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Project: Sears701 -
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Categories

Show All Entries - (257)
Research
Workshop - (1)
Tools
Rudder - (12)
Horizontal Tail - (27)
Fuselage - (60)
Firewall - (1)
Wings - (78)
Controls - (17)
Avionics - (36)
Lighting
Instrument Panel - (2)
Landing Gear - (7)
Engine - (7)
Propeller - (1)
Fuel System - (4)
Interior Finish
Paint / Decals - (3)
Inspection - (1)


Builder Name:	Richard Sears -

Project:	Zenith - CH 701 - VIEW REPORTS
Total Hours:	1372
Total Flight Time:
Start/Last Date:	Aug 01, 2021 - No Finish Date

Friendly URL:	https://eaabuilderslog.org?s=Sears701

Home or Last Project Picture

Feb 18, 2024 Test fit cowl; EAA counselor inspection - (3 hours)

Category: Inspection

Put together kit for bleeding brakes; test fit cowling; looked over cylinder differential compression tester; went over aircraft with Dave Gallagher, EAA technical counselor.

1testingCowlFit.jpg

2assemblingBrakeBleederCoupler.jpg

3assemblingBrakeBleeder.jpg

4lookingOverDiffCylCompressionTester.jpg

5preppingPlaneForEAAcounselor1.jpg

6preppingPlaneForEAAcounselor2.jpg

7preppingPlaneForEAAcounselor3.jpg

8preppingPlaneForEAAcounselor4.jpg

9preppingPlaneForEAAcounselor5.jpg

Feb 15, 2024 Mech Synching Carb Cables, Organizing Wiring - (8 hours)

Category: Engine

More G3X configuration; wire organizing and shielding; attached throttle cables and mechanically synchronized carbs; installed throttle idle stop; tightened regulator/rectifier wires; tightened exhaust nuts.

10securingFuelReturnLine.jpg

11tighteningExhaustNuts.jpg

12organizingEngineWiring.jpg

13shieldingCoolantTempWires.jpg

14installedThrottleIdleStop.jpg

15tighteningAvionicsConnectors.jpg

16securingPilotSideWires.jpg

17securingAvionicsWires.jpg

18configuringGEAdiscreteInputs.jpg

19shieldingEngineWires.jpg

1enteringVspeedsInG3X.jpg

2moreG3Xconfigurations.jpg

3securedRegRecWires.jpg

4organizingAvionicsWires.jpg

5attachingThrottleCables.jpg

6securingThrottleCables.jpg

7mechanicallySynchingThrottleCables.jpg

8securingThrottleCableWires.jpg

9attachingThrottleControlCables.jpg

Feb 13, 2024 Wiring and Configuring Engine Sensors - (7 hours)

Category: Avionics

Worked on engine wiring; placed markings on analog airspeed indicator and reinstalled; attached final throttle cable and organized engine wiring; assembled GEA connectors for engine instruments; configured instruments on G3X; troubleshooting fuel pressure connection; configured airspeed and other things on G3X.

10runningEGTsensorWires.jpg

11organizingEngineWiring.jpg

12attachingWiresToGEAconnector.jpg

13wiresAttachedToGEAconnector.jpg

14checkingG3XforCoolantTempSensors.jpg

15connectingEngineSensorsToGEAconnector.jpg

16connectedWiresToGEAengineSensorConnector.jpg

17calibratingEngineSensors.jpg

18calibratingAirspeeds.jpg

1heatShrinkOnOilPressureSenderWiring.jpg

2wrappingEngineWiring.jpg

3tightenedGroundBlockBolts.jpg

4attachingEGTprobeWires.jpg

5applyingAirspeedMarkings.jpg

6reinstalledAirspeedIndicator.jpg

7drillingOutThrottleCableHolder.jpg

8installingLeftThrottleCable.jpg

9installingThrottleCableToCarb.jpg

Feb 08, 2024 Throttle and choke cables - (6.5 hours)

Category: Engine

Planned, measured, cut, and installed throttle cable housings and cables; cushioned coolant hose; installed air intake filters; worked on wiring; installed choke cables and safety wired; swaged choke cable connections; soldered resistor and wires for oil pressure sensor.

10organizingEngineWires.jpg

11puttingHeatShieldOnOilPressureSensorWire.jpg

12drillingOutChokeCableHolder.jpg

13installedChokeCables.jpg

14safetyWiredChokeCables.jpg

15safetyWiredChokeCables.jpg

16swaged&HeatShrinkChokeCables.jpg

17resistorForOilPressureSender.jpg

18solderedWiresForOilPressureSender.jpg

1removingOldThrottleBrackets.jpg

2drillingOutCableHolder.jpg

3drillingOutThrottleCableHolder.jpg

4cuttingThrottleCableToSize.jpg

5installedRthrottleCable.jpg

6cuttingThrottleCableToSize.jpg

7installingLthrottleCable.jpg

8installedCushionForOilHose.jpg

9installedAirIntakeFilters.jpg

Feb 04, 2024 Installing EGT Probes, Muffler, & Cabin Heat Scat - (5 hours)

Category: Engine

Drilled holes in cylinder 3 and 4 exhaust pipes and installed EGT probes and safety wired; drained oil and attached bottom oil hose and torqued banjo bolt; attached cabin heat shroud to muffler and safety wired; safety wired engine plugs at 3 locations; attached muffler and springs; cut cabin heat scat tubing and installed.

12safetyWiredOilBanjoBolt.jpg

13appliedAntiseizeToMuffler.jpg

14assembledLsideMuffler.jpg

15assembledRsideMuffler.jpg

16cuttingCabinHeatScatTubing.jpg

17installedCabinHeatScatTubing.jpg

1drainingOilFromBanjoFitting.jpg

2drillingHolesForEGTprobes.jpg

3cleaningLabelsOffExhaust.jpg

4textFittingExhaustHeatShroud.jpg

5installedBottomOilHose.jpg

6torquedBottomOilHose.jpg

7installedHeatShroud&SafetyWired.jpg

8installedEGTprobes&SafetyWired.jpg

9reinstalledPassWarning.jpg

Feb 01, 2024 P-leads, pitot static connections, RPM wires - (5 hours)

Category: Avionics

Installed P-leads, replaced fuel hose from shutoff valve to fuel filter with proper size; connected power wire to fuel pump; created and installed RPM wires with diodes and resistor; installed pitot and static connections and tubing for analog airspeed indicator and altimeter; replaced comm radio BNC with 90 degree connector and tested continuity; replaced nylon fuel hose connectors with brass; worked on organizing hoses and wires behind pilot seat; looked over exhaust system.

10attachingPitotStaticConnectors&Tubing.jpg

11reinstalling90degCoaxConnectors.jpg

12testingCoaxConnectors.jpg

13reinstalled90degCommConnector.jpg

14replacedPlasticFuelConnectorWbrass.jpg

15organizingWiresBehindPilot.jpg

16lookingOverExhaust.jpg

17testFittingExhaust&EGTsensor.jpg

1installingPLeads&ShieldGrounds.jpg

2connectedPLeadsToStarter&GroundedShield.jpg

3cuttingFuelHoses.jpg

4installingFuelHoseToFilter.jpg

5labelingFuelPumpWire.jpg

6creating&solderingRPMwires.jpg

7crimpingRPMwires.jpg

8connectingRPMwires.jpg

9preparingPitotConnectors.jpg

Jan 31, 2024 Engine monitoring wires - (6.5 hours)

Category: Avionics

Lubricated throttle and choke cables; crimped pins onto fuel and manifold pressure wires; soldered EGT probes to thermocouple wires and crimped on connectors; planned fuel pressure gauge connections; finished installing fuel and manifold pressure sensors; labeled EGT wires and crimped pins; cut oil sensor wires to size; created P-leads.

1lubricatedThrottle&chokeCables.jpg

2crimpedPinsOnFuel&ManifoldPressureWires.jpg

3stripped&crimpedThermocoupleWiresForEGT.jpg

4created&installedFuelReturnLine&FuelPressureSensor.jpg

5labelingEngineSensorWires.jpg

6pluggedInOilPressureSensor.jpg

7cuttingOilPressureSensorWires.jpg

8preparingToInstallPLeads.jpg

9created&crimpedPleads.jpg

Jan 25, 2024 N numbers, fuel and manifold pressure wiring - (6 hours)

Category: Avionics

Applied N numbers to tail; finished installing compass, altimeter, and airspeed indicator, including wiring light for compass; soldered wiring for fuel pressure and manifold pressure gauges.

10solderingFuelPressureGauge.jpg

11solderedManifoldPressureGaugeWires.jpg

12strippingOtherEndsOfEngineWires.jpg

1attachingNnumbers.jpg

2rightSideNnumbers.jpg

4groundingEngineSensors.jpg

5cleaningCabin.jpg

6replacedPassWarning&CompassCard.jpg

7wiringCompassLight.jpg

8installingCompassLight.jpg

3installedSteamGauges.jpg

9testingCompassLight.jpg

Jan 24, 2024 Oil lines, fuel pump, pitot static instrument cutouts - (7 hours)

Category: Engine

Test fit prop; cut oil return line and installed fitting; turned oil banjo bolt; torqued a couple of oil line fittings; cushioned oil line; started adding oil to oil cooler; worked on installing fuel pump; worked on manifold pressure gauge; looking over and cutting out instrument panel for compass, airspeed indicator, and altimeter.

10removingOldFuelHose.jpg

11creatingFuelConnetionForFuelPump.jpg

12attachedNewHose&LabeledFuelShutoff.jpg

13assemblingFuelPump&Filter.jpg

14firesleeveOnFirewallPassThru.jpg

15madeWaterTrapForManifoldPressGauge.jpg

16workingOnGauges.jpg

18lookingOverPitotStaticInstruments.jpg

19cuttingInstrumentHoles.jpg

1preparingPropBolts.jpg

20cutoutForAltimeterKnob.jpg

2lightlyMountedProp.jpg

3lookingOverCowl.jpg

4makingOilHose.jpg

5movedOilBanjoFitting.jpg

6attachedHosesToOilTank.jpg

7attachedHoseToOilPump.jpg

8addingSomeOilToOilCooler.jpg

9cushioningOilHose.jpg

17placingManifoldPressGauge.jpg

Jan 17, 2024 Fuel pump, water hoses - (7.5 hours)

Category: Fuel System

Trial placement of fuel pump; measuring and crimping and placing oil temp sensor; drilled hole for fuel line and fuel return line in firewall; planning backup pitot and static instruments; secured starter cable to starter; installed electric fuel pump, wiring, switch, and labels; installed both radiator hoses.

10lookingOverExhaustSystem.jpg

11installed&labeledElecFuelPumpSwitch.jpg

12drilledHoles&InstalledFuelPump.jpg

13cuttingFuelHoseForFuelPump.jpg

14assemblingFuelBulkheadFitting.jpg

15connectorForFuelPump.jpg

16preparingFUelPUmpHose.jpg

17testingFuelPumpWiring.jpg

18fuelLinesThruFirewall.jpg

19runningUpperRadiatorHose.jpg

1planningFuelPumpPlacement.jpg

20securingUpperRadHose.jpg

21rearOfUpperRadHose.jpg

22connectedBottomRadHose.jpg

2labeled&CrimpedOilTempWire.jpg

3installedOilTempWires.jpg

4measured&cutFuelHose.jpg

5drillingHolesForFuelHose&FuelReturnHose.jpg

6measuringForFuelPressureSensor.jpg

7measuringForManifoldPressureSensor.jpg

8attachingStarterCable&Boot.jpg

9planningPitotStaticInstruments.jpg

Jan 05, 2024 Coolant and oil hoses - (8 hours)

Category: Engine

Attached easy start cable and starter wire and diode to starter relay; looked over hose connections; moved coolant connection; cut one of the coolant hoses; measured, cut, and attached oil cooler fittings (except bottom of engine banjo bolt); attached cotter pin on throttle control lever; looked over engine monitor connections; cut long coolant hose to size; looked over pressure sensors; cut coolant sensor wires to size; fitting coolant overflow bottle; added washers to engine mount bolts and retorqued and cotter pinned; attached coolant overflow hose; crimping and placing coolant sensors; looking over fuel pump parts.

10gluedHoseToCoolantOverflowBottleTop.jpg

11measuringLengthOfCoolantHose.jpg

12measuring&cuttingCoolantTempWire.jpg

13labeledCoolantTempWire.jpg

15retorquedEngineBoltsWextraWashers.jpg

16cotterPinsOnEngineBolts.jpg

17attachingCoolantOverflowHose.jpg

18installedCoolantOverflowBottle.jpg

19createdSecondCoolantTempWires.jpg

1lookingOverFuelSystem.jpg

20installedRearCoolantTempWires.jpg

21preparingFuelPump.jpg

22assembledFuelFilterToPump.jpg

2connectingDiode&EasyStartToStarterRelay.jpg

3planningOilHoses.jpg

4changedWaterPumpAngle.jpg

5measuringWaterRadiatorHose.jpg

6cuttingWaterRadiatorHose.jpg

7installingFittingsOnOilHoses.jpg

8oilTankHose.jpg

9cotterPinOnThrottleControl.jpg

14crimpingCoolantTempWires.jpg

Dec 31, 2023 Mounted engine, radiator, oil cooler - (6.5 hours)

Category: Engine

Moved angle of water pump and reattached hoses; mounted engine to airframe engine mount and torqued; mounted radiator and oil cooler; looked over engine sensors, labeled oil pressure wire; made and installed starter cable and engine ground cable.

