Project: bbellamy   -  
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Builder Name:Brad Bellamy   -  
Project:   Vans - RV-7A   -   VIEW REPORTS
Total Hours:1851.6
Total Flight Time:
Start/Last Date:Jan 01, 2001 - No Finish Date
Engine:IO-360
 
Friendly URL: https://eaabuilderslog.org?s=bbellamy

Home or Last Project Picture

Sep 01, 2024     GOAL - ready to fly grandkids!       Category: Milestones
My goal is to finish inspections, transition training and flight testing before 9/1/2024. I want to fly to visit the grandkids and start taking them on flights as soon as they are ready. The plane has to be safe and I have to be current. It is okay if the RV isn't painted.

I started the project in 2001 and made fairly good progress on the slow build empennage and wings. I started on the slow build fuselage in July 2005. I got stuck several times after that. Sometimes for valid reasons (Ellicia's health, 11 months of contract work in Washington state at Boeing, my health), but most of the time for no good reason at all. I always enjoyed it when I started working on the RV again and was always surprised that the short break turned out to be so long.

Project Restart Phase 1:
To get back into the routine, I have to work on it daily from 4/15/2022 to 7/22/2022. Even when I am traveling I have to do something such as research to support the project. The consequence for missing a day of work on it from 4/15 to 7/22/2022 is to send my daughter $50. And the reward for missing 5 or fewer days of work between 4/15 and 6/15 is I get to go to AirVenture 2022.

I only missed one day in phase 1, 7/22 when I was traveling to Oshkosh. I had a great time and learned a lot at Oshkosh this year. I bought some parts, finalized my decision to use a full Garmin panel, started thinking about a different IFR navigator, and found new options for engine suppliers. I plan to purchase avionics in August and an engine in the next month or two.

Project Restart Phase 2:
Continue trying to work on the project every day and increase the hours per week to at least 21 from August 7 to December 31, 2022.
I'll be ordering Avionics and the engine this phase. I don't have to work on it during days I am traveling (to visit the grandkids for example!!). The consequence for missing my weekly goal of 21 hours except on travel weeks is to send my daughter $50. I missed my weekly commitment 2 times this phase.

Project Restart Phase 3:
Continue to try to work on the project every day and increase the hours per week to at least 31.5 (average of 4.5 hours a day) for 1/8/2023 through 4/29/2023. I don't have to work on it during days I am traveling (to visit the grandkids for example!!) or when they are in town visiting me or we have other out of town guests. The consequence for missing my weekly goal of 31.5 hours except on travel weeks is to send my daughter $50. The reward is to get closer to flying. I completed phase 3 without missing any weekly commitments.

Project Restart Phase 4:
Took a break the week of 4/30 which included two days for contract work to help pay for some airplane parts. I did work on the project some days.
Starting Phase 4 on Sunday, May 7. Continue to try to work on the project every day and continue with the hours per week of at least 31.5 (average of 4.5 hours a day) for 5/7/2023 through 9/30/2023. I don't have to work on it during days I am traveling (to visit the grandkids for example!!) or when they are in town visiting me or we have other out of town guests. The consequence for missing my weekly goal of 31.5 hours except on travel or visit weeks is to send my daughter $50. The reward is to get closer to flying. I missed 4 out of 22 weekly goals.

Project Restart Phase 5:
Starting the week of 10/1/2023 and ending 12/30/2023. Continue with the hours per week of at least 31.5 (average of 4.5 hours a day). I don't have to work on it during days I am traveling (to visit the grandkids for example!!) or when they are in town visiting me or we have other out of town guests. I also get two full days off when we return from Hawaii trips to recover from the travel and time change. The consequence for missing my weekly goal of 31.5 hours except on travel or visit weeks is to send my daughter $50. The reward is to get closer to flying.

Project Restart Phase 6:
It was hard to get this phase started. Two weeks in Hawaii with the kids in December and February didn't help, but I sure enjoyed it.

Starting the week of 3/3/2024 and ending 6/29/2024. Same rules as phase 5 except I get the day off when I am working full time on contract work or I am sick or need to take it easy such as three days when I have oral surgery in March. I also plan to include time for documentation and for fiberglass training this phase. I doubt if it will be a problem, but I can change the phase 6 rules if the situation changes dramatically (such as I move the project to the airport or start working with fiberglass that limits when I can work).

Project Restart Phase 7:
I'll review progress at the end of Phase 6 and define Phase 7 goals, consequences and rewards.


 
May 02, 2024     Instrument Panel - (2.8 hours)       Category: Fuselage
Shoulder and neck is hurting. Taking a few light days to help recover fully.

Cleaned up the area around the instrument panel. Disconnected another avionics device from the wiring harness and installed protective covers. Covered up the GDU and access panel holes in the instrument panel and stacked wiring and remaining devices on the instrument panel. Ready to move it downstairs for now and to the garage when it is time to install the panel.

Labeled two more parts storage boxes and filled them with recently purchased hardware. Added more labels to a third box.


 
May 01, 2024     Firewall Throttle, Mixture and Alt Air Holes - (5 hours)       Category: Fuselage
I ground a clearance cut in the rotisserie mount with a large sanding drum so I could drill the hole for the Alternate Air control from the engine side of the firewall. Drilled a pilot hole with my smallest step drill. Used a larger step drill for the final hole. Cleaned up and deburred the hole with a debur tool and finally a Dremel tool with a sanding drum. The hole turned out to be very round and a 0.618 OD socket with one layer of tape (0.626") fit through nicely with a very small and even clearance all around. A dial caliper showed a hole ID of 0.0640" at one location. My goal was 0.625" - 0 + 0.030 and I think I achieved it.

The hole for the Mixture control was straightforward with great access on the engine side and good access on the cockpit side. The Hercules cobalt step drills that I purchased this morning didn't work as well as the Warrior titanium step drills I had already been using for smaller firewall holes. So I made a Harbor Freight run to get the larger Warrior titanium bits. I finished the Mixture hole with the Warrior step drill, but I'm not sure it was a lot better. I think the larger size jump between steps and the larger hole diameter made it not work as well as the small Warrior step drills. I had to work on the larger holes with a debur tool and a Dremel sanding drum to clean them up. The resulting hole turned out nice. I measured the hole ID of 1.140 after using the debur tool and 1.150 to 1.162 after using the Dremel sanding drum. Image 7907 shows a 1.158" socket will not fit through the hole. A 1.129" OD socket (socket with two wraps of tape) fit through the hole easily with a small even gap. My goal was 1.125" -0 + 0.030" and it seems I missed it by 0.005 to 0.010".

The hole for the Throttle control was more difficult with only access at an angle on the engine side and okay access on the cockpit side. I used the small and then large Warrior step drill. The resulting hole wasn't as clean as the hole for the mixture control and required more work to debur and clean up. The final hole was not as round as the mixture hole. Image 7917 shows a 1.158" socket will not fit through the hole, but there are approximately 0.030" gaps in some areas. A 1.129" OD socket (socket with two wraps of tape) fit through the hole easily, but there was a larger, uneven gap compared to the hole for the mixture control. My goal was 1.125" -0 + 0.030" and it seems I missed it by 0.030 to 0.035". I'm still confident it will work.


 
Apr 30, 2024     Firewall Fittings - (4.5 hours)       Category: Fuselage
Called Doug at double tee (firewallfittings.com) to ask the questions I sent on Saturday. He answered as hoped and promised to send more details later. He sent me a part drawing instead of trying to describe it and it answered my final questions. I placed an order for one of the 6100-0.240s and two of the 4200-0.375. It may be a month or more before I get the 4200's, but I can drill holes now and expect them to fit.

Made a final decision about where to locate the two EMT wire feedthrough. Drilled undersized holes to approximately match the flat width and then filed larger as needed.

Looked at the double tee drawing and tolerances. Tried to find thread sizes. Learned more about thread specifications, but decided to stop looking and just go with the 1.125" hole -0 +0.030 we discussed. Looked at my step drills and then at the hydraulic punch. The step drills are too small. The punch will just barely fit where I need it, but the sizes are wrong. Decided to buy a larger step drill at harbor freight along with larger sanding drums than my Dremel tool to use in smoothing out or enlarging the holes if needed.


 
Apr 29, 2024     Brake Line Brackets, Firewall Holes - (4.5 hours)       Category: Fuselage
Remade larger version of one of the parts of the firewall brake mount using a thinner material. After fitting, made the center spacer. Clamped all the parts together and drilled. Trimmed all the edges to match. Installed the completed bracket.

Considered different options for the brake line mount on the center rudder bar support. Mocked up several potential mounts with pasteboard.

Discussed the two options for location of the firewall feedthrough for GEA 24 signals with Ellicia. Looked at pictures from a project that Deene was supporting. Decided to use a third location that offers several benefits including more room to route wires, lower overall wire length and more clearance above the battery to allow easier replacement.


 
Apr 28, 2024     Brake Line Bracket on Firewall - (3.6 hours)       Category: Fuselage
Started fabrication of the original bracket idea which used a hole drilled at a 45 degree angle to allow the vertical run of the brake line through a bracket mounted on the 45 degree firewall stiffener. Tried using a step drill and then a drill bit. The results weren't great so decided a different approach was needed.

Decided on a new bracket design with slots to allow the lines to move side to side, but not forward and aft. Used a second part to secure the lines in the right and left direction. Realized I needed to make a new larger version of the second part.


 
Apr 27, 2024     Cables and Firewall Feedtrhroughs - (3.2 hours) Category: Fuselage
Met my goal for the 4th week in a row. I'm back on track.

Read email from Doug at DoubleTee. Made final(?) decision on fittings to use and sent questions to Doug and placed parts in the shopping cart. Created document with notes from phone call and additional questions. Downloaded pictures from DoubleTee. Saved notes and pics in the manuals and data sheets folder.

Searched for fiberglass project materials online. Ordered acrylic sheet and and roll of carpet (countertop) protector from Amazon. Searched for aluminum sheet on Amazon and online metals. Decided to use something I already have that is close enough to the 0.016" thickness specified.

Cut several paper templates to mock up several methods of securing brake lines.
 
Apr 26, 2024     Firewall, Controls, Fuel - (5.4 hours)       Category: Fuselage
Called Randy at McFarlane Aviation and decided which style cables to use. Received cable OD information needed for firewall feedthrough selection. Updated notes on cables and saved in data sheet folders. Also downloaded and saved additional cable documents.

Called Doug at DoubleTee (firewallfittings.com) to ask for guidance on fitting selection. Doug promised to send me information on TTP-S and 7100 sizes.

Placed order for Cherry Max rivets and assorted screws. Deleted the firewall feedthroughs from the order since I don't know which ones I want yet and I can order direct from DoubleTee.

Centerpunched firewall penetration locations for "A" Throttle, "F" mixture, "L" alternate (bypass) air, and "M" nosegear bolt access. Drilled the M hole using a step drill and deburred it. An earlier drawing revision said to use a 1" hole for the nosegear bolt access. The most recent revision said to use a 3/4" hole. I used the smaller hole and marked it to remind me to test the hole size before finishing the engine mount installation.

Opened nylon 6"x6" packages from McMaster and thought about how to use them. Decided to mock up a few different designs using cardboard.

Thought about options to enlarge the center hole of the grommets from McMaster for the fuel line openings on the side of the fuselage. The standard size grommets won't work in the 1" holes specified by Van's. Ended up sandwiching each grommet between two boards and using a 0.5" step drill to enlarge the grommet ID.


 
Apr 25, 2024     Controls and Firewall Penetrations - (3 hours) Category: Fuselage
Update notes from previous day conversation with Van's Builder Support and from additional research before and after the call. Created builder log entry for previous day.

Researched McFarlane control cable options. Researched DoubleTee Products Firewall Fittings at their website and at Aircraft Spruce. Researched Van's control options. Wrote down a list of questions for McFarlane and DoubleTee.
 
Apr 24, 2024     Research - (6 hours) Category: Fuselage
Reviewed drawing spreadsheet showing questions and associated drawings. Worked to detail list of questions to discuss with Van's builder support. Discussed the following with Van's builder support:

DWG 24 six rivets on each side for F-902 to F-7105B. Suggested solid rivets where possible. Suggested Cherry Max structural rivets in other places. Additional research found posts on vansairforce by Van's employees saying CR3213-4-x (-2 in my case) were used in some key places on Van's kits because they had higher shear strength. I'll try to squeeze the ones I can reach and use Cherry rivets in the other locations. Added Cherry Max rivets to my aircraft spruce cart.

Space needed above PC680 to remove battery. No guidance so I will be conservative and not place anything above the battery so it can be raised up to the flange on the firewall if needed. Instead of using the electrical feedthrough location above the battery suggested by Brian, I'll move the feedthroughs closer to the engine mount bolt by the brake fluid reservoir.

Engine and battery ground point. OP 27R2, OP 30 and OP 31 all show different options. It looks like sometimes the grounds could be common and other times separate. Since I used pro seal on the firewall recess and primer on the other firewall parts, I will use a common bolt for the engine and battery ground connection. And also run a wire from that location to the Avionics ground bus near the panel.

Nose gear access hole. DWG 19 R4 and R5 and some versions of OP 33 R1 stated a hole was needed for some of the engines, but didn't list the IO-360-M1B. The person I talked to at builder support wasn't familiar with the hole and guessed I was reading the drawing correctly. So I wasn't going to add the hole even though the hole plug is included in my FWF kit. After the call I completed additional research on vansairforce and found a note about using DWG 46A. Rev 2 shows use of a 1" diameter hole and R3 shows a 3/4" hole. Inspection of my engine mount made it obvious to me that I needed to add a hole. I'll use 3/4" and increase to 1" if it appears to be a problem when I install the engine mount.

Throttle, mixture, alternate air and cabin heat cable hole in stiffener. DWG 19 R4 and R5 and OP 26. Builder support didn't seem very familiar with the drawing or if they applied to IO-360-M1B or just to IO-360 vertical induction. Builder support did suggest looking at OP 22 which I had seen before, but forgotten about. I think it does work for my engine and the mixture and throttle parts included in my FWF parts order. Builder support did agree with my choice of DWG 19 F for mixture, A for throttle, and L for alt air, but that didn't give me a lot of confidence.

Discussed what I found out from builder support with Ellicia. She suggested finding someone that built using my configuration and ask them. I then remembered I had pictures from an RV-7, IO-360-M1B build that Deene had showed me. I looked back at the pictures and found they helped me confirm answers to most of my questions. And finding DWG46A helped answer a lot more.

Looked at McFarlane drawings, but didn't settle on what controls to use for cabin heat valve, throttle, mixture, and alt air.
 
Apr 23, 2024     Firewall - (3.8 hours) Category: Fuselage
Updated builder log and pictures for previous few days.

Looked up strap material to help remove battery from battery box and added to McMaster cart.

Match drilled pressure sensor manifold to firewall and instrument panel structure. Deburred holes.

Decided on change to make on cabin heat air diverter. Reviewed FWF documents and identified additional firewall holes battery ground, engine ground, oil pressure sensor line support. Found hole needed for cabin heat control cable. Looked up control cable OD at Van's and McFarlane. Added to list of Van's questions.

Updated maintenance manual with firewall fuel feedthrough changes, brake line R and L swap, and GMU 11 standoffs.
 
Apr 22, 2024     Brake, Fuel Lines - (6.3 hours)       Category: Fuselage
Reviewed notes for previous week to see what parts I needed to order. Reviewed plan for brake line mount. Considered several options for additional brake line mount for crossover hoses. Looked at options for modeling clay one final time and selected McMaster clay and added to order. Added additional nylon sheets to McMaster order. Added parts to Aircraft Spruce cart for future order. Placed McMaster order.

Removed fuel pump mounting plate, fuel pump and filter as one assembly by disconnecting the filter to valve fuel line. Wrapped silicone tape around the fitting that might contact the floor of the fuselage.

Swapped the right and left brake lines and confirmed the fit was much better.

Fit the heater box in place and confirmed the routing of the brake lines works. Also confirmed there is plenty of room for the instrument panel to aft fuselage wiring to fit. Thought about options to secure fuel and brake lines and wiring. Decided to use click bond mounts to locate them and additional foam (per Van's instructions) to protect them more. I probably won't need to use conduit to protect wires in the center tunnel. Found a CB4132 mount that would work better than a homemade mount to secure brake lines. Sent an email to theflightshop.com asking for price and availability.

Removed and smoothed OD and ID of firewall fuel bulkhead fitting spacer.


 
Apr 21, 2024     Fuel, Brake Lines - (3.9 hours)       Category: Fuselage
Continued work on fuel lines. Looked at fit of lines and fittings between fuel pump and firewall (look at the picture with the inspection mirror showing the fittings below the fuel pump mounting plate). Determined the fuel line under the pump mounting plate had to be routed outside the pump/filter assembly to keep the line from touching other fuel lines.

Reinstalled the fuel valve to check final location and fit of fuel filter and pump. Torqued a few of the AN fittings that could be reached and would likely not be disconnected.

Tested foam sheet fit. My guess for thickness and density was a good one that will work.

Checked squeezer yokes and how they will work with riveting the final instrument panel structure in place. Decided I needed a longer yoke to allow squeezing a few more of the rivets and placed an order with ATS.

Looked at options to install the six challenging rivets on each side for the F-7105 to F-902 rivets. I may be able to use a longeron yoke on a squeezer for a few of them. I may be able to use a rivet gun for the rest of them, but it will be challenging. I could use a blind rivet for some or all of them, but will need to see if that is acceptable to Van's before I do that.

Looked at brake line routing and decided I needed to swap the lines between the right and left firewall to landing gear mounts.


 
Apr 20, 2024     Brakes, Fuel, - (5.2 hours)       Category: Fuselage
Installed new drilled bolts and final cotter keys on copilot master cylinder bolts. Looked at options for brake line routing around fuel lines and how the brake lines routed and fit when connected to the trigear FW brake fittings. The routing may work, but it doesn't seem right.

Received new o-rings for Andair valves and installed them where the two fittings attach. Staked the screws for the fittings per Andair instructions.

Searched for nylon sheets for brake line supports. Searched for grommets for fuselage where fuel lines exit the cabin.

Installed fuel pump and filter mounting plate, pump, filter, valve and sheet metal around the valve. Started following Aircraft Specialty instructions for installing the fuel lines.

Clecoed the structure in front of the instrument panel in place. Looked at fit for brake lines, wiring and options for brake line support brackets.

Removed the fuel valve with the sheet metal and fuel pump and filter left in place. Procedure is remove screws attaching the valve to the top plate and the top plate to the spar and sheet metal. Then remove the top plate. Then the valve can be removed.


 
Apr 19, 2024     Parts, Documentation, Rudder Bar Mounts - (3.3 hours) Category: Fuselage
Inventoried Aircraft Spruce and Airline Hydraulics parts that arrived today.

Checked rudder bar mounting bolts and realized not enough threads were showing on the two bolts on the right side. Changed top and bottom washers to AN960-10L and retorqued. Marked all 6 nuts with torque seal.

Updated maintenance manual with Andair o-ring part numbers, details on rudder bar spacers, brake caliber potential alternate o-rings, some Van's part numbers and other information. Added a new section for Canopy modifications with Supertrack Canopy Track Extension. Started a new summary section of modifications for a quick way to identify changes.

Not included in hours... Picked up some supplies for fiberglass work from Harbor Freight (electrical tape, 2" chip brushes, "bondo" spreaders, non-powdered nitrile gloves).
 
Apr 18, 2024     Fuel Valve, Brake Lines and Rudder Bar - (4.8 hours)       Category: Fuselage
Received a response from Jenny at Andair saying the ORO020 is a 15 x 1.5 Viton 75 O-ring. Disassembled Andair valve and measured to confirm 15mm was the ID. Researched o-ring sources and placed an order with McMaster Carr for a one package of 9263K114 o-rings.

Looked up potential brake caliper o-rings to document in the maintenance manual. I had previously ordered caliper o-rings from Van's since the McMaster Carr o-rings did not meet the low temperature spec listed in the SB.

Completed the rudder bar install with the "0.090 thick spacer on the left and the 0.125" spacer on the right. Moved the assembly to the center position and installed with the final locknuts. Did not use lubricant on the UHMW PE block to rudder bar connection. Used one pair of AN960-10 washers on each end mounting block between the top and bottom half. Used a pair of AN960-10 and a pair of AN960-10L washers between the top and bottom half of the center block. Torqued the nuts to 20 inch pounds which included the friction drag of the new lock nuts. Started making updates in the maintenance manual.

Installed the crossover and pilot to firewall brake lines finger tight. Considered different options for securing the brake lines. Used tie wraps to temporarily secure the lines and check for freedom of movement. Sketched a few potential brackets to help secure the lines.


 
Apr 17, 2024     Brake and Fuel - (4.4 hours)       Category: Fuselage
Started final assembly of Andair valve. Andair instructions said to lubricate fitting to body seals and tighten and stake the screws. I pulled the fitting loose and found the seals were dry. I realized the dry seals that were over 10 years old had probably taken a set and maybe hardened. I decided to replace the seals now instead of later after I would have to deal with more disassembly as well as fuel in the lines. Researched replacement o-rings at Andair and Andair US distributors and found they weren't available. Researched options at vanairforce and didn't find any. Emailed Andair asking for US distributor or information so I could buy a standard o-ring.

Installed fuel line and brake line on left side in front of spar. The assembly order matters, but isn't too difficult. Decided I might want to route the lines differently. Installed the fuel and brake lines on the right side to see if the new way was actually better. Reworked the left side to match the right side. Still need to clean up silicone tape I used to prevent wear. The final routing has the brake line resting against the landing gear mount tube and the fuel line routing over it. This should work as long as the fuel line is able to reach the tank fitting okay. See IMG_7663 below.

Cleaned and glued rubber extrusion to the fuel pump and filter mounting plate using weldwood contact cement.

Cut the 1" UHMW PE rod received from McMaster on a bandsaw to create spacers to reduce side play on the right/rear. After several tries I was able to make flat disks. The trick was to use a miter gauge set to 90 degrees and not rotate the rod during or between cuts. If you rotate the rod between cuts you get a disk that is thicker on one side since the rod is not perfectly straight. I ended up using one that was 0.090" on the left side and one that was 0.125" thick on the right. This resulted in almost no side play when the rudder bars were mounted in the forward location and a small amount of side play in the center location. There will be additional side play in the rear location.


 
Apr 16, 2024     Brake and Fuel Lines, Firewall Rivets, Planning - (3.8 hours)       Category: Fuselage
Removed covers, Andair valve and fuel pump mount. Vacuumed and wiped down area. Cleaned up and primed where holes had been enlarged in F-783B R/L brackets. Primed face of reinforcement plates that contact the brackets.

Worked with Ellicia to rivet two top corner rivets near the firewall recess.

Reamed three Andair valve mounting holes to 0.190" to improve fit between valve and mounting plate. Deburred all four edges of the Andair valve mounting plate.

Jotted down additional tasks while working on the RV. Reviewed Trello and Notes RV lists. Consolidated notes in one spreadsheet and created general groups and more detail on near term items.


 
Apr 15, 2024     Fuel and Brake Line Brackets, Bleeder, Parts - (5 hours)       Category: Fuselage
Researched options, completed brake bleeder design and ordered parts.

Installed right fuel line from Andair valve through the F-783B R bracket. Determined position for reinforcement bracket and match drilled. Opened up holes in F-783B R bracket as needed. Deburred edges of holes in the R and L brackets and reinforcement plates. Deburred edges of both reinforcement plates. All pictures for this entry are for the right side only.


 
Apr 14, 2024     F-783B reinforcement plates, Parts - (5 hours)       Category: Fuselage
Used shear to trim reinforcement plates to final size. Installed sheet metal parts to ensure fuel valve and line is located the same as it will be in the final assembly. Connected right fuel line to the Andair valve. Determined location for the reinforcement plate on the right side and drilled holes for blind rivets. Removed fuel line and used a step drill and Dremel drum sander to open up the holes in F-783B R bracket to clear the new mounting holes. In some places the grommet edge covers two layers of sheet metal.

The maintenance manual was updated with information about the new brackets and the grommet part numbers.

Researched and found more parts and supplies for fiberglass class and for future maintenance. Ordered parts from McMaster and Aircraft Spruce.


 
Apr 13, 2024     Fuel and Brake Line Brackets, Seal Lube - (3 hours)       Category: Fuselage
Met my goal for the last week. Was out of town two days to take parents to a memorial service so goal was reduced by 9 hours.

Attended monthly EAA chapter 187 meeting. Discussed fiberglass options with Deene. The fiberglass class uses West Systems and also shows some stronger and more heat resistant options. After talking to Deene, planning to use West Systems epoxy for gear leg related fairings and windshield fairings and rudder, elevator and wing tips.

Researched greases and lubes for Andair valve. Was planning to bolt in valve for the last time, but need to lube o-ring seals before staking the screws. Ordering Krytox GPL 205.

Marked up 0.040 aluminum sheet with layout for F-783B inner bracket reinforcement plates. Drilled grommet holes.


 
Apr 12, 2024     Brake and Fuel line Brackets, Fiberglass Training - (5.8 hours)       Category: Fuselage
Deburred F-782B R/L bracket edges and holes. Countersunk holes for the nutplates and assembled the brackets. Cut outer flanges of some of the grommets to fit.

Started mocking up potential designs for a reinforcement plate to go on the F-783B brackets that are riveted to the spar and not easily replaced. The new fuel and brake line holes overlapped existing holes in the bracket. I decided to change the location of all three holes starting with centering the fuel line hole around the fuel line since the location is fixed by the Aircraft Specialties hard line. The circles on the template are the OD of the grommets.

Looked up West Systems fiberglass materials that I have on the Aircraft Spruce website. Downloaded and looked at the West Systems products manual.

Researched and downloaded data sheets for fiberglass cloth.


 
Apr 10, 2024     F-782B Brackets for Fuel, Brake and Wiring - (5.8 hours)       Category: Fuselage
Watched more of the SportAir Online fiberglass course.

Made holes and tested grommet and fuel and brake line clearance in sample sheet of 0.040" aluminum. Decided:
FUEL: Fuel line holes 0.790" for clearance of the nut with AN931-8-13 grommet was the best option. The grommet fits the bracket hole about right. The grommet hole is about .36" in diameter larger than the fuel line. The clearance provides enough room to install the grommet in the bracket after the fuel line is inserted and to allow the fuel line to angle through the bracket for better routing. A -7-11 grommet could also work, but it is too small for the hole and pulls out easier. I used a 20mm Unibit step drill.
BRAKE: Brake line holes about 0.690" for clearance of the nut 0.630 nut on the fitting with AN931-7-11 grommet was the best option. The brake hose is 3/8" OD and the grommet ID is 7/16" which provides enough room to install the grommet with the hose inserted. A 0.630 hole in the bracket made it almost impossible to install the grommet with the hose inserted without cutting the grommet so it isn't a complete circle. I was concerted that this wouldn't protect the brake hose as well and might be easier to pull out. I used a 11/16" unibit step drill.
WIRING: The wiring hole is the 5/8" Van's recommended hole with a hard plastic snap in bushing. The wires will be inserted through the bushing after installation of the bracket. I used a 5/8" unibit step drill.

The best hole layout seemed to be:
1) Placing the bottom edge of the large fuel line hole 1/2" above the bottom of the bracket and the aft edge of the hole as close as possible to the spar. This allows the best routing of the fuel line through the landing gear mount.
2) Leaving the wiring hole in the Van's designated location.
3) Placing the brake line hole between the other holes and as far away from the spar as possible.

I drilled the replacement F-782B R/L brackets using a clamp on the drill press. The center of the fuel line hole was on the edge of one of the prepunched holes so I used a 0.040" sheet of aluminum on top of the bracket to start the hole in the desired position with a # 40 drill. Then I slowly enlarged the hole with a unibit until the prepunched hole was drilled out. Then I finished enlarging the hole to the final size after verifying the hole was still centered in the desired location.


 
Apr 09, 2024     Paperwork and Training - (4.6 hours) Category: Fuselage
Completed log entries and picture uploads for last few days.

Updated Maintenance Manual with information on brake parts and brake master cylinder return spring addition.

Updated carts for Aircraft Spruce and McMaster Carr. Decided not to order yet because we are going out of town later this week during the expected delivery days and I may want to adjust my Aircraft Spruce order with material for the Fiberglass SportAir Online course.

Downloaded handouts and started watching the course and making notes.
 
Apr 08, 2024     Eclipse Day       Category: Fuselage
Took a break today for Ellicia's birthday and the Eclipse


 
Apr 07, 2024     Fuselage, Brakes - (3.5 hours)       Category: Fuselage
Finished pilot and copilot master cylinder install except for the AN3-7 bolt I need to order to replace the AN3-7A. Tested and decided to swap the position of the two bushings on the return spring assembly so the higher load one is on the end that moves. This matches the vansairforce picture, but not the order of the parts on the parts list. Reworked the pilot master cylinder install with the bushing swap. Adjusted all four of the spring retaining collar to have a 1/8" gap between it and the master cylinder mounting tab on the rudder bar.

Considered different options for which grommets and which hole pattern locations would work best for the brake and fuel line routing through the F-782B-R/L brackets and through the landing gear mounts.


 
Apr 06, 2024     Fuselage - (7 hours)       Category: Fuselage
Fabricated two new 1/16" bus bars between the contactors in place of the original 1/8" one I made. The thinner ones are easier to install/remove and are narrower so there is less chance of a short.

Installed cotter keys on rudder pedals. Installed one of the pilot master cylinders to test the operation of the spring return.

Measured battery height and marked areas on the firewall that need to be clear to allow the battery to be lifted out of the battery box.

Test fit the engine mount to look for potential places for firewall feedthroughs. Looked at pictures from Brian on locations he used for feedthroughs on his RV-7A and decided to match them. Decided not to add feedthroughs until after the instrument panel is installed. Measured wires in the harness that need to go through the new feedthrough and found I needed a 0.56" hole. One 1/2" EMT conduit fitting is 0.63" and is barely large enough. It might be better to use two of the 1/2" or one of the 3/4 in to allow more room for additional wires or to group them better.

Decided to move the rudder bar assemblies to the center mount point after I make the spacer to limit side to side play so I only have to disassemble the mounting blocks one more time.


 
Apr 05, 2024     Master Cylinders - (7.6 hours)       Category: Fuselage
Added UHMW rod to McMaster Carr cart for rudder bar spacer.

Opened and inspected McMaster Carr shipment. Installed one set of parts on a master cylinder and measured spring compression at the stop. It was about 0.85 inches. The spring has a rate of 15.9 pounds/inch so the addition spring force is approximately 13 pounds. I'm going to discuss the measurements with Brian at the next EAA chapter 187 meeting.

I measured the spring force of three cylinders with only the internal spring and got approximately 10 pounds. It isn't a clean measurement because the seals add friction.

Researched solvent to use for cleaning brake fittings. Used MEK. Disassembled and reassembled remaining master cylinders with new seals and springs per Matco documentation. Checked flow from top to bottom port. Checked movement of shaft before pressure reached. Checked for leaks and continued movement of shaft with pressure maintained. All okay.

Drained cylinders, cleaned threads and installed fittings in the orientation shown in drawings 36A and 37. Used Lactate 567 for the AN fittings. The Legris fittings had a sealant pre-applied. I really like that the Legris fittings are swivel type so you can tighten the fitting properly and then rotate it to the desired orientation. You have to compromise on tightness to get the desired installation orientation on the 90 degree AN NPT to flare fittings. Looked up Legris fitting specs. I would really like to use them for some of the other brake lines, but I think they are marginal on the pressure rating. The AN fittings are installed and I will use them and the Aircraft Specialty hoses I purchased.

Looked at potential places to install another wire feedthrough in the firewall. Need to research that more and install them before riveting the top skin in place. Also considered installing nutplates to allow easy installation and removal of the pressure sensor manifold. Looked to see if I am ready to install the brake fluid reservoir. The reservoir needs to be installed after the instrument panel structure and before the top skin. Or I can crawl around under the panel and install it later.


 
Apr 04, 2024     Brakes, Firewall Recess - (7.3 hours)       Category: Fuselage
I remembered there being a problem with my old C yokes spreading open when I tried to squeeze a 1/8" rivet. Brian Decker said he never had a problem. So I completed a test squeezing 1/8" rivets with all my yokes. In each case I used a 0.25" AN426AD4-4 long flush rivet and adjusted the pneumatic rivet squeezer to have an air gap of either 0.145" or 0.090" when the squeezer was closed with no part/rivet in the "C". The rivets all squeezed down. The gap and final length results by yoke were:
gap squeezed length yoke
0.145" 0.193 3.75" heavy duty (new)
0.145" 0.190 3.0" standard 2 die type
0.090" 0.153 3.0" standard 2 die type
0.145" 0.190 2.5" close fit 1 die type
0.090" 0.149 2.5" close fit 1 die type
0.145" 0.170 1.5" standard 2 die type
0.090" 0.125 1.5" standard 2 die type
0.145" 0.190 3.00" longeron 2 die type
0.090" 0.144 3.00" longeron 2 die type
So there was only a slight change when going to the longer reach yokes. And no difference between my old 3 inch and the new heavy duty one that worked so well yesterday. Maybe I need to change the test to squeeze a rivet in a piece of metal similar to a real situation. Or maybe I didn't have the squeezer gap set right in the old days. I'm not going to worry about it for now. I needed the longer reach yoke anyway to be able to squeeze rivets in more situations.

Riveted final 3/32" rivet close to the firewall recess using the new, heavy, squeezer yoke as the backplate. Tried to rivet one of the 1/8" rivets close the firewall recess the same way and decided to use the 3x rivet gun later after the nearby pro seal cures.

Worked with the rudder bar mounting blocks and center support.
-Checked fit and operation in all three positions in case I need to move the bars forward or aft after the seats are installed. Opened up center support mounting holes as needed.
-Determined I need to use a AN960-10 to as a spacer for the two side mounts that I cut in half. Determined I need to use an AN960-10 and a AN960-10L for the center mount.
-Identified where the rudder bar and/or brake petals hit the firewall stiffeners and determined I can use an edge grommet and/or split hose to protect the firewall stiffener.
-Measured the side play of the rudder bars in the most forward and aft mounting block locations. The forward rudder bar (right rudder) has almost no play in the most forward position and only 0.094" play in the most aft position. I consider that to be perfect since it allows the rudder to be able to mounted in any mounting block location with minimal side play. The left rudder bar (left rudder) has 0.094" of play in the most forward position and 0.186" of play in the aft position. I'm going to order some plastic to make a spacer to keep the max left rudder bar side play to approximately 0.094" to match the other rudder bar.
-Rechecked the movement of the center rudder bar support bracket now that it is riveted in place. The bracket movement is barely noticeable even when pulling on it with 20 pounds on the side where the TWC backup battery is installed.

Tested the right pilot master cylinder using emailed instructions from Matco (Compress the shaft and then allow it to extend. Lay the cylinder on a table with the ports up. Fill the port near the shaft [I used a syringe to keep from making a mess with the Royco 782 fluid]. I noticed I had to keep adding fluid slowly as the fluid flowed through the cylinder. Verify the fluid eventually starts flowing out of the other port. Cap off the other port, change the position of the cylinder to shaft up. Compress the shaft and verify it becomes firm with only about 1/8" of movement, that there aren't any leaks around the shaft and that the shaft does not slowly move under pressure). The test results show it was working okay.

I had previously disassembled the left pilot master cylinder using the Matco maintenance documents. I didn't test it before disassembly. I used a rebuild kit and reassembled it. I noticed the original seals had taken a set and were not as flexible as the seals in the new kit. I'm going to rebuild all the master cylinders while they are easy to reach and I don't have fluid in the lines that will make a mess.

Looked up documentation from Van's and vansairforce on thread sealant and NPT fitting torque. I'm going to use Loctite 567.


 
Apr 03, 2024     Rudder Bar Support, Firewall Recess and Feedthrough - (5.2 hours)       Category: Fuselage
Unpacked and tried new squeezer yoke. It is much wider and heavier than my other yokes and worked great. It had long enough reach to rivet the rudder bar support in place.

Cleaned firewall recess parts and removed rudder bars for better access. Worked with Ellicia to figure out how to set the rivets where the gun couldn't be used because access was blocked by the fuselage rotisserie bracket. Figured out Ellicia could hold a back rivet plate against the firewall and I could back rivet from the cockpit side.

Mixed up pro seal, applied a bead around the edge of the firewall recess and riveted the firewall recess in place. Also installed a wire feedthrough for the contactors using pro seal. Cleaned up tools, clecos, and extra pro seal on the firewall. Looks great! And was easier than expected.


 
Apr 02, 2024     Firewall Recess, Fuel line, Instrument Panel - (4.5 hours)       Category: Fuselage
Received replacement fuel line from Andair valve to AFP filter inlet and it fit perfectly.

Test fit recess into firewall opening and drilled a battery box mounting hole to final size.

Installed D-Sub covers on all the open connectors on the wiring harness and on the avionics. Disassembled instrument panel structure and riveted nutplates for Adele clamps and a final nut plate for one of the Garmin boxes in place. Decided to bolt the Diode-Or assemblies in place instead of using the double sided tape. Marked and drilled holes and installed nutplates.

Found brake cylinder return spring documentation on vansairforce and ordered parts from McMaster Carr.


 
Apr 01, 2024     Squeezer Yoke - (.3 hour) Category: Fuselage
Realized I ordered the close quarter yoke and really wanted the standard style that accepts two dies. Also I was concerned that the one I would order would be like my yoke and flex. Called ATS to discuss. Changed to their 14-8 squeezer yoke.
 
Mar 30, 2024     Squeezer Yoke - (.5 hour) Category: Fuselage
Yesterday I realized that I needed an extended reach squeezer yoke to install the rudder bar center support. Researched options. Reached out to Brian Decker to find out which yoke he had brought over for a similar problem. My extended reach yokes flex on 1/8 rivets and his didn't. Placed an order with aircraft tool supply.
 
Mar 29, 2024     Firewall Recess Assembly - (2 hours)       Category: Fuselage
Cleaned up the shop. Cleaned the firewall sealing surfaces with acetone. Mixed up pro seal and added some between overlapping skins on the recess and squeezed rivets. Then added pro seal to the gaps formed by relief cuts. Cleaned up tools.


 
Mar 28, 2024     Firewall Recess, Rudder Bar Center Support - (4.5 hours)       Category: Fuselage
Continued to consider the assembly order.

Became concerned about adding the extra weight of the TCW battery backup to the rudder bar center support bracket. After discussions with John, pulled on the end of the center support with about 12 pounds of force (extra weight is 34 oz spread over whole bracket). Didn't see any deflection pulling straight down at 12 or even 20 pounds. The bracket twisted slightly if pulled down and to the side where the backup battery will be mounted. The twisting was much smaller if the nylon support blocks were installed. In all cases, there was no significant change in the friction while moving the rudders.

Drilled holes and installed nutplates on the rudder bar center support to mount the TCW battery backup. Considered installing PEM studs or using nuts and bolts before deciding on nutplates.

Drilled and dimpled holes in the firewall recess. The recess box must be sealed and riveted before it is installed in the firewall. Decided to dimple both layers at the same time instead of unfolding the part enough to dimple each layer separately.

