Feb 24, 2024     MAP thru firewall but also to Emags - (2.75 hours)       Category: Firewall

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

  Oct 21, 2022     Firesleeve and new tool - (1 hour)       Category: Firewall

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

  Oct 18, 2022     Torquing the Mount - (2.5 hours) Category: Firewall

Inspected the firewall and engine mount screws/bolts. Torque wrenched and cotter pinned the 5 engine bolts. Of course my small torque wrench goes to 150 inch-lbs, and my large torque wrench starts at 240 inch-lbs. What's the spec for the mount bolt? 175 inch-pounds of course. Sheesh. Spent a lot of time sorting out the process....move on to prepping the engine and hanging it next, or instead, completing earlier items 90% done, eg the fuel lines and boost pump to through the firewall. Not clear which road to take at the moment. Will likely pull the engine out of the box and start engine work.

  Oct 17, 2022     Engine Mount Installed & Tech Counselor Visit - (4.5 hours)       Category: Firewall

Reamed mount and firewall engine holes, fought with the top bolt (interference with the top mount bolt tab.) Then successfully sumo-ed the engine mount in place, assisted by judicious use of a clamp with the final/top bolt. N2184 is asking me "...does this new item make me look fat?" I've reassured her that it's necessary when one is expecting a new engine. :)

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

  Oct 15, 2022     Fully loaded but no fries - (6.7 hours)       Category: Firewall

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

  Oct 14, 2022     Real front end progress - (3.5 hours)       Category: Firewall

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

  Oct 13, 2022     Back on his "feet" again - (4.5 hours)       Category: Firewall

Reinstalled the nose gear, which is a real load off my mind. (Concerned the sawhorse might collapse or the fuselage shift and land on it's front edge.)

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

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

  Oct 12, 2022     Lipstick on the pig - (5.5 hours)       Category: Firewall

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

  Oct 11, 2022     Final riveting of Firewall perimeter into fuselage joggles. - (5.3 hours)       Category: Firewall

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

  Oct 10, 2022     Pass through fittings and RTV - (2.7 hours)       Category: Firewall

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

  Oct 08, 2022     Putting on the blanket - (4.1 hours)       Category: Firewall

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

  Oct 07, 2022     Progress - (5 hours) Category: Firewall

Backordered parts showing up. Was able to assemble the cabin heat valve assembly (penetrates firewall so easiest to do now). Then moved back to the firewall itself; drilled the COWLING joggles to the firewall flanges. Removed the firewall (again!) and deburred the stainless steel one more time. Put in the fire barrier RTV to the firewall flanges. Countersunk the OUTSIDE of the fuselage joggles for final firewall installation. Ran a sloppy bead of the fire barrier RTV on the external firewall/flange junction. I am really tired of this firewall. Only need to install the insulation blanket, the pass-through fittings, and then rivet the darn assembly into the fuselage for the last time. No photos...how many times can I look at that firewall.

  Oct 06, 2022     Final Riveting - (3.5 hours)       Category: Firewall

The stainless steel firewall is connected to the stainless steel flanges by...what else, stainless steel rivets. These are one tough son of a gun to set. Got after it today with the rivet gun, and did the final riveting of flanges to firewall. Reinstalled the unit into the fuselage...getting a bit more difficult but still doable. Next to add the blanket, fingers crossed it will all still fit in.

  Oct 05, 2022     Firewall Flange Nutplates - (3.2 hours)       Category: Firewall

Used the squeezer to install nutplates on the bottom flange. Reinstalled the firewall into fuselage, then the trimmed flanges and removed as one assembly to confirm I could still get it out. The deburred the aft side of the stainless steel firewall. Fun.

  Oct 04, 2022     Exit Air Ramp - (3.2 hours)       Category: Firewall

Having carefully cut the lower flange for the nose wheel leg, I now have to cut out the exit air slot for that same flange which included the nose wheel slot. Sheesh. My beautifully cut slot is now part of the scrap box. And then more drilling and nutplate tooling.

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

  Oct 03, 2022     Final trimming of firewall flanges Category: Firewall

Pulled the clecos and the flanges. Used my red Klenk offset snips to trim the stainless steel flanges back to the forward edge of the fuselage. Cut out the slot for the nose wheel leg from the lower flange.