10testingTachometerFitting.jpg

11labeledOilPressureWire.jpg

12creatingStarterCable.jpg

13workingOnStarterRelay.jpg

14solderedStarterCable&Ground.jpg

15attachedStarterCable&EngineGround.jpg

1attachingEngineToAircraftEngineMount.jpg

2torquingEngineMountBolts.jpg

3removedHoistStrap.jpg

4installingRubberMountsOnRadiator.jpg

5mountedRadiator.jpg

6attachingFittingsToOilCooler.jpg

7attachedFittingsToOilTank.jpg

8attachedFittingsToOilCooler.jpg

9testFittingOilPressureSender.jpg

Dec 27, 2023 Attaching Ring Mount to Engine - (5 hours)

Category: Engine

Opened up Rotax box; disassembled electrical connections to make room for ring mount; filed radiator mounts; hoisted engine out of box; removed water pump; installed ring gear; added Loctite to bolts and torqued; replaced water pump and torqued bolts with Loctite.

10reassemblingWaterPump.jpg

1openedUpRotaxEngine.jpg

2disassemblingElecConnectionsForRingGear.jpg

3preparingParts&RadiatorMount.jpg

4hoistingEngine.jpg

5removedWaterPump.jpg

6attachingRingGear.jpg

7attachingRingGearBolts.jpg

8torquingRingGearBolts.jpg

9reattachingElectrical.jpg

Dec 22, 2023 Assembled prop, riveted tail fairings - (6 hours)

Category: Propeller

Assembled, set pitch to 3, and torqued propeller blades; checked elevator cable travel in tail and filed more clearance; riveted horizontal tail fairings; reset engine time on G3X to zero; looked over cowling; installed engine mount bolts and shock mounts; test fit engine ring mount; safety wired oil tank drain and nosewheel bolts; enlarged holes in throttle cable bolt; secured throttle cables on passenger and pilot sides; documented which wires connect where on ground block.

10lookingOverCowling.jpeg

11installingEngineMountBolts&ShockMounts.jpeg

12testFittingEngineRingMount.jpeg

13safetyWiredOilTankDrainPlug.jpeg

14safetyWiredNosewheel.jpeg

15enlargedHolesForThottleCables.jpeg

16securedPassThrottleCable.jpeg

17securedPilotThrottleCable.jpeg

18lookingOverGroundBlock.jpeg

19documentingGroundBlock.jpeg

1lookingOverProp.jpeg

2checkingElevCableClearance.jpeg

3filingClearanceForElevCable.jpeg

4securingElevTrimCable.jpeg

5clecoingHorizTailFairing.jpeg

6rivetingTailFairing.jpeg

7rivetedTailFairings.jpeg

8assembledSetPitch&TorquedProp.jpeg

9resetEngineTimeToZero.jpeg

Dec 20, 2023 ELT, elevator & rudder cables, throttle cables - (8.5 hours)

Category: Controls

Secured trim tab wires; installed ELT and secured wires; installed bungee for elevator cable; adjusted elevator and rudder cables for proper tension; cotter pinned castle nuts; safety wired turnbuckles; installed cotter pins and torqued nuts on rudder pedals; installed cabin heat cable control; installed choke cable control; planning throttle cable installation; cut throttle cables to size; moved ammeter shunt.

10attachedElevCableBungee.jpeg

11safetyWiringElevTurnbuckle.jpeg

12SafetyWiringUpperElevTurnbuckle.jpeg

13cotterPinOnRudderPedals.jpeg

14checkingCableTension.jpeg

15safetyWireRudderTurnbuckles.jpeg

16cotterPinsRudderCastleNuts.jpeg

17lookingOverChokeCable.jpeg

18cotterPin&torqueBrake&SteeringRodBolts.jpeg

19installingCabinHeatControlCable.jpeg

1makingBungeeCord.jpeg

20securedCabinHeatControlCable.jpeg

21installedChokeControlCable.jpeg

22clampingDownChokeCable.jpeg

23planningPassThrottleCable.jpeg

24determiningLengthOfPilotThrottle.jpeg

25cuttingThrottleCableToSize.jpeg

26movedAmmeterShuntToClearThrottleCable.jpeg

2drillingHoleForElevBungeeCord.jpeg

3installingElevTurnbuckles.jpeg

4securingElevTrimCableUnderBaggageArea.jpeg

5securingElevCable.jpeg

6installedELT.jpeg

7cotterPinnedElevControl.jpeg

8securingLowerElevCable.jpeg

9tighteningElevTurnbuckles.jpeg

Dec 14, 2023 Seat belts, leveled plane - (6 hours)

Category: Avionics

Installed seat belts; leveled plane and set G5, GSU, and GNX375 for pitch and roll; vacuumed; installed oil tank; zip tied wires; planning cabin heat control.

10installedOilTank.jpeg

11zipTyingPassWingWiring&FuelHose.jpeg

12zipTyingPilotSideWires&Tubing.jpeg

13positioningCabinHeatControl.jpeg

1installedSeatBelts.jpeg

2puttingCorkOnTopWindowBracket.jpeg

3levelingPlane.jpeg

4levelingPitch.jpeg

5settingG3XpitchRollOffset.jpeg

6settingG5pitchRollOffset.jpeg

7settingGNX375ahrs.jpeg

8configuringRS232&arinc.jpeg

9checkingOilTank.jpeg

Dec 10, 2023 Installing fuel hoses, organizing wiring, seats - (9.5 hours)

Category: Fuel System

Working on wiring under seats; attached fuel hoses to gascolator and riveted; attached fuel hoses to fuel shutoff valve; final under seat arrangement and cleaning; installed and riveted both seats; riveted buttons on seats and attached velcro to seat backs; cork on oil tank bracket; riveted trim motor and cover; tested elevator cable clearance; tested radios; finished up rivets and cotter pins on tail; installed and torqued elevator attach bolts.

10rivetedSeats.jpeg

11cleaningFrontWingRoots.jpeg

12corkOnOilTankBracket.jpeg

13testFittingSeats.jpeg

14configuringG5.jpeg

15securingTrimMotor.jpeg

16rivetedTrimCover.jpeg

17rivetedSeatButtons.jpeg

18applyingVelcroToSeatBacks.jpeg

19groundBlock.jpeg

1attachingFuelHosesToGascolator.jpeg

20rivetingElevatorBrackets.jpeg

21rivetingElevCableFairing.jpeg

22cotterPinInElevConnection.jpeg

23rivetedTrimMotor.jpeg

24tightened&torquedHorizStabAttachBrackets.jpeg

2fuelShutoffValve.jpeg

3AttachingFuelHosesToGascolatorInPlace.jpeg

4rivetedGascolator.jpeg

5adjustingWiringBehindPilotSeat.jpeg

6securingFuelHoses.jpeg

7securedWiresUnderPassSeat.jpeg

8securedWiresUnderPilotSeat.jpeg

9clecoSeats.jpeg

Dec 06, 2023 Wiring under seats - (7.5 hours)

Category: Avionics

Cleaned, organized, & secured wiring under both seats; ran and secure pilot PTT wires; put cotter pins on rudder pulleys; put Cortec on seats; crimped elevator trim wires; planning and running fuel hoses.

10zipTyingPassWires.jpeg

11securingPassWires.jpeg

12crimpingTrimWires.jpeg

13positioningFuelShutoffValve.jpeg

14measured&cutFuelHoseForGascolator.jpeg

15cortecOnGascolator.jpeg

1vacuumingSeats.jpeg

2securedPilotPTTwires.jpeg

3drillingHoleForPTTwires.jpeg

4drilledHoleForPilotPTTwires.jpeg

5pilotPTTwiresThruSnapBushing.jpeg

6organizingWiresUnderCopilotSeat.jpeg

7masterRelayWires.jpeg

8cortecOnSeats.jpeg

9securingPassBrakeLine&wires.jpeg

Nov 30, 2023 Fuel sender wires, CPC wing connectors - (7.5 hours)

Category: Avionics

Ran fuel sender wires; finished soldering and attaching pins to other ends; attached to GEA 50pin connector along with other wires; reattached and torqued right slat; tightened nav lights in place; connected and tested wing CPC connectors; configured pitot heat indicator on G3X; drilled out and replaced bad rivets.

10reinstalled&torquedRslat.jpeg

11tightenedNavLights.jpeg

12preparingCPCwingConnectors.jpeg

13passWingCPCconnector.jpeg

14pilotWingCPCconnector.jpeg

15cpcWiring.jpeg

16testingWingWireConnections.jpeg

17testingPitotHeatWiring.jpeg

18testingElevatorTravel.jpeg

19drilledOut&ReplacedBadRivets.jpeg

1labelingFuelSenderWires.jpeg

2fuelSenderWires.jpeg

3runningFuelSenderWires.jpeg

4madeBracketForFuseHolder.jpeg

5mountedFuseHolderVertically.jpeg

6fuseHolder.jpeg

7crimpingGrounds.jpeg

8preparingGEAconnector.jpeg

9installedGEA50pinConnector.jpeg

Nov 28, 2023 Finished steel nose bungee, wiring fuel senders - (4 hours)

Category: Landing Gear

Finished installing steel nose gear bungee; reinstalled 90 degree bnc connectors for comm and transponder antennae; cut wires for fuel senders; put labels on wires; put pins on one side of each fuel sender wire.

1torquingLowerNoseGearBrackets.jpeg

2attachedSteeringRods.jpeg

3finishedSteelBungeeInstallation.jpeg

4replacedCommAntennaWith90connector.jpeg

5replacedTxponderAntWith90connector.jpeg

6runningWiresForFuelSenders.jpeg

7crimpingFuelSenderWires.jpeg

8securingFuelSenderWires.jpeg

Nov 23, 2023 Riveting right wingtip and starting steel bungee nose gear - (6 hours)

Category: Landing Gear

Replaced and tested RG400 connectors; troubleshooting sound on G3X; running fuel lines; removed right slat, riveted right wingtip, and replaced right slat; started installing steel bungee nose gear.

10reattachedRslat.jpeg

11removingNoseGearLeg.jpeg

12noseGearLegRemoved.jpeg

13removingLargeGearSupport.jpeg

14drillingHolesForNewNoseGearSupports.jpeg

15FittingNewNoseGearSupports.jpeg

16testFittingSteelBungee.jpeg

1redoingCommAntenna.jpeg

2redidCommAntenna.jpeg

3redoingGPSantenna.jpeg

4redidADSBantenna.jpeg

5workingOnFuelLines.jpeg

6runningTubingThruWing.jpeg

7runningWiringThruDoorsill.jpeg

8removedRwingSlat.jpeg

9rivetedRwingTip.jpeg

Nov 17, 2023 Elev Cables, Nav/Strobe and Pitot Heat Wires - (7 hours)

Category: Avionics

Worked on elevator cables; wired nav/strobe wires and routed wires through wings; drilled holes for pitot heat wiring and connected and tested pitot heat.

10connectingNavLights.jpeg

11testingNavLights.jpeg

12testingLandingLight.jpeg

13testingStrobeLights.jpeg

14drillingHolesForPitotHeatWires.jpeg

15runningPitotHeatWires.jpeg

16crimpingPitotHeatWires.jpeg

17connectingPitotHeatWires.jpeg

1organizingWingWiring.jpeg

2workingOnElevCables.jpeg

3strippingPilotWingNavWires.jpeg

4crimpingPassWingNavLights.jpeg

5workingOnPassNavLights.jpeg

6crimpingCableToConnectNavStrobes.jpeg

7navWiringDiagram.jpeg

8preparingNavStrobeConnector.jpeg

9solderingNavStrobeConnectors.jpeg

Nov 15, 2023 Connecting GNX and fuel sender wires - (5 hours)

Category: Avionics

Installing and troubleshooting GNX 375; adjusted configuration setup for G3X; troubleshooting audio and GPS antennae; working on GMU 11 and fuel sender wires.

10connectingGMU11.jpeg

11passFuelSenderWires.jpeg

12pilotFuelSenderWires.jpeg

1organizingWiringBeneathGNX.jpeg

2connectingGNXwiring&antenna.jpeg

3attachingGNXwiringToBackplate.jpeg

4connectingGNX.jpeg

5GNXsetup.jpeg

6G3Xsetup.jpeg

7troubleshootingAudio.jpeg

8troubleshootingAntennae.jpeg

9wiringForPassengerWing.jpeg

Nov 10, 2023 Wiring GTP GMU and nav lights - (6 hours)

Category: Avionics

Avionics wiring, including nav/strobe lights and landing lights and switches; GTP and GMU wiring; running wires under seats; updating G3X software.

10runningWiresBehindPilotSeat.jpeg

11runningGTPwires.jpeg

12GTPwireConnections.jpeg

13testingLandingLight.jpeg

14runningGMU11wiring.jpeg

15stripping&crimpingGMUwires.jpeg

16updatingG3Xsoftware.jpeg

1wiringNavStrobeSwitch.jpeg

2solderingNavStrobeWires.jpeg

3wiringNavStrobeWiresToSwitch.jpeg

4installingNavStrobeSwitch.jpeg

5testingNavStrobeLightWiring.jpeg

6testingNavStrobeLights.jpeg

7landingLightWire.jpeg

8wiringLandingLight.jpeg

9runningWiresUnderPilotSeat.jpeg

Nov 08, 2023 Wiring and pitot tubing - (7 hours)

Category: Avionics

Finished attaching slat bolts; torqued slat bolts and flaperon bolts; planning wiring; running pitot and AOA tubing; final battery connections; turned on power and tested switches, LRUs, and circuit breakers; wired and tested trim; wired landing light.

