hours) Category: Interior Finish
Pulled down/uninstalled the overhead console frame. Dremeled the joggles for the metal inserts to allow for more room to move the jacks outboard on each side. Prepared for the new plate now enroute, marking up a paper template (will match drill the mounting holes). Reinstalled the OH console. Then routed the audio cables to the overhead and zip tied loosely (to be able to pull through for install work on new plate) per the manuals.
 
Feb 13, 2024     The Builder Two-Step - (5.25 hours) Category: Interior Finish
Evidently my favorite dance....two steps forward, one (or more) steps back.
Completed the overhead console, sanded smooth several unused rivet holes, mounted the frame to the ceiling, and then screwed in the 6 jacks on the metal insert plate. Then to insert the plate in the frame. GROAN. The plate would not fit...the jacks are hitting the cage pipe right down the middle. Started to try and salvage the piece by "ovaling" the holes, but nah...too visible and just not good enough. Ordered a new insert plate from Zach Chase. Will redo the piece, moving the jack holes as far lateral in each side to minimize hitting the pipe in the middle. Morale of the story....think forward in "3D" as much as possible.
 
Feb 12, 2024     Completed the Overhead Console - (3.1 hours) Category: Interior Finish
Cleaned off minor resin overflows on the console.
Tweaked the 2 gauge wire run locations from the aft battery to the firewall and zip tied in place.
Reinstalled the forward tunnel covers.
Mixed up a tiny batch of resin and mill fiber to plug several misdrilled rivet holes on the OH console...will sand smooth tomorrow.
Have not yet purchased an optional overhead "dome light" for the cabin. Easily installed at a later date; maybe after Airventure shopping.
 
Feb 11, 2024     Quick stop to turn down heat - (1 hour) Category: Interior Finish
Left the hangar warmer than usual last night to help the resin cure. Stopped by to turn down heat, and also removed the braces. Rookie mistake, I had not used mold release on the screw heads, and resin got into the screw holes. Slow work to chip it out and unscrew the OH console....and also had to also unscrew/remove the metal inserts (Which let me brace the brackets "inside" the console while pressuring the screw heads to turn. Success!
 
Feb 10, 2024     Resin batch - (0.75 hour)       Category: Interior Finish
Started the day in Lakeville where there is another Glastar under construction. Fun to look over a "sibling"....the Lakeville Glastar is a bit older...nice to find a big brother locally.
Then to my hangar and mixed a resin batch of promoted resin, cabosil and Qcell. More art than science for the mix (of course the resin and mekp are as precise as I can make it). But added the cabosil to "mayonaisse" texture, and the Qcell to "peanut butter".
Spread the mix on the six brackets, and mounted the overhead console in place with clamps in the front, and board/shims at the rear.

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Feb 09, 2024     Pre-lam of Overhead Console - (3.95 hours)       Category: Interior Finish
Sanded the fuselage ceiling at the bracket points of the overhead console. Then dug out the resin and mixture bags (Cabosil, mill fiber, Q cell); decided to run a test batch of resin, as the promoted resin I have is getting a little old (?). Mixed a batch of resin, mekp, mill fiber, and cabosil. Seemed to kick at 40 minutes or so. Will look at tomorrow and likely bond the console in place.

Also did some document reviews of the left aft baffle which has an unused flange. Found the answer in an old (2006) Glasair document on baffling...it needs a hose to the mechanical fuel pump cooling shroud.

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Feb 08, 2024     Still, still woring on OH Console - (2.45 hours) Category: Interior Finish
Fabricating the fiberglass brackets that will be glued into the ceiling with resin/cabosil/mill fiber blend. False start in visualization of how it all combines, and drilled in error several nutplate rivet holes in the wrong places. Corrected, minor cosmetic issue to catch at final qc. Will try and bond in tomorrow.
 
Feb 07, 2024     O/H console - (3.05 hours) Category: Interior Finish
Drilled the aft metal insert holes after sanding/ensuring the connectors will fit without interfering with each other. The big even was a visit from 3 EAA Chapter 25 members who are ALSO building a Glastar. What fun. They are certainly welcome anytime to benefit from all my mistakes. Will go by their project this weekend.

(the yellow wire is for a yet-to-be purchased overhead light).
 
Feb 06, 2024     Still on Audio in the O/H - (2.25 hours)       Category: Interior Finish
Working with the metal inserts for the overhead console. The audio connections (4 standard jacks) and the 2 bose lemo's need to squeeze into the narrow insert. Lots of measuring, fiberglass tweaking, etc.

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Feb 05, 2024     Overhead nutplates - (2.75 hours)       Category: Interior Finish
Next step installing the nutplates on the console. What a royal pia...they are #6's and -3 rivets. Tiny and/or shows how fat-fingered I am. Was able to use the pneumatic squeezer. Realized the headset jacks go in the narrow aft insert...will be a bit tight to fit in place. The forward insert will allow for future lights/vents/switches/whatever.

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Feb 03, 2024     Responding to Mayday - (2.05 hours) Category: Interior Finish
Went by Bob Collins RV12 build at South St. Paul airport; he'd put out a "mayday" for help getting his stabilizer mounted. Happy to respond, as I can't count the number of times I've asked for and received build help. Stopping enroute to my hangar, I realized I'd forgotten my glasses...back home and then to Bob's. BUT wonderfully, the other 4 "1st responders" had managed to align it enough that Bob could get it bolted in place just before I arrived. Must be a lesson there. But best of all, I met John Schmidt, the president of Chapter 25 who told me of another Glastar being built in Lakeville. GREAT contact.

Kept grinding away on the overhead console once I got back to KSTP.
 
Feb 02, 2024     OH trimming and cut outs - (3.95 hours)       Category: Interior Finish
Finished trimming the overhead console. Then drilling and clecoing the metal insert plates. Then cutting out the fiberglass to receive the insert plates with only a Joggle remaining. Also (not included in time entry) visit from the new airport manager Blaine. Fellow alumni of the Moorhead area (next to Fargo)

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Feb 01, 2024     Overhead Console from Zach - (1.25 hours)       Category: Interior Finish
Can't finish installing the wiring until I install the overhead console for the headsets; I purchased an overhead console blank from Zach Chase, guru of gurus. But the O/H requires trimming and fitting to go in place. Up and down, trim, and up and down. Repeat.

Also did a quick trip to South St. Paul at lunchtime to help Bob Collins but he'd gone home already for the day. Returned back to my hangar and continued trimming.

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Jan 31, 2024     Gone Fishing - (4 hours) Category: Instrument Panel
Drilled new holes in BH A for the 2nd main battery cable going to the aft battery placement. And another 3/4 inch hole for the ACK ELT cables and the horizontal stab trim motor cables. Ahhh...then realized I'd have to imitate a hot dog in the bun to get into the fuselage tail sections for BH B, C, etc to run the cable back to the trim. Instead, went fishing...as in using a variety of wires and strings to feed the cabling remotely through the other bulkheads. This of course after realizing that the other BH holes drilled long ago were too small for the cable already pinned into a molex connector to pass through. Thankfully had the molex pin removal tool from back in my Sportsman days. Unpinned, ran the cable, repinned. Time consuming but easy-peasey.
 
Jan 30, 2024     Reviewing - (2.3 hours) Category: Instrument Panel
Running cables back to the tail requires drilling new/addtional holes in Bulkhead A. Reviewed all manuals and TWTT photos for input on which setup to use. Also, realized I'd better trial fit the Autopilot tray that sits under the seats to be certain I've got clearances for the various cabling crossing the area....A-OK. Will drill in BH A tomorrow.
 
Jan 29, 2024     Getting wired - (4.15 hours) Category: Instrument Panel
Progresss on the power cables; crimped the positive battery cable end and then bolted to the master cylinder.
Spent much time actually running the wiring cables; fun to thread the various cables under/over the cage pipes, zip ties to be sure wiring not too close to the control cables, and so on. Also ran the long cable that controls the elevator trim servo, and was relieved to find it was not too short. Making progress.
 
Jan 26, 2024     Blast Cooling tubes - (2.2 hours) Category: Engine
Repositioned the mag blast cooling tubes to point at the ribs; simply wrapped safety wire around the ribs and used it to hold the tube end.
Reviewed my files to find out the wiring specifics for the booster pump in the cabin aft of the firewall. Red + 12 volts and Black is ground. Wired in the boost pump using red butt splices.
Moved on to (re)studying the Emags.
 
Jan 24, 2024     Mounted and wired MAP - (2.25 hours)       Category: Instrument Panel
Gingerly got under panel and mounted the MAP hose to firewall, then spent a very frustrating time twisting to put in an Adel clamp to Adel clamp on the right forward side of the cage. Then wired into the system with red butt clamps. whew. Did use some shrink wrap over the butt connections for protection.

Moved back forward of the FW and started redoing the mag blast cooling hoses' position...which have been pointed out as not being aimed correctly. Will finish repositioning tomorrow.

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Jan 23, 2024     Redid MAP hose - (1.8 hours) Category: Instrument Panel
Was not certain that one end of the MAP hose was secured well enough (as in leak free). Redid the clamptite wrap with the .032 safety wire.
Worked at bench, as still too restricted to work under panel, after a trip to Mayo late last week.
 
Jan 17, 2024     MAP connection aft of the firewall - (2.6 hours)       Category: Instrument Panel
Final sequence figured out for the MPA aft of the firewall and then fabricated. Used a new tool (Airventure 2023) called the clamptite to wire the AN fittings to the rubber hose.

In sequence from the firewall: bulkhead fitting AN832-3D, AN980-D616 washer, AN924 nut to fabricated hose on flared 3/16th tube with AN819-3D sleeve, 818-3D coupling nut to 1/4 inch ID/1/2 inch OD rubber hose and then the same tube AN819 and AN819 on the other end of the hose to an AN816-3D nipple, to AN910-1D coupling to the MAP probe itself. Used a double wrap clamptite of .032 on both hose over tube ends.

Spent way too much time on this connection. Oh well. Might have been a simpler way, but was definitely scrounging to use the bottom of my parts on hand.

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Jan 16, 2024     Trying to finish plumbing up the probes and power to the panel - (3.1 hours) Category: Instrument Panel
Decided how to plumb the MAP line through the firewall. Brief trip to Wipaire for parts. Decided to pause on the MAP install and jump over to the main battery cable positive from the rear. This required removal of the forward tunnel covers, which wil also let me get at wiring the booster pump. Did the final crimp of an Oring terminal to the positive battery cable. Then also finished the ring terminal crimp and bolting of the main battery negative to the aft cage.
 
Jan 12, 2024     The sniffles - (1.5 hours)       Category: Instrument Panel
Added firesleeve to the sniffle valve stem/hose, and adel clamped so that it would drain inboard of the gascolator.

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Jan 11, 2024     Stop dithering - (2.15 hours) Category: Instrument Panel
Well, realized I'm spending too much time proof-reading the Glasair documentation on trivial issues. Reread the sniffle-valve steps and detailed my on-hand inventory of AN fitting pieces. Time to restart building!
 
Jan 10, 2024     Frustrating - (.1 hour) Category: Instrument Panel
Total waste of time. TWTT 4000 has a typo/ommission regarding the MAP probe in the cockpit. Spent several hours looking/reviewing the Glasair documentation, the owners' site postings, and all my TWTT step pages. Also spent a crazy amount of time searching the plastic boxes for parts and referring to option picking lists. Put a token .1 hour in for the entry on the log. No joy, no solution yet. Thankfully it's an easy point to resolve if I simply accept that Glasair screwed up, and just do my own best practice which I will do tomorrow.
 
Jan 08, 2024     Looong Ratchet - (3.5 hours)       Category: Instrument Panel
Finally had success getting the adel clamp to sump bolt in place; "built" an extra long ratchet using all my extensions and was able to reach the bolt in from the top of the engine. Took almost 2 hours off for EAA committee meetings. Then finished fabricating the cable from starter to starter-solenoid. Cleaned up the wiring clusters FWF on right side, and then aft of Firewall on left side.

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Jan 06, 2024     Starter and also Adel-difficulty - (2.9 hours)       Category: Instrument Panel
Started the day re-reading the Emag installation notes. Then moved to finishing the wire fabrication for the starter motor connection. Got to use my new toy again...a hydraulic crimper from HF. Completed the connection, and then also cleaned up/adel clamps for the left side of the FWF.

Moved over to cylinders 1 and 3 for securing wiring bundles, but spent a crazy amount of time (unsuccessfully) trying to get the bolt into a previously installed adel clamp under #3. I waited to do so until all the wires routing forward were in place, but now very difficult to get at it. Will try again next week, hope I don't have to start taking things apart to get at it and finally get it in place.

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Jan 05, 2024     Shunt - (3.75 hours)       Category: Instrument Panel
Untangled document confusion over the amperage shunt connections to alternator B lead, the circuit breaker, jumper to the battery contacter, and the shunt instrumentation. Aerotronics was instantly helpful...they not only have schematics on each job, but also plenty of pictures of "actual as built". Completed the alternator power and field wiring.

Started on the starter wiring; cut to length and stripped. Crimp the 5/16th ring terminal tomorrow.

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Jan 04, 2024     Grinding forward on the FWF wiring - (3 hours) Category: Instrument Panel
Good light in the afternoon, so managed to complete the alternator field wiring.
Then moved on to the alternator's output wire...awg #8 so I got to use my new toy...a pneumatic crimper for larger wires. Completed the forward ring crimp with shrink tube. Ran the wiring through passthrough A and up to the right side accessory plate to the shunt connections.
 
Jan 03, 2024     FWF wiring progressing slowly - (5 hours) Category: Instrument Panel
Started wiring the engine oil temperature probe, but got distracted as I noticed an aft engine fitting still with a red plastic cap. Did not ring a bell. Lycoming manual 72-60 page 39 calls it out as a crankcase vent fitting. Also nearby, the tach RPM drive hole is capped; unclear if it was a simple "shipping" cap, or a permanent steel cap. Spoke to Lycoming tech service, who confirmed it's the steel cap (magnetic) and "good to go permanently" as is. Also finally found a photo of the crankcase vent hose on TWTT 039-0460-80 for Baffling (?), and also a hose in the TWTT 4000 steps.

Finished wiring the oil temp sensor, and then worked on wiring the alternator field wire; ran out of light/got too dark = finish the splice tomorrow.
 
Dec 30, 2023     Wired 1/3 egt/cht and red cube - (3.05 hours) Category: Instrument Panel
Completed the EGT and CHT probe wiring (cylinders 1 and 3); then moved on to reviewing and installing the fuel flow transducer wiring. Used the small barrell connectors that came with the red cube, but not convinced they will last. May redo and use butt joint connectors. Decide manana.
 
Dec 29, 2023     Traction FWF - (4.65 hours) Category: Instrument Panel
Finally! Got some traction in the front end.....wired in the fuel pressure transponder. Then wired in the oil pressure transponder. Then wired in Cylinder #4's EGT and CHT probes. Then wired in Cylinder #2's EGT and CHT probes. The EAA and Kitplane videos were priceless.
 
Dec 28, 2023     Ready to wire! - (0.9 hour) Category: Instrument Panel
Finally clear on which tool/techniques/FWF components to be wired. Unfortunately pulled away by unexpected phone call. Manana.
 
Dec 27, 2023     More of the same - (1.05 hours) Category: Instrument Panel
Re-watching how to videos from Stein Air, EAA's Hint for Homebuilders, Aerotronics folllowup. It is slowly coming into focus....whether a circuit needs to be replaceable/removable is a key factor. The sequence as an example for EGT wiring = Route the wires, determine length and where to "fold", actually trimming to length, stripping, crimping, connecting with tiny screws, heat tube shrinking, and overall coverage with the Alcor fiberglass tube. And do this 32 times for egt and cht wiries.
 
Dec 26, 2023     Dithering - (2 hours) Category: Instrument Panel
Still quite uncertain about the FWF wiring techniques. Twist/solder, butt joints, solder splices, mechanical crimping, handshakes, and so on. Spent time further studying the tools and methods. TWTT documents are in conflict with older Glasair info....some of it is the prevelance today of Garmin (which is 100% of my panel and plane) contrasted to the previoius dominance of other electronics firms. Studying!
 
Dec 22, 2023     Ed for Technique and transducers - (3.1 hours) Category: Instrument Panel
Viewed all the Stein videos, re: cutting/crimping/terminals/molex/d-sub connectors/soldering/ and so on. Also spoke to Aerotronics regarding Manifold Pressure Installation relative to silicon tubing as well as wiring. Insight was that Glasair had designed the MAP to be inside the cabin when Garmin was not prevalent. Now it's a bit of anachronism with the Garmin units and the electronic ignition. This all clarified the emag installation to be done, and the completion of the FWF wiring.

Took a quick drive (not in the hours reported) to Faribault to buy a sub-D crimper from Stein Air.
 
Dec 20, 2023     Ready to Terminate - (2.9 hours)       Category: Instrument Panel
Completed the right firewall wiring passthrough "B"; 13 wires (mostly multi-strand) firewall-forward. Required re-reading the P-Mag installation manual and the "red cube" fuel flow transducer installation information. Now ready to start making the bundles "pretty" and trimming almost all wires which came with extra lengths. The actual crimping and terminating should go quickly at this point.

Need to source several #2 gage cables; battery plus to master solenoid, and the starter power wire. May simply outsource the cable fabrication; nominal cost, no real "learning", and I don't have the parts. TBD.

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Dec 19, 2023     Going Backward to go Forward - (2.75 hours) Category: Instrument Panel
The wiring harnesses from Aerotronics are a thing of beauty. Completely obviates the need for the conduits in each wing I so carefully installed a year (?) ago, and I can think of no reason to leave them in place. Removed the conduit from each wing, although I'll leave the metal tabs installed. Then re-ran the wiring harnesses from Aerotronics in the wings.

Partial installation of the alternator, and capped the unused "alternator out" optional alarm.
 
Dec 13, 2023     Wiring Technique - (2 hours) Category: Instrument Panel
Review and research of various sources for aircraft wiring. Also spoke with Aerotronics for "best practices"....solder and/or crimping and/or heatsleeve vs heat resistant sleeves in the firewall, and so on.
 
Dec 12, 2023     EGT/CHT routing - (1.5 hours) Category: Instrument Panel
Pathed the egt and cht wires from the firewall to the cylinders. Nothing special.
 
Dec 11, 2023     Wiring Considerations - (1.65 hours) Category: Instrument Panel
Reviewed the panel documentation and wiring plans.
 
Dec 06, 2023     Wiring Fun - (3.55 hours)       Category: Instrument Panel
This really is fun for now. Routing the various wires to the appropriate destination. Boost pump
wiring was not to be found; finally (!) located it in a bundle of wires not opened, and lurking under the accessorty panel. Once I cut the bundle open, sure enough there was the boost pump wiring. This is fun!

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Dec 05, 2023     PITA Bracket for Bulkhead - (3.5 hours)       Category: Instrument Panel
After fabricating the bracket, riveted it to the belly of the plane. This made the install of the connector plugs a real PITA. Spent hours doing so, made more difficult by the likely reversal of the bracket after drilling. The documents showed it multiple ways in error. Did get it done.

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Dec 04, 2023     Bracket for "Bulkhead" - (5.05 hours)       Category: Instrument Panel
Fabricated the bracket which Glasair calls a "bulkhead".

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Dec 02, 2023     Wing Wiring - (4 hours) Category: Wings
Back on TWTT step 250, wing construction. Installed the harness CPC connector in the wings on each side to an L-bracket. Tight fit, as smaller wing area than the Sportsman, so angled each bracket into place being careful to leave 1 inch from the inspection hole doublers. Worked out very well.
 
Dec 01, 2023     Easter in December - (3.85 hours) Category: Instrument Panel
The further I get, the more I search for parts....like an Easter Egg Hunt. Looking for parts from Wing Laydown steps last seen or worked on a year or two ago.
Really fun to find a "missing" part. Returned to TWTT 250 for wing wiring, and had fun laying out the cables. Can't decide whether to remove the conduits I put in place back in 2021, since the actual cabling came ensleeved and not needing the conduit paths. TBD.
 
Nov 30, 2023     Spaghetti - (2.75 hours)       Category: Instrument Panel
Routing the cabling. Quite a tangle for the moment. There really is no interconnect schematic; TWTT experience is proving helpful, but there are significant differences.....eg Glastar a 2-seater = no need for wiring to "back 2 seats and headsets" = no need for right fixed bulkhead connection. And so on.

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Nov 29, 2023     Zippety-Do-Dah - (4.45 hours) Category: Instrument Panel
Zip tied the wiring bundles to the cage, center, left, and right sides. Connected the GEA24 (partially), the GMA 245, and the GAD 29.
Interestingly enough I noticed the led on the GEA24 was lit...and I have yet to install the main battery. Realized that the Standby Battery System was live, and that with the mains switch inadvertently "on"....that various system units were getting power! Turned it off before I shorted something out or ran down the battery.
 
Nov 28, 2023     Finished installing all three controls - (2.55 hours) Category: Controls
Received the new (shorter) 48 inch throttle cable and installed. Required removal of the partially installed throttle cable which was too long at 60 inches. Continuing my SOP (?) to try and install everything twice/over again. Nothing "exotic", just simply an exercise in manual dexterity. And to replace the remaining one not yet completed, required partial removal of the other two. But I have certainly been educated on push/pull cables and their construction.
 
Nov 27, 2023     Connecting the plugs - (2.95 hours)       Category: Instrument Panel
Sorted hardware leftover in various previously done steps and merged it into my parts' inventory. Then reviewed the wiring twtt 4600, and then started twtt 5300. Sorted out the various plugs and connected the GDL 51R, the GAD 29, the GTR comm #2, and the GMA 245. (all left side). Then connected the GEA24, the TCW Battery Backup System, and the grounds' plug.

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Nov 24, 2023     Finished Mixture Control Cable, waiting for new throttle cable - (2.65 hours) Category: Controls
Completed installation of the mixture control cable; may or may not eventually replace with the shorter cable on order. Key to get that darn interlock tab on the cable slot was to run it through the 3M wheel and smooth it down. Did so for the throttle cable as well.
Spent time reading again the wiring harness installation pages, and inspecting the Glastar frame. There are no convenient "welded tabs" like on the more recent Sportsman cages; will have to use adel clamps or "black string".
 
Nov 22, 2023     Progress on Control Cables - (5.05 hours)       Category: Engine
Installed the prop governor cable. Then installed the mixture cable, which required reclocking the ICO/R lever to avoid hitting the forward baffle when going full rich. Almost finished the rest of the mixture control cable; but will need to do a bit more sanding on the mounting fixture slot to allow the retaining clip to slide in more easily.

Bit the bullet and re-ordered shorter mixture and throttle cables from Aircraft Spruce, and those should arrive Tuesday. May or may not put in the shorter cable for mixture, but will certainly wait for the shorter throttle cable.

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Nov 21, 2023     Brain fog clearing - (2.25 hours) Category: Engine
Pathed the engine ground cable from the lower left cage bolt to the right rear engine sump. Time consuming, as this required 3 "double Adel" setups.

AND, more importantly, I realized the control cables' issue was my own brain fog. Easiest way to think about it and get the setup correct:
eg at Takeoff, all control knobs FORWARD. So forward is Rich setting for mixture, Wide Open butterfly/servo float for throttle, and max RPM for prop.
Now easy-peasy on engine settings with knobs forward.
 
Nov 20, 2023     Still puzzling over engine control cables - (6.1 hours) Category: Engine
Checked in with various gurus. Renee at Avstar confirms they only make 2 servos for Lycoming IO360, and both are the same throttle movement, CCW. They do make a "reverse" lever throttle for the O320, which I find worrying, since that was the original engine used on the Glastars. Both the rotation issue (CW or CCW) and length of the throttle cable (too long per my tech counselor) are of concern. Dropped back and reviewed what cables I received from Glasair....5 foot Mixture, 6 foot prop control, and 5 foot Throttle. But only the throttle seems too long. (?!)

As I puzzle over the engine/control cable topic, I realize I've made an error on another topic completely. There is a cable installed on the lower left engine mount bolt which is for the engine ground path. Inadvertently I routed it forward to the starter, and it is NOT the power cable. Whew, easy to remove, reroute and fix which I will do tomorrow.
 
Nov 18, 2023     Engine Control Cables' Confusion - (2.35 hours) Category: Engine
Unclear how to initially set/install the throttle/prop/mixture cable terminations at the engine.
Finally removed the induction air filter to make it clear when the engine was full throttle or not.
Concerned/confused about the cable movement relative to the lever movements of the engine; thinking I might have the wrong air servo setup, needing CW movement but having CCW movement. Research for tomorrow.
 
Nov 17, 2023     Tech Couselor visit # 5 - (2 hours)       Category: Engine
Tech counselor Mike Hilgar scheduled to stop by today at 10:30. Managed to install the double-Adel clamps I missed previously before he arrived. And also install the new fuel line just received from AFS. Their hoses are a thing of beauty. Then reviewed/inspected the project with Mike who as always had a good suggestion (this time about how to move scat tubing). The bottom Adel is for the fuel line, the upper Adel will channel the alternator wiring and EGT/CHT wires.

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Nov 14, 2023     Patching wires - (3 hours) Category: Instrument Panel
Finally returning to the wires I accidentally cut while trimming off an unused weld tab behind the panel. Spliced the broken wires and soldered.

Then AGAIN replaced the small accessory left panel which came from Aerotronics; this replaces the carbon fiber panel sent in error. Good fit.
 
Nov 13, 2023     Adel under #4 - (5.4 hours) Category: Engine
Put in another Adel clamp #14 by cylinder #4for routing the starter wire to the front of the engine to the starter solenoid. (was out of the #12's)
Then worked with the fuel line running under cylinder #1; finally decided to order a new shorter hose for the fuel servo to the red cube, and plan to add the double adel clamps specified in TWTT #165.(this will replace the original Lycoming hose received with the engine.).
 
Nov 11, 2023     Not much & stepping back - (1.5 hours) Category: Controls
Oshkosh for the last couple of days; tough to get restarted even after such a short departure.
Stepped back to prior points in the sequence to review what I inadvertently missed. Reviewed #165, #2300, #2400, #3300, #4400. Discovered I'd missed the Adel clamps under cylinder #4, and cylinder #1. May replace the fuel line from servo to red cube.....I can see why the adel clamp is specified under #1 if/when the fuel line is cut shorter.
 
Nov 07, 2023     Magic Wrenches - (3.65 hours)       Category: Controls
Distracted today. Airport electrician finallly came to replace ballasts and the ceiling lights apx 20 feet overhead. Also updated the G3X and GTN databases on my RV. Finally got to the project; took the special wrenches (fabricated by Ted) and tightened up the control cables behind the panel in the cockpit.