  Oct 02, 2022     Flanges drilled to Firewall - (1.5 hours) Category: Firewall

Slipped into the hangar on Sunday afternoon after watching the Twin Cities Marathon. Wanted to get the last bit of drilling to firewall completed.

  Oct 01, 2022     A necklace of cleco's - (2.7 hours)       Category: Firewall

Reinstalled the firewall. Reinstalled and adjusted the 4 flanges with 1 inch overlaps. Drilled 3 of 4 flanges.
Used "popcicle stick" spacers. If you want to win a trivia contest, remember that a popcicle stick is exactly 1/16th inch thick. (Still have to install the thermal blanket, and want to be sure the firewall still goes in after its glued in place.)

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

  Sep 30, 2022     Natch?....no, NOTCH - (3 hours)       Category: Firewall

Anytime the factory sends me a finished part with a "notch" cut out, my guard is up. The last major firewall hole is for the boost pump fuel line penetration....and evidently Glasair found it hit the oil cooler frame. Hence they send out a part already having a "notch". Finally drilled the 9/16th hole, hit the notch bullseye!, and now onward to installing the flanges. Yes it took forever...I was as cautious as I could be..

  Sep 29, 2022     one step backward - (4 hours) Category: Firewall

Now back to firewall. Before firewall installation, necessary to double check the forward frame parts that get very difficult to access after firewall installation. Rechecked the rudder pedal installation, rechecked the brake system plumbing, rechecked the rudder cables. Now ready to proceed on firewall installation.

  Sep 28, 2022     I've been framed - (6 hours)       Category: Firewall

Completed the oil cooler frame which includes the transponder manifolds and the gascolator.
Installed the hood on the cooler, mounted to bracket, sealed the edges with high temp RTV, installed the gascolator on the riveted brackets. whew.

  Sep 27, 2022     Riveting and bolting - (5 hours)       Category: Firewall

Enough measuring and procrastinating. Installed nutplates, countersunk the rivets, and actually got the oil cooler bracket mounted. Moved on to installation of the oil cooler itself and hood.

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

  Sep 26, 2022     Inside/Outside - (4.7 hours) Category: Firewall

Have now drilled the firewall hole for the manifold pressure line, and also the control cables' pass through. Remaining firewall hole is the boost pump fuel line (inside) which must not hit the frame assembly for the oil cooler (outside). Seems simple enough but it's difficult to measure precisely the inside spot to the outside spot. Interestingly (incriminatingly) enough, the factory supplied oil cooler and manifolds mounting frame comes with a "notch" cut into the top of a rail, looking very "after the fact".

  Sep 25, 2022     Finally mounted the oil cooler bracket assembly - (5 hours)       Category: Firewall

After measuring/installing and removing the firewall multiple times, actually drilled and mounted the bracket assembly for the oil cooler and manifolds on the firewall. Progress. Confirmed the gas colator lines up with fuselage belly, and that the boost pump fuel line will hit the bracket assembly rail at the notch.

  Sep 24, 2022     Oil cooler frame and firewall - (3.4 hours) Category: Firewall

Drilled and deburred the 3rd firewall hole, for the cabin heat valve assembly. Then back to assessing the fit for the frame for the oil cooler, manifolds, and gas colator. Trying very hard to avoid customizing the oil cooler frame, but it's complex. How it fits the existing cage tabs (not movable without welding and refinishing), how the dimensions of the oil cooler frame line up (they don't), where the boost pump line exits the firewall relative to the oil cooler frame, and so on. Ah, the "joy" of fitting new accessory pieces for the current model (Sportsman 4-seater) into the kit for the past model (Glastar 2-seater) from 20 years ago. "Sorta" interchangeable, but sorta not.

  Sep 23, 2022     Finally cutting holes in the firewall - (3.4 hours) Category: Firewall

There are six holes for pass through's in the Firewall. Still working on "where" for some of the six, but was able to drill and debur the 2 pass through's for wiring.