10yetMoreWiring.jpeg

11runningPitot&AOAtubing.jpeg

12moreWiringStill.jpeg

13runningPitot&AOAtubes.jpeg

14testingTrimConnections.jpeg

15testingTrim.jpeg

16crimpingTrimWires.jpeg

17preparingLandingLightConnections.jpeg

18connectingLandingLights.jpeg

1tighteningFlaperonBolts.jpeg

2cimpingWiring.jpeg

3batteryConnections.jpeg

4pullingCircuitBreakers.jpeg

5testingCircuitBreakerConnections.jpeg

6lookingOverWiring.jpeg

7installedG3XandG5gpsAntennae.jpeg

8testingTrimControl.jpeg

9makingPitot&AOAconnections.jpeg

Nov 06, 2023 Wiring and Attaching Wings - (6 hours)

Category: Avionics

Wiring dimmer, power, and ground for trim, etc. Reattached wings and jury struts. Organizing wing root wiring. Removed masking tape from pitot and lights. Installed G5. Connected pitot and static lines to instrument panel. Started attaching bolts to the wing slats.

10installingG5.jpeg

11installedG5.jpeg

12moreWiring.jpeg

13installingStaticTubing.jpeg

14installingPitotTubing.jpeg

15installingSlatBolts.jpeg

1wiringSwitches.jpeg

2moreWiringSwitches.jpeg

3reattachedWings.jpeg

4reattachedPassJuryStruts.jpeg

5reattachedPilotJuryStruts.jpeg

6organizingPilotWingRootWires.jpeg

7organizingPassWingRootWires.jpeg

8installedPitotCover.jpeg

9gatheringSlatBolts.jpeg

Oct 31, 2023 Riveting avionics tray, drilling holes for wires - (5 hours)

Category: Avionics

Hooked up wire from starter key to starter solenoid; crimped power wires and connected to rectifier/regulator; riveted avionics tray, instrument panel brackets, and flaperon control; drilled holes under seats and behind seats for wiring and tubing; ran wires for cockpit lights.

10drilledAnotherHoleUnderPilotSeat.jpeg

11planningFuelShutoffValve.jpeg

12drilled2holesBehindPassSeat.jpeg

13drilled2moreHolesBehindPilotSeat.jpeg

14ranWiresForCockpitLights.jpeg

15wiresForCockpitLights.jpeg

1wiringForRegRec.jpeg

2installedWiringToRegRec&Capacitor.jpeg

3drillingMoreHolesUnderPassSeat.jpeg

4drillingMoreHolesUnderPilotSeat.jpeg

5rivetedInstPanelBrakets.jpeg

6rivetedAvionicsTray.jpeg

7rivetedFlaperonBracket.jpeg

8cuttingMoreHolesUnderPilotSeat.jpeg

9drilledHoleWsnapBushingBehindPilotSeat.jpeg

Oct 27, 2023 Wiring battery cables and regulator rectifier - (6 hours)

Category: Avionics

Made and installed battery negative cable, cable from ammeter to starter solenoid, and various wires; wiring for regulator/rectifier and starter.

10wiringANLfuse.jpeg

11powerCableFromAltToBus.jpeg

12fuses.jpeg

13wiresForRegRec.jpeg

14wiresToRegRec.jpeg

15starterWires.jpeg

1wiringForRegRec.jpeg

2solderedWiresForRegRec.jpeg

3crimpingRegRecWires.jpeg

4solderingBatteryCable.jpeg

5finishedBatteryCables.jpeg

6installedBatteryNegCable.jpeg

7installingStarterRelayCable.jpeg

8AttachingCableForStarterRelay.jpeg

9bootsOnCables.jpeg

Oct 25, 2023 Installing avionics harness and wiring - (9 hours)

Category: Avionics

Placed avionics harness and began attaching; mounted rectifier/regulator; mounted ground tab; attached ANL fuse; reinstalled flaperon control bolt with proper size; attached pitot tubing connectors to backs of GSU and G5; attached GSU to GDU; crimped connectors to ground block and circuit breakers; attached avionics fan wires; installed headset jacks.

17cuttingGroundWiresToSize&Crimping.jpeg

10connectingMasterSwitchToRelay.jpeg

11groundForMasterSwitch.jpeg

12replacedBoltForFlaperonWcorrectSize.jpeg

13attachingGSUtoGDU.jpeg

14attachingG5tubingConnectors.jpeg

15placingWiringHarness.jpeg

16arrangingWiringHarness.jpeg

18attachingGroundsToGroundBlock.jpeg

19attachingWiresToBreakers.jpeg

1attachingPowerCableToAmmeter.jpeg

20wiringAvionicsFans.jpeg

21attachingCoPilotPTTandTrimmingForJacks.jpeg

22installingCopilotJacks.jpeg

23copilotJacks.jpeg

24installedPilotJacks.jpeg

2attachingPowerCableToMasterRelay.jpeg

3installedANLfuse.jpeg

4preparingRecReg.jpeg

5installedRegRec.jpeg

6installedBatteryInELTannunciator.jpeg

7installedELTannunciator.jpeg

8creatingCableForMasterSwitch.jpeg

9crimpingMasterSwitchWiring.jpeg

Oct 18, 2023 Installing coolant overflow bottle and avionics rack - (5.5 hours)

Category: Fuselage

Deburred and cortec L angles that attach to avionics rack; applied cortec to L angles at ends of avionics rack; installed wing access panel covers; applied Form-A-Gasket and assembled connectors on gascolator and fuel shutoff valve; created and riveted coolant overflow bottle mounting bracket; mounted avionics rack and instrument panel in plane.

10cortecBottleHolder.jpeg

11rivetedBottleHolder.jpeg

12reattachingSideLangles.jpeg

13reattachingInstPanel.jpeg

14attachingAvionicsRack.jpeg

15attachingAntennaCables.jpeg

16preparingPowerCable.jpeg

17solderingPowerCable.jpeg

18heatShrinkOnPowerCable.jpeg

1deburringLanglesThatSupportAvionicsTray.jpg

2CortecAvionicsTraySupports.jpg

3installingWingAccessCovers.jpg

4assemblingGascolator&fuelShutoff.jpg

5cuttingPartsForCoolantOverflowBottle.jpg

6foldingMetalForOverflowBottleHolder.jpg

7positioningOverflowBottle.jpg

8installingOilTank.jpg

9drillingHolesForOverflowBottleHolder.jpg

Oct 13, 2023 Installing wing access panels - (7.5 hours)

Category: Wings

Placed, cut holes for, filed, and drilled both inspection hatch covers for the wing roots. Filed and deburred wing hatch openings and hardware and cabin heater vent; cleaned and Cortec and riveted cabin heat vent and access panels; painted wing access panel covers.

10applyingCortecToWingAccessPanels.jpg

11deburringHolesForWingAccessPanels.jpg

12rivetingCabinHeatVent.jpg

13rivetingPilotWingAccessPanel.jpg

14rivetingWingAccessPanel.jpg

15paintingWingAccessPanels.jpg

1tracingCutoutsForWingAccesPanels.jpg

2cuttingOutWingAccessPanelOpenings.jpg

3positioningWingAccessPanels.jpg

4pilotDrilledPassWingAccessPanel.jpg

5pilotDrilledPilotWingAccessPanel.jpg

6finalDrilledPassWingAccessPanels.jpg

7removingWingAccessPanels.jpg

8deburringpilotDrilledPassWingAccessPanelOpenings.jpg

9deburringWingAccessPanels.jpg

Oct 05, 2023 Riveted door sills, mounting reg/rect, cabin heat vent - (6.5 hours)

Category: Fuselage

Painted other sides of door hinges and roof brace; filed and installed grommets and snap bushings on wings; put experimental decals on door sills; planning, drilling and test fitting ground block tabs, ANL fuse for alternator, regulator/rectifier with capacitor, and starter solenoid on firewall; riveted hinges to door sills; riveted door sills in place; riveted top window brace; planned and drilled holes for cabin heat vent.

10preparingCapacitorFuse&Starter.jpg

12rivetingPassDoorSill.jpg

13rivetingPilotDoorSill.jpg

14pilotDrillingCabinHeatVent.jpg

15drillingHoleForCabinHeatControlCable.jpg

16testFittingOilRadiator.jpg

17drillingCabinHeatOpeningInFirewall.jpg

18pilotDrillingCabinHeatVentInPlace.jpg

19finalDrillingCabinVentInPlace.jpg

1transferringExpermentalDecalsToDoorSills.jpg

2paintingOtherSidesOfDoorHinges.jpg

3installedPilotWingRootGrommets.jpg

4installedPassWingRootGrommets.jpg

5preparingToInstallB&CrectReg.jpg

6preparingToInstallRegFuseGroundBlock&Capacitor.jpg

7drillingHolesInFirewallForFuseGround&Reg.jpg

8mountedFuseGround&Reg.jpg

9installedGroundBlock.jpg

11rivetingHingesToDoorSills.jpg

Oct 03, 2023 Drilling Top Window in Place - (7.5 hours)

Category: Fuselage

Measured, cut, and pilot drilled top window in place; created (crimped and trimmed) and pilot drilled roof brace in place; deburred, cleaned, and started painting door sills, hinges, and roof brace; drilled top window holes out to 5/32.

10placingCorkOnRoofBrace.jpg

11pilotDrillingTopWindow.jpg

12deburringDoorSills&hinges&RoofBrace.jpg

13cleaningDoorSills&Hinges&RoofBrace.jpg

14paintingHingesWhite.jpg

15paintingDoorSills&RoofBrace.jpg

16drillingTopWindowLarger.jpg

17drillingTopWindowHolesFinalSize.jpg

18deburringHolesForDoorSillinCabinFrame.jpg

1measuring&markingTopWindow.jpg

2cuttingTopWindow.jpg

3testFittingTopWindow.jpg

4pilotDrillingTopWindow.jpg

5marking&crimpingRoofBrace.jpg

6trimmingBottomOfRoofBrace.jpg

7marking&predrillingRoofBrace.jpg

8pilotDrillingRoofBrace.jpg

9finalDrillingRoofBrace.jpg

Sep 29, 2023 Drilling door sills and holes for wing wires & hoses - (7 hours)

Category: Fuselage

Marked and predrilled door hinges, then pilot drilled onto door hinges; planning and measuring for top window; planned and drilled holes for wires and fuel hoses in door sills and wing roots.

10drilledHoleForCPCconnectors.jpg

1markingDrillHolesOnDoorSillHinges.jpg

2pilotDrillingPilotSideDoorHinge.jpg

3pilotDrillingPassSideDoorHinge.jpg

4finalDrillingDoorHinges.jpg

5measuring&planningTopWindow.jpg

6drilledFuelHosePassThruPassSide.jpg

7drilledHolesForWires&FuelHosesLeftWing.jpg

8drilledHolesForWires&FuelHosesLeftDoorSill.jpg

9drilledHolesForWires&FuelHosesRightDoorSill.jpg

Sep 24, 2023 Drilling Door Sills and Sealing Antennae - (7 hours)

Category: Fuselage

Drilled doors sills in place; planned door sill hinge placement and wiring connections for wings; sealed all four antennae with Alex Plus Clear.

10planningDoorSillHinges.jpg

11sealingGPSantenna.jpg

12sealingELTantenna.jpg

13sealingTxponderAntenna.jpg

14sealingCommAntenna.jpg

15planningWingWiring.jpg

1filingWingSkinsAwayFromDoorSills.jpg

2filingDoorSills.jpg

3determiningExperimentalDecalPlacement.jpg

4markingDrillHolesForDoorSills.jpg

5predrillingDoorSills.jpg

6pilotDrillingPilotDoorSill.jpg

7pilotDrillingPassDoorSill.jpg

8finalDrillingDoorSills.jpg

9measuringDoorHingePlacement.jpg

Sep 20, 2023 Fitting the door sills - (5 hours)

Category: Fuselage

Cut and shaped the door sills; removed both wings; filed and shaped both door sills to fit.

10trimmedFrontsOfDoorSills.jpg

11trimmedPilotDoorSillToFit.jpg

12trimmedPassDoorSillToFit.jpg

1marking&DrillingDoorSills.jpg

2trimmingDoorSills.jpg

3markingSlotsForDoorSills.jpg

4cuttingSlotsInDoorSills.jpg

5drillingHolesInDoorSills.jpg

6trimmingBottomsOfDoorSills.jpg

7moreDoorSillTrimming.jpg

8removingWingStruts.jpg

9detachedWings.jpg

Sep 19, 2023 Installing antenna cables and brake lines - (5 hours)

Category: Avionics

Crimped antenna cable connections; planned antenna cable routing and installed; drilled out rivets for door sill; installed brake line connections to brakes.