Then more time reviewing the AvstarFuel Injection Servo, as it's clear I will have to take apart the throttle and the mixture levers/hardware and reset to be consistent with my install.

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Nov 06, 2023     Rework and Review - (3 hours)       Category: Controls
Removed left accessory instrument panel and replaced with the new one received from Aerotronics. Excellent fit (now good clearance to cage tube) but unfortunately they sent a carbon fiber not satin black panel, so will have to redo it one more time. (Did install the carbon panel to verify the fitment, which is ok).

Then reviewed numerous TWTT documents....#165, #2300, #6000, #4400,etc for Adel clamps in the engine compartment. (for routing the fuel lines and the CHT lines and EGT lines.) Sure enough, I'd missed serveral ...will consider putting in/and or rigging my own. Also don't like the fuel hose length from fuel servo to red block...likely will redo/reorder.
LATER NOTE: Aerotronics is the best! Unasked they redid the left accessory panel and it fils perfectly.

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Nov 04, 2023     Control cable progress       Category: Controls
Posted a query in owner's site for info on a modified bolt (?) for the cabin heat which was a mystery to me. Good input asap...it's a "Cabin heat cable-end B nut"., and sure enough I'd seen it before. Located it, and installed it requiring yoga moves standing on my head under the panel.

Then continued my search for hardware for the control cable terminating ends. Whew, finally located the hardware; quite a feat when the kit is nearly 25 years old!

Installed Adel clamps on the control cables as they exit the firesleeve in the engine compartment.

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Nov 03, 2023     Control Spaghetti - (3.05 hours)       Category: Controls
Controls now finger tight at panel, waiting for the loan of the special Ted wrenches coming via Zach. Cut the heat control cable and installed. Then ported the 3 main controls (throttle, prop, mixture) through the firewall firesleeve previously put in place when I did the firewall itself. (Will caulk inside the firesleeve later when I'm positive the control cables are correct.

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Nov 01, 2023     Engine Controls - (4.15 hours) Category: Controls
Left accessory panel was done yesterday; decided to tie wrap the "floating corner" to avoid potential vibration/noise. Used some red gasket material as well.

Then moved on (!) to engine controls. Updrilled the mounting holes in the panel and brace for Throttle (1/2"), Mixture (3/4"), Prop (3/4"), and cabin heat (3/8").

Next step to remove control plate, debur, and grind down the cross-L brace so the control nuts fit flush/level.
 
Oct 31, 2023     Finalized left accessory panel - (2.05 hours)       Category: Instrument Panel
Checked and rechecked fitment of the left accy panel.Realized that the top component connectors will be so close to the fuselage as to not being usable. Took apart the top and reversed the COM2 box to better access the connector, which then meant moving the ACK audible alert. Redrilled 3 of the adel clamp holes. While the "pretty parallel lines" of the pre-assembled panel are no longer parallel or pretty, it's functional and the price to pay for having the panel preassembled as a unit.

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Oct 30, 2023     Left Accessory Instrument Panel - (4.15 hours) Category: Instrument Panel
First hour was getting the last 2 adel clamps on the RIGHT accessory panel, which required a redrill (dimension not the same as TWTT).

Then moved over to LEFT instrument accessory panel. Here we go again....this time it's Aerotronics using the Sportsman jig for the build. Sure enough, the Glastar cage pipe interferes with the Garmin 245R connectors. So ok, reverse the 245R to face the outher way...oops the other way is NOT symetrical, and has its "front panel" now interfering with the cage pipe. So take it off and redrill? Sure, except that means taking off the other side instruments (COM2) as they block the 245R's screws.

Basically had to disassemble both sides and 3 instruments to redrill for the one. Reassembled and put in place on the rails, but the Adel clamps do not have room to fit into the predrilled holes. Great. Man'ana!
 
Oct 28, 2023     Install of panel accessory sub-panel - (3 hours)       Category: Instrument Panel
Slow going in terms of available hardware. Many hardware items are now zero stock as they've been used. Spent a fair amount of time inventorying/searching for a variety of machine screws. At any rate, ground off the paint from one of the cage tubes, and removed the rubber from two Adel clamps to both mount the right panel as well as create a ground path to frame.

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Oct 27, 2023     Installation of fabricated braces - (4.05 hours) Category: Instrument Panel
Quite the search for mounting hardware; nothing unusual, just trying to be consistent. The Glastar pages spec one drill size and hardware set, the TWTT Sportsman pages spec another drill size and different hardware set. After ransacking my inventories looking for parts, finally redrilled the braces to #10 and used that set of hardware. Forward bracing, and center stack bracing now completed. Then retightened the lower cross cage tube to lower panel strut which is not easy to get to. Now need to install the right side and left side accessory panels which should be easy. Will use adel clamps in lieu of welded mounting tabs.
 
Oct 26, 2023     Center Radio Stack Brace - (3.55 hours)       Category: Instrument Panel
Fabricated a central cantilever brace for the readio stack; while newer kits assume a welded tab in the panel crossbar, my kit did not have one. Used an adel clamp instead. This of course required a trip to Wipaire at SSP to buy an assortment of adel clamps, and also some inset machine screw sizes.

Also a good excuse to chat with a friend at Aerotronics, confirming the screw (inset 6-32) that fits the Garmin chassis.

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Oct 25, 2023     Set the panel vertical - (3.5 hours)       Category: Instrument Panel
Completed fabrication of the new panel top-support braces, dialed in the degrees relative to the waterline, and drilled, therein setting the panel vertical. Very pleased to realize that the Sportsman approach to the hardware (which I've used) was an improvement over the original Glastar hardware shown in the Glastar manual pages.

Had to unscrew the key/ignition unit when mounting the panel in the cage. Contacts the cage frame pipe. See photos. Also spoke to Aerotronics, and I can easily move the key hole in the left small "ignition/accesories" panel faceplate to creat additional space for clearance behind the panel relative to the cage frame.

Mocked up the center radio support bracket, and will fabricate it tomorrow.

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Oct 24, 2023     Progress on instrument panel frame mounting - (4.9 hours)       Category: Instrument Panel
Prior kit owner had fabricated the two top panel support brackets....unfortunately upside down and/or reversed left/right. Considered reworking, but they were also the wrong length...or maybe were done for a 3rd party panel frame I chose not to use. Conclusion: fabricate new brackets. Did the fabrication and grinding, now just need to verify length prior to drilling mounting holes.

Lesson learned...moved the entire panel up and out of harms way to grind off the 2nd unused tab that intereferes with the wiring. Also smoothed the residual lip from the 1st tabs removal. Also ground a curve at the base of the two vertical fiberglass braces for better fit.

Installed the 4 screws/hardware for the lower rail of the panel. Tricky but got it done.

Note: Had to remove the ignition key as the current mount places the rear too close/in contact with a cage tube. Follow up required.

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Oct 23, 2023     Panel lines up - (2 hours)       Category: Instrument Panel
Success. Realized that tilting the panel from the top into the cabin (ie closer to 90 degrees) creates more lateral adjustment space. And also trimmed flat the base of the two vertical fiberglass posts. Holes finally line up.

Will remove 2nd interfering tab, and do a bit more fiberglass trimming before hard installation of lower tabs.

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Oct 21, 2023     Close but no cigar - (1.9 hours) Category: Instrument Panel
Trimming and stretching....getting closer to hole-lineup, but not there yet.
 
Oct 20, 2023     Instrument Panel Installation with Chris - (1.5 hours) Category: Instrument Panel
Visiting son-in-law too good an opportunity for a 2nd set of hands, and we made fast work of getting the panel inside the cage. Got instrument panel loosely in place, and then ran Chris back home. Then returned for putting hardware in place, but cage tab holes and panel bracket holes are not lining up. Also 2 of the 6 lower mounting tabs interfere with switch wiring. Ground off one of the interfering tabs, but unfortunately nicked one of the wire bundles going to the Nav lights switch. Will need to splice in new wires before final hard mounting of the panel.

Trimmed a bit of the panel fiberglass. Also aired the tires to 40 psi for both nose and mains, and measured the waterline at .9 degrees on left, and 1.1 degrees on right (nose a bit low.) Will use the angle for setting the vertical position of the panel relative to the airframe.
 
Oct 19, 2023     Panel guts - (3 hours)       Category: Instrument Panel
Removed the rest of the radios from the panel for security and safekeeping during the build, and also makes the panel frame lighter for the installation. Spent lots of time measuring the attached accessory panel which goes into the space first. As compared to later kits, mine does not have the grounding tabs welded in place, and studied/mused/reviewed several ways to eventually handle it. Man'ana is becoming a favorite word.

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Oct 18, 2023     Interior Completed, AND, Instrument Panel opened - (4.75 hours)       Category: Interior Finish
Good traction today. Wrestled with completing the forward tunnel cover....it was all together, but lacking the screw on each side of the tunnel cover that keeps it centered between rudder pedals. Unfortunately I've already plumbed the boost pump, which is on top of a center tunnel plate and protrudes through the firwall. I was loathe to disassemble the pump and fuel line and firewall connection which seemed necessary to install the nutplates for those two screw. However, finally mounted them in place using monel blind-rivets. Got it done, but now the gaskets aren't very cosmetic. Oh well, not looking for perfect/show quality.

THEN the big news....finally time to unpack the instrument panel. It's beautiful! Then removed the pfd and mfd for safety and security. It will be easier to install the panel with a lighter load....maybe tomorrow.

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Oct 17, 2023     Fwd Tunnel Cover assembled - (1.5 hours)       Category: Interior Finish
Screwed it all together, less the 2 side locating screws.

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Oct 16, 2023     Completion of forward tunnel cover - (7.5 hours)       Category: Interior Finish
Finished trimming side panel bolt relief holes. Shimmed and ziptied the aft end of the FTC. Then ziptied the forwared end of the boost pump plate. Installed nutplates (drilled, dimpled, riveted).

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Oct 14, 2023     Nearing the Forward Tunnel Cover finish-line - (3.25 hours) Category: Interior Finish
Still working on Forward Tunnel Cover pieces. Drilled locator holes to anchor to cage tunnel. Drilled in face plate flanges. Drilled lower side panels to upper tunnel cover with #30, then updrilled to #19. Cut in tricycle gear collar bolt relief in the upper tunnel cover. Now only nutplates remain.
 
Oct 13, 2023     Slow progress on forward tunnel cover - (3.6 hours) Category: Interior Finish
Just like the title says. Working on fitment of forward tunnel. It's a grind....glastar vs sportsman dimension deltas; original option did not expect nose wheel which has protruding collar bolt/nut; for whatever reason I'd used a 3/8th red-gasket shim for mounting the boost pump = higher mounting dimensions all around for the covers; did not use the 3-way fuel valve = different faceplate holes = custom cutout for on-off valve; etc, and so on. This is really quite the bespoke interior. But making progress. Also realized that the UPPER forward tunnel cover will need the missing holes on each side for the collar nut/bolt that was on the lower panel, but the upper overlaps enough to also require. Manana.
 
Oct 11, 2023     Go slow to go fast - (3.5 hours)       Category: Interior Finish
Continuing to work on forward covers. Very cautious/slow as the interior finish and fitment will be visible. And the Glasair forward tunnel cover option assumed a three way fuel valve (ie on a Sportsman) which my Glastar will not use.....so trimming in a different position for the on/off fuel valve. Also used a 3/8th shim when I mounted the boost pump (again, a small delta dimension Glastar to Glasair), which means everything in the tunnel cover must have a 3/8th trim adjust. I plan to use a simple cover plate on the aft end of the cover to hide the unused valve holes.

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Oct 10, 2023     Forward Covers - (4.15 hours)       Category: Interior Finish
Making progress on the forward console covers. Actually fit and drilled both left and right side panels.
Also a bit of "repositioning" of several factory drilled holes, as the Glastar dimensions are a bit off from the Sportsman dimensions.
Now a bit of a mongrel...the latest sheetmetal came (only) in black, which was the latest "initiative" at Glasair before they pulled up stakes.

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Oct 09, 2023     Forward Cover Panels - (2.9 hours) Category: Interior Finish
Started woriking on the forward console (pulleys/fuel boost pump/etc) covers. Lots of measuring to drill holes to allow bolts to stick out. Measure many times, cut once.
 
Oct 02, 2023     Hangar and Pans - (0.9 hour)       Category: Workshop
Preparing for travel to California, spent a bit of time cleaning up the hangar and reviewing control stick clearance to pans and the elt/battery shelves behind bulkhead A. Not much.

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Sep 29, 2023     Battery Ground. Seat Pans - (3.05 hours)       Category: Interior Finish
Realized that while I'd ground off the paint for the battery to cage ground on the inside of the fittings, I'd missed doing so to the outside. Did so.

Removed the seats and frames, and then put the seat pans in and out many times for trimming. Making progress.

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Sep 28, 2023     Seats, Pans, Floorboards - (6.15 hours)       Category: Interior Finish
Installed left cover nutplates; not pretty but will suffice. Replaced ground tab cage attachment to longer bolt. Installed seat pans trimmed by a previous owner. (Some interference with fuel lines; revisit later). Installed seat frames and seat upholstery done by Billie of Northcountry Interiors.

Made airplane noises.

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Sep 27, 2023     Got you covered - (3.45 hours)       Category: Interior Finish
Finished sanding the left tabs for the aft cable cover. Drilled the nutplates. Tailored a small patch of BDM to relaminate the one tab which had the material pull away from the tab, and laminated it in place. Cleaned and permanently assembled the left and right cable covers. Was able to use the pneumatic squeezer for the end pairs, but had to go old-school to rivet the others. Definitely a RElearning process. Took me several rivets and two dings/slips to finally recall the technique, then easey-peasey.

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Sep 26, 2023     Aft Cover Snake - (2.5 hours)       Category: Interior Finish
Photo of rear cable cover tabs laminated in place also shows the control cables wrapped in paper for protection from cover work. Looks like a snake. :)

Reinstalled the LEFT cover half yesterday before laminating the tabs in place. Today they're fairly rigid, so drilled the #19 holes through the cover and the individual tabs. Trimmed same (dremel and diamond cutting wheel), and then began sanding them smooth. One tab had the laminate pull away....cut it out, and will relaminate one layer of BDM cloth for the one tab tomorrow.

Also did one trip to Wipaire for some missing bolts, and Menards for a fresh cutting wheel.

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Sep 25, 2023     Guilty of a Cover-Up - (5.35 hours) Category: Interior Finish
Removed the cage to belly attach bolt to sand the paint off the OUTSIDE of the cage attach brackets. (For surety of the electrical ground connection). Also located the battery ground cable attachment tab and fit it in place...will require a longer bolt...order an AN4-8A and upsize the AN4-6A. Put off the fabrication of the actual cable itself to focus on cover completion.

Then finished installing the nutplates on the right side of the aft cable cover.

Then reinstalled the LEFT side aft cable cover, taped in place and catalyzed resin. Set up faster than I wanted (a recurring theme) so had to do a second batch half way through the 8 tabs for the left side. Used more "peanut butter" of cabosil and Qcell to set the tabs in place. as there is less "level" area on the left compared to the right.

Reviewed the process steps for the FORWARD covers....missing some of the panels....I have only those for the O-360...and will need to fabricate or buy (?) the upper closure panels for the boost pump.
 
Sep 23, 2023     Belly screws and Battery ground - (4.45 hours)       Category: Interior Finish
Realized that when I laminate the mounting tabs for the Left side of the aft cable cover, it will make accessing the aft center CAGE attach brackets awkward. And remembering that for an aft battery installation, I need to run a ground from the battery behind Bulkhead A to the cage. BUT as compared to newer kits, my cage does NOT have a convenient mounting tab on the cage; it's ok to terminate the ground at the lower cage attach tab BUT it's imperative to remove the brackets and remove all paint from the cage and bracket contact points.

This is a mandatory 2-person job...one outside and underneath the belly, and one inside at the center aft cage. Not hard, just need 2 people to do it.
My friend Owen is a trooper, and drove over from Flying Cloud within the hour of texting him!! What a great guy.
We made quick work of it relatively speaking. Also discovered a missing screw/nut, and a partially installed nut on the brackets, which was a factory step.

Also managed to install nutplates on half of the right cover tabs. Awkward to get at these nutplates with a pneumatic squeezer. Used 1097 (oops) rivets to avoid the countersinking.

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Sep 21, 2023     Laminated tabs - (2.8 hours)       Category: Interior Finish
Laminated one side/row of metal tabs to the fuselage belly yesterday. Removed the side cover today (the mold-release I applied worked just fine). Looks good, but of course now needs to be trimmed and drilled for nutplates.

Each metal tab gets "seated" in a 50/50 mix of Cagosil and Qcell, then two layers of BDM cloth that are wetted out with resin. Example shown loose.

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Sep 20, 2023     Too Warm - (2 hours) Category: Interior Finish
A key variable in working with resin is the ambient temperature. Surprise...it got to 80's in the hangar....translation, the resin "kicked" faster than yesterday. Only got through 6 tabs on the right side of the aft control cable cover before the catalyzed resin gelled. Did a fast 2nd batch on the fly, and ended up sloppy but adequate. Will see tomorrow how it all set up when I remove the defacto-form of the side cover. Then will put in place the Left cover and do it all over again. No photos...embarassingly sloppy. Oh well.
 
Sep 19, 2023     Mr. Wizard - (1.6 hours)       Category: Interior Finish
Did a test run. Felt like Mr. Wizard, testing and relearning resin; taking promoted resin and catalyzing same. Then tried mixing Cagosil plus Qcell plus resin to make a "peanut butter" to seat the aluminum tabs in place. Also "wetted out" several pieces of DBM cloth. Will do the actual 16 tabs tomorrow.

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Sep 18, 2023     Study Hall - (3.5 hours) Category: Interior Finish
Sanded the fuselage in spots where the aluminum tabs will be laminated in place. Applied mold-release to the other half of the cover (left).

Then studied all my resin/lamination/technical information to come back up to speed on fiberglass.
 
Sep 16, 2023     Resin Stocks - (1 hour) Category: Workshop
Collected all my resin tins in one place. Unpromoted quart from 6/23/22 (last year), promoted gallon from ?????, promoted quart from Dan 2/15/20, promoted gallon from 6/12/23, and another quart labelled 510 from ???? Various containers of Cobalt and MEKP.
 
Sep 14, 2023     Pre-lamination of covers - (2 hours)       Category: Interior Finish
Getting covers ready to laminate aluminum tabs previously fabricated. Consulted with guru Zach Chase.

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Sep 13, 2023     Pre-lamination of aft cable cover tabs - (4.5 hours)       Category: Interior Finish
Riveted back tabs of aft cable cover. Cut 32 bi-directional fiberglass patches to laminate the brackets to the fuselage floor.
My new favorite tool is the Fisk rotary cutter wheel.
Aft cable cover in and out multiple times for trim/fitment/etc.

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Sep 11, 2023     Short day - (1 hour) Category: Interior Finish
Removed aft cable cover for fitment.
 
Sep 09, 2023     Pause and reorganize - (2.2 hours) Category: Workshop
Inventoried the auto-pilot installation hardware I received from Glasair today. Then combined/resorted the plastic boxes of inventory on hand.
Will be (re) starting fiberglass work this coming week, and in particular needed to sort out the fiberglass stuff. Time to relearn the resins/cloths/catalysts which I've completely (?) forgotten.
 
Sep 08, 2023     Aft Cable Cover still... - (3.6 hours) Category: Interior Finish
Puzzled over the 4 tabs connecting to the Bulkhead A. #40 rivet holes on one side, #19 to a K1000-8 on the other side. Inadvertently used the #19 on both sides; upon review, simply redrill holes in the tabs....not structural. Then installed the nutplates behind the bulkhead; got the top two with the pneumatic squeezer, but had to dig out the rivet gun to get the other (lower) two. Thnk this means I'm multilingual or somesuch.
 
Sep 07, 2023     Tab-fab and drilling - (3.55 hours) Category: Interior Finish
Took the 20 blanks I'd cut out for aft control cover tabs; Polished the edges, marked and bent. Then taped 4 on the rear bulkhead and drilled the tabs in place on the cover. Busy work, but not unpleasant.
 
Sep 06, 2023     Aft Control Cable Cover Tabs - (2.55 hours)       Category: Interior Finish
Returning to interior finish work. Trimmed the bottom of the aft cover although not really much required. Then fabricated 20 mounting tabs from the scraps cut off from the length of the covers in a prior step. Seems like busy work to me.

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Sep 05, 2023     CHT's - (2.1 hours) Category: Engine
Installed 4 CHT probes. Checked with Lycoming...their recommendation is Copper Anti-Seize rather than Aluminum. (Copper good to 1800 degrees F, AL to 1600). Discovered that the forward left baffle covered the #2 CHT well....so simply clipped the baffle to clear the hole.
 
Sep 04, 2023     3 egt probes and cowling hear shield - (1.75 hours)       Category: Engine
97 degrees and warm in the hangar, didn't last long.
Did complete the egt probes' installation, as well as dropping back to the lower cowling steps to glue in the heat barrier where the exhaust is close.

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Sep 02, 2023     Cowling question and probe(s)? - (2.6 hours)       Category: Engine
Will the exhaust pipe exit the lower cowling? Almost, hurray. Will need to trim apx 1 or 2 inch corner at the nose gear cutout slot, but it will be invisible once done. Then on to marking the heat barrier material on the side closest to the collector...a cut and glue-on job. Will get both of these next week.

Measure twice and cut once is the mantra...but for aviation kits, it's more like measure 6 times and drill once. Installation of the four EGT probes is not difficult. The measuring is the complex part....need to miss the weld joints, need to avoid where the spark plugs live, need to angle to miss cowling insides, need to avoid closeness to the baffles where it might make it hard to replace, and so on. Must be within 1/8th inch max for all 4 egts. Used 5 and 1/2 inches down from the flanges.

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Sep 01, 2023     Let there be heat... - (4 hours)       Category: Engine
Finished mounting the belly heat shield, which then allowed me to drill and install the tail pipe clamp. Lost some time searching for the heat muff hoses, then installation was easy. Located the EGT probes which came from Aerotronics, and did the measuring on the exhaust pipes. Will drill them in place tomorrow when fresh....will be upper 90's today and the hangar heated up quickly.

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Aug 31, 2023     Over-Under for Exhaust System - (5.5 hours)       Category: Engine
The sharp eye viewer may have noticed the photo for the tail pipe installed yesterday was "over" the nose gear leg. Wrong. It should have been, and now is, "under" the leg. Of course my EAA tech counselor visitor late in the afternoon was the one who pointed it out/questioned the placement.

Also pass drilled the belly heat shield into the fuselage bottom, and then chemically treated and "washed" the shield. Installed same, and will need to recruit help to hold the nut plate inside the plane while screwing in the bolts from underneath. Quite difficult to do this simple step solo.

Also located and marked the drill location on the tail pipe itself which connects to the hangars coming off the shield. Progress!

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Aug 30, 2023     Exhaust Victory & Tech Counselor visit - (2 hours)       Category: Engine
Picked up the exhaust system from AWM on the way in to the hangar. Those guys are great!
Installed the system, and then initial installation of the tailpipe. VICTORY! Finally slips into place and without interference.
I can now drop off and (re)install the exhaust system blindfolded.

As initially put in place, it comes quite near the nose gear leg.
Will try a position "under" the leg tomorrow and see if that works.

Finally moving forward. Whew.

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Aug 29, 2023     Arts & Crafts time again - (1.3 hours)       Category: Engine
Continued work on the bits and pieces parts required to mount the tail pipe to the belly heat shield.

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Aug 28, 2023     Aerospace Welding Mpls one more time - (2.55 hours)       Category: Engine
Removed the entire exhaust system AGAIN. Drove over to Aerospace Welding Minneapolis and they'll again put it on their IO-360 jig and modify the pipe per the photos I gave them showing the contact of #3. Then moving on to fabricating the belly heat shield parts.

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Aug 27, 2023     Inspection/Consideration of Exhaust System - (1.2 hours) Category: Engine
Examined the exhaust system, focusing on where Cylinder #3 pipe touches the underlying intake pipe. Yep, will have to remove the system and try modifying one more time. No other way.
 
Aug 25, 2023     Finally installed all 4 manifolds - (3.5 hours)       Category: Engine
PIcked up the unit at AWM. They modified the #3 pipe to fit the jig for the IO-360. Getting good at installing the system...has to be the 3rd or 4th time doing so even though not all the pipes. BUT after installing all 4 pipes this time, torqueing them in place, the #3 pipe fits over the studs but contacts the underlying intake. Will sleep on it, but likely will want to drop the whole damn system again and have AWM modify the DESIGN of the pipe shape to clear the intake pipe.

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Aug 24, 2023     Whole system to Aerospace Welding Minneapolis - (1 hour) Category: Engine
Token one hour. Dropped the whole system and took over to AWM. These guys are the best! Sure enough, no way was Cylinder #3 pipe ever going to go over the studs. Simply out of spec/welding issues with the option as received from Glasair. Left the unit at AWM.
 
Aug 23, 2023     Call in the professionals - (1 hour) Category: Engine
When I did my TWTT build in 2016, I'd recorded the vendor supplying Glasair the exhaust system. They are local here in MN, only 15 minutes from the airport. Of course Glasair welds the exhaust in-house at this point.
Dropped off my exhaust pipe to cylinder #3 and had them insert a "splice" to try and make it fit. Picked it up a couple of hours later, and installed. Close but no cigar. Their recommendation: pull the whole system off, bring it over, and they'll mount to their jig for an IO-360 and know exactly what is off. What a great idea.
 
Aug 22, 2023     Exhaust System Again - (4.1 hours)       Category: Engine
The modified (?) exhaust pipes and collector arrived back from Glasair last night. Early to hangar to try and avoid the forecast 95 degree day with 85% humidity. The sequence is clear now...assemble the 4 pipes into the collector first (no problem, easy-peasy), then hang the system as a unit (also easy). Working solo, I simply built up a stack of boxes under the pipes until I could capture one side. Cylinder 2 and then 4 went on ok, although the outboard nut on #2 had minor interference due to the newly angled flange....but got them on. Cylinder 1 also went on ok. BUT no joy on the last one, cylinder 3. There was no logic to the sequence, just dealt with the most obvious "volunteer" at the moment.

No matter what I did, I could not get the flange over the cylinder # 3 studs. Clearly the issue is that the position of the collector "pulls" the last pipe towards the center so that it contacts the underlying intake pipe preventing the pipe and flange from moving inboard.

Spoke to the industry expert and confirmed I was neither doing something stupid/wrong nor any incorrect sequence. The factory welding/jig is clearly still in error.

To be continued.

