Jun 11, 2022     CoPilot Rudder Pedals. Also pitot mast assemblage - (3.3 hours) Category: Landing Gear

Used a T-handle reamer to fit the bushings into the copilot rudder pedals. Figured out how to put a spring on each peddle to avoid the pedals from "flopping over/jamming". Now to buy a couple of springs.
Riveted two of the pitot mast brackets onto the mast. Could NOT get to the other two brackets with either the squeezer, or even using rivet gun due to lack of thin bucking bar....finally ordered a thin-nose-profile pneumatic squeezer yoke from Cleaveland. The pitot mast will not be pretty, but it will be functional.

  Jun 07, 2022     Replumbed brake lines - (5.5 hours) Category: Landing Gear

Replaced all brass fittings from brake reservour to master cylinders, and from masters to junction under seat with steel lines running to calipers at wheels.

  Jun 04, 2022     Brake LInes - (2.5 hours) Category: Landing Gear

Not happy with the mix of Nylaflow and Nylo-Seal fittings inherited on this kit. Decided to remove all the master cylinder brake lines, order new fittings, and redo next week. Placed yet again another order with Aircraft Spruce & Specialty. In particular it is not clear whether compression ferrules are needed for 3/16th brake lines for all or just some, so will put in for all with the new compression tee and elbows.

  Jun 01, 2022     Jacking Collars (and FAA Documents) - (3.8 hours)       Category: Landing Gear

Minimal progress day...spent too much time looking for the correct NylaFlow fittings to complete the installation of the steel brake cable upgrade. Gave up and ordered additional parts. ACS must love me.
Then installed on each main gear leg "jacking collars" which are 2 piece clamping collars (McMaster Carr p/n 8A100). These give a jacking lift a surface/edge to lift up one side without risking the gear slipping off the lift.
Then completed the final (?) resubmittal of the Registration application to the FAA and mailed it off guaranteed delivery 6/3/22.

  May 27, 2022     Master Cylinders to Reservoir - (3 hours) Category: Landing Gear

Ran the brake lines from the master cylinders to the brake fluid reservoir. Silicon on steel brake lines through the fuselage wall.
Inventoried the heated static/pitot option kit for installation.

  May 26, 2022     Steel Brake Line Upgrade Option - (6 hours)       Category: Landing Gear

Installed steel brake line option. Disassembled current brake caliper and nylon lines assemblage, and replaced fittings. Drilled holes in fuselage next to tricycle gear legs (9/16th), and ran the steel lines into the fuselage. (Capped the holes previously drilled for the brake lines in the Taildragger configuration). Zip tied the new lines to the legs.

  May 23, 2022     Dual brake option - (1.9 hours) Category: Landing Gear

Reviewed again whether to order the dual brake option, which prior builders of this kit had not selected. Upon detailed review (steps and cost to do so), made final decision to NOT do so. Then located the copilot rudder pedals, and finally ordered AN3-35 drilled shank bolts to mount them.

  Feb 09, 2022     New Shoes and Baby Steps - (5 hours)       Category: Landing Gear

Completed the nose gear installation, aired all tires to 40 lbs, lifted the airplane, and "landed" on the tricycle gear!!
Remembered that it's now tail heavy....still had three 50 lb sandbags that I used to have for working on my Sportsman, and leveled the landing. :)

Also began work on the fuselage fuel system.

  Feb 08, 2022     Brakes...Pulling together parts - (1.5 hours) Category: Landing Gear

Two sets of brakes, one on old trike legs, one that was on the oem kit tailwheel. Moving the tailwheel setup to the trike.

  Feb 07, 2022     Tailwheel Review - (2 hours) Category: Landing Gear

Prior owner/builders had on tailwheel gear. Reviewed the construction pages for the TD gear.

  Feb 05, 2022     Brakes onto legs - (4 hours)       Category: Landing Gear

Worked with the brakes and reinstalling on the legs.

  Feb 04, 2022     Main Tricycle Gear Installed - (6 hours)       Category: Landing Gear

Final installation of main gear legs, followed by tires and brakes. Began the nose wheel installation, checking the fuselage cutout for the nose leg.

  Feb 03, 2022     Gear leg toe-in adjustment completion - (2.2 hours)       Category: Landing Gear

Gear set #1: Tailwheel legs (forward cage gear sockets) ok as received from prior builder(s)...toe-out.

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

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

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

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

  Feb 02, 2022     Redrilling aft left socket - (5.7 hours) Category: Landing Gear

Started redrilling left gear...both left cage socket, and left gear leg. Clamped with toe-in between .032 and .064 shim.

New #10 drill bit went through like butter. BUT struggled with a 9/32nd....big step up for hard steel, and got dull. finally quit when realizing I'd need another drill bit. Back to Grainger tomorrow morning.

  Jan 31, 2022     Legs and Left wing issue - (3.9 hours)       Category: Landing Gear

Left wing pulley guard interfered with the cable itself, noticed after wing removal. Took apart (cotter pin out, etc) and repositioned at 45 degrees to avoid interference. Also again inspected toe-angles with .032 and .064 shims.

  Jan 28, 2022     Gear and Socket Measurements - (4.1 hours) Category: Landing Gear

Spent time re-measuring all aspects of the gear and sockets, trying to decide course of action to correct aft left gear/socket issue.

  Jan 27, 2022     Landing gear legs and sockets. Photos of current state. - (3 hours)       Category: Landing Gear

Capturing the data and a bit of QC. All sockets good except Left aft/trike. Did notice prior owners had upsized all holes to 3/8th form the 5/16th. This is ok/tight.

  Jan 26, 2022     Toe-In and Toe-Out at Minus 14 degrees F - (6 hours)       Category: Landing Gear

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

  Jan 25, 2022     Disassembly of Two Gear Sets - (2.8 hours)       Category: Landing Gear

Took each set of gear apart; one set Tailwheel, and one set Trike. Captured the (previously) drilled cage socket angles.

  Dec 31, 2021     Trimming top skin for flap position clearance - (4.2 hours)       Category: Landing Gear

Trimming top skin/doubler to provide a bit more clearance for flaps to retract fully. Also working on cable guides.

  Sep 18, 2021     Right aileron - (3 hours) Category: Landing Gear

Hung the right aileron. Will have to redo as the spacer turns out too long.

  Aug 29, 2021     Removal/inspection of TD gear - (5.5 hours) Category: Landing Gear

Removed taildragger gear, bent bolts were difficult.
:( tool cart tipped over

  Jul 17, 2021     Inspection of left gear trunion...misdrilled hole from prior owner - (1.2 hours)       Category: Landing Gear

Prior kit owner slipped on trike gear trunion drilling, creating oval not round pin.
Researched variousl methods to repair....both the Glasair site, as well as the Vans RV site