Researched brake line fittings and ordered Legris 3109 56 11 push to connect fittings for master cylinder to brake fluid reservoir connections. These are fittings in the same family as the fitting Van supplies for the brake reservoir.


 
Mar 27, 2024     Test Fit and Next Steps - (2.1 hours)       Category: Fuselage
Studied drawings and test fit firewall recess, center rudder support and TCW backup battery. I want to make sure I know the right orientation and figure out the best assembly order before I start final riveting of any of these.

Determined the first thing to install is the rudder bar center support. Started second guessing myself on whether or not it is okay to install the 34 ounce TCW backup battery on the support. Need to ask for technical assistance.

Identified the remaining steps and order for completing and installing the firewall recess. I plan to use pro seal to block the large holes. I may spread fire block sealant over the pro seal later. I may use the fire block sealant to seal the recess to firewall flange gap as I rivet it in place.

Researched brake line routing and considered options for support brackets.


 
Mar 26, 2024     Avionics and Wiring - (4 hours)       Category: Fuselage
Removed wiring and avionics from the structure behind the instrument panel in preparation for installing the forward top fuselage structure and skin on the fuselage. Added labels to some of the connectors. Added tie wraps to help protect wiring from GDU 460 mounting screws. Added Aircraft Spruce 05-00675, M22529/2-2R edge grommet to two places on the CO Detector and used Dow 3145 RTV to help secure the edge grommet. Took pictures to help me reassemble and document the avionics and wiring. Added some potentially helpful tools to the McMaster Cart.

Added notes about the parts used to install the GMU 11 to the maintenance manual. Added additional notes about avionics and wiring to the maintenance manual.


 
Mar 25, 2024     GMU 11, Heater Valve - (1.5 hours)       Category: Fuselage
Installed the GMU 11 using the previously made spacers. Used a non-magnetic screwdriver and a homemade aluminum wrench for the GMU 11 screws. Installed a wire tie block (Mouser, MFG PN LHMS-55-D).

Cleaned up shop and tools from the pro seal session last week.

Found heater valve, bolts, nuts, sealant and instructions. Ready to install as soon as I get mineral spirits for cleanup.


 
Mar 22, 2024     More Parts - (.1 hour) Category: Fuselage
Missed my goal for the week by 3 hours. Had too much to do this week and it was a short week (out of town Friday and Saturday). But I did make some really good progress on things I had been dreading.

Ordered parts from Aircraft Spruce this morning. I had placed the items in my cart over the last few months.
 
Mar 22, 2024     Fuel Vent Screens - (1.3 hours)       Category: Fuselage
Cut disks out of sheets of screen and attached to fuel vent fittings with proseal. Used screen from amazon that had about the same size grid as the screens in the Van's FWF kits, but a slightly heavier gauge wire. For some reason I had thought modifying the vent fittings, cutting the screen and attaching it would be difficult. It turned out the screen was easily cut with scissors and didn't tend to fall apart.


 
Mar 20, 2024     Pitot, Static, AoA and Fuel Lines - (4.1 hours)       Category: Fuselage
Completed plan for Pitot Static, AoA connections and hardware.

Decided to use a capped tube for the test ports to keep the minimum number of connections possible (with a test port). I have an assortment of other fittings and can quickly make an adapter to match what an avionics shop might need for test and calibration.

Cut tubing to fit and installed color caps and fittings. Left enough tubing connected to the G5 that I should be able to pull it out enough to disconnect the tubing. Worst case I have to remove the GDU 460 or work from under the panel to reach the G5 tubing connections. Left tubing ends folded over and taped to keep out dust and be a placeholder for the lines to the pitot/AoA tube and static ports. Left long ends with SMC caps as a rough guess for test port connections. Will optimize fit when I install the panel in the fuselage. Sketched schematic (attached below).

The photos show:
IMG_7304 - Color coded connections to the GSU 25.
IMG_7310 - The Static Connections to the Alternate Static Port switch, GSU 25, G5 and the 4 port SMC union - finger points to the union. The other port of the SMC union goes to the SMC Y union which connects to the static port and test port IMG_7312.
IMG_7311 - The pitot connections to the GSU 25, G5 and the 4 port SMC union (near bottom of picture). The other two ports of the SMC union go to the pitot tube and the test port shown in IMG_7313.
IMG_7312 and IMG_7313 show the initial rough position of the Test ports and connections to pitot, AoA and static ports.

Worked more on the Fuel and Brake lines going through the 4 brackets. Drilled another few holes. Bent the formed tubing slightly to improve fit. Researched and added additional grommets to my Aircraft Spruce shopping cart that might be a better fit. Decided to order new F-782B R and L brackets. They will have a small pilot hole instead of the large holes and will be easier to modify and look better when I am done. I am continuing to work with the current brackets to make sure I know how to modify the new ones.


 
Mar 19, 2024     Fuel Line Routing, Static, Pitot, AoA - (5 hours)       Category: Fuselage
Finally I am tackling the problem of how to install the fuel lines from the valve to the tank. Routing wasn't clear to me. And it required modifying two parts that are already riveted in place and not practical to replace if I mess them up.

I started with the 783B-R and then L inner brackets. I took it slowly and test fitted as much as I could. I decided to move the hole down and towards the spar as I enlarged it. It seemed like I really needed to move it up slightly, but that creates other problems. It turned out I had to enlarge the hole in the up direction some and it probably needs more. I still have to decide if I want to move the hole up or try to bend the tubing slightly. And I still have to decide where to place the hole for the brake line.

Then I moved to the 782B-R and L outer brackets. These can be replaced easily. I'm not really happy with how the two holes intersect on the 782B-R side. I may try moving the holes to the locations shown by the two washers on the 782B-L bracket. And if that works better, then I can replace the one on the right side.

Then I moved on to routing both the brake and fuel lines through the gear leg mount. I think I understand how to route the lines at the gear leg now. I was trying to route them through the lightening holes in a landing gear gusset, but I think that just provides extra potential rubbing points and limits the movement of the fuel line enough that it might be difficult to mate the line with the fuel tank fitting.

Started work on pitot static angle of attack plumbing on instrument panel. Color coded the connections and cut a long piece of tubing for each connection. Explored different routing options. Thought about which lines, if any, needed a test port. Decided to use a test port on all three types of ports. Haven't decided where to run the lines or where to place the connectors and test ports.


 
Mar 18, 2024     Static Port Replacement, FlyLEDs Controller - (6.5 hours)       Category: Fuselage
I decided to go ahead and replace the Van's static ports (blind rivet with the mandrel driven out and a piece of tubing slid over the body of the rivet. Then a lot of sealant to help it hold together.

First I had to drill out the rivet and then reach in and cut the sealant loose. That was pretty easy. Then I had to enlarge the rivet hole to 1/4" to fit the showplaces.com static port and .030" spacer. The difficult part was keeping the port from rotating when I was torquing the nut. I thought I would try to run some of the tubing and tie it loosely in place by reaching in through small holes. It turned out to be a lot easier to place some foam blocks on the bottom of the fuselage to spread out my weight and keep sharp edges from poking me and then just climb in. It looks more uncomfortable than it was. I did scrape my head getting in and out. While I was in there I decided to clean everything up with a vacuum places in the baggage compartment or on a table next to the fuselage. I wish I had done this a long time ago instead of worrying about it so much.

I had to move the FlyLEDs strobe control board to install the crotch strap mounting bracket. So today I found a new location for it and installed the standoffs and PCB assembly. There is greater than 0.10 inches of clearance between the bottom of the parts on the board and the closest section of the seat rib.


 
Mar 17, 2024     Fuel Lines and Brakes - (2.5 hours)       Category: Fuselage
Read the response from Aircraft Specialty (they always respond quickly, even on Friday evening or weekends). Took the measurements they requested and sent pictures. Looks like I have the part for the Van's valve instead of the Andair valve. Tom later confirmed he was sending a new part.

Found updated caliper o-rings, researched alternatives and updated maintenance manual. Researched brake bleeding tools and materials compatible with MIL-PRF-83282.

Found GMU 11 mounting hardware and updated maintenance manual with details.

Reviewed McMaster Carr, Aircraft Spruce and Mouser shopping carts to see if it was time to place an order.


 
Mar 16, 2024     Fuel and Brake Lines and fittings - (6.4 hours)       Category: Fuselage
Met my goal for the week! It is the second week of the new phase. I did take off three days for surgery and recommended low activity recovery time.

Reviewed Van's drawings to confirm I installed the fuel pump and valve parts correctly. Took a bunch of pictures that should help show Aircraft Specialties the issue. Tried test fitting just the three tubes to the Andair valve to rule out any builder error. The valve to filter tube interferes with one of the other tubes which helps confirm I have the wrong part. Looked at Aircraft Specialties again and decided I probably have the tube for the Van's valve instead of the one for the Andair valve. Sent questions and pictures to Tom.

Installed the brake fittings on the tri-gear bracket on the firewall. Attached the brake lines that go to the gear legs and to the master cylinders and they look like they should fit.

Found the master cylinder rebuild kits and disassembled one master cylinder. Read response from Matco and decided I will rebuild the master cylinders. Also found the push to connect fitting for the brake fluid reservoir.

Installed the fuel line at the firewall feedthrough and it looks like it should attach to the pump plumbing okay.

Test fit the fuel vent lines in the cabin and decided they are close enough. I'll install them after I get the structure behind the instrument panel riveted together and bend and/or remake as needed. No reason to do it yet. Cut the 45 degree angle on the fuel vent outlet fittings. Filed a lot on the first one and then used a band saw on the second one and finished with some filing. Deburred the edges of the 4 thick AN fitting washers and installed them on the fitting through the side of the fuselage.

Torqued the final 4 nuts on the center section and marked all the landing gear nuts and other nuts on the center section with torque seal to remind me that I finished torquing those nuts.


 
Mar 15, 2024     Contactors, Fuel Lines, Brakes - (6.8 hours)       Category: Fuselage
Determined bolt length for contactor mounting and installed with final bolts. Made spacer for starter contactor. Finished copper strap between contactors. Decided I need to replace the strap with two thinner straps so the strap can flex as needed.

Struggled with how to install and mount the brake and fuel lines. Took pictures and sent questions to Tom and reviewed replies. Made some progress in understanding what to do and what to try next.

Test fit ring shims on the showplanes.com static port. Look great and I plan to use them. Updated maintenance document to show new parts.


 
Mar 14, 2024     COM Doubler, Crotch Strap Brackets - (5 hours)       Category: Fuselage
Took off three days to recover from surgery.

Completed riveting the COM antenna doubler with Ellicia. Used LP4-3s to tie the old doubler to the new doubler.

Completed assembly of the crotch strap brackets and installed the brackets. Installed the 6 nutplates on the center section that were removed for landing gear mount fitting. Opened up the clearance holes in the firewall nutplates as needed so the bolts would fit without rubbing.


 
Mar 09, 2024     Doublers - (1.2 hours)       Category: Fuselage
Attended EAA Chapter 187 meeting and got to talk to Brian. I told him I was having trouble finding the shim for the static port and he helped me find one. He also confirmed that he was able to get his static port working with the showplanes.com static port and a 0.030" spacer. I'm ordering the spacer and changing static ports.

Brian also said the SW cooler would work fine with a baffle mount for my stock 180 hp engine and no piston squirters. He did say it was likely I would see baffle cracking and suggested I use some reinforcements per previous discussions.

Ellicia and I riveted the firewall doubles, nut plates and transponder doubler in place.


 
Mar 08, 2024     Landing Gear Mounts and doublers - (3 hours)       Category: Fuselage
Worked with Ellicia to torque all the landing gear mount to fuselage side nuts.

Looked up drawings and test fit the doublers for the contactors and fuel lines on the firewall. Countersunk some of the holes in the stainless firewall so the rivets would fit more flush.


 
Mar 06, 2024     Landing Gear Weldments - (3.1 hours)       Category: Fuselage
Torqued all landing gear mount to center section bolts. Had to grind down the adapter even more to get it to fit. Saved a lot of time by extending the length of a ratcheting box end wrench to be able to tighten a nut lightly before switching to the torque wrench + torque extender. Had to use the wing spar holes in the fuselage to get to some of the bolts.


 
Mar 04, 2024     Static Ports, Torquing hard to reach parts - (2.9 hours)       Category: Fuselage
Starting work on a new commitment this week. I realize I will miss my commitment for the week, but I have to start somewhere. I planned to start several weeks ago, but things kept getting in the way. Maybe a firm commitment will help and I will meet my goal next week.

Put away firewall forward parts so I could have room to work on the bench and still be able to find them later.

Reviewed options for static parts. About to just give up and leave it the way Van's designed it even though two tech counselors I respect told me to replace them.

Finally time to grind down some sockets to see if I could get my torque wrench to fit in the center of the center section. Grinding was working, but not enough. I need to use the torque extenders, but can't use a normal 1/4 to 3/8 inch adapter. First made some shims to use as an adapter. That could work, but would be a pain to use. I was going to epoxy some parts together when it finally dawned on me that I could make a short adapter out of a socket. Made one and it looks like it will work.

Measured torque extender and torque wrench handle length. Created a spreadsheet to show torque wrench settings when used with a 2 inch extender and with friction torque added for -3 and -4 AN365 locknuts.


 
Feb 02, 2024     Unpacking the FWF box part 2 - (2.3 hours)       Category: Fuselage
Finished unpacking and inventorying the FWF parts. Everything looked great. I was impressed with how everything was packed. The only thing that didn't have a bill of materials that I could check was the exhaust system.


 
Jan 31, 2024     Unpacking FWF box part 1 - (.3 hour)       Category: Fuselage
Started unboxing the FWF parts. The exhaust box had been shipped from Vetterman to Van's and had some damage to the bottom. So I opened that box and checked out the parts. Looks like whatever caused the damage to the box didn't reach the parts.


 
Jan 22, 2024     EAA Homebuilder's Week Webinars - (.1 hour) Category: Fuselage
Spent many hours watching homebuilder's week presentations. Learned a lot of interesting things. Some of it will help me with building. I signed up for the online version of the SportAir fiberglass for RV aircraft workshop and will take the course later this year.
 
Jan 14, 2024     Received FWF parts - (.1 hour)       Category: Fuselage
Received the FWF parts I ordered from Van's. FedEx delivered a few days earlier than expected. I expected a larger box. I thought the exhaust system would take up a lot of space.


 
Dec 31, 2023     Prime - (3.5 hours)       Category: Fuselage
Today was a beautiful warm day with temperatures in the 70's so I decided I'd better prime all the parts I had been saving for later. Cleaned, scuffed and primed the 4 parts of the crotch strap bracket, two antenna doublers, two firewall doublers, two GMU 11 standoffs and the corresponding mating holes on the fuselage except for the ones on the firewall. Used P60G2 and my airbrush since the parts were small.


 
Dec 23, 2023     Parts - (3.3 hours) Category: Fuselage
Met my goal for another short week.

Entered all FWF components in my Van's shopping cart. Moved out of stock parts to my wish list. Placed an order for all parts in stock. Moved my wish list back to the cart and placed a second order for parts out of stock and requested delivery of parts when they were all available. This took a while since I researched a few of the out of stock or more expensive parts to find alternative sources.
 
Dec 22, 2023     Parts - (1.3 hours) Category: Fuselage
Updated my FWF parts spreadsheet with new prices from Van's updated website. Found about a 30% increase.

Discussed whether I should send an email or order parts through the website with someone at the order desk at Van's and decided I would just place my order. I want to keep as much control as I can.

Not included in the hours, but I also spent time reading the Vic Syracuse Maintenance Manual today.

Also not included in the hours, I downloaded and tested x-plane 12 with my Logitech joystick and MacBook Air. It worked great so I purchased it. I took a quick flight from HNL to the marine core base to check out the scenery. No comparison with the real thing, but a lot of fun.

Also not included in the hours, I started watching the Garmin G3X training course I purchased. I worked through the first few sections while we were in Hawaii and continued after we got home.

I also researched options for rusty pilot training to prepare for a flight review. I decided I am going to try the gold seal free trial first and then decide on whether to use it or the Sporty's training. King training is also available. I think I will start in March or April. Or maybe later depending on my RV progress.
 
Dec 05, 2023     FWF parts? - (0.1 hour) Category: Fuselage
Missed my goal this week. I needed to spend too much time preparing for Christmas and packing for our trip to see the grandkids on 12/6.

I sent a list of Fire Wall Forward parts to Vans on 11/14/2023. I haven't received a reply. I called about a week later and was told they should be getting to my order soon. I had seen the 10/27/2023 Van's business announcement so wasn't too surprised.

Today I saw the AvWeb alert "Van's Aircraft has filed for Chapter 11 protection while it reorganizes with the goal of maintaining existing services and emerging as a solvent company again." I feel confident that Van's will recover and that I will get my parts, they will just cost more than expected. Hopefully I will hear from them soon.
 
Dec 02, 2023     Fuselage - (8.8 hours)       Category: Fuselage
Met my weekly goal for another week.

Finished match drilling the pilot and copilot crotch strap F7117A and B brackets to the seat ribs. I thought the copilot side would be easier and that I had learned most of my lessons with the pilot side. That was only partially correct. The copilot side was easier and faster, but I still learned more. Also match drilled the seat belt bolt hole.

Match drilled the brackets to seat pans to #27. Removed the brackets while they were clamped together and enlarged the seat belt hole to 5/16". Used a #6 nut plate drill jig to drill all the nut plate attachment holes. Clecoed the clamped brackets to the seat pan and enlarged the screw holes to the final #19 size.

Disassembled and countersunk the nut plate rivet holes. Deburred all holes and edges on the brackets. Deburred all holes in the ribs.

Looked at options to modify the Transponder antenna doubler so it would work with the crotch strap mounting bracket. Decided I needed to give up on the plan to rivet the doubler flanges to the seat ribs. Trimmed the flanges to about 1/4" and deburred the doubler.

Received the torque extender parts from Napa. They seemed like they would work. Made a 3/8" to 1/4" drive adapter out of four pieces of 0.060" inch thick pieces of aluminum. See the picture below. I need this for my 1/4" drive torque wrench. After testing how all this fits between the center section I realized I might be able to just modify a socket to meet my needs. I'll pick up a cheap Harbor Freight socket set and modify it to see if it will work. If it doesn't the torque adapter and my "3/8" to 1/4" adapter will work.



 
Dec 01, 2023     Crotch Strap Mounts - (5.5 hours)       Category: Fuselage
Completed checks and match drilling of pilot side crotch strap brackets to seat ribs and pan.

Started working on copilot side and completed match drilling of F7117A and B to seat ribs. I thought I had it figured out on the first one, but I learned even more on the second one. I'm happy with the way they are turning out.


 
Nov 30, 2023     Crotch Strap Mounts - (5.2 hours)       Category: Fuselage
Added JIS#1 and JIS#2 screwdrivers to my McMaster Carr cart with the 1/4 ID static port washers and placed the order. It took 16 minutes before I received a shipping notification. Wow.

Worked on positioning the parts with a 0.130" spacer plus a 0.062" washer. Didn't like the way some things were turning out. Researched Crow harnesses and crotch strap mounts on vansairforce. Found Crow made a change in 2018/2019 that allowed it to work with the Van's mount without some of the previous modifications. Decided to just use a 0.130" spacer.

Was having difficulty with placing the mounting brackets to they would align with holes in the seat pan. Figured out what I hoped to be a better solution. Marked the fore/aft mark on the top of the ribs based on measurements from the seat pan screw holes to the seat pan pilot holes for the screws to the mounting bracket. That allowed me to mark the centerline of the mounting bracket flange, alight it to the fore aft mark, adjust fore/aft tilt with a 90 degree angle against the fuselage bottom skin and clamp the clamp the F7117B mounting bracket flanges for drilling.

Used an air 90 degree drill with a #30 bit. Drilled one mounting bracket flange to rib hole and held it in place using a cleco. Checked alignment and continued adding holes/clecos to the same flange. Rolled the fuselage over 180 degrees and checked, clamped and drilled and clecoed the other flange. I' really happy about how it turned out.

Taped spacer blocks to the F7117B bracket and positioned and checked the F7117A bracket alignment. It is almost ready to be drilled to the rib.


 
Nov 29, 2023     Landing Gear Mounts - (3.8 hours)       Category: Fuselage
Worked through DWG 34A to verify the loosely installed bolts and nuts were in the correct position. Verified the washer between the mount and the center section was installed on both landing gear mounts. Looked up articles and specs on the min and max threads showing on Kitplanes and vansairforce and changed the washers for some of the positions. Looked up my original kit drawing to see the notes showing which bolts had been replaced with a different size. They are all ready to be torqued to the final value.

After looking at and trying different tools, I had decided to use my SnapOn thin wrench and a luggage scale. I decided to run tests on 10-32 bolts/nuts and 1/4-28 bolts/nuts using a beam type wrench to compare running torque and final torque and the maximum value. At first everything looked great with the running torque using each method matching nicely. It was more difficult to compare final torque since I was dealing with running torque and static torque differences. My luggage scale mostly seemed to work, but sometimes seemed to show max torque instead of returning to 0. I still think I could use this method, but would prefer something better. I looked one more time and found and ordered set of 2" torque adapters from 3/8" to 3/4" in 1/16ths. I'll try using them and hope they will work better.


 
Nov 28, 2023     Parts, Static, Torque - (4.6 hours)       Category: Fuselage
Finished putting Aircraft Spruce parts in bins with labels.

Tried drilling out aluminum spacer washers for static port again hoping a new conical drill bit (like a step drill, but no discrete steps) would help. Nope. Tried stacking aluminum washers on a #8 screw, chucking the screw in a drill press and spinning them against a file to reduce the OD. Worked great so I need to order washers with the right ID and reduce the OD. Added two types of washers to my McMaster Carr shopping cart.

Tried extending my cheap set of harbor freight 3/8 and 7/16 inch wrenches using a 1/4" extension from a socket set and hose clamps. It sort of works, but is thicker and more awkward to use than I hoped. Looked again for options. Found a Matco extra long ratcheting wrench that might work, but it is hard to tell from the "specifications". Decided I should use my SnapOn Low Torque LTA1214 wrench. I had originally decided it would be better to try something else, but haven't found anything better.


 
Nov 27, 2023     Parts - (4.1 hours) Category: Fuselage
Decided it was time to organize and label the piles of small hardware I've received from Aircraft Spruce. Made good progress, but not done.
 
Nov 26, 2023     Tools - (.5 hour) Category: Fuselage
Went to Tractor Supply Co and Harbor Freight to look at long wrenches. Purchased a standard set of Harbor Freight wrenches that I can modify if needed.

Dropped off boxes and my road bike at the hangar. Picked up cotter keys and a Christmas tree.
 
Nov 25, 2023     Doublers - (6.4 hours)       Category: Fuselage
Met my weekly goal again. Only worked three days due to travel for the Thanksgiving holidays.

Completed COM antenna doubler by drilling and match drilling it to the rib and the original doubler. Trimmed the pop-rivet wedge I made earlier this week. Deburred holes.

Countersunk the contactors doubler/firewall with help from Ellicia. I realized too late that I should have dimpled many of the holes and countersunk the doubler. Using the small-head NAS rivets for the nutplates.

Countersunk the fuel bulkhead fitting doubler.

Deburred firewall holes for the contactor and fuel doublers. Deburred firewall holes for the cabin heat valve.

Searched for a tool to help torque the nuts that are on the center section near the bottom fuselage skin and difficult to reach. Found some interesting tools, but decided to check out harbor freight long reach combination wrenches and make my own if needed.


 
Nov 20, 2023     COM doubler, FWF parts, Static Port - (4.1 hours)       Category: Fuselage
Called Van's parts desk since I hadn't heard back regarding the FWF parts list I sent them on Tuesday evening, 11/14. They said they were about a week behind on emails and would get to my list and send something to me for review/approval.

Modified bends of COM antenna doubler for a final good fit. Match drilled doubler to fuselage skin, deburred and dimpled skin and doubler with help from Ellicia and her twin ;-). Realized my original plan to use a blind rivet to attach the doubler to a previous doubler creates a problem. Decided to use a technique I saw in Kitplanes so I started making a wedge to use between the rivet and the puller to allow me to tilt the puller at approximately 10 degrees to clear a flange. Hope it works.

Tried several different methods to modify the ID of the aluminum washers to fit on the showplaces static port fittings. It was hard to get a smooth ID centered on the OD with a file so I abandoned that. I eventually tried clamping the washer between two pieces of wood and using a step drill. That looks promising, but isn't good enough. I need to practice more and modify my technique. Later I searched YouTube and was pleased to see others were using the same technique of clamping a washer using wood.


 
Nov 19, 2023     Controls - (3.2 hours) Category: Fuselage
Worked on getting free play out of co-pilot stick. Tried several of the existing bushings and spacer washers. I was able to improve it, but not enough.

Made additional bushing and slowly adjusted length until it was 2.237". The stick width was 2.200". Added a 0.030" washer which allowed enough compression of the bushing between the yoke to remove the free play without adding friction.
 
Nov 18, 2023     GMU 11, Controls, plastic - (5.5 hours)       Category: Fuselage
Met my goal for another week. No misses for this phase.

Looked at GMU holes I drilled yesterday and realized only one was in the desired position. Measured and marked more and then slotted holes as needed and drilled and cleaned up the final holes. Modified the final small standoff and mounted the GMU with the two standoffs and screws closest to the bulkhead. It looked good so added the final two standoffs. Drilled a hole for a nylon cable support. Need to prime holes and mount with final hardware later. Made an aluminum "wrench" so I can tighten the final mounting locknuts without using a magnetic tool. I already have the beryllium copper non-magnetic screwdriver.

Started working on the control sticks again using the new bushing. Used 1/4-20 all-thread, nuts and washers to bend the yoke ears out slightly for the new bushings. Went through multiple iterations of washer stacks and modifying the length of the bushings on both the co-pilot and pilot stick. I got the pilot stick working great with very low friction and almost no free play. I think the combination that worked had a bushing about 0.040" longer than the control stick bushing enclosure and a 0.030" spacer taking up all but 0.010" of the extra space. The co-pilot stick still needs work. There is some free play if you move the sticks towards or away from each other and I hope the final tightening of the spherical bearings will fix that.

I peeled all the blue plastic off the bottom of the fuselage since it is easier to move while I don't have to crawl under the airplane to reach it.


 
Nov 17, 2023     Garmin, Aileron Trim, Control Sticks, GMU 11 - (7.9 hours)       Category: Fuselage
Completed registering Garmin products on their warranty website.

Opened, inspected and inventoried packages from McMaster Carr, Aircraft Spruce and Flyboys.

Selected type of screws to use for COM antenna mounting - MS24694C with length of 6, 7, 8 or 9.

Completed aileron electric trim install using longer clevis pin than specified on the servo side of the link. Watched the EAA video on cotter keys and read the section in AC43.13-1B. Clevis pin MS20392-1C9 wasn't long enough so used 1C11. Installed servo using shorter screws, MS32506-229 instead of AN515 6R8.

Started working with the replacement bushing for the control sticks. Figured out good ways to trim to length (drill press and file, disk sander, file) and to ream (two hand drills or a hand drill and a reamer held in a tapping handle). Made two bushings to test fit. Decided to use 1/4-20 all-thread, nuts and washers to spread the yoke apart before trying the new bushings. I made the bushings longer than the tube on the stick and want the yoke to squeeze against the bushing to keep it from rotating.

Worked with new standoffs to figure out how and where to mount the new GMU 11. Decided to nest it against the aft side of the F-709 bulkhead by using 5/8" standoffs to mount it above the F-714 aft deck. This requires grinding the edges of the small standoffs to provide clearance of the F-714 bend radius. This allows the most edge distance between the large standoffs and the two large holes in the F-714. Marked and drilled two of the holes.


 
Nov 15, 2023     Parts - (3.7 hours) Category: Fuselage
Updated maintenance manual with part numbers and serial numbers. Completed and documented research on the Garmin SB for pressure sensors.
 
Nov 14, 2023     Parts - (4.9 hours) Category: Fuselage
Reached out to Hooker and Crow with crotch strap thickness and attach bolt size. Received information from Crow.

Talked to Van's about Fire Wall Forward (FWF) kits and found I should work with the parts team instead of the kits team and that parts might be 4 to 6 weeks out. Van's is still evaluating operations per the announcement.

Talked to Van's support about firewall recess gaps, starter on my new M1B and clearance with the FAB part in the FWF kit, Alternator and the FWF kit and the ES WH-6/7/... shown in the FWF documentation, but not in the Van's online store.

Completed my FWF parts list review and markup. Decided I could use 27 top level parts or kits, didn't need 31 top level parts or kits, and might want the exhaust kit. Also finished up a cart of 8 other items. Didn't know if I should just add the 27 top level parts to my cart or let the parts team handle it. Sent color coded spreadsheet to Van's parts team and asked for a call back to discuss.

Sent email to Vetterman about exhaust options. Also included exhaust in parts list sent to Vans.

Researched fuel injection, alternators and starters on vanairforce.

Made final updates to McMaster Carr and Aircraft Spruce carts and placed orders.
 
Nov 13, 2023     Parts and drawing review - (4.9 hours) Category: Fuselage
Continued working through multi-level BOM for FWF kits. Also reviewed FWF documentation and got close to finishing markups on which parts to order. Need to call Van's to discuss.

Traded emails with Don R at Airflow Performance. May just keep the Avstar since it will cost around $3400 to buy all the AFP parts. Of course I may be able to sell some of the Avstar parts to offset the AFP cost. Not sure it is worth the effort.

Not included in this time: Went to Capitol Bearing and picked up a steel nut for the firewall fuel bulkhead fitting.
 
Nov 12, 2023     Parts - (5 hours) Category: Fuselage
Made final decision on where and how to mount the GMU 11 and added standoffs and screws to my McMaster Carr and Aircraft Spruce order.

Created a multi-level indented BOM from the list Van's sent me and from their store website and started researching which FWF parts I need.
 
Nov 11, 2023     Crotch Strap kit, Aileron Trim - (4.6 hours)       Category: Fuselage
Met my goal for another week. Starting the holiday stretch which will make it a little tougher to meet my goals. Also there will be some out of town travel that will slow progress.

Attended the EAA chapter 187 meeting this morning although the time wasn't included in the log.

Started out the day ready to install the aileron trim. I had assembled most of it before and removed it since it was in the way of other things. This time I also bent the C606 straps per the print and loosely attached them to the pilot and co-pilot stick. I realized I had missed one of the washers on the assembly drawing. The washer wouldn't fit so that is why I left it off last time. I decided I really should install the washer. I tried finding a thinner washer in my stock and filing some of the parts to make them thinner. I managed to get the cotter pin installed with the washer in place, but there is a lot of friction in the system and the motor and actuator arm aren't secured yet and any misalignment will cause more binding. Decided to order a longer clevis pin and added it to my Aircraft Spruce cart.

Decided it was time to install the crotch strap mounting kit and realized I had a problem. The kit installs in the same place I put the Transponder antenna doubler and the FlyLEDs controller board. I'll just move the FlyLEDs controller board, but I can't easily move the Transponder antenna doubler since I already match drilled and dimpled the fuselage skin. It looks like I will have to remove some or all of the flanges on the doubler that I planned to rivet to the seat ribs. I can make it work.

I've got a lot of things started that are held up by parts. I need to review tomorrow and get parts on order. Then start a few new things while I wait for parts.


 
Nov 10, 2023     Pitch Servo, Aft Power Port - (7.5 hours)       Category: Fuselage
Looked at flyboys super track canopy kit demo and installation video and placed an order.

Researched blind rivets and decided to use the LP4-3 rivets since I need a grip length of around 0.060" and the LP4-3 is 0.039" to 0.137". The other ones I had in stock had a top or bottom grip range of about 0.063". Marked and drilled the transponder doubler for the four blind rivets. Match drilled the fuselage for the blind rivets.

Removed the two ADAHRs mounting brackets installed for the Dynon parts since I am now mounting the Garmin GMU 11 in the Garmin recommended position. Looked at vansairforce and my project and the GMU 11 and Stein GMU 11 mounting bracket. Added a non-magnetic screwdriver to my shopping cart. Decided I didn't need the Stein bracket. I may use some standoffs to mount the GMU 11.

Mounted the pitch bell crank, Garmin GSA 28 pitch servo and all the associated parts. Used torque seal on the nuts I torqued and don't expect to remove.

Decided on a location for the aft power port. Cut a mounting hole.


 
Nov 09, 2023     Stick, Transponder Antenna... - (8.1 hours)       Category: Fuselage
Read SB about co-pilot stick attachment. Searched for and found multiple pins to use in place of the SB specified AN3-13A bolt and added the information to the maintenance manual to consider in the future since I won't know for sure what might fit. Removed and drilled the co-pilot stick for the AN3-13A bolt and reinstalled it. Used torque seal on the three nuts in the controls that are torqued to final spec and shouldn't have to be removed later.

Decided to replace the bushing in the two sticks so they will be captured by the yoke and kept from rotating. Placed the bushings in my Van's cart since I couldn't find a similar part at Aircraft Spruce or McMaster Carr.

Updated the Trim, Autopilot, Flaps and control information in the maintenance manual.

Drilled and deburred the holes in the transponder and COM antenna doublers. Match drilled the transponder antenna doubler to the fuselage. Dimpled the transponder antenna doubler and the holes in the fuselage skin. Still need to drill holes from the doubler to the seat ribs.


 
Nov 08, 2023     Controls - (5.2 hours)       Category: Fuselage
There was a lot of friction in the pitch motion of the control sticks after mounting the WD-610 control column to the F-633R and L. I found out (by trying it and then researching on vansairforce.com) that any side load on the bearings causes friction so it is critical to use the correct thickness of spacers. After several attempts, determined a good way to get this right was to install the WD-610 with bolts loose and a best guess at spacer washers. Then remove all the washers at one end of the control column and use a feeler gauge to determine the exact spacer needed on one side of the bearing. I had AN960-10 and AN960-10L washers I had purchased over the years and the thicknesses varied. So I could try a bunch of different washers and measure the total stack with calipers until I had what I needed. Then I would install those on one side of the bearing and then repeat for the other side of the bearing. After completing one end of the control column I repeated the process on the other end. I added this information to the maintenance manual.

Installed the WD-611 and WD-612 control sticks.

Set the F-665 length after installing the rod ends. Installed the assembly.

Realized I need to remove the co-pilot side components and drill a hole through the base and extension to secure the extension. I'm considering alternate methods to the one recommended by SB 07-2-6.


 
Nov 06, 2023     Controls and - (4.5 hours)       Category: Fuselage
Researched doublers in Garmin, Van's and FAA 43.13 documents. Decided on a hole pattern for the transponder antenna doubler. Started looking at the best forward/aft position for the transponder antenna doubler and realized it would be better to get the aileron/elevator controls installed first to give me a better idea of the required clearance around them.

Installed the F-633-R and L control column mounted. Worked to install the control column. Had problems with friction due to binding. Researched on vansairforce.


 
Nov 05, 2023     Antenna doublers - (1.7 hours)       Category: Fuselage
Completed trimming and bending the COM antenna doubler. Fabricated a second doubler for the transponder antenna using a previously made blank. This one fits nicely.


 
Nov 04, 2023     Firewall - (7.8 hours)       Category: Fuselage
Just met my hourly goal for another week. It is too easy to find other important things to do early in the week and then work more hours late in the week to catch up. For some reason, the commitment to my grandkids to work a certain number of hours helps.

I researched socket head screws to use in place of AN4 bolts for contactor mounting. These will really improve future access and maintainability. Calculated lengths and added to aircraft spruce cart.

Also pulled out insulating boots and 2 AWG and 6 AWG terminals terminals purchased from B&C. Looked for additional sizes of insulating boots at Aircraft Spruce, Mouser and McMaster Carr. Added a sample set of boots to my Aircraft Spruce cart.

I finally decided to match drill the fuel feedthrough doubler to firewall and installed a temporary fitting.

After verifying the 1/2" EMT fitting was large enough for all the necessary wires and carefully checking obstructions, drilled a 0.75" hole in the firewall where Van's OP 30 wiring document specified. Used a file and step drill to enlarge the hole to approximately 0.8". Removed the screw on the fitting and filed the boss flush.

Drilled two holes for Adele Clamps to secure the top ends of the conduit that will run from the back of the instrument panel to the floor of the fuselage. Used OP 30 Detail D as the example.

Drilled four holes to mount the FlyLEDs strobe and position lights control PCB. Drilled an addition hole for a local ground and for an Adele clamp to secure wiring to the PCB. Installed the PCB using 4-4 1/4" standoffs, AN365-440 nuts and 4-40 stainless steel sems screws (built in washer) from McMaster.

Considered where to install the ANL mounting block and whether to use the one I have with the cover or buy a smaller one without a cover. Walked through options with Ellicia. One key issue how to install and remove the parts as needed. That ruled out most of the options. The use of socket head screws helps a lot and I will use those to mount the ANL block. I decided to use a wire and terminals to connect the ANL to the main bus instead of a bus bar. A bus bar made things a lot more complicated and isn't insulated. I need to look at other drawings and make sure I put the ANL in a reasonable place.


 
Nov 03, 2023     Contactors and Fuel feedthrough Doublers - (6.9 hours)       Category: Fuselage
Completed drilling nut plate holes and other mounting holes in the firewall and contactor doubler. Rough fit parts and realized I should make the fuel feedthrough doubler even taller than needed to support the starter contactor mounting bracket so I can countersink the doubler instead of the firewall.

Fabricated new fuel feedthrough doubler and match drilled it to the firewall. All that remains is to drill the large hole for the bulkhead fitting after I decide the pilot hole is in the right spot.

Inspected the aircraft spruce and Airline Hydraulics shipments and the three mesh screens I purchased from Amazon.

Wrote Aircraft Specialty asking about where the 8 brake hoses should be located. Many of them were similar lengths. Got a prompt response from Tom. Added the information to the maintenance manual.

Drilled a 5/16" hole in a copper bar that will go between the two contactors. Need to finish up the final mounting before I drill the second hole.

Considered several options on where to locate the ANL fuse and how to mount it and connect it to the contactors. Reviewed the schematic and wire size tables to see if I really needed the 6 AWG wire and decided I should keep it that size. Thought about installation order of the contactors and copper bars and decided I might want to change the mounting bolts to socket head cap screws.

Created new symbol for the 24021 starter contactor by marking up the S702-1 B&C contactor to remove the internal diode. Updated the schematic with the new symbol.


 
Nov 02, 2023     Wheels, Brakes, Antennas - (6.8 hours)       Category: Fuselage
Received and inspected aircraft spruce and Aircraft Specialty (TS Flightlines) orders. Realized I ordered the wrong screws for the COM antenna. Researched antenna screws more and added the GA 35 GPS antenna to the research. Added screws to my new aircraft spruce cart.

Updated maintenance manual with details on nose wheel parts and tubes and tires.

Worked on the contactor mounting doubler. Completed a rough fit test on the contactors and fuel feedthrough doubler and decided to add to the fuel feedthrough doubler so that the doubler supports the whole end of the contactor mounting ear.


 
Nov 01, 2023     Contactor Disassembly - (.2 hour)       Category: Fuselage
Took the Van's starter contactor apart to see what was wrong. The plunger and or springs have a problem. When the riveted cover plate is installed the contact disk hits one main contact which is connected to the "I" terminal.