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Aug 21, 2023     Aft Cable Cover - (2.5 hours)       Category: Interior Finish
Fabricated the aft cable covers. Simple/fun/lots of drilling an clecoing. Yet to trim the bottom edges to the curvature of the fuselage bottom.

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Aug 19, 2023     Completed the BH A Closeout - (4.75 hours) Category: Interior Finish
Close-out for bulkhead A. Now that the close-out was finished yesterday, onward to installing the nutplates on the bulkhead. Countersunk all rivets, figured out the best way to enter and lay back into the fuselage, and installed the nutplates. Biggest issues included discovering the thickness of the interior fuselage and bulkhead varies based on number of reinforcing fabric layers = different rivet length required. Also "flinched" at inopportune times, mis-setting rivets and nuplates. A real test to be drilling out bad rivets on your back and while basically in the dark. Who said homebuilding was fun? But got it done.
 
Aug 18, 2023     Bulkead A Closeout - (4 hours)       Category: Interior Finish
Started on the interior while waiting for Glasair to return my exhaust pipes.The close out for the rear cabin (bulkhead A) starts with .020 flat stock, gets shaped, then drilled into the fuselage. Good progress. Simple step, but the gyrations to get into the rear area are challenging.

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Aug 16, 2023     Mag hoses & Adel's - (5 hours)       Category: Engine
Replaced the one screw in the duct to the oil cooler with an all-metal locking nut.
Replaced both oil lines to the oil cooler with the new integral firesleeved hoses from Aircraft Safety Flightlines.
Adel clamped both lines for interference-free stand off. PITA to do the "double Adel" method but works nice.
Zip tied the end of the mini-hoses to the magnetos now that the oil lines are final.
(One trip to HD, and a second trip to Wipair for parts, time not included in total.)

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Aug 15, 2023     Oil Temp Probe installation - (2 hours)       Category: Engine
Reviewed TWTT 2300 for mounting point under cylinder 3. Alternator, cht, egt wiring.

Installed the oil temperature probe next to the base of the spin on oil filter. Safety wired, a bit tricky.

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Aug 12, 2023     REclocked the Governor - (4.3 hours)       Category: Engine
Cut the safety wire from the 6 governor screws, loosened, and tried rotating the control head. But to do so, I then had to completely remove the two screws at the 6 oclock and 5 oclock positions, and was able to keep the small standoffs in place, rotated the control lever to a 10 o'clock position, and rescrewed the 6 back in place. Max stop screw now at 10 o'clock and the minimum stop screw now at 5 o'clock. Governor spec called out for a 14.2 to 15.9 in-lb torque.

A very educational exercise. Now know more about constant speed prop governors than I wanted to.

Replaced the desicant plugs in cylinders 3 and 2 which are showing color change.

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Aug 11, 2023     Scat & the Dog's Breakfast. - (4 hours)       Category: Engine
* The sharp duct bend now makes it difficult to get 4 inch SCAT tubing over the baffle end. Wrestled with it, got it on, and then decided to order a foot of 4.5 inch ducting. Will replace the 4" when the 4.5" comes from Aircraft Spruce for ease in future maintenance.

Then a little bit of everything left over:

* Also removed the two high pressure oil lines to the oil cooler itself; my EAA tech counselor recommended doing so and replacing with firesleeved lines. Measured and ordered the 2 lines from Aircraft Specialty Flightlines who make an integrated hose that is beautiful.
* Continued "clean up".....inspected Glasair Service Bulletin SB36 Rev A covering aux tank sumps....mine comply/are ok.
* Incoming inspection of a new PC680 battery; 12.87 volts and a very recent manufacturing date.
* Inspection of the prop governor for reclocking. Looks to be a simple job (spoke to the jihostroj prop-governor rep at Airventure, and got a mini-course on working with the unit.) Tomorrow.

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Aug 10, 2023     Tear(s) Duct - (2 hours) Category: Engine
Retrofitting the correct duct after drilling out/removing the incorrect flange (a Glasair documentation issue) turned into a royal PITA. The duct weld interferes with the baffle seal rivets. The sharp angle of the duct itself prevents drill access; using my 90 degree drill seems easy but access is blocked by cylinder #3 on one side, and the engine mount pipes on the other side. A real exercise in patience. Finally defaulted to 3 rivets and 1 screw/nut to make it work.
 
Aug 09, 2023     Continuing FWF Clean-Up - (3 hours) Category: Engine
When I'd installed the air-dam on the bottom of the firewall, I'd intentionally sliced 2 lines on the left side in case I needed to indent the dam for gascolator clearance. Did not need them, and planned to RTV the slices when convenient. However, upon inspection, it was more effective to simply use metallic tape over the slices.

Still waiting for Glasair to return my exhaust system pipes.

Then moved on to replacement of the baffle flange on the right aft side baffle that ducts air to the oil cooler. Drilled out the flange rivets, drilled out 3 of the the rivets holding the aft seals in place, and moved on to trimming the new/correct duct flange received to replace the one sent in error. Ready to rivet back in place but ran out of steam today. Hot and stuffy in the hangar. Man'ana!
 
Aug 08, 2023     Alternator Removal and Reinstallation - (2.7 hours) Category: Engine
Gritted my teeth and removed the alternator. The plug in the aft side of the unit with wiring (which I'd taken out to avoid any damage while installing the alternator itself) was too long to plug back in once the alternator was installed. Only solution was to uninstall the alternator, put the plug in, reinstall the alternator, retorque and safety everything. Did so.

Swept the hangar as penance.

Also connected the fuel delivery line from the red flow cube to the distribution spider on the top of the engin.

 
Jul 22, 2023     Airventure 2023 - (1 hour) Category: Research
Drove over to Oshkosh this year. 25th year in a row. July 22 to 28 and then to Lake Vermilion near the Boundary Waters area on the 29th for family vacation.
 
Jul 20, 2023     Treading water - (1.65 hours) Category: Engine
Tried putting each exhaust manifold pipe on each/every cylinder. Pipes for 1,2,3 slip over the studs on all cylinders easily. NOT pipe 4.....particularly at cylinder 1 and 4. Did a bit of hangar re-arrangement. Paul Thomas visited at 11:15.

Got a message from Glasair to ship back....ran back to hangar, boxed, and got to UPS in time for the 6pm cutoff. Air freight...will be there Tuesday.
 
Jul 19, 2023     Searching for answers - (2.7 hours) Category: Engine
Stumped at why the exhaust system will not install. Spoke to Lycoming Tech support, spoke to Glasair, researched. No luck. Took it all apart for a clean start.
 
Jul 18, 2023     Scraping off RTV - (2 hours) Category: Engine
Basically housekeeping; removed the exhaust gaskets and scraped off dried rtv.
 
Jul 17, 2023     Start over - (2 hours) Category: Engine
Removed all 4 exhaust headers; cylinder 4 the most difficult.
 
Jul 16, 2023     Sunday penance - (1.05 hours) Category: Engine
Can't recal ltiming. Short effort = frustration over the exhaust system.
 
Jul 15, 2023     Pipe dreams - (4.05 hours) Category: Engine
Worked on seating the 4 exhaust pipes into the collector. No joy. Issue at cylinder 3 and cylinder 2...the exhaust pipes contact the underlying intake manifold which prevents the requisite movement to get all 4 pipes into the collector.
 
Jul 14, 2023     Exhaust Pipes - (3.35 hours)       Category: Engine
Being very cautious with the engine manifold studs, do NOT want to strip/damage. Exhaust pipe was on for #1 and #2. Worked on #3 today, filing tiny bit by tiny bit. Switched over to #4 and got it on. Realized the trick is moving the upper ball joint. Then moved back over to #3 and finally got it, with liberal usage of beard balm. Now for the collector....manana. Will NOT torque the nuts if and until I get the collector on.

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Jul 13, 2023     Exhaust - (3.4 hours) Category: Engine
First finished up the last of the hoses, using Adel clamps for securing the sniffer hose assembly. Then moved on to the exhaust system only to find my Red Silicon High Temp was dead. The search was on for the next 3 hours, finally located some fresh CRC at the Grainger across town. Tried mounting the system as one piece, but no joy. Finally pulled all four legs out of the collector, and struggled to even mount them one by one. Got #1, #2 in place but just could not get #3 to fit. Stopped with fatigue...try again tomorrow. Time to get out the files. The real question is going to be can I get the four manifolds back into the common collector.
 
Jul 12, 2023     More Hoses - (6.1 hours)       Category: Engine
Reconfirmed plumbing/hoses installed: firewall to gascolator, gascolator to mechanical fuel pump, mechanical fuel pump to fuel servo inlet, fuel servo outlet to red cube flow transducer, red cube to fuel spider/dispenser. also oil pressure line to transducer. Fuel pressure line to transducer. Then installed the manifold pressure line to/through the firewall after significant time searching for parts. In spite of progress using parts, it seems I spend too much time searching for parts....probably time to re-sort out the inventory. Then fabricated and installed the sniffer valve relief hose. Then fabricated and installed the mechanical fuel pump vent hose. Photo shows a growing population of FWF hoses!

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Jul 11, 2023     Philippe the Plumber - (6.3 hours)       Category: Engine
Gorgeous day at my hangar at KSTP overlooking St. Paul.

Good progress today installing "plumbing"....fuel line hoses, oil hoses, fuel and oil transducers into the firewall mounted manifold. Specifically:
* Gascolator to mechanical fuel pump
* Both transducers into manifold
* Mech fuel pump to transducer
* Oil pressure transducer to engine low pressure port at Cylinder 3
* Installed red cube fuel flow transducer
* Red cube to fuel dispenser

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Jul 10, 2023     Exhaust System Arts & Crafts - (3.25 hours)       Category: Engine
Stopped by Wipaire for missing AN4-17A's and 3 inch scat tubing.
Then continued working on installation of the exhaust system; I'm planning to wait until hose installations are complete before actually mounting on the exhaust manifolds, since it will be so much easier to do so without the exhaust blocking access. Regardless, the exhaust system requires a fair amount of fabrication work that seems to be mostly "arts & crafts" type activity. eg Fabricating the tail pipe hangers. Mounting the hangers to the tail pipe clamp. etc. Kinda fun. Got to use the Niccopress again.

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Jul 08, 2023     Airventure Disposals - (2.05 hours) Category: Engine
Dug out large parts to sell at Airventure. The cowling too small for my IO360. The Instrument panel and glareshield pre-Garmin days. The extra set of aux fuel tanks. And so on.
Then located the Red Cube fuel flow transducer, and mounting parts to complete the FWF hoses.
 
Jul 07, 2023     Fuel line - (2.5 hours) Category: Engine
Installed the fuel delivery hose line with Sealube (provided by Lycoming as hose "C").
 
Jul 04, 2023     Exhaust - (2.5 hours)       Category: Engine
Researched the fuel and oil transducers (Garmin parts) to confirm 1/8-27 NPTF fitting and the Glasair manifold on the firewall. Will double check the manifold fitting size after the holiday to verify they'll work together.
Then opened up the exhaust system box and assembled. Took lots of time confirming the parts actually received. Progress!
Will wait until I install the fuel hoses (which are easier to get at right now) to physically bolt onto the exhaust ports, but placed the system on boxes to confirm the fit/cylinders.

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Jul 03, 2023     The Searchers - (3.7 hours) Category: Engine
Not the movie title...rather the name of the "build your plane" person a couple of years into the project. Some days it seems like a continuous search for parts or information. Spent time looking for confirmation I'd put in a restricted orifice from Lycoming (yes I did last November). Then searched for a new battery consistent with my old charger and ordered an Odyssey PC680. Then searched for mounting parts for the fuel flow cube (AN4-17...never did locate, will have to order.) Then searched for the 2nd of the Lycoming fuel delivery hoses...found it mixed in with other hoses. Then searched for the hose callouts for the 303 fabrication specs which I then ordered from TS Flightlines. Absolutely zero physical progress. Where's John Wayne when you need him.
 
Jul 01, 2023     Spark Plug Wiring - (3.45 hours) Category: Engine
Rerouted the spark plug wires to minimize crossovers/stress. Tried placing the battery tray, but discovered it requires a battery tray shelf to sit on. Ordered. Inspected/reviewed baffle seal gaps; decided to leave "RTV-ing" until later in the build and avoid the mess for now.
 
Jun 30, 2023     Routing the spark plug wires - (5.1 hours)       Category: Engine
Best input was on the Van's Airforce site:
* Shortest wires to bottom plugs.
* Right mag fires the bottom plugs on the right side and the top plugs on the left side.
* Left mag fires the bottom plugs on the left side and the top plugs on the right side.

However, Emag states "it doesn't matter which cylinder is connected to which post within a given pair. And the electronic magneto pairs are 1 & 2, and 3 & 4...which seems counterintuitive to the engine itself (eg Right side is cylinders 1 and 3, Left side is cylinders 2 an 4). So after routing the wires, I tried swapping a few cylinders (eg #2 cylinder lower plugs with #1 Cylinder upper plugs) to see if lengths were better...they were not, so reverted back to original.

(Significant time was lost recovering a dropped baffle clamp that went down behind the cylinder skirts. But fortuitously discovered an engine hose clamp that was loose while doing so).

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Jun 29, 2023     Ignition Wire Dithering - (2.05 hours) Category: Engine
The upper spark plug wires pass through the aft baffles, but this requires clarity on the mags and wiring decisions. Time for education again....researching the EAA site, the Glasair owners site, the Van's Airforce site, the Lycoming site, the Emag site (you get the idea). I purchased the Emag's from Lycoming with the engine, but the interconnect (spark plug) wires are a bit undefined. Not much physical progress, but incremental learning.
 
Jun 28, 2023     Cowl seals' tweaking - (2.5 hours) Category: Engine
Cowling top and bottom was still on...pulled off top, and tweaked the fit of the seals. Cut slots with a razor blade at assorted spots Then did the same with the bottom cowling. The challenge is to turn a 90 degree corner with the flat seal material. Almost but not quite done with the cowlling.
 
Jun 27, 2023     Cowling on to Trim Seals - (2.45 hours)       Category: Engine
Installed top cowling, pulled it off, reinstalled top cowling, pulled it off....repeat.
Trying to determine seal "overlaps" to rivet. Did so, not very pretty but functional.
Representative photos shot via the front, and proof I can still get the cowling to mount with seals.

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Jun 26, 2023     Final trimming for baffles - (2.5 hours) Category: Engine
Reviewed front right fiberglass baffle for correct alternator wiring holes and grommets. Some Glasair pages show two entry holes, other versions show one hole for all three alternator holes; test fit and chose the "one hole" version for alternator output wire and two alternator field wires. Then reinstalled bottom cowling and did some minor trimming of the bottom seals. Then loosely installed the upper cowling, but will neet to trim and rivet the seal overlaps before screwing it in place.
 
Jun 24, 2023     One step forward, two steps back - (3 hours)       Category: Engine
Installed the K&N air filter and cap on the front of the fuel controller....getting all the blue tape off the throat (put on to keep it clean months ago) was the hard part. A step forward. BUT then as I reviewed the alternator lead holes in the forward baffle, I realized that it is no longer possible to plug the alternator field leads' plug into the alternator....too close to the forward fiberglass baffle. That means removing the alternator to plug it in, and then reinstalling. This of course requires removal of fan belt, re-safetying everything, and re-tuning the fan belt tension. Two steps backward. Sheesh.

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Jun 23, 2023     Baffle Errata - (3.5 hours)       Category: Engine
Front left baffle was not originally used with constant speed prop; need to drill and grommet to allow the cable/rod for the prop governor to pass to the front. Defaulted into installing the control cable bracket to ascertain where the cable runs to estimate where the baffle hole needs to be. Did so after lots of measuring, as dimensions were that unclear. Then installed a hose flange on the pre-drilled hole in the same left front baffle for routing cooling air into the cablin.

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Jun 22, 2023     Magneto Cooling - (2 hours)       Category: Engine
While I have E-ignition set up, there is still cooling for the mags. Drilled and installed one cooling hose for left and one for right.

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Jun 21, 2023     Deal is Sealed - (3 hours)       Category: Engine
Riveted Aft left, Front left, Front right, Front central. Now just need to reinstall the upper and lower cowllings, determine the corner overlaps, and then rivet the corners.

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Jun 20, 2023     Sealing the deal part 3 - (3 hours)       Category: Engine
Mid 90's today.....hangar is cool enough to work until about 2pm. Continued work on the baffle seals. Got the aft seals riveted in place. Next the foreward left drilled and clecoed. And then the foreward right, got it sized, clamped and partially drilled. Will wait until the cool of the morning tomorrow to do the curves, which are always a bit more tricky.

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Jun 19, 2023     Sealing the Deal, Part 2 - (2.7 hours)       Category: Engine
Continued install of seals. "Cowl Saver" brand from McFarlane. Did aft sections. Slow but steady. Only had to redo one of the sections (initially installed in reverse.) Oh well.

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Jun 17, 2023     Sealing the deal, part 1 - (4.1 hours)       Category: Engine
installed right and left side seals, using "Cowl Saver" material instead of the kit's Garlock material.
Measuring, cutting, drilling, clecoing, riveting...the usual lineup of suspects.

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Jun 16, 2023     Cylinder skirt rods - (3.25 hours)       Category: Engine
Threaded rods connect the rounded baffle assemblies on the undersides of the cylinders. One rod connects cylinder 1 and 3, and one rod connects 2 and 4. Looks simple, but what a pain to get those rods threaded through the bottom of the engine areas into the flanges. Not fun.

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Jun 15, 2023     Drilling - (3.3 hours)       Category: Engine
"Conditioning" lower cowling nutplates with WD40 on an AN3 bolt...ran in and out to loosen the locking factor. Retrimmed more from left aft baffle corner. Marked and trimmed the front fiberglass baffle (dremel with diamond cutting disc).

Then taped the front baffles to minimize any random chips landing in the engine area; and then drilled the holes for the garlock seals.

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Jun 14, 2023     Seals' holes - (4 hours)       Category: Engine
Partially redid the paperclip technique on the aft left corner to confirm the trim amount. Then removed the left aft baffles, got out my trusty clippers, and trimmed. Reinstalled. Nope,not enough. Remove baffles again and "take a little (more) off the top". Reinstalled and that works.

Then taped in turn each baffle side, ala-body-shop-paint-prep, to minimize any chips while drilling the holes for Garlock seal installation. Drilled with the baffles left in place.

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Jun 13, 2023     Clip Joint - (2 hours)       Category: Engine
Need to confirm the gap between cowling and metal baffles before putting in the garlock seals. An old trick is using paperclips on the baffles, installing the cowl, removing the cowl, and seeing what the new paperclip heights are. Kinda fun. Good top gap except Left aft corner, will need to trim.

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Jun 12, 2023     Cowled but not Cowering - (3.5 hours)       Category: Engine
REmounted and screwed in both upper and lower cowling for the 1st time. Some screws/holes are fighting me....will decowl and fix them by using WD40 on a bolt and torque it in and out. Need to fill in the two holes redone/not in use. Aired front tire..slow leak (?), something more to replace later on.

Finally getting back into the build project after signing off on the annual condition inspection for the RV12iS.

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Jun 09, 2023     Took a break - (1 hour) Category: Engine
Found out just how hard it is to restart a project even after only 2 to 4 weeks. First couple of weeks away from the build (annual condition inspection for other plane) was ok, but the next 7 to 10 days were difficult. No motivation, reviewing work done to date and "missing steps" identified, searching for parts, ordering parts from Vans and Glasair, excuses and so on. Really is tough to get focused again. Man'ana.
 
May 15, 2023     Time to do the RV12iS annual condition inspection - (0.1 hour) Category: Engine
My RV12iS annual expired at the end of April. However I wanted to complete the Glastar cowling before shifting over to SLSA for awhile.
It will probably take me a couple of weeks to complete the annual condition inspection since I plan to "learn" the detailed KAI (kit assembly instructions) at the same time/as I go along. Sorta like learning to speak a foreign language. :) But no more Star project entries until I sign off the RV12iS.
 
May 12, 2023     Cowling Finished - (2.2 hours) Category: Engine
Completed all the nutplates. Then ran a AN3 bolt with some WD40 through all screw holes to loosen the locking pressure. The Cowling is finished, other than gluing in a heat shield panel in the lower section after installation of the exhaust system.
 
May 11, 2023     Panel Arrival and Cowling Completion - (6 hours)       Category: Engine
A good day on multiple fronts. The panel and electronics, all Garmin, arrived from Aerotronics. Larger box than I expected; on a pallet, and apx 150 lbs. One gash/cut on a box end, but opening it confirmed it had not gone through into the contents. Will unpack and check in tomorrow.

Happenstance to see a Glasair comment that the deburring of the stainless steel firewall perimeter is best done with a die-grinder and a burr. What a difference that makes in terms of cleaning up the holes in the stainless steel. Redrilled two of the cowling nutplate holes on lower aft edge. Countersunk all 42 (!) nutplate rivet holes...some using a cage, but some manual where the hole was too close to the joggle side to use the cage. Slow but effective.

Pneumatic squeezer to mount the K1000-3 nutplates; Now with the engine in place, the geometry forces the use of the moving ram side on the outside/flat countersunk rivet head. Did have to redo 2 or 3 when I slipped mid-squeeze. This should complete the cowling other than gluing in a heat barrier later on after the exhaust system installation.

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May 10, 2023     Firewall Nutplates - (2.2 hours) Category: Engine
1. Took a straight 3/16th inch flute and reamed the stainless (firewall perimeter) holes.
2. Drilled the nutplate rivet holes (#40) for all the firewall to cowling holes.
3. One of the firewall cowling holes was too close to an existing fuselage to firewall rivet and the nutplate rivet hole drilled into it. Then had to drill out the (now) bad rivet (difficult since in stainless steel) and reset a new rivet.
4. Also found one additional (so a total of 2) hole is too close to the existing rivet. At least I spotted this one before drilling. So tomorrow will reinstall the cowling and redrill both in a new location(s)....then do the nutplates.

Two steps forward, one step backward ?
 
May 09, 2023     Dropped Rivet Box - (2.9 hours)       Category: Engine
Good news, bad news. Made progress on the lower cowling's sides (where the upper cowling nests on the sides). Driled the nutplate rivet holes, countersunk the rivets, and installed the nutplates with the pneumatic squeezer.

Bad news....one of the compartmented plastic boxes with mostly rivets fell off the shelf and broke open upside down. A "rivet-stew". Great. Took the mess home and started the sorting. Ahh the joys of homebuilding.

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May 08, 2023     Tinnermans - (2.5 hours) Category: Engine
Using machine screws and tinnerman washers to secure the cowling. Thanks to Ted for pointing out this simple method (as compared to mounting camlocks or others) which coincided with the advent of compact battery operated portable drills. Easy-peasey to install, take off using the drill, etc. Countersunk all the cowling holes both on the sides and aft. Will get at the nutplates tomorrow which of course will require more countersinking of the #40 nutplate rivets (AN426's).

Also discovered there are at least 2 choices of 100 degree tinnerman's, stainess steel and steel/cadmium plate. I'm using stainless...same material as the screws, shinier, and THINNER than the others. (ie low(er) profile). A bit more expensive, but diminimous.
 
May 06, 2023     Cowling - (4 hours) Category: Engine
Riveted oil access door to upper cowling as well as the latch.
Updrilled all pilot holes on the upper and lower cowlings and aft/firewall to 3/16th. Ran out of gold 3/16th clecos, but was able to run over to momentum's hangar and borrow a dozen to finish the job.Minor sanding of side edges. Pulled the tapes, deburred the holes, and drilled the gascolator drain hole in the lower cowling. Realized I'd not updrilled the four spinner ring holes, and put it all back together to do so. Getting there on the cowling.

Airport is dismantleing the flood wall and repainting the runway. My eyeball says the river has dropped 2 to 3 feet from last week's peak. Good news.
 
Apr 29, 2023     Latch? natch! - (1.9 hours)       Category: Engine
Slipped out to hangar for short session. Almost immediately found the problem with the oil access door latch. I had not realized that the cutout for the mechanism required cutting the outline and not just for the lever. And I was all set to order a new door and start over!

Lesson learned: if you hit a wall, you can always knock off for the day and return the next to fight again. AND with fresh eyes, see immediately what needs to be done.

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Apr 28, 2023     Oil access door continued - (4.2 hours)       Category: Engine
Reordered from home the various parts missing for mounting the cowling.
Sure enough, I found the original shipment of parts within 5 minutes of arriving at the hangar. Sheesh.

Measured and drilled the oil access door latch. Did so accurately and well...BUT the latch does not close or close without the strength of Samson to do so. Very disappointed. Possibly the curvature of the cowl and access door are an issue. Will try shims next time.

I also note that in 2007 Glasair switched away from t he square tab Hartwell latch (in my kit) and went to a Hartwell latch with a round button. Bet they did so because the square tab is a poor fit/pain in the kiester. May decide to reorder another access door, the new latch, and redo the whole darn thing. To be continued.

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Apr 27, 2023     Oil Access Door - (3.1 hours)       Category: Engine
Searched for parts which Aircraft Spruce says were delivered March 30th...no joy. I'm thinking it's lost in the mail or stolen from mailbox (?), but thankfully not a big $$ shipment. So moved over to work on the oil access door. Fabricated the hinge, drilled the top cowling, sanding again (still), and on-off for yet more sanding.

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Apr 26, 2023     Floods and Cowling drills - (3.6 hours)       Category: Engine
Going to the hangar every day to work on the Glastar...but really going to keep an eye on the flood waters. So far the levee has held but water formally at flood stage level. If the levee broke it would be a mad scramble to get my hangar cleared. Also reluctant to start the annual condition inspection that's due this month because of the flood. (If need be, I could fly it out...but NOT if I tear it appart for annual). Will wait and see.

Eventually the builder has to commit. My cowling fit is not perfect, but it's pretty good with the major flaw being the raw upper cowling as received from the factory...it was definitely not to spec length, and took extra time to make it workable. So today I drilled the spinner ring holes, and the sides (upper to lower) and the final cowling to fuselage firewall drilling. Cleco'd all in place and called it a day.

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Apr 25, 2023     Sanding - (1.1 hours) Category: Engine
Short session sanding the forward left corner of the upper cowling.
 
Apr 24, 2023     Upper Cowling Tweaking - (2.2 hours) Category: Engine
Lower cowling is cleco-ed in place. Using cleco clamps to match upper cowling to lower cowling, at front air inlets, and marking sides for upper/lower cowling fit. Then removing upper cowling, manual sanding with 11 inch sanding block/220 grit, and reinstalling. Multiple times! Now nice fit on sides, but not happy with the top, aft, left side gap to fuselage joggle flange....wider than the 1/10th inch max mentioned. To be reviewed.
 
