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

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

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

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

  Nov 17, 2022     Swagelok Gauge - (1.7 hours) Category: Fuel System

Still not very motivated. Went by the Swagelok distributor in Chaska and picked up a "go-no go" gauge.
Gauged all the fittings with Swagelok fittings.....sure enough, several required more tightening per the new gauge.

  Oct 31, 2022     Final fuselage fuel line fitting & Engine "unwrap" - (2 hours)       Category: Fuel System

Reseller came through with the missing Swagelok union tee and it arrived in today's mail. Drove home to get it, and upon return to hangar finally got the last of the lines completed. Yea! Then moved on to the new engine, and removed the top box...fun to unwrap this present of a new engine. Also included was the dipstick tube, various hardware bits, and the fuel system (Avstar fuel injection servo).

  Oct 29, 2022     Swagelok re-read and Inside Fuselage fuel lines - (2.7 hours)       Category: Fuel System

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

  Oct 28, 2022     Fuel LInes Redux - (5.2 hours)       Category: Fuel System

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

  Oct 26, 2022     Firewall to Gascolator - (3.8 hours)       Category: Fuel System

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

  Oct 25, 2022     Firewall to Gascolator - (5 hours) Category: Fuel System

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

Waiting for a new Swagelok valve to redo inside the fuselage line from T junction to on-off valve.

  Oct 24, 2022     Fuselage Plumbing - (4 hours) Category: Fuel System

Installed the fuel boost pump after trimming, deburring, alodining the mounting plate. Used 3 layers of red rubber gasket material under the plate to align the fuel line with the firewall hole. Pulled out the fuselage fuel line to the shut off valve which needs to be resized to connect with a link to the boost pump. Basically ran out of old swagelok parts to/of the shut-off valve. Found a new swagelok valve later on ebay ($12) and ordered. Also found another one on amazon ($30) and ordered that one as well to have parts redundancy.

  Oct 22, 2022     Boost Pump Plate and Position - (3 hours)       Category: Fuel System

The boost pump for the fuel-injected Lycoming sits aft of the firewall. The mounting plate is basically supplied for a Sportsman, and needs to be cut down/modified for the Glastar. Lots of trimming, deburring, sanding, etc. And the Glastar position needs it in line with the fuselage cage, not at a diagonal like the Sportsman. Made it work. Photo shows the pump loosely positioned on the plate...off and on again multiple times. But I will eventually have to customize the tunnel close-outs since the pump/filter position bumps out from the center frame. It is what it is for the Glastar, and not like the Sportsman (diagonal to avoid this).

  Jul 06, 2022     Fuel shut-off - (2.9 hours) Category: Fuel System

Ran the fuel line from the central Tee forward to the on-off valve.

  Jul 02, 2022     Kind of a Miscellaneous Day - (3.8 hours) Category: Fuel System

Spent time trying to salvage the swagelok fittings from the old fuel line for future usage. Nuts came off, but could not get the two ferrules per fitting to come off (at least so far). Then mixed a small batch of resin to "pot" the pitot drain blind rivet heads...will see how it turns out tomorrow. Then back to fuel line and worked on union tee fitting forward to on-off valve.

  Jul 01, 2022     Frustrating fuel line replacement - (4.1 hours)       Category: Fuel System

Finally got around to removing a prior builder's fuel line from the sump to central tee. Could not get it to miss the flap cables which were not in place when he originally ran the fuel line. Bending the new segment was really quite frustrating for no good reason. Only 11 inches, and finished by using the aluminum swagelok fittings sent to me by a fellow owner.

  Jun 26, 2022     Bending....not pretty - (2 hours) Category: Fuel System

Catalyzed a small 25 g batch of resin to pot the blind rivet heads on the pitot drain. Waited too long to pour it into the "forms" I made around each rivet head...will have to try again. Also played with various bend approaches on the fuel line piece to be replaced, but nothing final. Somewhat a frustrating day. BUT had a fellow Glastar owner call with Swagelok fittings! Sent him my address and he will send tomorrow. Hurray!!

  May 18, 2022     Completed aux pump wiring & ran wing coax - (2.5 hours)       Category: Fuel System

Completed aux pump wiring, with crimping butt connectors on the positive leads to the longer wires to route to the instrument panel.
Also cut 30 foot length of nylon conduit into two, and ran in each wing in accordance with the manual.