 
Oct 31, 2023     Contactors and Parts order - (2.7 hours) Category: Fuselage
Tested the new contactor I received from Mouser and it worked as expected. I had received a defective contactor from Van's.

Confirmed the antenna screws I needed for the Comant CI 122 were 100 degree screws and added them to my Aircraft Spruce cart. Researched tubes and determined that I needed to order a Classic Aero LEAKGUARD INNER TUBE 11X400-5 TR87 (DTR20-400). Considered ordering the main gear tubes, but decided to wait until later. Went through lists and added other parts and placed the order using the Halloween discount code.
 
Oct 30, 2023     Contactors and parts - (5.8 hours)       Category: Fuselage
Decided to test the starter contactor before drilling mounting holes and found the "I" terminal was connected to the "Battery" terminal. This means it won't work they way I had planned to wire it. And it won't solve the starter back EMF problem that Van's was addressing with their lightweight starter schematic. Shared the information with another builder to verify I wasn't missing something. Ordered a replacement Littlefuse/Cole Hersee from Mouser. This will ensure I get a real Cole Hersee. It's possible that the one I got from Van's wasn't a Cole Hersee.

Proceeded with drilling holes for nutplates to mount the contactors per the Van's drawings. If the contactors don't work they way I expected, I can make minor wiring changes to make it work.

Figured out what spacers I needed to mount the FlyLED's control board and included those on the mouser order.

Worked to add firesleeve (for the firewall feedthroughs), bolts for the contactors and bolts for the cabin heat valve to my aircraft spruce order.

Researched and ordered three different types of stainless steel screen from Amazon to use for the fuel vent lines and cabin vent air inlets. I think I may also need some for other air vents.


 
Oct 29, 2023     Review - (1.3 hours)       Category: Fuselage
Reviewed and logged work from preview two days. Took the list of tasks I had created over the last few weeks and put it in a spreadsheet. Made notes on completed tasks, ones where I need to make decisions or order parts and some dependencies.

Drilled mounting holes in FlyLEDs control board mounting template after deciding to use 4-40 screws.

Added Dow Corning 3145 RTV to the capacitors on the FlyLEDs control board capacitors and the legs of the large power resistors to reduce the chance of problems due to vibration.


 
Oct 28, 2023     COM and Xpndr antennas, contactors - (8.6 hours)       Category: Fuselage
Met my weekly goal for another week.

Located the two contactors on the firewall and temporarily secured them with tape. Clecoed the bulkhead fuel feedthrough doubler in place. It was close but seemed like it might work. Looked at all of the drawings I received with the FWF documentation packs to see if there was any new information about firewall items. Decided the VA-136 fuel line from the bulkhead fitting to the engine driven pump was a problem since it turned toward towards the solenoids. Decided to ask some other builders about their experience.

Used the COM doubler paper template and started fabricating one out of 0.030" thick 2024. The angles lined up on the first try! Now I need to trim and bend up one of the edges and drill mounting holes.

Fabricated a doubler for the transponder that would nest between two seat ribs. Made it too large to fit. Made two more blanks so I can try again later.

Drilled the top hole for the VA-168 transducer manifold and the match drilled the second hole.

Started drafting an email to builder friends about the potential interference issue with the contactors and fuel bulkhead and hose assembly. Took screenshots of photos and parts of drawings to help explain the issue. After looking at my engine mount and some of the assembly drawings I realized the VA-136 fuel line for tricycle gears was added to route around the new (in 2019) elastomer nose gear mount. My nose gear is the older style and uses the same hose as the taildragger version. So I plan to install contactor nut plates and doubler per the drawing and install the contactors as far up and towards the copilot side as possible. Then I will see how much clearance I have and will adjust the fuel fitting double a small amount if needed.

I purchased two small enclosures for the flyLEDs controller board. After looking for a mounting location, I decided I would mount the bare board under the pilot seat. I cut a piece of aluminum sheet to size and marked the PCB mounting holes on it. I'll use the aluminum as a drill template and I plan to use 1/4" aluminum standoffs with 4-40 threads.


 
Oct 27, 2023     COM, XPNDR, and... - (3.7 hours)       Category: Fuselage
Fabricated a drill template and used it to mark and drill the antenna connector hole for the COM antenna. Taped a 48 inch ruler to line up with the center rib. Sighted along the antenna to rotate the antenna so it was parallel with the centerline of the airframe. Marked the final two holes using the properly rotated antenna as the template. Drilled the final two holes slightly undersized and filed as needed to enlarge the holes and exactly match the holes in the antenna base. The COM antenna uses two of the holes made for the transponder antenna and covers the large hole that was made for the transponder antenna connector. Made a paper template to follow when adding a COM doubler extension to the previous transponder doubler.

Made a final decision on the transponder antenna location.

Completed marking and drilling the two mounting holes for the cabin heat vent.


 
Oct 26, 2023     LED strip lights, Transponder and COM antenna - (9.5 hours) Category: Fuselage
Connected LED strip lights to a power supply and measured voltages and currents. I also researched some other LED options. I decided on three approaches I can use to limit current to the GAD 27 spec. Researched on vansairforce and confirmed I had determined good options. Added the test results and options to the maintenance manual. Made some other maintenance manual updates. I think was making this too hard. I think I will want to reduce the length of the strips to hide all the LEDs under the glare shield from direct view. That will reduce the current requirements. Then I can program the dimming curve on the GAD 27 to limit the maximum average current.

Studied options for transponder antenna mounting. The locations all have pros and cons. I'm struggling with make antenna decisions. My plan was to just decide today and do it, but I am not ready yet. I spent time looking up doublers and antenna mounting in AC43.13-1 and 2, vans airforce, Kitplanes, Stein and some others.

Studied the COM mount more and decided I can really put it where the transponder was. Started making drill templates and after partially completing two of them decided to stop for the night since my templates weren't as accurate as I wanted them to be.

Inspected all the cir clip pliers I received and removed the retaining clip from one of the Matco cylinders. Now I can work on them as needed.
 
Oct 25, 2023     Misc - (.5 hour) Category: Fuselage
Consolidated the many lists I have created to get one list of tasks to complete before and after I rivet on the top skin and install the engine mount.
 
Oct 24, 2023     Misc support stuff - (2.5 hours) Category: Fuselage
Counted 5 hours of time against my goal, but only logged 2.5 hour here. Called Airline Hydraulics to address a shipping issue. They shipped a $7 line item with a $25 shipping charge even though I had clearly requested "ship complete". I found a hole in their process and they are refunding.

Traded emails with Tom at TS Flightlines and eventually paid for fuel and brake lines that should ship no later than 10/31! Yay, feeling really good about my decision to buy prefabricated lines instead of making my own.

Received response from Vivo Home regarding the wheel balancer. Repaired it enough to be able to use it. Told Vivo I addressed the flange problem and asked them to go ahead and send the bubble level and weights.

Reviewed master cylinder information from Matco and considered options for improving the mounting. Tried to disassemble the master cylinder and then searched for cir clip pliers and ordered two different sets.

Continued work on maintenance manual.

 
Oct 23, 2023     Fuel lines and brake lines - (1.5 hours) Category: Fuselage
Updated the draft questions to Tom at Aircraft Specialties (TS Flightlines) and sent to Tom. Reviewed his response, decided to order the cabin brake lines and replied by email.
 
Oct 22, 2023     Van's parts, pitot static - (3.4 hours) Category: Fuselage
Unpacked delivery from Van's.

Needed to order at least one more pitot/static fitting. Sketched updated schematic and reviewed parts. Came off with a list of items and placed order with airline hydraulics.

Started outline of a maintenance manual. Added part numbers for the pitot static section. Added part numbers and some background in other sections.
 
Oct 21, 2023     Fuel and brake tubing - (5.3 hours)       Category: Fuselage
Met my work hour goal for another week.

Continued work on fuel and brake lines. Considered assembly order including access to wing spar bolts and how to determine final location of wing fuel fittings.

Confirmed the choice of locating the break in the fuel lines between the two brackets on the front of the main spar center section. Fabricated a piece of tubing with a fitting on the valve and a loose end near the break. Worked on fabricating the tubing from the valve to the right wing tank. Realized I would need to change the routing so the fuel lines would be routed on top, brake lines in the middle and wires on the bottom. Fabricated rough examples of tubing from wing tanks to the break and thought about the order for determining final length and flaring the ends of the tubing. Reconsidered the amount of work I was delaying to final assembly at the hangar and the risks of leaks due to flaring tubing in place and final fit of all the tubes.

Studied run of brake line tubing and how to fabricate them and the installation order. The brake lines can block access to some of the wing spar bolts. These are the easiest to form so they should be run last.

Decided to reconsider use of TS Flightlines hose kits and created list of questions for Tom. I know I could make the hard lines work, but I am not enjoying it and my lines will take a lot more time and have a higher risk of leaks. Also future maintenance will be more likely to be required and be more difficult. Seems like a good place to trade dollars for time and quality.


 
Oct 20, 2023     GSA 28 Bracket, Questions, and fuel and brake lines. - (8 hours)       Category: Fuselage
Prepared a list of questions for Brian's visit.

Used Brian's long reach yoke to squeeze the final four rivets to attach the GSA 28 Pitch Servo bracket.

Discussed my list of questions with Brian including:
- Pitot/Static/AOA tubing, static ports, routing, testing. I'm going to redo my static ports with ones from showplanes with and additional 0.032 spacer
- Firewall mount oil cooler questions. Got my questions answered. Still have to decide whether to use baffle or firewall mount.
- Wire conduit routing from panel to aft fuselage.
- Lycoming test report and Avstar vs AFP fuel injection. Close enough. I plan to call Don at AFP
- Master Cylinder Mounting. Okay? I'm still thinking about adding structure.
- Front fuselage rivets.
- Engine installation and hoist. Install mount first and then finish firewall penetrations where practical. Then install engine.
- Starter Contactor. Showed him the one I took apart.

Started working on fuel lines. Made up one fuel line and it didn't fit, but I learned a lot. Made a second fuel line that fits! Learned that the small tubing cutter works great and leaves a cleaner end. Still need to figure out a better way to debug the tubing after cutting it. Considered using the TS flightlines fuel and/or brake line kits and how parts I fabricate could work with the kit parts. Considered options on how to split the tubing from the valve to the wing into two parts to make it easier to fabricate and install. Decided to proceed with making the parts. I can always change to buying parts.



 
Oct 19, 2023     Shop cleanup and repair, Tubing Bender - (.5 hour) Category: Fuselage
Spent 5.3 hours working on the RV, cleaning up and replacing fittings on the air compressor to stop all the leaks. Counting all that time for my weekly goal, but only 0.5 hours in this log.

Added items to the list of things to discuss with Brian tomorrow. Found a second modified tubing bender and confirmed it is the one I should use and not the one I was trying a few weeks ago. Good thing I cleaned up. I've been working more and not cleaning up after each task and the mess grows.
 
Oct 18, 2023     GSA 28 Pitch Mount, Antennas and tubing - (4.9 hours)       Category: Fuselage
Arranged for help from Brian Decker on my Garmin pitch servo mount.

Researched and ordered pipe thread sealant.

Looked at transponder and GPS antenna requirements in the Garmin GNX375 installation manual. Decided to discuss location with Brian on Friday.

Looked at COM antenna mount requirements in the Garmin GTR200B installation manual. Decided to discuss location with Brian on Friday.

Ellicia and I set one rivet to block an unused hole and three rivets attaching the GSA28 pitch bracket to the fuselage skin. It has been awhile and we were a little rusty, but didn't have to drill out any rivets. I squeezed the four rivets along the bell crank rib stiffener. I had to drill out and replace one since the rivet was too short and didn't meet spec after I squeezed it. I'll set the final four rivets when Brian brings over a long reach yoke.

Opened, inspected and tried the SMC soft nylon and polyurethane tubing with the SMC push to connect fittings. I think I will use the polyurethane.


 
Oct 17, 2023     Fuselage, Pitch Servo Mount - (5.5 hours)       Category: Fuselage
Removed Dynon pitch servo mount and match drilled Garmin servo mount. Sent email to friend asking about long reach squeezer yokes. Will drill four new rivet holes after determining the reach I will have. Filed and sanded edges. Didn't like the sharp corners on the relief cut for the bends so used a round file to round them off. Primed the GSA 28 pitch servo mount and battery hold down bar.

Researched oil cooler options on vansairforce. Looked at oil cooler part numbers, mounting options, ducting and temperature control. Saved links and summary in an email for later discussion.


 
Oct 16, 2023     Tech counselor and project visit - (2 hours) Category: Fuselage
Met with tech counselor for lunch and discussed SB and SL documentation, build and maintenance documentation, the test report from my Lycoming engine run, engine sensor manifold, brake lines and fittings, push to connect fittings and static port for pitot/static plumbing, transponder and COM antenna locations, cabin heat valve, fuel line bulkhead fitting material, wheel corrosion and oil cooler options and locations.

Viewed and took a lot of pictures of a similar project which helped answer a lot of questions!
 
Oct 15, 2023     Prep for discussion with tech counselor - (.7 hour) Category: Fuselage
Consolidated and revised list of topics to discuss with tech counselor in preparation for a meeting on Monday.
 
Oct 11, 2023     Research, Documentation, Clean, Organize - (6.4 hours) Category: Fuselage
Opened engine box again and unwrapped fuel servo to see if it was Airflow Performance (as expected) or Avstar. Avstar... Sent email to Lycoming rep to see if I had any options. Next stop will be Don at AFP.

Opened main gear brake and wheel boxes and reviewed documentation. Researched on Parker/Cleveland website and downloaded latest documentation. Selected o-ring upgrade parts at Vans store and added to cart for the next order. Placed brake fluid in cart at Aircraft Spruce.

Researched Matco master cylinders and figured out which ones I have. Sent email to Matco tech support an email with a picture to get confirmation. Also asked if I should replace anything since the cylinders have been in the garage since 2005. Downloaded technical documentation and saved on iCloud Drive.

Read RV maintenance and researched tools and decided which ones I want to buy. Researched bead breakers (anti-splat), balancer (really like McFarlane, but purchased one on sale at Amazon day for now), window breaker (anti-splat and Amazon). Placed orders or added to carts for future orders.

Started deep clean and organizing in garage and workroom where I built the panel. The mess has been building and I needed to get organized again.

Really spent over 8 hours working on RV related things today but only logged the 6.4 I needed to meet my work goal.

Leaving town early tomorrow to visit friends and then parents. Met my goal for this short week.
 
Oct 10, 2023     Research and documentation - (4.5 hours) Category: Fuselage
Documented discussion with Kevin at Van's Builder support and saved pictures and related files.

Downloaded and specifications for Cole Hersee contactors and B&C pictures and wiring diagrams and saved.

Researched brake fluid and o-rings to use and found info on vansairforce and the final answer in a Van's service letter SL-00047. Use MIL-PRF-83282 fluid and Viton o-rings.

Saved some emails where I had documented findings and links on other issues such as pitot install information, GPS minima types and parameters, fuel flow restrictors and McMaster Carr part numbers and fitting torques.

Copied the kit BOM Van's sent me for my FF kit and created a spreadsheet with notes about which parts to use and which ones to skip or buy later. Researched and saved information on some of the parts such as exhaust systems and linkages for AirFlow Performance fuel injection and oil filter adapters. Added documentation packages included in the FF kit to my cart so I can see the details of how the kits are installed and make informed decisions on which parts to get. Placed an order with Van's.
 
Oct 09, 2023     Firewall and oil cooler - (2.2 hours) Category: Fuselage
Research day. Found that others on vansairforce had reported the same issues I found with the location of the Fuel Injection firewall bulkhead doubler and the starter solenoid. Also realized I need to consider the clearance between the starter connection and the firewall fitting. At the same time researched what others said about using steel or stainless steel instead of the vans specification for an aluminum AN833-6D fitting.

Looked for options for contactors for the starter and master solenoid. Researched Van's parts and Cole Hersee contactors from other sources. Decided to just order from Van's to make sure I get the right one. I'll wait to finish the bulkhead feedthrough and contactor mounting until I get all the parts.

Researched other options/sources for brake fluid reservoir fitting and decided to just use the Van's fitting instead of trying to cross over to an SMC part.

Called and talked to Kevin at Van's Builder Support. Another great experience with Van's! We discussed:

- Engine documentation and parts - As I suspected any AD or SB dated before my engine build date is not applicable per the engine documentation I received.

- Brake Fittings - Yes, use the FLF-00004 on the brake reservoir. Van's is supplying that part for all kits even though the documentation still shows the old valve that has been known to crack and leak more often. He recommended using the brass fittings with inserts and the tubing as shown in the documentation unless I wanted to consider changing to an aftermarket kit.

- Suggested using the AN833-6D per the instructions since the firewall is not a high vibration environment.

- Oil cooler, Baffle or firewall mount? And type? Long discussion with lots of information. He sent pictures on how others are beefing up the baffle if I used the baffle mounted cooler. I summarized a lot of his information in notes I'm keeping on iCloud.
 
Oct 08, 2023     Antennas, Pitch Servo, Firewall Penetrations - (4.9 hours)       Category: Fuselage
Checked the fit of the Garmin Pitch servo on the Dynon bracket. I was hoping it would be close enough to a bolt in, but it isn't. I need to talk to someone to help me decide if I need to drill out the old bracket and install the new one. The Garmin bracket will be located about an inch forward, be 0.060" thick instead of 0.050" thick, have a larger cut out so the servo mounts on the other side of the bracket, and has more rivets securing it to a rib.

Measured and marked up the transponder antenna mounting location to consider two options for converting it to a COM antenna mount. The transponder antenna mount is on the aft fuselage because I had planned to use a remote Dynon transponder. With the Garmin GNX375 GPS Nav/Transponder in the panel, I need to move the transponder antenna closer to the panel. I plan to use the old transponder location for the COM antenna. I also identified a few possible locations to install the transponder antenna. The locations look reasonable based on information I found in old Comat Literature and on vansairforce. I need to talk to someone.

I fabricated a doubler for the fuel line firewall bulkhead fitting. Then I realized it conflicts with the mounting of the starter contactor. I looked through drawings and on vansairforce and decided to remake the double and extend it so the starter contactor is supported completely instead of only halfway.


 
Oct 07, 2023     Battery Tray, Cabin Heat Valve and Brake Fluid Reservoir - (6 hours)       Category: Fuselage
I met my weekly goal for the first week of phase 5.

I worked to improve my list of things that need to be done before I hang the engine.

I decided to take apart the B&C starter contactor. As I suspected, it is a solid design and would have worked well if it didn't create mounting problems for me. See below for pictures of the contactor, brass contacts in the housing and the thick disk that bridges the contacts.

I did a little more research on starters since my Lycoming engine documentation lists the Lycoming part number for the Hartzel (Sky-Tec) starter, but I couldn't find any website that had a cross reference.

I installed the nut plates on the back of the battery tray using the small head NAS rivets. Then I enlarged the clearance holes in the firewall as needed so the bolts would line up with the nut plates. All done!

Then it was time to cut the large 1.95" hole for the cabin heat valve. I used a step drill to get to the 3/4" hole I needed for my hydraulic punch. Then I used the Harbor Freight hydraulic punch and it worked great. There was a small, sharp ridge around the hole that I removed using a small drum sander on a battery powered drill. I was pleased that the hole was only about 0.020" to the pilot side and about 0.010" low from where the center should have been. I figured the location would be worse with all the steps it took to finish the hole.

I was ready to drill the two holes that are used to attach the cabin heat valve to the firewall and realized I didn't know the exact orientation. I searched drawings and websites and found one website that showed the valve oriented in a way that makes sense to me, but I'm going to wait until after I hang the engine before I drill the holes.

I marked the holes for the brake fluid reservoir. Then I drilled the hole for the reservoir outlet. Then I drilled undersized holes to mount the reservoir and filed the reservoir and firewall holes for the final fit.

I spent about 8 hours on the project and research today and only logged 6 hours which was more than enough to meet my weekly goal.


 
Oct 06, 2023     Battery Tray - (5.2 hours)       Category: Fuselage
Finally time to mount the battery tray to the firewall. I've agonized over this for a long time. I tried clamping the battery tray in place so I could match drill the three holes, but I decided that would be tricky to keep things from moving and wouldn't give me much control on the hole locations. And if the holes on the battery tray bracket moved, I would have to figure out how to move the nut plate. It finally dawned on me that I should enlarge the three rivet holes and then file the holes as needed to match the holes on the battery box. I enlarged the three rivet holes in the firewall with a step drill and/or a #12 angle drill. I used boelube as a cutting lubricant, but think my drill bit dulled quickly. I filed on one of the holes in the firewall and now everything matches. I need to install the nut plates and then adjust the holes in the firewall with a file if needed.

Now time to finish the battery tray assembly. I enlarged the screw holes slightly so they are clearance holes. I drilled and countersunk the nut plate holes. I primed all the bare metal. I bought black spray paint and painted the front of the battery tray. I left the inside and back of the battery tray with primer only in the areas I had touched up.

While waiting for primer to dry I started looking at the mounting for the master and starter contactors. I purchased these from B&C based on information from AeroElectric. I have been rethinking my decision to use the B&C starter contactor because:
1) Using a copper bus bar between the two contactors is much more difficult and the bar is more exposed to accidental contact than if I use the Van's style contactor.
2) I have to figure out mounting and a doubler instead of just using the Van's documentation.
3) A presentation at an EAA chapter 187 meeting that showed problems with an automotive solenoid that looked similar to the B&C contactor.
I decided to use the B&C master contactor and the Van's starter contactor because of items 1 and 2. I don't think item 3 applies because I believe the B&C contactor is a good design. FYI, I took the B&C starter apart on 10/7 and verified the inside is much different than the inside of the one shown in the chapter meeting.

I called TJ at B&C to ask a few questions about the starter contactor and realized I really didn't know anything about the starter that is on my engine or how that fits into the Van's wiring instructions and my schematic. I researched on Van's website, Sky-Tec's website and Van's Airforce. If found out the starter I probably have installed is a 149NL. If so, this is not a permanent magnet motor and I should use my schematic which closely matches the Van's and Aeroelectric schematics. I need to confirm which one I really have.


 
Oct 05, 2023     Battery Tray - (6.8 hours)       Category: Fuselage
Match drilled mounting bracket to battery tray rivet holes. Deburred, dimpled and riveted brackets to the tray. Match drilled battery hold-down bar to mounting bracket and installed nut-plates.

I made a few minor mistakes, but it will work okay. I let one of the mounting brackets move while I was match drilling. I didn't center the bar that secures the battery when I was match drilling it. I tried different orientations of the bar and tray and found one where the errors cancel out. I may need to make longer spacers for the battery hold-down bar.

I sanded off the rough edges of the battery lightening holes using a small drum sander in a drill press.

I test fit the battery tray assembly on the firewall and and will drill those holes tomorrow.


 
Oct 04, 2023     Battery Tray - (6.3 hours)       Category: Firewall
Researched conduit punches since the 2 1/2" conduit has a hole size of 1.950 which is closer to what I need. Decided to get the hydraulic kit in stock at Harbor Freight since it seemed better than similarly priced conduit punches on Amazon that only had 20 or 30 reviewers. My backup plan is one at twice the price on Amazon. Picked up the hydraulic conduit punch set and tested it on a piece of aluminum. Also tried to get a 3/4" hole saw at Home Depot and ones that small looked terrible so decided to use a step drill instead.

Installed the alternate static port switch in the panel.

Worked on the battery tray and battery hold down bar today. DWG 31A ES PC680 Install Kit. Cut the F-712C battery hold down bar to length and rounded the corners. Drilled out all the lightening holes using two sizes of step drills. Chucked the F-712B spacers in a drill press and used sandpaper on the drill table to clean up the ends and adjust the length to 7/8" + .002 to .003 inches. Marked and drilled all the lightening holes in the battery tray using a #27 pilot (holes not round of course) then a small step drill, then a larger step drill to make the hole 3/4 inches and then the new hydraulic punch to bring the 8 holes to final size. Worked great.


 
Oct 03, 2023     Firewall - (3.8 hours)       Category: Fuselage
Researched hole saws for cabin heat valve hole in 0.020 stainless steel firewall. Decided on a few that I might order and some that might be available at Home Depot. Picked up a 2" hole saw and arbor at Home Depot and tested on a scrap of wood. The hole is over 2" and I would like something smaller. Looked up hole punches and found a 1 1/2 inch conduit punch (1.950" hole) might work.

Measured and marked the firewall for the center of the cabin heat valve location.

Studied DWG 31A ES PC680 Install Kit drawing (Battery holder, starter contactor and main contactor install). Marked up the F-712C battery hold down bar with cut and hole locations. Cut the F-712B spacers to the rough length.


 
Oct 02, 2023     Firewall Penetrations - (4 hours) Category: Fuselage
Called Airline Hydraulics and placed order for SMC components. I ordered soft nylon and polyurethane tubing that SMC says will work with the one touch fittings to see if I like it better than the stiff nylon tubing provided in the Stein kit.

Created a spreadsheet with a list of drawings that are related to the firewall penetrations and mounting of firewall items. Completed review and comparison of documents and made notes so I don't have to figure this out again. Some things show up on multiple documents and there are some differences between revisions that might affect me. Now I have a good understanding of which things I can install now and which things should wait until I have the engine installed and the parts ready for installation. Also I have notes about which drawings and revisions to use for each of the components or systems.
 
Sep 30, 2023     Pitot/Static, Gear Leg Mounts, Firewall Penetrations - (7.3 hours) Category: Fuselage
Successfully completed the last week of this phase with four days of work after our return from visiting my brother in Denver.

Found Airline Hydraulics Corp in Bensalem PA. They have a lot of SMC stock with no minimum order quantities. They also show SMC factory stock and you can order those parts from Airline (with SMC MOQ). Set up an account, added parts to the cart. Some parts were only available from factory stock so I need to call on Monday to see how that affect my shipping cost and delivery date.

Installed the app for the VA-855 borescope I purchased at Oshkosh in 2022 and used it to verify I had opened up the clearance holes in the landing gear mounts. It worked much better than my old scope. Thought about whether or not it is time for the final install of the landing gear mounts and control stick mounts and decided to wait until the fuel lines are done just in case I decide it is helpful to remove the mounts again.

Set up a KiCAD document to create the pitot static schematic. I'm ready to create and add symbols and connections and photos of the actual install after I finalize parts and complete more of the installation.

Started looking at the cabin fuel lines again to try to remember where I was and what is next. Looked at pictures and instructions for TS Flightlines kits and at Van's drawings. Decided the tool I made last summer would allow me to make all the parts. If that doesn't work, I will buy the TS Flightlines kits. I made a flare and a bend using the tool I made to make sure I remembered how to use it and that I didn't need to make additional modifications. Thought about fabricating the parts starting at the valve, then between filter and pump and then pump to firewall bulkhead. Or it might make sense to leave the pump to filter line to the last since it is fairly simple and it is the easiest line to reach for test fits. And I still need to decide if I will make the parts from the valve to the tanks before or after I make the valve to tank tubing.

I need to install the bulkhead fitting soon so I started looking at the Van's drawings to see where the firewall penetrations were located. I looked at OP 21, OP 22, OP 30, OP 32, OP 33, DWG 19 and DWG 36A and compared revisions if I had more than one revision. I need to make a lot of notes and decide which holes I can make now and which ones need to wait until the engine and control installs for verification.
 
Sep 29, 2023     Avionics - (7.9 hours)       Category: Avionics
Found markings on pitot static fittings in Stein kit and looked up specifications. Tried both the SMC KQ2 and MettleAir fittings. Decided I like the SMC best since it seemed to require the less force to use and still seemed to be secure. The release ring on the MettleAir fittings seemed to work better but I had trouble determining if the tube was seated.

Looked at the possible routing path for the static lines and the pitot and AoA lines.

Called Stein and discussion bending tubing, fitting torque and routing options with tech support.

Installed fittings in GSU and G5. Researched and ordered sealant with teflon for the alternate static switch. Tried several options and made up tubing assembly for the pitot line between the GSU and G5 (see picture). The bends in the tubing are left over from when it was packaged in a roll for shipment.

Tried several options and decided to use a SMC cross fitting for the static lines between the GSU, G5 and alternate static switch. Started research on where SMC parts could be purchased and what was in stock.

Tried heating and bending the tubing several different ways and found one that works well. Also researched other SMC tubing that works with the KQ2 one touch fittings and tried to find sources and colors. Need to call the distributor on Monday.

Tried to use the Stein tubing on the showplanes static port that was included in the Stein kit. Also researched the showplanes kit on vansairforce. I plan to stay with the Van's rivet solution unless I find problems later on.


 
Sep 28, 2023     Sent Registration to FAA - (1 hour) Category: Registration
Tried printing clean laser jet copies of forms at FedEx, but they printed with pdf "sign here" in all the signature blocks. Used inkjet forms printed at home. Had document notarized. Mailed forms and check at post office.
 
Sep 27, 2023     Registration - (1.9 hours) Category: Registration
Called FAA Aircraft Registration Branch and, after listening through in queue messages and waiting on hold, talked to a very friendly and helpful person that answered all my questions about the registration documentation. I finished drafting all my documentation, prepared the envelope and put on the files on a USB drive so I can print them tomorrow on a high quality printer.
 
Sep 20, 2023     Avionics and Electrical and Registration - (2 hours) Category: Avionics
Met my work goal for another week. I'll be out of town from tomorrow through 9/26.

Looked at pitot fittings and tubing and researched on the web and VansAirforce. Tried forming the tubing using a heat gun. Started to call Stein since I am using their kit and ended up submitting a question using their contact form.

Noticed the Garmin sensor section on the Stein website and looked up my sensors to confirm I had the post SB sensors. Also researched orifices and added three to my McMaster Carr cart and made research notes.

Worked on aircraft registration documentation and organized and researched a list of questions. Completed web searches. Called Vans and asked about the empty $ field in the bill of sale. Called EAA and left a message. Called FAA too late in the day. Dug through all my parts invoices and made a spreadsheet of all the parts from Van's so I could fill in the $ field in the bill of sale if needed.

Spent over 6.8 hours on my project and counted them towards my weekly goal, but only logged 2 hours on the builders log.
 
Sep 19, 2023     Avionics and Electrical - (3.2 hours) Category: Avionics
Opened engine box to retrieve documentation for FAA registration. Found out both numbers I needed were on the outside of the box. It looks like I got the Avstar fuel injection instead of the AirFlow performance.

I canceled my Solidworks subscription since I am through with mechanical drawings, at least for now. It was very handy for the instrument panel design.

I flipped the instrument panel assembly so it is now right side up and I have access to the locations where I need to install pitot static AOA lines. I opened the parts kit from Stein and was surprised that the tubing and connectors didn't have any markings on them. I expected the parts to indicate compliance to a DOT spec for air brakes like my old safeair1 kit from Avery. I'm going to call Stein tomorrow with a few questions.

Downloaded the new revision AU of the G3X install manual and reviewed all of the changes. I think the only one that affects me is the new capability to calibrate AOA with no flaps and full flaps which is a nice feature. I already have the wiring for a flap position sensor so I don't have to change anything to use the new feature. The manual also included more examples on how to the advanced gauge configuration which should help me when I get to that point.

I spent another 4.7 hours in the garage moving things around so I could open the engine box and be ready to work on the fuselage.
 
Sep 17, 2023     Avionics and Electrical - (3.3 hours)       Category: Avionics
Completed organizing and tying the bundle of wires on the copilot side. Now I have three groups of wires. One going to the engine compartment that are still in several bundles because I don't know how I will route them through the firewall. And two bundles that will go back to the airframe to components and sensors.

Take a look at the before and after pictures below.

Read the Paul Dye kit planes article about using a Piper blade pitot with the Garmin AOA system. I have a Piper blade pitot and made the mounting doubler. I'll have to rework it to use the Garmin Pitot that I purchased. I think I will use the Garmin Pitot, but reserve the right to change my mind if reworking the mount is too painful.

Logged in to Garmin to register my avionics and decided to wait since I don't have a registration number confirmed by the FAA.

Started working on registration documents after reviewing and deciding not to use the online CARES process due to privacy issues with the required Google Authenticator App. Need to call Van's with a question and open my engine box and get the documentation and engine serial number. Need to call the FAA about my N number reservation.


 
Sep 16, 2023     Avionics and Electrical - (6.1 hours) Category: Avionics
Met my goal for the week, but wish I had done better. I decided to allow myself two extra days off this week. We got in bed Wednesday at 2:30AM after a late flight from Hawaii and I decided to allow myself to take Wednesday off to recover. I felt sick on Thursday and took that day off also. I met my goal on Friday and Saturday.

Now that the instrument panel wiring is complete enough to allow testing I am continuing to clean and wrap a few things up.

I cut and applied heat shrink to about six quick connects on the fuse block that were incomplete due to previously running out of heat shrink. I pushed all the quick connects into final position on the fuse blocks, switches and diode-or diode blocks.

I checked and created labels storage for the Mouser order for D-Sub covers. I'll use these when I disassemble everything for installation into the airframe.

Continued to make notes about the assembly, remaining tasks and started new parts order from Aircraft Spruce.

Organized and tied wires going from the pilot side of the bulkhead back to the airframe. I had created rolls of single wires or groups of wires as I had cut and installed wires to each component in the airframe. I unrolled, combined wires, and tied the combined wires back to where the first wires ended. The combined bundle of wires is about 0.56 inches in diameter and should fit through one piece of conduit. The new bundle is ready to be installed in conduit.

I started the same wire organization task on the copilot side of the bulkhead.
 
Sep 15, 2023     Avionics and Electrical - (2.5 hours) Category: Avionics
Completed finding and labeling storage for all the remaining parts in the Aircraft Spruce order.

Reinstalled the bolt between the feed wire and the circuit breaker box using a metal locknut in the Aircraft Spruce order. Worked on notes for the assembly drawing while installing new screws for the fuse block, installing an Adele clamp on the ground wires and calculated screw lengths to use in other locations.
 
Sep 14, 2023     Avionics and Electrical - (0.8 hour) Category: Avionics
Missed my hourly goal the week of 8/20 and 8/27. Used the time to deal with work on the house (roof, solar panel removal), take care of work and preparation for leaving 8/28 for a two week trip to visit my daughter and her family in Hawaii for 2 weeks.

Completed unpacking the Aircraft Spruce parts order, making sure I received everything and storing all the Adele clamps in a plastic storage box with labels.

 
Aug 23, 2023     Avionics and Electrical - (6.3 hours) Category: Avionics
Received reply from Garmin on my issues. Worked some more and resolved all the issues.

Transponder fault - confirmed that it was most likely because I didn't enter the aircraft information yet. I may find a different problem when I do that, but for now it is working as expected.

Unable to select and configure some analog and digital inputs - there was a software bug that messed with some of the GAD 27 inputs so you could see ones you had configured, but not edit them. After I updated software that started working as I expected. The GEA 24 inputs seemed to have a similar problem even after the software update. Garmin explained how it really works so all is okay. There are two GEA 24 configuration tabs, GEA24 inputs and GEA24 discrete (digital) inputs. The GEA24 inputs tab shows all the analog inputs and 7 general purpose inputs. The GEA 24 discrete inputs tab also shows the 7 general purpose inputs. Before they are configured, they show up with a “-“ in the “type” column. You can see, select and configure them from either the inputs tab or the discrete tab. On the inputs tab, you can only configure them to be an analog type input. On the discrete tab, you can only configure them to be active high or active low. Once you configure them on one of the tabs, you can only edit them on the one tab (inputs or discrete). If you edit them and set the input type to “none” again you can select and edit them from either tab.

GAD 29 ARINC 429 not showing up on the main display, but LEDs flashing like the GAD 29 was communicating on the CAN bus and all was well. Garmin suggested sending it in for test/repair. I decided to do a little more testing and found out that if I left the power and CAN bus connector plugged in and disconnected the connector with the ARINC 429 bus signals the GAD 29 module showed up on the main display and had the latest software already installed. So I opened up the ARINC 429 bus signal connector and found I had put one of the pins in the wrong place. Why would that keep the system from working? Maybe because I had connected one ARINC 429 bus pin to a position that was marked as “reserved”. I had just put it in the wrong channel or swapped polarity I bet the GAD 29 would have shown up properly on the main display, but of course the ARINC 429 communications would have failed and I would have looked at the connector and found the problem easily.

Repaired the GAD 29 connector after completing the trouble shooting above. Replaced labels on the first blocks to match the way I had actually wired them. Updated the schematic to match the changes. Cleaned up wiring to the GAD 27 terminal block by reducing the length of some wires and rerouting. Cleaned up some other wire routing problems such as wires to the CO Detector and tied more wire bundles.

Reviewed shopping carts and notes to complete an Aircraft Spruce order.

The instrument panel wiring is basically complete and working although I need to move everything to the fuselage and connect up other components instead of just simulating them one at a time.
 
Aug 20, 2023     Avionics and Electrical - (4.2 hours)       Category: Avionics
Tried a few things to troubleshoot the three issues. Sent an update to Garmin with details of the GNX375 errors which just seem to be configuration issues.

Explored more G3X functionality and tried screenshots, configuration backup, and direct to navigation on the G3X and GNX375.

Replaced more tie wraps with lacing and cleaned up some more. I attached three pictures looking from the bottom up between the instrument panel and the bulkhead.


 
Aug 20, 2023     Avionics and Electrical - (7.2 hours)       Category: Avionics
Met my goal for another week!

Even better, today I finished all the initial testing of the wires to and devices on the instrument panel. I sent an email to Garmin G3Xperts asking for help on three things; GAD27/GEA24 configuration issues, GAD29 not recognized and a transponder fault message.

Updated software on the GNX 375 and installed the database. Updated software on the G5 and on the GDU460. The GDU handles updating all the other G3X system devices.

Continued testing and troubleshooting the issues after I sent the email and thought of more things to try.

Updated the spreadsheet and schematic to show the power to the P Mag circuit breakers coming from the main bus instead of from a fuse.

Updated the wire list spreadsheet with information on all the connections I tested.


 
Aug 18, 2023     Avionics and Electrical - (8.7 hours)       Category: Avionics
Continued testing fuse block, breaker and wire connections. Note: Skipped GTR discrete 1 and 2, pilot and copilot PTT and headset and mic jacks since they were previously tested. Connections tested were:
GAP status.
Seat Heat power for pilot and copilot.
Start active.
Pmag power and enable right and left.
Ignition switched and ground.
Master switch and ground.
Starter ignition switch and ground.
Trim power circuit breaker, GAD 27 pitch and roll trim motor power and trim switches from pilot and copilot. I temporarily connected a trim motor for the test. I thought I would be able to use the G3X "trim" menu in the configuration mode to move the motor, but found out I had to use the pilot/copilot controls. I assume the "trim" menu will work after I complete configuration and connections for the GSA autopilot. I also spliced one of the trim power motor wires that was damaged (probably before I received the wire).
Switch and power to the aft power port.
Strobe, NAV/POS and Taxi right and left switches
Landing light connections including switch to GAD 27, Light power to the GAD 27, and GAD 27 power to the landing light wires.
Flap motor power to the GAD 27, flap switch connections to the GAD 27 and GAD 27 power to the flap motor. I noticed that the GAD 27 applied a 8 to 10 volt signal to the flap motor wires even if the flap power circuit breaker was open if the wires were not connected to a load. I confirmed that a load of a small trim motor would not move unless the flap power circuit breaker was closed.
Fuel pump power and switch.
Pitot heat power and switch.
GNX to ELT RS-232 signal using a scope. Also spent time reviewing and testing other RS-232 signals between the GNX, G5, GDU and GSU. I don't think I was able to confirm all of them.
Alternator Field Breaker.
Alternator current sensor and battery current sensor wires to the GEA by connecting a Hall effect sensor. The power wires to the panel were looped through the Hall effect sensor twice and I could verify operation by turning the G5, GNX and GTR and verify the current changed.