10runningGPScableUnderSeat&installingCOMMantenna.jpg

11runningTxponderAntenna.jpg

12crimped90BNCtxponderAntenna.jpg

13installedTxponderAntenna.jpg

14strippingTNCforOtherEndOfCommAntenna.jpg

15teflonPasteOnBrakeLineConnectors.jpg

16installedPilotSideBrakeLine.jpg

17installedPassSideBrakeLine.jpg

1measuringAntennaCable.jpg

2strippingAntennaCable.jpg

3crimpedTNCconnector.jpg

4removingRivetsForDoorSill.jpg

5strippingCableForBNCconnector.jpg

6strippingCableFor90BNC.jpg

7crimped90BNC.jpg

8installedGPSantenna.jpg

9runningGPScableThruBaggageFloor.jpg

Sep 14, 2023 Master Relay and Brake Lines - (7 hours)

Category: Avionics

Deburred, Cortec, and riveted battery L angles and strap; installed master relay; created and soldered wire from battery to master relay; installed lighter plug and battery charger pigtail; trimmed wing skin for door sill; installed grommets for brake lines; looked over RG 400.

10wiringCigarPlug&BatteryChargerPlug.jpg

11DrilledHolesForBrakeLines.jpg

12installedBrakeLinesToBrakes.jpg

1preparingWiring.jpg

2solderingWiresToBatteryPigtail.jpg

3rivetedBatteryLangles.jpg

4installedMasterRelay.jpg

5cuttingBatteryCable.jpg

6solderingBatteryCable.jpg

7heatShrinkOnBatteryCable.jpg

8diodeForMasterRelay.jpg

9drillingHoleForCigarPlug.jpg

Sep 12, 2023 Installing ammeter shunt and battery - (7.5 hours)

Category: Avionics

Installed ammeter shunt; working on brake lines; created and soldered fuses for ammeter shunt and pitot heat to GEA; finalized master relay and battery; final drilled L angles and strap for battery.

10made&attachedDiodeAssemblyToMasterRelay.jpg

11planningMasterRelay&BatteryPlacements.jpg

12preDrillingBatteryExtrusion.jpg

13pilotDrillingBatteryExtrusion.jpg

14cuttingLanglesForBattery.jpg

15preDrilledBatteryLangles.jpg

16makingBatteryBracket.jpg

17pilotDrillingBatteryLangles.jpg

18pilotDrilledBatteryLangles.jpg

19finalDrillingBatteryLangles.jpg

1workingOnBrakeLines.jpg

2fusesForShuntToGEA.jpg

3teflonPasteOnBrakeLineAttachments.jpg

4installingLeftBrakeLine.jpg

5installingRightBrakeLine.jpg

6solderingGEAfuses.jpg

7boltedShunt&attachedFuses.jpg

8shuntInfo.jpg

9solderingFuseForPitotHeatMonitor.jpg

Sep 07, 2023 IBBS connector, zip tying harness, buss bar - (6 hours)

Category: Avionics

Recorded LRU info; finished IBBS connector; finished wiring harness with zip ties; riveted brackets and base to instrument panel; installing bolts and nuts on avionics rack; wiring buss bar.

10workingOnWireHarness.jpg

11backshell&zipTieIBBSconnector.jpg

12zipTyingHarness.jpg

13rivetingInstrumentPanelBase.jpg

14rivetedPanelSides.jpg

15boltingGEA24.jpg

16boltingAvionicsRack.jpg

17wiringBusBars.jpg

18wiringBusBarForShunt.jpg

1GAD29Clabel.jpg

2GTR20label.jpg

3IBBSlabel.jpg

5GNX375label.jpg

6GDU460label.jpg

7GSU25Clabel.jpg

8G5label.jpg

9pinningIBBSconnector.jpg

4GEA24label.jpg

Sep 06, 2023 More avionics harness, pinning connectors - (4 hours)

Category: Avionics

More avionics harness wiring, including GAD29, GNX 375, GSU25, and GDU460 connectors; organizing wires to prepare for zip ties.

10preppingHarnessForZipTies.jpg

1GNXconnectors.jpg

2GNXconnectors2.jpg

3GNXconnectors3.jpg

4finishedGNXconnectors.jpg

5moreHarnessWiring.jpg

6GSU25backshell.jpg

7testFittingGSUconnectors.jpg

8GDUconnectors.jpg

9testFittingGDUconnectors.jpg

Sep 02, 2023 More avionics wiring, ELT, GTR20 - (7.5 hours)

Category: Avionics

Avionics wiring, including splicing and soldering wires for ground and power for IBBS backup battery and GNX375; soldered and connected ELT cable; zip ties for GMU 11 wires; installed pins in GTR20

10testingELTconnecterFit.jpg

11sealingELTconnectionWithRTV.jpg

12completedELTconnection.jpg

13zipTiesOnWiresForGMU11.jpg

14pinningGTR20.jpg

1moreAvionicsWiring.jpg

2IBBSgroundWires.jpg

3GNXgrounds.jpg

4solderingIBBSpowerWires.jpg

5solderingGNXpowerWires.jpg

6heatShrinkOnGNXandIBBSwires.jpg

7runningAvionicsHarnessWires.jpg

8moreWiring.jpg

9solderedELTconnections.jpg

Aug 31, 2023 More wiring, avionics fan, cabin dimmer, headset jacks - (5 hours)

Category: Avionics

More avionics wiring, including dimmer circuit for IBBS switch light and cockpit light, soldered avionics fan switch, soldered headset jacks.

1testingWiringForLightOnIBBSswitch.jpg

2wiringDimmerForIBBSandCockpitLight.jpg

3solderingAvionicsFanSwitch.jpg

4heatShrinkAvionicsFanSwitch.jpg

5solderedPilotJacks.jpg

6createdCopilotJackWires.jpg

7solderedCopilotJacks.jpg

Aug 30, 2023 More harness wiring, config modules, GEA 9pin, copilot PTT - (6 hours)

Category: Avionics

More avionics harness wiring; finished 9 pin GEA connector; crimped and placed pins for config modules for both GDU460 and GNX375; started wiring for headsets; soldered wires onto copilot PTT switch.

10creatingPilotMicWires.jpg

1runningMoreAvionicsHarnessWires.jpg

2finished9pinGEAconnector.jpg

3crimpingGDUconfigModuleWires.jpg

4placingGDUconfigModuleWiresInConnector.jpg

5crimpingGNX375configModuleWires.jpg

6sortingGNX375backshells.jpg

7placingGNX375configModuleWiresInConnector.jpg

8assemblingGNX375backshell.jpg

9solderedCopilotPTTswitch.jpg

Aug 29, 2023 Adding more wires to avionics harness - (6.5 hours)

Category: Avionics

Adding and labeling and stripping wires for avionics harness; crimping dsub mini pins for GNX 375; finalizing larger GAD29 connector; measuring, labeling, and soldering wires for cabin lights.

1crimpingDsubMiniPins.jpg

2strippingWiresForHarness.jpg

3labelingWires.jpg

4runningMoreWiresForAvionics.jpg

5finishedLargerGAD29connector.jpg

6labelingCabinLightWires.jpg

7solderingWiresToCabinLights.jpg

8heatShrinkOnCabinLightSolders.jpg

9labelingHarnessWires.jpg

Aug 25, 2023 CAN bus wiring, G5 GAD29 GDU - (8 hours)

Category: Avionics

Completed G5 connector; planning, rerouting, and labeling ground wires; running more ground and power wires and labeling; attached 9 pin connector for GAD29; more wiring harness work, including 9 pin GDU connector.

10crimpingCANbusWires.jpg

11finsihedGDU9pinConnector.jpg

12moreWiringHarnessWork.jpg

1wiringG5lightningProtectionModule.jpg

2wiringG5.jpg

3moreCANbusPlanning.jpg

4finishedG5connector.jpg

5runningGroundWires.jpg

6addingWireLabels.jpg

7crimpingGAD29pins.jpg

8createdGAD29connector.jpg

9moreWiringWork.jpg

Aug 23, 2023 CAN bus and GDU nut plate - (6 hours)

Category: Avionics

Soldering CAN bus together; shrink tubing on solder joints; crimped ring connectors on ground wires; stripped and crimped pins onto CAN bus wires; drilling and countersinking holes for GDU nut plate; laying out avionics harness; Cortec and riveted GDU nut plate; more harness planning; riveted avionics rack; started wiring avionics fans; bolted on fuse block.

11wiringAvionicsFans.jpg

12boltingFuseHolder.jpg

13fittingTogetherAvionicsRack&Panel.jpg

14wiringGDUconfigModule.jpg

15moreConfigModuleWiring.jpg

1windowSplicingCANbusWires.jpg

2attachingShieldWiresOnCANbus.jpg

3crimpingPinsOnCanBusWires.jpg

4drillingGDUframe.jpg

5layingOutCANbus.jpg

6placingCANbusWires&Connectors.jpg

7cortecGDUframe.jpg

8rivetingGDUdoubler.jpg

9startingRivetingAvionicsTray.jpg

10boltingAvionicsFans.jpg

Aug 21, 2023 Inst Panel Work and CAN Bus Planning - (6 hours)

Category: Avionics

Made a printed avionics labels for wiring; riveted horizontal stabilizer brackets; attached GNX rack to instrument panel; attached trim switch and indicator to panel; positioned G5 and GNX; added labels for instrument panel; started working on CAN bus.

10separatingShieldFromCANwires.jpg

11preparingForWindowSplices.jpg

1printingWiringLabels.jpg

2rivetingHorizStabBrackets.jpg

3attachingGNXtray.jpg

4attachedTrimSwitch&Indicator.jpg

5positioningG5&GNX.jpg

6addingStickersToPanel.jpg

7instrumentPanelLabels.jpg

8labelingCANbusWires.jpg

9strippingCANbusWires.jpg

Aug 16, 2023 Vinyl Wrap on Instrument Panel - (4.5 hours)

Category: Avionics

Put vinyl wrap on instrument panel and cut openings; riveted L angle supports to back of instrument panel; installed diode on nav/strobe switch; installed breakers and buss bar; attached ELT cabin remote and alt static source switch; installed more switches and small buss bar for breaker switches; installed GNX backplate; painted master switch mount; installed master switch, trim indicator label; enraved and installed data plate.

10installedBussBar.jpg

11installingBatteryInELTannunciator.jpg

12teflonPasteOnAltStaticSwitch.jpg

13installedELTswitch.jpg

14mountedAltStaticSwitch.jpg

15installedBreakerSwitches&SmallBusBar.jpg

16installedSwitches.jpg

17installedGNXtrayBackerPlate.jpg

18etchingDataPlate.jpg

19installedDataPlate.jpg

1paintingBottomSupportOfInstrumentPanel.jpg

3CortecLangleSupportBracketsForInstPanel.jpg

4applyingVinylWrapToInstPanel.jpg

5cuttingHolesInVinylWrap.jpg

6rivetingLanglesToInstPanel.jpg

7trimmingVinylWrapFromBrackets.jpg

8addingDiodeForNavLightSwitch.jpg

9installedCircuitBreakers.jpg

Aug 04, 2023 Cutting switch and circuit breaker holes on panel - (5.5 hours)

Category: Avionics

Installed static ports and ran pitot line; planning of electrical wiring; made cutouts and test fit on instrument panel IBBS switch, choke, copilot PTT, cabin heat, ELT annunciator, cabin dimmer, and circuit breakers. Marked, drilled, and deburred buss bar; installed stick grips on yoke.

11cuttingELTcontrolOpening.jpg

12fittingELTcontrol.jpg

13installingDimmerControl.jpg

14planningCircuitBreakBussBar.jpg

15testFittingCircuitBreakers.jpg

16deburringInstrumentPanel.jpg

17markingBussBarCutouts.jpg

18drilled&deburredBussBar.jpg

19attachedYokeGrips.jpg

1cuttingPitotTubing.jpg

2installedPitotOpenings.jpg

3installingPitotTubes.jpg

4placingPitotTubes.jpg

5planningWiring.jpg

6cuttingOutIBBSswitchOpening.jpg

7fittingIBBSswitch.jpg

8fittingChokeControl.jpg

9installingPTTswitch.jpg

10fittingCabinHeatControl.jpg

Aug 02, 2023 Work on avionics panel - (7 hours)

Category: Avionics

Avionics planning; testing dimmers on AML switch and trim indicator; tested and installed avionics fan switch; made another L angle stiffener for right side of instrument panel; installed alternate static source switch; planned other switches and circuit breakers; drilled holes for pitot heat, landing light, nav/strobes, and cabin light switches.

10installingAltStaticSwitch.jpg

11installedAvionics&AltStaticSwitch.jpg

12planningSwitchPlacement.jpg

13planningCircuitBreakers.jpg

14drillingHolesForSwitches.jpg

1testingTrimINdicator.jpg

2testingWith12vBattery.jpg

3planningInstPanel.jpg

4inventoryOfElectricalSupplies.jpg

$gallery thumbnail$

5testingCockpitLight&BatteryBackupLight.jpg

6moreWorkOnInstPanel.jpg

7installingLangleSupportToInstPanel.jpg

8testingAvionicsFans.jpg

9installingAvionicsFanSwitch.jpg

Aug 01, 2023 Installing GPS, Comm, & Txponder Antennae - (7.5 hours)

Category: Avionics

Planning and drilling holes for GPS antenna; planning electrical wiring; final drilled upper L angles for aileron rod covers and deburred; installed GPS antenna and torqued screws; planning avionics wiring; final planning of antenna placements; installed comm antenna; cleaned and Cortec and riveted lower L angles for aileron rod covers; installed transponder antenna; disassembled ELT connector; planned CAN bus and cut wires; drilled holes for static ports.