  Apr 29, 2022     Sump Drains and Removal of Aux tanks and channels. - (6 hours)       Category: Fuel System

Chose to locate and drill the initial sump drain holes (2 in each aux tank) in the bottom skins a different way than manual directs. Manual has a convoluted measuring scheme of skins, struts, and so on...then to do a lot of arithmetic. I simply pulled tanks, measured the drain boss locations, reinstalled the tanks in place, and marked the bottom wing skins. Then pulled tanks, drilled from inside the wing, and updrilled with a 3/4 inch hole saw. 3 of the 4 holes were perfect, the 4th was off somewhat. As the final drill and hole locations come after the riveting of top skins, no problem.

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

  Apr 28, 2022     Aux Fuel Tank Holes & Registration Submittal to FAA - (3 hours) Category: Fuel System

Pulled together all the documents to register the plane. As I'm the 5th builder on this kit, needed to locate/submit 5 Bills of Sale.
Then to hangar to actually drill the stem holes in the top skins. VERY pleased at results/margin using a 2 and 3/4 hole saw in the drill press.

  Apr 25, 2022     Aux Fuel Tank Filler Holes - (2.5 hours) Category: Fuel System

Measuring and marking top wing skins to drill holes for filler stem/cap. Measured multiple times and multiple ways, as cost of mistake very high (can't imagine trying to replicate the predrilled top skins which match the holes in the wing spars. The Aux tank caps are the flush design, which basically requires a 3 inch hole, which is tough to drill with only a hand drill. Measure, measure, measure.

  Apr 15, 2022     Aux Tank Filler Holes - (4.1 hours)       Category: Fuel System

Read ahead in the assembly manual. Laid out precisely the location in the top wing skin for the filler neck holes.
Drilled #30 pilot holes. Stopped, as not certain at the moment how to cut in the larger 3 inch holes needed for the flush caps. Don't have a drill press.

  Apr 13, 2022     Aux Tank Fuel Lines & Fuel Filler top skin. - (3.8 hours)       Category: Fuel System

Completed fuel lines to/from Aux tank fuel pumps.
Started layout of top skin to drill filler stem holes.
Ordered LED landing/light kit from Glasair, and also the wing fold hardware.

  Apr 12, 2022     Installed Aux Pumps and fabricated lines - (4.9 hours) Category: Fuel System

Good day for progress. Fabricated the short fuel lines from aux fuel pump output to main tank input, and then installed the actual fuel pumps. Cut the lines for aux fuel pump input to aux tanks' outflow, determined how to bend and fabricate these long 82 inch lines. Inadvertently left wallet and phone home...no pictures until tomorrow. :)

  Apr 11, 2022     Wasted Day - (3.6 hours) Category: Fuel System

Fuel lines next. Manual refers the builder to the "technique section" to review tubing and fuel lines.....which states all fittings from Glasair are Swagelok. So ok, I then spent the next several hours looking for Swagelok hardware in my shelves/boxes...no joy. Only to get an email from Glasair...NO...they discontinued sending Swagelok hardware as the vendor wanted a mill-run of quantity to keep supplying such compression hardware, and they opted out and returned to AN hardware. Sheesh. At least I have a tube cutter, flaring tool, and a tube bender. Also watched EAA "Hint for Homebuilders" #615 several times, a really excellent resource, on the finer points of using the flare tool. And revisited manual AC43.13 for torque values for those AN fuel lines. (110 in-lbs)

  Apr 10, 2022     Aux Tank Fittings & Fuel LInes - (2.6 hours)       Category: Fuel System

Each aux tank requires 3 fittings at this point, one of which is a "finger screen". Installed using Sealube, and then did minor Dremel surgery on ribs where there was fitting interference.
AND...then pulled together the raw 3/8th lines to begin installing fuel lines tomorrow. Progress!

  Apr 08, 2022     Aux Tank Installation - (2.5 hours)       Category: Fuel System

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

  Apr 07, 2022     Wrong Fuel Level Senders Category: Fuel System

Glasair published a cross-reference from Glastar to Sportsman. Revealed that the fuel sender is different (4 hole square pattern) for the Glastar vs the Sportsman ( 5 hole circular pattern). Emailed Glasair to check on stock. I have (in error) 4 of the circular, and need 2 of each pattern.