Apr 22, 2023     Upper Cowling Right Side - (1.9 hours) Category: Engine
Taped right side edge of the upper cowling using the "tape line transfer trick". Then cut (dremel with diamond wheel) the right side edge and then sanded with a long sanding block. Technique has definitely improved. Also found using nitrile gloves and a mask is a good idea when doing lots of fiberglass sanding. Will do one more trial fit, a bit of final-final sanding, and drill the sides and aft screwholes next time in the hangar.
 
Apr 21, 2023     Upper cowling, left side - (2.1 hours) Category: Engine
Upper cowling needs to be trimmed on both left (pilot) and right (copilot) sides to fit the available circumfererence at the aft edges. Worked on left side...first sanding, then dremel and diamond blade, then sanding board again (220 grit). Making real progress, but slow. Sorta like Gibbs working on slowly planeing his boat.
 
Apr 20, 2023     Top Cowling - (3 hours) Category: Engine
Marked and cut the aft line of the upper cowling. Cleco-clamped the front. Did have to trim more from the aft upper corner baffles to get upper cowl to sit.
Taped the sides of the upper cowling to transfer cowling split line. Upper cowling will need to be trimmed apx and inch on each side. Man'ana
 
Apr 19, 2023     Drilled lower cowl to firewall - (3.5 hours)       Category: Engine
Played with the lower cowling position, and finally concluded it was not going to improve further. Perfection the enemy of progress. So clamped the aft corners and drilled and clecoed the lower cowling to firewall, alternating sides. Then laid the upper cowling on top...need to do some additional baffle trimming, this time on the rear upper baffles.

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Apr 19, 2023     Senior moment - (2.8 hours) Category: Engine
Forgot my hangar keys at home in a parka. Double trip. Pulled the lower cowling back off, made a "long sanding block" with 11 inch 2X4, taping a full sheet of 220 aluminum oxide grit paper. Sanded and looks pretty good. Then measured upper cowling and compared to firewall circumference measurement left....too wide by apx 2 inches. Will be trimming/cutting down the sides of the upper cowling before installing it and drilling the side screw holes.
 
Apr 17, 2023     Flood worry - (2.1 hours) Category: Engine
Airport was to be closed today, but rescheduled till tomorrow for runway repainting. River at flood stage and barriers put up. Started moving project pieces to the mezzanine level in my hangar "just in case". Struts, control surfaces, etc.
Then back to the cowling; Took both upper and lower cowls off the plane, tried to match...hard to do so due to amount of flex and bow. Ended up putting the bottom cowling back on and clearly the aft edges need to be sanded straighter.
 
Apr 14, 2023     Seats! - (2 hours)       Category: Interior Finish
Finished cutting aft edge of lower cowl.
Best news...10 months later my seats arrived! Yeahhhh!!

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Apr 13, 2023     Prop to Cowl Gap (Rube Goldberg) - (3.6 hours)       Category: Engine
Taped a 1/4 inch thick balsa shim behind the aft spinner edge.....this allows me to simply push the cowling forward until it bumps the shim. Then used 1/4 inch planks on each side of the nose gear leg, centering the bottom, aft side-to-side. Then ruler and laser to center forward cowl from side-to-side. With the bottom cowl about where it needs to be, finally can mark and cut aft edges.

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Apr 11, 2023     Mating, must be spring - (1.9 hours)       Category: Engine
Removed lower cowling (again) and made what I hope is the final baffle trim. Then dremel and diamond wheel to cut in lower cowling forward outside inlet flange bevel to facilitate mating top and bottom cowlings. Fit cowling together...must be spring. :)

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Apr 10, 2023     Easter Monday - (3.5 hours)       Category: Engine
Still comingle-ing (?) baffle work (trimming metal and fiberglass front baffles) and cowling work (want a consistent gap with the baffles).
Did a refresher on gaps....and also spinner must be off/higher than cowl to allow for 1/8th inch sag in the mounting donuts after the first 50 hours or so.
Also complicating the issue is that the engine is 1.8 degrees down and 1.5 degrees offset to the right to offset engine thrust. Bottom cowling on and off so many times today I lost count, but getting closer. One quick trip to Ace Hardware...they have "project panels/boards (balsa?)" that are perfect shims to set clearances...1/8, 3/32, 1/4 and so on. Very handy.

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Apr 07, 2023     Groundhog day - (2.7 hours)       Category: Engine
Just like yesteray. Lower cowling on in place....trim line for lower baffles....cowling off, trim baffles, put lower cowling back on in place. Repeat, and repeat again, and repeat a third time. Being very cautious/conservative...I'd hate to start over with the baffle pieces if I overtrim.

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Apr 06, 2023     Cowling Fit - (2.6 hours) Category: Engine
Removed cowling and clamped upper and lower to fit for match fit. Not too bad but needs work. Reinstalled lower cowling and used for trimming the lower baffles. Repeated twice, closer but still not there.
 
Apr 03, 2023     Oil Access Door and Eli - (1 hour) Category: Engine
Busy work waiting for grandson Eli's visit for "1st Taxi". Worked with fit of oil access door in upper cowling. Fun taxi/familiarization "flight" with Eli.
 
Mar 31, 2023     Back to the Future - (4 hours)       Category: Engine
When I did the baffles originally, I had to stop when it was time to trim the forward outline until I had the cowling installed. Now it's back to the forward baffle shapes which need to be trimmed to allow the lower cowling to even approximate the correct location. Mark the baffles, trim cut the baffles, install the lower cowling...and repeat multiple times...at least 3 or 4 times with more to come. Making progress, but not there yet.

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Mar 30, 2023     Serious trimming ahead - (3.1 hours)       Category: Engine
Cut the lower cowling nose gear leg slot with a diamond wheel on my dremel. Then strapped the upper and lower cowlings on the plane. Lots of interference with the baffles, which I knew were going to have to be trimmed (But needed the spinner and lower cowling in place to do so.). Now will do so.


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Mar 29, 2023     Not much - (2.2 hours) Category: Engine
Some days are like that....not much accomplished. Did clamp the upper to lower cowling for the first time. Pretty decent mating fit. Then spent time investigating the oil access door, . Main discovery is that Glastar was all gel-coated for finish. Sportsman switched over to a matte primer. Decided to order a new oil door and keep the gelcoat one with the original gelcoated fuselage and cowling for resale value.
 
Mar 28, 2023     Cowling Progress - (2.4 hours)       Category: Engine
Restarting the daily effort now that the cowling arrived. Both upper and lower cowls arrived in decent shape. Pleasant surprise is the oil access door is now cut in by the factory. Although no scribe lines to aid in trimming. And not gel coated, simply some base paint coat easily scratched. Marked center lines on upper/lower pieces; harder than I thought since the pieces are so sculpted, but got it done. Also marked the trimming necessary for the (trike) nose gear leg....tomorrow's work. Also leveled the fuselage on gear horizontally and longitudinally in anticipation of mounting the cowling.

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Mar 28, 2023     Cowling box Clobbered - (2.1 hours)       Category: Engine
Pilot Freight was not helpful as to where the box shipped over a week ago went. Finally decided to personally go by the depot and look around, and sure enough there was the box "....it just came in" ???.
Unpacked at the depot and regardless of box condition the new cowling upper/lower was not damaged.
Spent time inspecting and marking center lines.

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Mar 24, 2023     Speechless Category: Engine
The new cowling was to come via airfreight. Glasair has no idea why it instead went ground. Was to be picked up in Arlington on March 16th.
Worse, it went via “line haul truck routes” on Pilot Freight (?)…not a pun….and local office says it will be late next week/early April to arrive. Some thinking it might have gone from Washington to Ohio (?). No-one knows or can tell me where it is. Either at Glasair or at Pilot Freight.
 
Mar 22, 2023     Cowling Decisions - (1.7 hours)       Category: Engine
Waiting for new cowling to arrive this week. One more time reviewing the SEVEN (!) different installation approaches I've collected: Stoddard Hamilton's Glastar 063-09009-01 from 1996; Updates/errata from 1998 owner-site postings; Owner site directions from 2006; Glasair's Sportsman Lycoming with stainles screws 063-09049-02 from 2007; TWTT Step 3200 from 2009; Zach Chase approach from 2020; and lastly Kitplanes from 2023.

Deltas are not trivial; mounting differences (hinges, camlocks, machine screws). Cowl flaps (ground adjustable). Cowling shapes and designs. Exhaust exit treatments. Use of alignment jig(s) or not. And so on.

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Mar 21, 2023     Education - (2 hours) Category: Engine
Paused in the project for additional study/review on hoses and cowling installations. Saturday/Sunday/Monday/Tuesday spent time "in the books". Determined raw hose inventory, and which fabricated hosed to come from a supplier. Nominal couple of hours even though significantly higher actuals.
 
Mar 17, 2023     RV12-iS - (0.3 hour) Category: Engine
Additional paper review of hose requirements. Then shifted gears to Light Sport Maintenance (time logged not included in the Glastar project) and completed several mandatory service bulletins on my RV12-iS and signed off the logs.
 
Mar 16, 2023     Hosed - (2 hours) Category: Engine
Pausing on the cowling for now. Shifiting over to hoses to try and keep making progress. First tried installing the fuel and oil sensors into the manifold installed on the firewall, but don't seem to fit in place. Queried Aerotronics, and confirmed part numbers ok. Then reviewed the TWTT Hoses Task 4000 and recalled stopping part way through this sequence last October due to the need to fabricate Aeroquip hoses. (AKA303 Hoses and 491 fittings.) This needs an assembly manual for each size hose, and while available via Aircraft Spruce, each one rune $125 to $150. Not going to buy or borrow. Rather will order assembled hoses from Aircraft Specialty Flightlines!
 
Mar 15, 2023     Pickle Plugs - (1.2 hours)       Category: Engine
Spark plug adaptors arrived; replaced the top NGK plugs with dessicant plugs to further "pickle" the engine.
Also taped the fuselage firewall front flange in preparation for the new cowling; this is the approach to mark the cowling aft-cutoff line.
Lastly (not counted in this entry's time) completed SB-59 Rev1 for my RV12-IS and signed off as LSRM-Maintenance.

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Mar 14, 2023     Alternate Cowl Install Directions - (1.2 hours) Category: Engine
Not much accomplished. Did identify the correct installation process for the larger cowling. 063-09049-02. Downloaded and studied. Waiting to hear the new cowling shipped and a tracking number.
 
Mar 13, 2023     Tried again - (1 hour) Category: Engine
Insanity I guess. Measured all front end dimensions and tried squeezing the baffle/cowling interface together, but no joy. Cowling just too small. Interfaced with Glasair to order new cowling. Also spoke with Billie at North Country Upholstery about my seats...she's getting closer to completion, no date asked or given at this point.
 
Mar 12, 2023     Cowling Quandry - (2 hours) Category: Engine
Sunday meltdown.
Posted many queries/emails on the owner site. Received feedback from none other than the original designer!
Conclusion...I was thoughtful about whether the cowling would work with an IO-360 (it will, with slight modifications expected.) BUT
I did not think about cowling fit as I installed the BAFFLING....which is an option I ordered in 2022...and is basically the interchangeable Sportsman TWTT baffling.

This baffling will NOT work with the historic Glastar cowling. This is going to be a $2,500 hickey to order a Sportsman dimension cowl. At least Glasair has one in stock.
 
Mar 11, 2023     Cowling Foreplay - (3 hours)       Category: Engine
All the cowling assembly approaches detail prep activity; for example, tape the prop, valve cover, nose gear to protect the surfaces. Remove the forward engine lifting bracket for clearance.(then retorque engine bolt to 50 in-lbs.) Measurements of circumference, cage distances, etc. Re-air the tires and level the fuselage laterally and longitudinally. Confirm engine down/offset anges. Oh by the way, shoot WD40 into the spinner backplate nutplates to facilitate initial usage. Oh by the way...one of the safety wires for the prop bolts isn't correct - cut and redo.

Ta-daaa....Lay the cowling top on the top of the engine. :( :( Oh no, it is obviously too narrow and does not work with the baffling I've got installed. Go home.

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Mar 10, 2023     Cowling for engine. - (2 hours) Category: Engine
Did not go to hangar. Studied at home the documentation for cowling installation.. I've accumulated multiple approaches for this next step; original 2002 Glastar approach, TWTT from 2016 approach, 2023 Kitplanes jig/article approach, two different approaches from Van's, and so on.
 
Mar 09, 2023     Sump - (6 hours)       Category: Engine
Time to pickle the engine before spring. Tried to put in dessicant plugs but could not get the (automotive style) spark plugs to separate from the adapter. Plugs are electronic mag/automotive standard 14mm compared to the aviation standard of 18mm. And since I purchased the plugs at 12 mm, can't install them without adapters. Ordered a new set of plugs (cheap) and adapters (expensive). Then moved on to putting oil back into the sump (type M, ashless Philips in anticipation of the first 5 hours of engine time), only to remember I'd decided when prepping the engine to skip putting in the quick-drain valve and the sniffle valve until after the engine was hung.

So then the search begins again...where are the parts, and what is the torque spec for each. Oh, and by the way, you need a 7/8th crowfoot wrench to work with torquing the fast drain valve, requiring a quick trip to Ace Hardware (no joy, what's a crowsfoot), and then on to Napa.(pricey, but they had one). Finally got the valves into the sump, safety wired, and filled the engine with 6 quarts of type M. Will put the other 2 quarts in when the engine can circulate through the oil cooler.
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Mar 08, 2023     Spinner Finish & Pickle in a pickle - (4 hours) Category: Propeller
Countersunk the mounting holes in the spinner and filler pieces; ran the AN507-8R7's into/out of the nut plates. Don't want to leave the spinner mounted and in the way for the upcoming cowling work, but wanted to be sure the nutplates were good. Safety wired the prop mounting bolts. Measured the gap from starter ring to rear of spinner backplate (3 and 3/8th inches).

Tried to pickle the engine but education time again. Great. Duel E-mags allow the use of automotive plugs but require an adapter....and I'd been alert enough to order the 12mm sized dehydrator plugs. But when removing the plugs, out came the adapters as well. Can they be reused? What's the torque sequence as to adapter, plug, assembly? Where to buy the adapters if needed......Emag or A.C. S. or lycoming? And so on. Research time. Answers; yes, finger tight the adapter to plug, then torque ONLY the plug to 18 ft-lbs., ACS the source but pricey...no need to do so if undamaged. Will install the dessicant plugs and fill with ashless oil tomorrow.

Oh yah...Anti-Splat mailed me a replacement for the prop wrench today.
 
Mar 07, 2023     Torqued - (5 hours)       Category: Propeller
Did the final trim on the prop spinner cutout fill-ins (for aft of the prop blades). Took forever with a 3M buffing piece on a mandrel. PIA.

Then back to propeller to torque it in place, which I'd put on yesterday. Got to use my new prop wrench from Anti-Splat Aviation. Really liked the design of one end which is "ratcheting". BUT when I went to use the other end for torqeing, it BROKE.. Simply fractured. Finished the sequence the old way, using a crows foot. Bummer.

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Mar 06, 2023     Props to n2184! - (4.9 hours)       Category: Propeller
Reinstalled spinner backplate to propeller again (last time?). Then reread the process steps for installing the propeller assembly on the crankshaft. Also checked the EAA site, the Hartzell site, and in general for web tips. Then installed the propeller to the engine, using the engine lift to position it. After the hub was securely bolted in place, I was finally able to twist the blades to confirm clearance to spinner backplate, and clearance to spinner itself. looking good!

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Mar 04, 2023     Spinner, Backplate, Filler Pieces - (3 hours)       Category: Propeller
Pneumatic squeezer to put in nut plates on the spinner bulkhead. Then re-clecoed the spnner and bulkhead back together, and fit the cutout pieces (aft side of prop) to drill and fit on bulkhead as well. This is slightly out of sequence, as I'm not able to twist the prop blades to determine final fit/trim of cutouts until i can mount the prop on the engine. (Too difficult to twist otherwise, without a 2nd pair of hands.) So now I can mount the prop hopefully the one time, pull off the spinner by itself to trim and avoid multiple sessions of putting the prop off/on. Oh yah....unfortunately I've discovered the spinner is painted by Glasair, and acetone (which I've used to wipe off sharpie marks) eats the paint right off. :(

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Mar 03, 2023     spinner backplate - (2.6 hours)       Category: Propeller
Good thing I am doing this for enjoyment....I totally underestimate how long something is going to take. Time to put nut plates on the spinner's backplate. Pass drill upsizing to #19 holes, deburring, drilling #40 holes for the nutplates, deburring...then countersinking the nutplate holes for the riveting. But spent way too much time trying to educate myself on the difference between nut plate tools...AT518H is a one-lug-single wing standard, and the AT518B is a one-lug-double wing standard.....i have both, both work for a #8 screw, but so why use one vs the other for what situations? Spoke to ATI Tools in California, then to yardworks, etc. Lots of verbal "armwaving". Sort of have an idea of which as to when...but painful. oh well. The amount of handwork in some of the pieces (eg the spinner backplate) is astronomical. I think I'll claim the 'full merit badge" for this project. Scratch build might be the only way to spend more time, treasury and patience.

Also confirmed with Aerotronics the panel build is coming along. They sent a photo!

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Mar 01, 2023     Redrilling Spinner and finishing the circumference - (4.1 hours)       Category: Propeller
Measured and remeasured for hours trying to confirm the concentricity of the spinner relative to the backplate. Finally decided to redrill the initial anchor holes and go for less variation in the "spin". Then drilled the rest of the holes around the circle and clecoed.

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Feb 28, 2023     Drilled Spinner to Backplate - (2.1 hours)       Category: Propeller
Trimmed the spinner prop-cutouts a bit more. Not final trim yet, but allowed the spinner to fully seat in place to drill the anchor holes in the flange to the spinner itself. Then drilled additional holes from spinner through flange. Taped the prop root to protect against scratches while fitting the spinner.

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Feb 27, 2023     Spinner dome rough cut - (2.1 hours)       Category: Propeller
Marked spinner dome with template from Lycoming. Rough cut (for the forward arc of the spinner prop-cut outs. Will now do the fine trimming next time(s). The rough cut is to get the spinner to go into place enough to connect with the forward spinner bulkhead plate. Also will then need to trim out and shape the spinner filler pieces that go aft of the blade. Got to use my new diamond cutting blade on my dremel.

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Feb 25, 2023     Not much of a DJ - (1.1 hours) Category: Propeller
Brought an old turntable to the hangar to see how "plumb" the nose cone is from the factory. Unfortunately the turntable disc is not quite wide enough to "play/spin" the nosecone.
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Oh well, looks pretty good. Also searched tools for a thin, diamond cutoff wheel for my dremel (to minimize the gap of nose cone to filler pieces behind prop.) No joy, so a stop off at Menards (best/biggest/most complete selection of dremel stuff) on the way home.
 
Feb 24, 2023     Conehead - (2.5 hours)       Category: Propeller
Sorted out rivet sets, easy to get tools mixed up. Then finally got prop blades to twist by using a longer board for rotation....good clearance with the spinner back plate. Now that the spinner back plate was confirmed, on to the front spinner plate. Taped it with 3M spec per TWTT, bolted, torqued and safety wired. Finally then on to installing the spinner itself which will need prop cutouts next.

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Feb 23, 2023     Chubby Checker NOT - (1.7 hours)       Category: Propeller
Can't do the twist. Nyek, nyek. Got into hangar later in day after the snowstorm receded. STILL could not get the prop blades to twist....well I got them to budge by using an "iron cross" type of move, one arm on each end and using two twist boards. I gave up...it's a two man job. The twist is to verify the clearance from prop blades to the rear spinner bulkhead.

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Feb 21, 2023     Spinner Backplate Clamping Bolts - (4 hours)       Category: Propeller
Again working on the propeller spinner...backplate. I had 5 sets of conflicting instructions, and spent the first hour trying to sort them out. Did a run to Home Depot for a bucket to carve up as a propeller holding jig, and a second run to Ace when I realized I really did need a "soft" hammer to drive the prop clamping bolts back in place. Used my "secret" of homebuilding...aka beard balm. The stuff is magic and makes bolts slip in and out easily. Bolted the back spinner plate to the prop hub, retorqued. Could not get the blades to twist....will post on owners' site for an idea.

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Feb 20, 2023     Spinner Backplate Riveted - (4 hours)       Category: Propeller
Completed riveting the spinner backplate. These are larger rivets than I've been used to....5/32 and -6 long. Tried using my pneumatic squeezer...but really it was too much rivet, and went to my new manual squeezer. (real men ....you know the rest). Avoided waiting a couple more days for the order from A.C.S to come due to the kindness of friend Dan bringing the larger cup size die last Saturday.

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Feb 18, 2023     Prior Owner Visit - (1 hour) Category: Propeller
It takes a community....waiting for a die set for my squeezer and lo and behold the prior owner stops in with a loaner! Dan Kretchner is a prince...drove over from Lakeville with a 5/32nd squeezer die. After he completed a long inspection followed by a long chat, I drilled out the one bad rivet on the spinner backplate from last time and called it a day.
 
Feb 17, 2023     Supply chain search - (3.7 hours) Category: Propeller
How hard can it be to locate a manual rivet squeezer and/or a 5/32nd set in MN? (since of course local sourcing means progress over the coming weekend) Evidently harder than I can surmount....could just not find one to buy or borrow. So twin attack: ordered the die set from Aircraft Spruce (which won't show up till mid to late next week), AND, since I'm a tool geek at heart, ordered a manual squeezer and a 6-size die set to supplement my pneumatic squeezer. The real advantage is that it will be here Monday, as the company Pegasus Racing which also sells airplane bits is in Northern IL/South WI and shipping today will get it here fastest. Type A personality, I know.
 
Feb 16, 2023     One rivet and stop - (2 hours) Category: Propeller
RE-re-read the spinner installation sets. Confusing/they disagree on everything. eg drill selection, rivet selection, etc.
Finally drilled the spinner backplate, and decided to use AN470AD5-6 rivets....only to realize I don't have a 5/32nd squeezer die/set. Tried using a 1/4 set, and it left a smiley and did not give a rivet result that passed the gauge. Stopped. Drill out the rivet tomorrow and locate a 5/32 set.
 
Feb 15, 2023     Spinning the Propeller - (2.7 hours)       Category: Propeller
Studied/compared multiple sets of instructions for the prop/spinner....none of which agree.
Then unpacked the propeller from Hartzell...constant speed...and moved to a workbench.
Sanded the inside of the spinner dome to smooth out fiberglass wrinkles.

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Feb 13, 2023     Exhaust prelims - (2 hours) Category: Engine
Unboxed the exhaust manifold pieces and loosely assembled on the bench.
Numbered the pieces/junctions, and took back apart to box until ready.
Will not want to install until after completing a variety of the other engine prep steps...when the manifold pipes are in place it restricts the freedom of access for wiring, hoses, etc.
 
Feb 11, 2023     Exhaust parts arrived - (1.5 hours) Category: Engine
Glasair box arrived Friday afternoon. Spent time today unpacking and checking in all the parts. The various exhaust manifolds are not intuitive on which goes to which cylinder. Now back looking for directions/installation notes.
 
Feb 10, 2023     Spinner dry run - (2 hours) Category: Engine
To finish the baffling, the cowl must be done. To finish the cowl, the spinner must be done. To finish the spinner, the prop must be done. So did a dry-run on the spinner installation which is the first part of the cowl while waiting for exhaust option parts to arrive from Glasair.
 
Feb 09, 2023     Prep Panel & Cowl - (2 hours) Category: Engine
Aerotronics getting ready to start my panel.....responding to open questions and in particular antennas.
Then unpacked the cowling pieces all the way, and spent time rubbing off the residual 23 year tape pieces.
Also received my "ultimate prop wrench" from Anti Splat Company...should make putting on the prop next easy.
 
Feb 06, 2023     Cowling and Complexity - (3.4 hours)       Category: Engine
Finished baffles, and now moving to the Garlock seals. BUT...you first have to install the cowling to measure/trim/cut a uniform gap around the circumference(s). DOUBLE BUT....this assumes you've got the prop and backplate on as well to measure the gaps to the prop. So to do the seals I first need to install the prop and spinners, then the cowling, and only then (!) those seals. Well it's almost Easter, and appropriately I spent hours hunting for parts that were last seen 20 plus years ago in my kit inventories. The good news is that I found everything. Amazing. Did place the upper and lower cowlings to see how the fit is going to go...looks promising.

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Feb 03, 2023     Final baffle connection. Now only the seals to do....       Category: Engine
Finished trimming and nutplating the front baffles. Short one (!) pk screw...ordered several dozen for my inventory.
Next step is to put in the Garlock material seals on the baffles for an air-tight junction with the cowling. Will also then RTV seal all gaps in the plenum created by the baffles. Also, a final trim around the "circumference" of the babbles to ensure a uniform gap will be likely.

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Feb 02, 2023     Nutplates on baffle - (1.4 hours) Category: Engine
The Glasair baffle design basically uses pk sheet metal screws into nutclips wherever possible. I chose to use nutplates rather than nutclips on the fiberglass seam to the center induction baffle. While the nutplates are more work to install (dimple or countersink to take the flush AD426 rivets, then use the squeezer to set the rivets)...they don't fall out and are more reliable connection.
 
Feb 01, 2023     Seaming front baffle - (1.8 hours) Category: Engine
Trimmed left front baffle edge to seam it to the center induction baffle.
 
Jan 31, 2023     Baffles - (4 hours) Category: Engine
Right baffle fitting work.
Paperwork review ahead...cowling, propeller steps, etc.
Nothing special
 
Jan 30, 2023     Tech Counselor Visit - (4.7 hours)       Category: Engine
EAA has a tech counselor visit program that is really excellent, and I'd called Mike Hilger to come over again. Spent an hour prepping...ie what I'd accomplished since last time, and my "questions list". Then two hours working on the left baffle again...this time trimming it to match the adjoining center baffle. Used a die grinder as I don't have a band saw...next time I build I'll buy one. Then a couple of hours with Mike, really high value. One catch: he noticed I need to "reclock" my prop governor...it's too "over center" and will jam and/or not give me the full prop range. Also recommended fire-sleeving the oil lines to/from my oil cooler. Also agreed I should repair the (prior builder(s) issue) cutout on the horizontal stabilizer which is wrinkled/bent. Also put dessicant plugs into the engine, but my rust exposure if minimal at the moment...I keep the hangar at a constant temp and of course MN is very, very, quite dry this time of year.

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Jan 28, 2023     Grandpa Day and Study - (1.9 hours) Category: Engine
Enjoyed the morning at the ice rink with grandson #1. Then several hours studying the 90 pages of baffle install steps, AND, (optimistically) the cowling install pages (clearly you have to have the cowling on to install the Garlock seals to the baffles).
 