I continued troubleshooting two issues and am ready to send an email to Garmin support.:
GAD 29 CAN bus connectivity: I am unable to see the GAD 29 on the device list on the GDU. There is an "A429" in the list, but the box does not have a green check or a red x and the LRU information is not displayed. The GDU shows 0% network errors. The GAD 29 status led is blinking green which is supposed to indicate "On and communicating using the CAN Bus". I did notice that the green status LED on the GAD 29 starts flashing immediately when power is applied. The green status LED on the GEA, GAD 27 and GSU turn green when power is applied, but don't start flashing until about 20 seconds after power is applied to the GDU 460. I disassembled the J291 connector and verified the pinout was correct for the CAN-H and L signals. I made a temporary J291 connector that only had power. When I connect it to the GAD 29 the status LED illuminates to a solid green and does not start flashing.

When I go to the GDU configuration mode "Engine & Airframe" page I see 4 tabs: GEA 24 inputs, GEA 24 discrete, GAD 27 inputs, and Settings. I have been able to go to the input and discrete tabs and configure and calibration inputs and in many cases see the status of the input so I can test the wiring. Sometimes I see an input that I was previously able to configure and see blue text which means I can select it and change it. Other times I see an input that was I was previously able to configure (I can see the name I assigned) that is displayed in white. When that happens, I am unable to select it by touching it or using the knobs. I saw this when the Garmin LRUs were running the original software (purchased Fall 2022 and all received by Jan 2023). I updated the G3X LRU's with the latest software and now I only see this issue on the "GEA24 Discrete". I've only rebooted a few times so I don't know if the issue with the other tabs is really resolved or not.

I updated software on the G5 and the GNX375 after I updated software on the G3X LRUs.

I am also going to ask Garmin about a "GNX 375 needs service." "Transponder has failed." error message.


 
Aug 17, 2023     Avionics and Electrical - (5.5 hours)       Category: Avionics
Started testing wiring. Started with xxx PWR 2 (IBBS battery backup power). Tested all the grounds individually one at a time. Verified power to the GEA, GNX, GTR, GAD27, GAD29, GSU, GDU, GMC and GMU.

Then started testing power 1 connections by installing fuses in the avionics fuse block one at a time and verifying function of the same list of devices. Then started adding fuses to the main fuse block and checking power and ground to additional devices such as the G5, GSB (USB) charging port, landing light power to the GAD 27, IBBS battery backup and CO detector. Installed temporary "master" switch between main battery and main fuse block since I won't wire in the master contractor until I install the panel in the airframe. Verified proper operation and switching between using main power and backup power.

Verified power connections through Autopilot circuit breaker to GSA pitch and GSA roll. Updated schematic to show circuit breaker names that match the labels on the panel.

Started testing all the connections to the avionics by temporarily connecting sensors (pressure, temperature) or resistors (temperature, position) or frequency generator to airframe wires to simulate connections to final sensors. Tested CHT/EGT, oil temp, oil pressure, fuel pressure, manifold pressure, RPM left and right, fuel flow, fuel level left and right, position of pitch, roll and flaps, Trim power, pilot and copilot trim inputs (up, down, left, right). Also confirmed operation of flap up/down switch, OAT sensor. Did not repeat testing of headset and microphone connections for pilot and copilot.


 
Aug 16, 2023     Avionics and Electrical - (3.2 hours)       Category: Avionics
Finished connecting wires to avionics fuse block. Started connecting wires to the main fuse block.


 
Aug 14, 2023     Avionics and Electrical - (5 hours)       Category: Avionics
Continued wire routing cleanup by changing power and ground wiring to combine wires that were previously in separate bundles. Changed routing of some GAD 27 and power and ground wires. Installed another Adele clamp to support power wires going to the fuse block and grounds. Decided to change positions of some of the fuses on the avionics fuse block due to the length of some of the wires to the fuse block. Completed about 1/2 of the wire connections to the aviation fuse block.


 
Aug 13, 2023     Avionics and Electrical - (3.5 hours) Category: Avionics
Continued work on cleaning up wiring. Updated spreadsheet with connections that were tested. Worked on routing of wires to engine bridge, regulator and fuse and ground blocks. Rerouted wires to GAD 27 TB273. Ready to drill a hole for a new clamp and make all the fuse block connections.
 
Aug 12, 2023     Avionics and Electrical - (3.1 hours) Category: Avionics
Met my weekly hour goal for another week. Attended the Chapter 187 monthly meeting and talked to friends about progress and plans. Didn't get any of my questions answered (meeting time not included in hours today).

Tested more connections and found the way to test the flap up and down inputs. Still not sure how to test the other flap related signals and the A429 and GAD 29 connections. Decided I should wire power to all devices and then upgrade all the Garmin products before spending more time trying to test. Investigated and ordered SanDisk 32GB SDHC and microSDHC cards.

Looked at remaining wires to route and complete and investigated multiple options.
 
Aug 11, 2023     Avionics and Electrical - (5 hours)       Category: Avionics
Updated schematic with DC light wiring changes. Removed GNX PWR 2 connections except for the ones to the Diode-OR circuit.

Completed the IBBS/Backup Battery connector wiring and tested IBBS connections to the G3X.

Completed the connector for the IBBS/Battery current sensor and configured and tested it on the G3X.


 
Aug 10, 2023     Avionics and Electrical - (5.5 hours)       Category: Avionics
Completed panel lighting test, figured out a feature of the GAD 27 lighting controller. Decided to add the output for DC lighting control 2 and 3 and use for the GTR and GMC inputs. Made wiring changes and tested. Made final DC lighting control connections with a service loop for future changes if needed.

Continued to clean up wiring.


 
Aug 09, 2023     Avionics and Electrical - (6.3 hours)       Category: Avionics
Updated spreadsheet with connections that were tested on 8/8. Finished cutting remaining wires to switches and circuit breakers to final length and terminating them. Cleaned up routing and spliced all the panel grounds together. Cleaned up routing and spliced all the power 2 leads together (backup power bus). Temporarily connected battery power to fuse panel and circuit breakers. Temporarily connected battery to ground block forest of tabs. Temporarily connected battery to IBBS (backup battery) connector.

Powered up most of the Garmin devices and started testing the DC lighting bus. GTR, GSB, GNX, GDU and the GAD 27 control are working great. The GMC control works differently and needs more testing.


 
Aug 08, 2023     Avionics and Electrical - (5.8 hours)       Category: Avionics
Completed enough connections to the instrument panel to start power on testing. Verified separate power 1, power 2 and ground connections to the GMC, GDU, GSU, GEA, GAD 27, GAD 29, GNX, and GTR before powering up combinations of those components. Also checked power 1 and ground connections to the G5, CO detector and GSA 28 roll and pitch servos.

I needed to test power 2 connections separately before connecting all the power 2 connections together into one backup power bus. I needed to test all the ground connections separately because each device can also connect each other device to ground through the shield and chassis grounds. I wanted to verify I hadn't missed any individual connections.

Then I started powering up combinations of instruments and configured and verified the following connections using clip leads and switches or knobs:
GAD 27 discrete inputs.
GAD 27 dimmer inputs and outputs.
GEA discrete inputs.
GTR discrete inputs.
I started checking GEA general purpose inputs and configurations.

I learned a lot about G3X setup and configuration. It makes a lot of sense to me although I am still not able to find where to set and test the flap control inputs and outputs.

I found Revision AT of the G3X installation manual had been released. I downloaded and reviewed changes. Most were related to the new GHA 15 Height Advisor which I do not need.


 
Aug 07, 2023     Avionics and Electrical - (4.5 hours)       Category: Avionics
Started using lacing tape to tie small bundles of instrument panel wires together. Decided this would be easier and cleaner than trying to group, maintain and then tie large bundles.


 
Aug 06, 2023     Avionics and Electrical - (1.7 hours)       Category: Avionics
Started work on wiring cleanup and completion on items on the instrument panel. I'm working from left to right. Secured a few wire bundles using silicone fusion tape and tie wraps to attach bundles to click bond mounting points. Used silicone fusion tape where bundles might rub.


 
Aug 05, 2023     Avionics and Electrical - (8.3 hours)       Category: Avionics
Met my weekly goal for another week even though I had quite a bit of TK work to do.

Verified the new field voltage test jack worked with the plugs and fabricated a test plug and the cable for the test jack.

Completed the dimmer light cable by using two splices to convert a single ground and power connection to three grounds and power connections and installing three connectors.

Completed assembly of the engine bridge connector.

Installed more pins in the IBBS battery backup cable.

Started review of cable routing and moved some wires around to improve appearance and reduce the size of the wire bundle underneath the bulkhead and from the left side of the bulkhead to the back of the airplane.

Looked at GNX manual and calculations show I can't use the current location of the transponder antenna. Did some quick searches and realize I need to move the antenna to a location near the rudder pedals or just in front of the spar. I might be able to install the COM antenna near where the transponder had been located. The doubler I installed there isn't really big enough for the COM antenna footprint, but I could replace the doubler or let the COM antenna extend past it.


 
Aug 04, 2023     Avionics and Electrical - (3.1 hours)       Category: Avionics
Completed temporary connectors for GMU and both GSA autopilot servos. Started working through spreadsheet to cut wires needed for wiring in the instrument panel area and for bench testing.


 
Aug 03, 2023     Avionics and Electrical - (2 hours) Category: Avionics
Reviewed and placed Mouser order for terminals and a d-sub connector cover. Measured remaining Giga-flight CAN bus cable and estimated the remaining amount needed. I may have to order more. Started terminating wires for the GSA pitch and roll servo and the GMU..
 
Aug 02, 2023     Avionics and Electrical - (2 hours) Category: Avionics
Worked on IBBS connector and wires.
 
Aug 01, 2023     Avionics and Electrical - (9 hours) Category: Avionics
Continued cutting, routing, labeling and terminating wires to switches and other parts on the instrument panel and bulkheads. Made progress and ran into some problems such as not having the right d-sub connector for the engine bridge PMAG monitor and the field voltage test point jack and receptacle don't work together; the plug isn't long enough. Found a new connector to order. Searched for a new plug and jack combination.
 
Jul 31, 2023     Avionics and Electrical - (4.5 hours)       Category: Avionics
Continuing to cut wires, terminate them when practical and labeling wires for switches and circuit breakers from left to right on the panel. Removed brass bus strip from both circuit breaker sets and trimmed ends. Added #10 hole for power wire to the main circuit breaker bus.


 
Jul 30, 2023     Avionics and Electrical - (3 hours)       Category: Avionics
Cut, terminated and labeled wires for the master and ignition switches. Removed installation brackets from Click Bond tie wrap pads.


 
Jul 29, 2023     Avionics and Electrical - (6.3 hours)       Category: Avionics
Just met my weekly goal for the short week. We were visiting parents in San Antonio for three days.

Cut and routed wires for grounds on switches installed on the panel. Soldered wires to the timer, log event and toga switches. Soldered wires to the other side of each switch. Crimped quick connect terminals on the flap and back up enable switches.

Created a new panel ground symbol and updated 6 switches to use the panel ground instead of the avionics ground. Decided I needed to install Click Bond tie wrap pads before starting more wiring on the panel. Read up on click bond installation instructions, cleaned, scuffed and cleaned the panel locations. Mixed up CB200 adhesive and installed 8 CB9302V3 Click Bond pads. The before and after pictures below show the click bond pads with the installation fixtures still in place.


 
Jul 25, 2023     Avionics and Electrical - (6 hours)       Category: Avionics
Cut CAN bus cable to length for GEA. Terminated it and the CAN bus cable going to the Roll Servo which is the next CAN bus device in the chain. Finished assembly and organizing wires for the GEA J241, J243 and J244 connectors.


 
Jul 24, 2023     Avionics and Electrical - (3.8 hours)       Category: Avionics
Completed the CAN bus wire splice for the GAD 27. Assembled the J271 connector. Created markups to use when assembling the GEA connectors.

Decided to clean up the cable bundles more and separated and grouped the yellow DC lighting bus, Red Power 2 wires, Red Power 1 wires, and the black avionics ground wires. Started cleaning up routing for loose wires on the GAD J271 connector and for some of the wires coming from the back of the instrument panel.


 
Jul 23, 2023     Avionics and Electricalcs - (1.9 hours) Category: Avionics
Received heat shrink tubing for printer and printed remaining labels on list. Printed a few additional labels. Added labels to any GEA 24 wires that were missing them. Cut additional lengths of black heat shrink tubing so they are ready when I terminate shielded wires.

Looked at list of additional parts I need and reviewed carts at Aircraft Spruce, Sten Air, Mouser, Digikey and McMaster Carr. Added more parts to the list. Decided I can continue making progress with what I have and wait to order them.

 
Jul 22, 2023     Avionics and Electrical - (4.5 hours)       Category: Avionics
Missed my weekly goal and sent my daughter $50. I missed a few days and planned to make them up, but unexpected work came up Friday and Saturday and I ran out of heat shrink labels.

Installed shield terminations and crimped pins on all wires for the GEA engine monitor J241, J243 and J244 connectors except for the CAN bus connection and the GEA to GDU cable. Waiting on heat shrink tubing labels to arrive before installing pins in the connector body.


 
Jul 22, 2023     Avionics and Electrical - (4.7 hours)       Category: Avionics
Completed assembly of the GDU cable with the shorter CAN bus. Printed labels for more wires and ordered more heat shrink tubing for the printer. Measured and cut all the wires for three of the connectors on the GEA 24 engine monitor. The remaining connector only has wires for the EGT and CHT sensors and will be easy to complete later.


 
Jul 20, 2023     Avionics and Electrical - (4.5 hours)       Category: Avionics
Continued work on rerouting wires. Completed almost all the cleanup of existing wires. Decided on length of CAN bus cable to GDU and cut the cable and terminated the shorter cable.


 
Jul 19, 2023     Avionics and Electrical - (2.1 hours)       Category: Avionics
Drilled holes and temporarily installed adele clamps. Masked avionics areas with towels and tape to keep chips out and vacuumed work area after drilling. Continued working on wire routing.


 
Jul 17, 2023     Avionics and Electrical - (4 hours)       Category: Avionics
Cut and terminated the final wires for GAD J271 and installed the pins in the connector body except for the CAN bus.

Reviewed wire connections for each of the GEA 24 connections to help plan wire routing.

Removed CAN bus pins from GDU connector to allow rerouting the cable and reducing the length so it fits in the bundle better. Explored several options for bundling existing wires and decided where to install the next adele clamps.


 
Jul 16, 2023     Avionics and Electrical - (5 hours)       Category: Avionics
Worked on the dimmer harness today. Tried to use the 2x2 pin molex Micro-Fit 3.0 connectors that I had modified and realized while they barely fit through the instrument panel hole in one direction they didn't work so well in the other direction and wouldn't fit through the washer and nut. Decided to use the 3 pin one row connector and only install the connector housing after the dimmer potentiometer is installed in the panel.

Added connector connection and part number detail to the schematic now that I decided what parts to use. Cut wires for the pigtails on the potentiometers.

Struggled with crimping the pins and sockets and inserting pins and sockets into the housings. Finally figured it out after using some practice parts.

Soldered wires on the three potentiometers and crimped pins on the wires. Installed the three potentiometers in the panel and inserted pins into the housings.


 
Jul 15, 2023     Avionics and Electrical - (8 hours)       Category: Avionics
Met my hourly goal for the week and made some good progress today.

Started work on GAD 27 connectors. Completed cutting wires, making terminations and assembling connectors J272 and TB273. Completed all labels, wire cuts and terminations on J271 except CAN bus and Dimmer inputs. Renamed some wire names for the LED light and updated the schematic and spreadsheet.


 
Jul 14, 2023     Avionics and Electrical - (6.7 hours)       Category: Avionics
Started cutting wires and temporarily placed labels for the GAD 27 connections and some instrument panel switches and circuit breakers. Printed additional labels as needed. Many of these connections end with long wires that will go to components far away from the instrument panel. Terminated some of the wires such as the one to the fuel pump switch and added the current limiting resistor used to sense fuel pump active.

Updated schematic and spreadsheet to change the text from "FUEL P ON" to "FUEL P ACTIVE" to be consistent with starter active text.


 
Jul 13, 2023     Avionics and Electrical - (3.4 hours)       Category: Avionics
Started looking routing of existing wires. Pulled all power, ground and lighting bus wires loose from the shielded cables to clean up routing. Added an Adele Clamp at one end of the bundle. Decided to finish cutting wires to the GAD 27, GEA 24 and the rest of the airframe before finalizing wire bundle routing and clamp positions.


 
Jul 12, 2023     Avionics and Electrical - (1.3 hours)       Category: Avionics
Completed assembly of the GMC 507 connector and tested cable fit for GMC installed and GMC pulled out far enough to disconnect it.


 
Jul 11, 2023     Avionics and Electrical - (2 hours)       Category: Avionics
Disconnected the battery and antenna cables. Turned the panel and bulkhead assembly 180 degrees so I would have good access to the bulkhead panel.

Completed termination of CAN bus. Drilled 1" hole for GMC cable in bulkhead using step drill. To get the connector to fit through the hole the grommet and shell of the connector must be removed. Now I understand why they offer a tray for the GMC 507 and wish I had opted for that solution.


 
Jul 10, 2023     Avionics and Electrical - (6.2 hours)       Category: Avionics
Applied power to all the components and started configuration setup and checking connections and operations.

The GTR COM radio receives and transmits using either pilot or copilot headset. Right and left audio is correct. PTTs and discrete input 1 and 2 both work. The connections are all made to the GTR. I used test leads to connect the headsets, PTTs and discrete inputs. The audio connection to the GDU is working.

The GNX acquired enough satellites to determine position. Set up serial ports and ARINC ports and tried to test. Haven't finished testing.

GDU is still working. Continued setup for new components added. The GAD 29 doesn't seem to be recognized by the GDU even though the status LED on the GAD 29 indicates the CAN bus is connected with no errors. Maybe the GAD 29 connections are okay, but the GNX is not trying to connect over ARINC due to incomplete setup. The CAN bus between the GDU and GTR is working and I can see GTR frequency settings and transmit status on the GDU. I'm still trying to figure out how to use the configuration pages for all the Garmin components.

Printed labels and cut remaining wires for GMC 507. Terminated all wires except for the CAN bus.


 
Jul 09, 2023     Avionics and Electrical - (4.5 hours)       Category: Avionics
Completed terminating the CAN bus for the the GTR. Assembled GTR connector and backplane.

Made temporary ground planes for the COM, GPS and Transponder antenna. Applied power to the GTR and GNX and both powered up okay.


 
Jul 08, 2023     Avionics and Electrical - (3.7 hours)       Category: Avionics
Met weekly goal for hours on the project again. Back on track! Cut remaining wires for the GTR connector and terminated them all except for the CAN bus cable. Determined route and length of CAN bus cable between GTR and GMC and GMC and GAD 27 and cut two pieces.

Not included in the hours, but I also attended the EAA chapter meeting this morning and asked questions about the starter solenoid and showed pictures of progress on the panel to a few people.


 
Jul 07, 2023     Avionics and Electrical - (2 hours)       Category: Avionics
Double checked that there were pins in all the expected connector holes for the GNX. The pins looked good, but I discovered I had installed one connector upside down and corrected the problem. Decided not to power up the GNX without antennas before confirming nothing would be damaged by doing that. Ordered some low cost cables from Amazon to use for testing if needed.

Reviewed all the connections to the GTR200 and GMC507 and decided how to route the cables. Estimated GTR wire lengths again now that I know more about wire routing.


 
Jul 06, 2023     Avionics and Electrical - (6 hours)       Category: Avionics
Inserted terminated wires into the connector body for the GNX connector J3751. Inserted two of the pins in the wrong hole and had to extract and move them. Had a lot of problem with the extraction tool on this Positronics connector even though the extractor tool worked great on the other connector made by TE. Looked up tools and connector specs to verify I was using the correct tool. Finally I was able to extract and move the pins.

Completed power splice and some additional wires for J3752. Completed connector assembly and built and installed the backplane. [had to correct orientation of one of the connectors the next day - did you notice the problem from the picture 2532?]


 
Jul 05, 2023     Avionics and Electrical - (8.2 hours)       Category: Avionics
Terminated all wires for GNX connector J3751 after cutting a few missing wires to length. Made power and ground splices for J3751. Need to pin J3751 and then cut power and ground wires for J3752 and terminate them and pin J3752.

Updated the schematic and wire list to simplify wiring of these two connectors.


 
Jul 04, 2023     avionics and Electrical - (2.1 hours) Category: Avionics
Connected power to 5 components (G5, GDU, GSU, CO Detector and GAD 29) one at a time and then all together. Temporarily connected the OAT sensor to the GSU 25. The short CAN Bus is working even though one end is not terminated. Looked at diagnostics and configuration screens on the GDU and G5. Configured the serial ports. Tested the CO Detector to GDU serial connection and confirmed an error is displayed when the CO Detector is in test mode. Changed baro setting on GDU and confirmed the setting was updated automatically on the G5. Saw the OAT matched room temperature and was displayed on GDU and G5.
 
Jul 03, 2023     Avionics and Electrical - (5.1 hours)       Category: Avionics
Completed connections for CO detector including switch and LED.

Worked on wire routing for the GNX and GTR. Taped Diode-Or components in place. Covered unused pins.

Printed wire labels for GNX and GTR. Cut and terminated wires for GNX and GTR for power to the Diode-Or.

Looked up assembly instructions for GNX high density connectors with separate shield blocks. Labeled storage bin for high density pins.


 
Jul 02, 2023     Avionics and Electrical - (4.8 hours)       Category: Avionics
Finished up GAD 29 connector. Terminated shield wires and attached to shells. Worked on CO detector connections.


 
Jul 01, 2023     Avionics and Electrical - (2 hours) Category: Avionics
Missed my goal for the week and sent my daughter $50. I was planning on taking two or three days off due to oral surgery on Monday morning, but didn't get back to work until Saturday.

Completed terminating the GAD 29 wires, but didn't assemble the connectors.

Spent a few hours on Tuesday and Wednesday putting recent Aircraft Spruce and McMaster Carr parts in organizers and labeling them. Also drove out to the hangar to pick up some clamps and organizers.
 
Jun 25, 2023     Avionics and Electrical - (5.5 hours)       Category: Avionics
Realized I needed a better way to begin securing the harness during the assembly process. Cut short lengths of paint stir sticks, drilled holes for tie wraps, and clamped the pieces to the bulkhead.

Completed connections and connector assembly for GSU except for shield terminations to shell. Started working on GAD 29 connections and completed all except CAN related ones.


 
Jun 24, 2023     Avionics and Electrical - (4.5 hours)       Category: Avionics
Met my hourly goal for another week. I'm making progress although it seems slow to me. I need to step up the number of hours a week above my goal.

Still have a box full of Garmin install kits (connector bodies, housings, pins).

Completed the connector for the G5 J51. Started working on connectors for the GSU and finished one except for ground shields and the second one except for the CAN bus splice. I like the way the cables will route to the G5 and GSU although I did leave one CAN bus cable between the GDU and G5 a bit on the long side.


 
Jun 23, 2023     Avionics and Electrical and Engine - (6.6 hours)       Category: Avionics
Received the engine. The box seemed to be in great shape. I'll wait a while to open it...

Cut additional wires to length. Focusing on the G5, CO detector, GSU and GAD 29. Started terminating the connector for J51. It has the lightning protection module (LPM) and also has the CAN bus splice so it is different than all the others. Researched and also completed several practice splices. I'll verify I completed all the crimps tomorrow morning and then start heat shrinking splices and shield terminations and then assemble the connector.


 
Jun 22, 2023     Avionics and Electrical - (5.1 hours)       Category: Avionics
Assembled and completed connectors GDU P4601 and P4602 except for connecting the ground shields to the connector shell. Documented the CAN bus termination splice on the schematic and in the wire list. Connected Power 1 and then Power 2 to a battery to see the GDU 460 power up for the very first time and verify both power connections.

Explored and decided on an option for the cable service loop for the GDU. Decided on a similar loop that is ~19 inches long for the G5 and will wire it next.

Printed all the heat shrink tubing labels for the G5, GSU, GAD 29 and the CO detector.

I didn't log the hours, but spent another 3 hours in the garage organizing things so I can get rid of some file cabinets and have room for an engine crate.


 
Jun 21, 2023     Avionics and Electrical - (6.3 hours)       Category: Avionics
Ordered pitot/static/AOA parts from Stein Air. Ordered mechanical and electrical hardware from McMaster and Aircraft Spruce.

Worked on GDU connections. Prepared and terminated wires and shields so they are ready for connector assembly. Prepared CAN bus with a splice for CAN termination in the GDU connector. Prepared PDF1 ID jumper.

Received call from FedEx Freight and scheduled Lycoming engine delivery for Friday, 6/23/2023.


 
Jun 20, 2023     Avionics and Electrical - (5.2 hours)       Category: Avionics
Decided to place the backup power splices below the GAD 27 near the DC Lighting splices.

Figured out an approach to print and manage heat shrink labels and printed labels for the GDU connectors and for the labels on the other end of each of the GDU wires.

Finished cutting the remaining wires for the GDU connectors and started terminating them. Will shrink the labels when I assemble the connectors and figure out the best location for them. Read through the termination and connector housing assembly instructions again and found more parts I needed to order. I added the parts to my McMaster Carr and Aircraft Spruce shopping carts. I also added more ring terminals to my Mouser cart.

Continued looking at parts and options for completing the Pitot/Static/AOA plumbing and decided to use a kit from Stein Air.


 
Jun 18, 2023     Avionics and Electrical - (4.2 hours)       Category: Avionics
Completed all of the new "labels" column on the spreadsheet by changing GNX and GNX DOR information information. Made a few more GNX related schematic changes. Decided not to change fuse naming on the schematic and wire list. Decided on fuse positions and created labels for the fuse blocks using more pilot friendly names. Added the naming and position information to the schematic.


 
Jun 17, 2023     Avionics and Electrical - (6.2 hours) Category: Avionics
Met my hourly goal for another week. Went through the wiring spreadsheet and finished almost all of the new "labels" column by using the wire name column and adding wire color and pin number information. Modified some wire names and added lines for additional labels when needed. Modified schematic when needed. Added notes to the schematic. Decided on different wire splicing for GNX and completed changes on the schematic. Need to finish GNX changes on the spreadsheet.
 
Jun 16, 2023     Avionics and Electrical - (8 hours)       Category: Avionics
Finalized mounting location of Diode-Or blocks for the GNX, GTR and ELT. Decided on general location for the backup power splices. Updated schematic symbol to show connections to "AC" in and "+" terminals.

Updated schematic and wire list to show CAN bus order and changed CAN bus terminations. Assigned wire colors to all connections that used shielded cable. Added a column for wire labels and started entering data that includes pin numbers and, on shielded cable, wire colors.


 
Jun 15, 2023     Avionics and Electrical - (2.5 hours)       Category: Avionics
Decided on the location for the Diode-Or packages. Decided on a general location for the splice for the backup power connections between the TCW IBBS and Garmin Power 2 inputs. See picture.

Updated schematic and wire list spreadsheet with CAN Bus device order wire names for all the CAN Bus cables. Added the CAN Bus terminator for the GMU 11 and added a connection to the GDU for CAN bus termination.


 
Jun 14, 2023     Avionics and Electrical - (6.9 hours)       Category: Avionics
Printed and cut out paper labels to use for initial wiring while waiting for new heat shrink print cartridges. Grouped wire supply by size and labeled each group. Confirmed colors of wires in shielded cables.

Started cutting shielded wires for some of the cables going between two components installed in the panel. Then started working through questions that came up during connections to the GDU 460. Decided to run a single ground to the GDU. Decided on the order of components on the CAN bus.

Decided on device order for CAN bus routing. Starting from the end behind the instrument panel to the end in the fuselage:
GDU 470 (CAN termination), G5, GSU 25, GAD 29, GTR 200, GNX 375, GMC 507, GAD 27, GEA 24, GSA 28 Roll, GSA 28 Pitch, GMU 11 (CAN termination)

Started working on where to install the backup power bus and whether to use a terminal block or a yellow AMP PIDG butt splice. Decided to use a splice after testing how it worked to place thirteen 20 AWG wires in a single splice (7 on one side and 6 on the other). See picture with the protective plastic cut away for better visibility. I got this idea from an Aeroelectric example. Also worked on a mounting location for the Diode-Or packages and added a screw for mounting them to the McMaster Car order.

The plan is to route all the wires to the GDU and terminate the GDU connector. Then test to have enough service loop to allow the GDU to be unscrewed and disconnected without the service loop being too long and interfering with other components behind the panel. Then I will repeat this process on the G5.

Checked on engine status. It should ship any day now.

Sent email to Superior Components (Instrument panel company) asking about their new thin EL panel.


 
Jun 13, 2023     Avionics and Electrical - (5.5 hours) Category: Avionics
Determined I needed to use Click Bond parts to secure wiring to the instrument panel. Found my parts and determined I already had what I needed. Found a good source (The Flight Shop) for adhesive and cleaner and placed an order.

Modified Molex minifit 3 four pin connector by sanding enough of the housing off so it will fit through the dimmer switch holes in the panel. It is now a three pin connector which is all I needed.

Reviewed wire name list and prepared a file to use in printing the labels for the wires. Figured out how to print again using the label editor software and excel and started printing. Ran out of heat shrink tubing quickly. Estimated the amount of heat shrink I would need and placed an order. Also researched and placed an order for label tape with high adhesion and for vinyl self lamination overwrap labels for cables with BNC connectors already installed. Determined I need to update the wire name list to add pin numbers for the individual wires.
 
Jun 13, 2023     Avionics and Electrical - (2.6 hours)       Category: Avionics
Mocked up different examples of wire routing and discussed ideas with Ellicia. Thought through the process and decided I need to route most of the wires before terminating any and leave enough extra at each end of the wire so I can change routing before terminating wires if needed. Decided I need to label every non-shielded wire with the wire name and the pin number. Decided I need to label every shielded cable at each end (but not the individual wires in the shielded cable) with the wire name. I'll use printed heat shrink for labels and temporarily secure them with blue tape. I'll heat shrink the labels as I trim and terminate the wires. I may add pin number labels to all the individual wires in a shielded cable as I am terminating them.

Reviewed wiring section 11 of AC43.13-1B which covers wire routing, labels, bend radius, supports, service loops and other good information to help me use best practices.


 
Jun 10, 2023     Avionics and Electrical - (5.6 hours)       Category: Avionics
Met my hourly goal for another week.

Continued adding nut plates or drilling final mounting holes for the CO Detector and ELT Alert that use #4 mounting screws. Reassembled bulkhead and ribs to instrument panel so it is ready for wiring. Considered different options for wire routing.

Reviewed and added parts to McMaster and Aircraft Spruce shopping carts. Ordered replacement hose for pneumatic tools from Cleaveland.

Started looking at pitot/static/AOA plumbing options again. Looked more closely at my choice for a starter contactor and wiring after learning more about contactors at the chapter meeting.


 
Jun 09, 2023     Avionics and Electrical - (10 hours) Category: Avionics
Started marking, drilling #6 holes, drilling nutplate mounting holes and countersinking them, drilling initial hole to final size, deburring, priming and installing nut plates for the avionics. Almost done and will post pictures with the update tomorrow.
 
Jun 08, 2023     Avionics and Electrical       Category: Avionics
Verified previous McMaster and Aircraft Spruce shipments matched order. Started marking details of where avionics will be located and taking pictures. Considered trade-offs of moving some of the components. Created a mockup of two different center stack radio braces. Removed the bulkheads and ribs from the panel so I can start drilling holes and installing nut plates for avionics.

Scaled a document from enginebridge.com to make a template.

Added an extra jack to the Mouser list. Will use this as storage for the plug needed for the Alternator Field voltage test point.


 
Jun 07, 2023     Avionics and Electrical - (3.4 hours) Category: Avionics
Worked on list of parts to order next. Researched material that should be used for foam to cushion the fuel lines, selected polyethylene based on FAA lists of material for use in aircraft cabins and chemical compatibility with fuel. Worked through the list of screws needed for avionics that I previously missed. Decided to delay order for McMaster Carr and Aircraft Spruce until I make more progress and figure out other things I have missed.
 
Jun 06, 2023     Avionics and Electrical - (.5 hour) Category: Avionics
Researched shield terminations for floating shields in Garmin documentation. Increased insurance limit to cover the new engine that should ship in the next week.
 
Jun 05, 2023     Avionics and Electrical - (5.9 hours)       Category: Avionics
Determined mounting location for other avionics that will be located in the structure between the instrument panel and the firewall. Decided to install the IBBS battery backup on the rudder bar center support instead of the bulkhead. Decided to use nut plates for mounting installation and selected parts and placed orders for nut plates and other hardware. Forgot to order all the mounting screws.


 
Jun 04, 2023     Avionics and Electrical - (4.2 hours)       Category: Avionics
Continued installing the rest of the components in the instrument panel. Fabricated two bus bars for the circuit breakers using a fence on my drill press. The "completed" panel looks really good. Now all I have to do is figure out where to put the rest of the parts behind the panel and complete all the electrical wiring and pitot/static/AOA plumbing.


 
Jun 03, 2023     Avionics and Electrical - (8.8 hours) Category: Avionics
Met my goal for time spent on the project for another week.

Test fit panel with racks into RV. Increased the width of the cut out in the center bulkhead by 0.3" with a nibbler and hand shears and confirmed fit. Removed instrument panel, structure behind it and the top skin. Cleaned up the center opening in the bulkhead.

Assembled the instrument panel, bulkhead and ribs on my workbench. Made and installed wooden spacers between the instrument panel and bulkhead. Started installing components on the instrument panel to help identify best places for components on the bulkhead. Fabricated a nut plate for the ELT remote control and spacer washers for the BNC connectors.
 
Jun 02, 2023     Avionics and Electrical - (8.8 hours)       Category: Avionics
Continued the process of fitting the installation racks and replacing the nuts with nut plates. Added an 0.032 spacer between one of the angle brackets and the rack to center the rack better (compensates for uneven placement of the aluminum angle on the panel. All done except for replacing the 8 screws with new ones that are the right length and haven't been partially damaged by many installs and removals.

Filed on edges of instrument panel and screw holes to improve the fit and allow all the screws to be installed.

Test fit instrument panel with rack installed and then did a rough trim on the bulkhead center hole for clearance for the instrument rack on the left side (approximately 0.3").

Sat in the airplane with the instrument panel installed and thought about the assembly order. I want to leave the top skin off as long as possible, but it gets harder to install the longer I wait.


 
Jun 01, 2023     Avionics and Electrical - (4.2 hours)       Category: Avionics
Worked on fit and installation of the rack. Enlarged holes in angle aluminum on panel to allow the rack to be located properly. After holes were enlarged used nuts and a washer to install and check fit of the rack and the components in the racks. Started the process of replacing the nuts with nut plates one at a time. Test fit a lot of times.


 
May 30, 2023     Avionics and Electrical - (3 hours)       Category: Avionics
Studied the fit of GNX375 and GTR200B installation racks and marked and drilled holes. Test fit parts and started work to improve the position.

Received notice from Van's that my engine would ship in 7 to 10 days so I started the process to make the final payment.


 
May 29, 2023     Avionics and Electrical - (7.2 hours)       Category: Avionics
Completed install of top fuselage skin and test fit panel again. Checked for alignment and size of cutout in bulkhead and think I need to enlarge it.

Filed on instrument panel to correct fit problems previously found including:
Corners and one side of each rectangular switch hole.
Keyway and inside of ignition switch hole.
All sides of the dimmer potentiometer holes.
Access panel to get it to fit better.
All sides of the power port hole.
Bottom outside edges of panel to lower the panel and provide more clearance to the side rails and top of panel to fuselage skin.


 
May 27, 2023     Avionics and Electrical - (8 hours)       Category: Avionics
Met my weekly goal for a 6 day week.

Continued test fitting of components on new panel.

Things that fit: BNC bulkhead connectors, grommet for BNC cable, TOGA switch, Alternate Static Port switch, Circuit Breakers, GSB15, CO detector button and LED, ELT control panel, MyGoFlight mount, GMC507, install racks for GNX375 and GTR200.

Things that didn't fit: Power Port (too small), Access Panel (too tight even after removal of portion of panel affected by overdriving a rivet. Also noticed all the access panel screws had been longer and cut to rough length), Ignition Switch (too small), 10K Vishay potentiometer (dimmer controls - too small), Otto K1 switches (height and width okay, but corner radius not small enough). Noticed that round holes for circuit breakers and ignition switches didn't seem to be cut cleanly with a small bump where the cut might have started and ended.

Reviewed documentation and figured out how to install the racks for the GNX375 and GTR200 to the front panel and roughly marked hole location.

Started McMaster Cart for screws needed for: ELT control panel, MyGoFlight mount, install racks, access panel, ground bus, and instrument panel mounting screws.

Cut out center stack clearance hole in center bulkhead and added the 7 degree bend. Reinstalled the bulkheads and structure behind the panel to verify the new 7 degree bends didn't cause any fit problems and that the bulkhead surface was now flat. The clearance hole in the bulkhead may need to be enlarged on one side. Installed the top skin and test fit the panel again. It fits although it is tight against the top skin. Need to remove some tape, cleco more of the top skin and decide if I need to reduce the outside dimensions of the panel. I test fit the GMC507, G5, and GDU460 avionics in the panel.


 
May 26, 2023     Avionics and Electrical - (5.1 hours)       Category: Avionics
Picked up finished panel. Inspected and test fit panel. I didn't try the fuselage skin and the mounting holes to the skin, but so far it fits and overall it looks good. I'm finding some problems.

I fixed loose PEM nuts around the access panel using an arbor press. The access panel door has an interference fit and needs work. Some rivets attaching the backing plate for the access panel were over driven and distorted the backing plate.

Aluminum angle parts for radio trays were installed on wrong sides and do not align vertically with cut out in panel. The gap between the angles and the sides of the cut out are not equal. The parts were not deburred before they were riveted.

The line graphics on the copilot side had some breaks. The line width of the source material was the same on the pilot and copilot side and the pilot side printed okay.

The 90 degree bend at the bottom of the panel wasn't 90 degrees all the way across the panel.

Removed panel and bulkhead structure from the fuselage. Marked and bent the 7 degree angle in the two side bulkhead panels. Measured actual location of radios in finished panel and used SolidWorks to determine the cut out in the center bulkhead panel. Center bulkhead is marked and ready for cutting.


 
May 25, 2023     Avionics and Electrical - (3.7 hours) Category: Avionics
Found out panel was ready for pick up. Paid for panel and arranged to pick it up on Friday morning.