  Apr 07, 2022     Anti-Chafe Taping - (3.6 hours) Category: Fuel System

Aux tanks "float" in the wing tip, and need to add neoprene "bumpers" on the tank corners as well as anti-friction tape on the hat sections upper and lower. Cut and installed the tape.

  Apr 06, 2022     Corrosion Proofing Aux Tank Channels - (2.7 hours)       Category: Fuel System

Corrosion proofed the channels. Hardest part was to find "trays" to dip the channels which are 29 inches X 3 5/8th inches. Wallpaper Prep Trays turned out to be perfect at Ace Hardware.

  Apr 05, 2022     Drilled and clecoed the aux tank channels - (3.1 hours)       Category: Fuel System

Clecoed the upper hat sections in place and then drilled and clecoed the forward and aft aux fuel tank channels in place.

  Apr 04, 2022     Aux Tanks front mounting channel - (2.5 hours) Category: Fuel System

Drilled out the wing tip rib cherry rivets and removed the ribs on left and right wings.
Measured and marked the forward mounting channel for the aux tanks on both wings.

  Apr 03, 2022     Main tanks' vent fitttings - (2.1 hours) Category: Fuel System

Cut 1/4 inch nylon vent lines and fit the nylon connectors to main tanks.

  Apr 01, 2022     Finally riveting in the doublers - (1.5 hours)       Category: Fuel System

Friend and fellow builder (he's building a Sportsman 2+2 at Flying Cloud) Owen Schott stopped by to buck a few rivets. Finally got the aux tank fuel pump doublers actually riveted in place. Having Owen around helped move the wings vertical and position them for riveting.

  Mar 26, 2022     Anti corrosion treatment - (1.1 hours)       Category: Fuel System

Two part anti-corrosion treatment. Left to dry. Turns the aluminum "gold".
Photos show before and after.

  Mar 25, 2022     Miscellaneous Category: Fuel System

Checked plate fittings, added a 17th rivet to offset one rivet that ended up being too close to the edge.

  Mar 24, 2022     Completed Doubler plate fitting - (1.9 hours) Category: Fuel System

Prepping the doubler plates. Trim, deburr, drill, etc

  Mar 23, 2022     Transfer Pump Mounting Doubler - (2.7 hours)       Category: Fuel System

The Glastar uses a transfer pump to move fuel from the aux tanks to the mains. This requires a doubler plate on the wing bottom skin each side, and that in turn requires drilling out several rivets on the hat sections. Flipped over each wing on their respective tables, and drilled out the rivets. Right and left wing shown.

  Mar 22, 2022     Aux Fuel Tanks' Easter Egg Hunt (looking for parts!) - (2.9 hours)       Category: Fuel System

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

  Mar 21, 2022     Final top wing skin filler hole - (2.5 hours)       Category: Fuel System

Finished left wing filler hole. Used a 2 inch circular drill....and then a Dremel to enlarge for 1/16th gap around the filler neck.

  Mar 19, 2022     Filler Hole in Upper Inboard Wing Skin - (3.5 hours) Category: Fuel System

Final trim and expansion of hole in upper inboard wing skin. Used a 2 inch hole cutter knowing it requires 2.25 inches plus 1/16th margin all around....allowed precise locating by sanding with a Dremel since the tank filler hole location varies by tank. Completed the Right side wing, and did the measuring/marking to work on Left side wing next.

  Mar 18, 2022     Filler Neck holes for Main Tanks - (4 hours)       Category: Fuel System

Returned from 3 week LSRMA course in Missouri...now Repairman for Light Sport Aircraft.
Measured upper wing skins to locate the holes for filler necks to main fuel tanks. Then cut in undersize at 2 inch diameters to facilitate final filing to precisely locate and allow a 1/16th margin.

  Feb 10, 2022     Main Tanks - (3 hours)       Category: Fuel System

Drilled out the temporary pull-rivets from the end rib at the root. Removed the root rib.
Test fit the main left tank, and prepare to add ant-chafe tape tomorrow. Need to find someone to help me lift the right wing back onto it's table jig, as I'd had it off the table to put on fuselage landing gear.