Jan 27, 2023     Finals for Baffles - (3.5 hours) Category: Engine
Spent 1/2 hour refreshing the steps remaining. Then a break to watch one of the EAA homebuilders sessions...excellent.
Back at it:
1. Left, Aft, Rear INBOARD baffle came back from anodyzing. Riveted to the Left, Aft OUTboard baffle, and installed the assembly.
2. Cleco clamped the Right, fowaward fiberglass baffle to the #1 Cylinder bracket and drilled the five holes. It becomes clear you need to install nutplates, not nuclips, in the cylinder bracket (holes too far from edge to use nutclips). Searched to find my countersink and set up for #40 drill bit, drilled for the nutplates and installed AD426-3-3.5's with my squeezer. Workmanship is not pretty, but adequate/safe/serviceable.
3. Installed the left forward baffle. Next step to drill and attach to center induction baffle.
 
Jan 25, 2023     Dithering - (4 hours) Category: Engine
Going very slow on the baffles for whatever reason. Decided to go back to page one of the baffle option install document, and reread/analyze yet again. I can see the sequence for an IO-390/Sportsman is different for the IO-360 Glastar on the forward baffles. Center/Left/Right vs. Left/Center/Right. Analyzed the plenum chamber again. Decided to redrill the Left forward heat shield standoff. Getting closer, but now clear I need to grind off some of the standoff cross tab to allow the bottom bracket to fit properly. Tomorrow.
 
Jan 21, 2023     Over the hump - (2.7 hours)       Category: Engine
Finally got to the semi-finals on baffling. Using the photo from the owner's site as a guide (showed SIGNIFICANT modification) I was able to trim out the Left Front Baffle interference (really it's more accurate to say the Center Induction Baffle interference. Did trim the Left baffle to "almost" fit the center flanges, and rebent the bottom to match. Still a question regarding final trim for the center baffle, but the end for baffle fabrication is in site. It's a very mixed heritage...the Right baffle is a fiberglass piece, the center is really from the Sportsman, and the Left baffle is original Glastar. THEN next step is to add the Garlock seals to the baffles, which is a process I've done several times on other planes. Although it's likely I'll need to do the cowling fit and install before doing so. Whew.

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Jan 20, 2023     One step forward, two steps backward - (5 hours) Category: Engine
A frustrating day. These darn baffles just do NOT want to play nice together. Redid the heat shield that rivets to the left baffle...drilled new holes into the standoff and reriveted them back together (so much for the twtt info....did not work for a Glastar). Trimmed the center baffle further. But the *#*$*#*@ left front baffle continues to be defiant. Interferes with the center baffle. Interferes with the heat shield standoff. Uses (per instructions) sheet metal screws and nutplates that are almost worthless...stripping out quickly. And so on. Whine, whine. On the positive side, a guru-Glasair builder posted a photo on the Glasair owners's site of how he modifies the center baffle that is priceless. Tomorrow!
 
Jan 19, 2023     Interference and First Principles - (3 hours) Category: Engine
A real mental workout. Once again, the agglomeration of 20 plus years for parts is a factor. Front baffles just do not fit together without a struggle. Confirmed the best fitment for the Right fiberglass baffle relative to the center induction baffle (fiberglass on top for the bottom flange, the metal on top for the top flange.) But the Left metal forward baffle and heat shield standoff do not work together. Well, first principles rule, and the plenum concept trumps the parts conflict. Think I see the solution, will sleep on it, and have at it again tomorrow. 2023 kit purchasing builders just don't get a "full merit badge" compared to the kit pioneers from 25 years ago. But to be honest, this is a real PIA.
 
Jan 18, 2023     Paperwork and a bit of progress - (4.1 hours)       Category: Engine
Supporting paperwork/documentation for a 23 year old kit is feast or famine. Either there is NONE, or there is LOTS and LOTS, often with conflicting information. I end up comparing the original 5 inches of Glastar manuals, to countless pages from the Two Weeks to Taxi program (which I did in 2016), and to multiple postings from 20 plus years on the owner web site. Slows things down, but it is what it is.

Making progress on the baffles...now "doing" rather than "puzzling" or "studying". Got the Right Forward Baffle and the heat shield put together, trimmed, and riveted in place.

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Jan 17, 2023     A little off the top please - (3.7 hours)       Category: Engine
Left Aft Inboard baffle (from Van's) trimmed and cut...evidently Van's puts the Lycoming lower in the fuselage. Drilled the aft center attachment bracket that supports both the left and right baffle pieces. Match drilled the Left aft inboard with the Left aft outboard pieces. Dropped off the Van's piece at my neighborhood alodyne factory for the gold finish.

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Jan 16, 2023     Good day, again no longer baffled       Category: Engine
Moving ahead. Installed the Right Aft baffle and the Right side baffles. Installed the Left Aft baffle...still a work in progress (sourced this part from Van's as no longer available from Glasair). Lot of trimming...still needs to be cut off shorter to match the Right side, but this will work. Also needs to be alodyned to match the gold finish.

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Jan 14, 2023     No longer baffled, and No lunch - (4.5 hours) Category: Engine
Finally see with clarity what needs to be done. Restarted the baffle assembly with the front center induction piece, and realized there was still interference with the starter bolts (aft side). Drilled in a snowman shape the relief holes. Fits perfectly. Then on to the Left front baffle; hacked off part of the left quadrant to work with a more detailed fitting of the piece. Also flattened the bend, will need to redo a bend up to match the center.

Still don't have a resolution for the mystery piece of baffle sent by Glasair....I think it might be to fill in a gap between the bend in the original left baffle to the "new" center baffle bend.

Oh well, on a roll and didn't even stop for lunch.
 
Jan 13, 2023     (No longer) Baffled - (3.5 hours)       Category: Engine
Now moving forward with the baffling. Riveted the induction port doubler to the front, center induction baffle. Of course I didn't have any 470AD4-4 rivets...the option parts came with the incorrect 3-3.5 universal rivets. Thank goodness for Wipaire being local...drove down to South St. Paul airport mid-afternoon to buy a "pound of rivets". :) Yes that's correct, just like produce or meat, they only sell them by the pound. How much? $35 a pound and you can't bbq them.

And yes, one of those pieces has a different (no) finish. Glasair was out of stock, not planning to make again, etc. So I sourced a similar aft baffle piece from Van's Aircraft. Hey, it's all experimental on the inside. :)

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Jan 12, 2023     (less) Baffled - (1 hour) Category: Engine
Having digested all I can find, including lots of owner-site research, the approach is now clear. Will start working metal tomorrow.
 
Jan 11, 2023     Grinding toward action - (4 hours) Category: Engine
Just about done with the pause to study Glasair baffling. Clearly there was a product and design evolution.....primary factor was the move to fuel injection from carburated. This necessitated splitting the two front baffles, making the right front piece narrower, putting in a new middle front baffle to work with the induction servo facing forward, and ?????? for the left front baffle. I can see how to make that left front work, hacking and (re) bending...but the mystery is what did Glasair intend. And of course their design staff from the early 2000's is long gone. And to be fair, when the IO Lycomings came out, Stoddard Hamilton/Glasair was long out of the "Glastar Kit Model" business, discontinuing it to focus on Sportsman (and most with an IO-390) = no reason to go back to the Glastar manuals and update them.
 
Jan 10, 2023     Still Baffled - (2 hours) Category: Engine
See yesterday's entry...same for today. Grrrrr.....
 
Jan 06, 2023     Stopped - (2 hours) Category: Engine
Spent all day further analyzing the baffles; the 2 hours is merely representative, it was all day.
I can see how to make it all work. BUT I am stubborn and would like to understand Glasair's design intention/how it was all supposed to fit together.
 
Jan 04, 2023     Stymied - (2 hours) Category: Engine
Spent another couple of hours trying to understand the Glasair baffles. Front left still puzzles me...went through all the build manuals and also the TWTT manuals. No joy.
 
Jan 03, 2023     Baffled! - (4.05 hours)       Category: Engine
Spent way too much time trimming the left front baffle....only to realize Glasair must have sent me the wrong part. The forward left baffle I received (225-0180-001) does agree with the bill of material, BUT does not agree with TWTT steps which calls out 224-0110-02. Time to check in with the factory.

The verbage is quite confusing. Glasair was trying to cover 0-320, O-360, IO-360 and IO-390. Clearly some mixing going on.

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Dec 31, 2022     Baffle tailoring progress - (2.1 hours)       Category: Engine
Worked on forward center baffle piece to profile where it meets the engine block (above the induction air port). Slow but weirdly satisfying work to trim slowly, fit on the front, remove, and repeat multiple, multiple times. Primarily using the 1 inch wide sanding machine with judicious hand files. Finished the center piece, and clamped the fiberglass right forward baffle to be sure it overlaps properly. Forward left baffle day after tomorrow (which is new years day).

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Dec 30, 2022     Bespoke Baffles - (3 hours) Category: Engine
Front baffles are to fit tight to not only the cylinders, but also the engine block profile, and the starter/alternator....and then eventually with the flexible seals to the upper and lower cowling. The baffle option from Glasair is at best an assemblage of parts that approximate what's needed. Slow, detailed talioring is needed to make it all fit. Patience, grasshopper, patience.
 
Dec 29, 2022     Air...induction and baffles - (2.1 hours)       Category: Engine
Fuel servo spacer and gaskets arrived from Lycoming so completed the final installation of the fuel servo, torqued and marked.
Continuing work on baffles...trimming is needed and a bit tricky.

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Dec 28, 2022     Hangar Gas Supply and Working on Baffles - (2 hours)       Category: Engine
Mystery meter showed up on outside gas meter, AND, main radiant heat no longer works. Tracked down the meter to the Xcel engineering department. Also had MAC maintenance come by to work on heater. Part is needed, so it will be next Tuesday. TDhankfully not sub zero the next week.
Restarted yet again work on the baffling. Cut out the fiberglass front right baffle.

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Dec 26, 2022     Baffles continue - (3.5 hours)       Category: Engine
Returned to beginning step for baffles...had realized there was still some trimming needed (specifically since this is a fuel-injected engine, there needs to be another hole and grommet put in to run the fuel line back to the top fuel divider.) Drilled to 1 and 1/8th, expanded to 1 and 1/4, and deburred.

Removed the side aft baffles for ease in assembly to rear outer baffles, and put in the PK screws.

Inspected the one fiberglass plenum baffle piece. Located a scribe line in the fiberglass to trim before further assembly.

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Dec 21, 2022     More baffles - (1.1 hours)       Category: Engine
Still working on baffles. At first I was not so certain Glasair's option kit which I'd ordered were the correct ones for this engine configuration. Current conclusion is they are correct (although Van's uses a similar but DIFFERENT delineation as to baffles and engine designations for parallel valve or angle valve). What was, however, an AHA moment.....my forward and aft baffles need additional trimming. Initially it appeared to me they were ok as received. Not so.

Also, discovered a hidden (?) serial number stamp when I removed the aft engine hoist bracket to install a baffle support....it was under the hoist eye.

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Dec 20, 2022     Baffle search - (0.9 hour) Category: Engine
Still looking for the missing aft, left, inner baffle piece. No joy. Did order a similar piece from Van's....hopefully I can trim/make it fit/work.
 
Dec 19, 2022     Baffles, getting dressed - (3 hours)       Category: Engine
Starting to "dress" the engine. Attached the oil cooler flanges and then the baffles themselves. Still missing the aft, left inboard piece.
Assembling around the missing segment. New nomenclature....PK screws that connect the baffle corners. Not sure what "PK" refers to...maybe "Pain in the Kiester" as these little screws are an SOB to get installed. Finally took both pieces off the engine to get them screwed together, and reinstalled as one assembly.

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Dec 17, 2022     Early (baffle) Christmas (parts) - (1.5 hours) Category: Engine
UPS delivered two boxes from Glasair early. Spent time inventorying the baffle parts and prepping the engine baffles. Now have all the parts except the one aft, left, inboard sheet metal baffle. Still searching.
 
Dec 16, 2022     Fuel Servo Configuration - (1.1 hours)       Category: Engine
Fuel servo from Lycoming is actually from Avstar. Fuel in and out fittings are flexible, and unfortunately the Glasair BOM configuration was not followed or lost. So needed to switch the fuel outlfow from the servo bottom to servo top. Felt criminal to cut the safeties and crack open the brand new servo, but so be it. Did spend time educating myself on fuel servo diaphragm and air diaphragm balance; Avstar's documentation and manuals were pretty darn good. Hardest part was not swapping the fittings but rather the safety wiring after the torqueing. Got it done.

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Dec 12, 2022     Baffling "Legos" - (3.7 hours)       Category: Engine
Started actual assembly of the baffling sheet metal. Almost immediately had to sort through various boxes for parts....and in particular, a missing flange. Turns out I had received one mis-labeled part in July, and that was finally revealed missing today. Glasair response was great, in priority mail same day. Some progress, but not as much as I'd think 3 plus hours would give me. Oh well.

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Dec 09, 2022     No-Hoist Look - (5 hours)       Category: Engine
Pulled nosewheel to replace. Could NOT get tire off the wheel. Finally conceded and took it across the field to Signature (Sean) used his tire bead breaker AND magic juice (aka dishwashing soap and water) to get the tire off half the wheel (split wheel). Took it back to my hangar BUT deja vu all over again....could NOT get the tire off the other half the wheel. Back to Signature. Oh well. THEN could NOT get the wheel halves into the new tire. Fought at length, finally gave up and put the new inner tube in the old tire. Did repack the nose bearings. And reinstalled allowing me to remove the engine hoist (which I'd used expeditiously as a "jack" to lift the nose wheel to change it.

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Dec 08, 2022     AVstar Installation "Sort-of" - (3.5 hours)       Category: Engine
Lycoming shipped a brand new Avstar injector system with the engine. Unpacked it and installed it in accordance with the TWTT photos. Wait a minute....did I install it upside-down? Swapped it around BUT now the outlet fitting is on the bottom and not the top. Called Andrew at Glasair...also about a missing spacer shown on the TWTT photos. Sounds like the new (couple of years ago??) Lycoming rep replaced the BOM's for Glasair...reason(s) unknown. "Did they leave out BOM details such as fuel outlet fitting location, and the spacer between the sump and the injector system?

PAUSE while Glasair contacts their Lycoming rep! I'm shaking my head, but very appreciative Glasair is still in business and supporting a kit from 20 plus years ago.

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Dec 07, 2022     Governor and Alternator - (4.1 hours)       Category: Engine
Picked up a crows foot set; finished torqueing the governor bolts. Also the control bracket. Then installed the alternator and the alternator belt. Fairly straightforward except getting to the various bolts for torqueing.

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Dec 06, 2022     OIl Cooler LInes and Prop Governor - (5 hours)       Category: Engine
Installed the hose lines to/from the oil cooler. Then removed the prop governor plate and installed the Jihoszi governor. Unfortunately don't have the crow's foot size I need to torque the governor...do tomorrow after buying another crows foot. Spent a moderate amount of time digging through boxes to find the bracket parts for the next step...found them finally. whew. Governor is from the Czech Republic, same as I used on my Sportsman.

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Dec 05, 2022     Sequencing - (1.5 hours) Category: Engine
Reviewing the sequences possible per TWTT. Lots of choices, eg oil lines vs governor install vs baffling,etc.
Nothing visible in terms of progress but the puzzle is starting to come into view.
 
Dec 03, 2022     No good deed goes unpunished - (2 hours) Category: Engine
Finished the installation of the engine mounts...last (4th) cotter pin took an hour to get in place.
Then, with the engine hung, the hoist chains removed and all the weight on the front, the front nose wheel leaked flat.
Time to order a new inner tube and replace.
 
Dec 02, 2022     Cotter pins and engine mount - (3.1 hours) Category: Engine
Sorting out various parts and tools now that the engine is hung. Then did cotter-pin-yoga for the engine mount bolts. Line up the cotter pin, insert, twist the bolt 180 degrees and bend the legs. No room in the engine block areas to do it easily.
 
Dec 01, 2022     Finished Hanging Engine - (4 hours)       Category: Engine
Spent significant time on trying to line up engine mount bolt #4, left lower. Finally went out looking for a 'drift pin" aka a tapered pin to be able to align mount #4. No joy at retail outlets. Stopped off at Momentum (neighbor at the field) and they were gracious enough to lend me a large pin....perfect. Finished the 4th bolt, torqued all 4 at 39 foot-lbs. Will post photo tomorrow.

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Nov 30, 2022     Hang! - (4.5 hours)       Category: Engine
Big day. Hung the engine! Slightly different recommendations comparing TWTT step 3100 engine installation, the Van's predominant site ref SK-90A, and various postings on the Vans Airforce site. Both top mounts then both bottoms/or Visa-Versa. Large washer at engine only on bottoms/ or on both top and bottom. But nothing really huge. Did both tops first, one bottom then easy, other bottom difficult. Will work on the last mount (#4 of 4) tomorrow when fresh. But getting there!

Factors dealt with: Flattish front tire. Two chains on engine too flat/not helpful for adjusting engine/hoist up and down. Old mounts (are they too brittle?). Needed to grind off part of my 5/8th box end wrench to fit the nut on the mounting bolts. And so on.

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Nov 28, 2022     Continuing pre-hang engine work Category: Engine
Completed (ref TWTT 165) initial engine prep work prior to hanging. Continued on to (TWTT 2300) next level of engine prep, and replaced the upper left engine fitting for return line from oil cooler with a straight fitting. Other engine work prior to hanging the engine is optional, ie can be done after engine mounted on plane.
 
Nov 26, 2022     New Tool Bits and Grandaughter - (2.5 hours)       Category: Engine
Stopped at Ace and Harbour Freight for socket, male hex drive for torque wrench, and (finally) another torque wrench (5 to 80 flt-lbs) to fill in the missing gap of my other (two, this makes three) torque wrenches. Made fast work of finishing the fuel pump, shroud, fittings.

REAL priority today later in afternoon...1st "flight" for my grandaughter. Well, it was an extended taxi...2 seats mean no parent along so it was very exciting for a 4 year old to simply taxi "solo with grandpa" and take it all in! Grandpa was thrilled she was so confident & happy (after being spooked on a prior attempt). Very lucky on a sunny, warmish, dry day....eight inches of snow a few days later!

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Nov 25, 2022     Fuel Pump Cooling Shroud       Category: Engine
Priority is on the rear engine fittings/accessories to be done before hanging the engine. (eg once the engine is installed the mechanical fuel pump on the rear is mostly tough to get at). Busy today...progress but also frustration. Redid safety wire on left oil sump drain plug. Witness marked the various plugs and fittings I've been installing/relocating over the last couple days. Installed dipstick and rear sump extension tab for wiring. Removed and reinstalled the mechanical fuel pump WITH the cooling shroud over. GROAN...frustration....the inlet and outlet fittings require a very long/deep socket I'll have to go buy. The fuel pump bolts are allen heads...I don't have an allen head bit for my torque wrench. The torque settings are too high or too low for either of my two torque wrenches. and so on.

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Nov 23, 2022     Engine fittings - (5.2 hours) Category: Engine
Revisited all the items removed yesterday. Spent way too much time searching for parts...a quick drain plug, and a sniffer valve which I had seen in my inventory but had a hard time finding again. Found them but decided to wait till after engine hung before installing (to protect them as they protrude from bottom of engine).
Installed restricted orifices for oil pressure, swapped fitting from fuel flow divider to cylinder 3. Then final install of left oil drain plug, and safety wired. (Groan, driving home I realized I'd installed safety wire incorrectly...redo next time in hangar!)
 
Nov 22, 2022     Opening to drain residual preservative oil - (2.7 hours) Category: Engine
Removed:
induction manifold cover plate, lower spark plugs (automotive plugs with adaptor since I've got dual Emags), plastic exhaust port covers, both oil sump drain plugs, sniffer valve stem. And a fine (oil) mess it was! :)
Reinstalled all but only finger tight for now.
 
Nov 21, 2022     Finally starting the engine work - (2.5 hours)       Category: Engine
PLowed through all correspondence with Aerotronics on panel and accessories.
Then finally got going on the engine, removing the front plug for the prop/crankshaft oil plug

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Nov 18, 2022     Pitot link in the wing - (2.2 hours)       Category: Instrument Panel
Decided to redo/re-fabricate the tubing link from the pitot tube in the wing to the red tubing going over to fuselage.
MUCH easier/quicker to redo than the initial part fabrication. The tricky part is easy if you know about it....there is a 3/4 inch length minimum needed to use the flaring tool. And of course a minimum for the tube bender. And of course another minimum for the cutter. Easy-Peasy now! (the old one was ok, just oversized).

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Nov 17, 2022     Swagelok Gauge - (1.7 hours) Category: Fuel System
Still not very motivated. Went by the Swagelok distributor in Chaska and picked up a "go-no go" gauge.
Gauged all the fittings with Swagelok fittings.....sure enough, several required more tightening per the new gauge.
 
Nov 09, 2022     Wiring review - (0.1 hour) Category: Wings
Ditto yesterday. Looked over the wiring in the wings relative to ordering from Aerotronics.
 
Nov 07, 2022     Sorting parts - (0.1 hour) Category: Engine
Just not motivated. A bit of paper and parts sorting.
 
Nov 05, 2022     Parts! - (2 hours) Category: Engine
Box of parts from Glasair arrived; checked the picking sheets and inventoried. Spinner and backplates, Firewall Forward Wiring, Fuel Pump cooling shroud (this is a duplicate from an earlier order...return?)
 
Nov 04, 2022     Prep for Prep - (2 hours) Category: Engine
Working through virtual assembly of Engine Prep TWTT Step 165. Parts due in this afternoon from Glasair.
Spark plugs are NGK....7/8 inch socket too big, 13/16 closer. Bring in some metrics (need 14mm) from home tomorrow.
Not a lot accomplished. Friend Owen came by and we spent an hour on his 8050 registration documents.
 
Nov 02, 2022     Out of the Box and Onto the Table - (4.5 hours)       Category: Engine
Worked with TWTT Process Step Instructions #165. Used engine hoist to pull the engine off the pallet and over to a metal desk/table to work on. Kind of surprised flywheel wasn't bolted on/came off...thankfully when sitting on the table top. There were 2 bolts into the flywheel during shipment...hadn't realized they were the only bolts attaching the flywheel to the crank.

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Oct 31, 2022     Final fuselage fuel line fitting & Engine "unwrap" - (2 hours)       Category: Fuel System
Reseller came through with the missing Swagelok union tee and it arrived in today's mail. Drove home to get it, and upon return to hangar finally got the last of the lines completed. Yea! Then moved on to the new engine, and removed the top box...fun to unwrap this present of a new engine. Also included was the dipstick tube, various hardware bits, and the fuel system (Avstar fuel injection servo).

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Oct 29, 2022     Swagelok re-read and Inside Fuselage fuel lines - (2.7 hours)       Category: Fuel System
Finding that I needed to locate old Swagelok fittings, went back to the original Glastar manual and re-read their old tools & tips pages regarding Swagelok fittings. (Used by Glasair 20 plus years ago before they defaulted back to AN fittings.) Really like the Swagelok...you simply cut the tubing to length, and plug into the fitting....no flaring required. Received replacement Swagelok B-6P4T valves (from a seller on eBay) in the mail, so this gives me the missing tube-end fittings to go with my original valve. Installed the line from boost pump to shut off valve, and fabricated a new line from shut off valve aft to rear Swagelok Union Tee. Finally concluded that union tee was well and truly stripped and not re-usable. Removed said union tee, and located replacement on eBay and ordered. Should be here next Tuesday as it's only coming from Michigan. Is this "kit-building" or "archeological parts searching". Oh well.

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Oct 28, 2022     Fuel LInes Redux - (5.2 hours)       Category: Fuel System
Installed and torqued and witness marked the fuel line from firewall to gascolator. Drama trying to get the -008 sized firesleeve over it per manual; finally went to a larger size -012 (which seems to be what is pictured in the TWTT photos, rather than the smaller size stated in the instructions). Then back inside the fuselage aft of the firewall, installing the shut -off valve and the line to the boost pump. Discovered the fitting for the line from the union tee joining the two drop tanks and that feeds forward to the shut-off valve was stripped (one of the prior builders)....and will start the hunt tonight for the (no-longer used by Glasair) Swagelok union tee fittings. Good progress today.

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Oct 26, 2022     Firewall to Gascolator - (3.8 hours)       Category: Fuel System
The third time was the charm for the engine compartment fuel line from firewall to gascolator. But it was rocky going....first time I discovered the boost pump outflow fitting was not far enough through the firewall to allow the AN fitting on the line from firewall to fully seat. Fixed that. Then forgot to put the AN sleeve on the fuel line BEFORE I flared the end = can't put the AN nut on. Rookie mistake. But then, unbelievably I made the same mistake again.....this time it's an "old guy" mistake. Third time I got the sequence right, and the line to the gascolator now looks good.

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Oct 25, 2022     Firewall to Gascolator - (5 hours) Category: Fuel System
I really don't like working with aluminum fuel lines. Oh well. Got out the flaring tool, the cutting tool, the bender tool. Worked on the line forward of the firewall to the gascolator. Not easy, as gascolator to exit air dam is a tight (fingers) fit. Got close to the final, finish tomorrow. Took a lot of time re-learning the tubing nuances, and particularly the Swagelok vs AN flared specifics. Did try out something new..."bending springs" which you can even buy down at Lowes....basically thread the line inside and bend away without fear of a crimped/collapsed tube. Fairly clever, although a bit of an effort to do short bends with it.

Waiting for a new Swagelok valve to redo inside the fuselage line from T junction to on-off valve.
 
Oct 24, 2022     Fuselage Plumbing - (4 hours) Category: Fuel System
Installed the fuel boost pump after trimming, deburring, alodining the mounting plate. Used 3 layers of red rubber gasket material under the plate to align the fuel line with the firewall hole. Pulled out the fuselage fuel line to the shut off valve which needs to be resized to connect with a link to the boost pump. Basically ran out of old swagelok parts to/of the shut-off valve. Found a new swagelok valve later on ebay ($12) and ordered. Also found another one on amazon ($30) and ordered that one as well to have parts redundancy.
 
Oct 22, 2022     Boost Pump Plate and Position - (3 hours)       Category: Fuel System
The boost pump for the fuel-injected Lycoming sits aft of the firewall. The mounting plate is basically supplied for a Sportsman, and needs to be cut down/modified for the Glastar. Lots of trimming, deburring, sanding, etc. And the Glastar position needs it in line with the fuselage cage, not at a diagonal like the Sportsman. Made it work. Photo shows the pump loosely positioned on the plate...off and on again multiple times. But I will eventually have to customize the tunnel close-outs since the pump/filter position bumps out from the center frame. It is what it is for the Glastar, and not like the Sportsman (diagonal to avoid this).