10finalDrilledCommAntenna.jpg

11moreWiringPlanning.jpg

12attachedCorkGasketForCommAntenna.jpg

13attachedCommAntenna.jpg

14CommAntennaInstalled.jpg

15CortecLowerLanglesForAileronRodCovers.jpg

16rivetingLowerLanglesForAileronRodCovers.jpg

17deburringHoleForTransponderAntenna.jpg

18transponderAntenna.jpg

19SecuringTransponderAnt.jpg

1drillingHolesForGPSantenna.jpg

20transponderAntInstalled.jpg

21disassemblingELTconnector.jpg

22planningAvionicsHarnessLayout.jpg

23planningCANbusLayout.jpg

24drillingStaticPorts.jpg

25installedStaticPorts.jpg

26cuttingCANbusWires.jpg

2testFittingGPSantenna.jpg

3deburringHolesForGPSantenna.jpg

4finalDrillingUpperAileronRodCoverLangles.jpg

5finalDrilledUpperAileronRodCoverLangles.jpg

6deburringHolesForUpperAileronRodCoverLangles.jpg

7deburringUpperAileronRodCoverLangles.jpg

8installedGPSantenna.jpg

Jul 26, 2023 Work on torque tube, flaperon, and pitch controls - (4.5 hours)

Category: Controls

Cleaned and riveted plate for torque tube; attached bolt and cotter pin for flaperon rod; riveted pilot side flaperon control mount bracket; torqued flaperon control bolt and jam nut and aileron bolt and jam nuts. Cortec, reattached, and torqued control yoke and elevator pitch control rod; planning electrical wiring.

10planningWiring.jpg

11attachedElevBellcrank.jpg

12reattachedYoke.jpg

13attachedPitchControlRodToElevBellcrank.jpg

1rivetingTorqueTubePlate.jpg

2installingBolt&CotterPinForFlaperonControl.jpg

3rivetingFlaperonFrameBracket.jpg

4torquedFlaperonControlHandleConnections.jpg

5torquedTorqueTubeAssembly.jpg

6torquedFlaperonBellcranks.jpg

7torquedFlaperonRodConnections.jpg

8connectedPitchControlRodToYoke.jpg

9CortecTorqueTube.jpg

Jul 25, 2023 Finishing Upper Elev Fairing; Installing ELT - (6.5 hours)

Category: Avionics

Final drilled, trimmed, deburred, cleaned, Cortec, riveted, and painted upper elevator fairing; planned antenna installations; created, drilled, deburred, Cortec, and riveted ELT doubler plate; made ELT cradle attachment bolt holes; drilled holes for ELT antenna and installed.

10paintingUpperElevCableFairing.jpg

11testFittingUpperElevCableFairing.jpg

12planningCommAntenna.jpg

13planningGPSantenna.jpg

14planningConnectorsForGNXtray.jpg

15planningELTinstallation.jpg

16creatingELTdoublerPlate.jpg

17markingRivetHolesForELTdoublerPlate.jpg

18pilotDrillingELTdoublerPlate.jpg

19finalDrilledELTdoublerPlate.jpg

1workonTail.jpg

20drilledHoleForELTantenna.jpg

21drilledHoleInBaggageFloorForELTantenna.jpg

22deburringHoleForELTantenna.jpg

23grommetForELTantennaHole.jpg

24deburringELTdoublerPlateHoles.jpg

25cleaningAreaForELTdoublerPlate.jpg

26deburringELTdoublerPlate.jpg

27CortecELTdoublerPlate.jpg

28rivetingELTdoublerPlate.jpg

29installedELTcradle.jpg

2moreTail.jpg

30installedELTantenna.jpg

31attachedELTantennaWstaticSuppresor.jpg

3finalDrillingUpperElevCableFairing.jpg

4deburringAroundUpperElevFairing.jpg

5finalDrillingUpperElevCableFairingLangles.jpg

6deburringUpperElevCableFairing.jpg

7cleaningUpperElevCableFairing.jpg

8CortecUpperElevCableFairingLangles.jpg

9rivetingUpperElevCableFairingLangles.jpg

Jul 21, 2023 Work on upper elevator fairing - (6.5 hours)

Category: Horizontal Tail

Planning and preliminary trimming of upper elevator fairing and L angles and pilot drilling; planning wiring; pilot drilled upper elevator fairing to horizontal stabilizer; finished shaping upper elevator fairing to avoid rudder and elevator; made and pilot drilled L angle stiffeners for upper elevator fairing; test fit and trimmed fairing stiffeners.

10sandingUpperElevFairing.jpg

11measuringInternalLangleForUpperElevFairing.jpg

12markingLanglesForUpperElevFairing.jpg

13pilotDrillingInternalLanglesForUpperElevFairing.jpg

14testFittingUpperElevFairing.jpg

15trimmingInternalLanglesForUpperElevFairing.jpg

1checkingUpperElevFairing.jpg

2trimmingUpperElevFairing.jpg

3positioningUpperElevFairing.jpg

4sizingUpperElevFairing.jpg

5expandingAngleOfLforUpperElevFairing.jpg

6marking&pilotDrillingLanglesForUpperElevFairing.jpg

7planningWiringDiagram.jpg

8pilotDrilledLanglesForUpperElevFairing.jpg

9trimmingUpperElevFairingToClearElev.jpg

Jul 19, 2023 Work on torque tube travel - (4.5 hours)

Category: Controls

Final drilled and cut elevator fairlead and L angle; filed horizontal tail opening; made adjustments and cut torque tube to allow full range of elevator travel; cut and filed opening for pitch control rod and yoke; painted pitch control rod and yoke; final drilled GNX tray brackets; drilled headphone holes to final size for insulated washers.

10drillingCotterPinHoleOnYokeForPitchRod.jpg

11reinstalledYoke&PitchRod.jpg

12attachedUpperElevCable.jpg

13enlargingHoleForControlRods.jpg

14repaintingPitchControlRod.jpg

15repaintingYoke.jpg

16filingHoleForPitchControlRod.jpg

17finalDrillingGNXtray.jpg

18filingDeburringInstPanel.jpg

19enlargingHeadsetHolesForWashers.jpg

1cutting&sandingUpperElevFairlead.jpg

2finalDrilledUpperElevFairleadToLangle.jpg

3placingUpperElevFairlead.jpg

4testingThrottleCableClearance.jpg

5markedTorqueTubeForFullElevTravel.jpg

6CutTorqueTubeForFullElevTravel.jpg

7disassembledYoke&pitchRod.jpg

8filingPitchControlRodForClearance.jpg

9trimmingBottomOfYokeForClearance.jpg

Jul 18, 2023 Installing Elevator Control Cables - (4 hours)

Category: Horizontal Tail

Final filing and confirming down elevator travel; measured, cut, swaged, and installed elevator cables; pulled elevator trim wires through fuselage; checked elevator controls and set to neutral; creating upper elevator cable fairlead; tightened upper elevator horn bolt.

10drilledUpperElevFairleadToLangle.jpg

1finalConfirmationOfDownElevTravel.jpg

2attachingUpperElevCable.jpg

3pullingCables&TrimWiresThruFuselage.jpg

4assemblingElevControl.jpg

5checkingElevNeutralPosition.jpg

6SettingYokeToNeutral.jpg

7created&swagedElevCable1.jpg

10creatingUpperElevCableFairing.jpg

11drilledUpperElevFairleadToLangle.jpg

8created&swagedElevCable2.jpg

9attachedElevCables.jpg

Jul 17, 2023 Attaching elevator cables to elevator - (6 hours)

Category: Horizontal Tail

Measured and cut cable for upper and lower elevator controls; swaged cables with heat shrink; torqued and sealed elevator trim and added cotter pins; reassembled and torqued elevator; attached lower elevator to lower elevator horn; ran lower cable and trim wires through fuselage; reattached horizontal tail and elevator to fuselage; checked travel of rudder and trimmed rudder skin; measured and started trimming elevator horn for down elevator travel; mounted avionics fans.

10swagedElevTurnbuckle.jpg

11installedElevTrimTabCotterPin.jpg

12reattachedElevToHorizTail.jpg

13torqueingElevToHorizTailBolt.jpg

14attachedElevCable.jpg

15reattachedHorizTailToFuselage.jpg

16testingElevRangeOfMotion.jpg

17trimmingRudderSkinToClearElev.jpg

18filingRudderSkin.jpg

19checkingElevDownDeflection.jpg

1cuttingElevCable.jpg

20trimmingElevForDownwardTravel.jpg

21mountingAvioncisFans.jpg

2swagingElevCable.jpg

3torquedJamNutsOnElevTrim.jpg

4swagedElevCable.jpg

5checkingElevCableSwage.jpg

6shinkWrappingElevCables.jpg

7checkingElevCableLength.jpg

8cuttingElevCableToSize.jpg

9checkingElevSwage.jpg

Jul 15, 2023 More work on avionics rack - (7 hours)

Category: Avionics

Added support L angles to sides of avionics rack; installed L angles on sides of GNX and GEA; positioned and final drilled all remote avionics on rack; disassembled, deburred, and applied Cortec; reassembled avionics rack.

10drillingBoltHolesForVerticalLanglesForAvionicsRack.jpg

11planningAvionicsFan.jpg

12checkingAvionicsRackClearanceFromThrottleCables.jpg

13planningAvionicsPlacement.jpg

14deburringAileronRodCover.jpg

15positioningGAD29.jpg

16positioningGTR20.jpg

18positioningAvionicsFans.jpg

19trimmingLangleForGNXcables.jpg

1deburringFuselageHolesForAileronRodCover.jpg

21CortecAvionicsRack.jpg

22reassembledAvionicsRack.jpg

2pilotDrillingExtraLangleSupportForAvionicsRack.jpg

3LanglesForGNXrack.jpg

4testFittingGNXrack.jpg

5planningAvionicsRack.jpg

6adjustingGTR20mountingBrackets.jpg

7creatingLangleVerticalSupportsForAvionicsRack.jpg

8pilotDrillingLangleVerticalSupportForAvionicsRack.jpg

9finalDrillingAvionicsRack.jpg

17positioningIBBS.jpg

21CortecAvionicsRack.jpg

Jul 12, 2023 Creating avionics rack - (7 hours)

Category: Avionics

Riveted elevator stop; removed pilot seat; planning comm antenna placement; counted rivets and rivets needed; deburring L angles for aileron rod covers; trimmed L angle to clear GDU; created avionics rack with L angles, drilled together, drilled onto side L angles.

10planningWhatToPutOnAvionicsRack.jpg

11planningAvionicsRackClearance.jpg

12deburringSideLangles.jpg

13placingLanglesForAvionicsRack.jpg

14drillingAvionicsRack.jpg

15pilotDrillingLanglesForAvionicsRack.jpg

16adding2moreLanglesForAvionicsRack.jpg

17planningAvionicsBoxesPlacement.jpg

18deburringAileronRodCoverAngles.jpg

19finalDrillingAvionicsLanglesTogether.jpg

1rivetingElevStop.jpg

20checkingLangleClearance.jpg

2contemplatingAvionicsPlatformPlacement.jpg

3removedPilotSeat.jpg

4planningCommAntennaPlacement.jpg

5placingInstPanel&sideLangles.jpg

6takingStockOfRivets.jpg

7deburringAileronRodCoverLangleHoles.jpg

8trimmingLangleForG3X.jpg

9planningAvionicsRackPlacement.jpg

Jul 07, 2023 Elevator Stop and Aileron Rod Covers - (9.5 hours)

Category: Controls

Cut and positioned top side L angles, bottom front and side L angles, and started final drilling aileron rod covers; placed and final drilled elevator up stop bracket; planned antennae placements; final drilled and removed aileron rod covers.

10deburringElevStop.jpg

11paintingElevStop.jpg

12lookngOverAntennae.jpg

13planningAntennae.jpg

14finalDrillingPilotAileronRodCovers.jpg

15finalDrillingPassAileronRodCovers.jpg

16removingAileronRodCovers.jpg

17finalDrillingVerticalLanglesOnAileronRodCovers.jpg

1creatingLowerFrontLanglesForAileronRodCovers.jpg

2pilotDrillingFrontLowerLanglesForAileronRodCovers.jpg

3creatingLowerSideLanglesForAileronRodCovers.jpg

4pilotDrillingLowerSideLanglesForAileronRodCovers.jpg

5finalDrillingAileronRodCovers.jpg

6trimmingElevHorn.jpg

7checkingDegreeOfElevTravel.jpg

8pilotDrillingElevStop.jpg

9finalDrillingElevStop.jpg

Jul 05, 2023 Creating aileron rod covers - (6.5 hours)

Category: Fuselage

Assembling turnbuckles and elevator attach brackets; planning aileron rod covers and cutting to shape; creating and pilot drilling side and front top L angles for aileron rod covers; painted glare shield plate; riveted upper seat belt brackets.

