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

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.


 
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.
 
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.
 
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.


 
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.


 
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.).
 
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.


 
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.


 
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.


 
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!


 
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.


 
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.


 
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.


 
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.


 
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.


 
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.)


 
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.


 
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.


 
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.


 
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 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.


 
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!


 
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


 
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.


 
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.


 
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).


 
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.


 
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.


 
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.


 
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.


 
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.


 
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.


 
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.


 
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.


 
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.


 
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.


 
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.


 
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.


 
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.


 
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.


 
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.


 
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.


 
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.


 
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.


 
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.


 
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.


 
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 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.


 
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. :)


 
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.


 
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.


 
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.


 
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.



 
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.


 
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.


 
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.


 
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.


 
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.


 
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.
Productive day.


 
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.


 
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.


 
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.


 
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.


 
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.


 
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.


 
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.


 
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. :)


 
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.


 
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).


 
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.


 
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.


 
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.


 
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.


 
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.


 
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.


 
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.


 
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.


 
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.


 
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.


 
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.


 
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.


 
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.


 
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!


 
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.


 
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


 
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.


 
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.
 
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.


 
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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