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Oct 21, 2022     Firesleeve and new tool - (1 hour)       Category: Firewall
The stainless steel firewall pass-though's also get wrapped in a firesleeve. Ordered a new tool the "Clamptite" to use for the safety wiring. Did NOT like how it wrapped...did two with it, and chose to do the final one with traditional .032 safety wire. The clamptite is difficult to use when the fitting is flush, and also when the material is "soft" rather than hard.

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Oct 20, 2022     RV12-isT as a Freighter - (1 hour) Category: Engine
Flew my RV12 down to Faribault airport where Stein is located. Convenient/handy...easier to have the pro's fabricate an engine ground cable for my Glastar. Plus a fun excuse to go flying on a blue-bird sky day. Upon return, installed the cable in place of the spacer washer in the lower left engine mount. Torqued and safety wired. Few excuses remain to put off working on the engine and getting it hung. BUT...decided that I will finish the fuel line system completely first.
 
Oct 19, 2022     Barry Mount Rubrik's Cube - (3.75 hours) Category: Engine
The shock mounts/Barry isolation mounts are a complex puzzle. Lots of conflicting directions from various 20 year sources. Finally sorted it out/made sense of the installation stack-sequence....best resources were instructions and drawing SK90A from Van's Airforce site and Van's Aircraft. Hangar neighbor Paul came by to help me reach two bottom screws in the firewall that were almost impossible to tighten or remove solo. Finally got it done, vice-grips are my friend.
 
Oct 18, 2022     Torquing the Mount - (2.5 hours) Category: Firewall
Inspected the firewall and engine mount screws/bolts. Torque wrenched and cotter pinned the 5 engine bolts. Of course my small torque wrench goes to 150 inch-lbs, and my large torque wrench starts at 240 inch-lbs. What's the spec for the mount bolt? 175 inch-pounds of course. Sheesh. Spent a lot of time sorting out the process....move on to prepping the engine and hanging it next, or instead, completing earlier items 90% done, eg the fuel lines and boost pump to through the firewall. Not clear which road to take at the moment. Will likely pull the engine out of the box and start engine work.
 
Oct 17, 2022     Engine Mount Installed & Tech Counselor Visit - (4.5 hours)       Category: Firewall
Reamed mount and firewall engine holes, fought with the top bolt (interference with the top mount bolt tab.) Then successfully sumo-ed the engine mount in place, assisted by judicious use of a clamp with the final/top bolt. N2184 is asking me "...does this new item make me look fat?" I've reassured her that it's necessary when one is expecting a new engine. :)

Visited by EAA Tech Counselor Mike Hilger who really knows his stuff, engines in particular. Good visit, several valuable suggestions, and a great EAA resource.

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Oct 15, 2022     Fully loaded but no fries - (6.7 hours)       Category: Firewall
Reinstalled firewall with the air exit ramp, the frame and all goodies (oil cooler, fuel manifold, gascolator, and so on). First touched up the fireresistant RTV on the nose leg, Then finished trimming the exit air ramp after confirming it fits with the oil cooler frame in place. Assorted pass-through drilling. Starting to run out of individual fasteners. Was hoping to get to hanging the engine mount, but the frame bolts and drilling were time intensive. So no "extras" with the loaded burger.

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Oct 14, 2022     Real front end progress - (3.5 hours)       Category: Firewall
Building momentum on the front end. Trimmed/fit the separate exit air ramp for a nose gear leg forward of the firewall. Installed it knowing I'd need to remove and redo after caulking the nose gear leg...don't want to caulk first as that stuff gets on everything. But eager to install the air ramp and then the oil cooler and gascolator frame to see if there is interference. (I note some Glastar owners cutting out segments of the air ramp to make it all fit). But lo and behold, it all fits like clockwork. Hurray. Then removed the frame, removed the air ramp caulked the nose wheel and called it a day. Better to let the caulk cure overnight and then move to regain the forward progress. AND exciting next steps...to install the engine mount and then hang the engine.

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Oct 13, 2022     Back on his "feet" again - (4.5 hours)       Category: Firewall
Reinstalled the nose gear, which is a real load off my mind. (Concerned the sawhorse might collapse or the fuselage shift and land on it's front edge.)

Closely inspected the caulking from yesterday; this prevents carbon monoxide from entering the cabin, so it's serious business. A bit of touch up to be sure.
Also did a bit of measuring/thinking of how to cut through the air exit ramp for the nose gear leg; chose an approach that allows me to do so AFTER the nose gear is back on, rather than before it's on. Buried in the manual is the need to fabricate a doubler to install the brake reservoir on the aft firewall....no sweat. But the mounting hardware was mucho difficult....which seemed to cause me to drill a #10 hole in my left hand finger. Wonder what the builder protocol is for blood on the kit...remove it, label it, or simply ignore it.

Other than a bit of fireseal around the nose gear let hole, the firewall stage of the build is complete.

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Oct 12, 2022     Lipstick on the pig - (5.5 hours)       Category: Firewall
Inspected all firewall/joggle perimeter rivets, redid 2. Added washers per manual to make firewall sit "flat" against the cage. Drilled the bottom flange to fuselage holes for the exit air ramp....tricky. Die grinder to cut out the bottom fuselage slot for the exit air ramp. Caulked (lipsticked) the pass through fittings and lower exit air cut out...a nice shade of red for this pig as I fondly (?) think of it. Almost ready to reinstall the nose gear leg after I cut the hole in the exit air ramp tomorrow.

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Oct 11, 2022     Final riveting of Firewall perimeter into fuselage joggles. - (5.3 hours)       Category: Firewall
Trimmed the insulation around the pass through fittings, secured the firewall for the first time with the 10 cage screws, also the 5 engine mount bolts (using hardware store stand-in 3/8th bolts.) Then used the squeezer (best tool in the quiver) to rivet the perimeter. Will only have to drill out 2 of the rivets for a redo (tomorrow). ALSO...did not drill the exit air ramp at the bottom flange through the fuselage. (where was this instruction in the manual?) Manana for sure.

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Oct 10, 2022     Pass through fittings and RTV - (2.7 hours)       Category: Firewall
Stopped at Wipaire to buy monel rivets, then installed the 3 pass through fittings for wiring, and 1 pass through for the cabin heat valve assembly. Fireproof RTV sealant around flanges, and the gaps in the cabin heat valve (design). Then reinstalled the firewall, clecoed all, and as well taped the firewall in preparation for sealing the rest of the fittings. (not intentional, but I can see my RV12 peeking over my shoulder looking at the kitplane. Hey, what's going on there?!)

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Oct 08, 2022     Putting on the blanket - (4.1 hours)       Category: Firewall
Getting closer to completion on the firewall. Ground off the cage and the mount for a ground path. Spliced the Orcotek blanket to cover the firewall. Glued it to the firewall, cut out the excess, and used orcotek tape around the circumference. Drum roll....will it still fit back into the nose of the fuselage? Yes!!! Whew.
Can now rivet the assembly for the last time into the fuselage joggles. And rivet in the pass-through fittings.

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Oct 07, 2022     Progress - (5 hours) Category: Firewall
Backordered parts showing up. Was able to assemble the cabin heat valve assembly (penetrates firewall so easiest to do now). Then moved back to the firewall itself; drilled the COWLING joggles to the firewall flanges. Removed the firewall (again!) and deburred the stainless steel one more time. Put in the fire barrier RTV to the firewall flanges. Countersunk the OUTSIDE of the fuselage joggles for final firewall installation. Ran a sloppy bead of the fire barrier RTV on the external firewall/flange junction. I am really tired of this firewall. Only need to install the insulation blanket, the pass-through fittings, and then rivet the darn assembly into the fuselage for the last time. No photos...how many times can I look at that firewall.
 
Oct 06, 2022     Final Riveting - (3.5 hours)       Category: Firewall
The stainless steel firewall is connected to the stainless steel flanges by...what else, stainless steel rivets. These are one tough son of a gun to set. Got after it today with the rivet gun, and did the final riveting of flanges to firewall. Reinstalled the unit into the fuselage...getting a bit more difficult but still doable. Next to add the blanket, fingers crossed it will all still fit in.

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Oct 05, 2022     Firewall Flange Nutplates - (3.2 hours)       Category: Firewall
Used the squeezer to install nutplates on the bottom flange. Reinstalled the firewall into fuselage, then the trimmed flanges and removed as one assembly to confirm I could still get it out. The deburred the aft side of the stainless steel firewall. Fun.

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Oct 04, 2022     Exit Air Ramp - (3.2 hours)       Category: Firewall
Having carefully cut the lower flange for the nose wheel leg, I now have to cut out the exit air slot for that same flange which included the nose wheel slot. Sheesh. My beautifully cut slot is now part of the scrap box. And then more drilling and nutplate tooling.

One more time I realize how far kits have come vs the 20 plus year kit I'm building. There is simply an unlimited amount of time required to fabricate and manufacture various fittings before you can even think about installing it for the final time. As a very good friend has said, I'm "getting the full merit badge" this time (as compared to TWTT where I built a Sportsman).

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Oct 03, 2022     Final trimming of firewall flanges Category: Firewall
Pulled the clecos and the flanges. Used my red Klenk offset snips to trim the stainless steel flanges back to the forward edge of the fuselage. Cut out the slot for the nose wheel leg from the lower flange.
 
Oct 02, 2022     Flanges drilled to Firewall - (1.5 hours) Category: Firewall
Slipped into the hangar on Sunday afternoon after watching the Twin Cities Marathon. Wanted to get the last bit of drilling to firewall completed.
 
Oct 01, 2022     A necklace of cleco's - (2.7 hours)       Category: Firewall
Reinstalled the firewall. Reinstalled and adjusted the 4 flanges with 1 inch overlaps. Drilled 3 of 4 flanges.
Used "popcicle stick" spacers. If you want to win a trivia contest, remember that a popcicle stick is exactly 1/16th inch thick. (Still have to install the thermal blanket, and want to be sure the firewall still goes in after its glued in place.)

The firewall clecos look like a necklace at this point. :)

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Sep 30, 2022     Natch?....no, NOTCH - (3 hours)       Category: Firewall
Anytime the factory sends me a finished part with a "notch" cut out, my guard is up. The last major firewall hole is for the boost pump fuel line penetration....and evidently Glasair found it hit the oil cooler frame. Hence they send out a part already having a "notch". Finally drilled the 9/16th hole, hit the notch bullseye!, and now onward to installing the flanges. Yes it took forever...I was as cautious as I could be..

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Sep 29, 2022     one step backward - (4 hours) Category: Firewall
Now back to firewall. Before firewall installation, necessary to double check the forward frame parts that get very difficult to access after firewall installation. Rechecked the rudder pedal installation, rechecked the brake system plumbing, rechecked the rudder cables. Now ready to proceed on firewall installation.
 
Sep 28, 2022     I've been framed - (6 hours)       Category: Firewall
Completed the oil cooler frame which includes the transponder manifolds and the gascolator.
Installed the hood on the cooler, mounted to bracket, sealed the edges with high temp RTV, installed the gascolator on the riveted brackets. whew.

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Sep 27, 2022     Riveting and bolting - (5 hours)       Category: Firewall
Enough measuring and procrastinating. Installed nutplates, countersunk the rivets, and actually got the oil cooler bracket mounted. Moved on to installation of the oil cooler itself and hood.

I now realize that working with a 22 year old kit is participation in the "good old days" that really weren't so rosy. Predrilled holes are in the wrong place. Mounting plates have the wrong dimensions. Original frame fittings should be considered "approximate" not exact. Options that are compatible...may be so only after modifications. Expect that nothing fits and you are not disappointed. But in all seriousness, it really is challenging fun. Like immersion in a foreign language, one ends up dreaming of airplane parts and fitments at 3am.

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Sep 26, 2022     Inside/Outside - (4.7 hours) Category: Firewall
Have now drilled the firewall hole for the manifold pressure line, and also the control cables' pass through. Remaining firewall hole is the boost pump fuel line (inside) which must not hit the frame assembly for the oil cooler (outside). Seems simple enough but it's difficult to measure precisely the inside spot to the outside spot. Interestingly (incriminatingly) enough, the factory supplied oil cooler and manifolds mounting frame comes with a "notch" cut into the top of a rail, looking very "after the fact".
 
Sep 25, 2022     Finally mounted the oil cooler bracket assembly - (5 hours)       Category: Firewall
After measuring/installing and removing the firewall multiple times, actually drilled and mounted the bracket assembly for the oil cooler and manifolds on the firewall. Progress. Confirmed the gas colator lines up with fuselage belly, and that the boost pump fuel line will hit the bracket assembly rail at the notch.

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Sep 24, 2022     Oil cooler frame and firewall - (3.4 hours) Category: Firewall
Drilled and deburred the 3rd firewall hole, for the cabin heat valve assembly. Then back to assessing the fit for the frame for the oil cooler, manifolds, and gas colator. Trying very hard to avoid customizing the oil cooler frame, but it's complex. How it fits the existing cage tabs (not movable without welding and refinishing), how the dimensions of the oil cooler frame line up (they don't), where the boost pump line exits the firewall relative to the oil cooler frame, and so on. Ah, the "joy" of fitting new accessory pieces for the current model (Sportsman 4-seater) into the kit for the past model (Glastar 2-seater) from 20 years ago. "Sorta" interchangeable, but sorta not.
 
Sep 23, 2022     Finally cutting holes in the firewall - (3.4 hours) Category: Firewall
There are six holes for pass through's in the Firewall. Still working on "where" for some of the six, but was able to drill and debur the 2 pass through's for wiring.
 
Sep 22, 2022     Shin bone connected to the knee bone.... - (4.4 hours)       Category: Firewall
Just like the old song, one thing is connected/leads to another. Mounting the boost pump on its base plate also reveals that the current plate is sized for the current Sportsman, not the Glastar. Now to determine dimensions to resize/cut the plate. Which then in turn promptly leads to a question about the forward tunnel closing panels' fit and sizing. Spent significant time measuring both the fitting dimensions from the cage tabs, the fitting dimensions of the motor mount, and the vertical and horizontal positioning of the boost pump.

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Sep 21, 2022     Prelim installation of boost pump on mounting plate - (2.2 hours) Category: Firewall
Need to determine where fuel line from boost pump passes through the firewall = start putting the boost pump assemblage together on its base plate. Of course that reveals the need for rubber mounting material not in the kit. One step forward and one step backward.
 
Sep 17, 2022     Oil Cooler assembly....getting interesting. - (2.8 hours) Category: Engine
Turns out the cage tabs for the Glastar are in a slightly different location than line up with the pre-drilled pilot holes for the oil cooler frame. Also a difference on drill sizes relative to TWTT/Sportsman. Will be easy to take care of this BUT the frame interacts with the firewall aft boost pump required for fuel injected engine. Now to research the boost pump mounting plate location to determine the correct location for the oil frame assembly. Also need to double check the fuel cooling shroud to be sure it doesn't conflict with the firewall cabin heat valve location. Getting very complex, so going cautiously for sure.
 
Sep 16, 2022     Oil Cooler Assembly - (3.7 hours)       Category: Engine
Oil Cooler assembly/frame needs to be done before firewall can be installed. Got to use lots of my toys; various drills, cleco's, die grinder and so on. Got the frame and gascolator brackets attached, also the manifold transducer assemblage. Will pass drill to cage frame tomorrow.

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Sep 15, 2022     More fitting tweaks - (2 hours)       Category: Firewall
Small tweaks on the firewall where the nose gear leg passes through. VERY slow progress...do not want to have to redo the stainless steel firewall for sure. Getting good at cutting only 1/64th with my shears and then deburring, sanding, and repeat. Finally 99% happy with the fit.

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Sep 14, 2022     Orcotex and firewall fitting - (4 hours) Category: Firewall
Firewall blanket finally arrived. Inspecting the firewall to fuselage gap requires additional trimming to get a uniform (or at least minimum) gap of 3/16th. Took the firewall out, trimmed, reinstalled....repeat about 6 times. Then do it again for the nose gear leg slot. Progress, but slow.
 
Sep 12, 2022     Kaleidoscope of possibles - (4.5 hours) Category: Firewall
At the point where sequencing is complex and many directions possible. eg, Don't install the firewall until after you assemble the oil cooler and fuel manifolds. Be sure there's enough gap to allow for the firewall blanket to fit (orotek material still being shipped). Comments on builder forums about "...wish I'd put in the air vents before closing up the firewall". Consider doing the final inspection and witness marking of the front of the fuselage area before fitting the firewall, eg the rudder pedals, cables, brakes and brake lines. And on and on and on. Studied the various routes, and blocked out a sequence based on a combination of the original manuals, TWTT process books, builder forum suggestions, and so on. Hoping to NOT have to undo building steps for a forgotten action.
 
Sep 09, 2022     Gymnastics and a Bespoke Suit - (3.3 hours)       Category: Firewall
Mounted the firewall without flanges, using the engine mount bolt holes.
Gymnastic moves required to solo drill out the ten cage attachment brackets (without an assistant to back the drill location outside with a wooden board.
Then able to deburr again the firewall new holes as well as the cage attachment brackets, and cleco clamp it all together for fitment. Feel like a tailor doing a bespoke suit!

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Sep 08, 2022     Finally installed for the first time - (3.2 hours)       Category: Firewall
Worked up the nerve to install the firewall and actually drill the engine mount bolt holes. Then bolted in place with 3/8th bolts/nuts from Ace Hardware's best. Progress!

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Sep 07, 2022     Flange completion - (3.5 hours)       Category: Firewall
New hand seamer arrived from Cleaveland Tool, so was able to finish the flanges with 90 degree bending.

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Sep 06, 2022     Leg hole - (4 hours) Category: Firewall
Took an inordinate amount of time trying to figure out the position of the nose gear leg hole in the lower firewall. Measure twice or ten times trying to only cut once. Stainless steel is difficult to trim off the excess. Got it done.
 
Sep 05, 2022     Remove nose leg - (2 hours) Category: Firewall
Groan....process requires removal of nose leg gear to fit the firewall.
One step forward, two steps backwards.
 
Sep 02, 2022     Cutting out Flanges - (5 hours)       Category: Firewall
Cut out flange notches and deburred.

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Sep 01, 2022     Marking - (3 hours)       Category: Firewall
Took a lot of time to mark the flange points for fabrication

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Aug 30, 2022     Cleaned, Marked and Cut Out - (3 hours)       Category: Firewall
Cleaned and washed the 42 X 32 sheet metal piece. Marked center lines all 4 edges. Traced template and cut out. Rough deburring, finish tomorrow. FINALLY back in the shop, after Airventure, another week with family near Boundary Waters, another week road trip through North Dakota to visit family, etc.

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Aug 09, 2022     Lycoming Arrives! - (6 hours)       Category: Engine
Fed Ex due with engine between 11am and 3pm. Notified at 2:12pm that the engine did not make it on the truck :(((
Insisted they go get it, and it was delivered apx 5:30pm. Hurray. Some box damage but did not touch the engine itself. Whew.

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Jul 22, 2022     Installing nut plates in instrument panel mounting flange - (3 hours) Category: Instrument Panel
Countersunk all rivet holes for nut plates. Packed shell and support bracket to take to Airventure and pass to Aerotronics.
 
Jul 21, 2022     Panel skeleton progress - (5 hours)       Category: Instrument Panel
Located the old instruction sheets for the Hammershead panel. Fit the new panel skeleton frame to the old cross bracket, and drilled the new panel skeleton. Installed 8 nut plates across the bottom of the panel/bracket. Measured the vertical 90 degrees for preliminary fit.

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Jul 20, 2022     Frame fitting - (3 hours) Category: Instrument Panel
Received the previously owned new panel frame from Glasair. Worked with the cross panel L-bracket prior builder fabricated for the Hammershead panel.
 
Jul 15, 2022     Firewall Template - (2.2 hours)       Category: Fuselage
Outlined the whiteboard, and spent time trimming the inside dimensions.
Will trace on the stainless steel sheet next time, and start the metal trimming.

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Jul 15, 2022     Christmas in July - (2.5 hours) Category: Fuselage
Received a box from Glasair, and spent the morning checking in the kits and items:
Oil Cooler and mounting; induction kit; FWF Hoses (lots of parts); mag cooling kit; cables for throttle, prop, mix; boost pump and mounting plate. Now in pretty good shape for when the engine shows up.
 
Jul 13, 2022     Copilot Rudder Pedals and Rough version of firewall template - (3.2 hours)       Category: Fuselage
Simple is best relative to keeping the copilot rudder pedals vertical (without brakes). Used 2mm steel wire with plastic.

Whiteboard sourced for firewall template. Rough cut it, and taped. Will do internal trim tomorrow.

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Jul 11, 2022     Plumb-ing the Jig poles - (1 hour)       Category: Wings
Used a smartscale tool to dial in plumb of the jig posts. Will do more before actually hanging the wings on them.

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Jul 11, 2022     Wing Jigs cleanup & placement - (3 hours)       Category: Wings
Finished cleaning up the jigs. Also wrenched the leveling screws (rusted) back to even and WD-40'd. Moved to the right wing table, and Right on one side, Left on the other side. Both root ends at the same table end. Bought Ace hardware jig bolts. Taped to table to be sure no accidental tip-overs as unstable until I actually get the wings in the jigs.

My kit had the quick start wings, but came to realize I have to put them into a wing jig for final straightening and top skin riveting. These metal jigs look great.

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Jul 10, 2022     Initial Wing Jig Cleanup - (1 hour) Category: Wings
Fighting a cold. Spent a brief time inspecting and cleaning the wing jigs.
 
Jul 09, 2022     Success...FAA Registration!       Category: Research
Countless hours and apx one YEAR of effort to get the kit registered as N2184.
Five prior owners, one of whom was deceased in a Reno air-racer accident, made the process challenging.
Whew!

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Jul 08, 2022     Wing Jigs' Pickup - (0.1 hour) Category: Wings
Drove down to Madison WI (about 8 hours round trip, time not logged) to buy a L/R set of metal wing jigs being resold by a fellow Glastar builder. Just barely squeezed them into my Subaru Forester.
 
Jul 07, 2022     Riveted pitot mast inside wing - (2.2 hours)       Category: Wings
Riveted the actual pitot mast to the wing and doubler.
Maybe a slight side angle, but certainly functional.

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Jul 06, 2022     Fuel shut-off - (2.9 hours) Category: Fuel System
Ran the fuel line from the central Tee forward to the on-off valve.
 
Jul 05, 2022     Sorting the paperwork stack at the hangar - (1.5 hours) Category: Research
Just what it says. Not very motivated!
 
Jul 04, 2022     Assorted Puzzles - (1.9 hours) Category: Research
Didn't get very far....puzzled over how to modify the copilot rudder pedals, the original wing jig mounting brackets, and the fuel lines to the on-off switch.
 
Jul 02, 2022     Kind of a Miscellaneous Day - (3.8 hours) Category: Fuel System
Spent time trying to salvage the swagelok fittings from the old fuel line for future usage. Nuts came off, but could not get the two ferrules per fitting to come off (at least so far). Then mixed a small batch of resin to "pot" the pitot drain blind rivet heads...will see how it turns out tomorrow. Then back to fuel line and worked on union tee fitting forward to on-off valve.
 
Jul 01, 2022     Frustrating fuel line replacement - (4.1 hours)       Category: Fuel System
Finally got around to removing a prior builder's fuel line from the sump to central tee. Could not get it to miss the flap cables which were not in place when he originally ran the fuel line. Bending the new segment was really quite frustrating for no good reason. Only 11 inches, and finished by using the aluminum swagelok fittings sent to me by a fellow owner.

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Jun 26, 2022     Bending....not pretty - (2 hours) Category: Fuel System
Catalyzed a small 25 g batch of resin to pot the blind rivet heads on the pitot drain. Waited too long to pour it into the "forms" I made around each rivet head...will have to try again. Also played with various bend approaches on the fuel line piece to be replaced, but nothing final. Somewhat a frustrating day. BUT had a fellow Glastar owner call with Swagelok fittings! Sent him my address and he will send tomorrow. Hurray!!
 
Jun 25, 2022     Swagelok - (3 hours) Category: Research
Glasair was an early adopter of Swagelok fittings, only to discontinue usage (the aluminum version of the fittings were low volume). They retreated to AN fittings and flared tubing. However, all the original work on this Glastar was with the Swagelok aluminum fittings. Replacing the one segment of fuel line means coming up with several of the original aluminum Swagelok's to maintain consistency. Tough! Posted on the owners board forum as a WTB (wanted to buy).
 
Jun 24, 2022     Resin and Fuel Line bending - (3.5 hours) Category: Wings
Spent time at various stores looking for resin cups, etc. Then worked on replacing/rebending fuel line that rubs on flap cables. Got NOTHING completed.
 
Jun 23, 2022     triage - (5 hours) Category: Fuselage
Researched drilling out blind-rivets...the issue is that the methods are based on punching out the stem/mandril.... I do not want to do this as it will punch holes in my outer laminate fuselage. Got input from Glasair. finally decided to drill one more hole in the doubler and install another rivet for security. Basically the Glasair specified rivet is TOO long/tall. Went to an AAPQ-42 and that just fit. And next I'll "pot" the gap between the large head and the doubler plate that was the result of the original blind-riveting. Non-structural.

Worked on the fuel line segment that interferes with the flap cables.
 
Jun 22, 2022     Seats and Static Port Drain - (1.2 hours)       Category: Fuselage
Considered seating color selection. Using North Country in Arlington WA to do the seats. Selected a non-leather fabric in gray.
Drilled and blind-riveted the pitot drain into the fuselage belly. Only after riveting did I realize the rivets specified were too LONG. Groan. Sleep on it.
Removed the fuel line fabricated by Dan K. that hits the flap cables. Will have to redo.
Hot & humid in the hangar...good day to quit early.

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Jun 22, 2022     Wiring into Conduit - (2 hours)       Category: Wings
Soldered wire to pitot heat receptacle, wrapped in spiral.
Removed the red pitot line from the conduit (run it down the strut) as made it too tight for the wiring.
Ran the pitot power wires and the left aux pump wire down the conduit to the root.
Installed the elbows into the static ports.

The wiring shows the left wing...the yellow is 100# test fish-line that's in a loop allowing me to pull wires through without losing the pull line.

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Jun 17, 2022     Foot and Fold(ing) Wings - (2.5 hours) Category: Wings
Spent way too much time looking for the manual page that details where to install the empennage eyelets for a folded wing. No joy.
Then spent time on the copilot rudder pedals trying to figure out how to secure them without brakes. Springs didn't work, they simply "spin.
Lastly worked on the wiring for the pitot heat. Cut wire into 2 X 15 foot lengths
Not much progress today, guess some days are like that.
 