10paintingGlareShieldPlate.jpg

11rivetingSeatBeltAttachBrackets.jpg

12cutting&MarkingAileronRodCoverLangles.jpg

13predrillingAileronRodCoverLangles.jpg

14markingAileronRodCovers.jpg

15trimmingAileronRodCovers.jpg

16testFittingAileronRodCover.jpg

17trimmingEdgesOfAileronRodCovers.jpg

18markingVerticalLanglesForAileronRodCovers.jpg

19pilotDrillingVerticalLangesForAileronRodCovers.jpg

1assembingTurnbuckles.jpg

20markingRearOfAileronRodCovers.jpg

21pilotDrillingRearOfAileronRodCovers.jpg

22creatingUpperLanglesForAileronRodCovers.jpg

23pilotDrillingFrontUpperLanglesPilot.jpg

24pilotDrillingFrontUpperLanglesPass.jpg

2assemblingElevCableAttachBrackets.jpg

3planningAileronRodCovers.jpg

4cuttingLanglesForAileronRodCovers.jpg

5testFittingAileronRodLangle.jpg

6marking&cuttingAileronLangle.jpg

7pilotDrillingPassLangle.jpg

8pilotDrillingPilotLangle.jpg

9cleaningGlareShieldPlate.jpg

Jul 01, 2023 Working on instrument panel - (5.5 hours)

Category: Instrument Panel

Cut out GNX 375 opening; holes for all 4 jacks; openings for all trim switch and trim indicator; holes for both throttle controls; cut out holes for starter switch and master switch.

10testFittingTrimIndicator.jpg

11deburringTrimIndicatorOpening.jpg

12markingOpeningForElevTrimSwitch.jpg

13testFittingElevTrimSwitch.jpg

14cutHoleForPilotThrottle.jpg

15installedPilotHeadsetJacks.jpg

16installedCopilotThrottle&HeadsetJacks.jpg

17insertedStarterSwitch.jpg

18testFittingThrottle&Starter&Jacks.jpg

19markingMasterSwitchHole.jpg

1lookingOverStarterSwitch.jpg

20MasterSwitchHolderInPlace.jpg

2scoringTheGNXcutout.jpg

3GNXcutout.jpg

4testFittingGNX.jpg

5testFittingGNXandG5.jpg

6reinstalledInstrumentPanel.jpg

7installedSeatToTestInstrumentPositions.jpg

8positioningTrimIndicator.jpg

9cutoutTrimIndicatorHole.jpg

Jun 29, 2023 Aileron stops, trimming rudder, starting instrument panel - (9 hours)

Category: Instrument Panel

Drilled aileron stops in place; hand tightened jam nuts; deburred, Cortec, and riveted aileron stops in place; tested flaperon movements; riveted L angle on front of horizontal stabilizer; disassembled and deburred horizontal stabilizer support brackets; joined elevator and horizontal stabilizer; checked rudder clearance; marked and cut rudder skin; riveted upper rudder fairing; planning and cutting instrument panel for GDU, G5, and GNX, including making support brackets and pilot drilling.

7mountedHorizTailToFuselage.jpg

8planningInstrumentPanel.jpg

9drawingGDUcutout.jpg

1pilotDrillingAileronControlStops.jpg

2confirmingRangeOfAileronRodTravel.jpg

3cortecOnAileronStops.jpg

4rivetingAileronStops.jpg

5rivetingLangleToHorizStabilizer.jpg

6reattachingHorizStabToElevator.jpg

10drillingCornersOfGDUcutout.jpg

11CuttingOutGDUwithOlfaKnife.jpg

12markingCutoutForRudderSkin.jpg

13removedHorizTail.jpg

14usingOlfaOnGDUcutout.jpg

15trimmingRudderSkin.jpg

16rivetingUpperRudderFairing.jpg

17rivetedUpperRudderFairing.jpg

18cutoutGDUopening.jpg

19deburringGDUopening.jpg

20fittingGDU.jpg

21deburringGDUattachHoles.jpg

22attachingGDUsupportBracket.jpg

23cutting&markingInstrumentPanelSupportBrackets.jpg

24pilotDrillingInstPanelSupportBracket.jpg

25preparingToInstallG5.jpg

26markingG5position.jpg

27cuttingG5hole.jpg

28testFittingG5.jpg

29deburringG5opening.jpg

30installedG5mountingBracket.jpg

31positioningGNXmountingRack.jpg

32markingGNXbracket.jpg

33pilotDrilledGNXmountingBracket.jpg

34markedGNXopening&drilledCorners.jpg

35cuttingGNXopeningWithOlfaKnife.jpg

Jun 27, 2023 Forward Elevator Fairing and Installing Aileron Control Rods - (8 hours)

Category: Wings

Final shaping of forward fairing for horizontal tail, deburred, marked rivet holes and drilled into fuselage, and painted; deburred and painted L angles for horizontal stabilizer; painted other side of horizontal tail attach brackets; planned, measured, cut, tested, recut, and installed lower rods and upper rods for aileron controls; connected aileron rods and adjusted for neutral flaperons, tested for full range, confirmed 13 degrees up and down; marked aileron stops and predrilled.

10deburringForwardElevFairing.jpg

11deburringFuselage.jpg

12paintedForwardElevFairing.jpg

13measuringLengthOfAileronRods.jpg

14trimmingAileronRods.jpg

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15aileronControlRodsTrimmed.jpg

16cleaningUpCutThreads.jpg

17attachedAileronControlRods.jpg

18positioningAileronNeutral.jpg

19measuringUpperAileronControlRods.jpg

1trimmingFrontElevatorFairing.jpg

20cuttingUpperAileronRods.jpg

21paintedHorizTailLangles.jpg

22attachedUpperAileronRods.jpg

23flaperonsAttached.jpg

24settingFlaperonsToNeutral.jpg

25confirmingFlaperonAnglesOfTravel.jpg

26planningAileronStops.jpg

27predrillingAileronStops.jpg

2shapingFrontElevFairing.jpg

3deburringHorizTailLangles.jpg

4deburringForwardElevFairing.jpg

5markingFowardElevFairing.jpg

6paintingHorizTailLangles.jpg

7paintedOtherSidesOfElevBrackets.jpg

8predrillingForwardElevFairing.jpg

9pilotDrillingForwardElevFairing.jpg

Jun 25, 2023 Trim Tab Wiring - (3 hours)

Category: Horizontal Tail

Final drilled horizontal stabilizer to attach brackets; looked over and planned elevator; attached trim tab wiring; began trimming horizontal stabilizer forward fairing; painted one side of horizontal stabilizer attach brackets; removed instrument panel.

1finalDrilledHorizStabToAttachBrackets.jpg

2preparingToConnectElevTrimWires.jpg

3crimpingDsubPinsOnTrimWires.jpg

4shrinkWrappingTrimConnections.jpg

5shrinkWrappedShrinkWrappedTrimWires.jpg

6siliconTape&ZipTiesOnTrimWires.jpg

7beginningToTrimForwardHorizTailFairing.jpg

8paintedOneSideOfHorizStabAttachBrackets.jpg

9removedInstrumentPanel.jpg

Jun 22, 2023 Attaching flaperons and horizontal tail - (6.5 hours)

Category: Wings

Looked over tail fairings; attached quick release nuts to inboard flaperons; drilled out flaperon hinges to 1/4 inch and deburred; riveted flaperon hinge pins; installed flaperons; attached horizontal stabilizer and carefully aligned it; pilot drilled and trimmed horizontal tail attach brackets.

10hangingPilotFlaperon.jpg

11preparingToMountHorizStabilizer.jpg

12mountingHorizStabilizer.jpg

13measuringHorizStabAlignment.jpg

14pilotDrillingHorizStabBrackets.jpg

15horizStab&FlaperonsAttached.jpg

1planningElevatorFairings.jpg

2installedConnectorsForAileronRods.jpg

3finalDrilledFlaperonBrackets.jpg

4installingFlaperonHingeBushings.jpg

5rivetingFlaperonHingePins.jpg

6rivetedFlaperonHingePins.jpg

7preparingToHangFlaperons.jpg

8attachingFlaperons.jpg

9hangingPassengerFlaperon.jpg

Jun 20, 2023 Work on flaperons and elevator trim - (6 hours)

Category: Wings

Prepped and painted flaperons; marked and cut flaperon slots on fuselage and deburred; marked and drilled flaperon hinge pins into fuselage and deburred and painted; painted elevator trim cover plate; cut elevator trim rod to size; final filing of elevator trim rod slot; fished 5-wire bundle into elevator.

10drillingRootHingePins.jpg

11filingRootHingePins.jpg

12paintingRootHingePins.jpg

$gallery thumbnail$

13paintingUndersideOfFlaperons.jpg

14preparingElevTrim.jpg

15preparingElevTrimMotor.jpg

16paintingElevTrimCover.jpg

17paintingOtherSideOfRootHingePins.jpg

18determiningElevTrimArmLength.jpg

19trimmingElevTrimArm.jpg

1preppingForPaintingFlaperons.jpg

20settingElevTrimToNeutral.jpg

21filingElevTrimOpening.jpg

22planningElevTrimWiring.jpg

2paintingFlaperons.jpg

3markingFlaperonLevel.jpg

4markingFlaperonTravel.jpg

6drillingHolesForFlaperons.jpg

7cuttingOutFlaperonSlots.jpg

8markingRootHingePins.jpg

9pilotDrillingRootHingePins.jpg

5markingPilotSideFlaperonTravel.jpg

Jun 04, 2023 Riveting flaperon ribs, control horns, & splice plates - (4 hours)

Category: Wings

Disassembled, deburred, final drilled and sanded control horns; cleaned, cortec, and riveted flaperon end ribs, control horns, and rear splice plates; rehung flaperons and drilled bolt holes in rear splice plates; marked flaperon zero point and arc of travel; marked, predrilled, and drilled front flaperon splice plates, deburred, cortec, & riveted; cleaned all markings off of flaperons.

10drillingRearSplicePlatesForBolt.jpg

11measuringFlaperonZeroPoint.jpg

12marking&DrillingFlaperonFrontSplicePlate.jpg

13positioningFlaperonFrontSplicePlates.jpg

14finalDrillingFlaperonFrontSplicePlates.jpg

15deburring&CortecFlaperonFrontSplicePlates.jpg

16rivetingFlaperonFrontSplicePlates.jpg

17cleaningFlaperons.jpg

1deburringFlaperonControlHorn.jpg

2rivetingInboardFlaperonRibs.jpg

3finalDrillingFlaperonControlHorns.jpg

4shapingFlaperonControlHorns.jpg

5deburring&CortecIBflaperonRibs&Horns.jpg

6rivetedIBflaperonRearSplicePlates.jpg

7rivetedIBflaperonIBribs&controlHorns.jpg

8remountedFlaperons.jpg

9connectingFlaperons.jpg

Jun 01, 2023 Flaperon Control Horns and Rear Splice Plates - (5 hours)

Category: Wings

Marked and pilot drilled flaperon control horns; cut and pilot drilled L angles for flaperon control horns; pilot drilled inboard end ribs; pilot drilled control horns onto flaperons; set flaperon washout angle; made inboard flaperon rear splice plates and final drilled.

10finalDrilledLangleOnPassFlaperonControlHorn.jpg

11settingFlaperonWashout.jpg

12markingFlaperonRearSplicePlates.jpg

13FinalDrilledFlaperonRearSplicePlates.jpg

1cutLanglesForIBflaperons.jpg

2markedIBflaperonRibHoles.jpg

3pilotDrilledIBflaperonRibs.jpg

4drillingFlaperonControlHorns.jpg

5fpilotDrillingPassFlaperonControlHorn.jpg

6pilotDrilledLangleOnPassFlaperonControlHorn.jpg

7pilotDrillingPilotFlaperonControlHorn.jpg

8pilotDrilledLangleOnPilotFlaperonControlHorn.jpg

9finalDrilledLangleOnPilotFlaperonControlHorn.jpg

May 30, 2023 Riveted inboard flaperons - (6.5 hours)

Category: Wings

Sat in cockpit and did panel planning; planning flaperons; fitting and trimming flaperons up against fuselage; deburring, cleaning, Cortec inboard flaperons; made and riveted inboard flaperon ribs; riveted top skin of inboard flaperons; squeeze riveted trailing edges.

10cleaningIBflaperon.jpg

11cortecIBflaperon.jpg

12attachedOBflaperons.jpg

12attachingPilotIBflaperonRib.jpg

13drillingPilotIBflaperonRib.jpg

$gallery thumbnail$

14rivetedIBpilotFlaperonRib.jpg

15strappedDown&clecoedIBflaperons.jpg

16rivetedFlaperons.jpg

17squeezeRivetedIBflaperonTrailingEdges.jpg

1panelPlanning.jpg

2hangingOutboardFlaperons.jpg

3measuringPassIBflaperonAndMarking.jpg

4trimmingPassIBflaperon.jpg

5strappingDown&ClecoingINflaperon.jpg

6markingFlaperonBrackets.jpg

7drillingFlaperonBrackets.jpg

8strappingDownIBflaperonToOpen.jpg

9deburringIBFlaperon.jpg

May 28, 2023 Deburred and painted struts and jury struts - (6 hours)

Category: Wings

Disassembled struts; final drilled strut fittings; trimmed struts; deburred, cleaned and painted struts, strut fittings, and jury struts; bolted struts and jury struts back on plane.