Received Mouser parts and compared switches with switches from Stein and decided to use Mouser parts. Tried new connectors on Amploc sensors and decided to use the original connectors on the 100A sensors and the new connectors on the 25A sensor. Stored parts.

Used solidworks to created images showing cut out for center stack radio. Marked rough cut out on panel and tried to decide on where to install avionics and run wiring.
 
May 24, 2023     Avionics and Electrical - (4.7 hours) Category: Avionics
Printed a full scale instrument panel at Fedex for final review. Completed background, sizing and export to PNG of the graphics for the switches on the stick grip. Completed instrument panel markups with powder coat colors, graphics for the switches on the stick grip and some questions. Completed one more round of minor changes and then approved the final version.

Researched type of fittings to use for pitot/static/AOA lines.
 
May 23, 2023     Avionics and Electrical - (.5 hour) Category: Avionics
Received powder coat samples for instrument panel and made a decision to use "Viking Grey". Opened, inspected and put away splices received from Powell.

Checked for latest prices on solder sleeves and placed an order with online components.
 
May 22, 2023     Avionics and Electrical - (4.8 hours) Category: Avionics
Compared APEM and Stein TOGA switches and decided to use the Garmin recommended Apem. Tried the Stein PTT switch and decided to order some C&K switches that might work better. Tried the S03-03 solder sleeves and decided to order a pack of 100 that will be more than enough to finish the wiring. Tried the connector that Amploc recommends and don't like it for the 25 Amp sensor. Searched, found and ordered two other types from Mouser. Ordered some additional Otto gaskets now that the instrument panel thickness is finalized.

Decided not to run a long cable for a music jack to allow it to be installed near the headset jacks. Will use a 24 inch cable and hide the jack behind the instrument panel for future use if needed.

Updated the schematic by removing the CAN auxiliary connector, updating the bus current table and updating the reference designators. "Released" the revision 5 document and started a revision 6 where I will document as built changes such as wire color and CAN device order.

Archived a revision 5 wiring spreadsheet that matches the revision 5 schematic and started a revision 6 spreadsheet.
 
May 21, 2023     Avionics and Electrical - (1.1 hours) Category: Avionics
Was out of town almost all day. Opened and inventoried shipments from Digikey and Stein.
 
May 19, 2023     Avionics and Electrical - (2.8 hours) Category: Avionics
Met my goal for another week. Will be out of town Saturday so it was only a 6 day week.

Worked on new graphic for stick grip switches. Used two layers so I can change the background color easily.
 
May 18, 2023     Avionics and Electrical - (3.3 hours) Category: Avionics
Completed CAD work on ignition switch angles. Completed markup of panel and sent email to panel supplier.

Reviewed panel supplier responses. Considered options and ordered powder coat samples.
 
May 17, 2023     Avionics and Electrical - (6 hours) Category: Avionics
Resized second draft of panel and printed full scale drawing at FedEx Kinkos. Completed careful review of panel design and decided on changes and addition of two switches. Started work on sketches showing ignition switch graphics to allow good comparison between two options provided by designer and the metal plate provided by ACS. Found discrepancies.

Organized parts to be ready for wiring the panel assembly.
 
May 16, 2023     Avionics and Electrical - (6.5 hours) Category: Avionics
Continued work finding best source for parts.

Explored options for solder sleeves instead of the Garmin suggested sleeve with braid.

Researched and selected crimp on ferrules for use with connections to the P-mags and CO detector.

Ordered all the wire I calculated I will need so I won't need to order any more. Until I run out of something... Ordered from Stein Air, Aircraft Spruce and Wiremasters.

I had been planning on installing one or two defog/avionics bay exhaust fans. After talking to Van's support I decided I can do without a fan and add it later if needed.

Ordered more splices and a few of the Garmin recommended solder sleeves and some other random parts I'd been saving to combine into one order. Once I try the Garmin recommended solder sleeves I will make a final decision on what to buy and place one more order.
 
May 15, 2023     Avionics and Electrical - (7.8 hours) Category: Avionics
Created a pivot table on the spreadsheet and merged my wire inventory data with the wire needed. Noticed where some of the pivot table data didn't make sense so went through several iterations of corrections. Noticed I hadn't been consistent with wire color for power and switched power. Made final decisions on wire colors and updated the spreadsheet. Noticed and corrected some wire name inconsistencies. Decided on three sources for wire depending on availability and price. Started reviewing the existing cart for Stein Air and Aircraft Spruce and deleted or saved items not needed and added lines for all the wire.

Reviewed wire order list a final time and made decisions of how much extra to buy of each wire type.

Looked at splice and solder sleeve counts on the spreadsheet and determined I need to buy at least 30 blue splices and 6 sleeves for shield cable with 1 conductor, 33 sleeves for 2 conductor and 33 sleeves for 3 conductor. Started looking for sources.
 
May 14, 2023     Avionics and Electrical. - (4.5 hours) Category: Avionics
Added two new switches and wires to the spreadsheet and schematic. Reviewed spreadsheet and made final decisions on some wire sizes and updated the spreadsheet as needed. Made other corrections to the schematic. The spreadsheet is ready to use for purchasing wire.
 
May 13, 2023     Avionics and Electrical. - (6.4 hours) Category: Avionics
Met my time goal for the first week of this phase.

Completed review of changes in the G3X install manual revision AS. Discussed some of the changes with Brian at the EAA monthly meeting. Discussed how to route wiring and Pitot and AOA tubes from the panel area to aft of the main wing spar.

Continued work on spreadsheet by creating a pivot table to find the number and types of wires routed through the spar and other bottlenecks and by creating a pivot table to identify the total length of wire needed for each color and type of wire. Reviewed and cleaned up data as needed when the pivot tables didn't make sense.

Entered information from previous wire inventory in spreadsheet so I don't order wire I already have.
 
May 12, 2023     Avionics and Electrical - (3.9 hours) Category: Avionics
Continued adding wire length and path information to the spreadsheet and checking wire sizes. Finally completed full pass through spreadsheet. Completed checking spreadsheet to verify I didn't miss any entries. Saved a version of the spreadsheet. Then removed old tables and started updating some of the tables to show the new wire length, size and path information.

Started reviewing the G3X install manual revision AS changes to see if there were any impacts to my design. There are several new configuration options for discrete inputs that I may use or add such as "user timer start stop" and "log event marker".
 
May 11, 2023     Avionics and Electrical - (3.4 hours) Category: Avionics
Printed a larger version of the Superior ignition mounting hole and label and measured angles. Drafted a new version of the ignition mounting hole and sent to Superior.

Continued work adding wire lengths to the spreadsheet and checking wire sizes.
 
May 10, 2023     Avionics and Electrical - (3.3 hours) Category: Avionics
Completed review of panel and notes and markups. Sent notes and markups to Superior.

Continued work adding wire lengths to the spreadsheet and checking wire sizes. Decided to change the GMC 507 power wiring to get power 1 and power 2 from sources like the other avionics instead of from the same breaker as the autopilot servos. This allowed reduced wire size and length for the GMC 507. Updated spreadsheet and schematic.
 
May 09, 2023     Avionics and Electrical - (6.5 hours) Category: Avionics
Reviewed and, if needed, researched each item on draft panel layout from Superior and provided mounting hole details and hole dimensions. Marked up changes to add or modify text. Marked up changes to move some items. Drafted an email with additional questions and notes.
 
May 08, 2023     Avionics and Electrical - (6.1 hours)       Category: Avionics
Completed order of CAN bus cable. Continued work on spreadsheet by adding more wire lengths and routing and changing some wire sizes after seeing total lengths.

Discussed some panel questions with Superior ATX. Researched COM antenna questions. Reviewed first draft of panel layout. I like it better than the starting draft I submitted to them. Printed a full scale version and compared it to my full scale version using a "light table", AKA window, to verify the first draft component location doesn't interfere with structure behind the panel. Studied the first draft to decide what changes I want.


 
May 07, 2023     Avionics and Electrical - (2.4 hours) Category: Avionics
Starting phase 4. Continuing with the goal of 4.5 hours per day average when at home without guests from out of town.

Continued adding lengths and paths to spreadsheet.
 
May 06, 2023     Avionics and Electrical - (1.7 hours) Category: Avionics
Continued work on spreadsheet adding lengths and path information. Decided to order 65 feet of CAN bus cable and route it from the tail to the wing and then to the panel instead of having the panel in the middle.
 
May 05, 2023     Avionics and Electrical - (1.2 hours)       Category: Avionics
Completed update of panel notes and sent to Superior ATX along with pictures of the latest mockup. Also asked about project start date and found they didn't have a record of receiving my prepayment so paid with a credit card.

Filled out the two forms Van's Aircraft requires for generating a Bill of Sale and submitted them to Van's. I need to Bill of Sale to submit documents for registering my RV.


 
May 04, 2023     Avionics and Electrical - (1 hour) Category: Avionics
Sat in fuselage and tested the reach of the MyGoFlight iPad mount to see if the mounting position I picked would work for me and Ellicia.

Printed panel layout notes and compared against the panel mockup to verify I hadn't missed anything on the panel or the list. Made notes about missing parts and changes of names.
 
May 03, 2023     Avionics and Electrical - (1 hour)       Category: Avionics
Completed cut out and placement of labels on panel mockup. Sat in fuselage and tested the new locations.


 
May 02, 2023     Avionics and Electrical - (4.5 hours) Category: Avionics
Worked on panel changes. Made new labels and modified existing labels to show "final" design. Started cutting out labels and test fitting on the panel mockup.

Also cleaned up and organized the garage the last few days.
 
Apr 30, 2023     Avionics and Electrical - (2.4 hours) Category: Avionics
Starting phase 4. Need to decide on commitment.

Continued work on spreadsheet updates and wire length estimates. Made some schematic updates. Ordered a bus bar that I might use to connect the TCW battery backup to the "Power 2" connections of the avionics.
 
Apr 29, 2023     Avionics and Electrical - (6.7 hours) Category: Avionics
Met my goal for another week. I was out of town 3 days.

Continued work on spreadsheet by starting to add wire length estimates a finishing wire grouping.

Worked on updated panel layout by making new labels with labels on top of switches, new sizes for grommet feedthrough and grouping switches.
 
Apr 28, 2023     Avionics and Electrical - (1 hour) Category: Avionics
Added column to spreadsheet to help organize wiring to make counting numbers of shielded cables in a bundle easier and help calculate length of wire to order.
 
Apr 24, 2023     Avionics and Electrical - (3.8 hours) Category: Avionics
Reviewed the solder sleeve data sheets and measurements for different shielded cables and CAN bus. Determined I need to use S03-02-R-9035 for single conductor shielded cable. Determined I need to use S03-03-R-9035 for 2, 3 and 4 conductor shielded cable and Gigaflight CAN bus cable.

Searched for good sources of solder sleeves and splices.

Started updating spreadsheet with splice count and solder sleeve count. Also updated spreadsheet to be able to see the different sizes of solder sleeves. Made other minor updates to spreadsheet when I noticed missing or inconsistent data.

Searched Garmin documentation and videos and confirmed I should use blue wires for the CAN-L signal per the G5 install manual and one of the Garmin Aviation videos. Of course it doesn't matter as long and the wiring is consistent, but I wanted to match Garmin Documentation if possible.
 
Apr 23, 2023     Avionics and Electrical - (6.8 hours) Category: Avionics
Spent more time practicing using splices and solder sleeves and trying several configurations. Decided to use the blue splices on CAN bus with three 24AWG wires on the bus side and one 20AWG wire on the connector side. This should work great except for the GMC 507 high density connector where I will have to use a 22AWG wire which is too small for the blue splice. So I will add an additional small wire on the connector side of the GMC 507 splice. I wanted to use the red splices with two 24AWG CAN bus wires on one side and a single 22AWG wire on the other, but it was difficult and unreliable to get two 24AWG CAN bus cable wires into the red splice. I've also tried using the blue splices with two 24AWG wires on the bus side and one 22AWG wire on the connector side and it seems to work, but doesn't meet the blue splice specification for wire size.

Worked on the CAN bus wire label and decided to use 16pt Arial and text of " CAN " on the 1/4" HS. When shrunk, this label is just over the 0.75" length specified in the Garmin manual to cover the end of the shield.

Determined I was missing 4 connectors on the GEA 24 install kit. Inventoried the remaining install kits and sent and email to Aircraft Spruce to see if they will send the missing parts or if I have to order them. I wish I had inventoried the kits last fall.
 
Apr 22, 2023     Avionics and Electrical - (9.4 hours)       Category: Avionics
Met my goal for another week. Was out of town for three days.

I cleaned up my work bench and moved the light/magnifer to a better location before starting work today.

I actually made physical progress on wiring today. Completed a total of 8 crimps for the two configuration modules. The wires are tiny 28 AWG. I read up on what to use to strip the wires and almost bought a new strip tool. I ended up using the 26 AWG slot on my Ideal stripping tool that has the sharp edge blades for non tefzel insulation. Worked great. Luckily the Garmin documentation provided settings for the DMC crimper for this unusual wire size.

I practiced using the extraction tools on test crimps that I had inserted into D-Sub housings yesterday. I made some more CAN bus practice terminations and this time used a splice instead of crimping both wires into one D-Sub pin.

I tried using lacing cord for the first time and it seems easy. I'm glad I was planning on using lacing cord.

I made up sample labels for 22, 20, 18 and 14 gauge unshielded wires and for 1 conductor, 2 conductor, 3 conductor and 6 conductor shielded wire and RG-400 Coax and GigaFlight CAN bus cable.


 
Apr 21, 2023     Avionics and Electrical - (5.5 hours) Category: Avionics
Ordered mygoflight iPad mount so I can figure out the best place to mount it.

Opened and inspected the remaining parts from B&C.

Weighed wire we measured earlier this week. I will use this information to understand the weight penalty for using shielded cables instead of individual wires.

Looked up specs for temperature and heat gun nozzles to use on solder sleeves. Looked up specs on standard density d-sub contacts. Looked up specs to decide which wire stripper to use. Tested use of solder sleeves on both gigaflight CAN bus cable and twisted shielded pairs. Terminated 20, 22, and a pair of 24 AWG wires into M39029/63-368 and M39029/63-369 standard density contacts.

Installed test contacts into male and female D-Sub connectors.
 
Apr 20, 2023     Avionics and Electrical - (1.9 hours) Category: Avionics
Looked at wiring documentation and organized questions for meeting with John.

Reviewed panel and discussed wire routing with John. Discussed alternatives, maintenance and failure modes.

Tried different panel layouts and researched options for wiring changes. Mocked up a iPad to show how it fit into a panel.
 
Apr 19, 2023     Avionics and Electrical - (1.6 hours) Category: Avionics
Unpacked and inventoried parts received from B&C, Mouser, McMaster Carr and AMPLoc. Called B&C to report a shortage. Boxed and shipped some parts on a previous order to B&C.
Cut grommets from McMaster to see which size would work for a panel feedthrough for an antenna cable with BNC connector.
Measured wire lengths so I will know if I need to order additional wire.
 
Apr 15, 2023     Avionics and Electrical - (.6 hour) Category: Avionics
Looked and schematic, panel layout, feedback from John and Z13 schematic and decided to keep a single TCW IBBS and the current backup power plan.
 
Apr 13, 2023     Avionics and Electrical - (.2 hour) Category: Avionics
Read more feedback from John and responded.
 
Apr 11, 2023     Avionics and Electrical - (.4 hour)       Category: Avionics
Sent notes and final data package to Superior Aircraft Components for the panel design.


 
Apr 10, 2023     Avionics and Electrical - (.2 hour) Category: Avionics
Set up bill pay and scheduled payment for deposit for panel design and fabrication.
 
Apr 09, 2023     Avionics and Electrical - (3.3 hours) Category: Avionics
Created new labels for COM and NAV and GTR200 antenna and tried several different changes to the panel layout.

Reviewed parts in cart, added parts to press in pem studs and stand-offs and placed McMaster Carr order.

Placed order for additional hall effect sensor for backup battery current.

Reviewed parts in cart, added more and placed B&C specialty order.

Reviewed parts in cart and placed Mouser order.

Reviewed parts in Aircraft Spruce and Stein cart and decided to delay orders.
 
Apr 08, 2023     Avionics and Electrical - (3 hours) Category: Avionics
Met my goal of hours for the week in spite of finding out about and watching live streaming of four games our grandson's baseball tournament on Friday and Saturday.

Reviewed feedback from John on my panel and electrical design. Decided on several changes and explained some previous changes I had made. Drafted emergency procedures for alternator out situation.
 
Apr 07, 2023     Avionics and Electrical - (4.5 hours) Category: Avionics
Updated list of parts on the panel for the panel designer with all the changes made since February. Added links to details and sketches for the ignition switch and 12VDC power port.

Discussed returning parts no longer needed to B&C and filled out RMA form.
 
Apr 06, 2023     Avionics and Electrical - (4.5 hours)       Category: Avionics
Researched PEM standoffs for fuse block and avionics mounting. Reminded Superior Aircraft Components I was needing a quote.

Continued work on placing Avionics on the bulkhead between the instrument panel and firewall. Used solidworks and manual positioning of a few components. Found that my paper mockup had several issues and moved swapped a few parts to correct. Found that a missing 7 degree bend on the bulkhead causes the bulkhead to curve so the avionics aren't flat against the bulkhead surface. Progress, and a few more things to do. See pictures for the latest placement.


 
Apr 05, 2023     Avionics and Electrical - (7.5 hours)       Category: Avionics
Completed review and changes on schematic and spreadsheet. The only remaining updates are CAN bus device order and estimating wire lengths.

Picked rough locations for the Garmin items located behind the panel. I want to use SolidWorks to help me pick final locations.

Updated panel layout with the latest switches and circuit breakers.


 
Apr 04, 2023     Avionics and Electrical - (5.1 hours) Category: Avionics
Removed the second backup battery and associated connections. Moved the remaining battery backup connections to "Volts 2" since I only have two power busses. Researched and then added a 60A hall effect current sensor for the backup battery power. Updated the schematic and spreadsheet to show the 10 position avionics fuse block and the 16 position main fuse block and moved all the connections to the appropriate block. Added an avionics master switch. Still need to make all the connections to the fuse blocks and avionics master switch.
 
Apr 03, 2023     Avionics and Electrical - (3.2 hours) Category: Avionics
Discussed operation of the TCW backup battery with TCW. Confirmed that the "normal" operation will run the main battery down to ~11V which might be 10 or 20% capacity remaining and then switch to the TCW backup. Also the main battery will try to charge the backup battery until the main battery reaches ~ 11V.

If I want to run lights, fuel pump, flaps, etc on the main battery and run the avionics on the backup battery as soon as the alternator fails, then I will need to have an "avionics" master to disconnect avionics from the main bus and to remove power from the TCW sense/charge line. This allows me to decide when I will use each power source and whether the avionics will run from the main or backup battery.

I updated the wiring spreadsheet with several different options and decided I wanted to leave the trim and autopilot power connected to the main bus and the remaining avionics connected to the TCW backup battery. A single Otto K1 switch will work as the avionics master. I also confirmed a single TCW backup battery would be enough for my needs.

I created more panel switch labels. I created a 1:1 scale footprint for the ground tabs and TCW battery backup. Tried a few different switch layouts on the panel and started looking at where to mount all the avionics boxes.
 
Apr 02, 2023     Avionics and Electrical - (4.2 hours) Category: Avionics
Today is our wedding anniversary. 35 years!

Continued analysis of power distribution and loads and battery capacity. I have a list of questions to ask TCW tomorrow. I'm considering adding a "Avionics Master" switch and changing the TCW IBBS 1 charge/sense line from a fuse to a pull-able breaker. I think I need to be able to power the avionics from only the main bus OR only the TCW IBBS backup battery. The design currently powers the avionics from the main bus with the TCW as backup. I think the current design will deplete much of the main battery before the TCW backup starts powering the avionics. I could switch off the main bus, but don't want to do that because I need lighting and possibly pitot heat and other things. If I leave on the main bus on and powering avionics until it is time to land there might not be enough power left to run the boost pump and landing lights.
 
Apr 01, 2023     Avionics and Electrical - (6.4 hours) Category: Avionics
Met goal for another week. Was not able to spend any extra time.

Continued comparison and updates to schematic and wire list. Finished up all connections except CAN and details on power distribution. Reviewed counts of fuses, grounds, switches and other panel items to confirm I am not missing anything on the panel design. Archived copy of the schematic and wire list.

Started detailed work on power distribution and loads and capacity in case of alternator failure in hopes of being able to eliminate the second TCW IBBS backup battery.
 
Mar 31, 2023     Avionics and Electrical - (1 hour) Category: Avionics
Returned from trip to San Antonio. Continued work on spreadsheet and schematic. Checked and updated GAD27, GAD29 and Tosten CS-6 and CS-8 connections as needed.
 
Mar 29, 2023     Avionics and Electrical - (9.6 hours) Category: Avionics
Continued work comparing schematic and spreadsheet and making updates to delete some parts, fix discrepancies, improve wire names and add missing information such as wire routing and colors.
 
Mar 28, 2023     Avionics and Electrical - (3.2 hours) Category: Avionics
Continued work comparing schematic and spreadsheet and making updates to delete some parts, fix discrepancies, improve wire names and add missing information such as wire routing and colors.
 
Mar 26, 2023     Avionics and Electrical - (2.3 hours) Category: Avionics
Printed latest schematics at FedEx. Started comparing spreadsheet and schematic and making updates to both as needed. Added baggage USB switch to panel layout and sent final layout to Superior ATX for a quote.
 
Mar 25, 2023     Avionics and Electrical - (3.5 hours) Category: Avionics
Met goal for another week. Logged 35.3 hours which exceeds the 31.5 hour goal.

Continued work on spreadsheet and schematic cleanup. Reviewed and removed some duplicate columns. Made final decisions on antenna jacks and made graphics for panel layout. Inspected new 12VDC power port and made panel graphic for it. Tested the power port with the USB charger.
 
Mar 24, 2023     Avionics and Electrical - (3 hours) Category: Avionics
(Not counted in the hours today: watched several EAA videos about registering an amateur build airplane, process for getting an airworthiness certificate and wiring. One wiring video said not to crimp more than one wire in a terminal.)

Researched question about terminating more than one wire in a terminal and found a document created by Bob at AeroElectric Connection showing an example of multiple wires in a ring terminal and a splice. Found a Garmin G3X wiring video that showed using three wires in a splice connector.

Made a table of AWG wire sizes and copper cross sectional area to help me understand what combinations of wire I can crimp in different terminals and pins.

Continued considering options for putting a bulkhead BNC connector on the panel from the COM antenna. This would allow connecting either the GTR200 COM radio or a handheld if I needed to connect it to the external antenna in an emergency. Found BNC bulkhead fittings to use for the COM and NAV antennas. Made inkscape labels for the panel mockup and tried a few locations.

Looked up temperatures to use for installing heat shrink tubing.
 
Mar 23, 2023     Avionics and Electrical - (5.6 hours) Category: Avionics
Continued work on panel layout. Created new images for circuit breakers with space for a bus bar. Created images for fuse blocks of various sizes. Created images for headset jacks and LEMO connector. Created new, smaller, horizontal label for stick grip switches. Talked to Tosten about laser marking and found it wouldn't work on the grips I purchased. Traded emails with ACS products about the size of their ignition switch.

Explored locations for headset jacks and decided to leave them off the panel and put them on the armrest behind where your elbow will rest.

Researched options for mounting fuse blocks and didn't find a good one. Looked at standoffs and studs and click bond options.

Researched other options for USB power and ordered a MyGoFlight Dual digital USB charger and a power port for it to see if they will fit.

Ordered the ACS ignition switch since I'm not getting good information from ACS Products.

Looked at video for Anti Splat easy exit bar and held the one I borrowed from a friend in place in my RV. It does't seem like it will work well so I don't plan to install it.

Tried running the fan on the battery and I am happy with the airflow and noise. I don't like the Stein grill so plan to order a wire one from Mouser to replace it.

Continued cleanup of spreadsheet and schematic.
 
Mar 22, 2023     Avionics and Electrical - (5.4 hours)       Category: Avionics
Created images with labels for new circuit breakers and groupings of switches. Created images for the new ignition switch and throttle/mixture bracket. Created new label for the stick switches. Placed new images on the panel to create a new layout. Sent pictures and notes about the changes to see if I get more feedback.

Sent request for updated quote to the panel designer and fabricator.

Started looking at electrical loads to see if I want keep 1 or 2 of the TCW 6AH battery backups.


 
Mar 21, 2023     Avionics and Electrical - (6.7 hours) Category: Avionics
Started making wire list and schematic changes per discussions over the last few days. Removed start enable and starter button on the stick. Changed stick button to GTR200B Disc 2 which will be defined as Com Monitor. Removed wingtip COM antenna. Added powered LEMO connectors. Changed Trim Power, Flaps power, Autopilot Power, P-mag power left and right from fuse and switch to pull-able breaker. Changed from discrete switches for starter, emag enable and emag enable to a standard ACS ignition switch.
 
Mar 20, 2023     Avionics and Electrical - (7 hours) Category: Avionics
Prepared questions and panel layout parts for meeting with John H and Luis. Reviewed E-Mag test instructions to decide on E-Mag switch organization.

Met with John and discussed options for simplifying the layout and electrical design and removing components. Discussed wire routing.

Met with Luis and sat in his RV to look at panel visibility under the glare shield, stick and knee clearance under a standard height panel, and locations for headset jacks.

Archived the revision 4 schematic and wire list to capture the current state before I remove parts. Started revision 5 documents to be ready for changes. Reviewed meeting notes and started researching changes.
 
Mar 19, 2023     Avionics and Electrical - (4 hours) Category: Avionics
Unpacked the new Epson LW-PX700 heat shrink sleeve printer. Installed and learned how to use the software. Printed sample sleeves and tested different text sizes on 22AWG wire.

Unpacked TCW IBBS system and charger and connected cables to charge the IBBS. Unpacked the PC680 battery and Optimate charger and connected the charger to charge the battery. I'll use the IBBS and PC680 charger when I start the avionics wiring and testing.

Continued work on wiring spreadsheet.

Arranged to meet with a friend to discuss his panel feedback. Traded texts with another friend about panel feedback and arranged to see his RV on Monday.
 
Mar 18, 2023     Avionics and Electrical - (8 hours)       Category: Avionics
Took latest panel layout to the Saturday AM EAA chapter meeting and discussed the layout with Deene. Considered his feedback and moved existing labels around. Decided on new images and groupings of switches and labels and created in inkscape. Taped new images on panel layout and sent to two friends for review/feedback. The attached images are the latest version.

Created draft email with starting requirements for panel design/fabrication.

Continued work on spreadsheet. Renamed a lot of the wires for consistency and better grouping. Continuing to add wires and routing notes. Looked up connector types for GPS, Transponder and COM radios. Looked up TNC and BNC connectors and assembly instructions to verify I had the correct crimp tool.


 
Mar 17, 2023     Avionics and Electrical - (7.8 hours) Category: Avionics
Created a new panel layout with the G5 to the left of the G3X display. Added the fuse/access panel on the right. Moved the center stack radios up and changed the order with the GMC507 Autopilot is at the top. Printed 3 copies of the layout. Printed and placed existing switch grouping and label designs until I had one that seemed reasonable.

Continued work on wiring spreadsheet.
 
Mar 16, 2023     Avionics and Electrical - (3.9 hours) Category: Avionics
Continued work on wiring spreadsheet. Adding wire type and color. Adding path and count data. Updating wire names as needed to group wires differently and have names make more sense.
 
Mar 15, 2023     Engine Category: Engine
Received email from Lycoming saying they would delay my engine build until mid to late April so I will get an AirFlow Performance fuel injection system per my request.
 
Mar 14, 2023     Avionics and Electrical - (2.1 hours) Category: Avionics
Reviewed Aircraft Spruce quote, researched the optimate battery charger they quoted and ordered the PC680 battery, a TCW battery backup and charger and a stainless steel heat box. Ordered the optimate battery charger from Amazon.

Received an update saying my Lycoming engine build would start soon. I replied back asking if I would get AFP or Avstar fuel injection.

Printed three full size copies of the latest panel layout which has the G5 on the left and the center stack 0.5" to the right of center. Placed paper samples of switches, labels and other components on one print out.
 
Mar 13, 2023     Avionics and Electrical - (5.3 hours) Category: Avionics
Completed final research on heat shrink printers and placed an order.

Continued work on spreadsheet to add power and ground connections and wire names. Tried several different methods of looking at the data with pivot tables. Think I have what I need. One pivot table will show types of wire and total lengths. The other pivot table will show the number of different connections between key LRUs and the LRUs that connect to them. This might help me decide where to place the different Garmin LRUs.

Discussed mounting location with Deene and reviewed the instructions he told me to look at in the G3X installation manual.
 
Mar 12, 2023     Avionics and Electrical - (4.6 hours)       Category: Avionics
Tried up update a Solidworks panel assembly and ran across technical difficulties. Created a new assembly consisting of the panel structure, G5, GDU460, GMC507, GNX375, GTR200B and fuse panel and prepared a document for printing and test fitting.


 
Mar 11, 2023     Avionics and Electrical - (1.4 hours)       Category: Avionics
Met my goal for another week. Worked 31.8 hours which is just a bit more than the required 31.5 hours. Missed one day of working on it which is the only day I have missed since January 8 except for the week in California.

Created one new panel layout with G5 to the left of the GDU. Discussed panel layouts with Deene after the EAA Chapter 187 meeting. He recommended using my latest layout and had comments and suggestions about some of the switches.


 
Mar 10, 2023     Avionics and Electrical - (9.4 hours) Category: Avionics
Continued working on new columns on spreadsheet. Found and cleaned up problems and missing information in schematic and spreadsheet. Completed first pass except for power and ground connections.

Sent request for quote and for servo installation questions to Aircraft Spruce.

Looked up metal bus bar material at K&S and McMaster Carr.
 
Mar 09, 2023     Avionics and Electrical - (5.1 hours) Category: Avionics
Continued work on wire list spreadsheet. Gave up on current scheme to use pivot tables on existing rows to estimate wire to buy. It was too complicated and confusing. There were a lot of duplicates such as ones for multi-conductor cables and for entries from "A" to "B" and "B" to "A"

Added three columns (Wire type, length and path) and sorted spreadsheet by wire name. With all the wires grouped by name, I started filling in wire type and path (to/from info). With wire names grouped I was able to see multiple entries for each wire name and add wire type and path for each single conductor wire and for each bundle of wires (multi-conductor cable such as shielded twisted pair). All the duplicate entries got marked as "Copy" so they can be filtered out.

I realized I need to wait to estimate length and start wiring anything to the engine until I hang the engine and can determine best wire routing. I'm going to continue working on wiring between Avionics boxes and the rest of the airframe.
 
Mar 08, 2023     Avionics and Electrical - (7.3 hours) Category: Avionics
Spent some time looking at alternate panel layouts. Reviewed feedback from friend and printed two more copies of the panel so I can cut one up and move avionics around. Looked for smaller switches.

Found and studied information on firewall insulation and feedthroughs on VAF forums.

Sent firewall penetration types, location and grouping questions to another friend and studied drawings again after getting a reply. Also reviewed additional drawings for wiring routing information and for control cables.

Shopped for battery chargers for the PC680 main battery and the TCW backup batteries. I plan to order the main battery and a single backup battery and their chargers to use during testing of avionics wiring.

Started working with wire spreadsheet to figure out how to use pivot tables to provide wire counts and lengths. Considering manual entry by wire number.
 
Mar 07, 2023     Avionics and Electrical - (4.7 hours) Category: Avionics
Called Van's Builder support with questions. Emailed the Van's kit group to get a packing list for a firewall forward kit so I can get some of the components on order.

Updated the wire list and schematic to change from EI commander to Engine Bridge for E-Mag control and monitoring.

Printed two sets of instrument panels and labels and worked on new layouts.
 
Mar 06, 2023     Avionics and Electrical - (3.9 hours) Category: Avionics
Worked on panel layout. Made some changes to some of the labels so I could arrange them differently.

Worked on schematic and wire list changes. Changed from a Guardian CO detector to a Flight Data Systems GD 40. Ordered the GD 40.
 
Mar 04, 2023     Avionics and Electrical - (5.6 hours)       Category: Avionics
Met the weekly goal with a total of 32.1 hours.

Made a few final changes to the panel layout draft and sent a picture to a friend asking for review.

Finished paper templates for other components that need to be installed near the panel and started looking for places for them.

Started updating the schematic and wire list with the changes I made during panel layout.


 
Mar 03, 2023     Avionics and Electrical - (4.3 hours) Category: Avionics
Reviewed Garmin email about second GEA 24 limitations. Reviewed CO Detector and Engine Bridge documentation. Made final decision on CO detector (Flight Data Systems GD 40) based on lifetime, G3X serial connectivity and remote mount allowing easy future change without impacting panel design if needed.
Made final decision on E-Mag monitor and decided to use Engine Bridge with Wi-Fi instead of analog signals.

Continued work on locations for Avionics on the bulkheads behind the panel. Created a few more solid models and imported solid models into Solidworks assembly to get an idea of component fit.
 
Mar 02, 2023     Avionics and Electrical - (5.4 hours) Category: Avionics
Continued work on labels. Made new labels for missing or changed items. I think my work is ready for review and feedback.

Started working on position for other components. Created SolidWorks models for TCW IBBS, ACK E-04 alarm module. Imported starter relay model.

Traded emails with Garmin and Aithre about using dual GEA 24s and options for Aithre integration.
 
Mar 01, 2023     Avionics and Electrical - (2 hours) Category: Avionics
Started work on where to place the remaining Garmin Avionics. Need to consider space and access. Printed full size templates of the GAD 27, GAD 29 and GDU 460. Probably need to continue with printing templates for other components. I'm creating the templates by doing a screen capture of the G3X Install manual and then scaling to actual size using Inkscape.

Also after looking at the RV in the garage I decided I really need to use the Solidworks models for some of this.

I included a portion of the time I spent looking at different heat shrink tubing marking solutions for wire. I'm leaning towards Epson, but Demo Rhino 4200 or Brady M210 look like they would also work.
 
Feb 28, 2023     Avionics and Electrical - (5.7 hours)       Category: Avionics
Continued work on panel layout. Researched control cable options and called McFarlane with questions.


 
Feb 27, 2023     Avionics and Electrical - (3.6 hours)       Category: Avionics
Unpacked and inspected Catto Prop. Looks great.

Continued work on panel layout by printing and placing components/labels. Created additional missing labels and modified and reprinted as needed.


 
Feb 26, 2023     Avionics and Electrical - (5.5 hours) Category: Avionics
Created or updated inkscape labels for ELT, Master Switch, Circuit breaker, TOGA switch, Dimmers, group of ignition switches and K2 switch. Created groups of power and lighting switches with labels.
 
Feb 25, 2023     Avionics and Electrical - (6.9 hours)       Category: Avionics
Met weekly goal by working a total of 13.8 hours instead of the minimum of 13.5 hours.

Updated sample labels to use round corners. Found out the file formats I used for the panel layouts and labels wouldn't print. Converted files and figured out scaling. Printed layouts with G5 to the left and to the right of the centerline. Also printed labels. Cut up prints and sat in airplane to try various configurations. I decided I like the G5 on the left of centerline and continued to place switches in various locations. I included a picture of the one I liked.

Updated Solidworks G5, center stack and GDU locations to match the desired location.

Unpacked and inspected electrical parts order from B&C.

Downloaded and opened the solid model for the Clippard alternate static port.


 
Feb 24, 2023     Avionics and Electrical - (5.5 hours)       Category: Avionics
Discussed EX 3.0 CO detector with Aithre.

Modeled fuse blocks in Solidworks and created a Fuse Panel Assembly.

Worked on High Level Panel layouts and created a file to print a full size version for testing. One has the G5 left of the center support and the left edge of the center stack radios aligned with the left edge of the G5. The other has the G5 to the right of the center support and the right edge of the center stack radios aligned with the right edge of the G5. Both include the GDU 460.

Worked on several examples of switch layout and text using inkscape. Created several options to print for testing.


 
Feb 23, 2023     Avionics and Electrical - (.2 hour) Category: Avionics
Sent question about using multiple GEA 24s to gain an additional 7 analog input ports.
 
Feb 22, 2023     Avionics and Electrical - (1.2 hours) Category: Avionics
Back from a great trip visiting the grandkids...

Reviewed B&C catalog and shopping cart I had built. Added and deleted parts and placed the order.

Started research on the Aithre product line and CO Detector after reading about them in Aviation Consumer. May switch to their CO Detector to save panel space, allow G3X logging of data, use of their IOS app and potential for expansion to their oxygen system.
 
Feb 13, 2023     Avionics and Electrical - (5.2 hours) Category: Avionics
Met my goal for another week since I will be out of town for the rest of the week. I hope to get some work done during the week, but the goal of the trip is to spend time with kids and grandkids!

Continued work on spreadsheet to clean up connections and figure out best locations for devices based on number of connections between devices.

Talked to panel shop about the questions I had on stiffness of the overall panel and the fuse panel mounting.

Created solidworks drawings showing keep out areas on the panel and potential locations for the G5 and other radio stack items.

Talked to B&C about deleting the alternator field switch and confirmed it was reasonable since I have a pull-able breaker to use to disable the alternator for testing or emergencies.
 
Feb 12, 2023     Avionics and Electrical - (4.7 hours) Category: Avionics
Matched up fuse count of the schematic and spreadsheet. Decided on type and sizes of fuse and updated cart for the next B&C Specialty order.

Archived revision 2 of the schematic and corresponding spreadsheet and started revision 3.

Completed several more potential layouts of the G5 and center stack and printed views with key dimensions to share with the panel shop.

Not included in the time: Printed revision 2 of the schematic and a copy of all the sketches for the panel shop.
 
Feb 11, 2023     Avionics and Electrical - (5.6 hours) Category: Avionics
Exceeded time goal for another week. 32.7 hours instead of just 31.5.

Continued work on making some final decisions that affect the panel design and organizing material to had off to the designer.

Inspected parts from Digikey.
 
Feb 10, 2023     Avionics and Electricalcs - (3 hours) Category: Avionics
Continued work on spreadsheet and schematic. Mostly worked on adding power connections and information. Starting creating dataset to hand off panel design and fabrication.

Not included in time: Visited Superior
 
Feb 08, 2023     Avionics and Electrical - (4.6 hours) Category: Avionics
Continued work on spreadsheet and schematic. Corrected a problem with the ground and switch symbols on the schematic so the BOM now has an accurate summary count of switches and grounds.
 
Feb 07, 2023     Avionics and Electrical - (4.9 hours)       Category: Avionics
Continued work on the spreadsheet and schematic. Cleaning up labels and adding wire gauge information. Cleaning up the devices listed in the spreadsheet by adding missing ones and deleting some I am no longer using.

Not included in time: Discussed panel design and options with John H. Received FedEx delivery of Catto Prop. Didn't open the box yet.


 
Feb 06, 2023     Avionics and Electrical - (5.5 hours) Category: Avionics
Researched diodes to use for Diode-Or power connections to the GTR200B and GNX375 (second connector).