Jun 16, 2022     installed static ports - (4 hours) Category: Avionics
Reviewed pitot mast support tab locations.
Finished drilling the 3 rivet holes for the static port, installed with RTV.
 
Jun 16, 2022     Pitot/Static Small Victories - (4.3 hours)       Category: Wings
Finished the pitot tube mast...redid one of the brackets so the mast will sit flat on the lower wing skin doubler. then installed the two static ports. small victories!

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Jun 15, 2022     Fuselage foam sealing & Pitot mast riveting - (4 hours) Category: Wings
Played with resin and MEKP. Concerned about age of resin, and have forgotten most of my mixing experience it's been so long since not working with the resin on this project. Mixed a batch of Resin, catalyzed, added Q-cells for a "thin mix". Sealed the 3 drill holes in the fuselage.
Received the "thin nose yoke" from Cleaveland Tool...allowed me to use the squeezer on the final two mast rivets.
 
Jun 14, 2022     Pitot Tube Connections - (3 hours) Category: Wings
Got a new piece of 1/4 inch aluminum tube from Bolduc at Anoka County Airport. (screwed up the piece in the kit yesterday). The L-shaped tube connecting the pitot fitting to the red nylon tube fitting is a bitch. Forget to put both sets of fittings on before flaring? check. Forget to put one set of fittings on each end of the 90 degree bend? check. Forget to flare before bending? check. And on and on. Key...use a 6 inch piece not a 4 inch as the manual states. Work out a sequence of flaring, bending, fittings before beginning. (Need a minimum of 3/4 inch without fittings to flare. Need apx a minimum of 3 inches to flare. Finally got it done on the 4th (!) try.

Drilled the fuselage for the pitot drain and doubler.
Drilled the fuselage for the two static ports.
 
Jun 13, 2022     A Dog's Breakfast...little bit of everything - (5 hours) Category: Wings
Worked on repair of broken deburr tool. Tightened and clipped the zip ties holding conduits. Spiral wrapped the nylon brake lines where they pass under cage tubes. Cut hole in left wing conduit to feed pitot tube (red) to wing root. Ordered lock washers for pitot screws.
 
Jun 11, 2022     CoPilot Rudder Pedals. Also pitot mast assemblage - (3.3 hours) Category: Landing Gear
Used a T-handle reamer to fit the bushings into the copilot rudder pedals. Figured out how to put a spring on each peddle to avoid the pedals from "flopping over/jamming". Now to buy a couple of springs.
Riveted two of the pitot mast brackets onto the mast. Could NOT get to the other two brackets with either the squeezer, or even using rivet gun due to lack of thin bucking bar....finally ordered a thin-nose-profile pneumatic squeezer yoke from Cleaveland. The pitot mast will not be pretty, but it will be functional.
 
Jun 10, 2022     Pitot Mast Brackets - (4 hours) Category: Wings
Drilled the mast for the mounting brackets.
Two-step anti-corrosion treatment of mast brackets, mast itself, and pitot drain doubler previously fabricated.
 
Jun 08, 2022     Pitot Mast cutout lower left wing skin - (5.5 hours)       Category: Wings
Started on pitot installation yesterday, marking the doubler and beginning wing skin cutout to mast shape. Started with hole saw, and then spent way too much time with a Dremel and sanding bits to shape the skin. Not perfect, but happy with the outcome.

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Jun 07, 2022     Replumbed brake lines - (5.5 hours) Category: Landing Gear
Replaced all brass fittings from brake reservour to master cylinders, and from masters to junction under seat with steel lines running to calipers at wheels.
 
Jun 06, 2022     Secured the conduits - (5.9 hours) Category: Wings
Secured wiring conduit in each wings from root to tip. Required using small conduit braces fabricated earlier, drilling into hat sections to use nylon cable grips, drilling first 8 cove ribs, and zip-tie all, approximately 25 or 30 locations.

Also measured and marked for static ports in forward fuselage.
 
Jun 04, 2022     Brake LInes - (2.5 hours) Category: Landing Gear
Not happy with the mix of Nylaflow and Nylo-Seal fittings inherited on this kit. Decided to remove all the master cylinder brake lines, order new fittings, and redo next week. Placed yet again another order with Aircraft Spruce & Specialty. In particular it is not clear whether compression ferrules are needed for 3/16th brake lines for all or just some, so will put in for all with the new compression tee and elbows.
 
Jun 03, 2022     Fabricated rest of conduit braces - (2 hours) Category: Wings
Fabricated additional 12 conduit brace tabs after receipt of 3/4 X 3/4 piece. Corrosion treated all 25 parts.
Did some shop duty....replaced bench grinder wheel with new Scotchbrite wheel, cleaned grease off the air hoses, etc.
 
Jun 01, 2022     Jacking Collars (and FAA Documents) - (3.8 hours)       Category: Landing Gear
Minimal progress day...spent too much time looking for the correct NylaFlow fittings to complete the installation of the steel brake cable upgrade. Gave up and ordered additional parts. ACS must love me.
Then installed on each main gear leg "jacking collars" which are 2 piece clamping collars (McMaster Carr p/n 8A100). These give a jacking lift a surface/edge to lift up one side without risking the gear slipping off the lift.
Then completed the final (?) resubmittal of the Registration application to the FAA and mailed it off guaranteed delivery 6/3/22.

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May 31, 2022     Retro Work on Tail - (5 hours) Category: Tail Feathers
Inspection of the kit upon receipt last year found several items by prior builders best redone or modified. The vertical fin spar had a jagged lower edge where it had been trimmed, and needs work; best smoothed and dressed. Disconnected the rudder cables, removed the vertical fin, and used a small dremel wheel to dress the lower edge of the spar. Then reconnected all with final mounting hardware (not yet torqued). WAPITA.
 
May 30, 2022     Conduit "Soldiers" - (3.5 hours)       Category: Wings
Lots of work for seemingly minimal results. Fabricated the brackets that will secure the conduit to the ribs in each wing. Photo looks like little soldiers.

Also finished the fitment work to get the pitot probe to align in the mast.

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May 28, 2022     Pitot Tube into Mast - (3 hours) Category: Avionics
Began installation of the pitot/static system. Pitot would not fit into the steel mast...and so per manual, started the filing and drilling (for mounting holes) work. Slow going, as the mast is tough steel material, not aluminum.
 
May 27, 2022     Master Cylinders to Reservoir - (3 hours) Category: Landing Gear
Ran the brake lines from the master cylinders to the brake fluid reservoir. Silicon on steel brake lines through the fuselage wall.
Inventoried the heated static/pitot option kit for installation.
 
May 26, 2022     Steel Brake Line Upgrade Option - (6 hours)       Category: Landing Gear
Installed steel brake line option. Disassembled current brake caliper and nylon lines assemblage, and replaced fittings. Drilled holes in fuselage next to tricycle gear legs (9/16th), and ran the steel lines into the fuselage. (Capped the holes previously drilled for the brake lines in the Taildragger configuration). Zip tied the new lines to the legs.

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May 25, 2022     Located & Analyzed Current Instrument Panel & Glareshield - (3 hours) Category: Instrument Panel
Ordered instruments, all Garmin, from Aerotronics. Discussion regarding the fiberglass panel and glareshield currently in my inventory, which I will not be able to use. Likely have to grind off the vertical tabs of the crossbar frame.

Fabricated the support brackets for mounting the conduits in each wing, currently laying loose in place.
 
May 24, 2022     Ordered North Country Seats & removed seat back frames - (2.1 hours)       Category: Interior Finish
Took apart the seat to rail assembly. Need to send the back frames to Billie in North Country Upholstery (Arlington, WA) to do the seats.

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May 23, 2022     Dual brake option - (1.9 hours) Category: Landing Gear
Reviewed again whether to order the dual brake option, which prior builders of this kit had not selected. Upon detailed review (steps and cost to do so), made final decision to NOT do so. Then located the copilot rudder pedals, and finally ordered AN3-35 drilled shank bolts to mount them.
 
May 20, 2022     Fish lines in the conduits - (2.7 hours) Category: Wings
Ran 100 # test fish line through each conduit. Double loop (so pulling one side still has the other side in place). And 2 each of the double loops in each wing in case one breaks.
 
May 18, 2022     Completed aux pump wiring & ran wing coax - (2.5 hours)       Category: Fuel System
Completed aux pump wiring, with crimping butt connectors on the positive leads to the longer wires to route to the instrument panel.
Also cut 30 foot length of nylon conduit into two, and ran in each wing in accordance with the manual.

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May 17, 2022     Fuel pump wiring - (2 hours) Category: Wings
Scuffed the doubler plates under the aux pump flange for a good ground connection.
Connected the ground wires.
Had to drive to Steinaire to buy a new crimper.
 
May 13, 2022     Inspection Holes' Completion - (2.7 hours)       Category: Wings
Riveted nutplates on the doublers, clecoed into wings, and then clecoed hole covers in place for final fit and trim.
Then taped the completed doublers inside wing for future release and installation once top skins are riveted in place.

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May 12, 2022     Hanging out the (inspection doublers) laundry - (4.5 hours)       Category: Wings
Finished drilling the nutplate mounting holes on the inspection hole doublers. Did a 2-step corrosion prevention, and hung them to dry.

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May 11, 2022     Zen and Inspection Hole Doublers - (3 hours) Category: Wings
Each inspection hole doubler has 4 to 6 screw holes for the covers, 22 per side. Two holes per screw hole = 44. Two wings = 88. Both sides = 176 to debur after drilling. Ahhh...zen and the art of wing inspection hole drilling and deburring.
 
May 10, 2022     Fuel vent lines - (2.4 hours)       Category: Wings
Drilled ribs 3 and 4 to fit 7/16th grommets, and re-ran the main tank fuel vent lines to the wingtips.

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May 09, 2022     Anti-chafe tape the bottom hat sections - (4 hours) Category: Wings
Spent first couple of hours researching nutplates...seems like the K1000-8 nutplates in the kit may be mislabeled, as won't install with the #8 nutplate tool. Waiting on receipt of the #6 tool, but want to be certain the parts weren't mislabeled. Then took remaining anti-friction tape, cut strips, and installed on the remaining bottom hat sections in each wing that were not covered by the main and aux tank installations.
 
May 07, 2022     Engraved Inspection Hole Covers and Doublers - (2 hours) Category: Wings
Used my dremel to mark each port either Left or Right, and "aux" for the hole at "6" location. And of course the marked surfaces are "inside" the wing.
 
May 06, 2022     Finished Inspection Hole Doubler Drilling - (2.5 hours) Category: Wings
Fit and drilled D and E inspection holes, both wings. Solo work drilling = climb up on table, reach over with left hand to brace backing board while drilling with right hand. Glad this step is over, except for corrosion treatment, nutplate drilling, countersinking for 426 style rivets and riveting the 40 plus nutplates onto the doublers.
 
May 05, 2022     More Inspection Hole Doublers - (3.6 hours) Category: Wings
Fitting inspection covers and drilling B and C ports, both wings. Fit & taped D but too tired to drill.
Slow going!
 
May 04, 2022     Fun with Inspection Hole Doublers and Covers. AKA "slow but steady" - (4 hours)       Category: Wings
Five inspection holes per wing = total of 10. 3 different sizes/shapes. Nerdy I know, but this was fun work drilling in the wing skin doublers, and trimming the cover plates to fit as accurately as possible. Completed inspection hole A both wings. Will NOT final rivet onto wing until after riveting the top skins in place, as the inspection holes are the bucking bar access.

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May 03, 2022     Drill out and redo the wing fold strut nutplates - (3.2 hours) Category: Wings
Right wing nutplate ok, left wing nutplate not acceptable. Issue on the left wing was aligning the rivet holes of the nutplate without considering ease of getting a bucking bar on it. Right wing was done with this in mind, and turned out fine. Drilled out the original left nutplate and redrilled. Filled the original holes with AN470AD3-6's just like the re-riveted nutplate. Looks good, and brother Joel visiting from Ohio did the bucking bar duty.
 
May 02, 2022     Wing Support Strut Eyebolt Nutplates - (4.1 hours) Category: Wings
Selected wing brace/wing fold option. This requires usage of a steel support strut when folded, which in turn needs a small eyebolt drilled through lower flange of the forward wing spar. Removed main tanks to access the flange, drilled and installed the nutplate in each wing. Easy process, but did not do a very good job on the riveting of the nutplates. Will inspect tomorrow and determine whether to drill them out and redo. Should have considered using my squeezer, or even cherry rivets (issue making it difficult is how tight the spot is to the vertical part of the forward spar) rather than solo riveting/bucking with the gun.
 
Apr 30, 2022     Fuel Vents, Wingtip & Pump Wiring - (2.5 hours) Category: Wings
Manual simultaneously splits into multiple segments based on options. Reviewed various choices for internal wing routing of the vent lines and wiring. Decision is KISS....simple best. Will run two vent lines per wing out the tip, and one nylon conduit for all/most of the wiring for landing lights, position lights, fuel transfer pump wires, and so on. Requires a decision now as getting closer to riveting on the top skins when it gets tough to work inside the wings. Magnetometer, pitot tube, and fuel quantity senders' wiring all part of the consideration NOW.
 
Apr 29, 2022     Sump Drains and Removal of Aux tanks and channels. - (6 hours)       Category: Fuel System
Chose to locate and drill the initial sump drain holes (2 in each aux tank) in the bottom skins a different way than manual directs. Manual has a convoluted measuring scheme of skins, struts, and so on...then to do a lot of arithmetic. I simply pulled tanks, measured the drain boss locations, reinstalled the tanks in place, and marked the bottom wing skins. Then pulled tanks, drilled from inside the wing, and updrilled with a 3/4 inch hole saw. 3 of the 4 holes were perfect, the 4th was off somewhat. As the final drill and hole locations come after the riveting of top skins, no problem.

Then removed the tanks, drilled out the temp rivets holding the channels in place, and removed to facilitate the riveting to come.

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Apr 28, 2022     Aux Fuel Tank Holes & Registration Submittal to FAA - (3 hours) Category: Fuel System
Pulled together all the documents to register the plane. As I'm the 5th builder on this kit, needed to locate/submit 5 Bills of Sale.
Then to hangar to actually drill the stem holes in the top skins. VERY pleased at results/margin using a 2 and 3/4 hole saw in the drill press.
 
Apr 27, 2022     Covid Booster Wipeout - (0.5 hour) Category: Workshop
Feeling the covid booster #2...swept out the hangar and called it a day. :)
 
Apr 26, 2022     Drill Press - (0.5 hour) Category: Workshop
Finally purchased a drill press, listed on Craig's list, only 5 minutes from my house. 3/4 HP, Cal-Hawk (off) brand from Taiwan in 1993. Good shape.
 
Apr 25, 2022     Aux Fuel Tank Filler Holes - (2.5 hours) Category: Fuel System
Measuring and marking top wing skins to drill holes for filler stem/cap. Measured multiple times and multiple ways, as cost of mistake very high (can't imagine trying to replicate the predrilled top skins which match the holes in the wing spars. The Aux tank caps are the flush design, which basically requires a 3 inch hole, which is tough to drill with only a hand drill. Measure, measure, measure.
 
Apr 16, 2022     Wing Fold Option and LED light option Shipment - (1.5 hours) Category: Wings
Received ups shipment for several options. Wing Fold, LED lights, wing conduit, and connector bracket. Checked in items compared to pick list. All accounted per pick list.
 
Apr 15, 2022     Aux Tank Filler Holes - (4.1 hours)       Category: Fuel System
Read ahead in the assembly manual. Laid out precisely the location in the top wing skin for the filler neck holes.
Drilled #30 pilot holes. Stopped, as not certain at the moment how to cut in the larger 3 inch holes needed for the flush caps. Don't have a drill press.

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Apr 13, 2022     Aux Tank Fuel Lines & Fuel Filler top skin. - (3.8 hours)       Category: Fuel System
Completed fuel lines to/from Aux tank fuel pumps.
Started layout of top skin to drill filler stem holes.
Ordered LED landing/light kit from Glasair, and also the wing fold hardware.

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Apr 12, 2022     Installed Aux Pumps and fabricated lines - (4.9 hours) Category: Fuel System
Good day for progress. Fabricated the short fuel lines from aux fuel pump output to main tank input, and then installed the actual fuel pumps. Cut the lines for aux fuel pump input to aux tanks' outflow, determined how to bend and fabricate these long 82 inch lines. Inadvertently left wallet and phone home...no pictures until tomorrow. :)
 
Apr 11, 2022     Wasted Day - (3.6 hours) Category: Fuel System
Fuel lines next. Manual refers the builder to the "technique section" to review tubing and fuel lines.....which states all fittings from Glasair are Swagelok. So ok, I then spent the next several hours looking for Swagelok hardware in my shelves/boxes...no joy. Only to get an email from Glasair...NO...they discontinued sending Swagelok hardware as the vendor wanted a mill-run of quantity to keep supplying such compression hardware, and they opted out and returned to AN hardware. Sheesh. At least I have a tube cutter, flaring tool, and a tube bender. Also watched EAA "Hint for Homebuilders" #615 several times, a really excellent resource, on the finer points of using the flare tool. And revisited manual AC43.13 for torque values for those AN fuel lines. (110 in-lbs)
 
Apr 10, 2022     Aux Tank Fittings & Fuel LInes - (2.6 hours)       Category: Fuel System
Each aux tank requires 3 fittings at this point, one of which is a "finger screen". Installed using Sealube, and then did minor Dremel surgery on ribs where there was fitting interference.
AND...then pulled together the raw 3/8th lines to begin installing fuel lines tomorrow. Progress!

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Apr 08, 2022     Aux Tank Installation - (2.5 hours)       Category: Fuel System
Woahhh....counterintutive. Tried sliding aux tanks into newly riveted (temporarily) in place channels. Groan...too tight, a real struggle. Got them in but then really tough to get back out. BUT THEN....I put on anti-friction tape on the top and bottom channels (expecting to then NOT be able to get the tanks back in, and have to modify the channel mounting)...but instead the tanks slid in like butter instead! Thanks to the Glasair manual...wish they'd been more clear about the side benefit of the anti-friction tape.)

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Apr 07, 2022     Wrong Fuel Level Senders Category: Fuel System
Glasair published a cross-reference from Glastar to Sportsman. Revealed that the fuel sender is different (4 hole square pattern) for the Glastar vs the Sportsman ( 5 hole circular pattern). Emailed Glasair to check on stock. I have (in error) 4 of the circular, and need 2 of each pattern.
 
Apr 07, 2022     Anti-Chafe Taping - (3.6 hours) Category: Fuel System
Aux tanks "float" in the wing tip, and need to add neoprene "bumpers" on the tank corners as well as anti-friction tape on the hat sections upper and lower. Cut and installed the tape.
 
Apr 06, 2022     Corrosion Proofing Aux Tank Channels - (2.7 hours)       Category: Fuel System
Corrosion proofed the channels. Hardest part was to find "trays" to dip the channels which are 29 inches X 3 5/8th inches. Wallpaper Prep Trays turned out to be perfect at Ace Hardware.

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Apr 05, 2022     Drilled and clecoed the aux tank channels - (3.1 hours)       Category: Fuel System
Clecoed the upper hat sections in place and then drilled and clecoed the forward and aft aux fuel tank channels in place.

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Apr 04, 2022     Aux Tanks front mounting channel - (2.5 hours) Category: Fuel System
Drilled out the wing tip rib cherry rivets and removed the ribs on left and right wings.
Measured and marked the forward mounting channel for the aux tanks on both wings.
 
Apr 03, 2022     Main tanks' vent fitttings - (2.1 hours) Category: Fuel System
Cut 1/4 inch nylon vent lines and fit the nylon connectors to main tanks.
 
Apr 01, 2022     Finally riveting in the doublers - (1.5 hours)       Category: Fuel System
Friend and fellow builder (he's building a Sportsman 2+2 at Flying Cloud) Owen Schott stopped by to buck a few rivets. Finally got the aux tank fuel pump doublers actually riveted in place. Having Owen around helped move the wings vertical and position them for riveting.

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Mar 30, 2022     More riveting practice and new wing jig bracing - (2 hours) Category: Workshop
A bit more rivet practice. Hard to get rid of the smileys.
Cut new boards to add to wing jig tables so that I can stand the wings vertical to facilitate access to both sides for solo riveting.
 
Mar 29, 2022     Sorting aux tanks option to Bill of Materials - (1.2 hours) Category: Research
Glasair just sent the current BOM for the aux tanks. Helpful, several new items and several items deleted.
 
Mar 28, 2022     Practice riveting and countersinking Category: Research
3 hours, don't include in project times. Practiced on the RV class project with rivet gun, pneumatic squeezer, micro counter sink.
 
Mar 26, 2022     Anti corrosion treatment - (1.1 hours)       Category: Fuel System
Two part anti-corrosion treatment. Left to dry. Turns the aluminum "gold".
Photos show before and after.

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Mar 25, 2022     Miscellaneous Category: Fuel System
Checked plate fittings, added a 17th rivet to offset one rivet that ended up being too close to the edge.
 
Mar 24, 2022     Completed Doubler plate fitting - (1.9 hours) Category: Fuel System
Prepping the doubler plates. Trim, deburr, drill, etc
 
Mar 23, 2022     Transfer Pump Mounting Doubler - (2.7 hours)       Category: Fuel System
The Glastar uses a transfer pump to move fuel from the aux tanks to the mains. This requires a doubler plate on the wing bottom skin each side, and that in turn requires drilling out several rivets on the hat sections. Flipped over each wing on their respective tables, and drilled out the rivets. Right and left wing shown.

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Mar 22, 2022     Aux Fuel Tanks' Easter Egg Hunt (looking for parts!) - (2.9 hours)       Category: Fuel System
Time to install the auxilliary tank(s)' option. Received these parts last summer July of 2021 and they promptly mixed in with other parts and hid. And re-reading the parts list sent from Glasair with the option shipment, I (re) discover there were some parts not sent as they were on backorder. (But still never sent....think Glasair was too overwhelmed with new orders to go back to old ones looking for missed parts.)

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Mar 21, 2022     Final top wing skin filler hole - (2.5 hours)       Category: Fuel System
Finished left wing filler hole. Used a 2 inch circular drill....and then a Dremel to enlarge for 1/16th gap around the filler neck.

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Mar 19, 2022     Filler Hole in Upper Inboard Wing Skin - (3.5 hours) Category: Fuel System
Final trim and expansion of hole in upper inboard wing skin. Used a 2 inch hole cutter knowing it requires 2.25 inches plus 1/16th margin all around....allowed precise locating by sanding with a Dremel since the tank filler hole location varies by tank. Completed the Right side wing, and did the measuring/marking to work on Left side wing next.
 
Mar 18, 2022     Filler Neck holes for Main Tanks - (4 hours)       Category: Fuel System
Returned from 3 week LSRMA course in Missouri...now Repairman for Light Sport Aircraft.
Measured upper wing skins to locate the holes for filler necks to main fuel tanks. Then cut in undersize at 2 inch diameters to facilitate final filing to precisely locate and allow a 1/16th margin.

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Feb 21, 2022     Clecoed the root ribs - (2.3 hours)       Category: Wings
Clecoed the root ribs in place prior to cutting into top skins for fuel filler holes. More difficult than I expected, with the neoprene bumpers fighting the effort to cleco to the fore and aft main spars. Then started the measuring...required locating the correct top skins to confirm how they fit relative to the leading edges and mid-panel top skins.

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Feb 18, 2022     Fuel lines through the root ribs - (3.3 hours) Category: Wings
Cut the openings in the root ribs for the mail fuel line and vents.
 
Feb 17, 2022     Cutout in Root Ribs (L&R) for the fuel gauge mounting flange - (4.6 hours)       Category: Wings
Fun day using all my toys...drills, die grinder, unibits, jobber bits, and so on. My work is not pretty, but it's technically solid....rounded corners, deburred and debried, etc.

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Feb 16, 2022     Fuel Tank Bumpers - (3.5 hours)       Category: Wings
Cut neoprene sections into corner sections for both mains and installed.

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Feb 15, 2022     Sump drain holes in lower skins - (3 hours) Category: Wings
Drilled 7/8th inch hole in left and right wings.
 
Feb 14, 2022     Prep Hat Sections for anti-chafe tape - (3.5 hours) Category: Wings
Acetone wiped hat sections, and then installed anti friction tape
 
Feb 12, 2022     Anti-Chafe - (2.4 hours)       Category: Research
Took my only roll of anti-chafe tape and measured it out, and cut out 20 sections for the root area hat sections for the main tank support.

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Feb 11, 2022     Paperwork! - (2 hours) Category: Research
finally had to sort and 3-ring binder project pages now completed.
 
Feb 10, 2022     Main Tanks - (3 hours)       Category: Fuel System
Drilled out the temporary pull-rivets from the end rib at the root. Removed the root rib.
Test fit the main left tank, and prepare to add ant-chafe tape tomorrow. Need to find someone to help me lift the right wing back onto it's table jig, as I'd had it off the table to put on fuselage landing gear.

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Feb 09, 2022     New Shoes and Baby Steps - (5 hours)       Category: Landing Gear
Completed the nose gear installation, aired all tires to 40 lbs, lifted the airplane, and "landed" on the tricycle gear!!
Remembered that it's now tail heavy....still had three 50 lb sandbags that I used to have for working on my Sportsman, and leveled the landing. :)

Also began work on the fuselage fuel system.

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Feb 08, 2022     Brakes...Pulling together parts - (1.5 hours) Category: Landing Gear
Two sets of brakes, one on old trike legs, one that was on the oem kit tailwheel. Moving the tailwheel setup to the trike.
 
Feb 07, 2022     Tailwheel Review - (2 hours) Category: Landing Gear
Prior owner/builders had on tailwheel gear. Reviewed the construction pages for the TD gear.
 
Feb 05, 2022     Brakes onto legs - (4 hours)       Category: Landing Gear
Worked with the brakes and reinstalling on the legs.

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Feb 04, 2022     Main Tricycle Gear Installed - (6 hours)       Category: Landing Gear
Final installation of main gear legs, followed by tires and brakes. Began the nose wheel installation, checking the fuselage cutout for the nose leg.

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Feb 03, 2022     Gear leg toe-in adjustment completion - (2.2 hours)       Category: Landing Gear
Gear set #1: Tailwheel legs (forward cage gear sockets) ok as received from prior builder(s)...toe-out.

Gear set #2: Tricycle legs (aft cage gear sockets) ok for Right cage socket and leg, but were misdrilled in the past for Left cage and socket.

Discussed with Ted Setzer, and confirmed simple solution the best...simply start over on the left gear, and redrill a new hole through both cage socket and gear leg. Maintain minimum of 3/16th to old hole, and minimum of 1/4th down from top of cage socket. Completed drilling with 5/16th to 6/16th distance to old hole and more than 1/4th down from top.