10deburringRearBottomStrutFittings.jpg

11deburringFrontBottomStrutFittings.jpg

12deburringUpperStrutFittings.jpg

13deburredUpperStrutFittings.jpg

14paintingStrutFittings.jpg

15paintingJuryStruts.jpg

16boltingStrutFittings.jpg

17attachedWingStruts.jpg

18attachedPassJuryStruts.jpg

19attachedPilotJuryStruts.jpg

1disassembledStrutFittings.jpg

20atachedWing&JuryStruts.jpg

2trimmedRearStruts.jpg

3finalDrillingFrontStruts.jpg

4finalDrillingStruts.jpg

5strutsFinalDrilled.jpg

6disassembingUpperStrutFittingsForDeburring.jpg

7removingUpperStrutFittings.jpg

8deburringStruts.jpg

9paintingWingStruts.jpg

May 24, 2023 Installed jury struts - (7 hours)

Category: Wings

Drilled holes in struts for jury struts; drilled jury strut holes; installed bottom, front, cross, and rear jury struts.

10testFittingPassCrossJuryStrut.jpg

11trimmingPassCrossJuryStrut.jpg

12boltingPassCrossJuryStrut.jpg

13boltedBothCrossJuryStruts.jpg

14boltedPilotCrossJuryStrut.jpg

15installedPilotRearJuryStrut.jpg

16installedPassRearJuryStrut.jpg

17juryStrutsInstalled.jpg

1positioningBottomJuryStrut.jpg

2predrillingBOttomJuryStrut.jpg

3predrillingJuryStrut.jpg

4drilledBottomJuryStrut.jpg

5trimmingFrontJuryStrut.jpg

6bothBottomStrutsBolted.jpg

7testFittingFrontJuryStrut.jpg

8boltedPilotFrontJuryStrut.jpg

9boltedPassFrontJuryStrut.jpg

May 21, 2023 Attached wing struts - (5 hours)

Category: Wings

Reattached pilot seat; checked airplane level; adjusted for dihedral; cut front wing struts to size; positioned and drilled strut fittings; rechecked dihedral; cut rear struts to size; marked jury strut hole positions; drilled upper rear strut fitting to final size.

$gallery thumbnail$

10cuttingRearWingStruts.jpg

11markingJuryStruts.jpg

12attachedPilotRearWingStrut.jpg

13attachedPassRearWingStrut.jpg

14trimmingRearWingStruts.jpg

15testFittingRearWingStruts.jpg

16drillingRearWingStruts.jpg

1reattachedPilotSeat.jpg

2liningUpWingsAndMeasuringDihedral.jpg

3cuttingFrontWingStrutsToSize.jpg

4markingBoltHolesInFrontWingStruts.jpg

5drillingBoltHoles.jpg

6trimmingFrontWingStruts.jpg

7testFittingFrontWingStruts.jpg

8pilotDrillingFrontUpperWingStrutFittings.jpg

9drillingBoltsForUpperStrutFittings.jpg

May 17, 2023 Attached wings and upper strut fittings - (5 hours)

Category: Wings

Positioned wings and attached wing bolts; drilled and attached upper wing strut fittings; reattached instrument panel.

10drillingFrontPilotUpperFitting.jpg

11drillingRearUpperStrutFittings.jpg

12filingWingSkin.jpg

13reinstallingInstPanel.jpg

1positioningWings.jpg

2measuringWingSweep.jpg

3usingStringToMakeSureStraight.jpg

4drillingRearWingBoltHoles.jpg

5grindingFrontUpperStrutFittings.jpg

6preDrillingFrontUpperStrutFittings.jpg

7pilotDrillingFrontUpperStrutFitting.jpg

8markingRearUpperStrutFittings.jpg

9grindingRearUpperStrutFittings.jpg

May 16, 2023 Drilled wing attach brackets and wing strut fittings - (7 hours)

Category: Wings

Drilled holes for front wing attachments; attached rudder and torqued bolts; installed engine mount and torqued bolts; marked streamline struts; pilot drilled bottom strut fittings; drilled bottom strut fittings inside streamlined struts to final size.

10planningWingStruts.jpg

11markingWingStrutParts.jpg

12markingStrutBoltHoles.jpg

13pilotDrillingBottomStrutBrackets.jpg

14BottomStrutFittingsPilotDrilled.jpg

15finalDrillingStrutFittings.jpg

16markingStrutFittingCenterlines.jpg

17pilotDrillingStrutFittings.jpg

18drillingThroughStrutFittings.jpg

19finalDrilledWingStrutFittings.jpg

1markingCenterOfWingAttachBrackets.jpg

2pilotDrillingWingAttachBrackets.jpg

3finalDrillingWingAttachBrackets.jpg

4mountedRudder.jpg

5torquedBottomRudderBolt.jpg

6torquedUpperRudderBolts.jpg

7attachedEngineMount.jpg

8torquedEngineMountBolts.jpg

9engineMountAttached.jpg

May 09, 2023 Painting left wing and slat - (5.5 hours)

Category: Paint / Decals

Prepped left wing and slat for paint; moved wings; painted top side of left wing and left slat; touched up paint on right wing and fuselage; painted underside of left slat; torqued left wing flaperon brackets; prepped and painted underside of left wing; painted nosewheel strut; removed painters tape; positioned fuselage and wings for wing connection.

10paintingBottomOfLwing.jpg

11paintingNoseStrut.jpg

12removingPaintTapeFromFuselage.jpg

13placingWingsInPosition.jpg

1preppingForPainting.jpg

2positioningLwingForPainting.jpg

3rivetingLwingJuryStrutBracket.jpg

4paintingTopOfLslat.jpg

5paintingTopOfLwing.jpg

6touchingUpFuselagePaint.jpg

7cleaningBottomOfLwing.jpg

8torquingLwingFlaperonBrackets.jpg

9paintingBottomOfLslat.jpg

May 04, 2023 Attached left slat - (4 hours)

Category: Wings

Finished riveting left nose skin; attached left slat together and drilled holes in attach brackets; deburred, cortec, and riveted left slat together.

10LslatHalvesRiveted.jpg

1finishedRivetLnoseSkin.jpg

2cleaningLwing.jpg

3attachingLslat.jpg

4finalDrilledSlatAttachBrackets.jpg

5pilotDrillingLslatHalvesTogether.jpg

6finalDrillingSlatHalvesTogether.jpg

7deburringLslat.jpg

8cortecLslat.jpg

9rivetingLslatHalvesTogether.jpg

May 03, 2023 Installing left wing pitot, wiring, riveting nose skin - (6 hours)

Category: Wings

Flared pitot and AOA tubes, attached connectors; labeled wires, fuel lines, and pitot tubes; ran pitot and AOA tubes; closed up left wing nose skin and clecoed; started riveting left nose skin.

10insideLnose1.jpg

11insideLnose2.jpg

12insideLnose3.jpg

13insideLnose4.jpg

14insideLnose5.jpg

15insideLnose6.jpg

16insideLnose7.jpg

17insideLnose8.jpg

18strappingDown&ClecoingLnoseSkin.jpg

19rivetingLnoseSkin.jpg

1flaringPitot&AOAtubes.jpg

2attachingPitot&AOAconnectors.jpg

3labelingWires.jpg

4labelingFuelTubes.jpg

5labelingAOA&pitotTubes.jpg

6routingPitotTubes.jpg

7routingLwingWires.jpg

8connectingPitotHeatWires.jpg

9bundlingTubes&Wires.jpg

May 01, 2023 Riveting Left Wing Top Skin - (4 hours)

Category: Wings

Labeling wires and pitot tubes; riveted left wing top skin and squeeze riveted trailing edge.

1preppingLabelsForWiring.jpg

2heatShrinkingWireLabels.jpg

3clecoingLwingTopSkin.jpg

4rivetingLwingTopSkin.jpg

5rievtedLwingTopSkin.jpg

6squeezeRivetingLwingTrailingEdge.jpg

7leftWingRiveted.jpg

Apr 30, 2023 Riveted pitot access panel, cleaning nose skin - (4.5 hours)

Category: Wings

Finished pitot access panel and riveted to left wing; cleaned nose skin; planned pitot tubing and wiring connections.

10teflonPasteForPitotConnections.jpg

1pilotDrillingPitotPanelInPlace.jpg

2cuttingOutHoleForPitotTube.jpg

3drillingPitotTubeHolderToCover.jpg

4applyingCortecToPitotCover.jpg

5rivetedPitotTubeHolderToCover.jpg

6installingWireHolders.jpg

7assembledPitotTubeAccessPanel.jpg

8rivetingAccessPanel.jpg

9vacuumingLNoseSkin.jpg

Apr 28, 2023 Closing up left wing, pitot access panel - (6.5 hours)

Category: Wings

Touched up paint on fuselage; installed OAT probe; tested landing light; vacuumed left wing; riveted left wingtip; cleaned left wing and applied Cortec; clecoed left wing top skin and wing skin stiffeners in place; prepared and riveted nut plates on pitot tube access panel.

10LwingBeforeRiveting4.jpg

11LwingBeforeRiveting5.jpg

13LwingBeforeRiveting7.jpg

14LwingBeforeRiveting8.jpg

15LwingBeforeRiveting9.jpg

16LwingBeforeRiveting10.jpg

17clecoingLwingTopSkin.jpg

18insideLwing.jpg

19LwingTopSkinClecoed.jpg

1touchingUpFuselagePaint.jpg

20installingPitotPanelNutPlates.jpg

21countersinkingHolesForNutPlates.jpg

22cortecForPitotPanel.jpg

23rivetingNutPlates.jpg

24rivetingNutPlates2.jpg

2installedOATprobe.jpg

3rivetedLfuelTankGroundWire.jpg

4cleaningLwing.jpg

5rivetingLwingtip.jpg

6cortecOnLwing.jpg

7LwingBeforeRiveting1.jpg

8LwingBeforeRiveting2.jpg

9LwingBeforeRiveting3.jpg

Apr 26, 2023 Pitot Access Panel & Painting Fuselage - (5 hours)

Category: Paint / Decals

Drilled pitot access hatch cover to final size; prepped and painted fuselage.

1markingPitotAccessPanelHoles.jpg

2pilotDrillingPitotAccessPanelHoles.jpg

3finalDrillingPitotAccessPanelHoles.jpg

4finalDrilledPitotAccessPanelHoles.jpg

5cleaning&scuffingFuselage.jpg

6preppingFuselage.jpg

7tapingFuselageForPainting.jpg

8paintingFuselage.jpg

9paintingUndersideOfFuselage.jpg

Apr 24, 2023 painting, oil cooler, pitot access panel - (5 hours)

Category: Paint / Decals

Painted horizontal stabilizer brackets, horizontal stabilizer, and rudder; removed and painted engine mount and throttle bellcrank; prepared engine mount hardware; painted engine mount bolt struts; worked on oil cooler mount; planned pitot mount; planned and cut access panel for pitot mount.

10deburringOilCoolerMount.jpg

11attachingOilCoolerShockMounts.jpg

12trimmedScrewsOnShockMount.jpg

13markingPitotPosition&AccessPanelOutline.jpg

14cutoutForPitotAccessHatch.jpg

15markingPitotAccessHatch.jpg

16cuttingPitotAccessPanelDoubler.jpg

1paintingHorizStabBrackets.jpg

2paintingHorizStab&Rudder.jpg

3cleaningFuselage.jpg

4paintingThrottleBellcrank&EngineMount.jpg

5resprayingEngineMount.jpg

6preparingEngineBolts.jpg

7paintingEngineBoltTubes.jpg

8assemblingEngineBolts.jpg

9attachingOilCoolerMount.jpg

Apr 19, 2023 Installed Left Fuel Tank and Painting - (7 hours)

Category: Wings

Installed left fuel tank; tested left navigation and strobe lights; prepped and painted right wing, elevator, and horizontal stabilizer; torqued flaperon brackets on right wing; riveted jury strut fittings; painted rudder, access hatch, and glare shield.

10putCorkOnLfuelTankBracket.jpg

11cleaningElev.jpg

12finishingUpPaintingRslat.jpg

13paintingRwing.jpg

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14paintingElev.jpg

15paintingHortizStab.jpg

16unpackingEngingRingMount.jpg

17EngineRingMount.jpg

18cleaningBottomOfRightWing.jpg

19rivetingJuryStrutBrackets.jpg

1attachingFuelLine.jpg

20torquingRwingFlapBracketBolts.jpg

21paintedBottomOfRwing.jpg

22paintedFuselageAccessHatch.jpg

23paintedRudder.jpg

24paintedGlareShield.jpg

2vacuumingLeftWing.jpg

3attachingFuelReturnLine.jpg

4attachingLeftFuelTankLine.jpg

5siliconeTapeOnLsideOfFuelReturnLine.jpg

6siliconeTapeOnRsideOfFuelReturnLine.jpg

7rivetedFuelReturnLineHolder.jpg

8rivetingLOBfuelTankBrackets.jpg

9rivetingLfuelTankGround.jpg

Apr 14, 2023 Painting R wing, nav light wiring for left wing - (6 hours)

Category: Wings

Prepped and started painting right wing; made four wooden wing position holder; planning left wing wiring and pitot; painted more of right wing top; planned and wired left wing landing light and nav/strobe; ran fuel return line; looked over elevator.