  Sep 22, 2022     Shin bone connected to the knee bone.... - (4.4 hours)       Category: Firewall

Just like the old song, one thing is connected/leads to another. Mounting the boost pump on its base plate also reveals that the current plate is sized for the current Sportsman, not the Glastar. Now to determine dimensions to resize/cut the plate. Which then in turn promptly leads to a question about the forward tunnel closing panels' fit and sizing. Spent significant time measuring both the fitting dimensions from the cage tabs, the fitting dimensions of the motor mount, and the vertical and horizontal positioning of the boost pump.

  Sep 21, 2022     Prelim installation of boost pump on mounting plate - (2.2 hours) Category: Firewall

Need to determine where fuel line from boost pump passes through the firewall = start putting the boost pump assemblage together on its base plate. Of course that reveals the need for rubber mounting material not in the kit. One step forward and one step backward.

  Sep 15, 2022     More fitting tweaks - (2 hours)       Category: Firewall

Small tweaks on the firewall where the nose gear leg passes through. VERY slow progress...do not want to have to redo the stainless steel firewall for sure. Getting good at cutting only 1/64th with my shears and then deburring, sanding, and repeat. Finally 99% happy with the fit.

  Sep 14, 2022     Orcotex and firewall fitting - (4 hours) Category: Firewall

Firewall blanket finally arrived. Inspecting the firewall to fuselage gap requires additional trimming to get a uniform (or at least minimum) gap of 3/16th. Took the firewall out, trimmed, reinstalled....repeat about 6 times. Then do it again for the nose gear leg slot. Progress, but slow.

  Sep 12, 2022     Kaleidoscope of possibles - (4.5 hours) Category: Firewall

At the point where sequencing is complex and many directions possible. eg, Don't install the firewall until after you assemble the oil cooler and fuel manifolds. Be sure there's enough gap to allow for the firewall blanket to fit (orotek material still being shipped). Comments on builder forums about "...wish I'd put in the air vents before closing up the firewall". Consider doing the final inspection and witness marking of the front of the fuselage area before fitting the firewall, eg the rudder pedals, cables, brakes and brake lines. And on and on and on. Studied the various routes, and blocked out a sequence based on a combination of the original manuals, TWTT process books, builder forum suggestions, and so on. Hoping to NOT have to undo building steps for a forgotten action.

  Sep 09, 2022     Gymnastics and a Bespoke Suit - (3.3 hours)       Category: Firewall

Mounted the firewall without flanges, using the engine mount bolt holes.
Gymnastic moves required to solo drill out the ten cage attachment brackets (without an assistant to back the drill location outside with a wooden board.
Then able to deburr again the firewall new holes as well as the cage attachment brackets, and cleco clamp it all together for fitment. Feel like a tailor doing a bespoke suit!

  Sep 08, 2022     Finally installed for the first time - (3.2 hours)       Category: Firewall

Worked up the nerve to install the firewall and actually drill the engine mount bolt holes. Then bolted in place with 3/8th bolts/nuts from Ace Hardware's best. Progress!

  Sep 07, 2022     Flange completion - (3.5 hours)       Category: Firewall

New hand seamer arrived from Cleaveland Tool, so was able to finish the flanges with 90 degree bending.

  Sep 06, 2022     Leg hole - (4 hours) Category: Firewall

Took an inordinate amount of time trying to figure out the position of the nose gear leg hole in the lower firewall. Measure twice or ten times trying to only cut once. Stainless steel is difficult to trim off the excess. Got it done.

  Sep 05, 2022     Remove nose leg - (2 hours) Category: Firewall

Groan....process requires removal of nose leg gear to fit the firewall.
One step forward, two steps backwards.

  Sep 02, 2022     Cutting out Flanges - (5 hours)       Category: Firewall

Cut out flange notches and deburred.

  Sep 01, 2022     Marking - (3 hours)       Category: Firewall

Took a lot of time to mark the flange points for fabrication

  Aug 30, 2022     Cleaned, Marked and Cut Out - (3 hours)       Category: Firewall

Cleaned and washed the 42 X 32 sheet metal piece. Marked center lines all 4 edges. Traced template and cut out. Rough deburring, finish tomorrow. FINALLY back in the shop, after Airventure, another week with family near Boundary Waters, another week road trip through North Dakota to visit family, etc.