Final bolt size for Left cage/leg was 5/16th. Didn't change Right cage/leg at 3/8th, drilled by prior builder-owners.

Smartscale to confirm level...within .1 degree. And toe-in between .032 and .064 per spec.

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Feb 02, 2022     Redrilling aft left socket - (5.7 hours) Category: Landing Gear
Started redrilling left gear...both left cage socket, and left gear leg. Clamped with toe-in between .032 and .064 shim.

New #10 drill bit went through like butter. BUT struggled with a 9/32nd....big step up for hard steel, and got dull. finally quit when realizing I'd need another drill bit. Back to Grainger tomorrow morning.
 
Feb 01, 2022     EAA Tech Counselor Visit - (2 hours) Category: Inspection
Mike Hilger made initial visit to this project. Valuable inspection and discussions.
 
Jan 31, 2022     Legs and Left wing issue - (3.9 hours)       Category: Landing Gear
Left wing pulley guard interfered with the cable itself, noticed after wing removal. Took apart (cotter pin out, etc) and repositioned at 45 degrees to avoid interference. Also again inspected toe-angles with .032 and .064 shims.

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Jan 28, 2022     Gear and Socket Measurements - (4.1 hours) Category: Landing Gear
Spent time re-measuring all aspects of the gear and sockets, trying to decide course of action to correct aft left gear/socket issue.
 
Jan 27, 2022     Landing gear legs and sockets. Photos of current state. - (3 hours)       Category: Landing Gear
Capturing the data and a bit of QC. All sockets good except Left aft/trike. Did notice prior owners had upsized all holes to 3/8th form the 5/16th. This is ok/tight.

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Jan 26, 2022     Toe-In and Toe-Out at Minus 14 degrees F - (6 hours)       Category: Landing Gear
Took each set of gear legs, installed without wheels into cage sockets, set up measurement fixture and captured data. Tailwheel set (front cage gear sockets) are Toe-Out per spec. Tricycle set (aft cage gear sockets) are per spec on the Right leg, but NOT on the left which has a misdrilled/oval cage socket and let hole. A good day to be inside a heated hangar with windchills around Minus 30 to 40

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Jan 25, 2022     Disassembly of Two Gear Sets - (2.8 hours)       Category: Landing Gear
Took each set of gear apart; one set Tailwheel, and one set Trike. Captured the (previously) drilled cage socket angles.

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Jan 24, 2022     Waterline leveling and Wings' repositioning - (2.9 hours)       Category: Fuselage
Moved right wing off the jig table to rolling stand. Asked the police outside the door to help move it. :) Then asked St. Paul Flight Center (Pete) to help me get the fuselage on the wing jig table to work on the main gear. Previously had been on Tailwheel gear, now going to put on Tricycle gear.

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Jan 20, 2022     Labelled all cables, disconnected turnbuckles - (2.7 hours) Category: Controls
Getting ready to remove the wings. Labelled and disconnected all cables. Removed both wing struts.
 
Jan 19, 2022     Short day; Wrapped ailerons and flaps for WIP storage - (1 hour) Category: Controls
 
Jan 17, 2022     Removing all flight control surfaces - (4 hours)       Category: Controls
Removed both flaps. Removed both ailerons being careful to document the mounting hardware and segment into individual ziplock baggies.

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Jan 15, 2022     Shrink tubing for aileron cable ends - (2 hours)       Category: Controls
Heated/shrunk the tubing. Resecured the control stick interconnect tie-rod, check safety holes were ok.

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Jan 14, 2022     Nico Press practice and installation of new aileron sleeves - (6.5 hours) Category: Controls
Practiced working with Nico Press. ( A brand new swaging tool just received, so it's quite stiff. "Breaking it in" and practicing a solo technique.Then actually used it to complete the cable ends for the new aileron cables.
 
Jan 13, 2022     Tighten new cables and clamp - (3.5 hours) Category: Controls
Clamped ailerons to flaps, tightened the cables, tweaked setting left/right to even out.
 
Jan 12, 2022     Totally replace aileron cables - (2.6 hours) Category: Controls
Was not happy with the quality of my aileron cable ends/Nico pressed sleeves. Cut off ends and totally removed the aileron cables as well as the cross-over cable(s). Reran/reinstalled brand new cables received from Glasair.
 
Jan 11, 2022     Frustrating day on control stick interconnect - (4.2 hours) Category: Controls
Manual details shortening the control stick interconnect. A repetitive left/right in/out sequence trying to both shorten and ensure adequate aileron travel.
 
Jan 10, 2022     Checking on Aileron travel - (2.7 hours) Category: Wings
Rechecked all control tab connections, reset ailerons and bellcranks and control stick pivots to neutral, etc.
 
Jan 08, 2022     Finished aileron cable pulley guard installations. - (3 hours)       Category: Wings
In addition to guards, traced the path of all cables to ensure in place correctly.

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Jan 06, 2022     Right Wing Pulley Guards - (3.05 hours) Category: Wings
Working on guards.
 
Jan 05, 2022     Lower Aft Aileron Pulley - (1.7 hours)       Category: Tail Feathers
Worked on pulley clearance, adding 2nd AN960-516 washer.

First time back in hangar since Pasadena last week. "Beauty shot photos" attached.

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Dec 31, 2021     Shrink wrapping nico pressed ends - (2 hours) Category: Controls
Heated/shrank the heat wraps. Rechecked tie rod interconnect clevis.
 
Dec 31, 2021     Trimming top skin for flap position clearance - (4.2 hours)       Category: Landing Gear
Trimming top skin/doubler to provide a bit more clearance for flaps to retract fully. Also working on cable guides.

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Dec 28, 2021     Reran aileron control cables - (3.5 hours)       Category: Wings
Not happy with my Nico Press cable connections. Ordered new secondary aileron activation cables to redo.
Ran 4 new cables, the 2 secondaries, as well as 2 new crossover cables (left and right).

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Dec 27, 2021     Elevator pushrod connected - (3.1 hours)       Category: Tail Feathers

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Dec 26, 2021     Horiz Stab/Elev cables - (5 hours)       Category: Empennage
Reinstalled the rudder and horiz stab/elevator. Reconfirmed cables to tail were good.

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Dec 23, 2021     Anti-corrosion cable pulley straps. - (1.6 hours) Category: Wings
Also searched for tail parts...found in the steering box (?!)
 
Dec 22, 2021     rudder cables reset to neutral - (1 hour) Category: Controls
 
Dec 20, 2021     Finished the cotter pins - (1.5 hours) Category: Wings
 
Dec 18, 2021     Cotter Pins - (2.3 hours) Category: Wings
Working on putting the cotter pins into the guides and pulleys on the wing. Tough (overhead, upside down, etc).
 
Dec 17, 2021     Deburring cable guards & anti corrosion work - (3.4 hours) Category: Wings
 
Dec 16, 2021     pulley guards - (1.5 hours)       Category: Controls
Dropped off material at Valley Machining Shop for pulley guard work. Just too delicate for the single pulley guards to comply with the service bulletin on max/min clearance dimensions. then back for anti-corrosion treatments, etc. Also inspected closely (see photos) the left aft internal pulley.....decision leave as is with cage acting as "guards".

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Dec 14, 2021     Pivot brackets - (2 hours) Category: Controls
Started over on the pivot brackets interconnect tie rod. Completely removed. and then removed the attachment rods. Reset each side to 10 turns.
 
Dec 12, 2021     Rudder cables and bulkheads B and A - (1.4 hours) Category: Tail Feathers
Inspecting the rudder cables and the bulkheads while I'm in there.
 
Dec 08, 2021     Connecting all cables/Turnbuckles - (1.7 hours)       Category: Wings
See photos

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Dec 07, 2021     Ailerons - (1.7 hours) Category: Wings
Struggling with ailerons at neutral. There is 8 to 10 mm delta...if Right neutral, Left is off. If Left is neutral, Right is off. Grrrr.
 
Dec 06, 2021     Aileron adjustments - (3.9 hours) Category: Wings
Making progress, but still tweaking the aileron cables for balance and travel. Ordered some parts from Van's and Aircraft Spruce.
 
Dec 04, 2021     Guard fabrication - (3.3 hours) Category: Wings
Working on both single and double guard straps.
 
Dec 03, 2021     Cable pulley guards - (2.1 hours) Category: Wings
Anti-corrosion the cabel guards.
 
Dec 02, 2021     Riveting cable guides - (2 hours) Category: Wings
Pop rivets to hold guides in place. Difficult placement to get them in place.
 
Dec 01, 2021     Pivot interconnect - (4.9 hours) Category: Fuselage
Finally figured out the interconnect/how to shorten/adjust. Aileron travels are good.
 
Nov 29, 2021     Remeasured the dihedral angles again. - (1.5 hours) Category: Inspection
Excellent results. 1.4 to 1.5 , and a few spots at 1.3 degrees.
 
Nov 27, 2021     A dog's breakfast - (2.4 hours) Category: Inspection
A little bit of everything. workshop, parts ordering, clevis pin replacements, etc.
 
Nov 26, 2021     Still playing with Ailerons' Travel - (6 hours)       Category: Wings
Made wooden wing travel gauges, taped up flaps, set neutral for ailerons using the flap settings.

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Nov 22, 2021     Aileron balancing - (1.5 hours) Category: Wings
 
Nov 21, 2021     Aileron Travel and Tie Rod Balancing - (5.5 hours)       Category: Wings
Finished running the aileron cables. Had to remove the left lower aft pulley to route the cable, as too close to the fuselage wall to pass. Worked with the control stick pivot brackets to balance left and right. Total travel required 22.5 degrees up, and 17.5 degrees down. Balanced. Clevis pins difficult to work with.

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Nov 20, 2021     Aileron cable guides - (4.2 hours)       Category: Wings

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Nov 19, 2021     Nico pressing flap cables - (5 hours)       Category: Fuselage
Swaged the sleeves. Flap system works smoothly.
Photo shows clamps pre-noco-press.

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Nov 18, 2021     Flap cable routing - (5.9 hours)       Category: Wings
Tracing out flap cables and correcting left wing flap primary retract cable routing.

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Nov 14, 2021     Flap cable attach tab - (2.2 hours) Category: Fuselage
Put in a new bench vise. Used to finish bending the fap cable attach points.
 
Nov 13, 2021     Corrosion Treatment flap cable attachment tabs - (1.6 hours) Category: Fuselage
Used Aluma and Alodine for the tabs
 
Nov 10, 2021     Flap cables - (1.7 hours) Category: Fuselage
Did the attachments to the control lever. #11 clevis
 
Nov 09, 2021     Corrosion treatment of flap attach tabs - (1 hour) Category: Fuselage
Back from California last night. Treated attach tabs
 
Nov 03, 2021     Cable Spaghetti - (2.2 hours) Category: Fuselage
Cleaned up the cable runs to minimize crossovers.
 
Nov 02, 2021     Flap Cables and Corrosion Treating - (4.2 hours) Category: Fuselage
Fun day.....spliced the flap primary cables to lever both sides. Al clean and alodined MS turn barrels. Also corrosion treated the flap slot brackets.
 
Nov 01, 2021     Flap deployment cables - (2.8 hours) Category: Fuselage
Routed the left and right flap deployment cables
 
Oct 30, 2021     Tail shearweb - (4.1 hours) Category: Fuselage
Trimmed the shear web to fit without so much flex going in. Guest visitors...Chris & Bob (FCM) and Stephanie & Tom.
Started flap cable installation.
 
Oct 29, 2021     Still working on left strut - (2.2 hours) Category: Wings
Removed left strut and cleaned/deburred all points. Reinstalled. Drilled drain hole in bulkhead C (ref page 101)
 
Oct 28, 2021     Struts Forever (!) - (6 hours) Category: Wings
Finished cutting strut to length. Obsessive measuring of dihedrals. NAS bolts, etc.
 
Oct 27, 2021     Strut work - (5 hours) Category: Wings
Trimmed left strut's aft corner. Set up Hulse jig for drilling again. Cut length to 961/2 inches.
 
Oct 26, 2021     Hulse Jig for Strut Drilling - (6 hours) Category: Wings
Hulse jig arrived. Also the struts came from Arizona/Ken. Also tools came (90 degree drill, 3/8th chuck, etc)
Worked on bolt holes and setup
 
Oct 25, 2021     Nothing Special - (2.1 hours) Category: Workshop
Waiting for parts (the new struts) and tools. Miscellaneous sorting and cleaning
 
Oct 23, 2021     Strut drilling - (2 hours) Category: Wings
Preparing for redrill of left strut. Measured in detail other strut and new strut.
 
Oct 22, 2021     Strut bolts - (2.4 hours) Category: Wings
NAS precision bolts came....replaced right outboard strut bolt from -32 to -30. Rechecked dihedrals.
 
Oct 21, 2021     Drain Holes - (1.2 hours) Category: Fuselage
Noted that already have drain access between bulkheads D, E. Inspection holes between D and C provide the same....no benefit to another hole per manual.
 
Oct 19, 2021     Levelling - (1.5 hours) Category: Fuselage
Smart Tool battery replace, working to sandbag the fuselage for level to waterline for next steps.
 
Oct 17, 2021     Aligning - (1 hour) Category: Fuselage
Working with Smart Tool...battery going dead.
 
Oct 14, 2021     Aileron Cable Guides - (1.6 hours) Category: Wings
Fabricated guides and installed.
 
Oct 12, 2021     Rudder cables - (3.7 hours)       Category: Tail Feathers
Removed horizontal stabilizer and elevator...moved to sawhorses.
Inspected cutout for attach pins. Will need to dress up the sheetmetal on one side, distressed by prior owners.
Inspected and labelled the cables to the rudder.

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Oct 11, 2021     Assembly Manual #1 - (1.9 hours) Category: Research
Reviewed Assembly Manual #1 page by page.
 
Oct 09, 2021     Cable guide fabrication - (3.5 hours)       Category: Wings
Found a source for the UHMW poly for the guides, cut/fabricated.

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Oct 08, 2021     Aileron & Flap position tweaking. - (4.2 hours)       Category: Wings
Tweaking and also spent way too much time to get the cotter pins into the cable attach tabs at the bellcranks. Taped them with blue tape to keep from sliding back under when completed.

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Oct 07, 2021     Skin trim for flap positioning clearance - (1.5 hours)       Category: Wings
Continued filing on top skin aileron slot

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Oct 05, 2021     Cable guides - (1.1 hours) Category: Wings
Searched for piece of UHMWP
 
Oct 04, 2021     Ailerons spacers & flaps - (2 hours) Category: Wings
Flap guides and parts inventory
 
Oct 02, 2021     Aileron Travel - (4.1 hours) Category: Wings
Measured total travel for left aileron at 38 degrees. Right aileron at 48 degrees. Reset right aileron to 36.5 degrees.
 
Oct 01, 2021     Aileron Pushrods - (1.8 hours) Category: Wings
Started on pushrods plus visited by Owen for 2 hours.
 
Sep 30, 2021     Pushrods - (1.5 hours) Category: Wings
Time a guess. Worked on the aileron pushrods and parts.
 
Sep 29, 2021     Parts - (2.1 hours) Category: Wings
Moving on. Searched for anti-servo option parts. Also pulled the parts for step 39 (aileron pushrod and cable attachments)
 
Sep 28, 2021     Aileron - (2.4 hours) Category: Wings
Right aileron is hung. Captured outboard hinge detail.
 
Sep 27, 2021     Aileron hardware - (2.5 hours) Category: Wings
Capturing the mounting hardware detail and sequence for the right aileron.
 
Sep 25, 2021     Aileron Worries - (5 hours) Category: Wings
Still concerned about close tolerances. Measuring/drawing/analyzing. Corresponded with Ted Setzer...his reply...."those gaps don't seem to be a huge concern to me."
 
Sep 24, 2021     Ailerons - (6 hours) Category: Wings
Concerned about closeness of dimensions.Spent significant time measuring, analyzing, etc.
 
Sep 23, 2021     Right Aileron - (1.5 hours) Category: Wings
Captured the dimensions of the right aileron. Also used a machine shop to (re) drill AN970-3 washers to 9/32nd.
 
Sep 22, 2021     Left outboard aileron hinge - (1.7 hours) Category: Wings
Worked on the left outboard aileron hinge. drew a diagram showing the dimensions an clearances.
 
Sep 21, 2021     Left Aileron - (0.7 hour) Category: Wings
Hung left Aileron easily.
 
Sep 20, 2021     Aileron mounting - (3.1 hours) Category: Wings
Worked on tailoring the mounting spacers for the left Aileron. Also worked a bit on the right Aileron.
 
Sep 18, 2021     Right aileron - (3 hours) Category: Landing Gear
Hung the right aileron. Will have to redo as the spacer turns out too long.
 
Sep 17, 2021     Ailerons - (3 hours)       Category: Wings
Unpacked Ailerons. Look great. These were part of the jump start wing option, completed in the Czech Republic. Mil-Spec quality, and beautiful work. Modified the 8 washers for mounting. Ace for a 9/32nd drill bit.

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Sep 16, 2021     Flaps - (4 hours) Category: Wings
Good progress. Both flaps and all tracks are now on/together. Key was remembering the flap attach brackets flex outward allowing rollers to fit.
 
Sep 15, 2021     Flaps to flap tracks - (4.1 hours) Category: Wings
Pulled out new parts, began step 36. FINALLY past the strut drilling, onto wing control attaching.
 
Sep 14, 2021     Wing strut completion - (5.5 hours) Category: Wings
A lot of time reviewing the drilling process. Captured in my personal builder's notebook the numbers for inboard and outboard strut holes and NAS bolts.
 
Sep 13, 2021     Left strut - (3 hours) Category: Wings
Drilled left wing strut. Hard part was the preparation, as lower inboard fitting fought me to be bolted.
 
Sep 12, 2021     Right strut drilling - (3 hours) Category: Wings
Time a guess, bit of a blur. Holse jig for drilling struts. Unfortunately jig moved...caught it but forgot to put the forward position pin back tight.

Also finished cutting left strut length.
 
Sep 11, 2021     Cutting right strut to length - (7 hours) Category: Wings
Per manual. Used 96 inches for initial cuts, then trimmed 1/8th by 1/8th, multiple cuts to 95 11/16th
 
Sep 10, 2021     Wing Attach Pins & Bolts - (2.7 hours) Category: Wings
Difficult to get the wing attach points to go in easily. Polished with fine grade sandpaper. Used a Teflon lube. Finally all lanolin (BEARD WAX from Walgreens) does the trick.
 
Sep 09, 2021     Stepping through the struts.... - (6.5 hours) Category: Wings
Reinforced wing bracing....spent a lot of time dialing in the lateral and longitudinal alignment.
Dihedral measuring.....left 1.6 - 1.5 and right 1.4-1.6 using digital scale.
Drilled both wings LOWER strut fitting holes.
Worked on the wing attach pins and bolts.....BEARD WAX is the secret weapon!
 
Sep 08, 2021     Right wing hung! - (3.5 hours) Category: Wings
Fabricated wing braces to hold wings up while mounting.
Got 2nd wing hung on fuselage.
Checked longitudinal and lateral positioning to get to waterline.
Inspected struts.....each is 99 and 1/8th inches long.
Compared roots' angle(s) of incidence
Set shims to remove any twist in wings.
 
Sep 07, 2021     Actually got left wing hung on fuselage. - (4 hours) Category: Wings
Finished cutouts for wing to roots and got left wing bolted onto fuselage
 
Sep 06, 2021     Trimmed fiberglass fuselage at wing roots - (3 hours)       Category: Wings
Trimmed fuselage by pivot anchors to mount the wings to the fuselage.

Positioned wings on cardboard moving boxes to slide onto and mount to fuselage.

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Sep 04, 2021     NAS bolts - (3 hours) Category: Wings
Reviewed close tolerance bolts and sources for wing struts. Ordered from vans.
 
Sep 03, 2021     Sorting and Prep - (4 hours) Category: Workshop
Sorted tools, cleaned workshop, prepped for Hulse wing strut drilling.
 
Sep 02, 2021     Reposition and Wing dihedral - (3 hours) Category: Wings
Repositioned two wing jig tables (signature guys helped). Checked wing root dihedrals. Finished reviewing Section VIII.
 
Sep 01, 2021     Top Skin removal - (2 hours) Category: Wings
Finished drilling out the top wing skins.
 
Aug 31, 2021     Drilled out top skins - (4.5 hours) Category: Wings
Fuselage now on belly, waterline neutral set.
Hung rudder

Drilling out the top skins from the jump start wings.
 
Aug 29, 2021     Removal/inspection of TD gear - (5.5 hours) Category: Landing Gear
Removed taildragger gear, bent bolts were difficult.
:( tool cart tipped over
 
Aug 28, 2021     Continuing waterline work - (3.5 hours) Category: Fuselage
Continued analysis of waterline, aligning to neutral.

Drilled brace holes at both doors to install waterline angle bracket.
 
Aug 27, 2021     Waterline! - (5 hours) Category: Fuselage
Aligning the fuselage and using digital level and also trying the old fashioned water-level.
 
Aug 26, 2021     High Crane - (3.5 hours) Category: Workshop
Shop inherited a 20 foot crane. Unfortunately found it would not clear the ceiling lights.
Engine hoist will have to do the trick. (Harbor Freight)
 
Aug 25, 2021     Removal of fiberglass panel and brackets - (3 hours) Category: Instrument Panel
Removed fiberglass panel I don't intend to use and associated brackets.
Pulled brake lines (plastic) which were installed. Planning to upgrade to metal lines.
 
Aug 24, 2021     Set up short term action plan - (5 hours) Category: Research
Short term: verify Waterline. Install rudder/HS/elevator and check travels. Remove TD gear. Hang wings & drill struts.
Reviewed prior owners' work to decide: prune (eg not TD but trike), panel I will not use, etc.
Ditto: repair (eg vertical fin spar hack. Missing drain holes.. Misdrilled gear (trike) sockets. etc.
Ditto: transition (Reinstall trike gear)
 
Aug 23, 2021     Struts - (2.3 hours) Category: Wings
Worked with the two struts, identical.
 
Aug 21, 2021     Repositioned fuselage on belly - (2.5 hours) Category: Wings
Moved fuselage off gear and onto belly on pads to install wings per Glasair manual recommendation.
Moved with engine hoist.
 
Aug 19, 2021     Prep to mount the wings to the fuselage - (3 hours) Category: Wings
Some inspection (hangar very hot) and prep reading for the next steps to mount wings.
 
Aug 18, 2021     Rudder cables - (3.2 hours) Category: Empennage
Inspected pulley group and installed various retention clevis and missing cotter pins.
 
Aug 17, 2021     New shop vac - (3.5 hours) Category: Workshop
Cleaned both wings and elevator with new shop vac.
Started rudder control cables installation
 
Aug 14, 2021     Control Yoke Assembly Removal - (3.5 hours) Category: Inspection
Removed and inspected control yoke assembly.
Reinstalled...very difficult.
 
Aug 14, 2021     Shearwebs and ANOR - (3 hours) Category: Inspection
Reviewed sections VIII and IX for ANORS applicability.
Detailed inspection of shearwebs as well as templates.
 
Aug 13, 2021     Dual Brakes - (2.5 hours) Category: Inspection
Section IV step 4, page 30. Inspection of pilot and copilot rudder and brake pedals.
Email ordered dual brake option from Glasaier. p/n 991-01000-01
 
Aug 12, 2021     Hang rudder - (3 hours) Category: Inspection
Vertical fin spar at bottom needs rework and anti-corrosion.
Rudder travel 25 degrees both sides OK.
Missing drain holes in bulkhead D and E
 
Aug 11, 2021     Removal of seat frames, seat pans, seats & Inspection - (4 hours) Category: Inspection
Removal basically identical to Sportsman twtt work. Then to ongoing inspection of prior work to step 40
 
Aug 09, 2021     Starting Volume II Assembly Manual - (2 hours) Category: Research
Continuing on with Jump Start Section reviews.
 
Aug 07, 2021     Aileron and Flaps - (2.5 hours) Category: Wings
Continuing on with review and inspection of work done by the jump start options. Section VII this time for aileron, flap assemblies, flap tracks.
 
Aug 06, 2021     Horizontal Stab/Elevator then onto Wings - (3.7 hours) Category: Wings
Backed up from page 90 onward. Then to wings section for review and inspection.
 
Aug 05, 2021     Volume I Jump Start Wings - (3 hours) Category: Wings
Reviewed and inspected Wings IAW Steps 1 to 26 (to page 100)
 
Aug 03, 2021     Section V Elevator Assembly - (2 hours) Category: Empennage
Reviewing jump start steps already completed Steps 60 to 92 of Section V
 
Aug 02, 2021     Review of Jump Start steps - (4 hours)       Category: Empennage
Section IV Horizontal Stabilizer Assembly, Volume I section pages 1 to 45
Section V Elevator Assembly, Volume I section pages 1 to 32

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Jul 31, 2021     Finished both wing jig tables - (3 hours)       Category: Workshop
Building two tables so I can work on both wings at the same time.

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Jul 23, 2021     Building wing jig tables - (3 hours) Category: Workshop
Finished one of the two tables I'm building
 
Jul 22, 2021     Building wing jig tables - (6 hours) Category: Workshop
 
Jul 21, 2021     Building wing tables - (4 hours) Category: Workshop
 
Jul 20, 2021     New Saw - (2 hours) Category: Tools
Selected Dewalt DW S713 and table.
 
Jul 17, 2021     Inspection of left gear trunion...misdrilled hole from prior owner - (1.2 hours)       Category: Landing Gear
Prior kit owner slipped on trike gear trunion drilling, creating oval not round pin.
Researched variousl methods to repair....both the Glasair site, as well as the Vans RV site

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Jul 15, 2021     Kit inventory update, physical to picking list comparison - (3 hours) Category: Research
 
Jul 14, 2021     Compiling ownership lineage documents - (2.0 hours) Category: Research
 
Jul 12, 2021     Jump Start Tail Inspection - (1 hour)       Category: Empennage
Czech Aircraft Works s.r.o. Rudder assembly. Detailed inspection.

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Jul 09, 2021     Menards & Home Depot - (1 hour) Category: Workshop
Shopping for materials for Wing Jig Table construction.....16 foot length the (delivery) dilemma.
 
Jul 05, 2021     Jump Start Wings Inspection - (2.5 hours)       Category: Wings
Jump start wings were done by the Czech Aircraft Works s.r.o. and QC inspected 28-5-2002. (Same company that makes MIG aircraft for Russia). Did my own detailed inspection of interior....beautiful work.

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Jul 03, 2021     Paperwork & Parts - (3 hours) Category: Workshop
 
Jul 02, 2021     Repositioning inventory - (2 hours) Category: Workshop
 
 


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