10fuleReturnLineInPlace.jpg

11lookingOverElevator.jpg

1paintingRwing.jpg

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2touchingUpRslat.jpg

3cuttingWoordForWingHolders.jpg

4woodenWingHolders.jpg

5planningPitotConnections.jpg

6paintingRwingMore.jpg

7wiringLnavLights.jpg

8runningLwingLanding&NavLightWires.jpg

9drillingFuelReturnLineHoles.jpg

Apr 12, 2023 Left Wing Landing Light & Nav Lights - (7 hours)

Category: Wings

Worked on landing light bracket, deburred and riveted; cut landing light lens to shape; applied Cortec and riveted left wingtip angles; vacuumed left wing; drilled holes for fuel return line; painted right slat; drilled holes in pitot tube holder; worked on left nav and landing light wiring; applied form a gasket to left fuel tank fittings; drilled hole in left wing noseskin fo landing light wiring; window spliced landing light ground to nav light ground; attached Molex connectors to nav light wiring; startied installing landing light wiring and nav light in left wingtip.

10drillingHolesForFuelReturnLine.jpg

11drilledHoleForFuelReturnFitting.jpg

12paintingBottomOfRslat.jpg

13markingHolesForPitotTube.jpg

14attachingPitotTubeToHolder.jpg

15cuttingBackLwingNavLights.jpg

16puttingFormAGasketOnFuelTankFittings.jpg

17hole&grommetForLandingLightWire.jpg

18splicingLandLightGroundWithNavLightGround.jpg

19solderingGround&AttachingMolexConnectors.jpg

1wiringLandingLight.jpg

20navLightShrinkTubing&MolexHousings.jpg

21placingLandLightWires&NavLightInLwingtip.jpg

22paintedTopOfRslat.jpg

2shrinkWrappingLandingLightWires.jpg

3landingLightWires.jpg

4finalDrillingLandingLightBracket&Cover.jpg

5rivetingLandingLIghtBracket.jpg

6cortecForLwingtipLangles.jpg

7clecoingLwingtip.jpg

8rivetingLwingtip.jpg

9vacuumingLwing.jpg

Apr 07, 2023 Working on left wing and landing light - (7 hours)

Category: Wings

Planning pitot and OAT probe placements; more deburring of left wing skeleton and top skin; cleaned skin; planned landing light; trimmed landing light lens; pilot and final drilled landing light bracket; test fit landing light; grinded down landing light cooling fins; deburred and applied Cortec to landing light bracket.

10testFittingLandingLight.jpg

11sandingBackLandingLightFins.jpg

12deburred&CortecLandingLightBracket.jpg

1planningPitotAndOATprobePlacements.jpg

2deburringLwingSkeleton.jpg

3deburringLwingTopSkin.jpg

4cleaningLwingTopSkin.jpg

5planningLandingLight.jpg

6trimmingLandingLightLens.jpg

7pilotDrilledLandingLightBracket.jpg

8finalDrilledLandingLightBracket.jpg

9installingLandingLightToBracket.jpg

Apr 05, 2023 Working on left wing - (4.5 hours)

Category: Wings

Final drilled right wing slat attach brackets; drilled between inboard and outboard right slats to attach them; deburred; cleaned and applied Cortec to right slat; riveted. Moved wings; unclecoed left wing top skin and nose skin; used edge roller on left nose skin; marked pitot tube location; filed left wing slat slots; started deburring left wing nose skin.

10removedLwingNoseClecoes.jpg

11removedLwingTopSkin.jpg

12edgeRollingLnoseSkin.jpg

13filingLwingNoseSlots.jpg

14markedPitotTubeLocation.jpg

1finalDrilledRslatBrackets.jpg

2pilotDrillingRightIBtoOBslat.jpg

3finalDrillingRightIBtoOBslat.jpg

4finalDrilledBackOfRslats.jpg

5deburringRslats.jpg

6deburringRslatBrackets.jpg

7applyingCortecToSlatConnection&Brackets.jpg

8rivetedRslatSectionsTogether.jpg

9movedRwing.jpg

Mar 31, 2023 Riveted right wing - (7.5 hours)

Category: Wings

Final drilled and deburred bottom of instrument panel; connect GMU 11; strapped right wing nose skin and clecoed; Clecoed right wing trailing edge; riveted right wing nose and top skin; squeeze-riveted right wing trailing edge; fit together right wing inboard and outboard slats, made jigs for positioning, and pilot drilled to attach brackets.

10createdTopSlatEdgeSpacers.jpg

11createdBottomEdgeSlatSpacer.jpg

12spacingRwingSlat.jpg

13rightWingSlatAligned.jpg

1connectedGMU11.jpg

2gmuWiring.jpg

3clecoedRwingSkin.jpg

4clecoedRwingTrailingEdge.jpg

5rivetedRwingTopSkin.jpg

6squeezeRivetedRwingTrailingEdge.jpg

7rightWingRiveted.jpg

8markingRwingSlatsToFitTogether.jpg

9testFittingRwingSlat.jpg

Mar 29, 2023 Ran GMU wires, pictures of Right Wing, Clecoed Top Skin - (4 hours)

Category: Wings

Finished GMU 11 connector; ran GMU wires with zip ties; applied labels to wires; vacuumed and cleaned right wing; applied Cortec; took pictures of inside of right wing; secured nav wires; clecoed top skin of right wing.

10insideRwing4.jpg

11insideRwing5.jpg

12insideRwing6.jpg

13insideRwing7.jpg

14insideRwing8.jpg

15insideRwing9.jpg

16insideRwing10.jpg

17insideRwing11.jpg

18insideRwing12.jpg

19insideRwing13.jpg

1connectedBackshellToGMU11.jpg

20insideRwing14.jpg

21insideRwing15.jpg

22insideRwing16.jpg

23insideRwing17.jpg

24insideRwing18.jpg

25insideRwing19.jpg

26insideRwing20.jpg

27insideRwing21.jpg

28insideRwing22.jpg

29insideRwing23.jpg

30insideRwing24.jpg

31insideRwing25.jpg

32insideRwing26.jpg

33securedNavWires.jpg

34installedRwingTopSkin.jpg

35clecoedRwingTopSkin.jpg

3zipTyingGMUwires.jpg

4labeledFuelSender.jpg

5labeledRwingWires.jpg

6cleaningRwing.jpg

7cortecRwing.jpg

8insideRwing1.jpg

9insideRwing2.jpg

Mar 28, 2023 fuel tank install and right wingtip - (3.5 hours)

Category: Wings

Installed right wing fuel tank; inserted fuel strainer and fuel nipple with form-a-gasket; put cork on right fuel tank rear bracket; riveted right tank ground wire; riveted outboard tank brackets; assembled right wingtip; installed right nav lights and routed wire; riveted back half of right wingtip.

10attachingRnavLights.jpg

11Rwingtip.jpg

12routingRnavWiring.jpg

13rivetedZipTieForNavWiring.jpg

14runningNavWire.jpg

15rivetingRwingtip.jpg

16rivetedNavWireCableHolder.jpg

1fuelTankFittings.jpg

2applyingFormAGasket.jpg

3connectingRfuelTankHose.jpg

4installedRfuelTank.jpg

5clecoedInboardFuelTankBrackets.jpg

6attachedCorkToRearFuelTankBracket.jpg

7attachedRfuelTankGroundWire.jpg

8rivetedInboardFuelTankBrackets.jpg

9assemblingRwingtip.jpg

Mar 27, 2023 Work on GMU and R Fuel Tank - (5 hours)

Category: Avionics

Put Cortec on Right wingtip angles; avionics planning; tested dimmer for cockpit light; twisted and added zip ties to navigation lights; drilled holes, deburred, and installed grommets for GMU 11 wiring; cleaned nose area of right wing; put cork on both fuel tanks; test fit right fuel tank; cut wires and crimped connectors for GMU 11.

10corkAroundTankOpening.jpg

11cleaningFuelTankBay.jpg

12installingRfuelTank.jpg

13crimpingWiresForGMU.jpg

14installingGMUconnector.jpg

15creatingCANbusConnectorForGMU.jpg

1cortecRwingtipAngles.jpg

2testingCockpitLightDimmer.jpg

3twisting&ziptyingNavLights.jpg

4drillingHolesForGMUwiring.jpg

5installingGrommetsForGMU.jpg

6cleaningOutRwingNose.jpg

7cleaningFuelTanks.jpg

8installingFuelTankCork.jpg

9moreCorkOnTanks.jpg

Mar 16, 2023 Fuel Tank Test - (4 hours)

Category: Fuel System

Looked over oil cooler and trimmed and smoothed fiberglass cover; installed cork; crimped and attached wires to fuel senders; tested fuel tanks for leaks and fuel flow; crimped Molex connectors to right nav light wires; vacuumed right wing; discussed GNX375 installation and other avionics with Levi Self; mounted GMU11.

10installedNavLightMolexOnShieldedCable.jpg

11vacuumingRwing.jpg

12planningGNXinstallation.jpg

13boltedGMU11.jpg

1lookingOverOilCooler.jpg

2smoothedWarpsWithHeat&trimmedFiberGlassOilCoolerAirGuide.jpg

3testFittingOilCoolerCover.jpg

4installedCorkOnOilCooler.jpg

5crimpedConnectorsOnFuelSenderWires.jpg

6installedWiresOnRfuelSender.jpg

7installedWiresOnLfuelSender.jpg

8testingFuelTankForLeaks.jpg

9testingFuelCapForFuelFlow.jpg

Mar 10, 2023 Electrical and firewall cable pass throughs - (5.5 hours)

Category: Firewall

Tested SPDT switch for cockpit light; attached Molex connectors to nav lights; hammered and drilled throttle bellcrank and attached cable stops; inventoried electrical supplies from SteinAir; created and riveted fuel tank grounding wires; drilled holes, deburred, and installed cable pass throughs in firewall for throttle and choke; attached CAN terminal to GMU 11; started stripping shielded cable; applied Cortec to right wingtip brackets.

10drillingHolesForThottleCables&ChokeCable.jpg

11deburringCablePassThroughs.jpg

12installedCablePassThroughs.jpg

13installedCanTerminalOnGMU11.jpg

14strippingShieldedCable.jpg

1testingSPDTswitchForCockpitLight.jpg

2crimpedMolexConnectorsToNavLights.jpg

3preparingThrottleBellcrankForCableStops.jpg

4drilledHolesInThrottleBellcrankForThrottleCableStops.jpg

5attachedThrottleCableStopsAndMarkedFirewallPassThroughs.jpg

6inventoryOfSteinAirElectricalSupplies.jpg

7preparingFirewallThrottleCablePassThroughs.jpg

8crimpingFuelTankGroundWires.jpg

9rivetedFuelTankGroundWires.jpg

Mar 08, 2023 Nav lights, fuel senders, GMU 11 - (6.5 hours)

Category: Wings

Mounted navigation/position/strobe lights on both wingtips; vacuumed and cleaned fuel tanks; installed fuel drain valves with Aviation Form-A-Gasket; installed plug on right fuel tank in hole for fuel return line; started installing fuel senders; planning wing wiring, drilled, deburred, installed grommets; installed right wing nav light wire; test fit right fuel tank; did inventory of avionics/electrical supplies; tested and installed cockpit light; rolled edges of glareshield and right nose skin; calculated that GMU 11 needed to be 1mm higher on one side to match dihedral of wing; final drilled and deburred holes for GMU 11 and shim; applied Cortec to GMU 11 shim.

10rivetedLnavLightBracket.jpg

11testFitLnavLight.jpg

12deburringFuelSenderHoles.jpg

13blowingOutFuelTanks.jpg

14sealingFuelDrainsWformAGasket.jpg

15sealingRtankFuelReturnHole.jpg

16installingRfuelSender.jpg

17installingLfuelSender.jpg

18planningRwingWiring.jpg

19drillingHolesForNavLightWire.jpg

1creatingDoublerPlatesForNavLights.jpg

20testFittingRfuelTank.jpg

21ranNavLightWire.jpg

22takingInventoryOfAvionicsSupplies.jpg

23testingCockpitLight.jpg

24mountedCockpitLight.jpg

25edgeRollingGlareshield.jpg

26edgeRollingRwingNoseSkin.jpg

27planningGMU11mounting.jpg

29pilotDrillingHolesForGMU11.jpg

2pilotDrillingNavLightDoublerPlates.jpg

30drilling&DeburringGMU11holes&plate.jpg

31cortecForGMU11plate.jpg

3pilotDrilledNavLightBracket.jpg

4finalDrilledNavLightBracket.jpg

5deburringWingtips.jpg

6deburringNavLightDoublerPlates.jpg

7rivetingNavLightHolder.jpg

8testFittingNavLights.jpg

9cuttingLnavLightHoles.jpg

Mar 04, 2023 Epoxy, fuel senders, nav lights - (6 hours)

Category: Controls

Final drilled, sanded, & deburred instrument panel gussets; deburred, cleaned, and positioned brake line retainers and nose gear tow bar hole; applied epoxy weld; studied and bent fuel senders; cleaned fuel tanks; looked over right wing; tested nav lights; put correct bolts on brake cylinders.

10bentRightFuelSender.jpg

11testingNavLights.jpg

12gatheringMaterialsToMountNavLights.jpg

13installingBoltsOnBrakes.jpg

1BeltSandingInstrumentPanelGussets.jpg

2finalDrillingInstrumentPanelGussets.jpg

3deburringInstrumentPanelGussets.jpg

4preppingNoseGearForEpoxy.jpg

5testFittingBrakeLineRetainers.jpg

6applyingEpoxyWeldToBrakeLineRetainers.jpg

7applyingEpoxyWeldToNoseGearTowbarHoles.jpg

8studyingFuelSenders.jpg

9bentLeftFuelSender.jpg