Reviewed Digikey, Mouser and Stein Air carts, made some updates and placed orders.
The Mouser order included K1 and K2 panel switches, the key switch (master), relays for the small starter switch on the stick, diodes for the solenoids and relays and resistors.
The Digikey order included limit switches for flap position, a connector for the wires going to the pilot and copilot stick, diode-or dual diode packs, QC terminals (.187 and .110) and a isolated music input jack.
The Stein Air cart included a mounting bracket for the GMU 11, a defrost fan and grill, headset and mic jacks, the field circuit breaker, an LED strip light and a pitot static toggle valve for alternate static.

Continued update of schematic and spreadsheet.
 
Feb 05, 2023     Avionics and Electrical - (6.8 hours) Category: Avionics
Continued work on spreadsheet and schematic. Continued to add wire sizes, labels and shield connection and wire types to both. Added part numbers to many of the parts. Generated a BOM from the schematic to count switches, resistors and diodes.
 
Feb 04, 2023     Avionics and Electrical - (8.7 hours) Category: Avionics
Barely exceeded my weekly goal of 31.5 hours with a total of 32. But I was out of town most of two days so not bad.

Still working on the spreadsheet and schematic. Also adding parts to my Mouser, Digikey and Stein shopping cart and planning to place an order soon. Waiting for my Catto prop to be delivered. It was delayed by the bad weather last week.
 
Feb 03, 2023     Avionics and Electrical - (3.1 hours)       Category: Avionics
Continued updating schematic and wireless with wire names. Changed fuel pump to use fuse. Discussed fuses and EI commander with Brad at EMAG and updated schematic to use fuses for Emag power. Researched and found isolated jack for music input.

Not included in time: Picked up spinner, backing plate and crush plate weight from Michael's (UPS shipment from Catto Prop).


 
Feb 02, 2023     Avionics and Electrical - (6.1 hours) Category: Avionics
Continued updating schematic and spreadsheet and adding wire names and types.

Talked to Tosten to get switch ratings. Researched and selected a relay for the starter switch in the Tosten grip.

Researched and selected limit switches and related parts for flap motor up and down limits.
 
Feb 01, 2023     Avionics and Electrical - (6.2 hours) Category: Avionics
Continued work on schematic and spreadsheet.

Updated Revision 2 schematic with changes.
Deleted horn and beacon.
Changed Fuel Pump power to use fuse and added diode to fuel pump.
Changed master switch circuit to use a single keyswitch.
Added starter enable button, relay, diode and connection to pilot stick.
Increased wire gauge on battery connections and changed to brass strip between contactors and between contactor and ANL.
Starting updating wire gauges, wire labels, and adding shield information.

Started updating the schematic and adding wire gauges, wire labels and adding shield information. Making sure schematic and spreadsheet match as I go.
 
Jan 31, 2023     Avionics and Electrical - (2.2 hours) Category: Avionics
Traveled home a day early due to winter weather warnings and need to be home when my prop is delivered. The trip was quick since not many people were on the road and we picked a time where it wasn't raining/sleeting and was just above freezing. Arrived home at 4:15PM so another day off, but decided to get some work done anyway.

FedEx still shows delivery of my prop Wednesday (tomorrow). But there is also a general FexEx warning about weather delays. And my prop is still showing in transit to or located in Flagstaff.

Updated Solidworks document to add a switch for Pitot heat and two spares.

Imported Larry's dxf and AI into Solidworks to try to see what was in it. Tried exporting Solidworks into dxf to understand what was possible. Imported Van's dxf into Solidworks. I am learning, but none of that seems too promising.

Downloaded Inkscape (open source program similar to Adobe Illustrator) and started figuring out how to use it. I think this will work to create the graphics file I need.

Figured out how to take the Van's 3D model of the front panel and unfold it. This will allow me to increase the panel height if I decide I need it.
 
Jan 30, 2023     Avionics and Electrical - (.2 hour) Category: Avionics
Traveled to San Antonio this morning so a day off.

Read VAF postings and traded PMs with Larry about using a mechanical CAD package and Adobe Illustrator for panel layout and labeling. Read his December 2022 Kitplanes article.
 
Jan 29, 2023     Avionics and Electrical - (6.2 hours)       Category: Avionics
Continuing work on the panel layout. Finished creating sub panels for the switch groups and a model for the ELT remote panel. Placed everything on the panel except for the pitot heat switch, cutout for fuse access, and the iPad mount. I'll need to move some things around. At least this shows I should be able to fit everything in the panel.


 
Jan 28, 2023     Avionics and Electrical - (4.4 hours)       Category: Avionics
Met my weekly goal of 31.5 hours. Actually worked some every dat for a total of 35.9 hours.

Continued work on panel layout. Created a model for the Klixon 7277 circuit breaker. I am still learning new things about Solidworks. Cleaned up a rough panel I had started by removing components from the panel and placing and defining position one by one. The center stack component are now grouped together and can be moved up/down or right/left with one dimension change. I am creating sub-panels with switches grouped together so I can add them to the main panel and move them around easily. Also worked with adding labels and decals in Solidworks and think I need to use a different program to create them.


 
Jan 27, 2023     Avionics and Electrical - (4.3 hours) Category: Avionics
Continued work on panel. Downloaded cad models from Otto and Apem and imported them into Solidworks.

Reviewed recent service bulletin. Looked at avionics bay access panel kit. Looked at Van's firewall forward kits. Starting a list of questions for Vans Support.

Looked at availability of lighted Otto K1 switches and found a couple that were special order. Decided to use unlighted switches.
 
Jan 26, 2023     Avionics and Electrical - (1.8 hours) Category: Avionics
Continuing work on panel. Sketched ideas for grouping and labeling switches.

Emailed questions related to wiring and panel labels to AFP, Emag, Oplite and TWC.
 
Jan 25, 2023     Avionics and Electrical - (3.1 hours)       Category: Avionics
Worked on the panel layout some more. Moved the center stack 3" to the right to provide more space for switches. Cleaned up list of questions and topics to discuss with Brian.

Summarized notes from meeting with Brian. Created the guardian CO detector and EI commander parts for the panel layout.

Not included in the time: Met Brian for lunch, looked at his beautiful RV-7, and asked a lot of questions. Brian provided tips, ideas and reviewed the schematic.


 
Jan 24, 2023     Avionics and Electrical - (8.1 hours)       Category: Avionics
Finished final review of Revision 1 of schematic and spreadsheet. Changed some colors and cleaned up the schematic some. Created PDFs to take to FedEx to print. Saved copies of all Revision 1 documents and started Revision 2 for any future changes.

Started work on on panel layout using SolidWorks. Created parts for the GSB 15 and K1 and K2 switches. Imported all the other Garmin and Van's Aircraft parts. Started creating top assembly. Discovered the hole in the center of the panel is not really in the center. See the attached prints for the initial rough layout.

Inspected and logged Mouser parts including 1)Otto K1 flap, SPST and SPDT. 2) Otto P3 pushbutton starter and horn. 3)And a few other parts.

Not included in the time: Trip to FedEx to use their large format printer to print revision 1 of the schematic.


 
Jan 23, 2023     Avionics and Electrical - (8.9 hours) Category: Avionics
Continued working on schematic and wiring spreadsheet. Completed first complete pass through all items on the spreadsheet and the schematic. Added switches and power and ground connections to the schematic and spreadsheet as needed. Still have some open questions to discuss with other builders, but the initial plan is documented. Next steps:
- quick review and cleanup to make the schematic easier to read and then print a copy and send to others for review (1/24)
- need to complete panel layout including switches to verify I have room for the parts in the current design or if I need to revise it to use fewer switches.
- need to complete determining wire size and type and shielding connections (future).
 
Jan 22, 2023     Avionics and Electrical - (5.3 hours) Category: Avionics
Continued working on schematic and wire list. Started adding connections for power distribution. Added PMAG, fuel pump and alternator field circuit breakers and connections. Added more devices and switches. Added connection information for IBBS.
 
Jan 21, 2023     Avionics and Electrical - (8.3 hours) Category: Avionics
Met my weekly goal of 31.5 hours. Actually worked some every dat for a total of 44.3 hours.

Continued work on schematic and wireless. Added some lights and switches. Researched and selected push button switches for the starter and horn. Looked for shrouds to protect the start button. Added connection to GAD 027 discrete to monitor fuel pump.
 
Jan 20, 2023     Avionics and Electrical - (7.2 hours) Category: Avionics
Continued work on schematic and spreadsheet. Finished most signal connections except power, CAN bus details, lights and switches. Started working on power and switches. Still need to finish that and add wire types and more wire labels and shielding information.

Researched starter types and circuits. Added a sensor connection to the starter to detect starter activated.
 
Jan 19, 2023     Avionics and Electronics - (3 hours) Category: Avionics
Continued work on schematic. Created flap and toga switch symbols and added to schematic. Researched switches and alternator field wire test points. Added other connections to schematic.
 
Jan 18, 2023     Avionics and Electrical - (4.5 hours) Category: Avionics
Continued work on the schematic and wire list. Added and started connecting GTR 200B, Jacks, Dimmer switches, flap and trim motors and stick grip switches to the schematic. Continued work on the GEA 24 and GAD 27 parts. Verified connections on the spreadsheet and updated spreadsheet and schematic symbols as needed.
 
Jan 17, 2023     Avionics and Electrical - (8.8 hours) Category: Avionics
Continued work on schematic. Adding connections on schematic and checking against the spreadsheet. Updating symbols and the spreadsheet as needed. Except for power and ground connections and showing shielding on wires, completed pin connections on G5, GAD 29, ELT, GAP 26, GDU 460, GMC 507, GMU 11 and GNX 375. Sent question to Garmin about GNX 375 power connections. Completed GEA 24 J242 connector and reworked thermocouple symbols to fit better. Created connector symbol for OLC-2 connector. Started GEA 24 J244 connections.

Created 4 symbols for showing shielded wire (single wire, twisted pair, three wire and four wire).
 
Jan 16, 2023     Avionics and Electrical - (6.9 hours) Category: Avionics
Sent payment to Catto Propeller for my prop. The prop should be delivered in early February.

Sent question to Lycoming about engine configuration. I'm hoping the change to AFP fuel injection was made in time to be installed on my engine. I haven't heard any schedule updates since Van's told me Lycoming would ship on 4/11/2023.

Continued working on schematic and wire list. Completed pin connections for RS-232 and ARINC signals. Worked on CO Detector, EI Commander and Emag ignition pin connections.

Found and fixed a few more problems with the wiring spreadsheet.

Researched circuit breaker options after determining I should use circuit breakers instead of fuses for the EMag electronic ignition power since ATC fuses are not available in slow-blow.
 
Jan 15, 2023     Avionics and Electrical - (5.6 hours) Category: Avionics
Continuing work on schematic. Added new Garmin symbols to sheet two and started working on interconnects. Created configuration module symbol. Started experimenting with options to use buses and labels for RS-232 connections. Tried a few work arounds for showing shielded wire and decided I need to create some new shielded wire symbols in Solidworks.

Completed clean up of wireless and imported into Numbers from Excel. Now I can work on the wireless, schematic and look at supplier documentation all from the MacBook.
 
Jan 14, 2023     Avionics and Electrical - (5.3 hours) Category: Avionics
Continued work on the schematic. Added symbols for seat heater, horn, jack for testing, FlyLEDs lights and controller, flap and trim motors and position sensors, lights for map, glare shield, and baggage area.

Started cleanup of wirelist spreadsheet. Moved circuit protection and current information from main tab to the LRU tab. Explored options using vlookup for documenting wire label text, size, type and length since I have each connection listed twice in the spreadsheet. I and ended up deciding to simplify and just enter the wire label text, size, type and length for the first connection and using the wire label text only for the second connection.
 
Jan 13, 2023     Avionics and Electrical - (2.8 hours) Category: Avionics
Continued work on schematic. Created symbols for GAP 26, Antennas (NAV, COM, COM, XPDR, GPS, GPS), ELT, Music Jack, CO detector, EI Commander, Fan and fuel level sensor.
 
Jan 12, 2023     Avionics and Electrical - (5.4 hours) Category: Avionics
Continued work on schematic. Reworked GSA 28, GNX 375, and GEA 24 symbols. Reworked GEA 24 to split out each connector into a separate symbol. Added symbols for G5, EGT, CHT, fuel flow, oil pressure, fuel pressure, manifold pressure, oil temperature, headset jack, microphone jack and pilot and copilot stick grips.
 
Jan 11, 2023     Avionics and Electrical - (4.5 hours) Category: Avionics
Continued work on schematic. Realized the symbols I created with the pins in order would look confusing on the schematic. Reworked GRT 200, GAD 29, GMC 507, GAD 27 and GDU 460 to group pins by function. Reworked GAD 27 to split out each connector into a separate symbol.
 
Jan 10, 2023     Avionics and Electrical - (5.5 hours) Category: Avionics
Continued work on schematic. Created symbols for GAD 27, GAD 29C, GDU 460, GEA 24, GMC 507, GMU11, GNX 375, GSA 28, GSB 15, GTP 59 and GTR 200B.
 
Jan 09, 2023     Avionics and Electrical - (4.2 hours) Category: Avionics
Continued work on power distribution portion of schematic. Created Hall Effect and several switch symbols.
 
Jan 08, 2023     Avionics and Electrical - (4.7 hours) Category: Avionics
Started phase 3 commitment. Worked on power distribution schematic and creating symbols for components. Tried several different power distribution layouts. Created ground block and electronic ignition symbols. Realized the battery, contactors, fuse, starter and alternator symbols were too large so recreated them.
 
Jan 07, 2023     Avionics and Electrical - (6.7 hours) Category: Avionics
Continued work on symbols for schematic. Figured out how to sketch symbol graphics in Solidworks and import into the symbol library and add information and pins. May have completed symbols for Main/Battery Switch, Starter, Alternator, Battery Contactor, Starter Contactor, Fuse and Battery.
 
Jan 06, 2023     Avionics and Electrical - (3.2 hours) Category: Avionics
Back at it again after a break to enjoy Christmas and New Year's Eve with family.

Started creating symbols that I need for the power distribution schematic. Completed a family of fuse boxes. Using square boxes for contactors, Alternator, Battery and Main/Start switch and don't like it. Needs to be more graphical so you don't have to read details to understand the big picture.
 
Dec 24, 2022     Weekly update Category: Avionics
I missed my goal this week. I was supposed to work an average of three hours a day for Sunday, Monday, Tuesday and Wednesday and didn't. My daughter and her family arrived Thursday for Christmas and I'm treating 12/22 through 12/31 as holiday from building.

Phase three of my commitment runs from 1/8 through 4/8 and I'm increasing the average daily time from 3 to 4.5 hours. The major focus will be on finishing wiring and testing of the panel.
 
Dec 20, 2022     Avionics and Electrical - (2.1 hours) Category: Avionics
Continued working with KiCad. Tried using multiple sheets and sizing each sheet differently. The second and fourth sheet seemed linked. When I changed the size of one of them the other changed. Tried again later and had a problem using sheet 4. Maybe sheet 4 is the problem or maybe I don't know how to use it.

Tried using hierarchical labels and global labels to understand how to use them and figure out which one works best for me.
 
Dec 19, 2022     Avionics and Electrical. - (2 hours) Category: Avionics
Worked with the first symbol on several sheet sizes to see how things would look and how much I could put on each sheet. Looked at examples to see if I liked how others had created schematics. I plan to use at least a C sized sheet and possible a D sized sheet. I think an E sized sheet will be too difficult to handle and I don't plan to use it. Watched more tutorials on using multi-sheet schematics and the two ways to organize them.

Added a LRU column to the wiring spreadsheet and used a pivot table to see connections between different LRU pairs. I was surprised to see how few connections there were between boxes. This will help me know how to place LRUs in the airframe and on the schematic pages.
 
Dec 18, 2022     Avionics and Electrical - (4 hours) Category: Avionics
Watched and practiced the schematic portions of the KiCAD tutorials. Started building Garmin symbols and ran into a problem with creating box graphics on the new symbols. Researched and found the bug was fixed in a later version. Upgraded and confirmed I could complete a symbol.
 
Dec 17, 2022     Avionics and Electrical - (9.2 hours) Category: Avionics
Met my weekly commitment again, barely. 21 hours over 7 days. I would not have spent as much time yesterday and today if I had not committed to 21 hours a week so making a commitment to my grandkids helped me.

Continued work on the wiring spreadsheet. Worked through most of the signal connections. Need to work on finalizing power and switches next. Creating a list of questions to ask and things to look for the next time I visit an RV builder.
 
Dec 16, 2022     Avionics and Electrical - (4.7 hours) Category: Avionics
Continued work on the wiring spreadsheet. Spent most of my time on GEA 24 and GAD 27 and related components and research. Found a nice dimmer switch and plan to order them soon.
 
Dec 15, 2022     Landing Light Mounts - (.5 hour) Category: Avionics
Removed landing light mounting plates from the wings at the hangar today. Also made measurements to help with pitot location and wire lengths to pitot and autopilot roll servo.
 
Dec 14, 2022     Avionics and Electrical - (4.8 hours) Category: Avionics
Started out looking at GEA signals on the wiring spreadsheet and GEA configuration settings and options.

I'm trying to decide if I should use Gigaflight CAN bus cable as recommended in the G3X documentation even though wire size is 24 instead of the Garmin recommended 22 AWG minimum. The other option is to use the shielded twisted pair that is also recommended by Garmin that has the 22 AWG wire. While looking at cable size I noticed I had selected the wrong type of solder sleeves. Spent time researching the correct solder sleeves, d-sub tools, AFM8 and positioned settings, splice sizing and CAN bus recommendations in the Garmin documentation, on VAF and on Garmin youtube channels.
 
Dec 11, 2022     Avionics and Electrical - (1.8 hours) Category: Avionics
Continued working on the wiring spreadsheet. Continuing with the GEA 24 and associated components.
 
Dec 10, 2022     Avionics and Electrical - (6.9 hours) Category: Avionics
Met my commitment for another week. 21.2 hours over 7 days. I was thinking I was on a roll and would not need to make a commitment in 2023, but you can tell from my tracking spreadsheet that I am just barely making my commitment and I know there are lots of times I would have skipped working on it except for the commitment.

Continued working on the wiring spreadsheet. Continuing with the GEA 24 and associated components. Spent time trying to understand which pressure sensors I have and which ones were the older versions that had leak issues.
 
Dec 09, 2022     Avionics and Electrical - (6.5 hours) Category: Avionics
Continuing work on the wiring spreadsheet. Except for power, CAN and lighting bus, working through all signals one device at a time. Finished GAD 29 and GNX 375. Finished GDU460, G5, GSU 25, GMC 507 and working on GEA 24.
 
Dec 08, 2022     Avionics and Electrical - (3.8 hours) Category: Avionics
Updated wiring spreadsheet with all RS-232 and ARINC 429 connections using the responses from Garmin and the example spreadsheet. Working on finalizing all connections for the GAD 29 and GNX 375.
 
Dec 07, 2022     Avionics and Electrical - (4 hours) Category: Avionics
Reviewed response on GDU, G5, GNX 375 questions and sent thank you note. All interconnect questions are resolved. Started review of example schematic and wiring spreadsheet and starting to make changes per Garmin response. Researched a few devices and connections on the example schematic that I may want to use.

Found there was a new revision of the G3X Touch install manual (AQ) and reviewed all changes. The most useful new change was additional information on the GAP 26 pitot mount installation.
 
Dec 03, 2022     Avionics and Electrical - (5.8 hours) Category: Avionics
Getting back on track. Met my weekly commitment again. 3.1 hours per day for 4 days.

Continued work on RS-232 and ARINC connections document, studied manuals more and sent the remaining open questions in a different format to Garmin. I'm still confused, but understand my questions better.

Added all the Garmin serial numbers to my Garmin parts spreadsheet and entered them into a Garmin website to confirm they were correct. Need to call Garmin before submitting all of them.

Worked with Gigaflight CAN bus cable to verify the acceptable solder sleeve size and started practice with stripping the cable for solder sleeves and splices.
 
Dec 02, 2022     RS-232 and ARINC - (4.2 hours) Category: Avionics
Reviewed Garmin reply to my connections questions and started review of documentation and example schematic from Deene to make sure I understand the Garmin reply. Started draft of "RS-232 and ARINC Connections and settings R1". This is all starting to make sense now.
 
Dec 01, 2022     Follow up and supply BOM - (2.2 hours) Category: Avionics
Back to it after a long break for a 11/8 to 11/17 trip to see the grandkids that got extended to 11/29 due to Covid. I missed one week of my commitment and sent $50 to my daughter.

Followed up with Aircraft Spruce on pitot install kit. Followed up with Brad at Garmin on connection questions.

Reviewed Aircraft Spruce orders and created spreadsheet with wiring supplies and Garmin equipment. Reviewed Skygeek order and added parts to the wiring supply spreadsheet.
 
Nov 07, 2022     Panel Design - (2.1 hours) Category: Avionics
Spent 2.1 hours importing Garmin and Van's models into an assembly and learning trying different methods of import, export, and mating surfaces to do what I need. The training helped.
Also spent more time getting an annual license and trying 3D experience on the macBook.
 
Nov 05, 2022     Training Category: Avionics
Spent 0.7 hours watching the final intermediate level parts project. Haven't been working through the details since I won't need to do any of these things for the panel project.

Managed to spend 21 hours this week. I need to get out of training mode and back into completing the wiring spreadsheet and building a panel model and figuring out how many switches I need. Also I found a reply from GigaFlight about the CAN bus cable so I need to make a sample splice in the cable I bought from Aircraft Spruce to confirm it will work for me, then figure out the rough length and then place an order.
 
Nov 04, 2022     Training Category: Avionics
Spent 3 hours reviewing more intermediate level part videos. I didn't spend time practicing because most of the tools and commands shown won't help me in laying out the panel. I did want to see them all just in case. The next step is the intermediate final part project.
 
Nov 03, 2022     Training Category: Avionics
Spent 3 hours continuing Solidworks training. Completed assembly practice, watched drawing videos and practiced. Started intermediate level parts videos.
 
Nov 02, 2022     Training Category: Avionics
Continued SolidWorks training for another 3.8 hours. Practiced by creating another version of the the beginner level final part project. Submitted comments about an error in the video. Watched all the beginner level assembly training and worked on the assembly final project before watching the final video. Need to work through the assembly project one more time before moving on.
 
Nov 01, 2022     Training       Category: Avionics
Spent 3.4 hours on training today. Watched Aryan build the beginner level final project part to see how his approach was different than mine. Then started from scratch and built the project much more quickly. Starting to learn how to find my way around and create and fix things. I'm going to do the project one more time tomorrow before moving on.

The attached picture is the solid model I created from a 2D drawing. It doesn't look like an instrument panel, but I learned a lot of basic solid works skills in the process of creating it.

Tried panel planner again after getting some responses from Gene. I may be working with him tomorrow.


 
Oct 31, 2022     Training Category: Avionics
Working on the beginner level parts final project for 7.1 hours. It is taking a while and it is good practice.
 
Oct 28, 2022     Training Category: Avionics
We are headed out of town Saturday so this is the last entry for this week. It has been a short week with a two day trip to Dallas for a funeral and the trip tomorrow to see family. I've completed 12.3 hours of training for the 4 days home so slightly exceeded my goal of 3 hours a day.

Today I spent 0.2 hours watching the last few beginner level training on parts. The only one left is the final project for beginner level parts to see if I really learned it and to see a few new tips.
 
Oct 27, 2022     Training Category: Avionics
Continued training for another 0.8 hours. Couldn't do much since we were leaving town for a funeral in Arlington, TX.
 
Oct 26, 2022     Training Category: Avionics
Spent 4.3 hours continuing SolidWorks training. I'm learning a lot.
 
Oct 25, 2022     Panel Design - training Category: Avionics
Monday, 10/24, I spent about 1 hour looking at sample solid works training and sent questions to Aryan at Solidworks Course Pro. Today I signed up for the Lite Course and spent 3.5 hours going through online courses and practicing. I'm counting this time against my 3 hours a day commitment to RV building, but not logging the time in this formal builders log.

The Solidworks Pro Course is great so far.
 
Oct 23, 2022     Panel Design - (2.5 hours) Category: Avionics
Started looking for tutorials for solid works. Found solidworkstutorials.net SolidworksCoursePro and watched the introduction, top 10 mistakes and first 5 free videos. I'm trying to decide on whether to sign up for the full or lite course. I've already learned quite a bit just from the demos.
 
Oct 22, 2022     Panel Design - (3.8 hours) Category: Avionics
Worked on RV things for 21.2 hours this week. Did miss one day when I just needed a break. The commitment to average 3 hours a day is helping. I would have skipped more days and not worked on it as much.

Spent a little more time with hangarflying.com panel designer and decided it isn't what I want.

Started looking at Solidworks 3D experience and bought a month long license. Set it up for use on my macBook and a PC. Installed Solidworks on the PC. Was able to import the Van's panel iges file and also the Garmin GDU 460 step file. Now I just need to figure out how to use Solidworks.
 
Oct 21, 2022     Panel Planner - (6.2 hours) Category: Avionics
Started using panel planner. The goal was to update my original draft to match the Garmin equipment I selected and to lay in all the switches to see how much room I had and how they looked. I started using the application and ran into problems and reported them. And when I started to create switches in panel planner I ran into more problems. We had a long meeting so I could show them what I was doing and seeing. They plan to work on it and created and added the switches for me.

I started using the new switches and found another issue and reported it.

The good news is I started work on the switch layout using the panel planner. The bad news is I didn't make much progress. I'm really frustrated.

Started looking at alternates to panel planner.
 
Oct 20, 2022     Avionics and Electrical - (3.5 hours) Category: Avionics
Skipped a day yesterday. I did spend some time cleaning up my office working area organizing the Garmin parts, tools and supplies and clearing my workbench.

Fired up panel planner looked for switches and some other parts. Remembered why I don't like it.

Searched for, read and downloaded Carling Tech and Otto switch information. Worked on switch groupings and compared size and features of different switch series.

Received an email today from Van's saying Lycoming expected my engine to be ready 4/11/2023. Yay! Great timing. I was hoping for March or April.
 
Oct 18, 2022     Avionics and Electrical - (3.1 hours) Category: Avionics
Continued work on wiring spreadsheet and wiring design. Discussed TCW IBBS connections and function with TCW tech support. Discussed how modern avionics and TCW, in their opinion, obviates (new word of the day!) the need for the endurance bus. Decided to change my approach to match the TCW recommended approach which is also shown in the Garmin install manual.

Looking at how many switches I have on the panel and how many I can combine...
 
Oct 17, 2022     Avionics and Electrical - (2.5 hours) Category: Avionics
Continued work on the wiring spreadsheet. Added more starter, regulator and alternator parts and lines.

Discussed switches, circuit breakers/fuses and wiring with Deene. Studied an avionics schematic for a Garmin G3X/G5/GNX375 configuration that is similar to mine.
 
Oct 16, 2022     Avionics and Electrical - (1.5 hours) Category: Avionics
Completed renaming LRUs and all the places where the LRU names were referenced. Did a quick v-lookup and identified all the LRUs that were missing from the main data tab and added all of them. I'm starting Revision 15 of the spreadsheet now.
 
Oct 15, 2022     Avionics and Electrical - (5 hours) Category: Avionics
Just reached my weekly goal. I was out of town three days so only needed 12 hours. Researched and downloaded data sheets on Otto and Carling Switches. Planned to use progressive switches for several functions to reduce switch count.

Visited Luis again at Breakaway Airport to look at the panel again and ask some switch questions. He didn't use any progressive switches. I liked the simplicity and clear on/off labels on the Otto K1 and K2 switches. Didn't include any time at Breakaway in the daily time. May change back to simple on/off switches. Will know after I get a final switch count and try them on a new panel layout.

Continued work on the wiring spreadsheet. Added the "always hot" fuse block. Eliminated some columns on the LRU tab. Renamed many of the LRUs to eliminate extra "-1"s and make naming more consistent, Started modifying the main data tab to use the new LRU names.

Researched engine bridge which is an alternative to EI commander.
 
Oct 14, 2022     Avionics and Electrical - (.5 hour)       Category: Avionics
Made, installed and tested new jumper wires between the strobe/position light PCBs. FlyLeds recommended just stripped wires with no ferrules due to space limitations. They seem to work well.


 
Oct 13, 2022     Avionics and Electrical - (2.5 hours) Category: Avionics
Continued work on the wiring spreadsheet. Added seat heaters and investigated seat heater options. Changed 12V outlet currents and may eliminate them. Added second USB port in baggage area.
 
Oct 10, 2022     Avionics and Electrical - (1 hour) Category: Avionics
Bus maximum currents exceed alternator capability so started reviewing data. Added current column to show max currents excluding intermittent loads such as flap, autopilot servo and trim loads. Adjusted assumption on pitot heater. Reviewing other power data and rethinking decision to add power outlets and only one USB outlet.

Reviewed and downloaded Stratus 3 data.
 
Oct 10, 2022     Avionics and Electrical - (3 hours) Category: Avionics
Continued work on wiring spreadsheet. Added two fuse blocks and deleted individual fuses. Completed first pass of listing fuses, max current and typical current for all devices. Completed identifying which devices connect to each of the battery backups. Created a pivot table showing fuse counts on the main and endurance bus and total currents for the main, endurance and two battery backup buses. Updated autopilot power schematic. Started looking at details of the battery, starter, regulator and alternator circuits.
 
Oct 08, 2022     Avionics and Electrical - (5.5 hours)       Category: Avionics
Met goals for another week. 26.1 hours which is more than the 21 hour commitment. Missed working on the project one day, but more than made up for it on other days.

Continued work on wiring spreadsheet and figured out final format for showing fuse sizes, max current and typical current. Searched through Van's docs, VAF and Ray Allen docs and FAQs to find flap and trim motor currents.

Searched through Garmin docs for CAN bus and wiring notes and summarized in wiring spreadsheet.

Sent quote request to Gigaflight CAN bus wire to see if they sell it cheaper than Aircraft Spruce ($6.50 per foot).

Inventoried single wire size and shielded wire already on hand. Found bags of ferrules and marked with AWG size. Made up 4 individual interconnect wires with ferrules and replaced the ribbon cable jumper and sent pictures to FlyLeds for comment. The ferrules are touching some of the power resistors.


 
Oct 07, 2022     Avionics and Electrical - (6.2 hours)       Category: Avionics
Looked through Aeroelectric schematics and printed several schematics for markup. Printed Z-11P on tabloid sized printer for markup. Looked up D-Sub connector information and added summary to spreadsheet. Continued working on wiring spreadsheet.

Worked on lens for right wingtip and cut out clearance hole in wingtip for light board parts. Used dremel tool with cut-off wheel and permagrit files. Still need to work on one half of the lens.


 
Oct 06, 2022     Avionics and Electrical - (4.6 hours) Category: Avionics
Continued working on power and ground signals on the wiring spreadsheet.

Downloaded and saved install manuals as I went to build a document library for this RV.

Created spreadsheet tables for 2, 4, 6, 8, 10, 12, 14, 16, 18, 20, 22 and 24 AWG wires. Each table shows voltage drops for currents of 1 to 30 amps and wire lengths from 1 to 30.

Marked up existing Garmin and FlyLed docs to create 4 rough looking schematics to go along with the wiring spreadsheet. I'll create clean and complete schematics after I wire and test the design.
Power, Backup
Power, Autopilot
Lights, Position, Strobe
Lights, Taxi, Landing
 
Oct 04, 2022     Avionics and Electrical - (1.8 hours) Category: Avionics
Continued working on power and ground signals on the wiring spreadsheet.
 
Oct 03, 2022     Avionics and Electrical - (4.5 hours) Category: Avionics
Continued work on the wire list spreadsheet. Added more devices and columns. Started adding information on power sources and fuse sizes.

Reached out to Aircraft Spruce to add the fine version of permagrit files to my order and ask about the status of the pitot install kit which seems to have been ordered, ordered again, canceled and previously shipped.

Looked up more options for red beacon lighting. Looked up sizes of fuse blocks and ground blocks available from B&C.
 
Oct 02, 2022     Avionics and Electricalcs - (3.5 hours) Category: Avionics
Continued work on the wiring spreadsheet. Added alternator, regulator, ANR and some switches and fuses. Added information about location and one power source. Added seat heaters and looked for seat and heater sources.
 
Oct 01, 2022     Avionics and Electrical - (3 hours) Category: Avionics
Barely exceeded my weekly goal of 21 hours by completing 21.7. I did work on it every day. The commitment to the grandkids really helped this week. I got really busy with some non RV stuff and I would have skipped several days and spent a lot less time on some days.

Today I worked on cleaning up wiring spreadsheet and adding information on locations of switches. I need to identify every potential switch and fuse/breaker to complete the panel design.
 
Sep 30, 2022     Position and Strobe Lights - (7.2 hours)       Category: Lighting
Completed build of FlyLeds wingtip position and strobe lights. Connected the light boards and tail light to the control board and tested using a 9V battery. Got a chance to use the new heat gun and Hakko soldering tips. It took me a lot longer than the estimated time. I enjoyed the process and it works great. The only thing that needs to improve is the connection between the pairs of wing boards. I struggled to make the ribbon cable work and it has come loose twice. I'm going to try individual wires with ferrules and see if I can get that to fit in the space allowed.

I test fit the pair of boards in the left wingtip and the cut-out was sufficient.


 
Sep 29, 2022     Project visit - (2.5 hours) Category: Research
Got a project tour from my tech counselor. It was an RV-7 slider so very similar to mine. The same engine I've ordered was installed and work had started on the baffling. The panel was being modified for instrument and switch cut-outs. Some Stein built wiring harnesses were in the airframe. It was a great chance to see the early stages of the next steps for me and a chance to take lots of pictures and ask lots of questions. I got a lot of practical tips.

I started follow up research on some of the topics. I decided to use the Nuckolls Z-11 design as the starting point for my power distribution. I plan to incorporate one or two TCW IBBS battery backups.
 
Sep 28, 2022     Wingtips - (1.7 hours)       Category: Lighting
Reviewed avionics questions and resent previous list and new questions to Garmin again. Printed questions to discuss when I meet with tech counselor. Meeting got delayed until later this week.

Filed wingtip lens until it is almost small enough to fit. Decided to leave just a bit to allow options when I polish the edges and clean up the wingtip for paint. Plan to ask the tech counselor for ideas. Removed part of the wingtip per FlyLed instructions so the parts on the back side of the board can fit inside the wingtip. Used permagrit files on the lens and a dremel tool with cut-off wheel for plastics on the wingtip. Cleaned up edges of fiberglass and added relief holes on corners with permagrit files.


 
Sep 27, 2022     Wingtip Lighting - (2.2 hours)       Category: Lighting
Completed cutting and filing FlyLEDs PCBs to size assuming they still fit after I finish the lenses.

Filed one lens to where it almost fits. Need to finish final filing and cleanup of edges.

Arranged to meet up with tech counselor to discuss power distribution and look at a G3X Touch based system.


 
Sep 26, 2022     Avionics and Lighting - (3.1 hours) Category: Avionics
Sent status update and list of questions about power distribution to technical counselor.

Placed Mouser resistor, APEM switch and Amploc connector order. Placed Amploc Key100 Hall Effect sensor order.

Started cutting wingtip lighting PCBs with aviation tin snips and filing edges smooth with permagrit files. One set is near final size.
 
Sep 25, 2022     Avionics and Electrical - (2 hours) Category: Avionics
Studied Aeroelectric appendix Z power distribution architecture and notes.
 
Sep 24, 2022     Avionics and Electrical - (3.5 hours) Category: Avionics
Met my goal of 21 hours for another week. Worked on the project every day. Had expected to work more than the actual 22.7 hours.

Continued working on wiring spreadsheet. I have now looked at and researched at least some of the connections for all the avionics. Spent time today wrapping up details related to CWS/Disc, TO/GA, and Pitot. Also changed fuel sensors to eliminate 2.2K pull-ups since a circuit without pull-ups is sufficient for a metal airplane per Garmin. Researched Glide Activate and decided to just use the G3X Touch interface instead of a dedicated Garmin button.

Researched methods to trim the FlyLEDs and found this helpful website: https://www.youtube.com/watch?v=uBkPX_QhRI0

The next major task on the spreadsheet is to decide on an electrical distribution architecture.
 
Sep 23, 2022     Avionics and Electrical - (2.1 hours) Category: Avionics
Searched for flap switch options on VAF and found one at Mouser that should work. Added it to the Mouser cart.

Read response from EI-Commander and plan to wire up the G3X Touch and EI-Commander and e-mag per their guidance.

Searched for panel layout guidelines in VAF and Kitplanes magazine. Got some ideas.

Read about options for power distribution, avionics bus, endurance bus, single bus on VAF.

Picked two Hammond Enclosure boxes that should work with the FlyLeds controller board and added them to the Mouser cart.
 
Sep 22, 2022     Avionics and Electrical - (4 hours) Category: Avionics
Reviewed tach signals and associated data sheets. Sent tach signal connection questions to EI-Commander.

Reviewed fuel level schematics and information in G3X touch again and found out I don't need to add the 2.2K ohm resistors.

Also spent time on CWS/DISC and TO/GA signals and researching ideas for which signals to connect to the stick grip. Added TO/GA switch and 5K pull-up resistors to Mouser cart.

Researched flap switch location and types on VAF and started searching for a flap switch.
 
Sep 21, 2022     Avionics and Electrical - (2.7 hours) Category: Avionics
Continued work on wiring spreadsheet. Added details for many of the engine and airframe sensors and made connections to the GEA 24. Still more to go.
 
Sep 20, 2022     Avionics and Electrical - (3.1 hours) Category: Avionics
Continued working on wiring spreadsheet.

Completed lights and associated connections to GAD 27. Added engine and airframe sensors to spreadsheet and started on GEA 24 Engine Interface connections.
 
Sep 19, 2022     Avionics and Electrical - (2.5 hours) Category: Avionics
Continued working on wireless spreadsheet. Started adding GAD 27 connections after adding switches, potentiometers for dimming, trim motors, flap motor and FlyLEDs devices to the spreadsheet.
 
Sep 18, 2022     Wiring Spreadsheet - (4.8 hours) Category: Avionics
Worked through all GNX 375 connections and started email to Garmin with several questions.

Added lots of details and devices to the spreadsheet. Lighting control pots, flap switches, headset and music jacks, power outlets, antennas, and added details of pilot and copilot stick grips.

Completed most connections to the GTR 200B VHF COM radio.

Reviewed and completed most of the connections to the GAD 29 except waiting on information before assigning ARINC pins.

Started review of signals and adding connections to the GAD 27 flap, trim and lighting controller.

Opened up all the Garmin boxes and packages to verify the parts looked okay and verify GA 26x antennas came with cables. Didn't check serial numbers.
 
Sep 17, 2022     More RS-232, ARINC 429 and other connections - (6.7 hours) Category: Avionics
Met my goal for another week. I was in town the full week so the goal was 21 hours. I actually worked 29.5 hours and worked on it every day. The main accomplishment for the week was making a lot of progress on understanding the system architecture and connection details and figuring out my first guess at all the RS-232 connections. I also received another third of my Garmin Avionics order.

Completed updating the wiring connection spreadsheet with all the RS-232 connections. Reviewed ARINC 429 connections in the manual. Sent a list of assumptions and questions to Garmin for review.

