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 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 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.

  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.

  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.

  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.

  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.

  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.

  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.

  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.

  Dec 31, 2021     Shrink wrapping nico pressed ends - (2 hours) Category: Controls

Heated/shrank the heat wraps. Rechecked tie rod interconnect clevis.

  Dec 22, 2021     rudder cables reset to neutral - (1 hour) Category: Controls

  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".

  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.