Researched EI Commander on VAF at and the EI Commander website and decided I probably want to include it. Added an EI Commander to the spreadsheet and completed the connections between the E-Mags and the EI commander after studying the installation instructions for both.
 
Sep 16, 2022     RS-232 and ARINC - (3 hours) Category: Avionics
Finally things seemed to click. I spent more time with the G3X Touch, G5 and GNX 375 installation manuals. I think I understand all the RS-232 connections and settings. I've updated the wiring spreadsheet with RS-232 connections for the ACK ELT and the TBD CO Detector. I also checked most of the RS-232 connections I made yesterday. I should be able to complete both RS-232 and ARINC connections in the spreadsheet and send my plans to Garmin for confirmation.
 
Sep 15, 2022     Garmin G3X Touch, G5 and GNX375 - (5.2 hours) Category: Avionics
Worked on wiring connection spreadsheet. Added CO detector, TCW IBBS battery backup, E-mags and ELT connections. Moved columns around to make it easier to use. Started making entries for RS-232 connections. Spent a lot of time looking at examples and reading details in the Garmin documentation and on VAF and still don't have the RS-232 connections figured out.
 
Sep 15, 2022     Temporary pictures       Category: Fuel System
just posting a picture for someone


 
Sep 14, 2022     RS-232 and Audio - (6.3 hours) Category: Avionics
Discussed audio questions with Garmin by email. Got questions from yesterday as well as a new question answered.

Read through G3X Touch, G5 and GNX375 pinout descriptions and configuration information related to serial connections between devices and started documenting RS-232 connections. Searched through VAF for additional information. Making progress understanding the required connections.
 
Sep 13, 2022     Audio connections - (1.7 hours) Category: Avionics
Continued research on audio connections between Garmin LRUs and muting. Sent questions to Garmin experts.
 
Sep 12, 2022     Avionics - (1.8 hours) Category: Avionics
Started work on pinout spreadsheet focusing on GNX375 connections. Creating list of questions for Garmin.
 
Sep 11, 2022     Avionics - (4.5 hours) Category: Avionics
Continued understanding and documenting effects of avionics and power failures. Also looking at overall power structure with main, endurance (avionics) and autopilot buses. Considering using two TCW IBBS systems and identified potential split of critical items. It might be more reasonable to use a single TCW. Started a list of questions for Garmin.
 
Sep 10, 2022     FlyLEDs and Wingtip Lens - (1 hour)       Category: Lighting
Met goal for another week. Was in town 3 full days so goal was 9 hours. Actually worked 11.8 hours. Also did some work or research every day. The main accomplishment for the week was finalizing and placing the Garmin Avionics order (received a third of it this week and will get another third of it next week and should get the final parts by early January). I also placed an order for a lot of the tooling and supplies I will need for the avionics.

Marked the wingtip boards to match the wingtip pocket and started filing the PCBs using a Perma-Grit coarse file that arrived a few days ago. Slow, but it will work. Will work on it again in the mornings so I can file outside when it is cooler.

Marked and cut the VA-172 wingtip lens into two pieces using a Dremel SawMax and CM500 blade. I need to cut them to size while it is still warm. It looks like they will fit nicely.


 
Sep 09, 2022     Supplies and Tools - (4.8 hours) Category: Avionics
Completed review of materials needed for the G3X Touch installation. Found sources for splices, heat shrink tubing, crimp tool for splices, positioner for high density d-sub contact crimp tool, and insertion/removal tool for high density d-sub contacts. Looked for other parts that will be needed during the build and put some items on supplier wishlists. I know I need a lot more, but won't know more until I finish the design and start building it.

Researched shrink tube wire label options. My contact uses industrial labels which are about $0.60 in bulk. The M23053/5 mil spec labels are 2 or 3 times more. I still have a Kroy printer and a mix of mil spec and commercial labels and will try getting the printer running first.

Unpacked the shipping box and inventoried shipment of Garmin Avionics.
 
Sep 08, 2022     Tools and Supplies - (4.5 hours) Category: Avionics
Continued work on Failure modes document.

Started searching for sources for splices and crimp tools for splices.
 
Sep 07, 2022     Insurance - (.4 hour) Category: Research
Discussed hull insurance (not in motion) insurance with Jim at Falcon and requested coverage.

Reviewed Aircraft Spruce response on Garmin Autopilot part number changes. Ready to buy.

Looked at wire gauges and d-sub pins and DMC crimp tool settings.
 
Sep 06, 2022     Garmin quote - (.4 hour) Category: Avionics
Reviewed revised quote from Aircraft Spruce and sent one question about the part number for the Garmin autopilot.
 
Sep 05, 2022     Tools and supplies - (.4 hour) Category: Avionics
Ordered heat gun kit for solder sleeves.

Decided which solder sleeves would work with the Gigabit CAN cable recommended by Garmin. Placed order for some test parts of three sizes of solder sleeves, a piece of CAN cable and silicone tape for use on the wiring. Also ordered some perma-grit files for use on the FlyLEDs wingtip light boards.
 
Sep 04, 2022     Avionics - (.3 hour) Category: Avionics
Drafted and sent email to Aircraft Spruce with quote changes and questions about ordering supplies and Garmin Avionics.
 
Sep 03, 2022     Quote review - (.5 hour) Category: Avionics
Completed review and markup of Aircraft Spruce quote.

Met my goal for another week. Was in town 3 full days and averaged 4 hours a day for the 3 days. Also did something related to the project on 6 of the 7 days. This week I made a key decision about what avionics to install and where to buy them. The only day I didn't actually work or research anything was the day we travelled to Camarillo to visit the grandkids. I continued to make a little progress while we were visiting.
 
Sep 02, 2022     Avionics - (.6 hour) Category: Avionics
Reviewed Garmin response to my questions about CAN and power failures and was glad to see my assumptions were correct. Started review of the Aircraft Spruce quote to delete and add items. Plan to order Avionics next week.
 
Sep 01, 2022     Aircraft Spruce and Garmin - (.5 hour) Category: Research
Called Aircraft Spruce about order to confirm I could pay by credit card without an extra charge and that I would be billed when parts shipped. Discussed sales and tech support with Aircraft Spruce. Scanned sections of the G3X Touch maintenance manual and GNX375 installation manual that Jaycee sent me.

Two years remain on my goal to be ready to fly the grandkids.
 
Aug 30, 2022     Wiring and... - (2.1 hours) Category: Research
Received confirmation that my prop order was accepted and is in the queue. Looks like February delivery.

Called Vans about the engine order conformation since it has been a week. They said it had been received and sent to Lycoming and was in the queue. They would probably hear back in a month or so. And that the lead time is 8 to 14 months. I'm a little worried that my order might have been dropped somewhere so I emailed my contact at Lycoming asking if he could confirm my order had been received and was in the queue. I also asked if he had a preliminary schedule yet.

Spent the rest of the day adding the GNX 375 connector signals to my wiring spreadsheet and reorganizing the spreadsheet with all the avionics I finally selected. I still need to add any battery backup boxes and lights and ELT and other non Garmin items. I'd like to get answers for the questions I sent to Garmin before I spend much time on the spreadsheet connections.

Headed to Camarillo tomorrow to visit my daughter and her family.
 
Aug 29, 2022     More Failure Mode Research - (3.3 hours) Category: Research
Took one final look at Whirlwind and Catto propeller information and finalized my order with Catto. Expecting February 2023 delivery. Should be here long before the engine that has a March/April date, I hope...

Continued detail review of G3X Touch system component pinouts and descriptions. Completed my questions about what happens with CAN bus failures. Also spent time on power wiring, sample TCW wiring, and power failure effects. Completed and emailed my list of questions about CAN and power failures to Brad at Garmin.

Searched for engine baffling and plenum ideas on VAF.

 
Aug 28, 2022     RV-7A flight!!! and lots of research - (6.6 hours)       Category: Research
Amazing day! Had a great flight in Luis's beautiful RV-7A to experience flight with a Catto propeller. Also got a chance to ask a lot of other questions and look at how he did things. It has has been too long since I've been flying. And then I went across the runway and talked to John about failure modes and how his Bonanza works with the new Garmin avionics upgrades. Some of the topics I covered this morning were trim control and failures, flap control and failures, Foreflight/Garmin interaction, single vs dual COM and CAN bus failures and antenna locations and installation. I spent 4 hours at Breakaway Park and am counting 1 hour of actual research.

Continued research at home and started email with questions for Garmin support. Read and searched through VAF forums and Garmin documentation as I created my questions and tried to answer as many as I could (or at least ask better questions). Spent time reviewing the details of post installation configuration for the Garmin LRUs to learn more about the settings and options available.

Also searched for information on PermaGrit files, Otto Switches (used in Luis's RV), antenna mounts and more.


 
Aug 27, 2022     More Research - (6.8 hours) Category: Research
Ended the week with 21.3 hours so met my requirement, barely. Worked every day, but not much on one day. The commitment is working and helped me to put in a longer day today to meet the weekly goal.

Arranged to meet Luis at Breakaway Sunday AM to look at his RV-7A and to hopefully fly. After Luis and I are done I will probably go look at John's Bonanza with the Garmin avionics upgrades. I created a list of topics and questions to discuss with Luis and John and hope I learn a lot. I'm sure I will enjoy the day!

I spent a lot of time on the Garmin documents trying to understand more about CAN bus wiring, autopilot and trim, G3X and GTR 200B and GMA 245 audio inputs and outputs, antenna locations and constraints, GSU 25 and GMU 11 mounting locations. I also spent time trying to understand how the GAD 27 works and what kind of problems I would have when it fails. That all gave me more information and questions I hope to discuss tomorrow.

I also reviewed FlyLed documentation to understand how it works with the GAD 27 and think about backups. My next step in FlyLeds assembly is to trim the boards to fit in the wingtip. I used some scrap PCB and tried filing and using a band saw to cut it. I think I will rough cut to size with the band saw and then file.

Studied a panel layout someone posted on VAF. Looks interesting. He is going to post more later and provide details.
 
Aug 26, 2022     CO Detectors and Garmin - (3.2 hours) Category: Research
Researched CO detector options and connections to the G3X Touch. Found three that interface the same way and added them to the Avionics BOM. Can decide which one later.

Decided I should come up with a list of questions for Garmin before completing my initial draft of the Failure Modes Document. I need to understand the equipment better before identifying all the potential failure modes.

Read Garmin docs and VAF to understand the autopilot and trim connections and function. That lead to me reading Garmin docs and VAF posts to understand CAN routing and recommended wire type. Started thinking about the order of items on the CAN bus and the location of some items.

Looked at mounting location of GAP 26 pitot and angle of attack mounting location and routing of tubes to the panel and added alternate static port to the list of things to consider in the future.

Rethinking the plan to use a single COM with a handheld backup radio. Calculated a cost difference between single GTR 200B and the cost of two GTR 200 and a GMA 245 audio panel to be $2545. Hmmm. Looked for options on VAF to eliminate the audio panel and didn't find one I liked.

If the weather cooperates I will meet up with Luis and get a flight in his RV-7A and get the chance to ask lots of questions. He is using a Catto three bladed prop. Created a list of topics to cover when I meet with him.
 
Aug 25, 2022     Propellers - (2.1 hours) Category: Research
Reviewed Catto and Whirl Wind quotes and researched Whirl Wind more on VAF and Kitplanes. Decision time...

Searched for the wing tip lenses I haven't seen in 10 to 15 years and found them. Looked up information on Van's and VAF to get ideas on how to cut and install them.
 
Aug 24, 2022     G5 Pilot manual - (.4 hour) Category: Research
Read portions of the G5 Pilot manual trying to understand dependencies on other G3X Touch components and the autopilot functions.
 
Aug 23, 2022     Ordered an Engine! - (2.8 hours) Category: Research
Talked to Van's builders support one last time and then placed an order for a Lycoming IO-360 M1B 180 hp horizontal induction engine with dual e-mags.

Discussed the FWF kit with Van's support and copied the part numbers for the bill of material into a spreadsheet so I can start looking things up and decide what changes to make. I'm starting with the FWF kit for the IO-360 M1B with constant speed prop. Of course I need to eliminate the CS prop parts since I am going with FP. And I probably want to make other changes such as a firewall mounted oil cooler.

Continued reading the G3X touch pilot manual.
 
Aug 22, 2022     Props and Ignition - (4.2 hours) Category: Research
Continued research of props and ignition on VAF and other websites. Talked to Nicole at Catto twice to learn more and then requested a quote. Researched whirlwind and requested a quote.

Had a very helpful phone call with an RV-7A builder at breakaway about Catto and electronic ignitions.

Was holding off on ordering an engine until I made a decision on the prop. Van's has a $1000 discount if you order a Lycoming engine and a Sensenich or Hartzell or MT Prop from them on the same day.
 
Aug 21, 2022     More Prop and Avionics - (1.8 hours) Category: Research
Still researching Catto props in VAF forums.

Started reading the G3X pilot guide to understand operation and fault handling.

Saw VAF posting for PC-680 battery box and purchased it.
 
Aug 20, 2022     Ignition, Props, Avionics and power distribution - (4.5 hours) Category: Research
25.1 hours last week or 3.6 per day. Made some real progress understanding the tradeoffs for different engines, ignition and props. Plan to place an engine/prop order early next week.

Continued work on Avionics costs and options. Started a failure mode document listing parts, failures, and backup plans. Realize I need to dig in more to understand how the Garmin components work together and what happens during various failures.

Reviewed feedback from a friend on Catto props and e-mag ignition and sent some questions.

Researched electronic ignition more. Leaning towards using dual e-mags for faster starts, some fuel efficiency in cruise and potentially lower maintenance cost.

Researched props more. Still waiting on response from Catto. Leaning away from Catto due to more maintenance for prop bolt torque and lighter weight will affect CG more and limit baggage weight. Leaning towards Sensenich FP prop since it has a low cost, low maintenance and weight is between Hartzell CS and Catto FP so CG might be okay. Found one used, but may pay for new one through Van's with discount for engine/prop order. Would like to go with Hartzell CS but initial cost is much greater and maintenance costs increase. It is always possible to upgrade to Hartzell later.
 
Aug 20, 2022     Props and Ignition - (.8 hour) Category: Research
Researched e-mag and props more. Sent an email to another builder I know asking about his experience with both.

Subscribed to Aviation Consumer and read several articles on electronic ignition, but didn't log that time. Also spent time on VAF, but didn't log time.
 
Aug 18, 2022     Magnetos and Props - (7.1 hours)       Category: Research
Started researching e-mags more carefully by reading the install and operations manual, reviewing service letters and bulletins and searching through VAF. John H talked to other builders and provided a summary and links to CAFE Foundation reports on dual mags vs dual EIS vs mag/EIS. I read the CAFE report.

John also said one of his friends had used a Catto prop so I researched Catto and researched FP vs CS on VAF. Emailed Catto with questions. PM'd several people on VAF with questions. Had a great phone discussion with someone that flys an RV-14 with a constant speed prop that flies with a friend with the same airframe and engine and FP prop. Had a great phone discussion with a RV-7 owner that recently changed from a Catto to a Hartzell due to W&B issues and to help with formation flying.

Picked up prints of 29 potential paint options created by scheme designers back in 2011 so I can compare them easily and decide what to try next. Also picked up a large format print that was supposed to match the panel. It was about an inch off, but will work for now.

The attached picture shows the two wingtips with the bare position and strobe boards in place. I have to trim them to fit and then assemble. The print of the panel is not quite to scale, but close enough for me to use to see how it works when I sit in the airplane.


 
Aug 17, 2022     Engines, Avionics, Lights - (3.5 hours)       Category: Fuselage
Discussed engine options and lead times with sales manager at Lycoming.

Discussed engine suppliers, ignition systems, fuel injection systems, fixed pitch vs constant speed props, need or lack of need for VHF Nav, GTN650Xi vs GNX375 for IFR GPS Navigator, Foreflight, Jepp and government charts and other aviation and backup topics with John H. Have a lot of ideas to research and think about.

Decided I should probably purchase engine from Lycoming and use AFP fuel injection. Now considering using standard magnetos instead of E-Mags to save $2,500. Still thinking about a constant speed prop, but maybe I just need the fixed pitch prop to reduce initial cost, weight and future maintenance.

Decided I will probably use VHF Nav handheld with external for NAV backup, skip the GTN650Xi GPS/NAV/COM and use the GNX375 for IFR GPS Navigation. Need to rework the Garmin Avionics list and make final decisions. Started updating Garmin Avionics spreadsheet and considering options.

Removed wingtips and brought them home to fit the FlyLEDs lighting. Checked fit of FlyLEDs landing lights in Duckworth mounting bracket. (see pictures)

Took panel and paint scheme files to FedEx Kinkos for printing.


 
Aug 16, 2022     Which Engine? - (1.8 hours) Category: Engine
Followed up with Barrett asking for quote. Discussed lead time for Lycoming engines with Van's kit sales. Called and left voicemail and followed up with an email to Lycoming asking about lead-times and engine options we had discussed at Oshkosh. Organized thoughts and concerns about my options in an email and sent to a friend and asked for advice.
 
Aug 15, 2022     Avionics and Engine - (3.7 hours) Category: Fuselage
Traded emails with Aerosport power. Tried calling Van's about Lycoming Engine.

Reviewed Sarasota, Aircraft Spruce and Stein quotes and information and updated my Garmin spreadsheet so I could compare options.
 
Aug 14, 2022     Engine, Wiring, Antennas, Vendors - (3.7 hours) Category: Fuselage
Reviewed Aerosport Power engine quote and sent questions. Provided more information to Barrett Precision and still waiting on quote. Looked at current Lycoming prices at Van's. I need to order an engine soon if lead-time is a year.

Reviewed TCW wiring documentation and Garmin recommendations for using TCW with their system and thought about backup plans.

Reviewed Antenna and GMU-11 mounting considerations.

Completed review of Stein quote and suggestions and sent a list of questions to Stein. Requested a quote from another supplier. Sent an email to Aircraft Spruce to verify they received my spreadsheet since I haven't heard from them in about a week.
 
Aug 13, 2022     Avionics List and Power Distribution - (2.5 hours)       Category: Instrument Panel
Logged 12.9 hours and met the weekly requirement of working more than 12 hours for the week ending 8/13. I was in town Sunday, Monday, Tuesday and Wednesday so the requirement was 12 hours. I left town Thursday AM and returned Saturday around 4PM.

This evening I:
Reviewed the Stein avionics quote and compared prices to Garmin list. Reviewed proposed changes. Started work on response with list of questions and changes.

Reviewed Carl's power distribution power points, word docs, and email to understand it more fully. Reviewed PC-680, PC-625 and TCW capacity and size. Thought about power distribution strategy.

Unpacked grips for control sticks that I had ordered at Oshkosh and received today. See photo. Both have a hat switch for pitch and roll trim, a Push-to-talk switch and one other button. And the pilot grip has two other switches.


 
Aug 10, 2022     Position and Strobe Controller - (2.5 hours)       Category: Lighting
Completed assembly and testing of the FlyLEDs controller board. The picture shows one LED illuminated. What was actually happening was the three different LEDs were blinking in different patterns depending on the settings on the red switch. Very cool!

Discussed how to scale the panel printout with Marwan from FedEx Kinkos and also searched for options to scale PNG, JPG or PDF files.


 
Aug 09, 2022     Panel, Paint and Electrical system - (1.5 hours) Category: Instrument Panel
Received information about how to print the panel full size. Discussed printing with FedEx Kinko's and sent instructions and request for price and lead time.

Received email from Scheme Design about restarting the paint design. Started back in 2011 and I discussed completing the design when I was at Oshkosh this year. Reviewed all but the last two designs which had a broken link.

Requested and reviewed email and documentation about an electrical system design by Carl Froehlich.. There are some interesting ideas and I need to study it more and consider using some or all of it.
 
Aug 08, 2022     Instrument Panel, Avionics, External lights - (3.2 hours)       Category: Instrument Panel
Glanced at Stein Quote for Garmin avionics. Sent spreadsheet with Garmin parts list to Aircraft Spruce after they responded to my Sunday contact request.

Clecoed the panel structure to the fuselage to look for best fit for "center" radio stack. Decided to shift it to the right of center (about 4 inch shift total). Boy that original panel layout looks outdated now. Compare it to the panel layout from a few days ago.

Updated and printed PDFs of the panel, but found out the scaling was wrong when I took it to Kinko's to get a full size printout. Sent request for help to panel planner. Sent picture of panel to Stryker.

Unpacked FlyLEDs strobe, position and landing light kits and started assembly of control board.


 
Aug 07, 2022     Avionics and Electrical - (3.2 hours) Category: Instrument Panel
Today was the start of week 1 of Project Restart Phase 2. This phase will last through 12/31/2022.

I cleaned up a copy of my Garmin avionics list to remove prices and notes and all the different configuration options except for the two I am considering. I sent the list and some questions to two suppliers for quotes.

Added max and typical currents to each of the items on my list. Added strobe, position and landing lights and current to the list. Added up the maximum and typical or minimum value for both configurations to estimate what alternator size I needed. Max current was 63 and 65 Amps. Minimum or typical was around 32. So I think I had better get the 60 Amp alternator and figure out how I am going to handle an alternator failure. The next step will be to create a list of essential loads.
 
Aug 06, 2022     Avionics and Panel - (5.6 hours)       Category: Instrument Panel
Updated Garmin Avionics spreadsheet with three final configurations and two of them are real possibilities. Reviewed documentation and identified which parts needed to be on the panel and which could be remote mounted. Continued working with Panel Planner and dropped key components on two different panels to see how the two different configurations fit and look. Read the Panel Planner documentation and sent questions to the support email address. The third configuration was just a dream and I can't really afford or justify the extra $5,800 so I didn't even create a panel mock up for it.

Started researching lighted switches and found some built already included in Panel Planner and dropped them in as place holders. Need to find something better.


 
Aug 05, 2022     Started Instrument panel design - (.5 hour) Category: Instrument Panel
Installed panel planner and started using it. Also reviewed and organized all the cards, brochures and notes I picked up at Osh.

Documented my plan for phase 2 and sent it to the grandkids.
 
Aug 03, 2022     Oshkosh 2022       Category: Milestones
I just returned from Oshkosh 2022. Started my journey by train to Denton on 7/21, then drove to Fond du Lac with a good friend with stops in Kansas City, MO (Blue Room at the American Jazz Museum!) and Plattville, WI. Had a great time talking to vendors, buying parts and tools, looking at airplanes and watching the airshow. The Saturday night airshow was amazing. Then drove back to Denton with stops in Madison, WI and Kansas City. The final leg on 8/3 to Austin was by Greyhound bus since the train was full by the time I decided to buy tickets.

I confirmed my decision to go all Garmin on the avionics was a good one for me after getting some hands on time in the Garmin booth and talking to Stein. I also am rethinking my decision on which IFR navigator to use.

I made decisions on what accessories to use on the engine and then complicated my engine decisions by considering Aerosport Power and Barrett Precision as potential suppliers along with my original choice of Lycoming.

I purchased FlyLEDs strobe, position and landing light DIY kits.

I purchased a panel planner software license for my panel design.

I learned a lot about engines from attending 3 of the 13 different sessions presented by Mike Busch. Then I bought his "Engines" book and have started reading it. I also bought an inspection camera and later learned that Mike recommends using one anytime a spark plug is removed from the engine.

I bought an Aerocreeper that should come in handy during the build.


 
Jul 22, 2022     End of Phase 1, Day 2 of travel to Oshkosh Category: Research
Missed working and researching today. This is the first day I missed since I started on 4/15. And it is the last day of my commitment for phase 1. I was on the road from Denton to Kansas City most of the day. I am traveling to Oshkosh as my reward and to do research, make final decisions and buy parts.

Phase 1 thoughts:
It really was a good idea to include working every day in the commitment. It helped me build the habit of working on and thinking about the airplane daily. Some days I really didn't want to work. In many of the cases I was not sure how to solve a problem. If I had skipped a day, it would have been even easier to skip the next day. Also every time I went into the garage I knew what I had done the day before and usually knew what was next.

I spent a lot more time thinking about the RV that what I logged. I'd mull over problems or research them on VAF or search for tools. I also read VAF forums daily and read threads that were interesting even if they didn't apply to me right now. I also spent time planning the trip to Oshkosh. One thing I have to watch is not to let my planning and research go on so long that it turns into a way to procrastinate. Some research and planning is good, but it is best to try things and make progress even if I make some mistakes, because I will make mistakes anyway.

I worked through some of my biggest areas of concern (landing gear mounts, Rudder bar/brake pedal mounts, fuel pump selection and mount and lines, brake lines, and finishing the fuel tank service bulletins) but didn't finish most of it. I thought I would have made more progress by now. I really need to spend more hours in the garage (or assembling avionics) in phase 2 if I ever want to finish this airplane. I'm mulling over the next commitment. Continue to work every day or give myself some time off? Commit to at least x hours per week while in town? Other?
 
Jul 21, 2022     Travel and Research - (.5 hour) Category: Research
Started journey to Oshkosh this morning. Added vendor booth locations to the list of vendor questions to help me find them. Reviewed presentations and added a few to the list that I want to see.
 
Jul 20, 2022     Avionics, wiring and Oshkosh prep. - (0.5 hour) Category: Research
Found spreadsheet with avionics wiring, reviewed it to remember where I was and sent a copy to take to Oshkosh. Found and printed copies of the Garmin parts list to take to Oshkosh. Opened KiCAD and practiced placing parts and making connections on a schematic. Rewatched part of a tutorial on KiCAD.

Also spent additional time gathering and packing clothes and parts for the trip.
 
Jul 19, 2022     Fuel System - (.4 hour) Category: Fuselage
Started making tube sample from fuel valve to right wing. Made flare and initial bend, but couldn't decide on the best way to run it to allow room for the pump to firewall tube. Decided to make the fuel valve to filter tube so I can see how much space I have to run the fuel valve to right wing and fuel pump to firewall tubes.

Also spent time on VAF reading and responding to posts for the Dynon parts I've decided not to use. Also spent some time planning the trip to Oshkosh! I will be packing tomorrow and leaving Thursday AM.
 
Jul 18, 2022     Fuel System - (.7 hour)       Category: Fuselage
The obvious answer, after fiddling with it for a while, was to avoid a bunch of 90 degree bends and make smaller bends. The bend close to the fitting is still important, but maybe 60 degrees is good enough for the first bend. I'm making some templates with 12 awg solid wire and then starting to make a sample, modifying the template, continuing on the sample and so on. Picture 9117 was the original plan and picture 9118 is the direction I am headed now.

In addition to the time actually working on the RV or tooling, I continue to review VAF postings. Today someone wanted to buy some Dynon parts I just happen to have. So I took pictures, created a list and replied to the posting. I plan to take the parts to Oshkosh with me and hope to sell some of them to help me buy other parts and tools.


 
Jul 17, 2022     Fuel System - (.8 hour) Category: Fuselage
Cleaned up the shop after making all the tool modifications and some sample bends. Started working on parts using the modified bender. I was able to adjust the position of the pump and filter and have plenty of space for the tubes from the firewall to pump and pump to filter. I started running into problems when planning the runs from the fuel selector to the wings. The new bender allows me to miss hitting the fuel pump fitting, but then I need to make more bends and the bend to bend spacing is causing a problem. Tried some sample bends on a piece of spare tubing to see how close I could make the bends. I'm still working on options. I ordered another OTC bender so I have one unmodified bender for normal tube bends.
 
Jul 16, 2022     Fuel System - (1.2 hours)       Category: Fuselage
Finished modifications on the tube bender and made a sample bend really close to the fitting. Picture 9107 shows the before and after bends. Now I am ready to start making parts.


 
Jul 15, 2022     Fuel System - (1 hour)       Category: Fuselage
Started work on the changes to the tool that hold the sleeve and tube in place during bending. Finished fabrication and mounting of a spacer. Ready to start on the part that holds the sleeve in place.


 
Jul 14, 2022     Fuel System - (.8 hour)       Category: Fuselage
Decided to adjust the pocket for the sleeve to change the angle and continued machining the pocket with a straight burr, drill press and drill press vise. Picture 9083 shows the before with the sleeve at an angle to the top of the tool. The other pictures show the fit after additional machining.


 
Jul 13, 2022     Fuel System - (1 hour)       Category: Fuselage
Worked more on bender modifications. Getting closer. The tube and sleeve will nest in place now, but the angle isn't quite right yet. Also determined I can make the hold down clamp out of three pieces of 1/4" sheet aluminum similar to the last hold down.


 
Jul 12, 2022     Fuel System - (1.2 hours)       Category: Fuselage
Received the new bender and it looks great. It was making a small dent in the tube (the same way the initial pittsburg bender did) and I fixed that with a file. Then I started modifications to the tool similar to the pittsburg, but am making the pocket for the flare and sleeve closer to the 0 degree mark on the tool so the distance from the sealing surface to the outside of the bend will be smaller. I attached some pictures.


 
Jul 11, 2022     Fuel System - (0.4 hour)       Category: Fuselage
Made a test bend with the new pittsburg bender just to see how it worked before modifications. The new tool flattens the bend and I am going to return it. The box still says 1/4", 5/16 and 3/8". The tool has a molded in description of 6, 8, 10 mm. I measured both the old and new tools to confirm and sure enough the old one is 0.375" and the new one is 0.394 (10mm). This allows the 0.375" tubing to spread sideways and flatten instead of maintaining a round cross section. The tube in the picture with "new" written on it is the one that is flattened.

Researched other options and ordered an OTC 6515 bender that Amazon should deliver tomorrow.

I also spent time researching panel layout and preparing for Airventure, but didn't include any of the time in this entry. I hid a bunch of columns in the Garmin configuration and pricing worksheet and printed it so I will have it for Garmin and Stein to review and comment on configuration options. I also found and printed two good drawings to use as the basis for showing component locations.


 
Jul 10, 2022     Fuel System - (1 hour)       Category: Fuselage
Completed screw on clamp modification on the pittsburg bending tool. Now I can make bends where the edge of the tubing extends about 2 1/8 inches from the sealing surface. This might be good enough. I plan to buy another bender and modify it to make a tighter bend. The pictures show the modified bender and a before (using a standard bender with the proper method) and after (using the modified bender).

This weekend I also spent time reviewing forum and presentation schedules at Airventure to decide which ones I would like to attend. As always, I managed to triple book my time and will have to make some hard choices. Also I reviewed all my trello lists of vendor questions, things to buy and things to take and organized them into three clean lists for easy access at Airventure. I didn't include any of the time in the entry yesterday or today.


 
Jul 09, 2022     Fuel System - (1.2 hours) Category: Fuselage
Showed Ellicia progress I had made and issues I was having. I hoped she would have some good ideas or ask questions that would help me think of something new. No magic solution popped up. I just need to try different things and I need to be able to make consistent bends close to fittings. Started making improvements on the hold down on the pittsburg bender. I have an improved bracket and need a good way to secure it to the bender.
 
Jul 08, 2022     Fuel System - (1.3 hours)       Category: Fuselage
Cleaned up the mess I have made in the shop over the last few days. Started bending some small pieces (just a portion of the full run) to show how everything will fit together in the small space around the valves and pump. I already see some changes are needed to make it work. The one tube on the left coming down from the valve is going to interfere with the fuel pump outlet.

I also think I will need more tight bends than expected so I need to improve my modified bending tool to make it easier to use.


 
Jul 07, 2022     Fuel System - (2.3 hours)       Category: Fuselage
Took sample bends by River City Hydraulics and found out they didn't have any tools for me or provide the service of bending that type of tubing.

I was previously able to make a bend that was small enough by misusing the steel parker 3/8 bender, but it damaged the sleeve of the fitting. Also the Pittsburg tools bender would make a small dent in the tubing even when it was used correctly.

I started modifying the Pittsburg tools bender to eliminate the cause of the dent and to make a pocket where the sleeve could nest during the bend process and hopefully not get damaged. I started with a file, moved to a dremel tool with a small sanding drum and then changed to using a cutting tool on the drill press. I placed the Pittsburg tools bender in a vise and then moved the vise around to cut pockets in the bender. It worked fairly well to let me mill a pocket.

Then I needed something to secure the sleeve and end of tube during bending. I drilled a hole the size of the sleeve in a piece of aluminum and then sawed it in half. I used a small clamp to hold the block in place and it worked reasonably well. There are only two really tight bends so the extra setup effort for the tight bends shouldn't be a problem. I should be able to use the parker bender in the normal way for all the other bends.

UPS says my 50 foot of tubing will be here tomorrow so I'll have enough to give me lots of tries to make parts that fit.


 
Jul 06, 2022     Fuel System - (.8 hour)       Category: Fuselage
Cut off one of the bends I made yesterday and connected to each end of the fuel pump. It is going to be a really tight fit under the cover. I need a smaller bend radius. I tried a few other bends with the new spring bender and some of the tools from yesterday in a different way and the results were bad. I'm going to a hydraulics shop tomorrow and see if they can make some bends for me.

Also took a picture of one part I made that looks like with a small amount of work that it could connect to the fuel selector valve (three red caps on the fittings), and run out to the wing root. My roll of practice tubing is now scheduled to arrive Friday!


 
Jul 05, 2022     Fuel system - (1.2 hours) Category: Fuselage
Made additional test bends and was able to make a smaller sample. Managed to get one tube run from the valve area to the left wing root in a test. Now I think I can make most if not all the parts needed. Ordered additional tubing and some other parts from Aircraft Spruce. Tried some additional bends with a new tool purchased this evening. The spring type bender I purchased last week should arrive tomorrow and maybe that will help. The new tubing will arrive Monday.
 
Jul 04, 2022     Fuel System - (1 hour) Category: Fuselage
Made several test flares and bends with 3/8" tubing to see if I could make the tube connections in the tight space allowed. Not sure I can do this. Made more measurements to see if I could move the pump and filter slightly and make it fit.
 
Jul 03, 2022     Fuel System and Brake Lines - (2.3 hours)       Category: Fuselage
Cut rubber seal parts to length and removed the flange. Installed fuel pump and filter on the mounting plate. Started working with the 3/8" fuel line tubing and found it was much more difficult to bend than the 1/4" brake line. Tried to figure out the best way to approach bending the fuel and brake lines. Got stuck and searched VAF for clues for about 45 minutes. Found some ideas, ordered some spring type benders to help with "in place" bending as I snake the fuel line through the landing gear weldments.

Test fit the pump/filter mounting plate and some covers in the fuselage. Used #12 solid copper wire to make a template for the fuel and brake lines where they fit near the spar carry through.


 
Jul 02, 2022     Fuel System - (1.3 hours)       Category: Fuselage
Cleaned up and loosely installed two brackets on the front of the center spar that support fuel and brake lines and wiring (they are the ones nested in the landing gear mounts). Riveted three nut plates on the Andair fuel valve. Cut the triangular portion of the fuel valve plate off so I could mount it upside down. Installed the two nut plates on the fuel valve plate and installed the plate and the valve in the fuselage.


 
Jul 01, 2022     Fuel System - (2.1 hours)       Category: Fuselage
Called Van's Support and got some questions answered.
- Fuel/brake lines - push through support brackets, bend and then flare? Yes, mostly. Might be able to make some bends away from fuselage, but all final bends and flaring will be with the tubing in the fuselage.
- Location of holes in firewall for brake reservoir and fuel bulkhead fitting. Drill now or wait for engine? Drawings probably good. May want to check on VAF. I currently have the drawings that came with the kit (probably the best match for the parts I received) and the 2017 USB key I purchased. I found out I can also download all the latest drawings. I'll use the drawings that came with my kit and cross check against the latest drawings to see if there were corrections or changes that might be helpful.
- Type and material fitting for firewall fuel line? Found my current drawing calls for aluminum. Will check the latest to see if it is still aluminum.
- VA-107 brake reservoir and fitting doesn't work? Fitting too large? Didn't ask. Measured more and seems the fitting is oversized. I'm ordering the new fitting so I'll just try it and see if I still have a problem.

Found a support bracket I've been trying to find for days!

Test fit the fuel pump housing, valve mounting plate and valve cover on the bench. Studied Andair drawings, marked and drilled the 1" center hole and three #8 clearance holes in a valve mounting plate. Need to decide if the mounting plate with the bend is better than the flat one and then finish whichever one I select.


 
Jun 30, 2022     Snap Bushings, Fuel Valve Installation - (.9 hour) Category: Fuselage
Installed the eight 625-8 snap bushings for wiring through the holes in the center spar. Hopefully that will be enough room for all the wires going between the front and the back of the airplane.

Looked at plans and marked up with changes (-8 instead of -7 snap bushings, extra washers on landing gear bolts since I used slightly longer bolts to replace the ones that were too short, F-6116 cut in half and use of AN960-10L washers as spacers).

Test fit the fuel valve mounting plate and the fuel valve enclosure to see how the extra cover I made works in filling the gap between the two. Looked at the Van's valve and the Andair valve mounting. There are a lot of covers in the area and the assembly order matters. Also looked at brackets on front of the center spar to see how the brake and fuel lines run. I think I have to run tubing then bend and flare it and will not be able to remove the tubing without cutting it.

Will call Van's builder support tomorrow with the following questions:
- Fuel/brake lines - push through support brackets, bend and then flare?
- Location of holes in firewall for brake reservoir and fuel bulkhead fitting. Drill now or wait for engine?
- Type and material fitting for firewall fuel line?
- VA-107 brake reservoir and fitting doesn't work? Fitting too large?
 
Jun 29, 2022     Rudder Bar and Brake Pedals - (1.1 hours)       Category: Fuselage
Tried using a fence on my bandsaw to cut a precise straight line on a piece of wood. Made and an adjustment and tried again. Did some research and decided just to do it freehand. Tested on wood okay. Measured and marked the F-6116 blocks and cut. It worked!

Installed the bottom half of the F-6116 blocks in the fuselage and it was easy to install the two rudder bars. Added the top half of the F-6116s and the middle support. It all looks and fits good.

I installed bolts and nuts loosely on the brake master cylinders. Ready to move forward.


 
Jun 28, 2022     Rudder Bars, Brake Pedals - (1.7 hours)       Category: Fuselage
Set up the rudder bars and brake pedals horizontally on the worktable. Used the F-6116 blocks to align and support the rudder bars. Shimmed rudder bar and brake pedals to the proper relative height. Reviewed and discussed Drawing 37 with Ellicia. It helps to talk through some things. Changed the relative position per our discussion. Marked the location for the master cylinder mounting hole on each brake pedal. Removed, drilled and reassembled each brake pedal one at a time.

Now it is time to cut the F-6116 blocks in half to make installation and removal of the rudder bars easier and to allow me to add a shim so the bars have less side to side play. The side to side play is required if the blocks aren't split. Measured a F-6116, decided where to cut and set up the band saw for a test cut. Tried a sample cut on wood and it didn't go well. Need to readjust and try again.

Also spent another hour and a half cleaning up the garage and putting away tools. I need to get better about cleaning up while I work.


 
Jun 27, 2022     Landing Gear mounts - (.9 hour) Category: Fuselage
Completed loosely installing all (except the 8 main wing spar) bolts on left gear mount. Completed the same on the right landing gear. The two bolts I used for alignment on each side are tight, but none of the bolts will be torqued to the final values until after I complete other work and make sure I don't need to remove them again.
Spent about 90 minutes cleaning up the hangar this morning and picked up a few short wing piper tools and parts to give away.
 
Jun 26, 2022     Rudder Bars, Brake Pedals, Landing Gear Mounts - (1. hour)       Category: Fuselage
Sat in temporary seat, made measurements and estimated proper position and angle for rudder bar and brake pedals. Asked people on VAF for rudder bar travel.
Started reinstallation of landing gear weldments.
Used my new Handee Clamp tool to start nuts in hard to reach places. Used the Crescent double jointed long needle nose pliers to place washers in hard to reach places.


 
Jun 25, 2022     Fuel Vent Lines Complete! - (2.7 hours)       Category: Fuselage
I finished the left vent line tonight. I was concerned that it wouldn't go well and would take several tries. The first try worked! I started with about 5 ft of aluminum tubing and started at the fuselage side this time. That was the more complex end with less room for adjustment. That allowed me to complete the final three bends and flare and adjust it to fit easily.


 
Jun 24, 2022     More Fun with Fuel Vent Lines - (1.6 hours)       Category: Fuselage
Received and installed the final brake pedal bolt. It went quickly since I had figured out exactly what I wanted on the other three.

Used a new tool to install the Adel clamps. That allowed me to finish forming and flaring the right vent line. See pictures below. I'm happy with the way the first one turned out.

I wish I had bought that tool a long time ago! It was a SMA Tools Cushioned Clamp Installation Pliers,


 
Jun 23, 2022     Rudder Pedals - (.5 hour) Category: Fuselage
Received and installed one more of the bolts that attach the brake pedal to the rudder bar. Reinstalled a second one with a different washer stack. Cut a test board on the band saw to verify the kerf would work when I use it to cut the two F-6116s in half.
 
Jun 22, 2022     Fun with Fuel Vent Line - (1 hour)       Category: Fuselage
Continued work on the fuel vent line in the cabin. Made one bend in the wrong direction so moved the part over to the right side of the fuselage where it would work. Continued making bends. The bending tool works great on bends greater than 45, especially 90 degree and more. I find it is easier to make smaller bends by hand. The copper wire pattern helped on a few bends, but I found it easier to test fit the part whenever possible. I need to finish the bends on the right side of the picture, use the Adel clamps to hold everything and make final adjustments and cut to length and flare the tubing for the fitting on the right.

I may get good at this if I keep working at it. At least I am enjoying it for now. I think I am going to use aluminum tubing per the plans instead of buying preformed tubing and a lot of fabricated hoses.


 
Jun 21, 2022     Tubing, Rudder Bars and Brake Pedals - (1 hour) Category: Research
Read up more on the how to measure and fabricate tubing.
Researched rudder and brake pedal angles more on VAF.
Thought about assembly order of all the different parts going in the area under the panel.
Called Van's support and:
- found it was okay to split the F-6116 rudder bar mounting blocks for better access.
- no change in the F-69-F-04 fitting at the bottom of the tube from the brake fluid reservoir
- discussed access to the 6 rivets at the top of the F-902L and R bulkheads and potential option to use pulled rivets.
Posted and sold Adair Gascolator parts on VAF today! Will ship tomorrow assuming I receive the payment.
 
Jun 21, 2022     Fuel vent line and... - (.7 hour)       Category: Fuselage
Used black 12AWG solid copper wire purchased yesterday to make a pattern for the fuel vent line. Added a sleeve and nut and flared the end of the tubing that I had started bending yesterday. It's been a long time since I used the flaring tool.
The thin black line in the picture is the copper wire. Now I just need to make the bends in the aluminum so the aluminum tubing fits the same way.


 
Jun 20, 2022     Tubing Bending - (1.5 hours)       Category: Fuselage
Started work on brake and fuel vent lines. Found and test fit fuel vent line fittings. Found tubing cutter, tubing and bending tools. Studied drawings. Started test bends on 1/4" diameter, 0.032 wall thickness aluminum tubing.
Additional time not included in reported hours:
Discussed questions about cabin fuel and brake line kits with Tom at Aircraft Specialty Flightlines. Decided to try fabricating some of the tubing myself before purchasing manufactured assemblies. I still plan to buy some fabricated hoses, but not full kits. Found and started study of "Principles of Tube Line Fabrication" from Parker Hannifin Corporation.


 
Jun 19, 2022     Rudder Bars, Brake & Fuel lines and other things - (1.5 hours) Category: Research
Spent a lot of time on VAF today.
Researched for any history on cutting F-6116 rudder bar mounting blocks. Couldn't find much and plan to call Van's support on Monday.
Researched brake line fittings and tubings on Van's store, Aircraft Spruce and VAF. Sent email to Bonaco and have questions for Van's and Aircraft Specialty Flightlines.
Looked at fuel pump related parts and drawings. Will discuss my questions with Aircraft Specialty Flightlines when I call tomorrow.
Spent a lot more time than 1.5 hours, but my search on VAF drifted some...
 
Jun 18, 2022     Rudder Bar and Pedals - (1.9 hours)       Category: Fuselage
Tried working with the rudder bar installed in the fuselage and it wasn't going well. Removed rudder bars and F-6116 mounting blocks and moved to a shop bench. Enlarged holes as needed and installed the brake pedals and master cylinders using existing bolt holes. Started looking at how to align parts and mark/drill the final mounting holes to attach the bottom of the master cylinders. Thinking about the impact of cutting the F-6116 blocks in half for easier installation and future access. Searched for history in VAF.


 
Jun 17, 2022     Landing Gear and Rudder Pedals. - (1.1 hours) Category: Fuselage
Confirmed Landing gear weldment to spar bolts were not long enough to extend through the locknuts and that the next longer bolts will work (AN4-12A will be replaced with AN4-13A).
Started looking at rudder bar and pedals. Considering cutting the two outside rudder bar blocks in half similar to the center rudder bar block. It appears the AN3-56 bolts for rudder pedals will work although the holes are too small and/or don't line up enough for the long single bolt. Working on rudder pedals now. an.
 
Jun 16, 2022     More Main Gear Weldments - (.9 hour)       Category: Fuselage
Finished cleanup, located weldment, looked at drawings to verify I was using the new hardware I bought in the right places. Inserted all the weldment to spar bolts, washers and tightened the locking nuts finger tight. It looks like most of the bolts are too short to extend through the lock nuts. Will try a few and measure more carefully tomorrow. I may need to order longer bolts.

I got to use two tools I bought long ago and never needed until now. They both allow you to reach into narrow deep slots. One grips a washer the other grips a bolt or a nut. The one for the washer needed to be another 5 or 6 inches longer to really work for some of these washers.

I also got a chance to use my Crescent brand long reach X2 needle nose pliers. They were easier to use than the tool that grips a nut. I'm going to try them on the washers tomorrow.


 
Jun 15, 2022     Wiring Spreadsheet - (0.5 hour) Category: Avionics
Added remaining Garmin avionics and control boxes to the wiring spreadsheet.
 
Jun 15, 2022     Landing Gear Weldments - (1.5 hours)       Category: Fuselage
Checked clearance for wire bushing on right weldment and filed some more until it fit. Carefully checked clearance and fit of all mounting holes one last time before final paint. Cleaned, masked and painted areas on the weldment and fuselage that had exposed metal.


 
Jun 14, 2022     Landing Gear Weldments, Electrical Design and Documentation - (1.7 hours) Category: Fuselage
Marked and filed on wire bushing hole in both landing gear weldments to allow them to work with the holes through the center section. Completed left side and need another fit test and possibly more filing on the right side. Cleaned up scratches on the center section flanges where the landing gear weldments had hit during fit testing.

Spent about 1/2 hour on improving the spreadsheet formulas and automatic formatting to make it easier to use.
 
Jun 13, 2022     KiCAD - (2 hours) Category: Research
Installed KiCAD on macBook Pro and started to read documentation. Searched for and found a great series of youtube training videos. This looks like it will work great for any electrical drawings I might want to complete.
Software and Documentation: https://www.kicad.org
Youtube Tutorial Series: https://www.youtube.com/watch?v=9hcQQQxoRl0&list=PL3by7evD3F51fKkyrUbH-PCdwPCWc9F8a

 
Jun 13, 2022     Landing Gear Weldments, Electrical Design and Documentation - (2.5 hours) Category: Fuselage
Cleaned up weldments with MEK to remove sharpie marks. Cleaned up fuselage and test installed weldments. Checked alignment of wiring feedthrough holes and realized I have more filing before I can do the final install. Plan to use the SB625-8 instead of the SB625-7 for the wiring bushings to gain extra space.

Worked with Excel spreadsheet and decided how to show connections and use vLookup formulas to reduce effort and chance of mistakes.

Cut and pasted more connector information into a numbers spreadsheet for transfer to Excel. Completed entry for G5, GTX45R, GNC255, GTR200, GSA28, GMU11, GEA24, GMC507, GSU25, GTP59 and GMA245. That might be all of the avionics. Now to figure out which ones to connect... Lots of wires...
 
Jun 12, 2022     Landing Gear Weldments - (1 hour)       Category: Fuselage
Reviewed drawings, set depth on micro-stop countersink, tested on scrap and then countersunk 4 of the holes on the fuselage going to the landing gear weldment.
Cleaned, masked and painted the holes.
Not counted in the time, but worked on route planning for trip to Oshkosh, WI. Also looked at Airventure Exhibitor list.


 
Jun 11, 2022     Wire documentation - (1 hour) Category: Research
Completed defining most of the columns and testing plan for documenting Garmin (or Dynon) wiring. Reviewed previous spreadsheet for wiring and decided one combined list would work.
Also attended FAA Wings event and talked about Avionics plan with another builder (time not counted for building or research).
 
Jun 10, 2022     Brake lines - (1.2 hours)       Category: Fuselage
Inventoried Aircraft Spruce shipment of bolts.
Test fit brake line fittings in hole through landing gear weldments and bottom of fuselage. Marked areas of interference on bottom skin and filed on holes to enlarge then until there was enough clearance for the fittings. Started looking at the controls to find all the pieces and learn how they might impact installation of the landing gear bolts.


 
Jun 09, 2022     Documentation of Garmin Avionics Wiring - (1 hour) Category: Research
Worked on potential method of documenting Garmin avionics wiring with a spreadsheet wirelist. Decided best method was to cut and paste IO connections for each LRU from tables in the G3X Touch installation manual into Numbers. Then clean up and combine LRU, Connector and Pin into one field for vlookups. All LRUs will be listed in a left set of columns so that it is easy to see all the wires to every connector pin on each LRU. Next I need to add a right set of columns to define the connections. The right set of columns will use the combined LRU, Connector and Pin to define the connection and then vlookup to show all the other data.
This will result in two entries for every wire, but should make it easy to use with many options for sorting and filtering.
Need to consider graphical schematics. I'm thinking of using marked up examples taken from the G3X Touch installation manual. This won't be clean, but may be sufficient when used with the spreadsheet.
 
Jun 09, 2022     Finished Right Tank Cover rework (and all fuel tank cover changes!!!) - (1.4 hours)       Category: Wings
Worked at the hangar today. Finally completed the fuel tank related SBs. The vent connection on the right tank was previously torqued and covered with proseal so I did not try to retorque it. Otherwise work was completed the same as on the left tank.
Used McMaster-Carr 92185A194 super-corrosion-resistant 316 Stainless Steel Socket Head 8-32 x 1/2 screws for easier access if tank covers must be removed with wings installed.
Complied with SB 06-2-23, Safetying of standard and flop type fuel pickup tubes, terminating.
Complied with SB 04-2-1, Inspect fuel tanks, terminating.


 
Jun 08, 2022     Finished Left tank cover rework! - (1.5 hours)       Category: Wings
Worked at hangar today. Torqued vent line fitting to 58 inch pounds. Mixed up proseal using my new triple beam balance to get the right ratio. Cleaned up sealing surfaces, applied a thin layer of proseal to the outside surface of the tank and the inside of the cover. I did not use the optional cork gasket. The difficult part was inserting the fuel pickup and level sensor into the tank and getting the first two screws in the holes to ensure the cover is properly positioned without smearing proseal around on everything. Then I added a small dab of proseal around each hole and at the bottom of the head of each screw and started all the screws. Then tightened all the screws a little at a time until proseal started squeezing out slightly around the cover.
I started out with two gloves and had to remove them eventually because I got proseal all over them and had trouble holding the small screws. The next tank cover should be easier.


 
Jun 07, 2022     Landing gear mounts and fuel/brake lines - (.8 hour)       Category: Fuselage
Inspected gear mount paint and then did a test install. Looked for alignment of holes for brake lines and wiring. Looked at fit of places that need pro seal after landing gear mount installation. Started a list of questions for Van's Support. Reviewed instructions for fuel line routing.


 
Jun 07, 2022     Garmin Meeting - (1.8 hours) Category: Research
Discussed my Garmin questions and configuration options with a Garmin rep for just over an hour this morning. Learned a lot! Updated Garmin pricing spreadsheet with notes and started looking at new options. Need to pick a configuration or two, try Garmin and Dynon at Airventure and make a decision.
 
Jun 06, 2022     FlyLEDs, Monkworkz, KiCAD - (1 hour) Category: Research
Completed conversation with Paul at FlyLEDs. Will pick up parts at AirVenture. Reviewed responses from Bill at Monkworkz. Very helpful and interesting things to consider. Found and downloaded KiCAD (open source software for schematics and PCB design) started experimenting with it and it looks really promising! Organized questions and spreadsheet for the Garmin meeting tomorrow.
 
Jun 06, 2022     Main Gear Weldments - (.5 hour) Category: Fuselage
Cleanup parts where holes had been filed. Masked off the rest of the part. Sprayed bare metal spots with Mar-hyde primer.
 
Jun 06, 2022     Tank cover again - (.5 hour) Category: Wings
Worked at hangar today. Got there and found I was missing a few tools. Picked up tools at a local Harbor Freight. Cleaned loose proseal from inside tank (left over from removing the covers). Realized I was still missing tools and gave up for the day. Took up a lot of the day without much progress.
On the bright side we found a new restaurant in Taylor that has some interesting vegan options!
 
Jun 05, 2022     FlyLeds and Monkworkz - (.5 hour) Category: Research
Continued conversation with FlyLeds after reviewing the information provided.
Sent some questions to Monkworkz about their backup generator.
 
Jun 05, 2022     Main Gear Weldment - (2.7 hours)       Category: Fuselage
Finished filing on right main gear weldment!!! Ready to paint. And install for the last time.
Ordered new bolts to replaced the scratched ones on the landing gear weldment. Also ordered bolts for the pilot rudder pedals and longer bolts for the roll bar mounting.


 
Jun 04, 2022     External Lights - (1 hour) Category: Research
Read Kitplanes Lighting article again. Studied details on Flyleds website, selected a set of lights and sent questions to Paul. Planning on using:
Qty 1 - The Original" Flyleds Position and Strobe Lighting Kit
Qty 1 - Tail Light-kit model
Qty 2 - Quad Spotlight - Landing/Taxi light
 
Jun 04, 2022     Right Main Gear Weldment - (2.2 hours) Category: Fuselage
Sent pictures and measurements to friend for review. Consensus is my work on the main gear weldments is acceptable and I should just continue on my current path. Left gear mount weldment is ready for final assembly.
Continued work on increasing size of clearance holes on right gear weldment. Top eight to spar are good. Two of the seven at the bottom of the spar are good and the other five are closer, but still need work. The seven holes to the fuselage are closer, but still need work.
 
Jun 03, 2022     Left Main Gear Weldment - (1.4 hours)       Category: Fuselage
Summarized my concerns about the clearance holes in the main gear weldment and sent a request for review to a friend that is a builder and mechanical engineer.
Completed matching the two final holes on the left gear weldment. Took pictures and measured final hole sizes to send to my friend for review.


 
Jun 02, 2022     Electrical Tool Research - (3.5 hours) Category: Research
Searched for source of heat gun specified in TE Connectivity/Raychem documents for use with shield solder sleeves. Selected a heat gun kit with the necessary accessories.
Searched for positioners needed for my DMC crimp tool for the High Density D-Sub connector pins.
Looked up specifications for the Ideal wire stripper tools I bought and the ones Bill Moody gave me to make sure they were acceptable for the wire I am using. Reviewed other wiring tools and tested the D-Sub pin insertion and removal tools.
Looked at components and tools on the Stein Air and B and C Aviation websites.
Continued research on Garmin and Dynon to prepare for meeting the Garmin next week. Researched configuration of engine and airframe sensors and inputs.
 
Jun 02, 2022     Landing gear weldment - (3 hours) Category: Fuselage
Continued work on left main gear weldment. Completed opening up 5 holes so they align with the holes in the side of the fuselage. Only two more holes remain. I plan to check it again tomorrow and then ask a builder/ME to look at my work to see if it is acceptable.
Opened up the reworked AFP fuel pump that arrived today. It looks great and will be easier to install and maintain.
 
Jun 01, 2022     Landing Gear Weldments - (.5 hour) Category: Fuselage
Used new files to enlarge one hole on the left landing gear weldment to get it to line up with the hole in the side of the fuselage. The new files work much better than the old ones. Getting close to finishing one hole.
 
Jun 01, 2022     Garmin/Dynon - (2 hours) Category: Research
Updated pricing spreadsheet to add more configuration columns. Selected three different Garmin only configurations and one Garmin/Dynon configuration to compare pricing. Will discuss the three Garmin options with Garmin next week to answer questions and get recommendations.
Selected and ordered socket head screws for fuel tank covers from McMaster Carr.
Reviewed TCW backup battery options.
Downloaded and tried Garmin Checklist creation tool. Very cool!
Watched Garmin videos on wiring (shield attach, strip, crimp, and splices) and using G3X and a GPS Navigator and Autopilot to complete an instrument approach.
Bought a set of small files with handles at Harbor Freight.
 
May 31, 2022     Garmin/Dynon - (4 hours) Category: Research
Traveled home from Camarillo by train and plane. Reviewed portions of Dynon and Garmin pilot manuals and installation manuals and updated list of feature comparisons and questions. Considered different configurations to reduce antenna count and coax cable routing and antenna location.
 
May 30, 2022     Dynon/Garmin - (1.5 hours) Category: Research
Reviewed portions of Dynon and Garmin pilot manuals and installation manuals and updated list of feature comparisons and questions.
 
May 29, 2022     Dynon/Garmin - (1 hour) Category: Research
Completed reading of Dynon manuals and started working on comparison list.
 
May 28, 2022     G3X Touch Pilot Manual, G5 Pilot Manual, Dynon install manual - (1.5 hours) Category: Research
Completed reading G3X Touch Pilot Manual. Quickly scanned through the G5 Pilot Manual since much of it was similar to the G3X Touch.
Started reading the Dynon Installation manual.
 
May 27, 2022     G3X Touch Pilot Manual - (1 hour) Category: Research
Continued reading G3X Touch Pilot Manual.
 
May 26, 2022     G3X Touch Pilot Manual - (1.5 hours) Category: Research
Continued reading G3X Touch Pilot Manual.
 
May 25, 2022     G3X Touch Pilot Manual - (1 hour) Category: Research
Continued reading G3X Touch Pilot Manual.
 
May 24, 2022     G3X Touch Pilot Manual - (1.2 hours) Category: Research
Started reading G3X Touch Pilot Manual
 
May 23, 2022     Garmin G3X Touch Installation Manual, G5 Installation manual - (1.2 hours) Category: Research
Completed reading the G3X Touch Installation Manual. Completed reading the G5 installation Manual. Skipped over the sections that were similar to the G3X Touch installation manual.
 
May 22, 2022     Garmin G3X Touch Installation Manual - (1 hour) Category: Research
Continued reading the G3X Touch Installation manual.
 
May 21, 2022     Continued reading Garmin G3X Installation manual - (1.8 hours) Category: Research
Continued reading Garmin G3X Touch installation manual.
Responded to Garmin sales rep to set up a meeting the week of 6/6.
Also downloaded the Garmin G3X Touch and G5 Pilots manual.
 
May 20, 2022     Garmin G3X Touch research. - (1 hour) Category: Research
Continued reading the Garmin G3X Touch installation manual.
 
May 19, 2022     Garmin G3X Touch Installation Manual - (3 hours) Category: Research
Touched the RV before leaving the house to fly to Camarillo to visit family.
Started reading the G3X Touch installation manual. Read through page 317 (out of 944) as well as jumping ahead some to get more information on a topic during the flight and train ride. Learning lots about the functions and detailed connections between the components of the G3X Touch System.
 
May 18, 2022     Landing gear mounts and fuel boost pump - (1.4 hours) Category: Fuselage
Discussed Airflow Performance boost pump upgrade to new style with Don, packed and shipped the boost pump.
Started work on engine mount to fuselage hole matching on left main gear weldment. Tried to mark carefully, remove material slowly and keep hole in weldment as small as possible. Still working on the first hole.
Time not logged: Continued reading Garmin installation manual. Copied Garmin installation manuals to iPad to read on the flight to Camarillo. Downloaded copies of Kitplane magazines for reading on the flight. Updated Garmin pricing spreadsheet to show List and MAP totals. Made list of topics to research in Camarillo.
 
May 17, 2022     Tech Counselor, Van's and Garmin - (1.5 hours) Category: Research
Organized list of questions for tech counselor visit. Discussed landing gear weldments and looked at progress. Inspected fuel cover plate SB changes. Discussed Garmin vs Dynon. Discussed other topics included NAV radios, Parking Brake need, Andair vs AFP, Lycoming vs Thunderbolt and fixed pitch vs CS.
Followed up with Van's Builder support to verify my approach on landing gear weldments is acceptable.
Reviewed several Garmin installation manuals to see installation details.
 
May 16, 2022     Landing Gear Weldments Continued - (1.1 hours) Category: Fuselage
Completed filing to match the remaining 3 holes in the top row of 8 holes. Filed 2 of the 7 holes in the bottom row of holes. Would like a tech counselor to look before I finish filing all the remaining holes in the bottom row.
Time not logged: Talked to Garmin tech support to get a few of my questions answered. They didn't seem to be willing to spend much time with me. Dynon was much more helpful.
 
May 15, 2022     Fuel tank covers and gear mount weldments - (1.1 hours) Category: Wings
Inspected fuel tank cover safety wire and determined they are acceptable to use.
Started install, inspect and filing on right gear leg mount so holes line up with holes in the spar. Completed 5 of the top 8 holes. See paper notes for details on fit and which two holes are the master ones used for alignment of weldment.
Work not included in hours logged included keeping up with VAF posts and working on budget for 2022, 2023 and 2024.
 
May 14, 2022     More Safety Wire - (.9 hour)       Category: Wings
Redid safety wire on both cover plates after filing a small notch in the brackets to help keep the safety wire from slipping over the bracket. I think I am happy with these, but will inspect tomorrow.
The following are not included in the time logged for today, but are aviation related.
I volunteered at the EAA Chapter 187 Young Eagle Event all morning. I escorted a lot of excited kids out to the airplanes so they could get their first flight in a small airplane. I can't wait to fly my grandkids for the first time.
I also read more aviation magazines and searched for software to help with electrical schematics.
I also unpacked my new triple beam balance that I will use to weigh two part epoxies for tank sealant and fiberglass. The resolution is about 10 times better than the scale I was trying to use.


 
May 13, 2022     Torqued fuel pick fittings and started safety wire - (1 hour)       Category: Wings
Reviewed SB instructions, tested torque wrench, torqued both fuel pickup fittings with pickup rotated to proper position and made first attempt at safety wire for both fittings. Will inspect tomorrow and may redo the safety wire.


 
May 12, 2022     Fuel System, Brakes - (1 hour) Category: Research
Found and reviewed drawings for the Andair fuel pump installation and the original AFP fuel pump installation. Viewed Aircraft Specialty fuel and brake hose kits to see how they worked with Andair and/or AFP. Made notes for items to discuss with Deene, Vans Aircraft Support and Aircraft Specialty.
Read Kitplanes June 2022 article on large screen EFIS panels from Garmin, Dynon and others (Not included in the logged time).
 
May 11, 2022     Fuel tank Service Bulletins - (.8 hour)       Category: Wings
Worked in the hangar today. Figured out where I quit working on the two fuel tank service bulletins. Test fit fuel tank cover plates and adjusted fuel pickup lines. Tried to tighten AN nuts and decided to bring the cover plates and tools back to the house and complete the tightening and safety wire work before doing the final install at the hangar.


 
May 11, 2022     Discussed questions and options with Dynon - (.8 hour) Category: Research
Discussed my list of questions with Dynon rep on video conference. Kyle was extremely helpful.
 
May 10, 2022     More Research, Fuel Pump - (1.3 hours)       Category: Research
Finished reading chapters 14 (temperature) and 15 (pressure) of Aero Electric. Read portions of Chapter 17, reliability. Will refer to this chapter during the electrical design.
Reviewed fuel pump drawings and associated mounting and cover plates to figure out where I had stopped building and what was needed next.


 
May 09, 2022     Dynon and Garmin - (1.9 hours) Category: Research
Completed review of Dynon and Garmin docs. Sent final list of questions and proposed configuration to Dynon for our 5/11 meeting. Sent Garmin a list of questions and proposed configuration and requested a meeting.
Finished chapter 13 of Aero Electric book.
 
May 08, 2022     Service Bulletins, Notifications, Letters and Document Revisions - (3.3 hours) Category: Research
Downloaded and quickly reviewed all RV-7(A) related service bulletins, notifications and letters as well as new documentation revisions. Made notes for next steps on any that require research or rework.
Read chapter 12 (lighting) and 16 (EMC) of Aero Electric Revision 12 and made notes. Started chapter 13, Antennas.
Looked at spar and step that are associated with a service bulletin and service letter.
 
May 07, 2022     Dynon and AeroElectric Research - (4.2 hours) Category: Research
Continued review and price estimates of Dynon components.
Studied chapters 3 through 11 of Aero Electric and made notes.
 
May 06, 2022     More Research - (.8 hour) Category: Research
Called Air Flow Performance and talked to Kyle about the fuel injection prototype on the RV-8. He assured me it would work the same on my RV-7A. Also discussed my original style AFP fuel pump, Andair Fuel Pump and converting my original AFP fuel pump into the current model fuel pump. Continued review of Garmin components and system pricing.
Studied chapters 1 and 2 of Aero Electric.
 
May 05, 2022     Research and more research - (8 hours) Category: Research
Searched through VAF and other web sites for information. Compiled a list of questions for Vans Support and had an extremely helpful and pleasant discussion with Eric and got most of my questions answered and suggestions for other people to contact.
Spent a lot of time reading Garmin and Dynon documentation, creating pricing spreadsheets and working to select an initial panel for discussion with Garmin and Dynon. Bought ticket to AOPA Aviator Showcase in Fort Worth on 6/16 and 6/17. Dynon, Garmin, Foreflight, Jeppesen and many other vendors will be there to answer questions about their products.
 
May 04, 2022     More Landing Gear Weldment work - (1.2 hours) Category: Fuselage
Inspected left weldment mounting hole to spar alignment and decided the clearances were enough. Removed the weldment and measured the largest dimension of each of the holes. Also examined the alignment of the holes between the weldment and the side of the fuselage. Sent information and questions to Deene.
Test fit right weldment and used two holes as the initial alignment. Verified rivet clearance holes were adequate. Verified alignment of remaining holes to the spar were close enough for filing to fit. Inspected alignment of holes between mount and fuselage and decided they might not be close enough. Included information in email to Deene.
 
May 04, 2022     Garmin? - (2.7 hours) Category: Research
Started careful review of Garmin products, created a pricing spreadsheet and started a list of questions for Garmin.
 
May 03, 2022     Still working on left gear leg mount weldment... - (.9 hour) Category: Milestones
Light day today. Continued install, inspect, file and repeat. One mounting hole out of the 15 that attache the weldment to the spar carry through needs a tiny bit of work.
 
May 02, 2022     More Landing Gear Weldment work - (3.3 hours) Category: Fuselage
Progress and more to do. More install, inspect, file, repeat on the left landing gear. There are 15 mounting holes on the front side of the spar carry through and now all but two of them match. The final two are close. Then I have seven more mounting holes between the weldment and the side of the fuselage to match up. Then repeat on the right side.
 
May 01, 2022     Landing Gear Mounts continued... - (2.3 hours)       Category: Fuselage
Rosie (aka Ellicia, aka Mimi) and I riveted the 8 double flush rivets that are located under the landing gear. If feels great to finally be putting something together.
Now it is time to finish the landing gear mount install. I placed bolts in three small holes on the top of the landing gear weldment and verified all the other holes were in reasonably close alignment. Then I started marking the holes to show where to file, removed the mount, filed, and then repeated. I have 9 mounting holes completed on the left landing gear mount.


 
May 01, 2022     Andair Fuel Pump and Filter Research - (1.3 hours)       Category: Research
Researched Andair fuel pumps and filters on VAF. There were some failures reported. Repairs and factory response time varied from shipping two days to waits of a week or two. They haven't responded to an email with questions I sent late Thursday their time. Someone on VAF is selling an Andair pump and filter and I sent a message asking why he is selling it. I'm not sure what I will do yet.


 
Apr 30, 2022     More landing gear weldments - (2.5 hours) Category: Fuselage
Continued opening up rivet clearance holes and confirmed rivets are no longer in the way of putting the weldment in the correct position. Matched a few key holes using bolts and inspected alignment of all other holes. Filing is required on the weldment, but the amount is acceptable.
Reviewed drawings and planned next few steps.
 
Apr 30, 2022     Garmin vs Dynon - (1 hour) Category: Research
Watched the rest of the Dynon HDX demo video. Searched and read more Garmin vs Dynon postings and reviews.
Started parts order on AircraftSpruce.com.
 
Apr 29, 2022     Landing Gear Weldments - (1.8 hours)       Category: Fuselage
Continued fitting, inspecting, filing and repeat. Right side is getting close. Holes don't line up as well on the left side so I am continuing to open up some rivet clearance holes to allow better positioning of the weldment before I work on mounting holes.
I included a picture of me using the Giraffe Inspection camera to check clearance holes around one of the rivets. The image is displayed on my iPad.
I also included a picture of the part of the mounting gear weldment that extends outside the fuselage and the landing gear.


 
Apr 29, 2022     EFIS...Dynon? Garmin? - (2 hours) Category: Research
Provided background information on my experience and missions to Dynon representative in preparation for a video meeting. Probably meeting 5/11 or 5/13. Started watching Dynon youtube video that walks through capabilities and using the HDX. Started copying part and pricing information from the Dynon website into a spreadsheet so I can pick all the parts and see current cost totals.
Looked at the Garmin website and watched a demo of the Garmin G3X Touch system. Very impressive. I plan to have a video meeting with them and get hands on both Garmin and Dynon at AirVenture.
 
Apr 28, 2022     Rudder/Brake Pedals - (.8 hour)       Category: Fuselage
Worked a long day so didn't have much time for the RV.
Planned to continue on landing gear weldments, but had a dead battery in the inspection camera. Note to self: Turn camera off when done with it.
Test fit brake pedals to rudder bar with specified hardware. Searched to see if a single long bolt was available. Need to ream holes and order some additional hardware.


 
Apr 27, 2022     Main Gear Weldments - (1.4 hours) Category: Research
Lubricated rudder bars per discussion with Deene with not much change. Should be okay anyway.

Test fit both main gear mounts. Deene had mentioned getting in close with a camera to check hole alignments. I remembered I have a GiraffeCam Inspection camera and it worked great to get in close and magnify the view. I found several rivets that were against the sides of clearance holes in the weldment and keeping me from moving it to align bolt holes better. Completed several cycles of view, mark, file and repeat. Fit is improving. I'll continue tomorrow and include some pictures. Once I can position the weldment and move it some I will start to work on the mounting bolt holes.
 
Apr 27, 2022     Research, Emails and Organizing - (2 hours) Category: Research
Organized notes from Deene's visit into several todo lists, prioritized and started some of the follow up.
Researched Andair fuel system recommendations and sent email asking if there were any bulletins or issues with the parts I purchased at Airventure in 2010 or 2012.
Contacted Carl F on VAF with questions about the AFP FM150C that was prototyped on his RV-8(A?) and still plan to use AFP after his response.
Researched solder shrink sleeves on Stein's website and on Mouser and Digikey.
Started looking at some of the Garmin products such as the G5 backup instruments and 375 Navigator.
 
Apr 26, 2022     Landing gear weldments - new start - (.5 hour)       Category: Fuselage
I can't believe I was making it so hard. The technical counselor helped get me on the right track. I think. I still have to finish installing them.

First step was to remove the six nut plates that are in the way of installing or removing the weldment. This will allow me to easily insert and remove the gear leg. I thought about this before but didn't want to go through the work of removing and then reinstalling the 6 nut plates. But that made everything else really hard. Now it will be easy to fit the part, inspect the holes, remove the part, file a little bit and then repeat until all the holes are aligned (without touching the precision holes in the spar carry through structure). Why couldn't I see that on my own?

It has been too long. At first my air drill wouldn't turn. I had to work on it some to break things loose. Now I just need to use it every day. I need to try all the other air tools...


 
Apr 26, 2022     Help Arrived! - (3.2 hours) Category: Research
Explored VAF web site for fuel injection, mags and other topics.

Discussed Airflow Performance fuel injection systems for my application with Don Rivera of AFP. I will probably use AFP instead of AVStar. I plan to talk to a few more people before final commitment.

Had a very helpful, enlightening and inspiring visit from technical counselor, Deene Ogden!!! Thanks Deene! Determined next steps on landing gear weldment installation. Also discussed many other topics such as high level assembly order, fuel pumps/filters, fuel injection, ignition, Dynon vs Garmin EFIS, roll bar handles, fuses vs circuit breakers, electrical power distribution (single battery, single alternator, strategic backup batteries), alternate oil cooler, forward fuselage access panels, rudder bar fit and play, IFR instruments (Garmin 375, Val NAV), backup flight instruments (Garmin G5, Dynon), control grips with switches (coolie trim, PTT, Flaps?, Boost pump?, flip flop, starter?) and other topics.

Decided I will probably use Lycoming EIS ignition after talking to Deene. I plan to talk to Van's and Lycoming before a final commitment.
 
Apr 25, 2022     Preparing for tech counselor visit - (4.2 hours) Category: Research
Tech counselor graciously agreed to come by on Wednesday, 4/26, to help me with the landing gear mounting weldment and discuss other topics. I spent the day today trying to answer open questions and find new ones. Prepared a list of questions/topics to discuss.

Researched information on firewall forward kit components, engine order form and lycoming website and found to answer my prop governor questions.

Researched Airflow Performance and AVStar fuel injection systems and sent list of questions to both suppliers.

Requested a virtual meeting with Dynon Avionics to discuss my needs and get recommendations. Also started preparing a summary of my requirements and a list of topics. Found additional online documentation that I need to review before we meet.

I also discussed plans and options for attending AirVenture 2022 with a friend (not included in the hours logged AND I still have to miss 5 or fewer days between now and 6/15 or I don't get to go).
 
Apr 24, 2022     Making lists of questions - (3.5 hours)       Category: Research
Started searching online and at VAF for information about main gear weldment installation. Sent request for help to local tech counselor. Included some other topics for discussion during visit.
Moved rudder bar to a location closest to the seats. Reviewed drawing for rudders and brakes and added more questions to the list for the tech counselor.
Temporarily installed firewall recess to check fit and added more questions.
Reviewed drawings related to firewall penetrations, battery mounting, constant speed prop and added to the list of questions.
Measured thickness of structure behind instrument panel to determine length of bolt to use instead of a rivet.


 
Apr 23, 2022     Main Landing Gear Weldment - (2.4 hours)       Category: Fuselage
Searched for and found more parts. Reviewed main gear mount weldment instructions and drawings. Studied log entries for original installation work. Removed the left gear mount weldment and tried fit of bolts without weldment in place. Searched for sources for LPS-1, 2 or 3. Bought 30 weight non detergent mineral oil and tried fit of standard bolts and NAS close tolerance bolts. Inspected the install of the right gear mount weldment and removed it. I am going to ask for help.


 
Apr 22, 2022     Removed more parts - (2 hours)       Category: Fuselage
Removed additional forward fuselage structure to allow better access for to cockpit for brake and fuel system installation and installation of gear leg weldments. Vacuumed and cleaned interior.
Did a quick review of all builder logs and summarized date ranges and kits. Identified sections of logs needing more careful review. Key dates are: 9/12/01 started empennage kit. 5/25/02 unpacked wing kit. 7/10/05 started fuselage kit.


 
Apr 21, 2022     Progress? - (2 hours)       Category: Fuselage
Sat in pilot seat with temporary cushion to evaluate seat position and rudder bar placement. Decided I need to try sitting in a finished RV-7A and note the rudder bar location, seat back settings, cushion thickness and how it fits me.
Removed instrument panel, roll bar, forward top fuselage skin and seat pans for better access to brakes, fuel system and gear leg mounting weldments. It doesn't feel like progress, but I am working on the RV and doing things that have to be done.
Mixed up a small batch of tank sealant to test new can of sealant and new scale.


 
Apr 20, 2022     A little cleaning, more research. - (1.5 hours) Category: Research
Arrived home around 8PM.

Looked for information on rudder position on VAF. Found and inspected brake, tire and wheel parts. Unpacked additional boxes of parts. Studied brake system drawings. Rolled fuselage upside down and verified minimum clearance between rudder bar mounts and firewall.
 
Apr 19, 2022     Research while out of town. - (1.5 hours) Category: Research
Happy Birthday, Dad!

Researched electrical and avionics design options. Ordered updated Aeroelectric aviation wiring handbook.
 
Apr 18, 2022     Cleaning and Research - (1.2 hours) Category: Research
Loaded and took hazardous garage waste to the disposal facility. Continued review of electrical design documents and online research. Left Austin at 9:30 AM for trip to San Antonio. Signed up for an online builders log through EAA.
 
Apr 17, 2022     Where Am I and What's Next? - (1.7 hours) Category: Research
Dug through all the electrical and fuel system parts and tools and made notes. Reviewed instruction manual to help figure out where I was when I stopped building. Found and started review of electrical design documents.
 
Apr 16, 2022     Cleaning and research. - (2.5 hours) Category: Workshop
Continued cleaning garage for 2 hours. Started looking for parts and documentation in garage and started research.
 
Apr 15, 2022     The Big Project Restart - (1.5 hours)       Category: Milestones
I've been storing my project RV-7A too long!!! I remember sage advice from Deene Ogden, something like "get building, you don't have that many more years left to fly". And I want to be able to fly my grandkids while they are young and they are growing up fast. So I am finally taking steps to restart and, this time, keep going until I finish the project.

I made a contract with my grandkids to work on it every day between 4/15 and 7/22. And there will be consequences when I miss. I will send their mom $50 every day I don't complete work as defined in the contract. And rewards if I miss less than 5 times between now and 6/15! My rewards are: 1) Progress on a goal that is important to me. 2) I get to buy an air cooler for the hangar or garage. 3) I get to attend Airventure 2022 (and hopefully place orders for some final big expensive parts).

Thank you Austin, Sarah, Lily and Mae for the encouragement and motivation to finish this project!

Day one of "building" is to start cleaning out the garage so I have space to work on the RV.

Created plan and agreement. Touched airplane. Cleaned up garage for 1.5 hours - sorted and recycled boxes, started putting up tools, gathered hazardous waste to take to recycle place.


 


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